RTA48T

Maintenance Manual
“Marine”

Vessel:

Type:

Engine No.:
Book No.:

Wärtsilä Switzerland Ltd 24hrs Support: +41 52 262 80 10

PO Box 414 technicalsupport.chts@wartsila.com
CH-8401 Winterthur
Switzerland

E 2008 Wärtsilä Switzerland Ltd, Printed in Switzerland

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 0 General Information

1 Bedplate and Tie Rod

2 Cylinder Liner and Cylinder Cover

3 Crankshaft, Connecting Rod and Piston

4 Camshaft and Control Elements

5 Governor, Injection Pump and Actuator Pump

6 Scavenge Air Receiver and Auxiliary Blower

7 Balancer

8 Piping
MM / RTA / Register

9 Tools
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 RTA48T
Betrieb Group0

General Information Group 0

For Particular Attention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0000–1/A1

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001–1/A1

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002–1/A1

Engine Numbering and Designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008–1/A1

 General Guidelines for Maintenance

– Safety Measures and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011–1/A1

 Clearance Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0330–1/A1

– Main Bearing and Thrust Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
– Crosshead Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2
– Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3
– Cylinder Liner (with Vertical Cooling Groove) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
– Piston Rod Gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
– Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 6
– Top and Bottom End Bearings to Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 7
– Piston Cooling and Crosshead Lubricating Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8
– Working Piston and Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 9
– Wheels for Camshaft Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 10
– Camshaft and Reversing Servomotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 11
– Gearing for Auxiliary Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 12
– Gearing for Auxiliary Drives (Driving End) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 13
– Starting Air Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 14
– Roller Guides for Fuel Injection and Actuator Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 15
– Balancer 2nd Order (Driving End) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 16
– ELBA (Electrical Balancer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 17

 Tightening Values of Important Screwed Connections

– Tightening Values of Important Screwed Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0352–1/A1
– Tightening Instructions for Normal Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0352–2/A1

Wärtsilä Switzerland Ltd 1 RTA48T / MM / 7.03

Group0 Betrieb RTA48T

 Masses (Weights)
– Individual Components per Piece in kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0360–1/A1

 Dimensions and Material Specification

– O-rings, Round Rubber Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0370–1/A1
– Piston and Rod Seal Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0370–2/A1
– Supporting Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0370–2/A1

 Maintenance Schedule
– Inspection and Overhaul Intervals (Guidelines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0380–1/A1

Engine Cross and Longitudinal Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0803–1/A1

Taking Oil Samples for Laboratory Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0900–1/A1

1998 / MM / RTA48T 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 0000–1/A1

For Particular Attention

This manual is put at the disposal of the recipient solely for use in connection with the corresponding type of diesel
engine.
It has always to be treated as confidential.

The intellectual property regarding any and all of the contents of this manual, particularly the copyright, remains with
Wärtsilä Switzerland Ltd. 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 intends to use the engine or before maintenance work is undertaken, the Operating Instructions
or the Maintenance Manual respectively is to be read carefully.

To ensure the best efficiency, reliability and lifetime of the engine and its 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 data, instructions and graphical illustrations etc. in this manual are based on drawings made by Wärtsilä
Switzerland Ltd and correspond to the actual standard at the time of printing (year of printing is indicated on title
page).
Those specifications and recommendations of the classification societies which are essential for the design have
been considered therein. It must be recognized that such data, instructions and graphical illustrations may be sub-
ject to changes due to further development, widened experience or any other reason.

This manual is primarily intended for use by the engine operating and maintenance personnel. It must be ensured
that it will always be at the disposal of such personnel for the operation of the engines and/or for the required mainte-
nance work.

This manual has been prepared on the assumption that operation and maintenance of the engines concerned will
always be carried out by qualified personnel having the special knowledge, training and qualifications needed to
handle in a workman-like manner diesel engines of the corresponding size, the associated auxiliary equipment, as
well as fuel and other operating media.

Therefore, generally applicable rules, which may also concern such items as protection against danger, are speci-
fied in this manual in exceptional cases only.
It must be made sure that the operating and maintenance personnel are familiar with the rules concerned.

This manual has been prepared to the best knowledge and ability of its authors. However, neither Wärtsilä
Switzerland Ltd nor their employees assume any liability – under any legal aspect whatsoever, including
possible negligence – in connection with this manual, its contents, or modifications to it or in connection
with its use.
Claims relating to any damage whatsoever or claims of other nature such as, but not limited to, demands for
additional spares supplies, service or others are expressly excluded.

Wärtsilä Switzerland Ltd

Winterthur
Switzerland

Wärtsilä Switzerland Ltd 1 u 2004

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 RTA48T
Maintenance 0001–1/A1

Preface

The instructions contained in this ”Maintenance Manual” are intended to help to ensure that the maintenance
which must be carried out at specific intervals is correctly carried out.
It is a precondition that the personnel charged with such important work possesses the necessary training and expe-
rience.
Information about the operation of the engine as well as descriptions of the function of the various systems are part
of a separate book, the ”Operating Manual”. In this manual you can find also under group 0010–1 and 0040–1 ex-
planations of the layout and use of the Operating Instructions as well as of the Maintenance Manual.
More detailed instructions on the operation and maintenance of components from sub-suppliers can be gathered
from the instruction leaflets of the respective manufacturers. Outside makes are, for example, such engine compo-
nents, tools or devices which are not manufactured in accordance with production drawings from Wärtsilä Switzer-
land Ltd.
The ”Maintenance Manual” is divided into the following main chapters:

 General guidelines for maintenance

 Clearance tables, tightening values of screwed connections, masses (weights), seal rings

 Maintenance schedule

 Design groups

 Tool lists

A few explanations to the above:

The ’General Guidelines for Maintenance’ contain, in addition to recommendations on precautionary measures to
be taken, also suggestions for carrying out the work.
The above mentioned tables inform about normal and maximum acceptable clearances, the tightening of important
screwed connections, weights of individual engine components as well as the type and use of various sealing rings.
The normal clearances given in the clearance tables group 0330–1 correspond to those resulting from manufactur-
ing tolerances or clearances as adjusted on the new engine.
The maximum clearances or max/min dimensions represent values resulting from wear due to long periods of op-
eration, which, however, must not be exceeded nor gone below, respectively. For parts where the clearance can be
corrected by changing shim thickness, discs or spacers, the normal clearance should always be aimed at and ad-
justed. Where this is not possible, the worn parts must be replaced or reconditioned by building-up (chromium plat-
ing, resurfacing by welding or by metal spray).
If, during an overhaul, clearances or dimensions are found which nearly attain the permissible limits, then it must be
left to the engineer responsible for the operation of the engine to decide whether to replace the parts. This depends,
for example, on the duration of the next operating period till the next overhaul and what wear has to be expected
based on experience gained.
The ’Maintenance Schedule’ indicates nominal intervals in which various maintenance operations are to be carried
out. Please note that maintenance intervals are based on experience and are subject to operation of the engine
under standard conditions.
Detailed instructions are given in the ’Design Groups’ on the procedure of maintenance work on certain engine
parts.
Tools and devices necessary to carry out maintenance are described in the ’Tool Lists’, and are generally supplied
with the engine.
All information contained in the text and illustrations of this manual are valid at the time of printing.
Modifications will be incorporated in the next edition!

Wärtsilä Switzerland Ltd 1 u 7.04

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 RTA48T Maintenance 0002–1/A1

Table of Contents
Table of Contents

General Information Group 0

For Particular Attention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0000–1/A1

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001–1/A1

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002–1/A1

Engine Numbering and Designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008–1/A1

 General Guidelines for Maintenance

– Safety Measures and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011–1/A1

 Clearance Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0330–1/A1

– Main Bearing and Thrust Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
– Crosshead Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2
– Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3
– Cylinder Liner (with Vertical Cooling Groove) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
– Piston Rod Gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
– Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 6
– Top and Bottom End Bearings to Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 7
– Piston Cooling and Crosshead Lubricating Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8
– Working Piston and Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 9
– Wheels for Camshaft Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 10
– Camshaft and Reversing Servomotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 11
– Gearing for Auxiliary Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 12
– Gearing for Auxiliary Drives (Driving End) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 13
– Starting Air Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 14
– Roller Guides for Fuel Injection and Actuator Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 15
– Balancer 2nd Order (Driving End) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 16
– ELBA (Electrical Balancer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 17

 Tightening Values of Important Screwed Connections

– Tightening Values of Important Screwed Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0352–1/A1
– Tightening Instructions for Normal Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0352–2/A1

 Masses (Weights)
– Individual Components per Piece in kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0360–1/A1

Wärtsilä Switzerland Ltd 1 2.06

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Table of Contents

 Dimensions and Material Specification

– O-rings, Round Rubber Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0370–1/A1
– Piston and Rod Seal Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0370–2/A1
– Supporting Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0370–2/A1

 Maintenance Schedule
– Inspection and Overhaul Intervals (Guidelines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0380–1/A1

Engine Cross and Longitudinal Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0803–1/A1

Taking Oil Samples for Laboratory Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0900–1/A1

Bedplate and Tie Rod Group 1

 Bedplate and Thrust Bearing

– Checking the Foundation Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1112–1/A1

 Main Bearing
– Loosening and Tensioning of Waisted Studs and Jack Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1132–1/A1
– Removing and Fitting a Main Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1132–2/A1

 Thrust Bearing
– Checking the Axial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1203–1/A1
– Removal and Fitting the Thrust Bearing Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1224–1/A1

 Engine Stays with Friction Shims

– Checking the Pre-tension of the Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1715–1/A1

 Hydraulic Engine Stays

– Checking the Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1715–1/A2

 Tie Rod
– Checking the Tie Rod Pre-tension and Tensioning the Tie Rods . . . . . . . . . . . . . . . . . . . . . . . . . 1903–1/A1

Cylinder Liner and Cylinder Cover Group 2

 Cylinder Liner
– Measuring Bore Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2124–1/A1
– Removing and Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2124–2/A1
– Removing Wear Ridge, Re-dressing Lubricating Grooves, and Edges . . . . . . . . . . . . . . . . . . . 2124–3/A1
of the Scavenge Ports

2.06 2 Wärtsilä Switzerland Ltd

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Table of Contents

 Lubricating Quills and Accumulators

– Removal and Fitting, Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2136–1/A1

 Piston Rod Gland

– Dismantling and Assembling as well as Measuring the Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . 2303–1/A1

 Cylinder Cover
– Removal and Fitting of the Cylinder Cover and Water Guide Jacket . . . . . . . . . . . . . . . . . . . . . 2708–1/A1
– Loosening and Tensioning of Cylinder Cover Waisted Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2708–2/A1
– Manual Overhaul of Sealing Face for the Injection Valve in the Cylinder Cover . . . . . . . . . . . . 2708–3/A1

 Injection Valve
– Checking, Dismantling, Assembling and Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2722–1/A1

 Starting Valve
– Removing, Fitting and Dismantling, Grinding-in and Assembling . . . . . . . . . . . . . . . . . . . . . . . . 2728–1/A1

 Relief Valve for Cylinder Cover

– Dismantling, Assembling and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2740–1/A1

 Exhaust Valve
– Removal and Fitting of the Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2751–1/A1
– Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2751–2/A1
– Replacing and Grinding the Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2751–3/A1
– Grinding the Seating Surface on the Valve Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2751–4/A1

Crankshaft, Connecting Rod and Piston Group 3

 Crankshaft
– Measuring Crank Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3103–1/A1

 Vibration Damper
– Taking a Silicone Fluid Sample (for Engines with Viscous Vibration Damper) . . . . . . . . . . . . . . 3130–1/A1
– Inspection (GEISLINGER Vibration Damper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3130–2/A1

 Axial Detuner
– Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3146–1/A1

 Crankcase
– Utilization of the Working Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3301–1/A1

Wärtsilä Switzerland Ltd 3 2.06

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Table of Contents

 Connecting Rod
– Loosening and Tensioning the Connecting Rod Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303–1/A1

 Connecting Rod and Connecting Rod Bearing

– Inspection, Removing and Fitting of Bottom End Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303–2/A1
– Inspection, Removing and Fitting of Top End Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303–3/A1

 Connecting Rod
– Removing and Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303–4/A1

 Crosshead
– Checking Clearances and Fitting the Guide Shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3326–1/A1
– Removal and Fitting of a Crosshead Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3326–2/A1

 Piston
– Removal and Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3403–1/A1
– Changing the Compression Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3403–2/A1
– Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3403–3/A1
– Checking Piston Top Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3403–4/A1

 Piston Rings
– Checking Piston Ring Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3425–1/A1

Camshaft and Control Elements Group 4

 Camshaft Driving Wheels

– Checking the Running and Backlash Clearances and Condition of the Teeth . . . . . . . . . . . . . . 4103–1/A1
– Removal and Fitting of Intermediate Gear Wheels, Replacing a Toothed Rim . . . . . . . . . . . . . 4103–2/A1
– Replacing the Gear Wheel on the Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4103–3/A1

 Camshaft
– Removing and Fitting a Camshaft Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4203–1/A1
– Removing and Fitting of Hydraulic Locking Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4203–2/A1
– Removing and Fitting of Hydraulic Locking Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4203–3/A1
– Removing and Fitting of an SKF Shaft Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4203–4/A1
– Removing and Fitting the Gear Wheel on the Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4203–5/A1

 Starting Air Distributor

– Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4303–1/A1

 Shut-off Valve for Starting Air

– Cleaning and Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4325–1/A1

 Rotating Direction Safeguard

– Inspection and Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4506–1/A1

2.06 4 Wärtsilä Switzerland Ltd

 RTA48T Maintenance 0002–1/A1

Table of Contents

Governor, Injection Pump and Actuator Pump Group 5

 WOODWARD Governor PGA 200

– Installing, Removing and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5103–1/A1

 Safety Cut-out Device

– Maintenance and Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5307–1/A1

 Fuel Injection Pump

– Adjusting and Checking the Control with Load-dependent V.I.T. (Variable Injection Timing) . 5512–1/A1
– Lapping the Sealing Faces for the Covers of the Suction, Delivery and Spill Valves . . . . . . . . 5512–2/A1
– Checking and Setting of the Relief Valve with L’ORANGE Test Stand . . . . . . . . . . . . . . . . . . . . 5512–3/A1
– Removing and Fitting of a Pump Plunger and Plunger Bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5512–4/A1

 Actuator Pump
– Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5513–1/A1

 Regulating Linkage and Roller Guide of Injection Pump

– Fitting and Removal of Eccentric Shafts and Roller Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5520–1/A1

Scavenge Air Receiver and Auxiliary Blower Group 6

 Scavenge Air Receiver

– Checking the Air Flaps and Cleaning the Scavenge Air Receiver . . . . . . . . . . . . . . . . . . . . . . . . 6420–1/A1

 Auxiliary Blower
– Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6545–1/A1

 Scavenge Air Cooler

– Cleaning (Water Side) on Engine at Standstill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6606–1/A1
– Removing and Fitting a Cooler Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6606–2/A1

 Scavenge Air Receiver

– Maintenance of Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6708–1/A1

Balancer Group 7

 Integrated Balancer of 2nd Order

– Removal and Fitting of Compensating Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7722–1/A1

 ELBA (ELectrical BAlancer)

– Checking, Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7734–1/A1

Piping Group 8

 Hydraulic Piping for the Exhaust Valve Drive

– Removing and Fitting the Pipes and Re-facing the Sealing Faces . . . . . . . . . . . . . . . . . . . . . . . 8460–1/A1

 Fuel Pressure Piping

– Fitting and Dismantling, Re-conditioning the Sealing Faces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8733–1/A1

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Table of Contents

Tools Group 9

 Tools
– Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403–1/A1

 Hydraulic Jacks and Pumps

– Arrangement and Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403–2/A1

 Hydraulic Pre-Tensioning Jacks

– Storing, Servicing and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403–3/A1
– General Application Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403–4/A1

 Tool List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403–5/A1

– Standard Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1–36
– Recommended Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 37–39
– Special Tools Obtainable on Loan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 40

2.06 6 u Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 0008–1/A1

General
Engine Numbering and Designation

Turbocharger

Cylinder
1 2 3 4 5 6 7 8 Numbering

Driving End Free End

1 2 3 4 5 6 7 8 9 10

Thrust Bearing Pads Main Bearing Numbering

Fuel Pump Side Exhaust Side

Anti-clockwise Rotation Clockwise Rotation

96.7439

Wärtsilä Switzerland Ltd 1 u 1998

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 RTA48T
Maintenance 0011–1/A1

General Guidelines for Maintenance

Safety Measures and Warnings

The maintenance work which is required to be carried out on the engine at regular intervals is described in the Main-
tenance Schedule group 0380–1 of this manual and is to be understood as a general guide. The maintenance
intervals are dependent on the mode of operation, on the power as well as on the quality of the fuel used.
Further details are set out in the maintenance schedule.
Experience will show whether the intervals may be extended or need to be shortened.
Strict compliance with the below mentioned recommendations regarding safety measures and mainte-
nance work is mandatory; the recommendations are not exhaustive.

1. General safety precautions

– It is the operator’s duty to assure that all personnel is familiar with all safety, health as well as environment
protection rules released for operating and maintaining a diesel engine plant. In particular greatest atten-
tion has to be given to the functioning, handling and dangers of cranes and lifting devices.
– The safety officer has to make sure that all precautions have been taken in order to avoid dangerous situa-
tions.
– The operator has to nominate a person responsible for assigning work tasks to every person who is partici-
pating in maintenance work.
– Make sure that fluids or gases draining or escaping cannot cause accidents, fires or explosions during
maintenance work. Keep the engine and the surroundings clean. Cleanliness increases the quality of the
work and helps to prevent accidents.
Before beginning maintenance work on the diesel engine the corresponding systems which are influenced
by the maintenance work must be relieved of pressure and/or drained if necessary. A protocol must be
established evidencing these activities.
– Certain media, i.e. fuels etc., are highly inflammable, therefore all precautionary measures have to be
taken that they do not come into contact with fires, glowing or hot parts. Smoking in the engine room is
strictly forbidden.
Special attention has to be paid to the rules of fire fighting.
Make absolutely sure that in case of fire alarm no fire extinguishing gases can be released into the engine
room while people are still inside. Emergency escapes are to be marked and personnel is to be instructed
of what to do in case of fire.
– Oils and other media can cause slippery surfaces. In order to avoid injury all surfaces which can be stepped
on must be kept clean and dry.

2. Precautionary measures before beginning of maintenance work

Before starting any maintenance work on the engine (particularly on the running gear), take the following
precautionary measures:
– Close the shut-off valves on the starting air bottles.
– Close all the shut-off valves in the control air supply unit and open the drain cocks in the two air bottles.
– Close by hand the (automatic) shut-off valve for starting air and open the drain valves placed in the pipes
before and after the shut-off valve for starting air, and leave them in this position until maintenance work is
completed.
– Open all indicator cocks on the cylinder covers and leave them in this position until maintenance work is
completed.
– Engage turning gear (gear pinion must be in engaged position) and lock the lever.
– Where the engine has been stopped due to overheated running gear or bearings, wait at least 20 minutes
before opening the crankcase doors.
– The crankcase doors must always be locked with all the closing dogs whenever the engine is run-
ning, even if this is only for a short time in order to make temperature checks (e.g. after changing bearings
during an overhaul, etc.).
– In the case of a fire in the engine having been extinguished by means of CO2, the spaces affected must be
well ventilated before work can be carried out within them.

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0011–1/A1 Maintenance RTA48T

Safety Measures and Warnings

3. Special safety measures

– Prior to turning the crankshaft with the turning gear, make sure that no person is inside the engine and no
loose parts, tools or devices can get jammed. Also bear in mind that the coupled propeller turns too (danger
in surroundings).
– At all times when somebody is inside the engine casing another person must stand by in order that he can
give the necessary aid if something unexpected happens to the person inside the engine. The person who
is inside the engine casing must be equipped with all safety gears which are required to prevent suffocation
within the limited space and atmospheric conditions.
– The allowed load capacity of the engine room crane, the lifting tools, ropes and chains must be sufficient
for the parts to be lifted (see group 0360–1).
– Pay attention to the weight distribution and attachment of the lifting tackle in order that the part which must
be lifted cannot tip over or crash down.
– Sharp edges, mating faces etc. as well as ropes are to be protected by wooden pieces, leather or special
edge guards which are placed between the part and the rope or chain.
– Always wear safety goggles when working with hydraulic tools.
– For your own safety keep away from under hanging loads, never undersling hanging parts with
your fingers or hands and never embrace lifting ropes with your hands.
– For reasons of safety, openings resulting from removed engine components must be closed.
– Removed parts must be secured in the engine room.

Remark For further notes regarding safety precautions and warnings (general remarks) see also Operat-
ing Manual group 0210–1.

4. Recommendations for performing work

– Carry out all work carefully, observing utmost cleanliness!
– For maintenance work on the engine use the tools and devices intended for the particular job, which, as a
rule, are supplied with the engine (refer to the tool list at the end of this manual).
– Tools and devices should be made ready prior to use, make sure they are in perfect condition.
– Calibrate gauge tools before using and at periodical intervals.
– Check hydraulic tools periodically for tightness and perfect functioning.
– Protect running faces and sealing faces of removed parts by suitable means to prevent damages.
– Close all openings which form when certain parts are removed e.g. pipes, oil holes etc. to prevent dirt from
entering the engine. (This includes also the pipes which are removed).
– Check all repaired, overhauled or replaced parts for perfect functioning before starting the engine.
– Check all pipes, which have been removed for tightness after they are refitted.
– Clearances of moving parts must be checked periodically. Should the maximum permissible values (see
clearance and wear table group 0330–1) have been reached or even exceeded, these parts must be re-
placed.
– Arrange to replace all parts taken from spares stock. When ordering new parts refer to Code Book, men-
tion code numbers and description.

7.04 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 0011–1/A1

Safety Measures and Warnings

– When tightening studs, nuts or screws, take the utmost care not to damage their thread. They must be
screwed in by hand until metal to metal contact is achieved. Always use the specified lubricants on the
threads.
– Adhere to tightening values wherever they are indicated. Use the specified lubricant on the threads (see
groups 0352–1 and 0352–2).
– Locking devices of bolts, nuts, etc. must be fitted correctly and secured properly. Use locking plates and
locking wires only once.
– For threads of screws and studs which are getting very hot, (i.e. exhaust pipe or turbocharger fastenings)
apply a high temperature resistant lubricant before assembly, to prevent a heat seizure.
– Used O-rings must always be replaced by new ones when an overhaul of any engine component takes
place; they must conform in dimension and quality to the specifications in the groups 0370–1 and 0370–2.
The fitting of piston seal rings and rod seal rings requires the greatest of care to prevent damage, over
expansion or deformation. Before fitting the rings heat them first in boiling water.

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 RTA48T
Maintenance 0330–1/A1

Clearance Table
Main Bearing and Thrust Bearing

Hauptlager
MAIN BEARING

Zulässige Differenz
a1–a2 = max. 0.3 mm
b1

mit gespannten Denbolzen

a1

a2
ADMISSIBLE DIFFERENCE
a1–a2 = MAX. 0.3 MM
WITH WAISTED STUDS
B

TENSIONED

d1 d d2

i1 i2
b1

c1
b

95.7721

f1
f
f

Clearance Clearance

Nominal normal, new max. due Nominal normal, new max. due
dimension to wear dimension to wear
B = 572 f1 = 0.80–1.30 2.50
– 0.50
b = 572 b1 = 0.35–0.65 0.80 f = 55 – 0.60 i1+i2 = 6

c = 572 c1 = 0.45–0.75 0.90

d = 200 d1+d2 = 20

Wärtsilä Switzerland Ltd 1 1998

0330–1/A1 Maintenance RTA48T

Clearance Table
Crosshead Guide

e
Abgasseite
EXHAUST SIDE

c1
B

C
b
A

c
a
b1

95.7723
d d1

Zum Messen der Spiele siehe Angaben in Gruppe 3326–1.

Das Spiel ’b1’ gilt nur bei angezogenen Zugankern.
FOR MEASURING CLEARANCES SEE INSTRUCTIONS IN GROUP 3326–1.
CLEARANCE ’b1’ IS ONLY VALID WITH TIE RODS TIGHTENED.

Clearance Clearance

Nominal normal, new max. due Nominal normal, new max. due
dimension to wear dimension to wear

+ 0.052
A = 480 C = 270 0

0 –0.03
a = 480 – 0.08 c = 270 –0.06
c1 = 0.03–0.112 0.25

+ 0.25
B = 820 0 d = 462.3–463.3 d1 = 0.6–1.8 2.20

–0.20
b = 820 –0.31 b1 = 0.2 –0.9 1.1 e = 0.2–0.4

2.06 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 0330–1/A1

Clearance Table
Cylinder Liner

A
a1 (a2)
B C
b1 (b2)

approx. 65 – 110 mm
F
f1 (f2)

d1 (d2)
D
e1 (e2)
E

g1 (g2)
G

* Für Zylindereinsatz mit O-Ring Ø 12 mm

00.7643
* FOR CYL. LINER WITH O-RING Ø 12 mm

Clearance Clearance

Nominal normal, new max. due Nominal normal, new max. due
dimension to wear dimension to wear
+ 0.6 + 0.2
A = 730 + 0.4 a1+a2 = 0.7–1.1 F = 597.5 0 f1+f2 = 1.0–1.4

+ 0.65 + 0.2
B = 670 +0.5 b1+b2 = 0.8–1.15 G = 571 0 g1+g2 = 0.65–1.05

C = 480 483.36
+ 0.6
D = 700 + 0.4 d1+d2 = 0.6–1.0 *f1 + f2 = 1.3–1.7

+ 0.6
E = 730 + 0.4 e1+e2 = 0.6–1.0 *g1 + g2 = 1.2–1.6

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0330–1/A1 Maintenance RTA48T

Clearance Table
Cylinder Liner (with Vertical Cooling Groove)

A
a1 (a2)
B C
b1 (b2)

approx. 96 – 150 mm
F
f1 (f2)

d1 (d2)
D
e1 (e2)
E

VERTICAL
COOLING GROOVE

010.934/03

Clearance Clearance

Nominal normal, new max. due Nominal normal, new max. due
dimension to wear dimension to wear
+ 0.6 + 0.2
A = 730 a1+a2 = 0.7–1.1 F = 640 f1+f2 = 1.7–2.1
+ 0.4 0

+ 0.65
B = 670 b1+b2 = 0.8–1.15
+ 0.5

C = 480 483.36
+ 0.6
D = 700 d1+d2 = 0.6–1.0
+ 0.4

+ 0.6
E = 730 e1+e2 = 0.6–1.0
+ 0.4

2003 4 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 0330–1/A1

Clearance Table
Piston Rod Gland

a a1

b1

b
c1
b
d1

d1

c
d1

d1

d1

d1
006.097/99

013.747/06
Ring wear
The differential value between nominal
dimension and max. wear is equal for
all rings, i.e. also for undersize rings.

Clearance Clearance

Nominal normal, new max. due Nominal normal, new max. due
dimension to wear dimension to wear

a = 31 min. = 25 c = 22 min. = 20.20

a1 = 0.10–0.26 0.50 c1 = 0.05–0.16 0.40

b = 31 min. = 25 d=5 min. = 3.20

b1 = 0.10–0.26 0.50 d1 = 0.10–0.17 0.40

Wärtsilä Switzerland Ltd 5 2.06

0330–1/A1 Maintenance RTA48T

Clearance Table
Exhaust Valve

Ventilspindel Luftzylinder
VALVE SPINDLE AIR CYLINDER

Führungsbüchse
GUIDE BUSH

~ 2/3 L
A

LENGTH
Länge
L=
~ 1/3 L

93.7092

Clearance Clearance

Nominal normal, new max. due Nominal normal, new max. due
dimension to wear dimension to wear

– 0.19
a = 48 – 0.23 47.40

+ 0.025
A = 48 0 48.25

+ 0.025
B = 48 0 49.10

+ 0.040
C = 160 0 160.20

7.03 6 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 0330–1/A1

Clearance Table
Top and Bottom End Bearings to Connecting Rod

b1
10 mm
f2 f1

b
B
d2 d1

10 mm
h1 h2

10 mm

m2 m1
A
a
50 mm

n2 n1
a1

g1
g2
93.7072

Clearance Clearance

Nominal normal, new max. due Nominal normal, new max. due
dimension to wear dimension to wear
A = 572 f1+f2 = 0.39–0.53
0
a = 572 – 0.08 a1 = 0.32–0.54 0.70 g1+g2 = 12

B = 480 h1+h2 = 0.40–0.80 1.20

0
b = 480 – 0.08 b1 = 0.25–0.46 0.62 m1+m2 = 0.32–0.49

d1+d2 = 0.25–0.41 n1+n2 = 0.50–0.70

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0330–1/A1 Maintenance RTA48T

Clearance Table
Piston Cooling and Crosshead Lubricating Link

c1 c c2

a1
a

c1 c c2
a1
a

b1 b b2
a1
a

95.7726

Clearance Clearance

Nominal normal, new max. due Nominal normal, new max. due
dimension to wear dimension to wear

a = 48 a1 = 0.025–0.075 0.20 c = 128 c1+c2 = min. 1

b = 128 b1+b2 = min. 2

7.03 8 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 0330–1/A1

Clearance Table
Piston and Piston Rings

a H
b j1
C
c m J
d

k1
B A
m K

40
l 40
e

The ring width at the positions A, B and C is the decisive

criterion for re-fitting of used piston rings. Used piston
rings may be re-fitted if they will keep within their min.
ring width till the next overhaul (for judging and re-using
the piston rings see also group 3425–1)

[mm]
16
lmin
15

Piston ring
width ’I’ 14
l
min N
13

12
480 481 482 483 484 [mm]
Cylinder liner bore ’a’

Clearance Clearance

Nominal normal, new max. due Nominal normal, new max. due
dimension to wear dimension to wear
a = 480 H = 16.5
+0.38
b = 476.2 3.8–4.155 J = 15 +0.33
j1 = 0.33–0.41 0.55

+ 0.33
c = 477 3–3.55 K = 15 + 0.28 k1 = 0.28–0.36 0.50

d = 478.2 1.8–2.155
e = 479.3 0.7–1.055 dmin. = 478.3 l = 16 " 0.25 see diagram
– 0.050 0
g = 182 – 0.096 dmin. = 181.4 m = 15 – 0.03

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0330–1/A1 Maintenance RTA48T

Clearance Table
Wheels for Camshaft Drive

b1 b b2

+0.08
1416 0

2 a1
A
a

95.7727

Clearance Clearance

Nominal normal, new max. due Nominal normal, new max. due
dimension to wear dimension to wear

A = 180 Tooth backlash

normal max.

a = 180 a1 = 0.122–0.207 0.30 1 = 0.24–0.39 0.55

b = 140 b1+b2 = 0.60–1.10 1.50 2 = 0.24–0.39 0.55

3 = 0.33–0.48 0.65

7.03 10 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 0330–1/A1

Clearance Table
Camshaft and Reversing Servomotor

f1

e1
d1

e
d2

a1
b1
b
B

A
a

96.7581

95.7728
c1 c2

Clearance Clearance

Nominal normal, new max. due Nominal normal, new max. due
dimension to wear dimension to wear
A = 180.50 c1+c2 = 0.30–0.54 0.65
a = 180 a1 = 0.544–0.681 d1 = 0.075–0.128 0.25
B = 180 d2 = 0.075–0.128 0.25
b = 180 b1 = 0.100–0.145 0.25 e = 402 e1 = 0.135–0.295
f1 = 0.100–0.200 0.30

Wärtsilä Switzerland Ltd 11 7.03

0330–1/A1 Maintenance RTA48T

Clearance Table
Gearing for Auxiliary Drives

b1
2

a1
a
c1
I
1
I-I

d1

a1 a1
a a
95.7730

Clearance Clearance

Nominal normal, new max. due Nominal normal, new max. due
dimension to wear dimension to wear
a = 50 a1 = 0.11–0.175 0.30

b1 = 0.15–0.20 Tooth backlash

normal max.
c1 = 0.15–0.20 1 = 0.28–0.46 0.65

d1 = 0.50–1 2 = 0.10–0.20 0.35

3 = 0.10–0.20 0.35

7.03 12 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 0330–1/A1

Clearance Table
Gearing for Auxiliary Drives (Driving End)

a1
a
2

b1

95.7731

Clearance Clearance

Nominal normal, new max. due Nominal normal, new max. due
dimension to wear dimension to wear
a = 22 a1 = 0.04–0.094 0.20

b1 = 0.20–0.50 Tooth backlash

normal max.
1 = 0.10–0.19 0.35

2 = 0.10–0.20 0.35

3 = 0.10–0.19 0.35

Wärtsilä Switzerland Ltd 13 7.03

0330–1/A1 Maintenance RTA48T

Clearance Table
Starting Air Distributor

2
a1

b1
a

b
3

95.7732

Clearance Clearance

Nominal normal, new max. due Nominal normal, new max. due
dimension to wear dimension to wear

a = 100 a1 = 0.201–0.271 0.40 1 = 0.35–0.65 0.80

b = 55 b1 = 0.060–0.090 0.15 2 =1

3 = 0.20–0.50

7.03 14 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 0330–1/A1

Clearance Table
Roller Guides for Fuel Injection and Actuator Pumps

a1
a

c1
d1
d2

C
c
d

95.7733

e1 e e2
E

b1 b b2
B

Clearance Clearance

Nominal normal, new max. due Nominal normal, new max. due
dimension to wear dimension to wear

– 0.025 0
a = 42 – 0.050 a1 = 0.025–0.075 0.30 d = 72 – 0.019 d1 = 0.025–0.074 0.10

– 0.22 + 0.055
b = 192 – 0.27 b1+b2 = 0.22–0.316 0.40 D = 72 + 0.025 d2 = 0.010–0.059 0.08

+ 0.046 – 0.45
B = 192 0 e = 96 – 0.75 e1+e2 = 0.35–0.85 1.30

– 0.07 + 0.10
c = 86 – 0.10 c1 = 0.070–0.135 0.17 E = 96 – 0.10

+ 0.035
C = 86 0

Wärtsilä Switzerland Ltd 15 7.03

0330–1/A1 Maintenance RTA48T

Clearance Table
Balancer 2nd Order (Driving End)

Obere Ausgleichswelle
UPPER
COMPENSATING SHAFT
a1 a a2
b1
b

93.7102
2

Untere Ausgleichswelle
LOWER
COMPENSATING SHAFT
a1 a a2
b1

1
b

93.7102
95.7734

Clearance Clearance

Nominal normal, new max. due Nominal normal, new max. due
dimension to wear dimension to wear

– 0.20
a = 152 – 0.30 a1+a2 = 0.60–1.10 1.50

b =135 b1 = 0.087–0.152 0.25 Tooth backlash

normal max.

1 = 0.33–0.48 0.60

2 = 0.24–0.38 0.55

7.03 16 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 0330–1/A1

Clearance Table
ELBA (Electrical Balancer)

98.7315

Clearance Clearance

Nominal normal, new max. due Nominal normal, new max. due
dimension to wear dimension to wear

Tooth backlash
nominal

1 = 0.10–0.26

2 = 0.10–0.25

3 = 0.10–0.26

Wärtsilä Switzerland Ltd 17 u 7.03

This page is intentionally left blank
 RTA48T
Maintenance 0352–1/A1

Tightening Values of Important Screwed Connections

Tightening angle 
Tightening torque

Elongation (mm)
With hydr. jacks
pressure (bar)
group No.

Lubricant
Details in

Description

Thread

(Nm)
1
1112–1 1 Foundation bolts (metal and synthetic M48 1000 MOLYKOTE G
chocks) 1st step 600 bar
2nd step 1000 bar

1132–1 2 Main bearing, nut for waisted stud M42x3 1000 (145) Oil

1715–1 3 Engine stays (friction type) M48 180 Oil

1903–1 4 Tie rod M90x6 1000 MOLYKOTE G

1st step 100 bar
2nd step 600 bar
3rd step 1000 bar

5 Cylinder jacket bolting connection, screw M36 Elongation 0.45±
0.04 mm Oil

5 Cylinder jacket bolting connection, fitted M36 Elongation 0.26±
0.04 mm Oil

screw

2
2708–2 6 Cylinder cover, nut for waisted stud M56 1000 (400) Oil

2722–1 7 Injection valve, screws M12 Tighten spring packs to MOLYKOTE G

block length, then loosen
by 90 

8 Injection valve, retaining nut M52x1.5 30 MOLYKOTE G

(see instructions in group 2722–1)  When using a L’ORANGE test stand:

pre-tighten with 20 bar or hammer blow.
 When using an O.M.T. test bench:
pre-tighten with 100 Nm.
(loosen retaining nut after initial assembly and
then repeat tightening procedure)

2728–1 9 Starting valve spindle, nut M18x1.5 (130) 50 MOLYKOTE G

(spindle thread not to be lubricated in the region of
locking ring)

10 Starting valve, nut for waisted stud M16 (160) 130 MOLYKOTE G

When using other jacks, the required pressure in bar must be calculated in relation to the effective jack piston surface!
Conversion factor: 1 Nm = 0.102 mkp 1 bar = 1.02 kp/cm2

 The numbers in refer to the illustrations on pages 6 to 8.

 The values in parentheses (...) are for information only, to be used for comparison.
 The screwed connections must be tightened in accordance with the values not in parentheses.

Wärtsilä Switzerland Ltd 1 3.00

0352–1/A1 Maintenance RTA48T

Tightening Values of Important Screwed Connections

Tightening angle 
Tightening torque

Elongation (mm)
With hydr. jacks
pressure (bar)
group No.

Lubricant
Details in

Description

Thread

(Nm)
2751–1 11 Exhaust valve cage, nut for waisted stud M56 1000 (150) Oil

2751–2 12 Exhaust valve, screw for grooved valve M10 40 MOLYKOTE G

cone piece

13 Exhaust valve, screw for cylinder M10 35 MOLYKOTE G

14 Indicator valve, screw M20 80 MOLYKOTE G

3 15 Coupling bolt for flywheel M56 15 MOLYKOTE G

16 Coupling bolt for propeller shaft M76x4 40 MOLYKOTE G

3130–1 17 Coupling bolts, crankshaft – vibration M76x4 30 MOLYKOTE G

damper

18 Coupling bolts, crankshaft – M76x4 30 MOLYKOTE G

counterweight

3146–1 19 Fixing bolt for axial detuner with bedplate M24 (630) 45 MOLYKOTE G

3303–1 20 Connecting rod, stud for top end bearing M42 1000 Oil
1st step 600 bar (gap = 0)
2nd step 1000 bar

Check: 1st step to 2nd step (25)

21 Connecting rod, stud for bottom end M52 1000 Oil

bearing 1st step 300 bar (gap = 0)
2nd step 1000 bar

Check: 1st step to 2nd step (60)

3403–1 22 Piston rod, waisted stud for crosshead M30 1000 (55) Oil
fastening 1st step 600 bar
2nd step 1000 bar

3403–3 23 Piston rod, waisted screw for piston M24x2 (250) 75 MOLYKOTE G
crown

24 Spraying plate, piston rod M10 25 no additional lu-

pre-tighten with 10 Nm bricant required

When using other jacks, the required pressure in bar must be calculated in relation to the effective jack piston surface!
Conversion factor: 1 Nm = 0.102 mkp 1 bar = 1.02 kp/cm2

 The numbers in refer to the illustrations on pages 6 to 8.

 The values in parentheses (...) are for information only, to be used for comparison.
 The screwed connections must be tightened in accordance with the values not in parentheses.

3.00 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 0352–1/A1

Tightening Values of Important Screwed Connections

Tightening angle 
Tightening torque

Elongation (mm)
With hydr. jacks
pressure (bar)
group No.

Lubricant
Details in

Description

Thread

(Nm)
4
4103–2 25 Intermediate gear bearing for camshaft M36 40 MOLYKOTE G
drive, waisted screw

26 Screwed connection, gear rim – hub of M24x2 (800) 70 no additional lu-
intermediate wheel bricant required

(nut secured with LOCTITE No. 262)

4103–3 27 Gear wheel on crankshaft, nuts to M24x2 (800) 65 see details in
flanged connection group 4103–3

(secured with LOCTITE No. 262)

28 Two-part gear wheel on crankshaft, M30x2 Elongation 1.20±
0.06 see details in

waisted stud (spare wheel) mm group 4103–3

4203–1 29 Camshaft, screw for flange coupling M20 30 no additional lu-
bricant required
(5 and 7 cylinders)

30 Reversing servomotor, longitudinal M16 30 no additional lu-

fastening bricant required

31 Reversing servomotor, fastening M27 70 no additional lu-

between shaft and wing bricant required

32 Vibration damper – camshaft coupling M24 40 no additional lu-

bricant required

33 Waisted stud for injection pump housing, M45 1000 (60) Oil
bearing cover for camshaft bearing

4203–5 Two-part gear wheel on camshaft, M24x2 (800) 70 no additional lu-
34
screwed connection gear rim – hub bricant required

(nut secured with LOCTITE No. 262)

Waisted stud for bearing cover, camshaft M42 1000 (75) no additional lu-
35
drive bricant required

5 36 Waisted stud for injection pump housing M39 30 Oil

– cylinder jacket

37 Hexagon nut for injection pump housing M39 45 Oil

– cylinder jacket

When using other jacks, the required pressure in bar must be calculated in relation to the effective jack piston surface!
Conversion factor: 1 Nm = 0.102 mkp 1 bar = 1.02 kp/cm2

 The numbers in refer to the illustrations on pages 6 to 8.

 The values in parentheses (...) are for information only, to be used for comparison.
 The screwed connections must be tightened in accordance with the values not in parentheses.

Wärtsilä Switzerland Ltd 3 3.00

0352–1/A1 Maintenance RTA48T

Tightening Values of Important Screwed Connections

Tightening angle 
Tightening torque

Elongation (mm)
With hydr. jacks
pressure (bar)
group No.

Lubricant
Details in

Description

Thread

(Nm)
38 Hexagon nut for injection pump housing M45 40 Oil
– cylinder jacket
(loosen waisted studs and nuts after initial assem-
bly and then repeat tightening procedure of items
36 37 38 )

5512–1 39 Injection pump block, hexagon nut for M27 90 no additional lu-
bricant required
waisted stud

40 Injection pump block, pressure bush for M45x1.5 30 MOLYKOTE G

valves
(loosen pressure bush after initial assembly and
then repeat tightening procedure)

41 Injection pump block, screwed M12 60 MOLYKOTE G

connection for valve cover

5512–4 42 Nipple for plunger bush M10 40 MOLYKOTE G

5513–1 43 Actuator pump, hexagon nut for waisted M20 60 no additional lu-
stud bricant required

7
7722–1 44 Compensating shaft of integrated M27 45 MOLYKOTE G
balancer, waisted stud and screw for
bearing fastening

7734–1 45 Screwed connection column – housing M24 85 MOLYKOTE G

of electrical balancer

46 Shaft to compensating shaft (engine M16 (200) 30 no additional lu-

side) bricant required

(screws secured with LOCTITE No. 262)

47 Screws for annular spring of the M8 65 Oil

compensating shaft, outside

48 Screwed connection counterweight – M12 45 MOLYKOTE G

gear wheel

When using other jacks, the required pressure in bar must be calculated in relation to the effective jack piston surface!
Conversion factor: 1 Nm = 0.102 mkp 1 bar = 1.02 kp/cm2

 The numbers in refer to the illustrations on pages 6 to 8.

 The values in parentheses (...) are for information only, to be used for comparison.
 The screwed connections must be tightened in accordance with the values not in parentheses.

10.08 4 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 0352–1/A1

Tightening Values of Important Screwed Connections

Tightening angle 
Tightening torque

Elongation (mm)
With hydr. jacks
pressure (bar)
group No.

Lubricant
Details in

Description

Thread

(Nm)
8
8733–1 49 Cap nut for screwed connection of fuel M30x2 180 Oil
pressure piping, injection pump – fuel
distributor
(see instructions in group 8733–1)

50 Cap nut for screwed connection of fuel M27x2 140 Oil

pressure piping, fuel distributor –
injection valve
(see instructions in group 8733–1)

9314 51 Clamping nut to oil mist detector G ¾” 15 Oil

52 Screws for opening head of oil mist 5 Oil

detector
Tools
53 Lifting gear, tool 94202, screw M24 30 no additional lu-
bricant required
(see instructions in 2124–2)

54 Special screw, tool 94207 M48 30 no additional lu-

bricant required
(see instructions in 2124–2)

When using other jacks, the required pressure in bar must be calculated in relation to the effective jack piston surface!
Conversion factor: 1 Nm = 0.102 mkp 1 bar = 1.02 kp/cm2

 The numbers in refer to the illustrations on pages 6 to 8.

 The values in parentheses (...) are for information only, to be used for comparison.
 The screwed connections must be tightened in accordance with the values not in parentheses.

Wärtsilä Switzerland Ltd 5 2.06

0352–1/A1 Maintenance RTA48T

Tightening Values of Important Screwed Connections

Motorabstützung (mit Reibbelägen)

3
ENGINE STAY (FRICTION TYPE)

13

Aufhängetraverse
12
14 LIFTING GEAR
53
11
10 54
7
9
013.758/06
8

50 6

49 24

23 4

5
52
51

Lagergehäuse für 22 20
Steuerwellenantrieb
BEARING HOUSING
FOR CAMSHAFT DRIVE
I
21
I-I

I
013.757/06
35

2.06 6 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 0352–1/A1

Tightening Values of Important Screwed Connections

Integrierter Massenausgleich
ELBA
INTEGRATED BALANCER

45

47

44 46

48

34

26

25

26

25
2
27 18

17

19

28 16 15
99.7707

Wärtsilä Switzerland Ltd 7 2000

0352–1/A1 Maintenance RTA48T

Tightening Values of Important Screwed Connections

41

40

39
42

43

37 36

32

38

98.7595

29
Umsteuerservomotor
REVERSING SERVOMOTOR

30 31

33

2000 8 u Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 0352–2/A1

Tightening Values of Standard Screwed Connections

This table is valid for all screws that are not considered in group 0352–1.

Attention These tightening instructions are valid only if:

a) the screws are made of the 8.8 material.
b) the threads have been lubricated with oil.

Remark It is recommended to lubricate the threads for screws which come into contact with ’hot parts’ like
exhaust pipings, expansion pieces, etc. with a heat-resisting lubricant, e.g. THREAD GARD or
Never-Seez NSBT-8, etc.

Standard thread Fine thread Tightening torque [Nm]

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

Wärtsilä Switzerland Ltd 1 1998

0352–2/A1 Maintenance RTA48T

Tightening Values of Standard Screwed Connections

Waisted studs must be tightened according to the values in the following diagram:
D Before fitting a waisted stud clean and degrease the stud thread and the tap hole. The sealing faces must be
degreased (e.g. using white spirit) and subsequently primed.
D Screw in the waisted stud without lubricant on the thread right to the bottom of the tap hole, and tighten. Always
utilize a stud driver or two nuts.

Attention Tools like a pipe wrench etc. which would damage the stud shank must never be used.

D For the protection of the waisted stud in the cylinder block and cylinder cover, fill the annular space above the
thread with a non-hardening jointing compound (see group 2751–1).

TIGHTENING TORQUE
FOR WAISTED STUDS

3500

3000 400
TIGHTENING TORQUE

2500
300
2000
[Nm]

1500 200

1000
100
500

0 001.769/97 0
10 20 30 40 50 60 70 80 90 100 110 120 10 20 30 40 50 60

THREAD DIAMETER
[mm]

1998 2 u Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 0360–1/A1

Masses (Weights)
Individual Components per Piece in kg

Design Component kg
Group
1134 Main bearing shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1137 Main bearing cover (normal bearing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

1224 Thrust bearing pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

1717 Casing (free end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 742

1903 Tie rod complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363

1903 Tie rod nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1903 Intermediate ring for tie rod nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2106 Waisted stud in cylinder jacket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2120 Supporting ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050

2124 Cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1900

2130 Water guide jacket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

2303 Piston rod gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

2708 Waisted stud for valve cage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2708 Cylinder cover without accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 821
2708 Cylinder cover complete with valves and water guide jacket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500

2722 Injection valve complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2728 Starting valve complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2740 Relief valve complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5

2751 Exhaust valve complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446

2754 Exhaust valve spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3122 Flywheel (light) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1506–1612

Flywheel (heavy) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3381–9544

Balance weight on crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193–419

3140 Axial detuner, cylinder (2-part) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400

3303 Connecting rod complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1094

3303 Waisted stud with nut for bottom end bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3303 Waisted stud with nut for top end bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3306 Connecting rod shank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 767
3309 Lower bearing half for bottom end bearing with waisted stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
3310 Bearing shell for bottom end bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3312 Upper bearing half for top end bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
3315 Bearing shell for top end bearing (crosshead) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3326 Crosshead without guide shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 653

3326 Crosshead complete with guide shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1015
3326 Guide shoe complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

3403 Working piston complete with piston rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 836

3406 Piston crown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
3409 Piston skirt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3415 Piston rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 524

3603 Toggle lever to piston cooling and crosshead lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Wärtsilä Switzerland Ltd 1 7.03

0360–1/A1 Maintenance RTA48T

Individual Components per Piece in kg

4106 Gear wheel on crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 547

4106 Gear wheel (2-part) on crankshaft complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 894
4108 Intermediate gear wheel complete with bearing pins and bearings for camshaft drive . . . . . . . . . . . 855
4108 Intermediate wheel bearing to camshaft drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4112 Gear wheel (2-part) complete with shaft on camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010
4112 Gear wheel (2-part) complete with shaft on camshaft and bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . 1116

4206 Cam to fuel injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

4210 Cam to exhaust valve actuator pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Camshaft section complete without couplings (5 + 7 cylinders) . . . . . . . . . . . . . . . . . . . . . . . . . . . 476–660
Camshaft section complete without couplings (6 + 8 cylinders) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 662
SKF shaft coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Flange coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

4215 Vibration damper for camshaft according to design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320–530

Balance disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

5103 WOODWARD governor (PGA-200) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

5512 Bearing cover for fuel pump housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5522 Plunger and guide bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

5524 Fuel pump body complete without plunger and guide bush (2 cylinders) . . . . . . . . . . . . . . . . . . . . . . . 341
Fuel pump body complete without plunger and guide bush (1 cylinder) . . . . . . . . . . . . . . . . . . . . . . . . 230

5536 Trough for fuel pump housing (2 cylinders) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

5537 Trough for fuel pump housing (1 cylinder) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

6506 Exhaust gas turbocharger VTR 564 D (complete) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6’900

Exhaust gas turbocharger VTR 454 D (complete) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3’600

6545 Auxiliary blower complete with electric motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475–520

Electric motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135–180

6606 Scavenge air cooler GEA 120/30/24/6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2600

Scavenge air cooler GEA 150/38/24/6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3700

6708 Water separator after scavenge air cooler (turbocharger VTR 564) . . . . . . . . . . . . . . . . . . . . . . . . . 38–43
Water separator after scavenge air cooler (turbocharger VTR 454) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

7722 Balancer (driving end)

Compensating shaft with bearing (5 cylinders) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530
Compensating shaft with bearing (6 cylinders) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410

8103 Fixed support complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807

8139 Expansion piece DN250 after exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

8140 Expansion piece DN350 before exhaust turbocharger VTR 454 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Expansion piece DN350 before exhaust turbocharger VTR 564 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

7.03 2 u Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 0370–1/A1

Dimensions and Material Specification of O-rings and Round Rubber Rings

Thickness mm
Material specification
Design group

Inner Ø mm
NBR = Nitrile
Place of application of O-rings FPM = Viton
MVQ = Silicon

1903 Tie rod 5.33 81.92 FPM 70 Sh

Cylinder liner
2124 Cylinder liner – supporting ring (with vertical cooling groove) 9 600 FPM 77 Sh
Cylinder liner – cylinder jacket (groove hight of 15 mm) 12 540 FPM 77 Sh
Cylinder liner – supporting ring (groove hight of 15 mm) 12 565 FPM 77 Sh
Cylinder liner – water guide jacket 7 685 MVQ 50 Sh
Cylinder liner – water guide jacket 7 660 MVQ 50 Sh

2136 Lubricating quill 3.53 36.09 FPM 70 Sh

Non-return valve – cylinder liner 2.62 15.88 FPM 70 Sh
2303 Piston rod gland – housing 6.99 329.57 FPM 70 Sh

Cylinder cover
2708 Cylinder cover – water guide jacket 7 685 MVQ 50 Sh
Cylinder cover – water guide jacket 7 630 MVQ 50 Sh
2722 Injection valve – spring tensioner 1.78 28.30 FPM 70 Sh

Starting valve
2728 Starting valve 5.33 69.22 FPM 70 Sh
Starting valve 1.78 14 FPM 70 Sh
Starting valve 1.78 10.82 FPM 70 Sh
2740 Relief valve for cylinder cover 5.33 40.64 FPM 70 Sh

Exhaust valve
2751 Valve cage – cylinder cover 6.99 367.67 FPM 90 Sh
Valve seat – cylinder cover 6.99 316.87 FPM 90 Sh
Valve cage – guide bush 5.33 69.22 FPM 70 Sh
Valve cage – air cylinder housing 6.99 170.82 FPM 70 Sh
Valve cage – valve drive 6.99 215.27 FPM 70 Sh
Valve cage – valve seat 6.99 227.97 FPM 90 Sh
Piston – valve spindle 5.33 46.99 FPM 70 Sh
Lubricating oil connection valve cage – valve drive 3.53 21.82 FPM 70 Sh
Valve drive – vent screw 2.62 13.94 NBR 70 Sh
Valve drive – damper 5.33 78.74 NBR 70 Sh

Vibration damper
3130 Intermediate flange for damper 9 625 NBR 65 Sh

Piston
3403 Piston – oil pipe 5.33 75.57 FPM 70 Sh
Piston – spraying plate 6.99 291.47 FPM 70 Sh
Piston – spraying plate 6.99 278.77 FPM 70 Sh

Camshaft
4203 Camshaft – oil connection for trough 3.53 28.17 NBR 70 Sh
Camshaft – oil connection for slide ring 3.53 23.39 NBR 70 Sh
Camshaft – sleeve 6.99 354.97 NBR 70 Sh

Wärtsilä Switzerland Ltd 1 2.06

0370–1/A1 Maintenance RTA48T

Dimensions and Material Specification of O-rings and Round Rubber Rings

Thickness mm
Material specification
Design group

Inner Ø mm
NBR = Nitrile
Place of application of O-rings FPM = Viton
MVQ = Silicon

Auxiliary drives
4240 Cover for auxiliary drives 2.62 15.54 NBR 70 Sh

Starting air distributor

4303 Housing – flange 5.33 40.64 NBR 70 Sh
Guide flange – cylinder 5.33 88.27 NBR 70 Sh
Housing – Intermediate piece 6.99 177.17 NBR 70 Sh
Solenoid valve 1.78 14 NBR 70 Sh
Valve plate – Solenoid valve 3.53 28.17 NBR 70 Sh

Starting air shut-off valve

4325 Bush for starting air housing – cover 6.99 148.59 FPM 70 Sh
Shut-off valve guide – housing 6.99 170.82 FPM 70 Sh
Shut-off valve guide – starting air pipe 6.99 170.82 FPM 70 Sh
Control valve – cover 3.53 44.04 NBR 70 Sh
Control valve – housing 2.62 13.94 NBR 70 Sh
Shut-off valve – distributing pipe 6.99 145.42 NBR 70 Sh
4503 Reversing valve 5.33 110.49 NBR 70 Sh

4605 Control air supply unit 2.4 20.3 NBR 70 Sh

4614 Valve group B for governor and air cylinder 2.62 4.42 NBR 70 Sh

4628 Pick-up 5.33 88.27 NBR 70 Sh

Pneumatic logic unit

4630 Pneumatic logic unit 2 12 NBR 65 Sh
Pneumatic logic unit 2.62 4.42 NBR 70 Sh
Pneumatic logic unit 1.78 6.86 NBR 70 Sh
4807 Valve group E in pneumatic logic unit 2 12 NBR 65 Sh

Safety cut-out device 3.53 63.09 MVQ 50 Sh

5307 Safety cut-out device – casing
Safety cut-out device – valve plate 4.42 2.62 FPM 70 Sh
Safety cut-out device – cover / tie rod 1.78 9.25 NBR 70 Sh

Fuel injection pump

5512 Pump housing – trough 5 360 NBR 45 Sh
Trough – O-ring 5.33 221.84 NBR 70 Sh
Pump housing – actuator housing 5.33 183.52 NBR 70 Sh
Pump housing – roller guide of actuator pump 5.33 50.17 NBR 70 Sh
Safety cut-out device for fuel injection pump 5.33 50.17 NBR 70 Sh
Safety cut-out device for fuel injection pump 5.33 32.92 NBR 70 Sh
5520 Excentric shaft for fuel pump 5.33 40.64 NBR 70 Sh

5524 Relief valve for fuel pump 3.53 66.27 FPM 90 Sh

5807 Regulating linkage – air cylinder, cover, intermediate piece 3.53 72.62 MVQ 50 Sh

1998 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 0370–1/A1

Dimensions and Material Specification of O-rings and Round Rubber Rings

Thickness mm
Material specification
Design group

Inner Ø mm
NBR = Nitrile
Place of application of O-rings FPM = Viton
MVQ = Silicon

6420 Relief valve type 224 EVT at the charge air receiver 8 210 NBR 70 Sh

8310 Cylinder cooling water outlet main – throttling orifice 5.33 120.02 NBR 70 Sh

8426 Oil pipe after reversing servomotor – connection to trough 3.53 34.52 NBR 70 Sh

8460 Hydraulic piping for exhaust valve 5.33 85.09 NBR 70 Sh

8704 Fuel pressure retaining valve 2.62 18.72 NBR 70 Sh

Fuel oil system

8705 Fuel cock, valve spindle – spindle guide 3.53 29.74 FPM 75 Sh
Fuel cock, valve housing – spindle guide 3.53 37.69 FPM 75 Sh
Fuel pump block – suction piping 3.53 37.69 FPM 75 Sh
Fuel pump block – spill piping 3.53 37.69 FPM 75 Sh
Fuel shut-off cock – suction piping 5.34 40.65 FPM 75 Sh
Fuel shut-off cock – spill piping 5.34 40.65 FPM 75 Sh

8733 Priming valve at the fuel distributor 1.78 9.25 NBR 70 Sh

Priming valve at the fuel distributor 3.53 21.82 NBR 70 Sh
Measuring instruments
9258 Pressure switch and transmitter 1.78 6.07 NBR 70 Sh

9314 Oil mist detector

Connection piece – column plate 3.53 40.87 NBR 70 Sh

Tools
Tool 94349 Pressure testing device for working piston 6.99 177.17 NBR 70 Sh
Tool 94430 Device for cutting out an exhaust valve actuator 5.33 32.92 NBR 70 Sh

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 RTA48T
Maintenance 0370–2/A1

Dimensions and Material Specification of Piston and Rod Seal Rings

PTF / MoS2 / Glass

Carbon / Graphit

70 ± 5 Shore A

70 ± 5 Shore A
Fluorelastomer
Design group

PTF / Bronze
Designation

Nitrile NBR
Viton FPM
Place of application of Piston Seal Rings (PSR) Nominal dimension

FKM 75
or of Rod Seal Rings (RSR) (Order dimension)

4303 Starting air distributor – piston PSR 100 x 95 x 3.8 x x

Starting air distributor – guide flange RSR 75 x 79 x 3.8 x x
Starting air distributor – cylinder RSR 75 x 79 x 3.8 x x

4325 Shut-off valve for starting air – valve PSR 160 x 155 x 3.8 x x
Shut-off valve for starting air – spindle RSR 30 x 33 x 2.8 x x

4503 Reversing valve – slide valve PSR 100 x 95 x 3.8 x x

Reversing valve – cover RSR 30 x 33 x 2.8 x x

5307 Safety cut-out device – piston PSR 80 x 76 x 3.8 x x

Safety cut-out device – casing RSR 28 x 31 x 2.8 x x

5807 Regulating linkage, air cylinder – piston PSR 80 x 76 x 3.8 x x

Regulating linkage, air cylinder – cover RSR 45 x 48 x 2.8 x x
Regulating linkage, air cylinder – intermediate RSR 28 x 31 x 2.8 x x
piece

9403 Tool 94424 PSR 60 x 56 x 3.8 x x

Hydr. jacking tool for camshaft RSR 32 x 35 x 2.8 x x

Piston Seal Ring (PSR) Rod Seal Ring (RSR)

(Nominal dimension da x di x b) (Nominal dimension di x da x b)

Cylinder Bush
O-ring
Seal ring
Seal ring b

O-ring
b

Piston Rod

di da di da

Wärtsilä Switzerland Ltd 1 7.03

0370–2/A1 Maintenance RTA48T

Dimensions and Material Specification of Piston and Rod Seal Rings

Seal ring O-ring

PTF / MoS2 / Glass

Carbon / fiber T40

70 ± 5 Shore A

70 ± 5 Shore A
Design group

PTF / Bronze
Designation

Nitrile NBR
Viton FPM
Turcon 46
Place of application of Piston Seal Rings (PSR) Nominal dimension
or of Rod Seal Rings (RSR) (Order dimension)

2751 Exhaust valve – piston for air cylinder PSR 160 x 139 x 7.8 x x
Exhaust valve – valve guide RSR 63.1 x 48 x 6.1 x x

Piston Seal Ring (PSR) Rod Seal Ring (RSR)

(Nominal dimension da x di x b) (Nominal dimension da x di x b)

Cylinder Bush
O-ring

b Seal ring
Seal ring
O-ring
b

Piston Rod di da
di da 00.7384

da = Cylinder diameter da = Groove diameter

di = Groove diameter di = Rod diameter
b = Groove width b = Groove width

7.03 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 0370–2/A1

Dimensions and Material Specification of Supporting Rings

Supporting ring O-ring

(slotted)
Material: Material:
Turcon 46 (PTB) NBR 90

Outside Ø (A)

Thickness (T)
Inner Ø (B)

Thickness
Tool No.

Inner Ø
Place of application of pre-tensioning jack

94114 Waisted studs to main bearing piston 77.6 x 87 x 1.7 5.33 x 75.57
cylinder 58 x 67.4 x 1.7 5.33 x 56.52

94145 Foundation bolts and engine stays piston 90. 6x 100 x 1.7 5.33 x 88.27
cylinder 73 x 82.4 x 1.7 5.33 x 72.39

94180 Tie rods piston 182.8 x 195 x 2.5 6.99 x 183.52

cylinder 148.2 x 136 x 2.5 6.99 x 135.89

94215a Cylinder cover studs piston 120.6 x 130 x 2.5 5.33 x 120.02
cylinder 73 x 82.4 x 1.7 5.33 x 72.39

94252 Waisted studs to exhaust valve piston 137.8 x 150 x 2.5 6.99 x 135.89
cylinder 85 x 94.4 x 1.7 5.33 x 85.09

94314 Waisted bolts to bottom end bearing piston 115.6 x 125 x 1.7 5.33 x 113.67
cylinder 80 x 89.4 x 1.7 5.33 x 78.74

94315 Waisted studs to crosshead bearing and piston 90.6 x 100 x 1.7 5.33 x 91.44
camshaft bearing housing cylinder 65 x 74.4 x 1.7 5.33 x 66.04

94340 Waisted studs of piston rod – screw connection piston 60.6 x 70 x 1.7 5.33 x 59.69
cylinder 45 x 54.4 x 1.7 5.33 x 43.82

94415 Waisted studs of camshaft bearing piston 98.6 x 108 x 1.7 5.33 x 97.79
cylinder 73 x 82.4 x 1.7 5.33 x 72.39

O-ring Supporting ring T

ØB
ØA
ØB
ØA

98.7510

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 RTA48T
Maintenance 0380–1/A1

Maintenance Schedule
Inspection and Overhaul Intervals (Guidelines)

Group Component Work to be carried out Intervals

0
0900–1 Lubricating oil – Laboratory analysis 3000 Op. h (operating
hours)

Cooling water – Check concentration of inhibitor

(as per supplier’s instructions)
1
1112–1 Bedplate – Check pre-tension of foundation bolts, 12 000 Op. h
first time after 1500 Op. h

Crankcase – Visual examination 1500–3000 Op. h

1132–2 Main bearing – Remove bearing upper half for inspection according to
classification society

– Remove bottom bearing shell for inspection acc. to class. society

1203–1 Thrust bearing – Check axial and radial clearances 6000–8000 Op. h

– Check bottom drain for free passage 6000–8000 Op. h

1224–1 – Remove thrust bearing pads for inspection acc. to class. society

1715–1 Engine stays with – Check pre-tension of waisted studs, 6000–8000 Op. h
friction shims first time after sea trial

1715–1 Hydraulic engine – Check oil pressure in hydraulic cylinder, 6000–8000 Op. h
stays first time after sea trial
(if necessary correct pressure)

1903–1 Tie rod – Check pre-tension, first time after one year 24 000–30 000 Op. h
(if necessary re-tension)
2
2124–1 Cylinder liner – Establish wear in bore (in fitted condition) at every piston removal

2124–2 – Remove cylinder liner as required

– Replace O-rings at every removal

– Replace (soft iron) joint ring between cylinder liner at every piston removal
and cylinder cover

– Water guide jacket, replace O-rings at every piston removal

– Check condition of antipolishing ring (if fitted) at every piston removal

2124–3 – Grind off wear ridge in bore at every piston removal

– Clean scavenge ports and refinish their edges as required

– Refinish lubricating grooves as required

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0380–1/A1 Maintenance RTA48T

Inspection and Overhaul Intervals (Guidelines)

Group Component Work to be carried out Intervals

2136–1 Lubricating quill – Check function and tightness at every piston removal
and accumulator
– Check function of non-return valves at every liner removal

– Replace O-rings at every liner removal

– Check diaphragm of accumulator at every piston removal

2303–1 Piston rod gland – Clean rings, establish wear at every piston removal

2708–1 Cylinder cover – Check combustion space for damage at every piston removal

2722–1 Injection valve – Check externally for tightness before starting engine
after a longer standstill

– Check spray pressure, tightness and condition of 3000 Op. h

nozzle tip (life time about 6000 Op. h)

2728–1 Starting valve – Check piping before the valve during operation, from time to time
if piping is too hot dismantle starting valve

– Remove and dismantle one starting valve at 6000–8000 Op. h

random. From its condition determine time of
overhaul for remaining valves

2740–1 Relief valve to – Check, dismantle, assemble and set 18 000 Op. h
cylinder cover

2751–1 Exhaust valve – General inspection of valve housing, valve at every piston removal
to spindle and valve seat
(without dismantling of exhaust valve)

2751–4 – Valve spindle, check condition and wear 24 000–36 000 Op. h
(if necessary regrind seat by machining)

– Check piston seal ring / air spring & rod seal ring / 24 000–36 000 Op. h
guide bush

– Valve seat, check condition and wear 24 000–36 000 Op. h

(if necessary regrind seat by machining)
3
3103–1 Crankshaft – Measure crank deflection 6000–8000 Op. h
(always in case of grounding of the ship as well as
before and after every docking)

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

3130–2 – Inspection interval and dismantling of acc. to instructions of

GEISLINGER damper damper manufacturer

3146–1 Axial damper – Dismantling and inspection 36 000–48 000 Op. h

Turning gear – Inspection interval acc. to instructions of

turn. gear manufacturer

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 RTA48T
Maintenance 0380–1/A1

Inspection and Overhaul Intervals (Guidelines)

Group Component Work to be carried out Intervals

0330–1 Connecting rod – Check bearing clearances 6000–8000 Op. h

bearings

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

(life time of shell 60 000–72 000 Op. h) acc. to class. society

3303–3 – Inspect top end bearing 30 000–36 000 Op. h or

acc. to class. society

3326–1 Guide shoe, – Check clearances 6000–8000 Op. h

Crosshead pin

3326–2 – Remove crosshead as required

3403–1 Piston – Remove, clean and measure ring grooves 18 000–20 000 Op. h
(cylinder liner with antipolishing ring and chrome-
ceramic uppermost piston ring)

– Remove, clean and measure ring grooves 12 000–14 000 Op. h

(cylinder liner without antipolishing ring)

– Check tightness on piston in situ and with running after refitting

oil pump, visual check through scavenge ports

3403–3 – Dismantling and assembling (open cooling space as required

& clean same, min. one piston every three years)

3403–4 – Check condition of the piston top surface at every piston removal

– Visual check through scavenge ports to piston, 1500–3000 Op. h

piston rings and cylinder liner
(rotate crankshaft with turning gear)

Piston underside – Check condition of space and clean it as required 1500–3000 Op. h

– Check drains for free passage 1500–3000 Op. h

3425–1 Piston rings – Remove, clean and establish wear rate, at every piston removal
if necessary fit new rings

– Replace uppermost piston ring 18 000–20 000 Op. h

4
4103–1 Camshaft driving – Check condition of teeth 6000–8000 Op. h
wheels

– Check running clearance and backlash of teeth 6000–8000 Op. h

Camshaft bearing – Visual examination of camshaft housing 1500–3000 Op. h

Fuel cam – Check running surface 1500–3000 Op. h

Actuator cam – Check running surface 1500–3000 Op. h

Roller to injection – Check running surface 1500–3000 Op. h

& actuator pump

4303–1 Starting air – Dismantle, clean and inspect pilot valves for ease 24 000–36 000 Op. h
distributor of movement

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0380–1/A1 Maintenance RTA48T

Inspection and Overhaul Intervals (Guidelines)

Group Component Work to be carried out Intervals

4325–1 Starting air – Vent after each manoeuvring

shut-off valve period

– Dismantle, clean and check 24 000–36 000 Op. h

(particularly seat, springs and seal rings)

4506–1 Rotation direc- – Dismantle, clean and establish wear, 24 000–36 000 Op. h
tion safeguard functional check

5
5103–1 WOODWARD – Check oil level daily
governor
– Oil change (rinse housing) 3000 Op. h

5307–1 Safety cut-out – Dismantle, clean, inspect 24 000–36 000 Op. h

device (if necessary replace sealing and O-rings)

– Functional check 6000–8000 Op. h

5512–1 Injection pump – Clean, remove valves and inspect 12 000–18 000 Op. h

– Check controls, if necessary re-set 12 000–18 000 Op. h

5512–2 – Lap sealing faces of valve covers as required

5512–3 – Check relief valves and set them 24 000–36 000 Op. h

– Check drain bore for relief valve in injection pump 1500 Op. h
block for leakage during operation as well as for
free passage and for indication of a possible
discharge

5512–4 – Lap sealing face of guide bush and tighten it as required

– Check at random plungers and bushes 24 000–36 000 Op. h

– Check sealing face between injection pump block 1500 Op. h

and plunger bush (check bore) for leakage during
operation

5513–1 Actuator pump – Dismantle and check one actuator pump 24 000–36 000 Op. h

5520–1 Regulating – Lubricate spherical connections with MOLYKOTE weekly

linkage of paste G
injection pump

– Check spring link for free movement on eccentric monthly

shaft

– Check wear of spherical bearings monthly

6
6420–1 Scavenge air – Check and clean air flaps 4000–6000 Op. h
receiver

– Clean receiver 4000–6000 Op. h

– Check water drain piping for free passage 1500–3000 Op. h

7.03 4 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 0380–1/A1

Inspection and Overhaul Intervals (Guidelines)

Group Component Work to be carried out Intervals

Exhaust gas – Wash-cleaning of blower in service (see Operating Manual)

turbocharger

– Wash-cleaning of turbine in service (see Operating Manual)

– Dry cleaning of turbine in service (see Operating Manual)

– Air filter cleaning (p max. 10 mbar) as required

6545–1 Auxiliary blower – Clean impeller and casing 24 000–36 000 Op. h

– Replace ball bearing 24 000–36 000 Op. h

Scavenge air – Cleaning of scavenge air cooler (air side) in as required

cooler service at the beginning weekly, later if p
(pressure drop through SAC) reaches 50 mbar
(for further instructions see Operating Manual)

6606–1 – Cleaning (water side) on engine at standstill as required

6606–2 – Remove cooler for general overhaul as required

– Check drains for free passage 1500–3000 Op. h

6708–1 Water separator – Check the permanent drainage daily

(outlet either air or a mixture of air/water)

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

clean them), check drains for free passage

7
Cylinder – Drain and wash out casing, 18 000–24 000 Op. h
lubricating pump first time after 1000 Op. h according to instruction
of pump manufacturer

7722–1 Integrated – Check the condition of teeth 6000–8000 Op. h

balancer
(driving end)

0330–1 – Measure backlash of teeth and bearing clearance 6000–8000 Op. h

of the balancer

7734–1 ELBA – Check condition of gear wheels 6000–8000 Op. h

(el. balancer) – Check oil flow to spray nozzles 6000–8000 Op. h

– Check tightening of screws to compensating shaft 3000 Op. h

fastening

– Check tightening of screws ELBA – eng. column 3000 Op. h

– Check tightening of cover fastening to annular 1500 Op. h

spring packs

– Noise check 1500 Op. h

Wärtsilä Switzerland Ltd 5 7.03

0380–1/A1 Maintenance RTA48T

Inspection and Overhaul Intervals (Guidelines)

Group Component Work to be carried out Intervals

8
8460–1 Hydraulic piping – Recondition sealing faces as required
to exhaust valve

Starting air – Drain (de-water) before and after every

piping manoeuvring period

Pressure gauges – Compare and calibrate according to master 6000–8000 Op. h

and pyrometers instruments

Fuel and – Clean or replace filter elements as required

lubricating oil (depending on make, follow special maintenance
filters instructions by manufacturer)

8733–1 Fuel pressure – Re-condition the sealing faces as required

piping

The indicated maintenance intervals must be taken as guidance and may vary depending on the installation. The
proper intervals are subject to the points mentioned below. Experience will show whether these intervals can be
extended or must be shortened.
– Environmental and operating conditions
– Heavy fuel oil and lubricating oil qualities (see Operating Manual 0710–1 and 0750–1)
– Engine load
– Fuel, lubricating oil and cooling water care (see Operating Manual 0720–1 and 0760–1)
– Overhaul according to Maintenance Manual
– Genuine spare parts used
– Engine monitoring
– Engines according to specifications of Wärtsilä Switzerland Ltd.
On the engine sectional drawings 0803–1, those parts are marked with group numbers, as they are found in the
Maintenance Manual.
Group numbers exist of the following engine components, although these parts are not marked on the sectional
drawings:

Engine component Group No.

Engine stays with friction shims / hydraulic engine stays . . . . . . . 1715–1

Starting air distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4303–1
Rotation direction safeguard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4506–1
Safety cut-out device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5307–1
Integrated balancer of 2nd order (driving end) . . . . . . . . . . . . . . . . 7722–1

7.03 6 u Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 0803–1/A1

Engine Cross Section and Longitudinal Section

8460–1
8733–1
2728–1

3403–1 to 3403–4

6545–1

5512–1 to 5512–4
5513–1

5520–1
4203–1 to 4203–5
1903–1

6606–1
6606–2

6708–1
6420–1

3326–1 to 3326–2

3303–1 to 3303–4

3301–1
3103–1

1132–1 to 1132–2

1112–1

96.7593

Wärtsilä Switzerland Ltd 1 1998

0803–1/A1 Maintenance RTA48T

Engine Cross Section and Longitudinal Section

2740–1

2751–1 to 2751–4

3425–1
2722–1
5103–1 2708–1 to 2708–3
2124–1 to 2124–3
2136–1

4325–1

4203–5

2303–1

7734–1
4103–1 to 4103–2

3130–1 to 3130–2

1203–1

1224–1

4103–3
3146–1

96.7594

3.00 2 u Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 0900–1/A1

Taking Oil Samples for Laboratory Analysis

At intervals of approx. 3000 operating hours, a sample should be taken of the engine oil and sent to a laboratory for
an analysis.
With the oil pump running and the engine oil at operating temperature drain a small quantity of oil from a cock in the
lubricating system to flush out any dirt accumulated in this cock.
Following this take an oil sample in a clean glass for the test.
The receptacle with the sample of oil must be marked with the following information for the laboratory:
– Ship’s name or name of plant
– Engine type
– Engine serial number
– Date of sampling
– Operating hours of oil and of engine
– Oil brand and quality

Oil inspection
The condition of the lubricating oil charge or its alteration during operation can be assessed on the basis of some
analysis data. With regular checks a deterioration can be detected at an early stage and remedial measures taken.
The indications for limiting values are to be taken as guiding ones, which should not be exceeded in service, and in
the case of the flash point not fall below (see also group 0750–1 of the Operating Manual).

Parameter Unit Limit

Kin. Viscosity at 40 C mm2/s [cSt] max. 160
Flash point (COC) C min. 180
Total insolubles m/m [%] max. 2.0
Base Number (BN) mgKOH/g max. 30
Water m/m [%] max 0.5

Recommended test method is IP 316/88.

If one of the limits is reached appropriate remedial action should be considered to correct the situation. Such action
may be intensified purification (reduction of throughput, adjustment of temperatures), treating in a renovating tank
or partial exchange of the oil charge.
These limits are set out as a guidance. The quality condition of the oil in circulation, however, cannot be fully judged
by a single parameter. Other oil parameters as well must be used in context to be able to find the cause of the prob-
lem and the appropriate remedy for correction.
Experience shows that with correctly designed installations and carefully performed oil care measures, generally a
sufficient safety margin to the above values can be maintained.

Wärtsilä Switzerland Ltd 1 u 7.03

This page is intentionally left blank
 RTA48T
Betrieb Group1

Bedplate and Tie Rod Group 1

 Bedplate and Thrust Bearing

– Checking the Foundation Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1112–1/A1

 Main Bearing
– Loosening and Tensioning of Waisted Studs and Jack Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1132–1/A1
– Removing and Fitting a Main Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1132–2/A1

 Thrust Bearing
– Checking the Axial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1203–1/A1
– Removal and Fitting the Thrust Bearing Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1224–1/A1

 Engine Stays with Friction Shims

– Checking the Pre-tension of the Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1715–1/A1

 Hydraulic Engine Stays

– Checking the Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1715–1/A2

 Tie Rod
– Checking the Tie Rod Pre-tension and Tensioning the Tie Rods . . . . . . . . . . . . . . . . . . . . . . . . . 1903–1/A1

Wärtsilä Switzerland Ltd 1 RTA48T / MM / 3.00

This page is intentionally left blank
 RTA48T
Maintenance 1112–1/A1

Bedplate and Thrust Bearing

Checking the Foundation Bolts

Tools: Key to Illustrations:

1 Feeler gauge 94122 1 Pin 11 Chock
1 Pre-tensioning jack 94145 2 Vent screw 12 Ship’s foundation plate
1 HP oil pump 94931 3 Cylinder 13 Nut
1 Connection piece 94934a 4 Piston 14 Conical socket
1 HP hose 94935 5 Sealing ring
6 Nut K Slot
7 Bedplate P Closing piece
8 Foundation bolt R Round bar
9 Foundation fitted stud S Gap
10 Sleeve V Relief valve

The foundation bolts (holding down studs) shall be checked at longer intervals e.g. during overhauls, for their tight-
ening condition (see group 0380–1).
In the area of the thrust bearing the foundation may be fastened with foundation bolt and sleeve (Fig. ’A’), or with a
foundation fitted stud (Fig. ’B’).
The remaining area is fastened with foundation bolts without sleeves (Fig. ’C’).

A B C

6
6 6
10
8 9 8
7 7 7

11 12 11 12 11 12

14 14 14
13 13 13

99.7327

Wärtsilä Switzerland Ltd 1 3.00

1112–1/A1 Maintenance RTA48T

Checking the Foundation Bolts

Remark The ’General Application Instructions’ for the utilization of hydraulic pre-tensioning jacks and
screw fasteners are applicable (see group 9403–4).

Checking of the pre-tension

– Clean the threads of the foundation bolts and the seating surfaces around the nuts 6.
– Place the pre-tensioning jack 94145 on the foundation bolt 8 or fitted stud 9 to be checked, and screw it com-
pletely down with the vent screw 2 open until there is only little or no clearance at ’x’ (Fig. ’D’).
– Connect the pre-tensioning jack 94145 by HP hoses 94935 and 94935a as well as connection piece 94934a
with the HP oil pump 94931 as shown in Fig. ’D’, whereby one side of the connection piece must be plugged with
closing piece ’P’.
– Shut relief valve ’V’ at the HP oil pump. Actuate HP oil pump till oil flows bubble-free at the vent screw 2 of the
pre-tensioning jack 94145.
– Close vent screw 2, tension the foundation bolt with 1000 bar and keep pressure constant. Attention should be
paid to ensure that the pin 1 always protrudes slightly compared with the piston 4 on the pre-tensioning jack.
Check with feeler gauge through the slot ’K’ if there is any clearance between the nut 6 and its seating.
– If there is no clearance, this means that the tightening condition of the foundation bolt has remained unchanged
since the last check. The pressure can be released to zero with relief valve ’V’ and the pre-tensioning jack re-
moved.
Should, however, a clearance be found, the nut 6 must be tightened down onto its seating with round bar ’R’
while the pressure is kept at 1000 bar (then check again the clearance with the feeler gauge). Lower the pres-
sure to zero and remove the pre-tensioning jack.

D 94932a
94935a

2 94934a
4
1
x
94935

3 5
94932
6
R
K
7
V 94931
8(9)

99.7712

Remark Should clearance exist at 1000 bar between nut 6 and seating surface and the nut can not be
tightened down with the round bar, this means that the nut is jammed on the foundation bolt and
the thread has first to be freed.
Then the respective foundation bolt has to be tensioned with 1000 bar and the nut tightened onto
its seating. The bolt thread must be smeared before with MOLYKOTE paste.
If the foundation bolts have completely loosened and have to be tensioned again, then all the
foundation bolts have to be pre-tensioned with 600 bar in the first instance (1st step). Subse-
quently all foundation bolts are to be tensioned with 1000 bar (2nd step).

3.00 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 1112–1/A1

Checking the Foundation Bolts

Loosening of the foundation bolts

– First screw down the pre-tensioning jack 94145 as for checking the pre-tension, then turn back by half a turn
(gap ’S’ in Fig. ’E’).
– Connect the pre-tensioning jack to the HP oil pump 94931 according to Fig. ’E’.
– Shut relief valve ’V’ at the HP oil pump. Actuate HP oil pump till oil flows bubble-free at the vent screw 2 of the
pre-tensioning jack 94145.
– Close the vent screw 2 and pump until a pressure of 1020 bar has been reached.
Attention should be paid to ensure that the pin 1 always protrudes slightly compared with the piston 4 on the
pre-tensioning jack!
– Turn back nut 6 by one turn, and release the pressure to ’0’.
The pre-tensioning jack can now be removed.

E
94932a
94935a

P
2
94934a
1 4
94935
3
5
94932
6

S
7
8(9) V 94931

99.7713

Tensioning of the foundation bolts

Tensioning of the foundation bolts must be carried out in two steps without exception, for both metal and synthetic
chocks, i.e. tension all foundation bolts first with 600 bar (1st step), then finish tensioning with 1000 bar (2nd step).
Tensioning must be carried out as described above, in ’Checking of the pre-tension’.
Attention should be paid to ensure that the pin 1 always protrudes slightly compared with the piston 4 on the pre-ten-
sioning jack!

Wärtsilä Switzerland Ltd 3 u 3.00

This page is intentionally left blank
 RTA48T
Maintenance 1132–1/A1

Main Bearing
Loosening and Tensioning of Waisted Studs

Tools: Key to Illustrations:

2 Pre-tensioning jacks 94114 1 Pin 8 Waisted stud
1 Feeler gauge 94122 2 Vent screw 9 Bearing shell
1 Special feeler gauge 94123 3 Cylinder 10 Main bearing girder
1 Depth gauge 94124 4 Piston
1 HP oil pump 94931 5 Sealing rings K Slot
1 Pressure gauge 94932 6 Nut R Round bar
1 Pressure gauge 94932a 7 Bearing cover V Relief valve
1 Connection piece 94934a
1 HP Hose 94935
2 HP hoses 94935a

Loosening the waisted studs

– Screw both pre-tensioning jacks 94114 completely onto the waisted studs 8 for the main bearing.
– Then loosen both pre-tensioning jacks by about ½ turn.
– Connect both pre-tensioning jacks with the HP oil pump 94931 according to Fig. ’A’.
– Subsequently tension the waisted studs with 1020 bar and unscrew both nuts 6 by one turn with a round bar ’R’.
Attention should be paid to ensure that the pins 1 always protrude slightly compared with the pistons 4 on the
pre-tensioning jacks!
– Release pressure to zero with the aid of relief valve ’V’ at the HP oil pump 94931 and then remove both pre-ten-
sioning jacks and the nuts 6.

Tensioning the waisted studs

– Fit bearing cover 7 and tighten both nuts 6 with the aid of round bar ’R’.
– Establish distances ’a1’ and ’a2’ with depth gauge 94124. The difference between the two distances must not
exceed 0.30 mm. If necessary adjust the correct distance by means of loosening and tightening of the nuts 6.
– Check with the feeler gauge 94122 whether the nuts are fully seated on the bearing cover.
– Mark position of the nuts against the bearing cover with a felt-tip pen.
– Screw both pre-tensioning jacks 94114 completely onto the waisted studs 8. Moreover the vent screw 2 is to be
opened slightly so that the piston 4 can slide back to its initial position, i.e. there is no or very little clearance at ’x’.
– Connect both pre-tensioning jacks with the HP oil pump 94931 according to Fig. ’A’.
– Shut the relief valve ’V’ and start up HP oil pump till bubble-free oil flows out through the vent screw 2. Shut the
vent screw.
– Slowly raise the pressure to 1000 bar and keep it constant until both nuts 6 have been tightened with a round
bar ’R’ till firmly seated. Attention should be paid to ensure that the pins 1 always protrude slightly compared
with the pistons 4 on the pre-tensioning jacks! Using the feeler gauge 94122 inserted through the slot ’K’, check
if there is no clearance at hand between the nuts and the bearing cover.
– Release pressure to zero with the aid of relief valve ’V’ at the HP oil pump and then remove both pre-tensioning
jacks.
– After tightening the nuts check that these have been turned by about the same angle of 145.
For a final check the distances ’a1’ and ’a2’ are to be measured again. Should the difference exceed 0.30 mm,
loosen the waisted studs, adjust the bearing cover 7 correspondingly and repeat the tensioning procedure.

Wärtsilä Switzerland Ltd 1 3.00

1132–1/A1 Maintenance RTA48T

Main Bearing: Loosening and Tensioning of Waisted Studs

A
4

x
1

3
5

6
R
K
94932 94931
7
8

V
94935

94935a 94932a

94934a

94114
94935a

6
a2
a1

10

99.7711

3.00 2 u Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 1132–2/A1

Main Bearing
Removing and Fitting a Main Bearing

Tools: Key to Illustrations:

1 Assembly template 94107 1 Crankshaft
1 Wire rope 94117 2 Main bearing cover
1 Removal device for bearing shell 94118 3 Main bearing shell
2 Wire ropes 94119 4 Locating dowel pin
1 Special feeler gauge 94123 5 Groove
1 Support 94141 6 Locating dowel pin
2 Working platforms 94142 7 Flywheel
2 Girders (of different lengths) 94335 8 Main bearing girder
1 HP oil pump 94931 9 Waisted stud
1 Pressure gauge 94932 10 Support
1 Pressure gauge 94932a 11 Middle piece
1 Connection piece 94934a
1 HP hose 94935 H Wooden board
2 HP hoses 94935a R Eye bolts
2 Hydraulic jacks 94936 V Relief valve
Various eye bolts
Dial gauge with magnetic base
Lifting tackles
Various ropes

Removing
– Turn the crankshaft 1 so that the crank web by the respective bearing stands approximately 90 after T.D.C. on
exhaust side. Loosen the nuts to the waisted studs 9 (Fig. ’A’) as described in group 1132–1.
– Screw in the eye bolts ’R’ as shown in Fig. ’D’ and ’F’ in the main bearing cover and also in the appropriate
middle piece 11 of the crosshead. Connect these with rope ’a’ and the lifting tackle.
– To simplify the removal, the ropes ’b’ and ’c’ with the lifting tackle are to be mounted on the adjacent cylinder as
shown in Fig. ’D’ and ’F’.
– Lift the main bearing cover with rope ’a’ and with the help of ropes ’b’ and ’c’. Lift the main bearing cover far
enough till it is above the crank web.
– Screw one of the two girders 94335 tightly on the appropriate support 10.
– With the help of the lifting tackle affixed to the girder 94335 and rope ’d’, the main bearing cover can be removed
from the crankcase.
The same procedure is to be followed as described above for the removal of main bearing cover 2 of the second
main bearing, whereby for easier removal of the main bearing cover, the bearing at the lower intermediate wheel
should be looped with a rope (Fig. ’F’) on to which the lifting tackle can then be affixed.
For the removal of the main bearing cover 2 of the first main bearing on the driving end, the upper part of the oil baffle
should be dismounted beforehand.
Mount the appropriate ropes as shown in Fig. ’E’ and ’F’ for lifting the main bearing cover. After the main bearing
cover has been lifted off, it can be withdrawn from the engine with ropes ’e’ and ’f’ which are to be affixed outside the
engine to the brackets shown in Fig. ’E’. The slide ring on the crankshaft should be protected against damage during
this process.

Removal of a main bearing shell 3:

If a main bearing shell 3 also has to be removed, then in addition to the above described removal of a main bearing
cover, proceed as follows:
– Turn the crankshaft that the respective crank web stands 90 after T.D.C. on exhaust side (Fig. ’H’).
– Place support 94141 along the engine axis on two main bearing girders 8 as shown in Fig. ’G’.
– Fasten the removal device 94118 on one dividing face of the main bearing shell, utilizing a special Allen wrench
from the tool set.
– Attach a wire rope 94119 to one of the short hooks of device 94118 (Fig. ’G’ and ’H’) and lead it along the bearing
side edge to the other side and further to the eye bolt ’R’ (fitted into the middle piece 11) and then to the cross-
head (if necessary two wire ropes can be used).

Wärtsilä Switzerland Ltd 1 3.00

1132–2/A1 Maintenance RTA48T

Removing and Fitting a Main Bearing

– Install a dial gauge (if possible with magnetic base) and set it to zero above the crankshaft journal to the main
bearing to be removed.
– Place hydraulic jacks 94936 on support 94141 and connect them to the HP oil pump 94931 by means of the
connection piece 94934a, HP hoses 94935 and 94935a as shown in Fig. ’G’ and ’H’.
– Operate the HP oil pump 94931 in order to lift the crankshaft by about 0.30 mm (check with dial gauge).
Lift the crankshaft max. to the point where the neighbouring main bearings show no clearance any
more. This process is to be checked by means of the special feeler gauge 94123.
Keep the pressure at the jacks constant!
– By pulling on the wire rope turn out the main bearing shell.
– If the bearing shell lies on top of the crankshaft journal remove the wire rope. Screw in the eye bolts on the main
bearing shell rear side, and lift the shell out of the engine with the wire rope.

Attention Never remove two neighbouring main bearing shells from the main bearing girder at a time!

The same procedure is to be followed as described above for the removal of the main bearing shell 3 at the first main
bearing at the driving end, whereby the crankshaft is to be lifted up with the help of a hydraulic jack put under the
flywheel (Fig. ’G’). A copper or aluminium plate should be used as a spacer between the hydraulic jack and the
flywheel to protect the flywheel teeth.
Likewise for the removal of the main bearing cover, the wire ropes 94119 may be fixed to ropes ’e’ and ’f’ (Fig. ’F’) to
draw out the main bearing shell.

3
4

8
5

96.7465

3.00 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 1132–2/A1

Removing and Fitting a Main Bearing

Fitting
Before fitting the main bearing shell 3 smear its rear surface lightly with MOLYKOTE paste G. Lubricate crank-
shaft journal and running surface of the main bearing shell lavishly with clean engine oil. Check the bore surface of
the main bearing girder for possible damage and ensure its cleanliness!

Remark Apply LOCTITE type A to the locating dowel pins 6 and fit them into the main bearing shell 3. The
location of the locating dowel pins 6 must be properly adjusted with the assembly template 94107
as shown in Fig. ’B’.

B
3 94107

6 6

00.7015

– Place the main bearing shell on the crankshaft journal i.e. analogous to the removal but in reverse sequence.
Make sure the bearing shell numbering figure matches with the one on the main bearing girder.
– Lift the crankshaft again as described for the removal in case it has meanwhile been lowered.
– Push in the main bearing shell 3 by means of the removing device 94118, a wire rope 94119, and the eye bolt ’R’
screwed into the middle piece 11. For this, lead the wire rope 94119 around the lateral edge of the main bearing
shell in order to hold it, so that it slides slowly into the bore of the main bearing girder 8.
– Both joint faces of the main bearing shell must show the same distance to the upper edge of the bedplate (mea-
sure with a depth gauge, see also group 1132–1).
– Release pressure to zero with the aid of relief valve ’V’ at the HP oil pump. Fit the main bearing cover 2 with lifting
tackle and ropes as shown in Fig. ’D’, ’E’ and ’F’. Pay attention that the locating dowel pins 6 fit into the respec-
tive bores in the main bearing shell 3 (Fig. ’A’).
– Tension waisted studs 9 according to the instructions in group 1132–1.

Remark The bearing clearances and the crank deflection must be measured after a new lower main bear-
ing shell has been fitted and the main bearing cover has been tightened (see group 0330–1 and
3103–1).
After assembly, check if lubricating oil is supplied to the main bearing with the oil pump in opera-
tion!

C
Attention Should the crankshaft need to be H
turned before the main bearing
cover is fitted, then care must be 9
taken that the bearing shell does
not turn. Therefore, the main
bearing shell 3 must be blocked 1
with two suitable wooden boards
’H’ (Fig. ’C’).

8
00.7145

Wärtsilä Switzerland Ltd 3 3.00

1132–2/A1 Maintenance RTA48T

Removing and Fitting a Main Bearing

c
94335 b
10

Brennstoffseite
FUEL SIDE 11

2
a

94142 1 99.7686a

Brennstoffseite
f e
FUEL SIDE

00.7020

3.00 4 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 1132–2/A1

Removing and Fitting a Main Bearing

F
b/c

R
2
a a

1 2 3

Antriebsseite Freies Ende

DRIVING END
R FREE END

7 94119

94118

94936 7 8 8

96.7470

94141 94936

Wärtsilä Switzerland Ltd 5 1998

1132–2/A1 Maintenance RTA48T

Removing and Fitting a Main Bearing

H
10

94335

11
Brennsoffseite
FUEL SIDE

R
94119 94117

94142

94932

94118

94931 V 94935

94934a
94932a

94935a

99.7685a

94936 94141 8

3.00 6 u Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 1203–1/A1

Thrust Bearing
Checking the Axial Clearance

Tools: Key to Illustrations:

1 Inside micrometer 94101 1 Coupling flange 7a Thrust bearing pads
1 Feeler gauge 94238 2 Oil baffle, upper part for AHEAD
1 Dial gauge with magnetic base 3 Oil baffle, lower part 8 Cover
4, 4a Holding stirrups
5 Thrust flange
6 Crankshaft
7 Thrust bearing pads f1 Axial clearance
for ASTERN X Check dimension

Should the classification society demand measuring of axial clearance of the thrust bearing flange in the thrust bear-
ing, or should other reasons call for it, this can be done in various ways:

Method 1
The total displacement which results from pushing the crankshaft axially both ways until it contacts the thrust bear-
ing pads AHEAD and ASTERN, is measured with a clock gauge. This is then checked against the figure marked on
the sheet ’Check Dimensions’ in the engine documents supplied.
A possible increase compared with the nominal figure signifies wear of the thrust bearing pads.
Axial clearances f1 = 0.80–1.30 mm (see Clearance Table group 0330–1)

Method 2
The crankshaft is displaced axially until it rests on the engine side thrust bearing pads (AHEAD) and is then fixed in
this position. The distance between the coupling flange and the upper part of the oil baffle is measured with an inside
micrometer 94101 at the position indicated (see Fig. ’B’).
The amount by which the distance ’X’ is smaller than that given on the sheet ’Check Dimensions’ corresponds to the
wear of the engine side thrust bearing pads (AHEAD). By displacing the crankshaft axially until it rests on the thrust
bearing pads for ASTERN, the inside micrometer can be used to determine the total axial clearance as well.

Remark If during checking or repair work any objects should fall into the thrust bearing housing, they can
be removed after dismantling cover 8. After more major work has been carried out in the thrust
bearing space it is in any case recommended to dismantle cover 8 for a check-up on the thrust
bearing housing.

Wärtsilä Switzerland Ltd 1 1998

1203–1/A1 Maintenance RTA48T

Thrust Bearing: Checking the Axial Clearance

2
5

4a 4

Schub

THRUST

6
1
8 7a 3

f1

Alle 6000–8000 Betriebsstunden ist

die Bohrung auf freien Durchgang
zu kontrollieren
EVERY 6000–8000 OPERATING
HOURS THE HOLE IS TO BE
CHECKED FOR FREE PASSAGE 95.7739a

1998 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 1203–1/A1

Thrust Bearing: Checking the Axial Clearance

I
2

I-I
X

95.7740

94101 2 1

Wärtsilä Switzerland Ltd 3 u 1998

This page is intentionally left blank
 RTA48T
Maintenance 1224–1/A1

Thrust Bearing
Removal and Fitting the Thrust Bearing Pads

Tools: Key to Illustrations:

1 Turning-out device 94155 1 Thrust bearing flange 5 Screws with spacer
for engines with 1-part 2, 2a Thrust bearing pads sleeves
gear wheel 3 Gear wheel (2-part) 6 Bearing cover
1 Turning-out device 94155a on thrust bearing flange 7 Oil baffle, upper part
for engines with 2-part 4 Bracket
gear wheel
1 Eye bolt M16

Removal
Should it become necessary to remove thrust bearing pads, firstly the screws 5 to both brackets 4 (Fig. ’A’) must be
removed. Then the brackets are to be removed laterally through the column opening. In addition, to ensure a better
access for the removal of the thrust bearing pads 2 (ASTERN operation), the upper part of the oil baffle 7 (Fig. ’B’)
and the first main bearing cover are also to be removed (see group 1132–2).
The access to the thrust bearing pads being now freed by the removal of the brackets, insert and laterally fasten the
turning-out device 94155 (for engines with a 1-part gear wheel 3) or turning-out device 94155a (for engines with a
2-part gear wheel 3) as illustrated on Fig. ’B’.
The crankshaft is then to be turned with the turning gear until an eye bolt M16 can be screwed into a pad which can
then be lifted up and removed one by one.

Remark When only a few thrust bearing pads of a row are to be removed the crankshaft is located in its
axial position by the remaining pads. Should, however, the necessity arise that all thrust bearing
pads must be removed then the crankshaft must be prevented from sliding axially from its spe-
cific position. This might happen for example if the ship is heavily stern trimmed. (In order to avoid
such shifting, insert a piece of hardwood of the same thickness as the thrust bearing pad).
Fitting
Make absolutely sure that all the thrust bearing pads are meticulously clean and smeared with fresh engine oil; the
thrust bearing pads must all be replaced in their original position. Note the numbering of the individual pads! Please
also refer to the following sheets for the arrangement of thrust bearing pads on engines with fixed pitch propellers
(F.P.P.) and controllable pitch propellers (C.P.P.) respectively.
Fitting the thrust bearing pads for AHEAD operation should pose no problems, as the crankshaft in a stern trimmed
ship rests against the ASTERN thrust bearing pads.
For fitting the thrust bearing pads tools 94155 or 94155a respectively can also be utilized. Please note in this respect
that the first pad, when pushed in, rests against the tool. The following thrust bearing pads can then be fitted one
after the other while simultaneously turning the crankshaft. The thrust bearing pads should slide in without effort to
their end position.
With all the thrust bearing pads in position the distances from the outermost pads on the fuel pump side and on the
exhaust side to the upper edge of the bedplate must be equal. The brackets 4 can now be refitted.
When fitting the thrust bearing pads for ASTERN operation it may possibly be necessary to shift the crankshaft
slightly in an axial direction towards the free end.
After fitting the thrust bearing pads immediately remove tool 94155 or 94155a respectively.
Prior to fitting of the screws 5 their threads and the corresponding threads in the bedplate are to be cleaned carefully.
The threads of screws 5 are to be coated with LOCTITE No. 222 before fitting them. After mounting of the bracket 4,
the clearances between bracket and thrust bearing pads 2 and 2a are to be checked (see Clearance Table group
0330–1).

Attention When fitting new or remetalled thrust bearing pads, care must be taken that their thickness (final
dimension) corresponds exactly with the neighbouring pads.
When replacing a complete row of new or remetalled thrust bearing pads the clearance must be
adjusted to the original values (as shown in the Clearance Table group 0330–1) by using the
inside micrometer tool 94101 as shown in group 1203–1.

Wärtsilä Switzerland Ltd 1 1998

1224–1/A1 Maintenance RTA48T

Removal and Fitting the Thrust Bearing Pads

A
6
4
4
5
5
2/2a
Brennstoffpumpenseite
FUEL PUMP SIDE

EXHAUST SIDE
Abgasseite
B I II - II

2/2a 1 I-I 3 94155/94155a

II
7

II
1

2 2a

95.7741

94155/94155a

1998 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 1224–1/A1

Removal and Fitting the Thrust Bearing Pads

Anordnung der Drucklagerklötze für Motoren mit Festpropeller

ARRANGEMENT OF THRUST BEARING PADS FOR ENGINES
WITH FIXED PITCH PROPELLER
zurück voraus
ASTERN AHEAD

rechtsdrehender Motor
CLOCKWISE ROTATING ENGINE
Auflagefläche Auflagefläche
SUPPORT SURFACE SUPPORT SURFACE

Antriebseite Motorseite
DRIVING END ENGINE END

Propellerschub ”S”
PROPELLER THRUST ”S”

von Antriebsseite gesehen von Antriebsseite gesehen

Klötze auf Antriebsseite ”S” voraus Klötze auf Motorseite
LOOKING FROM DRIVING ”S” AHEAD LOOKING FROM DRIVING
END PADS ON DRIVING END END PADS ON ENGINE END
”S” zurück

”S” ASTERN
95.7742

Klötze für ”Zurück” Klötze für ”Voraus”

PADS FOR ”ASTERN” PADS FOR ”AHEAD”

zurück voraus
ASTERN AHEAD

Auflagefläche linksdrehender Motor Auflagefläche

SUPPORT SURFACE COUNTER-CLOCKWISE ROTATING ENGINE SUPPORT SURFACE

Wärtsilä Switzerland Ltd 3 1998

1224–1/A1 Maintenance RTA48T

Removal and Fitting the Thrust Bearing Pads

Anordnung der Drucklagerklötze für Motoren mit Verstellpropeller

ARRANGEMENT OF THRUST BEARING PADS FOR ENGINES WITH
CONTROLLABLE PITCH PROPELLER

zurück voraus
ASTERN AHEAD

rechtsdrehender Motor
CLOCKWISE ROTATING ENGINE
Auflagefläche Auflagefläche
SUPPORT SURFACE Antriebseite Motorseite SUPPORT SURFACE
DRIVING END ENGINE END

Propellerschub ”S”
PROPELLER THRUST ”S”
von Antriebsseite gesehen von Antriebsseite gesehen
Klötze auf Antriebsseite ”S” voraus Klötze auf Motorseite
LOOKING FROM DRIVING ”S” AHEAD LOOKING FROM DRIVING
END PADS ON DRIVING END END PADS ON ENGINE END
”S” zurück

”S” ASTERN

95.7743

Klötze für ”Zurück” Klötze für ”Voraus”

PADS FOR ”ASTERN” PADS FOR ”AHEAD”

zurück voraus
ASTERN AHEAD

Auflagefläche linksdrehender Motor Auflagefläche

SUPPORT SURFACE COUNTER-CLOCKWISE ROTATING ENGINE SUPPORT SURFACE

1998 4 u Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 1715–1/A1

Engine Stays with Friction Shims

Checking the Pre-tension of the Waisted Studs

Tools: Key to Illustrations:

1 Feeler gauge 94122 1 Engine stays 9 Piston
1 Pre-tensioning jack 94145 2 Friction shims 10 Cylinder
1 HP oil pump 94931 3 Waisted stud 11 Sealing ring
1 Pressure gauge 94932 4 Nut
1 Pressure gauge 94932a 5 Ring
1 Connection piece 94934a 6 Disc spring K Slot
1 HP hose 94935 7 Vent screw R Round bar
1 HP hose 94935a 8 Pin V Relief valve

Two friction type stays 1 each are installed on the exhaust side and at the free end of the engine (Fig. ’A’).
The pre-tension of the waisted studs 3 shall be checked at specified intervals (see group 0380–1).

Freies Ende
A I
FREE END

I II
1

EXHAUST SIDE
Abgasseite

II
3
94145
4
ENGINE SIDE
Motorseite

6
98.7605
5
1 2

Wärtsilä Switzerland Ltd 1 2000

1715–1/A1 Maintenance RTA48T

Engine Stays with Friction Shims: Checking the Pre-tension of the Waisted Studs

Checking of the pre-tension:

– Clean the thread of the screw and the seating surface around the nut 4.
– Place the pre-tensioning jack 94145 on the waisted stud to be checked, and screw it completely down with the
vent screw 7 open until there is only little or no clearance at ’x’ (Fig. ’B’).
– As shown in Fig. ’B’, connect the pre-tensioning jack 94145 with the HP hoses 94935 and 94935a as well as the
connection piece 94934a to the HP oil pump 94931, whereby one side of the connection piece must be plugged
with closing piece ’P’.
– Close the relief valve ’V’ at the HP oil pump, then actuate the HP oil pump until the oil comes out without bubbles
from the opened vent screw 7 of the pre-tensioning jack 94145.
– Close vent screw 7, tension the waisted stud with 180 bar and keep the pressure constant until checking for a
possible clearance between nut 4 and its seating surface by inserting a feeler gauge into check slot ’K’ has been
finished.
– If there is no clearance it means that the tensioned condition of the waisted stud has remained the same since
the last check. The pressure can now be lowered to ’0’ and the pre-tensioning jack may be removed.
Should, however, a clearance be found, the nut 4 must be tightened down onto its seating with round bar ’R’
while the pressure is kept at 180 bar (then check again the clearance with the feeler gauge). Lower the pressure
to zero and remove the pre-tensioning jack.

Remark If, with a pre-tension of 180 bar, there is still a clearance between the nut 4 and its seating sur-
face, it means that the nut is stuck on the waisted stud and that it must first be released.
Afterwards pre-tension the waisted stud concerned again with 180 bar and tighten the nut till
firmly seated. Lubricate the thread beforehand.

94932a 94935a
B
P
94934a 7
94935 8
x

94932 9
11
10
4 3
R
K
1
94931 V

99.7714

Loosening of waisted studs

If the waisted studs must be loosened, first screw on the pre-tensioning jack 94145 completely, then loosen it by
about ½ turn. Afterwards tension the waisted stud with 200 bar, and turn nut 4 back by one turn. Attention should be
paid to ensure that the pin 8 always protrudes slightly compared with the piston 9 on the pre-tensioning jack! After
lowering the pressure to ’0’ first remove the pre-tensioning jack and then the nut.

2000 2 u Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 1715–1/A2

Hydraulic Engine Stays

Checking the Oil Pressure

Key to Illustrations:
1 Hydraulic engine stays 5 Ball valve
2 Hydraulic cylinder 6 Plug 3/8 NPT
3 Bladder accumulator 7 Pressure gauge
4 Rod

Two hydraulic type stays 1 are installed each on the exhaust side and fuel side of the engine.
The oil pressures on the pressure gauges of the hydraulic cylinders shall be checked and compared with each other
at regular intervals.
If one of the hydraulic cylinders shows a pressure below 30 bar, which could be caused by defective O-rings, leaking
valves or screwed connections, the opposite hydraulic cylinder must also be released of its pressure till 30 bar.
The defective engine stays must be repaired at the first opportunity. Afterwards the oil pressure must be readjusted
to the required value on all the engine stays, whereby the detailed instructions of the respective maker must be
considered.

Freies Ende
I I FREE END

1 1 1

EXHAUST SIDE
1

Abgasseite
II

II
3

2
7
4
Schiff-Seite
SHIP SIDE

98.7611

6 5

Wärtsilä Switzerland Ltd 1 u 2000

This page is intentionally left blank
 RTA48T
Maintenance 1903–1/A1

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

Tools: Key to Illustrations:

2 Pre-tensioning jacks 94180 1 Cylinder jacket 14 Clamp screw
1 Pressure gauge 94932a 2 Intermediate ring 15 Column
1 Connection piece 94934a 3 Upper tie rod nut 16 Bedplate
1 HP hose 94935 4 Cylinder 17 O-ring
2 HP hoses 94935a 5 Piston 18 Lower backing ring
1 Hydraulic unit 94942 6 Sealing ring 19 Lower tie rod nut
7 Round bar 20 Bush
8 Pin
9 Vent screw
10 Tie rod AN Drain slot
11 Screw K Slot
12 Protection cap L Thread protrusion
13 Bore for solvent S Measuring place

We recommend that about one year after commissioning the engine all the tie rods are checked for their correct
pre-tensioning and if necessary to tension them to the specified value. Later it is sufficient to make random checks
during major overhauls, or the pre-tension of all tie rods has to be checked within 4 years and corrected where nec-
essary.
For such checks it is not required to loosen the waisted studs of the main bearings nor the clamp screws 14 of the tie
rods.

Checking the pre-tension of tie rods

– Remove the thread protection cap 12 from all tie rods and clean the contact face of the intermediate ring 2.
– Screw both pre-tensioning jacks 94180 onto two tie rods lying opposite each other until the cylinder 4 rests on
the intermediate ring 2, i.e. there is only little or no clearance at ’x’ (Fig. ’A’). If necessary, turn the whole pre-ten-
sioning jack back a little so that the holes in the tie rod nuts are easily accessible. Slightly slacken vent screws 9.
– Connect both pre-tensioning jacks 94180 with the hydraulic unit 94942 according to Fig. ’A’.
– Actuate the hydraulic unit till bubble-free oil flows out through the vent screws 9; then close vent screws.
– Operate hydraulic unit up to 1000 bar and maintain this pressure. Attention should be paid to ensure that the
pins 8 protrude slightly compared with the pistons 5 on the pre-tensioning jacks.
– Using a feeler gauge inserted through the slot ’K’, check at ’S’ if there is any clearance between the tie rod nut 3
and the intermediate ring 2.

94932a
8 9 94935a 9 8 94934a
x

94935
6
94180 5
7 4
13 3
K 94942
S 2
1 00.7021

Wärtsilä Switzerland Ltd 1 3.00

1903–1/A1 Maintenance RTA48T

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

– If any clearance does exist, tighten the tie rod nut with round bar 7 until it rests firmly on the intermediate ring
(check with feeler gauge). Subsequently release the pressure to zero at the hydraulic unit. If no clearance ex-
ists, the pressure can immediately be released and the pre-tensioning jacks removed. All the tie rods have to be
checked in this manner and, wherever necessary, the tie rod nut has to be tightened.
– The tie rod threads have to be protected against corrosion by coating them with non-acidic grease after check-
ing has been completed. The protection cap must then be screwed on tightly.

Remark If it is impossible to tighten the tie rod nut with the round bar although there is clearance at ’S’, this
means that the thread is blocked/seized. In this case it may be attempted to press in oil or solvent
through the bore 13 (3/8” NPT) using an appropriate tool with the pre-tensioning jacks placed and
pressurized so that the tie rods are lifted. At the same time insert a strong brass or copper bar into
a hole in the tie rod nut through the slotted aperture of cylinder 4 and first loosen, then tighten the
nut with several heavy hammer blows. Make sure, however, that the edge of the hole is not seri-
ously deformed or it will be impossible to remove the pre-tensioning jack. Seal off the bore 13.

Loosening and tightening the tie rods

Should, for some reason or other, tie rods have to be removed or fitted, the following points have to be carefully
observed:
 Remove clamp screws 14 (Fig. ’D’).
 Tensioning has to be carried out in three steps. The order in which the tie rods are to be loosened or tensioned is
shown in schematic illustration (Fig. ’C’), i.e. in pairs, first tie rods a/a, then b/b, etc.
 If the tie rods have been newly tightened, then the waisted studs of the main bearings also have to be checked
for correct pretensioning (see group 1132–1).

Loosening
The procedure for loosening the tie rods is the same as the one described above for checking the pretension, except
that the pre-tensioning jacks must be released by 1½ turns after being completely screwed down. At this starting
point (Fig. ’A’) connect the jacks with the hydraulic unit and operate it until a pressure of 1020 bar is reached. The tie
rod nuts are now loose and can be unscrewed with the round bar 7 until they touch the piston 5.
Before releasing the hydraulic pressure to zero, it is of advantage to place a hardwood wedge under the lower tie rod
nut in the bed plate, whereby the wedge will take the full weight of the tie rod.
The pre-tensioning jacks can now be removed.

Tensioning

Preliminary work:
 Clamp screws 14 must not be tightened up.
 The lower nut 19 of the tie rod is screwed on.
 Clean the seating surface for intermediate ring 2 and the upper nut 3 and smear them with MOLYKOTE paste G.
 Smear the tie rod thread for the upper nut 3 lavishly with MOLYKOTE paste G and screw the nut on (check for
easy threading).
 Screw ring screw into the tie rod and lift carefully till the lower tie rod nut rests snugly against the bearing girder.
 The safest way is to use lifting tackle hooked onto the crane, with which the tie rod can be lifted manually till the
lower nut is snug on its seating, as with the crane the landing of the nut cannot easily be felt and the rope might
break.
 In this position tighten the upper tie rod nut with the round bar 7 till firmly seated on the intermediate ring, sepa-
rate lifting tackle from tie rod and remove ring screw (there must now be no clearance between bearing girder
and lower tie rod nut and the lower tie rod nut must be flush with the tie rod end).

3.00 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 1903–1/A1

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

L
10
B C

L2
L1
L

DRIVING END
Antriebseite
Working sequence for tensioning
– If all the preliminary work has been carried out, then the pre-
tensioning jacks 94180 with loosened vent screws 9 have to
be screwed onto both tie rods a/a (Fig. ’C’). Attention should
be paid to easy access to one of the slotted apertures to
tighten the upper tie rod nuts 3.
– Connect pre-tensioning jacks with the hydraulic unit 94942 as
shown in Fig. ’A’.
– Actuate hydraulic unit till oil flows out bubble-free at the vent e c a b d
screws, then tighten these.
– Verify that no, or only little clearance remains at ’x’ (Fig. ’A’)
and that the pins 8 protrude compared with the pistons 5 at
every following tensioning procedure. This is very important,
as otherwise the required pretensioning pressure will not be
attained.
– Actuate the hydraulic unit and raise a pressure of 100 bar (1st e c a b d
step), keep pressure constant till the two upper tie rod nuts 3
have been tightened down firmly with the round bar 7. Then 95.7748

release pressure to zero at the hydraulic unit.

– Measure and record the distance ’L’ (Fig. ’B’) (initial position).
– Repeat the procedure, but raise the pressure to 600 bar (2nd step).
– Measure again the distance ’L’ and record it as ’L1’. The tie rods are correctly tensioned when with a pressure
of 600 bar the following reference value is measured: ’L1’ – ’L’ = about 4.20 mm.
– In this manner tension all tie rods in the sequence as described above.
– After all tie rods have been pretensioned with 600 bar, these are to be tensioned with 1000 bar in the same
sequence (3rd step).
Measure again the distance ’L’ and record it as ’L2’.
The tie rods are correctly tensioned when with a pressure of 1000 bar the following reference value is mea-
sured: total elongation L = about 7.50 mm (’L2’ – ’L’).
– After completing the tensioning, smear the protruding thread portions of all the tie rods lavishly with acid free
grease and fit the protection caps 12. All the clamp screws 14 must be firmly tightened!
Follow the remark at the end of ’Checking the pre-tension of tie rods’!

Wärtsilä Switzerland Ltd 3 3.00

1903–1/A1 Maintenance RTA48T

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

IV
D
IV
11

12
III - III
10

14 3
1
13 2

1
II 20

15 II

10

III
III

I
10 20 1 14
16
16

17

18
AN
19
I
96.7603

Bündig
FLUSH

3.00 4 u Wärtsilä Switzerland Ltd

 RTA48T
Betrieb Group2

Cylinder Liner and Cylinder Cover Group 2

 Cylinder Liner
– Measuring Bore Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2124–1/A1
– Removing and Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2124–2/A1
– Removing Wear Ridge, Re-dressing Lubricating Grooves, and Edges . . . . . . . . . . . . . . . . . . . 2124–3/A1
of the Scavenge Ports

 Lubricating Quills and Accumulators

– Removal and Fitting, Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2136–1/A1

 Piston Rod Gland

– Dismantling and Assembling as well as Measuring the Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . 2303–1/A1

 Cylinder Cover
– Removal and Fitting of the Cylinder Cover and Water Guide Jacket . . . . . . . . . . . . . . . . . . . . . 2708–1/A1
– Loosening and Tensioning of Cylinder Cover Waisted Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2708–2/A1
– Manual Overhaul of Sealing Face for the Injection Valve in the Cylinder Cover . . . . . . . . . . . . 2708–3/A1

 Injection Valve
– Checking, Dismantling, Assembling and Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2722–1/A1

 Starting Valve
– Removing, Fitting and Dismantling, Grinding-in and Assembling . . . . . . . . . . . . . . . . . . . . . . . . 2728–1/A1

 Relief Valve for Cylinder Cover

– Dismantling, Assembling and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2740–1/A1

 Exhaust Valve
– Removal and Fitting of the Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2751–1/A1
– Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2751–2/A1
– Replacing and Grinding the Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2751–3/A1
– Grinding the Seating Surface on the Valve Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2751–4/A1

Wärtsilä Switzerland Ltd 1 RTA48T / MM / 2.06

This page is intentionally left blank
 RTA48T
Maintenance 2124–1/A1

Cylinder Liner
Measuring Bore Wear

Tools: Key to Illustrations:

1 Measuring gauge 94225 1 Cylinder liner
1 Measuring tool 94226 S Setting screws
1 Setting gauge 94227

The wear of the cylinder liners should be checked

S during every overhaul or whenever a piston is re-
moved. Always measure cylinder liners in fitted
position.
To permit comparisons with previous measures it
is inevitable that measuring is always done in the
same place and that the measured values are
noted in a log.
To this end always use the measuring gauge
94225 which is available in the engine tools. It is
so designed that it can simply be hooked over the
top face of the liner.
Measure at the ten points in the engine axis and
94225 at right angles to it.
1 Before beginning the measurement the measur-
ing tool 94226 must be adjusted by means of the
setting gauge 94227.
For maximum permissible inside diameter refer
to Clearance Table group 0330–1.
Should the thickness of the compression shims
be altered after putting the engine into operation,
then the length of the setting screw ’S’ has to be
adjusted accordingly on measuring gauge
94225. By this the measuring bores of the gauge
94225 are again brought to the original setting
relative to the position of the piston.
94226
The ridge formed at the top of the cylinder bore in
the course of operation has to be removed care-
fully without damaging the running surface for the
piston rings (see group 2124–3).
The lower part of the measuring gauge 94225
must be removed if the cylinder liner should be
measured with installed working piston at B.D.C.

013.764/06

Wärtsilä Switzerland Ltd 1 u 2.06

This page is intentionally left blank
 RTA48T
Maintenance 2124–2/A1

Cylinder Liner
Removing and Fitting

Tools: Key to Illustrations:

1 Lifting gear 94202 1 Screw 11 Antipolishing ring
2 Distance plates 94202d 2 Water guide jacket 12 O-ring
2 Supporting beams 94203 3 Supporting ring 13 O-ring
2 Suspension straps 94206 4 Cylinder liner 14 O-ring
2 Special screws 94207 5 Cylinder jacket
4 Suspension straps 94208 6 Allen screw
1 HP oil pump 94931 7 Centring pin
1 Pressure gauge 94932 8 Centring pin AF Seating surface
1 Pressure gauge 94932a 9 Cylinder cover HU Wooden underlay
1 Connection piece 94934a 10 Screw EV Relief valve
1 HP hose 94935
2 HP hoses 94935a
2 Hydr. jacks 94936

Preparations for the removal of a cylinder liner

Drain cylinder cooling water from the respective cylinder, remove cylinder cover (see group 2708–1).
Remove piston together with piston rod gland (see group 3403–1 and 2303–1).
The two screws 1 fastening supporting ring 3 to cylinder liner 4 must be loosened and removed (Fig. ’F’).
Separate all piping connections for cylinder oil from the lubricating quills. All the passages for lubricating quills
and their protecting bushes (see group 2136–1) must be removed whenever a cylinder liner is being pulled out.

Normal removal
A cylinder liner can be removed normally by the crane and lifting gear only, whereby the following must be observed:
– Place lifting gear 94202 with the lightly fastened suspension straps 94206 onto cylinder liner 4.
– Loosen screws 10 correspondingly so that suspension straps can be fastened to cylinder liner with special
screws 94207. Hand-tighten the latter with approx. 30 Nm.
– Equally screw in the four screws 10 till the suspension straps touche the special screws. Hand-tighten screws
10 with approx. 30 Nm.

Remark Remark: Subsequently length ’x’ of the thread screwed-in should be min. 1.2-fold of the thread
diameter.

– Pull cylinder liner fully out by the crane.

10
94202
x

94202d
94206

94207

013.760/06

Wärtsilä Switzerland Ltd 1 2.06

2124–2/A1 Maintenance RTA48T

Cylinder Liner: Removing and Fitting

Removal of a jammed cylinder liner

Should a cylinder liner jam in the cylinder jacket bore, proceed as follows:
– Place two supporting beams 94203 on both sides of the piston rod gland bore in the cylinder jacket 5. Thereby
the bigger end of the supporting beams must point towards the fuel side.
– Place both hydr. jacks 94936 divided on the supporting beams 94203 under the cylinder liner.
– Connect hydr. jacks by HP hoses 94935 and 94935a as well as connection piece 94934a to HP oil pump 94931.
– Close relief valve ’EV’ at the HP oil pump, and jack the cylinder liner out of its guide portion by slowly pumping.
– Pull cylinder liner fully out by the crane according to Fig. ’A’.

B
I I

4
Brennstoffseite

94936
FUEL SIDE

94203

I-I

94932a
94934a

4
94932
94203

98.7529
94936

94931 EV 94935 94935a

2.06 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 2124–2/A1

Cylinder Liner: Removing and Fitting

Removal
– Fit four suspension straps 94208.
C – Turn the piston to T.D.C. whereby anti-
94208 11 4 polishing ring 11 is pushed out of its
seating and then it can be removed.
Fitting
– Clean the seating surfaces on the anti-
polishing ring and cylinder liner.
– Fit four suspension straps 94208.
 Pay attention that one of the holes for
fastening the suspension straps lies
003.468/00
on fuel side.
– Smear the antipolishing ring lightly
with oil.
– Fasten the ropes to the suspension
straps and fit the antipolishing ring by
means of the crane.

Removal and fitting of a supporting ring

The supporting ring 3 (Fig. D’ and ’F’) is fastened with three Allen screws 6 to the cylinder jacket 5 and located on the
fuel side by centring pin 7. For the removal of the supporting ring the three Allen screws 6 can be used as jacking
screws (Fig. ’E’) whereby the screws to the connection of the cooling water inlet at the supporting ring have to be
previously removed.
Prior to re-fitting the supporting ring, the sealing surfaces on the supporting ring and on the cylinder jacket must be
carefully cleaned, and then smeared with a non-hardening sealing compound (e.g. silicone).

D E

3 3 3

7 6 6

5 5 5

98.7645

Wärtsilä Switzerland Ltd 3 2.06

2124–2/A1 Maintenance RTA48T

Cylinder Liner: Removing and Fitting

F I-I
9
1

III 2

8 8

III II
4
I

3 AF
II
3
4
8 1
I

Brennstoffseite
FUEL SIDE
II - II
9
2
12
Brennstoffseite

IV
FUEL SIDE

13
1 1
IV
4

3 14 3
3 4
4 5

98.7530

013.779/06

2.06 4 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 2124–2/A1

Cylinder Liner: Removing and Fitting

Preparations for fitting cylinder liner

– Clean all guide areas and sealing surfaces on cylinder liner 4, cylinder jacket 5 and on supporting ring 3.
– Place O-rings 14 of the specified quality and dimension into the grooves on the cylinder liner.
– Smear O-rings and guide areas of cylinder liner, cylinder jacket and supporting ring with lubricating oil.
– Clean seating surfaces ’AF’ of supporting ring 3 and cylinder liner 4 carefully.

Fitting cylinder liner

– Mount lifting gear 94202 as described for Fig. ’A’.
– Move the cylinder liner hanging on the crane above the supporting ring 3.
– Lower the cylinder liner and apply a non-hardening sealing compound to the seating surfaces ’AF’ (Fig. ’F’ sec-
tion I-I).
– Turn cylinder liner and align the centring pin 8 with the centring holes of the supporting ring and cylinder liner.
Lower cylinder liner.
– Fit screws 1 and tighten them firmly for locking the cylinder liner onto the supporting ring (Fig. ’F’ section II-II).

Wärtsilä Switzerland Ltd 5 2.06

2124–2/A1 Maintenance RTA48T

Cylinder Liner: Removing and Fitting

Laying down and raising cylinder liner

– Place lifting gear 94202 as described for Fig. ’A’.
– Connect rope ’a’ (lifting capacity 3000 kg) with crane and lifting gear. Lay down the cylinder liner as shown in
Fig. ’G’ to ’I’ and secure it against rolling away.
 Raising the cylinder liner is carried out in reversed sequence.

Attention Risk of accident! Laying down and raising a cylinder liner must not be done in any other way
than as shown in the figure, i.e. in longitudinal direction of lifting gear 94202!

G H

a
94202
I

012.066/04
HU HU HU

2.06 6 u Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 2124–3/A1

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

Tools: Key to Illustrations:

1 Wear ridge grinding device 94299 1 Roller support 9 Thread nozzle
Emery cloth 2 Holder 10 Carbide milling cutter
Assorted files 3 Holder 11 Cylinder liner
Fine grain carborundum 4 Spacer roller 12 Top piston ring
5 Pipe (column)
6 Grinder G Lubricating grooves
7 Air hose P Scavenge port
8 Hose oiler

Due to wear by the piston movement in the cylinder liner running surface ridges are formed on top and bottom to
where the piston does not reach. Due to the wear the lubricating grooves in the cylinder liner lose their depth, further-
more the corner radii of the scavenge port edges become smaller and thereby sharper. It also happens that the
edges get damaged.
When a piston is removed the opportunity should be taken to measure the bore of the cylinder liner (see group
2124–1) and to remedy any irregularities which occurred. The following points are of particular importance:
Protect the space below the cylinder liner from falling particles with suitable material.
After completing the reconditioning clean the bore of the cylinder liner thoroughly and remove
any trace of metal dust (particularly from the lubricating grooves).
Carefully remove waste particles which may have passed into the scavenge space through the
ports.
Actuate the cylinder lubrication until oil flows from all the lubricating points, thereby flushing any
metal dust which accumulated there.

Removing the wear ridge

When grinding away the wear ridge take greatest care not to damage the running surface within the area covered
by the piston and piston ring stroke from T.D.C. to B.D.C. The machining of the wear ridge has to be carried out as
shown in Fig. ’B’.
We therefore recommend using a wear ridge grinding device (Fig. ’B’) for carrying out this work. It is listed in the tools
list under ’Recommended Special Tools’.

Re-dressing the lubricating grooves

If the depth of the lubricating grooves ’G’ 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.

Re-dressing the edges on the scavenge ports

The shape of the scavenge ports shown in Fig. ’A’ corresponds to new cylinder liners. If the condition of the edges
requires reconditioning (depending on the degree of wear or damage) aim at matching these shapes. Take great
care not to damage the running surface in the cylinder liner bore. Polish the passages into the running surface with
emery cloth.

Wärtsilä Switzerland Ltd 1 1998

2124–3/A1 Maintenance RTA48T

Re-dressing Lubricating Grooves, and Edges of the Scavenge Ports

Kanten gebrochen
SHARP EDGES REMOVED
Brennstoffseite
FUEL SIDE

I-I
II

P
II

99.7706

3.00 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 2124–3/A1

Removing Wear Ridge

B
5 1

94299

11

10

3
2
6

OTP
TDC

2 - 3mm

1mm

98.7661
4
12 11

7 8 9

Wärtsilä Switzerland Ltd 3 u 1998

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 RTA48T
Maintenance 2136–1/A1

Lubricating Quills and Accumulators

Removal and Fitting, Function Check

Key to Illustrations:
1 Accumulator cylinder 18 Screw
2 Spring 19 Support ring
3 Accumulator piston 20 Flange
4 Cap nut 21 Joint
5 Diaphragm 22 Compression spring
6 Accumulator casing 23 Non-return valve housing
7 Cap nut 24 Steel ball
8 Backing screw 25 Compression spring
9 CU-gasket 26 Spring guide
10 Cylinder liner 27 CU-gasket
11 Lubricating quill 28 O-ring
12 Passage for lubricating quill 29 O-ring
13 Filling pin
14 Filling pin
15 Steel ball BO Bore
16 Non-return valve housing DF Sealing surface
17 Flange ring GW Thread

Upper lubricating quill

The upper lubricating quills 11 are directly fitted into cylinder liner 10, pressing against filling pins 14.

I I 1
2
II
3
4
5
III 10 14 11 6

7
8

012.639/05 13 9 15 16 9

012.638/05

Wärtsilä Switzerland Ltd 1 2.06

2136–1/A1 Maintenance RTA48T

Lubricating Quills and Accumulators: Removal and Fitting, Function Check

B II Non-return valve in cylinder liner

Removal or fitting of a non-return valve can only be
carried out on a removed cylinder liner (Fig. ’A’ view
25 24 BO GW II).

Fitting
– Apply LOCTITE 620 to thread ’GW’ of non-return
valve housing 23.
Make sure that no liquid retaining
Attention compound enters in bore ’BO’!
– Screw non-return valve into cylinder liner and
tighten it to an angle of 90.

012.640/05 27 26 10 28 23 Check: A flow test must be carried out after every fit-
ting of a non-return valve.

Lower lubricating quill

The lower lubricating quills 11 are fitted into passages 12, pressing against filling pins 14.
The passages for lubricating quills are led through supporting ring 19 and fastened to cylinder liner 10.

C III

20

17

14

11 12 18 29

009.645/02

19 21 10 DF

2.06 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 2136–1/A1

Lubricating Quills and Accumulators: Removal and Fitting, Function Check

Removal and fitting of non-return valve in lubricating quill

D – For removal of a non-return valve which is fitted in lu-

13 22 15 16
bricating quill 11, loosen cap nut 7 and backing screw 8
(Fig. ’E’).
– After fitting a non-return valve, tighten backing screw
moderately and lock it with a centre punch.
009.647/02 Remark Non-return valves for lubricating quills
are only supplied complete as shown in
Fig. ’D’.

 When fitting the passage for lubricating quill take care that sealing surface ’DF’ between cylinder liner 10 and
passage for lubricating quill 12 is absolutely clean. Sealing surface ’DF’ must seal metallically and the use of
gaskets is prohibited.
 All filling pins 14 are identical.

Check of accumulator
During a major overhaul check at random several accumulators. Open them to inspect diaphragm 5. If oil is found in
the inner space of accumulator piston 3 or in the cylinder 1, the diaphragm is leaking or brittle and must be replaced
with a new one. Do not use any sharp-edged objects for fitting new diaphragms!

Check of non-return valve in lubricating quill

E 1
3 The non-return valve must also be checked for correct
functioning.
Therefore, the complete lubricating quill and accumulator
(Fig. ’E’) must be removed.
Check: If compressed air is blown into X ⇒ no air must
8 emerge from Y.
X If compressed air is blown into Y ⇒ air must
7 emerge from X.

009.646/02

Function check of lubricating quill

After fitting the cylinder liner and the pipings are reconnected to their lubricating quills, actuate the cylinder lubricat-
ing pump until oil emerges from all the lubricating points in the bore of the corresponding cylinder liner. Note that the
oil delivery for upper and lower row of lubricating grooves may be differently set (correct setting is recorded on the
acceptance records). Whatever the settings, make sure that on all the lubricating points of the same row of lubricat-
ing grooves the oil outflow quantity is equal.

Wärtsilä Switzerland Ltd 3 u 2.06

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 RTA48T
Maintenance 2303–1/A1

Piston Rod Gland

Dismantling and Assembling as well as Measuring the Wear

Tools: Key to Illustrations:

1 Dismantling device 94344 1 Housing, 2-part 11 Cylinder cover stud
(recommended special tool) 2 Scraper ring 12 Screw
2 Distance holders 94345 3 Sealing ring 12a Fitted bolt
1 Clamp ring (2-part) 94345b 4 Sealing ring 13 Locking plate
1 Gauge 94345c 5 Ring support 14 Screw
2 Spring assembly tools 94345e 6 Scraper ring 15 Ring (2-part)
6 Distance pieces 94345f 7 Locating pin 16 Cylinder jacket
1 Piston supporting device 94350 7a Locating pin 17 Piston rod
8 Tension spring 18 Hinged cover
9 Tension spring 19 O-ring
10 Screw

The removal of the piston rod gland (hereafter called gland) can be carried out in two different ways, i.e. removing
the gland together with the piston (variant 1) or removing the gland downwards into the crankcase leaving the piston
in situ and using dismantling device 94344 (variant 2).
On every piston overhaul, the gland must also be dismantled and inspected. Excessively worn or damaged parts are
to be replaced.
It is important that the gland be in perfect condition when assembled. A possible earlier than planned inspection of
the gland with piston in situ can only be carried out under difficult conditions and with the help of dismantling device
94344.

Removing, dismantling and assembling (variant 1)

Removing a gland
– Both distance holders 94345 are to be screwed on the foot of piston rod 17 (Fig. ’A’).
– Unscrew the four outer screws 14 to 2-part ring 15 (Fig. ’C’).

Attention For reasons of safety, the ten inner screws 10 to 2-part ring 15 are to be loosened and removed
after dismantling the gland (Fig. ’C’).

 Remove the piston including gland (see group 3403–1 ’Removal of a piston’).

1
A
15

94345

17
11

012.168/04

Wärtsilä Switzerland Ltd 1 2.06

2303–1/A1 Maintenance RTA48T

Piston Rod Gland: Dismantling and Assembling as well as Measuring the Wear

Dismantling a gland
– Place the piston in piston supporting device 94350. For this 2-part housing 1 of the gland must rest on the two
hinged covers 18 of the device.
– Loosen screws 10 and remove 2-part ring 15 (Fig. ’C’).
– Loosen and remove screws 12 and fitted bolts 12a to 2-part housing 1.
– Push both halves of the 2-part housing away from the piston rod.
– Remove all tension springs, scraper rings, sealing rings, and ring supports.
– Determine the wear on the following parts (Fig. ’E’) and compare it with the permissible values mentioned in
clearance table group 0330–1:
 scraper rings 2 and 6
 sealing rings 3 and 4

– Parts which are beyond the admissible tolerance must be replaced. If necessary remove scraper rings 6 from
ring supports 5 and replace them with new ones.
– Defective tension springs 8, 9 and O-rings 19 have to be replaced with new ones.

1
15

18

94350

94345

012.169/04

2.06 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 2303–1/A1

Piston Rod Gland: Dismantling and Assembling as well as Measuring the Wear

C II-II
I

1
10
14
15
19
12a

12

16

19

013.749/06

I
13 10
14 15
II

II

12a
FUEL SIDE

Wärtsilä Switzerland Ltd 3 2.06

2303–1/A1 Maintenance RTA48T

Piston Rod Gland: Dismantling and Assembling as well as Measuring the Wear

Assembling a gland
– Place the piston in piston supporting device 94350, its hinged covers 18 must be folded down.
– Attach clamp ring (2-part) 94345b – resting on the hinged cover – to piston rod 17.
– Place the three parts of a ring support 5 on the clamp ring with scraper ring 6 (Fig. ’E’) fitted. Distribute the dis-
tances evenly.
– Use assembly tool 94345e (see 9403–5) for fitting tension spring 9.
– Place two distance pieces 94345f (10 mm) on ring support 5 and fit another ring support with scraper ring 6 and
tension spring 9 as described above.
 The height of distance pieces 94345f corresponds to the respective web height of the ring grooves in 2-part
housing 1.

11mm
2 94345f
2 009.655/02

3
4
3
4

19 mm
94345f
009.654/02
94345b

18

5
11mm

94345b
94345f
012.173/04
009.655/02

17
94345

012.171/04

2.06 4 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 2303–1/A1

Piston Rod Gland: Dismantling and Assembling as well as Measuring the Wear

– After assembly of the ring supports for grooves ’d’ – ’i’ (Fig. ’E’), place two distance pieces 94345f (16 mm) on
the uppermost ring support 5 and fit sealing rings 3, 4 and tension spring 8 for groove ’c’.
 Take care that one segment is always provided with two horizontal locating pins 7a lying side by side on sealing
ring 4. These locating pins must fit into the corresponding bores in sealing ring 3. Remove possibly existing
vertical locating pins 7.
The remaining three segments are provided only with one horizontal locating pin each.
– Place distance pieces 94345f (16 mm) on the assembled sealing ring 3 and fit again sealing rings 3, 4 and
scraper ring 2 with tension springs 8 for groove ’b’.
 Proceed in the same way as mentioned above for sealing rings 3 and 4, however, a vertical locating pin 7 in
sealing ring 3 must fit into the respective recess in scraper ring 2.
No vertical locating pin may be fitted in the scraper ring.
– Place distance pieces 94345f (11 mm) on the assembled scraper ring 2 and fit the two uppermost scraper rings
2 with their tension springs 8 for groove ’a’.
No vertical locating pin may be fitted in the uppermost scraper ring.

E
2
17

Nute a
GROOVE a
8
2 7
3
4 Nute b
GROOVE b 7a

3
Nute c
4 GROOVE c

16
5 Nuten d–i 9
GROOVES d–i 1

6
006.097/99

013.773/06

Wärtsilä Switzerland Ltd 5 2.06

2303–1/A1 Maintenance RTA48T

Piston Rod Gland: Dismantling and Assembling as well as Measuring the Wear

– Remove all distance pieces 94345f and clamp ring

94345b.
– Check proper position of all rings with gauge
94345c resting on hinged cover 18 (Fig. ’F’).
– Smear piston rod as well as all rings with bearing
oil.

94350 – Push both housing halves 1 on hinged covers 18

over the ring pairs against the piston rod, then
screw them together with screws 12 and fitted
bolts 12a according Fig. ’C’.
94345c
– Place O-rings 19.
– Place 2-part ring 15 on the housing and screw it to-
gether by means of screws 10 and 14 (Fig. ’C’).
18
Secure screws 10 with locking plates 13 on the
housing division.
– Just before the gland is fitted with the piston, apply
lubricating oil to the respective bores in the cylin-
der jacket as well as to the gland housing in the re-
gion of the O-rings.
 When fitting the gland into the cylinder jacket dis-
tance holders 94345 must be mounted on the foot
of the piston rod.
 For fitting the gland in the cylinder jacket see also
17 group 3403–1.
94345

012.172/04

Removing, dismantling and assembling (variant 2)

For removing the gland with piston in situ using dismantling device 94344 (Fig. ’G’) the following procedure should
be observed:
– Turn the piston to B.D.C.
– Dismantling device 94344 (2-part) as shown in Fig. ’G’ is to be set on the stud nuts of the crosshead/piston rod
connection and both halves of the dismantling device are to be screwed together.
– Loosen and remove the four outer screws 14 from 2-part ring 15 (Fig. ’C’).
– Turn the piston with the mounted dismantling device carefully to T.D.C. until 2-part ring 15 is pushed a little
upwards (Fig. ’G’).
– Loosen and remove the ten inner screws 10 together with 2-part ring 15 (Fig. ’C’).

2.06 6 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 2303–1/A1

Piston Rod Gland: Dismantling and Assembling as well as Measuring the Wear

G 94345b
1
15
94345b
16

94344
17

I I

94345b
94344

– Clamp 2-part clamp ring 94345b onto the piston

rod lying on housing 1 (Fig. ’G’).
– Turn the piston slowly to B.D.C. again and pay
attention that the gland slides out of the gland bore
in the cylinder jacket without jamming.
 The same procedure as mentioned in the previous
section (variant 1) is to be applied here for disman-
tling and assembling a gland, with the exception
012.176/04 that the dismantling and assembling is carried out
using dismantling device 94344 instead of piston
supporting device 94350.
Check: Attention should be paid that the gland slides in the
I-I cylinder jacket without jamming when assem-
bling it using dismantling device 94344 and the
turning gear.
– Turn the piston to T.D.C. Fit 2-part ring 15, fasten it
with inner screws 10 and secure it with locking
plates 13 on the housing division (Fig. ’C’).
– Turn the piston to B.D.C. and remove dismantling
device 94344. Subsequently screw in and tighten
94344 1 outer screws 14.

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This page is intentionally left blank
 RTA48T
Maintenance 2708–1/A1

Cylinder Cover
Removal and Fitting

Tools: Key to Illustrations:

1 Hydr. tensioning device 94215 1 Cylinder cover 8 Air inlet for valve spring
1 Suspension device 94265 2 Nut 9 Water guide jacket
2 Spec. eye nuts 94265a 2a Cylinder cover stud 10 Allen screw
3 Protection caps 94265b 3 Cyl. cooling water outlet 11 O-ring
2 Lifting lugs 94811 4 Leak oil outlet 12 O-ring
5 Exhaust valve cage
5a Stud of exhaust valve cage
6 Connection for valve G Threaded hole
shank lubrication H Wooden underlay
7 Connection for hydr. oil R Eye bolt
A
1 8
5a 2
2a
3

EXHAUST SIDE
Brennstoffseite
FUEL SIDE

7 Abgasseite

6 5

R 4
96.7461

Removal of the cylinder cover

Drain the cylinder cooling water from the affected cylinder, i.e. first shut the valves for cylinder cooling water inlet
and outlet at the supporting ring on the exhaust side and above the cylinder cover respectively.
Open drain cock to the respective cylinder. This cock is situated on the exhaust side below the cock for cylinder
cooling water inlet.
Then open the vent valve in the cylinder cooling water outlet pipe of the respective cylinder!
– Disconnect all the pipes to the cylinder cover and to the exhaust valve as well as the expansion piece between
exhaust valve and exhaust manifold (removal see group 2751–1).
– Clean all the thread protrusions on the cylinder cover studs.
– Loosen and remove the nuts of the cylinder cover studs in accordance with the instructions in group 2708–2.
– Screw the spec. eye nuts 94265a to suspension device 94265 onto the studs 5a of the exhaust valve cage.
Insert the two hooks of the suspension device into the spec. eye nuts.
– Lift the cylinder cover 1 and water guide jacket 9 together with the crane (see Fig. ’C’).

Attention For the removal and fitting as well as for transporting a cylinder cover with its valve cage fitted in
place, the use of eye bolts ’R’ is not permitted. In this case the tools according to Fig. ’C’ are
provided.

Wärtsilä Switzerland Ltd 1 3.00

2708–1/A1 Maintenance RTA48T

Cylinder Cover: Removal and Fitting

Alternative (see Fig. ’B’)

Removing and transporting the cylinder cover is the same after the exhaust valve cage 5 has already been removed.

Fitting
Before placing the cylinder cover in position the following points must be taken care of:
 The compression space must be absolutely free of foreign particles or dirt.
 The seating surfaces on cylinder cover and cylinder liner must be clean and undamaged.
 A new soft iron joint ring 2 mm thick must be placed on the cylinder liner in such a way that it lies flat all over.
 The inner surface of the water guide jacket which is screw fastened to the cylinder liner as well as the respective
guide surface at the collar of the cylinder liner must be clean and smeared with bearing oil.
 Place new O-rings into the grooves of the cylinder liner and smear these with bearing oil.
 The threads of the cylinder cover studs must be clean and smeared with MOLYKOTE paste.
 Place three protection caps 94265b on cylinder cover waisted studs 2a (see Fig. ’C’).
When these conditions are all met, lower the cylinder cover, attached to the suspension device 94265, slowly over
the cylinder cover studs, whereby a centring pin assures the correct position (see group 2124–2).
After the removal of the suspension device screw all the nuts by hand onto the cylinder cover studs, paying attention
to easy turning. If necessary the stud threads may have to be reconditioned, so that the nuts can be screwed on by
hand.
Pre-tension the studs with the hydraulic pre-tensioning device 94215 in accordance with group 2708–2 then fit all
pipes to cylinder cover and exhaust valve. Concerning the fitting of the expansion piece between exhaust valve and
exhaust manifold see group 2751–1.
Finally shut drain and vent cock, and open the cocks for cooling water inlet and outlet.

94265 94265
B C

94265a
94265a

5
5a

5a

1 1
94265b
9 9
2a
96.7463

3.00 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 2708–1/A1

Cylinder Cover: Removal and Fitting

Removal of the water guide jacket

– Place the cylinder cover with screwed-down water guide jacket on the wooden underlays ’H’ as shown in Fig.
’D’.
– Unscrew all Allen screws 10, then screw them into the three threaded holes ’G’ till they stop at the cylinder
cover.
– Lift the cylinder cover slightly with the crane (10–20 mm), and continue to screw in the screws 10. Repeat this
action until the water guide jacket, lying on the wooden underlays ’H’, is withdrawn from the cylinder cover.
– Lift off the cylinder cover and carry it away.

Attention Danger of accident! Never put your hands between the water guide jacket and the wooden un-
derlays!

When the cylinder cover is lifted off, the water guide jacket must either be screwed down on it, or
completely removed!

1 ’G’
12
9
11

10
98.7648

’H’ ’H’

Fitting of the water guide jacket

– Clean all the sealing faces and ring grooves.
– Unscrew the Allen screws 10 from the threaded holes ’G’ and insert them in the through holes.
– Put the water guide jacket on the wooden underlays ’H’, and lubricate the sealing faces, as well as the O-rings.
Use new O-rings only!
– Lower and align the cylinder cover above the water guide jacket as far as to allow the Allen screws 10 to be
screwed in the cylinder cover.
– Screw in the Allen screws evenly, until the water guide jacket contacts the cylinder cover, then tighten the
screws.

Wärtsilä Switzerland Ltd 3 u 3.00

This page is intentionally left blank
 RTA48T
Maintenance 2708–2/A1

Cylinder Cover
Hydraulic Loosening and Tensioning of Cylinder Cover Waisted Studs

Tools: Key to Illustrations

1 Hydr. tensioning device 94215 1 Cylinder cover stud 10 Exhaust valve cage
consisting of: 2 Nut 11 Nut
8 Pre-tensioning jacks 94215a 3 Vent screw for exhaust valve cage
8 HP hoses 94215b 4 Piston 12 Handle
2 Piston reset devices 94215d 5 Round nut
2 Holders 94215e 6 Pin
1 Suspension device 94265 7a,b Supporting and O-ring
1 Pressure gauge 94932a 8a,b Supporting and O-ring
1 Connection piece 94934a 9 Cylinder R Round bar
1 HP hose 94935
2 HP hoses 94935a
1 Hydraulic unit 94942

Remark The instructions in group 9403–4 concerning the application of hydraulic pre-tensioning jacks for
screwed fastenings must be followed. Should a cylinder cover stud have to be replaced, please
observe the indication in group 2751–1.

Set-up of the pre-tensioning jacks

– Clean the threads of all cylinder cover studs 1 (Fig. ’B’) as well as the area around nuts 2.
– Mount all pre-tensioning jacks 94215a over the cylinder cover studs and rest them on the cylinder cover (ar-
rangement according to Fig. ’A’).
– Place both holders 94215e and the respective HP hoses 94215b upon the nuts for the studs of the exhaust
valve cage 10, then connect the HP hoses to the pre-tensioning jacks 94215a (Fig. ‘A’).
– Open the vent screws 3 (Fig. ‘B’) of all pre-tensioning jacks.
– Connect the pre-tensioning jacks with the hydraulic unit 94942, using HP hoses 94935 and 94935a, as well as
the connection piece 94934a (Fig. ‘A’).
– Press the pistons 4 of all pre-tensioning jacks 94215a downwards upon cylinder 9, either by screwing on the
round nuts 5 (Fig. ‘A’), or – without round nuts – by using the piston reset devices 94215d (Fig. ‘C’).
– When the pistons are resting on the cylinders there should be little or no clearance at ‘x’.
– After using the piston reset device screw the round nuts 5 until they sit firmly on piston 4.

Remark For loosening the waisted studs screw back the round nuts by about 1¾ turns.
For tensioning the waisted studs the round nuts must lie on piston 4.

Wärtsilä Switzerland Ltd 1 3.00

2708–2/A1 Maintenance RTA48T

Hydraulic Loosening and Tensioning of Cylinder Cover Waisted Studs

Loosening
– Set-up of the pre-tensioning jacks as mentioned already. Open the vent screws 3 of the pre-tensioning jacks.
– Start up hydraulic unit 94942.
– Close vent screws 3 on the jacks as soon as oil flows bubble-free.
– Actuate hydraulic unit until a pressure of 1020 bar is indicated on its pressure gauge and on the pressure gauge
94932a. Attention should be paid to ensure that the pins 6 always protrude slightly compared with the pistons 4
on the pre-tensioning jacks!
– Turn all the nuts 2 upwards till the stop, using round bar ’R’. Store round bar ’R’ in the holder 94215e while not in
use (see Fig. ’A’).
– Release pressure to zero. Check if the round nuts can be turned.
– Disconnect and remove the HP hoses 94215b from the pre-tensioning jacks.
– Unscrew round nuts 5 and remove them together with the pre-tensioning jacks.

Tensioning
– Smear threads and seating surface of nuts 2 with MOLYKOTE paste G.
– Tighten all nuts down with the round bar ’R’ till fully seated (check with feeler gauge).
– Mark position of all nuts, with a line on nuts and cylinder cover, with a felt-tip pen (this will serve for a later check).
– Set-up of the pre-tensioning jacks as mentioned already. Open the vent screws 3 of the pre-tensioning jacks.
– Start up hydraulic unit 94942.
– Shut vent screws 3 on the pre-tensioning jacks as soon as oil flows bubble-free.
– Actuate hydraulic unit until a pressure of 1000 bar is indicated on its pressure gauge and on the pressure gauge
94932a. Attention should be paid to ensure that the pins 6 always protrude slightly compared with the pistons 4
on the pre-tensioning jacks!
– While keeping this pressure constant tighten all nuts 2 with round bar ’R’ till fully seated on the cylinder cover
(check seating with feeler gauge), verify while tightening that all nuts can be turned by about the same angle of
400.
– Where it is found that a nut can be turned considerably less than the others, it must be assumed that the respec-
tive cylinder cover stud has become insufficiently tensioned. This may occur if supporting and O-rings 7a, b and
8a, b (Fig. ’B’) of a pre-tensioning jack are defective or if a piston 4 has been jammed. A further possibility is that
a connection piece of HP hoses 94215b is leaky or incorrectly connected. If necessary the whole tensioning
procedure must be repeated after the cylinder cover stud nuts have been loosened again.
– When all nuts have been tightened by practically the same angle, release the oil pressure to zero.
– Disconnect and remove the HP hoses 94215b from the pre-tensioning jacks.
– Unscrew round nuts 5 and remove them together with the pre-tensioning jacks.
– Verify by the previously applied marks that all nuts have been turned equally by an angle of about 400.

3.00 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 2708–2/A1

Hydraulic Loosening and Tensioning of Cylinder Cover Waisted Studs

I 94265
A

10

94215e R

94215d
94215d
11

10

94215b

94935a 94932a 94935a

94934a

94935
94215a

94942

B 12 C
94215d
5 1 3 6 R

3
x

7a,b
8a,b 4 9
2
9
R R

98.7415

Wärtsilä Switzerland Ltd 3 u 3.00

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 RTA48T
Maintenance 2708–3/A1

Cylinder Cover
Manual Overhaul of Sealing Face for the Injection Valve in the Cylinder Cover

Tools: Key to Illustrations:

1 Overhauling device 94270 1 Cylinder cover 6 Centring mandril
1 Ring spanner AF 24 2 Milling cutter holder S Screw
3 Guide flange * Threaded holes to take
4 Setscrews the screws ’S’ when the tool
5 Profiling cutter is not in use

* 2 3 S

When fitting the injection valve, the seat sealing

face in the cylinder cover must be clean and undam-
aged as the sealing is metallic.

Should any blow-by of combustion gases have

been noticed during engine operation, the spring
packets with their screws of the injection valve are
not, under any circumstances, to be tightened fur-
ther as a counter measure as this might lead to de-
formation of the injection valve.

Dirty or slightly damaged sealing faces can be re-

conditioned on the spot by using the overhauling
device 94270, which is part of the tool kit. This is
done by carefully inserting the profiling cutter,
bolted to the milling cutter holder, into the hole in the
cylinder cover with the guide flange. This flange is
clamped down with two screws ’S’ which are kept
screwed into the threaded holes marked * when not
in use.
1
When the tool is being used, the centring mandril on
the profiling cutter on the one hand and the guide
4 flange on the other, give the tool the necessary sta-
bility and direction. Cutting is done by pressing
down lightly with the hand on the milling cutter
holder at the same time as turning the hex. cover
5
evenly with the other hand using the ring spanner.
Try to remove as little material as possible but suffi-
cient, however, to obtain the desired standard for
6 the seating area.

Putting some sticky grease on the profiling cutter

will prevent any foreign matter from entering the
combustion chamber during overhaul.

99.7697

Wärtsilä Switzerland Ltd 1 u 3.00

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 RTA48T
Maintenance 2722–1/A1

Injection Valve
Checking, Dismantling, Assembling and Adjusting

Tools: Key to Illustrations:

1 Hydr. tightening device with 94269 1 Injection valve 15 Nozzle body with
1 Special spanner 94269a 2 Allen screw needle seat
1 Hydr. jack 94269b 3 Spring plate 16 Nozzle needle
1 HP hand oil pump 94269c 4 Cup spring 17 Locating pin
1 Protective cap 94271 (spring packet) 18 Locating pin
1 Valve test stand L’ORANGE 94272 5 Nozzle holder 19 Nipple
1 Holding angle 94273 6 Spring tensioner 20 Tip retainer
1 Support 94273a 7 Collar nut 21 Nozzle tip
1 Connection piece 94274 8 O-ring 22 Snap ring
1 HP hose (1500 bar) 94275 9 Compression spring 23 Locating pin
10 Spring cage
11 Guide bush
12 Tappet EV Relief valve
13 Stop bush H Pump lever
14 Retaining nut M Pressure gauge

For checking, dismantling, assembling and adjusting the injection valve use the valve test stand L’ORANGE 94272.
Before commissioning the instructions and directions of the test stand manufacturer must be observed.
Keep the test stand in perfect condition and always put clean diesel fuel oil (gas oil) into the fuel tank.
From time to time check the pressure gauges of the valve test stand with a master pressure gauge and adjust them if
necessary.

Remark The work station must be clean; welding and grinding should not be done nearby!

Checking of an injection valve (Fig. ’A’)

A
– Remove the combustion residues at the nozzle tip 94272 94275
with a brass wire brush.
– Screw down the support 94273a on the holding angle
94273. 94273
– Screw down the injection valve 1 on the holding angle 94274
94273 of the test stand with the Allen screws 2 and the M H
spring packets 4. 2
– Screw down the connection piece 94274 on the nipple 4
19 (Fig. ’D’) of the injection valve and connect it to the 1
HP hose 94275.
94273a
– First check the atomization of the fuel oil by short and
vigorous pumping, then watch at what pressure the
injection valve opens while pumping slowly and
steadily. The pressure can be read on pressure gauge
’M’ and should correspond to the value specified in
the engine setting table.

Attention Danger of injuries! When pumping 98.7673

never hold fingers or hands in front of

the spray holes of the injection nozzle!

Wärtsilä Switzerland Ltd 1 3.00

2722–1/A1 Maintenance RTA48T

Injection Valve: Checking, Dismantling, Assembling and Adjusting

Judging an injection valve

The correct functioning of an injection valve can be seen when the fuel oil is equally sprayed out from all holes of the
nozzle tip under the specified pressure.
A loud ’chattering’ should be heard then, and after the pump jerk is completed no fuel oil may drip from the nozzle tip.
It is simple to check if the atomization is regular: hold a clean paper in front of the spray holes of the nozzle tip, then
bring the injection valve to spraying by one, short pump jerk. The sprayed ‘image’ which has been formed by this
clearly indicates if some spray holes of the nozzle tip are partly or even completely choked.
Injection valves with poor atomization must be dismantled and repaired, or replaced. It is often sufficient to clean
them thoroughly to put them into working order again.

B
Dismantling of an injection valve 94269b 94273 94269a
– Unscrew the support 94273a (Fig. ’A’) from the holding
angle 94273.
– Turn the holding angle 94273 into the vertical position,
and screw down the injection valve 1 on it with the Allen
screws 2 and the spring packets 4.
– Loosen the collar nut 7 and unscrew the spring tensioner
6 until the compression spring 9 is completely released
(Fig. ‘D’).
– Turn the holding angle with the injection valve mounted
on it into the horizontal position (Fig. ‘B’).
– Put the special spanner 94269a on retaining nut 14, and EV
loosen the latter by means of the hydraulic jack 94269b
and the HP hand oil pump 94269c according to Fig. ‘B’.
94269c
Attention Never completely retract the piston of the
jack 94269b.
98.7263
– Remove the special spanner, screw off the retaining nut
14, and remove it together with nozzle needle 16, tip re-
tainer 20 and nozzle tip 21. Be careful that the nozzle
needle does not fall out (Fig. ‘D’).

– Dismantle the spring tensioner 6, the compression spring 9, the tappet 12, and check their condition (Fig. ‘D’).
– Dismantle the tip retainer 20 by means of two screw drivers as described under “Replacing a nozzle tip” (Fig.
’C’).
Nozzle holder 5 and nozzle body 15 (Fig. ‘D’) with poor sealing faces must either be replaced or repaired by the
manufacturer or a special company.
Nozzle tips with eroded holes must be replaced.

Attention Each nozzle needle 16 belongs to its defined nozzle body 15 where it has been individually fitted
in. Therefore, never interchange nozzle needles and nozzle bodies!

3.00 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 2722–1/A1

Injection Valve: Checking, Dismantling, Assembling and Adjusting

Replacing a nozzle tip

C
If the nozzle tip 21 should be dismantled only, it is
sufficient to remove the tip retainer 20.

Removal: Schraubenzieher
– Using two screw drivers inserted between both SCREW DRIVER
recesses in the retaining nut 14, press the snap
ring 22 out of the groove in the retaining nut, 21
whereby the tip retainer can be withdrawn (Fig.
’C’).
Watch that the snap ring does not jump off un-
expectedly.
– Remove nozzle tip. 23
20
Fitting:
For fitting it is advantageous to clamp the injection 22
valve on its flange into a vice (nozzle body pointing 14
upwards), and then proceed as follows:
15
– Clean all parts with clean diesel oil or kerosine
and blow them out with compressed air.
5
– Place nozzle tip on the nozzle body 15 whereby
the position is fixed by the locating pin 23.
– Put the tip retainer 20 over the nozzle tip, and
press the snap ring 22 into the groove of the re-
taining nut by means of the screw drivers.

98.7674

Wärtsilä Switzerland Ltd 3 3.00

2722–1/A1 Maintenance RTA48T

Injection Valve: Checking, Dismantling, Assembling and Adjusting

Assembling of an injection valve

– Clean all parts with clean diesel oil or kerosine and blow them out with compressed air.
– Screw down the nozzle holder on the holding angle of the valve test stand, then turn the holding angle so that
the sealing face of the nozzle holder is on the top.

Remark The fitted positions of nozzle body 15 and nozzle tip 21 are fixed by locating pins, so that the parts
cannot be assembled wrongly.

– Clean the sealing faces of nozzle holder 5 and

nozzle body 15 with a clean hand and put the D
nozzle body with the nozzle needle on the
nozzle holder while taking care that the nozzle
19
needle does not fall out.
(If tappet 12, compression spring 9, and 6
spring tensioner 6 are already fitted, the
spring tensioner must be screwed in with 7
approx. 1 turn only, to prevent the nozzle body 8
from being pushed away by the spring force.)
– Grease the thread and the seating surface of
retaining nut 14 with MOLYKOTE G and
screw it on by hand (without spanner) as far
as the stop.
If the tappet, the compression spring, and the
spring tensioner are not yet fitted, they can be
installed now (screw in the spring tensioner by 1 9
turn only).
Assembly of nozzle tip and tip retainer see under
“Replacing a nozzle tip”.
12

13
17
15

14 16
22

20
23
21

98.7693

3.00 4 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 2722–1/A1

Injection Valve: Checking, Dismantling, Assembling and Adjusting

Tightening the retaining nut:

– Place the special spanner 94269a on the retaining nut
and pre-tighten the latter by means of HP hand oil E 94269b 94273 94269a
pump 94269c and hydr. Jack 94269b with a pressure of
20 bar, or by a hammer blow on the special spanner.
– Remove the special spanner and mark retaining nut
and nozzle holder together with a felt pen (‘0’ mark).
Taking this ‘0’ mark as a reference, the retaining nut is
now tightened with the hydr. jack by another 30°.
These 30° correspond to 16.8 mm on the circumference of
the retaining nut if its diameter is 64 mm.
If some parts such as nozzle body 15, nozzle holder 5, or
retaining nut 14 have been replaced, loosen the retaining
nut after tightening with 30°, and repeat the whole tightening
process. EV
Attention Never completely retract the piston of
the jack 94269b. 94269c

98.7260

Adjusting the opening pressure:

Install the injection valve in the valve test stand as shown in Fig. ’A’.
Set the opening pressure given in the engine setting table by pumping regularly while adjusting spring tensioner 6.
Check with some short, quick pump jerks if the injection nozzle is spraying evenly while ‘chattering’. When this con-
dition has been reached, hold the spring tensioner 6 while tightening collar nut 7.

Protecting the nozzle tip

To protect the nozzle tip integrated in the injection valve from F
damage, always fit the protective cap 94271 for transport,
storage, etc. (Fig. ‘F’).

94271 98.7676

Wärtsilä Switzerland Ltd 5 3.00

2722–1/A1 Maintenance RTA48T

Injection Valve: Checking, Dismantling, Assembling and Adjusting

Fitting an injection valve in the cylinder cover

– Clean the seating surface of the injection valve in the cylinder cover and check for damages.
If necessary recondition the seating surface with the special tool supplied with the tools set (see group 2708–3).
The sealing must be metal-to-metal, i.e. no joint must be put in between.
– Put the injection valve carefully in the cylinder cover.

G
Screwing down the injection valve: 18 2
Grease the threads and the seating surfaces of the Allen 4
screws 2 with MOLYKOTE G and screw them in.
Press the injection valve onto its seat in the cylinder cover by
equally tightening the Allen screws 2.
The correct pressure is reached when both spring packets 4
are completely compressed (solid length).
The solid length is reached when the resistance increases
noticeably during tightening of the Allen screws.
After the solid length has been reached both Allen screws
must be loosened by 90° (¼ turn).

98.7694

4 Arrangement of the cup springs (spring packet)

– The cup springs 4 are fitted in the spring cage 10.
10
– The spring packet consists of three packs composed of
five cup springs which are arranged as shown in Fig. ‘H’.

98.7694

3.00 6 u Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 2728–1/A1

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

Tools: Key to Illustrations:

1 Depth gauge 94124 1 Nut 12 Joint ring
2 Jacking screws 2 Cover 13 Control valve
3 Intermediate ring 14 Connecting pipe
4 Casing 15 O-ring
5 O-ring to casing 16 Piston ring
6 Cylinder cover H Control air pipe
7 Self-locking nut (from starting air distributor)
8 Piston J Control air pipe
9 Valve spindle (from starting air pipe)
10 Allen screws R Eye bolt
11 Compression spring S Air gap

Should functional difficulties occur with the starting valves when starting or during manoeuvring, or should a starting
air pipe near to where it joins the cylinder cover become noticeably hotter in operation than on the neighbouring
cylinders, then the starting valve must be dismantled and reconditioned at the very next opportunity.
If no such difficulties occur it is recommended to dismantle yearly at random one starting valve for a thorough check
and to overhaul the other starting valves in frequencies determined by such checking.

Removal from the cylinder cover

Loosen control air connections. Push control air pipes ’H’ and ’J’ aside, then remove the swivel connection to control
air pipe ’H’.
Loosen and remove all four nuts 1.
Loosen and remove allen screws 10. Screw jacking screws into the threaded holes in the casing 4 and by tightening
them jack the complete starting valve from the bore in the cylinder cover 6. The valve can then, suspended by the
two ring screws ’R’, be lifted from the cylinder cover.
When the removal is carried out with the cylinder cover fitted on the engine, the vacated opening must be immedi-
ately covered by suitable means to prevent the possibility of foreign particles entering the combustion space.

Dismantling a starting valve

– Lift cover 2 with mounted control valve 13. Take care that during lifting, the cover does not get jammed, whereby
connecting pipe 14 risks being damaged.
– Remove intermediate ring 3 from casing 4.
– For further dismantling clamp the valve on the milled faces below the spindle cover (spanner purchase) in a
vice.
– Loosen self-locking nut 7 with a socket spanner, and remove it.
– Pull piston 8 and compression spring 11 from the casing.
– Lift casing 4 up over valve spindle 9.

Grinding-in
Should the valve seat require re-grinding, apply some grinding paste to the spindle seat and grind it in on the valve
seating.
Badly worn seat faces must first be machined and only then ground in (lapped) manually.
The valve spindle has an angle of 61, however, the valve seat angle amounts to 60.

Wärtsilä Switzerland Ltd 1 11.01

2728–1/A1 Maintenance RTA48T

Starting Valve: Removing, Fitting and Dismantling, Grinding-in and Assembling

Assembling
Assemble the valve (excluding the cover 2) in reverse sequence to the dismantling.
Clean all parts and smear them lightly with oil.
Apply MOLYKOTE paste G to the thread of spindle 9 and tighten the self-locking nut 7 with 130 Nm or by a tightening
angle of 50. The spindle thread in the region of the locking ring of the self-locking nut 7 must not be lubricated.
Place new O-rings 5 and 15 in the groove in the valve casing and connecting pipe 14 respectively and oil lightly.
After completing the assembly (without cover 2) check the easy movement of the spindle by moderately tapping the
spindle top several times with a lead block in an axial direction; the spindle must jump every time back on the seat.
Should the valve seat have been ground/machined several times, check the air gap ’S’, as it diminishes with every
reconditioning of spindle or seat, in the extreme case the valve will no longer shut.
The air gap ’S’ (see Fig.) must be minimum 1 mm;
it can be measured with depth gauge (tool No. 94124) from the upper edge of intermediate ring 3 onto the piston 8.
Fit cover 2 and tighten it with allen screws 10. Take care that when assembling the cover 2, the transfer sleeve 14
does not interfere.

Fitting in the cylinder cover

Place a new joint ring 12 on the shoulder of the bore in the cylinder cover.
Smear bore in cylinder cover lightly with oil and fit the assembled starting valve.
Screw in the nuts 1 and tighten them crosswise through an angle of 130.

1998 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 2728–1/A1

Starting Valve: Removing, Fitting and Dismantling, Grinding-in and Assembling

I-I II

13
III - III IV - IV
1
10 2

2 7
2
S
15
3 14

16 4 15
4
4
8

16

9
5
6

II
11

R
J

H IV

12

IV
I III
I
13

1 96.7621

III

Wärtsilä Switzerland Ltd 3 u 1998

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 RTA48T
Maintenance 2740–1/A1

Relief Valve for Cylinder Cover

Dismantling, Assembling and Testing

Tools: Key to Illustrations:

1 Valve test stand L’ORANGE 94272 1 Spring tensioner 10 Valve seat
1 Holding angle 94273 2 Distance ring 11 Cylinder cover
1 HP hose line (1500 bar) 94275 3 Nut 11a Copper joint
1 Testing device 94276 4 Studs 12 Screw
2 Jacking screws M12 5 O-ring 13 Copper joint
6 Housing
7 Compression spring
8 Spring plate H Pump lever
9 Valve body MA Pressure gauge

A I
All relief valves of the cylinder covers are
to be overhauled according to the inter-
vals mentioned in the maintenance
schedule group 0380–1. After loosening
both nuts 3 the relief valve can be with-
drawn from the cylinder cover using two
1 jacking screws M12. Check relief valve
2 for absolute tightness and correct open-
ing pressure, with the aid of the valve
test stand 94272 (Fig. ’C’ and ’D’).
3
Even if the opening pressures are still
correct, it is advisable to check a few re-
4 lief valves at random. Depending on the
condition found, possibly check the re-
maining relief valves too.

5 The correct opening pressure is marked

on the flange of the housing 6 and en-
tered in the setting tables of the engine.

Dismantling (Fig. ’A’)

6
For dismantling clamp the relief valve at
the rectangular upper part in the vice.
Unscrew spring tensioner 1 and remove
compression spring 7 with spring plate 8
and valve body 9. Then loosen valve
seat 10.
All components should be cleaned and
checked thoroughly.
7
I
8
9
10 1

3
11

11a

98.7731

Wärtsilä Switzerland Ltd 1 3.00

2740–1/A1 Maintenance RTA48T

Relief Valve: Dismantling, Assembling and Testing

Procedure for grinding-in

Valve seats of which the contact surfaces are in bad condition are best re-ground by machine, aiming at the following
angles:
– Seat of valve body 9 = 43
+ 10’
– Seat of valve seat 10 = 45 0

Valve seats which are only slightly damaged, however, can be re-conditioned by grinding-in by hand. In this case
follow the procedure below (Fig. ’B’):
Clamp valve body 9 into a bench vice (use protection). Using a small pointed stick, place a few dots of grinding paste
onto the seat of the valve body, towards the greater diameter (Fig. ’B’, detail ’a’).
Put valve seat 10 onto valve body 9 and turn valve seat backwards and forwards. Clean the faces several times and
repeat the grinding process until a relatively narrow, shiny band – towards the smaller diameter – indicates the con-
tact area (Fig. ’B’ detail ’b’).
Finally thoroughly clean valve seat and body.

B 10
a
45° + 010’

9 43°
b
Schutz
PROTECTION

98.7660

Assembly
– Thoroughly clean all components and lightly oil them.
– Apply MOLYKOTE paste G to the valve body 9, the landing faces of compression spring 7 and the threads of
spring tensioner 1.
– Use a high temperature resistant lubricant, such as THREAD GARD or LOCTITE ANTI SEIZE COMPOUND,
for coating the threads of valve seat 10.
– Clamp the relief valve at the rectangular upper part in the vice and screw the valve seat 10 – with valve body 9
fitted – into the housing 6 and tighten firmly.
– Fit spring plate 8 and compression spring 7 and screw in the spring tensioner 1 – at first without distance ring 2 –
until the distance to the valve housing corresponds approximately to the height of the distance ring.

7.03 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 2740–1/A1

Relief Valve: Dismantling, Assembling and Testing

C 1 D 94272
2
12
6

94275
MA
94276
13 94275

94273

98.7532

Testing the relief valve

Pay attention to the manufacturer’s detailed instructions and working specifications of the valve test stand (Fig.
’D’), in particular prior to commissioning.
– Place relief valve vertically into the testing device 94276 (Figs. ’C’ and ’D’) that is already screwed into the hold-
ing angle 94273 of the valve test stand 94272 and tighten it with both screws 12 (first insert copper joint 13).
– Connect HP hose line 94275 to connecting piece of the testing device 94276 and valve test stand (Figs. ’C’ and
’D’) and operate pump lever ’H’ until the relief valve opens. Check the opening pressure at the pressure gauge
’MA’.
– Depending on the opening pressure found, further tighten or loosen spring tensioner 1 until the correct opening
pressure has been established.
– Now measure the distance between the spring tensioner 1 and the housing 6 and prepare a distance ring 2 of
corresponding height.
– Unscrew the spring tensioner and insert distance ring.
– Tighten the spring tensioner 1 once again and re-check the relief valve.

Fitting the relief valve into the cylinder cover (see Fig. ’A’)
Before fitting the relief valve, thoroughly clean the bore and contact surface in the cylinder cover. Make sure that no
foreign matter enters the combustion chamber when carrying out the work with the cylinder cover fitted.
Fit the relief valve with an O-ring 5 in perfect condition and place a new copper joint 11a onto the contact surface in
the cylinder cover. Coat the outside of the valve housing with a little grease or oil to protect it against rust.
Apply MOLYKOTE paste G to the threads of the studs 4 and, after fitting the relief valve, firmly tighten the nuts cross-
wise and in even stages.

Wärtsilä Switzerland Ltd 3 u 3.00

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 RTA48T
Maintenance 2751–1/A1

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

Tools: Key to Illustrations:

2 Pre-tensioning jacks 94252 1 Waisted stud 9 Valve cage
1 Valve protector 94262 2 Nut 10 Expansion piece
1 Suspension device 94265 3 Pin 11 Protection pipe
2 Lifting lugs 94811 4 Vent screw
1 Pressure gauge 94932a 5 Piston
1 Connection piece 94934a 6 Cylinder
1 HP hose 94935 7 Sealing ring K Slot
2 HP hoses 94935a 8 Valve spindle R Round bar
1 Hydraulic unit 94942

Prior to the removal of an exhaust valve, drain first the cylinder cooling water from the respective cylinder (see group
2708–1) and close the air inlet to the air spring at the control air supply.
Remove all connected pipes. Expansion piece 10 (Fig. ’A’) has to be removed with the aid of lifting lug 94811 and the
suspension device 94265. Therefore, the two screws of each suspension strap have to be screwed into the expan-
sion piece flange. After removing the connecting screws from the expansion piece flanges the expansion piece can
be taken out in the engine longitudinal direction.
After loosening both nuts which fasten the exhaust valve to the cylinder cover, the complete exhaust valve can be
pulled out of the cylinder cover by the crane with suspension device 94265 (Fig. ‘E‘).

Remark It is essential that the instructions in group 9403–4 referring to the application of hydraulic pre-
tensioning jacks to screwed fastenings be strictly followed.
Regarding draining cylinder cooling water please refer to group 2708–1.

Working sequence for removal

– Clean the threads of waisted studs 1 of the valve cage as well as the area around the nuts 2 (Fig. ‘C‘).
– Place both the pre-tensioning jacks 94252 on the two waisted studs 1 (Fig. ’C’) which have to be loosened and
completely screw them on with opened vent screw 4 (arrangement according to Fig. ’B’).
– Then both pre-tensioning jacks are to be loosened by about ¾ turn.
– Connect the pre-tensioning jacks 94252 by HP hoses 94935 and 94935a as well as connection piece 94934a
with the hydraulic unit 94942 as shown in Fig. ’B’.
– Verify the oil level in the hydraulic unit.
– Actuate hydraulic unit.
– Close vent screws 4 on the pre-tensioning jacks as soon as oil flows bubble-free.
– Actuate hydraulic unit till a pressure of 1020 bar is indicated on the pressure gauge 94932a and on the pressure
gauge at the hydraulic unit. Attention should be paid to ensure that the pins 3 always protrude slightly compared
with the pistons 5 on the pre-tensioning jacks!
– Turn all the nuts 2 back by one turn, using round bar ’R’.
– Release pressure to zero at the hydraulic unit and then remove pre-tensioning jacks 94252.
– Hang the hooks of suspension device 94265 (Fig. ’E’) into the eye screws of the valve cage 9, then lift complete
exhaust valve with the crane.
– If the exhaust valve is not to be dismantled at site immediately, mount the valve protector 94262 (Fig. ’D’).

Wärtsilä Switzerland Ltd 1 3.00

2751–1/A1 Maintenance RTA48T

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

Working sequence for fitting

– Before fitting the exhaust valve into the cylinder cover, the sealing surfaces must be checked for cleanliness
and possible damage.
– Make sure that the soft iron gasket of 2 mm thickness lies flat in its recess in the cylinder cover.
– Replace all O-rings by new ones of specified dimensions and quality, oil O-rings slightly before fitting.
– Fit the complete exhaust valve with the help of the suspension device 94265, taking greatest care not to dam-
age the thread of the waisted studs.
– The correct position of the exhaust valve cage is determined by the cylindrical dowel pin set in the cylinder
cover.
– Smear thread of waisted stud lightly with MOLYKOTE paste G.
– Fit nuts 2 and tighten them firmly with the round bar ’R’ till fully seated before mounting the pre-tensioning jacks
94252 (check seating with feeler gauge).
– Mark position of stud nuts on a corner and their position on the valve cage 9 with a felt-tip pen (for later checks).
– Screw the pre-tensioning jacks 94252 onto the waisted studs 1 completely (Fig. ’C’). Moreover, the vent screws
4 are to be opened slightly so that the pistons 5 can slide back to their initial position i.e. there is no or very little
clearance at ’x’.
– Connect the pre-tensioning jacks 94252 by HP hoses 94935 and 94935a as well as connection piece 94934a
with the hydraulic unit 94942 as shown in Fig. ’B’.
– Verify the oil level in the hydraulic unit.
– Actuate hydraulic unit.
– Close vent screws 4 on the pre-tensioning jacks as soon as oil flows bubble-free.
– Slowly raise the pressure to 1000 bar. Attention should be paid to ensure that the pins 3 always protrude slightly
compared with the pistons 5 on the pre-tensioning jacks! Keep this pressure constant and tighten the nuts 2
with a round bar ’R’ till firmly seated on exhaust valve cage 9 (check seating with a feeler gauge through the slot
’K’). After tightening the nuts ascertain that these have been turned by about the same angle of 150.
– Release pressure to zero and remove both pre-tensioning jacks 94252.

Remark When fitting expansion piece 10 (Fig. ’A’) smear its flange surfaces and connecting screws lightly
with a heat resisting lubricant. The expansion piece has to be fitted in such a way that protection
pipe 11 of the expansion piece comes to lie in the flow direction i.e. on the valve cage side, as
shown in Fig. ’A’.

A 94265

94811
10
10
I

94811 94811 I
I-I

11 10
011.046/03 011.047/03

7.03 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 2751–1/A1

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

94252
B
94935a

94934a 94932a

94935

94935a

94252

94942 C

4
3
5

6 x

2
R

98.7534

Wärtsilä Switzerland Ltd 3 3.00

2751–1/A1 Maintenance RTA48T

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

D E

9
94265

94262

96.7456

3.00 4 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 2751–1/A1

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

Replacement of waisted studs

Should waisted studs 1 (in the following text called stud for short) of the valve drive, cylinder cover, relief valve or
starting valve have to be replaced, then their annular spaces must be filled with a jointing compound! Moreover the
following points must be observed:
 Before fitting a stud clean its thread and corresponding tap hole. The sealing faces (Fig. ’F’) must be degreased
(e.g. using white spirit) and subsequently primed.
 Screw in the stud without lubricant on the thread, right to the bottom, and tighten it according to the instructions
0352–2. Always utilize a stud driver or two nuts.
STOP: Tools like a pipe wrench etc. which would damage the stud shank must never be used.
 For the protection of the stud in the cylinder cover, fill the annular space above the thread with a well adhering,
water and oil proof jointing compound (as shown in Fig. ’F’). The jointing compound must remain plastic at nor-
mal operating temperatures.

Recommended jointing compound and adhesive primers

Jointing Hardener Adhesive Manufacturer

compound primer
Elastosil RT 622 B G 790 Wacker-Chemie Gmbh
RT 622 A Geschäftsbereich Silicone
Hanns-Seidel-Platz 4
D-81737 München
Silcoset Silcoset Silcoset Primer AMBERSIL LTD
105 RTV Curing Agent A Wylds Rd
Bridgwater
Somerset
TA6 4DD
Uk-Great Britain

Equivalent products of other manufacturers may also be used.

1
F
Dichtmittel
SEALING COMPOUND
Ringraum
ANNULAR SPACE Dichtfläche
SEALING FACE

003.465/00

Wärtsilä Switzerland Ltd 5 u 2.06

This page is intentionally left blank
 RTA48T
Maintenance 2751–2/A1

Exhaust Valve
Dismantling and Assembling

Tools: Key to Illustrations:

1 Feeler gauge 94122 1 Valve cage 20 Rotation wing
1 Depth gauge 94124 2 Valve drive housing 21 Valve seat
2 Jack screws 94263 3 Screw 22 Cylinder cover
1 Rotation device for 94290 4 Damper 23 O-ring
valve cage 5 Piston (hydraulic part) 24 Vent screw
1 Torque wrench 6 Bush 25 Spacer ring
7 Retaining ring 26 Locating dowel
8 Pressure flange 27 Shim
9 Screw 28 O-ring
10 Ridged valve cone piece 29 Bush
11 Piston 30 O-ring
11a Piston seal ring 31 O-ring
12 Air cylinder housing 32 O-ring
13 Guide bush 33 O-ring
14 Screw with lock washer 34 O-ring
15 Screw with lock washer 35 O-ring
16 Screw 36 O-ring
17 Piston ring
18 Rod seal ring R Eye bolt
19 Valve spindle S Support

In order to dismantle the exhaust valve fasten it with screws to the rotation device 94290 as shown in Fig. ’A’. The
support ’S’ belonging to the rotation device is not needed for this purpose.

Attention Danger of accident! The entire exhaust valve must only be transported by means of the sus-
pension device mentioned in group 2751–1!

Dismantling of the exhaust valve

– Loosen and remove all four screws 3 which are used for fastening the valve drive housing 2 (Fig. ’A’).
– Separate the damper 4, together with the valve drive housing 2, the piston 5, and the bush 6, from the valve
cage 1 by means of a lifting tackle which is fastened to eye bolt ’R’. During this the piston which remains in the
bush is taken together with the retaining ring 7, by which it is protected from falling out (Fig. ’A’).
– Put the valve cage to horizontal position by means of the rotation device.
– Push the valve spindle 19 against the valve seat.
– Loosen the screws 9 and remove them together with pressure flange 8.
– Push piston 11 away from the ridged valve cone pieces 10, then remove them.
– Dismantle the piston 11 by means of two screws 9.
– Remove the valve spindle. If there is sufficient dismantling height, the exhaust valve can be turned by means of
the rotation device, allowing it to be removed from the top.

Wärtsilä Switzerland Ltd 1 3.00

 2751–2/A1 Maintenance RTA48T

Exhaust Valve: Dismantling and Assembling

A
R

2
5
7

94290 S

98.7670a

3.00 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 2751–2/A1

Exhaust Valve: Dismantling and Assembling

B R

4
28
2
17
6
17 5 24 23 2 24

15 15
7
9
8
11a 10
11
33
12 2
25 14 29
18 30
16 Lecköl
34
OIL LEAKAGE

32 31
13
19
20

26
35
22
36
21

00.7022

Wärtsilä Switzerland Ltd 3 3.00

2751–2/A1 Maintenance RTA48T

Exhaust Valve: Dismantling and Assembling

Removal of the guide bush

– Unbend lock washers to the screws 14 and re-
move the screws (Fig. ’B’).
C
94263
Remark Before unbending the lock
washers to the screws 14 for
the guide bush, dismantle the
air cylinder housing 12 to avoid
damaging the running surface. 13
– Screw both jack screws 94263 into the flange
until the guide bush 13 can be removed.

D
94263

OB 13

34 Fitting the guide bush

1 – Clean the corresponding bore in the valve
cage 1.
– Clean guide bush 13 and check the oil bores
’OB’ for free passage.
– Check O-rings 34 and apply lube oil, replace
them if necessary.
– Press the guide bush into its bore until fully
seated by means of jack screws 94263.

99.7543

Assembling of the exhaust valve

The condition of the piston ring 11a has to be checked at every opportunity, at the latest however during an exhaust
valve overhaul according to the maintenance schedule. Defective piston rings 11a as well as rod seal rings 18 must
be replaced without fail. For the admissible dimensions of the exhaust valve see Clearance Table in group 0330–1.
When an exhaust valve is equipped with a new valve seat or valve spindle, in every case without exception the valve
seat must be reconditioned in the fitted condition with the valve seat grinding machine (see instructions in group
2751–3).

3.00 4 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 2751–2/A1

Exhaust Valve: Dismantling and Assembling

Assembling is to be carried out analogously to dismantling, but in reverse order. Always fit the rod seal ring 18 and
the spacer ring 25 after assembling the valve spindle, otherwise the rod seal ring might be damaged when the
valve spindle is inserted.
If the piston 5 and its piston rings 17 have been dismantled, note that the marking TOP must always be facing up-
wards during assembling. MOLYKOTE paste G must be applied to the threads of the screws 15 before assembling.
The screws 15 are to be tightened with a torque of 35 Nm and then secured.
Check all O-rings of the removed parts for damages and replace them if necessary.
Smear threads of screws 9 to pressure flange 8 lightly with MOLYKOTE paste G, then screw them in.
Tighten the screws equally to a tightening torque of 40 Nm. After tightening all screws 9, check them repeatedly for
correct tightening, as the valve cone pieces 10 embed themselves during the tightening procedure. The screws
which have already been fully tightened can thereby lose their pre-tension, and must therefore be checked again for
correct pre-tension.
After each overhaul the vent screw 24 (Fig. ’B’) must be checked and cleaned.

Determination of thickness of shims

After every overhaul of the exhaust valve seat/spindle the damper 4 (Fig. ’B’) must be removed. Establish with a
depth gauge the measure ’H’ from the upper edge of valve drive housing 2 to the bottom of the damper bore in piston
5 (Fig. ’E’); for this the exhaust valve must be closed (check with feeler gauge whether the valve plate lies against the
valve seat without clearance). According to the following formula establish the thickness ’h’ for the new shims 27 to
be fitted:
h = 138 – H ± 0.50 mm

Fit damper with newly adjusted shim packet. Single shim rings of 1 mm thickness are available.

27
+ 0,5
h

H
–106

00.7023

Wärtsilä Switzerland Ltd 5 u 3.00

This page is intentionally left blank
 RTA48T
Maintenance 2751–3/A1

Exhaust Valve
Replacing and Grinding the Valve Seat

Tools: Key to Illustrations:

1 Feeler gauge 94122 1 Valve seat AF Seating face
1 Valve seat fitting and dismantling device 94261 2 Valve cage H Hammer
1 Valve seat grinding machine 94278 3 O-ring P Pilot
1 Milling cutter 94278c R Eye bolt
1 Gauge 94279 Z Centring aid
1 Rotation device for valve cage 94290

Valve seats of which the seat surfaces are badly damaged, or on which the wear limit has been reached through
frequent grinding, must be replaced.
The most advantageous position for replacing the valve seat is to bring the valve cage to the vertical (see Fig. ’C’).
This is also the position required for grinding with the valve seat grinding machine.
The guide bush (spindle guide) does not have to be removed.

Removing the valve seat (Fig. ’A’)

Fit both pairs of ring halves of the valve seat fitting and dismantling device 94261 into the groove on the circumfer-
ence of the valve cage 2 and valve seat 1 respectively.
With the aid of the three jack screws of the valve seat fitting and dismantling device, the valve seat can be pressed
out of its seating in the valve cage.
Should a used valve seat be re-used, then it must be marked together with the valve cage before removing. When
re-fitting the valve seat the previously applied markings must be brought in line.

A
1

94261

93.7195

Wärtsilä Switzerland Ltd 1 1998

2751–3/A1 Maintenance RTA48T

Exhaust Valve: Replacing and Grinding the Valve Seat

Fitting the valve seat (Fig. ’B’)

– Place valve cage - as for the seat removal - vertically.
– Clean bore as well as seating shoulder at ’AF’ meticulously and with greatest care. Unevenness or damage to
seating face ’AF’ would lead to leaks.
– Smear the bore into which the valve seat has to fit with oil, or lubricants such as THREAD GARD, LOCTITE,
ANTI-SEIZE COMPOUND etc.
– Smear new O-ring of original specification with the same lubricant and place it into the groove in the valve gage.
– Push valve seat as far as possible into the bore, then mount valve seat fitting and dismantling device 94261
(Fig. ’B’) and by equal tightening of the jack screws press the valve seat down till fully seated. Through the
control openings in the valve seat fitting and dismantling device check with the feeler gauge 94122 all around
the circumference that no clearance remains at ’AF’. For this check the fitting device has still to be fitted fast as
required for the subsequent grinding of the valve seat.

B
1

94261

94122

94261

93.7196
3 AF

1998 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 2751–3/A1

Exhaust Valve: Replacing and Grinding the Valve Seat

94278

+2’
30 0

Z
1

94261

Gezeichnet für
Schleifmaschine
mit pneum. Antrieb

DRAWN FOR 2
GRINDING MACHINE
WITH PNEUM. DRIVE
P

96.7608
Grinding the valve seats (Fig. ’C’)
Valve seats must be ground only with the valve seat grinding machine. Grinding in valve seats using the valve
spindle with grinding paste must be avoided as a matter of principle!

When should valve seats be ground in the valve cage?

 Whenever a valve seat is fitted to the valve cage.
 When new or reconditioned valve spindles are fitted. An exception can be made if the seating surface is neither
worn nor damaged by corrosion.
 When the seat surface on the valve seat is badly damaged through operation with heavy fuel oil (impacts, corro-
sion scars).

Wärtsilä Switzerland Ltd 3 1998

2751–3/A1 Maintenance RTA48T

Exhaust Valve: Replacing and Grinding the Valve Seat

The machines from the makers HUNGER and CHRIS - MARINE are well proven for valve grinding.
When grinding the valve seat, take care that as little grinding dust as possible falls into the valve cage or even stays
there. A thorough cleaning after completion is absolutely essential.
Regarding the operation of the grinding machine please refer to the operating instructions supplied with it.
The grinding must produce an even and smooth surface.
It is particularly important that the grinding machine be mounted in such a way that it is correctly centred in the valve
guide bush. The chamfers in the valve guide bush provide fixed setting surfaces for the cones on the ’Pilot’ (see
details in Fig. ’C’). Before inserting the grinding machine remove carbon deposits from the chamfers with tool
94278c. With the help of centring aid ’Z’ fitted to the ’Pilot’ fasten the grinding machine optimally.
Furthermore remove rod seal ring 18 to save it from being damaged. For grinding fit spacer ring 25 (without rod seal
ring), as its chamfer serves as a guide (see Fig. ’B’ group 2751–2).
Experience has shown that when grinding valve seat surfaces ’chatter’ marks are generated if vibrations are set up
by motors or other machines in the vicinity. To prevent such ’chatter’ marks, always mount the valve cage for grind-
ing the valve seat on the rotation device 94290.
+ 2’
Valve seat angle = 30 0

The grinding allowance on the valve seat is maximum 3 mm. The wear condition can be checked efficiently with
gauge 94279 in combination with feeler gauge 94122 (see Fig. ’D’). Possible burn scars at the inside of the valve
seat must not exceed 7 mm. The depth of the burn scars can also be verified with the gauge 94279 as shown in Fig.
‘D’. Valve seats which exceed the above mentioned values must be replaced.

D
ÎÎÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎÎÎ E
R H

ÎÎÎÎÎÎÎÎÎÎÎÎ 94279

ÎÎÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎÎÎ 97.7079

max. 7 mm

3.00 4 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 2751–3/A1

Exhaust Valve: Replacing and Grinding the Valve Seat

After grinding it is necessary to check whether the new or re-ground valve makes correct contact with the valve seat.
For this the spindle head seat face is stained with a thin coating of blueing paste, then inserted vertically into the
valve guide bush.
The angle difference is chosen such that in the hot operating condition the valves makes contact by 50%–100%
from the outer edge (Fig. ’F’). The blueing check should show that the cold valve makes contact only from inside
around the whole circumference. The angle difference can be checked at the gap ’S’ on the outer edge with a feeler
gauge (Fig. ’G’).
For careful attention: The ’Remarks’ in group 2751–2 concerning the fitting of re-ground valves or valve seats
must be considered.
The blueing on the valve seat must be checked by tapping three or four times with a hammer on a wooden block
which is placed on the valve head (Fig. ’E’).
Do not rotate the valve spindle on the valve seat face, as this risks seizure of the seating.

30  + 2’
0

50–100%

S = 0.02 – 0.04 mm

93.7199

Wärtsilä Switzerland Ltd 5 u 1998

This page is intentionally left blank
 RTA48T
Maintenance 2751–4/A1

Exhaust Valve
Grinding the Seating Surface on the Valve Head

Tools:
1 Feeler gauge 94122
1 Valve grinding machine 94291
1 Gauge 94292

Grinding in a valve together with its valve seat with grinding paste is not permitted. Information concerning
the grinding of valve seats in valve cages is given in group 2751–3.
Valves which have had the seating surfaces badly damaged by pitting or corrosion have to be reground by machine.
It is strongly recommended that a suitable grinding machine such as tool 94291 be made available.
The machines from the makers HUNGER and CHRIS - MARINE are well proven for valve grinding and can also be
ordered directly from Wärtsilä Switzerland Ltd, Winterthur.

 Only as little material as necessary

should be ground off the valve seat- A
ing face to provide a clean and
smooth finished surface.
Only grind with cooling (wet).
Seating face angle on valve
 In order to avoid the appearance of +8’
a = 30  +6’
chatter marks on the seating surface,
the grinding machine should be
placed in an area which is free of
vibration from running machinery or
engines, etc. If necessary the grind-
ing machine should be stood on a
rubber mat.

 For the application of the grinding

machine please refer to the operating 94291
instructions.

Gezeichnet für Schleifmaschine mit

pneum. Antrieb

DRAWN FOR GRINDING MACHINE

WITH PNEUMATIC DRIVE

96.7613

Wärtsilä Switzerland Ltd 1 1998

2751–4/A1 Maintenance RTA48T

Exhaust Valve: Grinding the Seating Surface on the Valve Head

A maximum of 3 mm may be ground off the valve

B
seating face.
The wear condition can be checked at any time with the
gauge (tool 94292) and feeler gauge (Fig. ’B’).

94292

max. 3mm

On engines with heavy operation duty, corrosion may

form at the bottom of the valve plate, after a longer oper-
ating time. Valve plates, on which the corrosion layer is
deeper than 9 mm or where the seat surface has been
ground back by more than 6 mm (Fig. ’B’), can be re-
conditioned by build-up welding.
max. 6 mm

Such a repair process may, however, only be carried out

by a Wärtsilä Switzerland Ltd authorized repair work-
shop.

Where the precise angle required has been obtained

during grinding, a check with marking blue with the valve
on the reground valve seat in the valve cage will show
only a line contact or a very narrow band (extent of con-
tact) starting from the smaller diameter (Fig. ’C’).
See also remarks in group 2751–3 regarding the valve
behaviour at running temperature. 95.7977a

Remark A valve spindle with missing rotation wings may not be reground. The wing hub must be shrink-
fitted on the valve shaft by heating it to 480 C. Grinding may first begin after the whole unit has
cooled down.

7.03 2 u Wärtsilä Switzerland Ltd

 RTA48T
Betrieb Group3

Crankshaft, Connecting Rod and Piston Group 3

 Crankshaft
– Measuring Crank Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3103–1/A1

 Vibration Damper
– Taking a Silicone Fluid Sample (for Engines with Viscous Vibration Damper) . . . . . . . . . . . . . . 3130–1/A1
– Inspection (GEISLINGER Vibration Damper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3130–2/A1

 Axial Detuner
– Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3146–1/A1

 Crankcase
– Utilization of the Working Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3301–1/A1

 Connecting Rod
– Loosening and Tensioning the Connecting Rod Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303–1/A1

 Connecting Rod and Connecting Rod Bearing

– Inspection, Removing and Fitting of Bottom End Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303–2/A1
– Inspection, Removing and Fitting of Top End Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303–3/A1

 Connecting Rod
– Removing and Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3303–4/A1

 Crosshead
– Checking Clearances and Fitting the Guide Shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3326–1/A1
– Removal and Fitting of a Crosshead Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3326–2/A1

 Piston
– Removal and Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3403–1/A1
– Changing the Compression Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3403–2/A1
– Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3403–3/A1
– Checking Piston Top Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3403–4/A1

 Piston Rings
– Checking Piston Ring Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3425–1/A1

Wärtsilä Switzerland Ltd 1 RTA48T / MM / 1998

This page is intentionally left blank
 RTA48T
Maintenance 3103–1/A1

Crankshaft
Measuring Crank Deflection

Tools: Key to Illustration:

1 Dial gauge 94305 1 Flywheel
2 Pinion

In order to ascertain whether the axes of the crank journals deviate from the theoretical shaft axis, the crank deflec-
tions must be measured. When doing so the ship must be floating freely.
Under normal circumstances, it is sufficient to measure the crank deflections once a year. They must, however, be
measured as soon as possible in case the ship has grounded or after replacing the main bearing shells. The deflec-
tions have to be measured again approx. 100 service hours after replacing the bearing shells.
Should signs of damage to the main bearings be found during inspection of the crankcase, the crank deflections
should also be measured.
Measuring is carried out using a crankshaft dial gauge (tool 94305) which, for this purpose, is inserted between the
crank webs of the crank to be measured. When turning the crankshaft, the change in distance between the crank
webs can be read from the dial gauge as it indicates any opening or closing up. The smaller the variations the better
the position of the shaft.

Rotation direction of crankshaft:

To measure the crank deflection the crankshaft must always be turned in such a manner – despite the ordinary rota-
tion direction of the engine – that flywheel 1 and pinion 2 of the turning gear are rotating as indicated by the arrow
(see Fig. ’A’).

99.7009

Wärtsilä Switzerland Ltd 1 3.00

3103–1/A1 Maintenance RTA48T

Measuring Crank Deflection

Measuring procedure (indicator valves must be open)

With the running gear in place, the crank to be measured has to be turned towards (before or after) B.D.C. until the
dial gauge can be fitted next to the connecting rod at the position indicated. Pretension the dial gauge slightly and set
it to ’0’ (see Fig. ’B’).
Turn the crankshaft with the turning gear, reading the dial gauge in the crank positions which are indicated in Fig. ’B’
and noting down the values. The last value is for checking; if everything has been carried out correctly it should be
nearly ’0’.

Kurbel im O.T.P.
B Measuring points CRANK AT T.D.C.

Dial gauage
94305

000.266/93

Noting down the values:

The values which have been read are to be noted down in a table containing the following data:
– Positions of the crankpin in terms of B.D.C. – EXHAUST SIDE – T.D.C. – FUEL SIDE – B.D.C.
– Rotation direction of the crankshaft when measuring the crank deflection.

2.06 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 3103–1/A1

Measuring Crank Deflection

The difference (Da) between the indicated values at B.D.C. and T.D.C. shows the amount of crank deflection during
one revolution (see Fig. ’C’).
All influences which cause a temporary deformation of the hull and/or the engine affect the crank deflection.

These are for example: – loaded condition of the ship

– engine cold or at service temperature
– differing air/water temperatures
– strong sunshine
The values of Da given below are valid for all conditions independent of outside influences.
Where values are measured which lie above the maximum permissible limits, the cause has to be found and the
necessary remedial measures taken (defective main bearing, engine support altered due to hull deformation, loose
holding-down bolts, defective shaftline bearings, etc.).
When measuring the crank deflection, ensure that the crank journals are fully seated in their bearings.

STROKE S
Dial gauage
94305

a B.D.C.
D

a T.D.C.

Difference Da = a T.D.C. – a B.D.C.

Good values Da = 0 – 0.31 mm
Values still admissible Da = 0.31 – 0.62 mm

Wärtsilä Switzerland Ltd 3 u 3.00

This page is intentionally left blank
 RTA48T
Maintenance 3130–1/A1

Vibration Damper
Taking a Silicone Fluid Sample (for Engines with Viscous Vibration Damper)

Key to Illustrations:
1 Casing trough 8 Crankshaft
2 Casing cover 9 Cap nut
3 Screw plug 10 Vibration damper
4 O-ring
5 Sealing ring
6 Coupling bolt P Sample container
7 Camshaft K Lock by centre punch

Viscous vibration dampers manufactured by ’HASSE and WREDE’ or by ’Simpson International’ (former ’HOL-
SET’), and ’STE’ Schwingungstechnik may be, depending on the design execution of the engine, mounted either on
the camshaft, or also at the free end of the crankshaft.
The service life of a vibration damper is largely dependent on the speed range in which the engine is run. Wear of the
inner parts as well as changes in the silicone oil properties can contribute to a reduction in the damper’s effective-
ness. By periodic examination of the silicone oil the makers of the vibration damper can draw conclusions on its
condition.
Therefore, it is recommended to have the silicone oil examined periodically, the first time after about 15’000–18’000
operating hours. Future intervals for examinations depend on the result of these first findings.
Special sample containers ’P’ (Fig. ’E’) can be obtained from the vibration damper makers.
Before taking a sample, or before working on a vibration damper, always follow first the instructions of the vibration
damper manufacturer.
In the casing trough 1 and in the casing cover 2, two oil sampling holes are carefully closed and sealed with screw
plugs 3.

A
8
B
3 3

6
7

1
2

99.7033

Wärtsilä Switzerland Ltd 1 3.00

3130–1/A1 Maintenance RTA48T

Taking a Silicone Fluid Sample (for Engines with Viscous Vibration Damper)

Preparation for taking a silicone fluid sample

– Remove the casing of the respective vibration damper. C 3

– Turn camshaft and crankshaft in such a way that both

screw plugs 3 of the vibration damper 10 are positioned
horizontally to each other, whenever possible. If in this
position the screw plugs cannot be loosened , then the 7
vertical position can also be chosen.
3
Before removing the screw plug for taking the silicon 10
fluid sample, carefully clean the area around it in order
to prevent, under any circumstances, impurities from
entering the sample container.

– Leave the damper in the mentioned position for at least

two hours. (If the oil sample is to be withdrawn from a
removed vibration damper the same conditions apply
as regards the positions and the waiting time).

98.7597

– Using a flat caulker, hammer back the squeezed material in the corresponding slot, which serves as locking
means of the screw plug 3.

– Loosen the screw plug, but do not unscrew it yet, it must still seal.

3 3

1 2
4 4

3.00 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 3130–1/A1

Taking a Silicone Fluid Sample (for Engines with Viscous Vibration Damper)

Taking the sample

– Prepare the sample container ’P’, i.e. remove both cap nuts 9 and examine the bore which must be meticulously
clean.

Remark Two different threads are used for the sample bores of the ’Simpson International’ and STE
vibration dampers. Therefore, the ends of the sample container are provided with different
threads (Fig. ’E’).

– Remove the previously loosened screw plug 3, and screw in the sample container ’P’ instead.
– After fully screwing in the sample container, screw it back by 1 turn to prevent it from touching the flywheel inside
the vibration damper.
– Wait until the silicon fluid appears at the open end of the sample container. Depending on the viscosity of the
fluid, this may take some seconds only, or much longer.
– As soon as the silicon fluid flows out of the sample container, close its open end with the respective cap nut.
– Unscrew the sample container from the vibration damper housing (taking care not to let escape the fluid), then
immediately set in the screw plug 3 with a new O-ring 4 or sealing ring 5. (Avoid any leaking of silicon fluid.)
– Screw the second cap nut on the sample container and tighten it moderately.
– For the ’Simpson International’ vibration damper, tighten the screw plug 3 with 25 Nm, and for the HASSE &
WREDE vibration damper, tighten it with 20 Nm; then secure it with centre punch ’K’ (Fig. ’E’).
– For the STE vibration damper, tighten the screw plug with 15 Nm for M10 threads, or with 45 Nm for M16
threads, then secure with centre punch (Fig. ’E’).

Probebehälter
E SAMPLE CONTAINER
Simpson International+STE

9 3/8”BSF
Hasse & Wrede

M10x1

P
P
M10x1

9 5/16”BSF

3 3
10 10
K
5 4
K

97.8166

Wärtsilä Switzerland Ltd 3 3.00

3130–1/A1 Maintenance RTA48T

Taking a Silicone Fluid Sample (for Engines with Viscous Vibration Damper)

If a sample is not obtained by the method described, proceed as follows:

1. Leave sample container in position.
2. Remove the opposite screw plug, connect a compressed air supply and apply about 3.5 bar pressure.
3. Only dried and filtered air may be used (connections and air hose must be clean, free from any fouling).
4. As soon as fluid reaches open end of sample container shut off compressed air supply and then fit one of the two
cap nuts 9 to the sampling container.
5. Disconnect compressed air supply. Remove sample container and fit the other cap nut 9.
6. Re-fit the corresponding screw plugs to all withdrawal openings.
7. Tighten and lock the screw plugs as already mentioned under Taking the sample.

Attention The special sample container permits drawing a specific quantity of silicone oil from the damper.
The total number of samplings should be limited to 10.

The filled sample container has to be labelled and sent to the following address for examination:

Carl Hasse & Wrede GmbH Simpson International (UK) Ltd STE Schwingungstechnik GmbH
Mohriner Allee 30–42 131 Parkinson Lane Bahnhofstrasse 9–11
D–12347 Berlin 47 GB-Halifax HX1 3RD D-06869 Klieken
Germany United Kingdom Germany
Tel: 0049 30 70 181-0 Tel: 0044 1422 357 234 Tel: 0049 34 903 68501
Fax: 0049 30 700 90 8-11 Fax: 0044 1422 354432 Tax: 0049 34 903 68505

The label must contain the following information:

Engine type,

Engine No.,

Number of operating hours of the vibration damper,

also its manufacturing serial number (this number is stamped in the cover in the vicinity of the warning plate).

3.00 4 u Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 3130–2/A1

Vibration Damper
Inspection (GEISLINGER Vibration Damper)

Key to Illustrations:
1 Damper casing 6 Coupling bolt
2 Vent nozzles 7 Torsiograph drive
3 Sealing rings 8 Vibration damper
4 Oil supply piping 9 Sealing ring
5 Crankshaft

1. General
Depending on the design execution of an engine, a vibration damper of GEISLINGER make may be mounted at the
free end of the crankshaft.
The service life of a vibration damper depends largely on the speed range in which the engine is operated. Water, in
particular sea-water, in the lubricating oil leads to increased wear and loss of damping action.

2. Check
 The engine filters should regularly be checked for steel or bronze chippings. If such chippings are found also in
the damper housing, the damper supplier is to be informed accordingly.

Attention Until the reasons for such findings are not clarified and rectified, it is not allowed to put the damp-
er back into service.
 Should the oil pressure drop below 1 bar, it may not be corrected by adjustment of the adjustable throttle in the
supply piping. Instead, the cause of the pressure drop must be investigated (defective oil supply piping).
 Should damage be noticed on the engine bearings which is due to water contamination of the lubricating oil,
then the vibration damper must also be inspected for possible damage at the very earliest opportunity.
 To check the inner spring tips and groove flanks the inspection cover on the face of the damper casing (Fig. ’A’)
can be removed (with stopped engine). For wear limits refer to the manual of the damper manufacturer.
 Dismantling of a vibration damper should only take place if there is a reasonable suspicion that the damper is
damaged or wear rates have exceeded their limits. In this case contact the damper manufacturer for further
instructions.

Attention Adjustments on the vibration damper may only be carried out by a specialist, with simultaneous
torsional vibration measurements.
Prior to removing a vibration damper and balance weight mark their positions with reference to
the crankshaft.

Remark For the test run after the first commissioning, as well as the normal checking and servicing inter-
vals, refer to the manual of the damper manufacturer.

Contact address for GEISLINGER vibration dampers:

Geislinger GmbH
A–5300 Hallwang / Salzburg
Austria

Wärtsilä Switzerland Ltd 1 11.01

3130–2/A1 Maintenance RTA48T

Inspection (GEISLINGER Vibration Damper)

A B

8
1

2 8

Freies Ende
FREE END

Oelzufuhr
7
OIL SUPPLY

96.7623

Gezeichnet für GEISLINGER - Schwingungsdämpfer

93.7622
DRAWN FOR GEISLINGER VIBRATION DAMPER

1998 2 u Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 3146–1/A1

Axial Detuner
Dismantling and Assembling

Tools: Key to Illustrations:

1 Steel rope with two shackles 94309 1 Upper part of cylinder 14 Diaphragms
1 Roller support 94310 2 Lower part of cylinder 15 Oil inlet pipe
2 Eye bolts M24 3 Screw 16 Main bearing cover
4 Screw 17 Crankshaft
5 Screw 18 Main bearing shell
6 Large seal ring 19 Oil drain pipe
7 Small seal ring 20 Upper casing
8 Self-locking nut 21 ELBA (El. balancer)
9 Allen screw 22 Screw
10 Throttling valve 23 Piping for detuner
11 Spindle monitoring
12 Locking screw with
locking plate H Lifting tackle
13 Locking plate R Eye bolt

When the seal ring 6 or 7 has to be removed from an axial detuner, proceed as follows:
– Switch off the bearing oil pump.
– Remove the oil drain pipe 19.
– Unscrew and remove the oil inlet pipes 15 and the piping for detuner monitoring 23 internally and externally
from the upper casing 20. Take care that no dirt enters the oil pipe!
– Remove the upper casing 20.

A 21 19

23 15

20

99.7159

Wärtsilä Switzerland Ltd 1 3.00

3146–1/A1 Maintenance RTA48T

Axial Detuner: Dismantling and Assembling

Dismantling
– Remove the oil inlet pipe 15.
– Loosen screws 22 and remove the throttling valve 10.
– Pull out both taper pins locating the upper and lower part of cylinder 1 and 2 by means of the withdrawing device
which is part of the standard tools. For this purpose the taper pins have been provided with a thread of M10.
– Loosen and remove all the screws 5 and 3 (Fig. ’B’).
– Loosen all screws 4 to the upper part of cylinder 1 and pull them out as far as possible on engines provided with
vibration damper; on other engines, however, the screws can be removed completly.

B
14

10
I-I
I
22 11
10
10 15
6

16
5
1

17
4
3 7 7

I 99.7698

3.00 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 3146–1/A1

Axial Detuner: Dismantling and Assembling

C
Removal of the upper part of cylinder
– Fasten roller support 94310 to the face of
the free end of the engine as shown in Fig.
’C’. H
– Screw the two eye bolts ’R’ into the upper 94310
part of cylinder 1, then join these by
means of shackles and steel rope 94309
to a lifting tackle.
– Using lifting tackle carefully raise upper
part of cylinder . Make absolutely sure that 94309
the upper part of cylinder slides out of
the seal rings 6 and 7 without jamming, I
as otherwise the seal rings risk being
damaged.
R
6
7

16 17

99.7699

94310

94309

R
1

99.7700

Wärtsilä Switzerland Ltd 3 3.00

3146–1/A1 Maintenance RTA48T

Axial Detuner: Dismantling and Assembling

6 (7)
Removal of the seal rings
Should the two-part seal rings 6 and 7 have to be
replaced, loosen first self-locking nut 8 and remove
9 Allen screw 9. The sealing rings can then be turned
out of their grooves in the lower part of cylinder 2
without any problems.

E
11 12

99.7050
13
X

Checking the throttling valve 10

When overhauling the axial detuner check also the

condition of throttling valve 10. The spindle position
has been locked by locking screw 12 and a locking
plate 13. Changing the position of the throttling
valve is forbidden.
For pre-setting the spindle 11 has to be turned back
by about four turns starting from the closed position.
This adjustment must be verified on the basis of
14
vibration measurements during sea trial; otherwise
the spindle must be readjusted. The final adjustment
has to be engraved in the name plate fitted to the up-
per part of the cylinder 1.

Should it become necessary to unscrew or replace a spindle for any reason, then the distance ’x’ must be measured
first (Fig. E’). The spindle has to be adjusted to the same distance on reassembling.

Remark The spindle must not be turned back by more than 17.5 turns , that corresponds to a stroke of
x=35 mm.

When the above check brings to light any defect of throttling valve 10 then diaphragms 14 (Fig. ’B’) screwed into the
throttling valve must also be checked for possible damage and replaced if necessary.

Attention The engine must not be operated with the spindle 11 removed or with the oil supply to the axial
detuner interrupted!

3.00 4 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 3146–1/A1

Axial Detuner: Dismantling and Assembling

Assembling
Badly worn or damaged seal rings 6 and 7 must be replaced. The seal rings are fastened by two Allen screws 9 and
self-locking nuts 8. Immediately before fitting the seal rings smear them with clean engine oil.
Newly fitted seal rings must allow radial movement when fitted.
The assembling of the axial detuner is done analogously to dismantling but in reverse sequence. Pay the utmost
attention when lowering upper part of cylinder 1 into place, to prevent seal rings 6 and 7 from being damaged.
Before tightening screws 3 as well as 4 and 5 fit the taper pins for the upper part and lower part of the cylinder.
Apply MOLYKOTE and tighten screw 4 between axial detuner and bedplate with a tightening angle of 45 (see also
group 0352–1).
New packings must be used for the assembly of the throttling valve 10 and the oil inlet pipe 15.

Wärtsilä Switzerland Ltd 5 u 3.00

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 RTA48T
Maintenance 3301–1/A1

Crankcase
Utilization of the Working Platform

Tools: Key to Illustrations:

2 Working platforms, 94142 1 Engine longitudinal beam
consisting of 2 grids each 2 Crank web
2 Working supports 94143 3 Step
4 Strap

To avoid accidents, the grids of working platform 94142 and working supports 94143 should be used for inspections
or work in the crankcase. The grids must always be fitted in such a way that their U-profiles come to lie between
engine longitudinal beam 1 and that the opposite end rests on crank web 2, as shown in Fig. ’A’.
Working support 94143 can be fitted between the columns at the desired height, on steps 3. These are safeguarded
against falling down by shoving straps 4 against the steps.

Attention Never rotate the crankshaft while the grids or working supports are in position.

I-I I
A

94143
94143 4

3
94142

94142

2
Brennstoffseite
FUEL SIDE

002.900/03
002.900/03

Wärtsilä Switzerland Ltd 1 u 7.03

This page is intentionally left blank
 RTA48T
Maintenance 3303–1/A1

Connecting Rod
Loosening and Tensioning the Connecting Rod Studs

Tools: Key to Illustrations:

1 Feeler gauge 94122 1 Connecting rod stud
1 Depth gauge 94124 2 Nut
2 Pre-tensioning jacks 94314 3 Pin
2 Pre-tensioning jacks 94315 4 Vent screw
1 Pressure gauge 94932a 5 Piston
1 Connection piece 94934a 6 Cylinder
1 HP hose 94935 7 Sealing ring K Slot
2 HP hoses 94935a 8 Bottom end bearing R Round bar
1 Hydraulic unit 94942 9 Top end bearing S Gap

 Clean the threads of connecting rod studs 1 and the area around the nuts 2.
 Lubricate the threads of the connecting rod studs with oil before screwing on the nuts.
 Check that the nuts turn freely on the threads.

Attention Never rotate the crankshaft (with the turning gear) when the pre-tensioning jacks are mounted
on the connecting rod studs!

A
Vorspannpresse Vorspannpresse
aufgeschraubt zum Lösen aufgeschraubt zum Spannen
PRE-TENSIONING JACK PRE-TENSIONING JACK
PLACED FOR LOOSENING PLACED FOR TENSIONING

3
x

7
5

2
6
R

S K

99.7053

Wärtsilä Switzerland Ltd 1 3.00

3303–1/A1 Maintenance RTA48T

Loosening and Tensioning the Connecting Rod Studs

Loosening the connecting rod stud of the

bottom end bearing
– Place pre-tensioning jacks 94314 on the two
connecting rod studs 1 (Fig. ’B’) which have to be
loosened and completely screw them on with
opened vent screw 4 (Fig. ’A’). B
– The pre-tensioning jacks are to be loosened by
about ½ turn (gap ’S’ in Fig. ’A’).
– Connect the pre-tensioning jacks by HP hoses
94935 and 94935a as well as connection piece
94934a with the hydraulic unit 94942 as shown in
Fig. ’B’.
– Verify the oil level in the hydraulic unit.
– Actuate hydraulic unit.
– Close vent screws 4 on the pre-tensioning jacks
as soon as oil flows bubble-free.
– Actuate hydraulic unit till a pressure of 1020 bar
is indicated on the pressure gauge 94932a and
on the pressure gauge at the hydraulic unit.
Attention should be paid to ensure that the pins 3
always protrude slightly compared with the pis-
tons 5 on the pre-tensioning jacks!
Turn back nuts 2 by one turn, using round bar ’R’.
– Release pressure to zero at the hydraulic unit
and then remove pre-tensioning jacks.
94314

8
94935a

94942 94935

99.7058

94934a 94932a

3.00 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 3303–1/A1

Loosening and Tensioning the Connecting Rod Studs

Tensioning the connecting rod stud of the bottom end bearing

– The previously mentioned directions must be considered.
– Tighten the nuts first with a round bar ’R’ by hand with a smart jerk.
– Check whether the nuts rest flush on the connecting rod shank.
– Check the clearance between the bearing halves by using feeler gauge 94122 (the bearing projection must be
equally distributed).
– Screw pre-tensioning jacks 94314 onto the connecting rod studs 1 until these rest against the connecting rod
shank. Moreover, the vent screws 4 are to be opened slightly so that the pistons 5 can slide back to their initial
position i.e. there is no or very little clearance at ’x’ (Fig. ’A’).
– Connect the pre-tensioning jacks to the hydraulic unit 94942 with the HP hoses 94935, 94935a and connection
piece 94934a as shown in Fig. ’B’.
– Verify the oil level in the hydraulic unit.
– Start up hydraulic unit till bubble-free oil flows out through the vent screws 4. Shut the vent screws.
– Actuate the hydraulic unit and set pressure to 300 bar (1st step) and keep pressure constant.
Attention should be paid to ensure that the pins 3 always protrude slightly compared with the pistons 5 on the
pre-tensioning jacks!
– Tighten the nuts with the round bar ’R’ and check with the feeler gauge through slot ’K’ (Fig. ’A’) that no clear-
ance remains between nut and supporting surface.
– Check with the feeler gauge that no clearance remains between bearing cover and connecting rod shank.
(Should clearance remain, loosen the fastening and compare the bearing projection with the nominal value as
indicated in group 3303–3).
– After tensioning to the 1st step mark the position of the nuts against the connecting rod shank as shown in Fig.
’a’, with a felt marker or similar.
– Raise the pressure to 1000 bar (2nd step) and keep constant.
– Tighten nuts down and check correct seating with the feeler gauge.
– Check from the markings applied by how much the nuts were turned after pre-tightening (1st step).
Tightening angle to be about 60 (Fig. ’b’).
– Release pressure to zero at the hydraulic unit and then remove pre-tensioning jacks.
– Should considerable differences to these nominal values be encountered then repeat the tensioning process.
– Finally check the vertical bearing clearance (compare with Clearance Table group 0330–1).

Fig. ’a’ Fig. ’b’

y 98.7700

x x
Tightening angle

x = Mark with felt marker on connecting rod shank

y = Mark with felt marker on the nut

Wärtsilä Switzerland Ltd 3 3.00

3303–1/A1 Maintenance RTA48T

Loosening and Tensioning the Connecting Rod Studs

I 94315
C
Loosening the connecting rod stud of the top
end bearing b a
Attention For loosening the studs always
follow the sequence shown in Fig.
’C’ i.e. a+a and b+b.
a b
– Place pre-tensioning jacks 94315 diagonally on
two connecting rod studs 1 (Fig. ’C’) which have to
be loosened and completely screw them on with
opened vent screw 4 (Fig. ’A’).
I
– The pre-tensioning jacks are to be loosened by
about ½ turn (gap ’S’ in Fig. ’A’).
– Connect the pre-tensioning jacks by HP hoses
94935 and 94935a as well as connection piece
94934a with the hydraulic unit 94942 as shown in
9
Fig. ’C’.
– Verify the oil level in the hydraulic unit.
– Actuate hydraulic unit.
1
– Close vent screws 4 on the pre-tensioning jacks
as soon as oil flows bubble-free.
– Actuate hydraulic unit till a pressure of 1020 bar is
indicated on the pressure gauge 94932a and on
the pressure gauge at the hydraulic unit.
Attention should be paid to ensure that the pins 3
always protrude slightly compared with the pis-
tons 5 on the pre-tensioning jacks!
Turn back nuts 2 by one turn, using round bar ’R’.
– Release pressure to zero at the hydraulic unit and
then remove pre-tensioning jacks.
– Proceed in the same manner for the second pair
of connecting rod studs.

94935a

94942 94935

99.7059

94934a 94932a

3.00 4 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 3303–1/A1

Loosening and Tensioning the Connecting Rod Studs

Tensioning the connecting rod stud of the top end bearing

Attention For tensioning the studs always follow the sequence shown in Fig. ’C’ i.e. a+a and b+b for each
step.
– The previously mentioned directions must be considered.
– Tighten the nuts first with a round bar ’R’ by hand with a smart jerk.
– Check whether the nuts rest flush on the bearing cover.
– Check the clearance between the bearing halves by using feeler gauge 94122 (the bearing projection must be
equally distributed).
– Screw pre-tensioning jacks 94315 diagonally onto two connecting rod studs 1 until these rest against the bear-
ing cover. Moreover, the vent screws 4 are to be opened slightly so that the pistons 5 can slide back to their initial
position i.e. there is no or very little clearance at ’x’ (Fig. ’A’).
– Connect the pre-tensioning jacks to the hydraulic unit 94942 with the HP hoses 94935, 94935a and connection
piece 94934a as shown in Fig. ’C’.
– Verify the oil level in the hydraulic unit.
– Start up hydraulic unit till bubble-free oil flows out through the vent screws 4. Shut the vent screws.
– Actuate the hydraulic unit and set pressure to 600 bar (1st step) and keep pressure constant.
Attention should be paid to ensure that the pins 3 always protrude slightly compared with the pistons 5 on the
pre-tensioning jacks!
– Tighten the nuts with the round bar ’R’ and check with the feeler gauge through slot ’K’ (Fig. ’A’) that no clear-
ance remains between nut and supporting surface.
– Check with the feeler gauge that no clearance remains between bearing cover and connecting rod shank.
(Should clearance remain, loosen the fastening and compare the bearing projection with the nominal value as
indicated in group 3303–3).
– Proceed in the same manner for the second pair of connecting rod studs.
– After tensioning to the 1st step mark the position of the nuts against the bearing cover as shown in Fig. ’a’, with a
felt marker or similar.
– Raise the pressure to 1000 bar (2nd step) and keep constant.
– Tighten nuts down and check correct seating with the feeler gauge.
– Check from the markings applied by how much the nuts were turned after pre-tightening (1st step).
Tightening angle to be about 25 (Fig. ’b’).
– Release pressure to zero at the hydraulic unit and then remove pre-tensioning jacks.
– Should considerable differences to these nominal values be encountered then repeat the tensioning process.
– Finally check the vertical bearing clearance (compare with Clearance Table group 0330–1).
Fig. ’a’ Fig. ’b’

y
y 98.7700

x x
Tightening angle
x = Mark with felt marker on connecting rod shank
y = Mark with felt marker on the nut

Wärtsilä Switzerland Ltd 5 u 3.00

This page is intentionally left blank
 RTA48T
Maintenance 3303–2/A1

Connecting Rod and Connecting Rod Bearing

Inspection, Removing and Fitting of Bottom End Bearing

Tools: Key to Illustrations:

2 Working platforms 94142 1 Studs of connecting rod bearing 8 Guide way
4 Retaining pins 94323 2 Nut 9 Threaded holes for
2 Girders (of different lengths) 94335 3 Crank ring screws
Hydr. tools according to group 3303–1 4 Toggle lever 10 Bearing shell
Lifting tackle 5 Support 11 Allen screw
Various eye bolts 6 Bearing cover 12 Cylindrical pin
Various wire ropes 7 Connecting rod shank

Inspection and removing

When a bottom end bearing has to be removed, the nuts 2 of the connecting rod bearing studs 1 (Fig. ’A’) have to
be loosened hydraulically as per group 3303–1, for which the respective crank must be at T.D.C.
A ring screw is fitted on each side of the bearing cover 6 immediately below the bearing separation. The bearing
cover is then secured with two steel ropes and suitable lifting tackle (Fig. ’B’).
Attach one of the two girders 94335 to the corresponding supports 5.
Remove nuts 2.
Carefully lower the bearing cover while taking care that the threads of the studs of connecting rod bearing as well as
the surface of the crankpin are not damaged (Fig. ’B’).
Remove the bearing cover together with the connecting rod studs.
Should the running surface of bearing shell 10 have to be inspected or the bearing shell have to be removed, pro-
ceed as follows:
– Loosen and remove the screws fastening toggle lever 4 of piston cooling and crosshead lubrication and sepa-
rate toggle lever from connecting rod 7. Suspend toggle lever with lifting tackle inside the crankcase as shown
in Fig. ’C’.
– Place four retaining pins 94323 into the guide ways 8, thereby the retaining pins with their eccentrics are to be
turned in such a way that they touch the guide shoes.
– Secure the connecting rod with a rope ’c’ and lifting tackle on the fuel pump side (Fig. ’C’).
– Turn crankshaft carefully towards fuel pump side while pulling the lower part of the connecting rod with rope and
lifting tackle so far outwards that the distances ”X” (Fig. ’C’) between crank 3 and bearing shell are equal on both
sides.
– Install working platforms 94142 according to the instructions in group 3301–1.
– For the removal of bearing shell 10 Fig. ’D’, but before loosening Allen screws 11, first screw in two eye bolts
into the front faces of bearing shell 10. After Allen screws 11 have been loosened the bearing shell can be low-
ered and then lifted out of the crankcase.

Fitting
The fitting of bearing shell 10 (see also group 3303–3) and of the bearing cover 6 is carried out analogous to remov-
ing but in reverse sequence. The running surfaces have to be lavishly smeared with clean bearing oil. The tension-
ing of the bearing studs must be carried out according to the instructions in group 3303–1.

Attention Never turn the crankshaft as long as the hydraulic jacks are screwed onto the connecting rod
studs.
Always fit toggle lever 4 in such a way that its curvature (knee) stands upwards.
After completing the work the retaining pins 94323 must be removed without fail.

Wärtsilä Switzerland Ltd 1 1998

3303–2/A1 Maintenance RTA48T

Inspection, Removing and Fitting of Bottom End Bearing

B
94335 5

7
A
7
2

1
2
6
10 b a

6
12
9

11
6

C D
94335

4
94323
7

X c
11 c
X 8 94142

3
3
Brennstoffseite
FUEL SIDE

96.7505a

3.00 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 3303–2/A1

Inspection, Removing and Fitting of Bottom End Bearing

Remarks on the fitting of a bearing shell:

Should it become necessary to replace a bearing shell to the bottom end bearing then care must be taken that
the surface of the crankpin is in perfect condition.
While fitting a bearing shell the utmost attention must be given to prevent dirt or foreign particles from entering be-
tween the shell rear surface and its seating! The contact surfaces of the shell rear side and the bearing bore must be
free from any damage. Immediately before inserting the bearing shell they have to be wiped with a slightly oily
hand, so that a trace of oil is on them.
The bearing shell should be placed in the connecting rod head such that it protrudes by the same distance at both
ends of the separating face. This protrusion is a must and under no circumstances may the separating face of
the bearing shell be filed to reduce it!

New bearing shell Fig. Protrusion x1 + x2

Bottom end bearing ’E’ about 0.32–0.40 mm

E
x1

x2

99.7676

Remark Above measuring checks must be carried out without fail when fitting a new bearing shell. For
this the bearing shell is placed in position the bearing cover fitted and the nuts tightened by hand
with a round bar.

Prior to final assembly smear the running surfaces lavishly with clean bearing oil. Should, however, the engine have
to be frequently turned after the fitting of the bearing, or should a re-start of the engine not be immediately planned,
then instead of bearing oil a mixture of 2/3 steam-engine cylinder oil and 1/3 normal bearing oil should be used. Spe-
cial oils suited to this purpose are also available from reliable suppliers.
In order to further reduce the risk of dry running on newly fitted bearing shells, the latter can be post-lubricated by
means of a lubricating pump (see group 3303–3).

Wärtsilä Switzerland Ltd 3 u 3.00

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 RTA48T
Maintenance 3303–3/A1

Connecting Rod and Connecting Rod Bearing

Inspection, Removing and Fitting of Top End Bearing

Tools: Key to Illustrations:

1 Working platform 94142 1 Crankshaft 12 Allen screw
2 Retaining pins 94323 2 Toggle lever 13 Bearing cover
2 Roller supports 94331 3 Connecting rod 14 Guide shoe
1 Carrying roller 94332 4 Support 15 Guide segment
2 Suspension straps 94333a 5 Guide way 16 Bolt with nut
2 Wire ropes 94333b 6 Crosshead pin 17 Supporting sheet
2 Eye bolts 94333c 7 Nut 18 Piston rod foot
1 Girder 94335 8 Connecting rod stud
1 Connecting flange 94336 9 Threaded hole
for eye bolt L Oil pressure pipe
10 Cylindrical pin P Lubricating pump
11 Bearing shell R Eye bolt

Inspection and removal

When a top end bearing has to be inspected or removed, proceed as follows:
– Turn crank of the corresponding cylinder to approx. 40° before B.D.C., and install the working platform 94142
(Fig. ’A’). For details see also group 3301–1.

94142

1
Brennstoffseite
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3303–3/A1 Maintenance RTA48T

Inspection, Removing and Fitting of Top End Bearing

B
– Loosen the screws fastening the toggle lever
2 of the crosshead lubrication and piston cool-
2 ing, and separate the toggle lever from the
connecting rod 3. Suspend toggle lever with
lifting tackle inside the crankcase as shown in
(Fig. ’B’).
– Remove the working platform and turn crank
to B.D.C.
3 – Loosen all four nuts 7 to the connecting rod
94142 studs 8 of the top end bearing (Fig. ’K’) with
the hydraulic device as instructed in group
1 3303–1, then remove the nuts.
– Turn crank to T.D.C.

99.7670

– Place two retaining pins 94323 into the guide ways 5 on the exhaust side and turn them so that the eccentrics
support the guide shoes 14.
– Fix the two roller supports 94331 with distance pipes on the guide ways 5 on the fuel side, using bolt and nut 16
belonging to the roller support (Fig. ’B’ and ’C’).
– The carrying roller 94332 is to be fitted to the end of the connecting rod 3 on the fuel side, using eye bolt ’R’ (Fig.
’C’) screwed into the threaded hole 9 (Fig. ’K’). Therefore, supporting sheet 17 to the carrying roller must rest on
the supporting sheet below the connecting rod head (Fig. ’C’).
– Turn the crankshaft 1 carefully down-
wards to the exhaust side.
C
– Take care that the cylindrical pins
10 and the bearing studs 8 slide out
of their bores without jamming.

6 13 14 5

94331
EXHAUST SIDE

8
Abgasseite

16
R
17
5

99.7671

94332 94323

3.00 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 3303–3/A1

Inspection, Removing and Fitting of Top End Bearing

Examining the bearing shell:

– Turn the crank to max. 60 after T.D.C. for
examining the bearing shell surface. Install
the working platform again (Fig. ’D’).

E 99.7672

94335 4 94335

Removal of the bearing shell:

Screw down the girder 94335 on the
respective supports 4 and suspend a
I I lifting tackle as shown in Fig. ’E’.

94335
99.7673

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3303–3/A1 Maintenance RTA48T

Inspection, Removing and Fitting of Top End Bearing

– Screw eye bolt ’R’ into the connecting rod

a R head and connect it with rope ’a’.
– Tighten rope ’a’ by means of the lifting tackle
3 until the carrying roller 94332 is lifted slightly
8 from the roller supports 94331.
– Dismantle carrying roller.
94331
Attention Risk of accident!
The piston must not be re-
94332 moved without securing the
bearing covers against falling
down, when the connecting
1 rod studs 8 are no longer
meshing with the bearing co-
vers.

99.7674

94335 94331

– Turn crankshaft to 10 after B.D.C. while

evenly tightening rope ’a’. Swing out and
lower the connecting rod until it contacts the a
side member of the crankcase as shown in b
Fig. ’G’ (place protection underneath).
– Unscrew Allen screws 12 (Fig. ’K’).
Fit two eye bolts M6 into the front faces of
11
the bearing shell 11 and connect these with
the lifting tackle as shown in Fig. ’G’.
– Lift the bearing shell out of the connecting
rod whereby the threads of the connecting
rod studs must be covered with lugs in order 11
not to damage the bearing shell. 3

99.7675

3.00 4 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 3303–3/A1

Inspection, Removing and Fitting of Top End Bearing

Remarks on the fitting of a bearing shell:

Should it become necessary to replace a bearing shell to the top end bearing then care must be taken that the
running surface of the crosshead pin is in perfect condition.
While fitting a bearing shell the utmost attention must be given to prevent dirt or foreign particles from entering be-
tween the shell rear surface and its seating! The contact surfaces of the shell rear side and the bearing bore must be
free from any damage. Immediately before inserting the bearing shell they have to be wiped with a slightly oily
hand, so that a trace of oil is on them.
The bearing shell should be placed in the connecting rod head such that it protrudes by the same distance at both
ends of the separating face. This protrusion is a must and under no circumstances may the separating face of
the bearing shell be filed to reduce it!

New bearing shell Fig. Protrusion x1 + x2

Top end bearing ’H’ about 0.30–0.38 mm

H
x1

x2

90.7060

Remark Above measuring checks must be carried out without fail when fitting a new bearing shell. For
this the bearing shell is placed in position the bearing cover fitted and the nuts tightened by hand
with a round bar.

Prior to final assembly smear the running surfaces lavishly with clean bearing oil. Should, however, the engine have
to be frequently turned after the fitting of the bearing, or should a re-start of the engine not be immediately planned,
then instead of bearing oil a mixture of 2/3 steam-engine cylinder oil and 1/3 normal bearing oil should be used. Spe-
cial oils suited to this purpose are also available from reliable suppliers.

Wärtsilä Switzerland Ltd 5 3.00

3303–3/A1 Maintenance RTA48T

Inspection, Removing and Fitting of Top End Bearing

Post lubrication of the connecting rod bearing:

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

6
L

94336
3
Brennstoffseite
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3.00 6 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 3303–3/A1

Inspection, Removing and Fitting of Top End Bearing

Fitting
The fitting of bearing shell 11 and of bearing cover 13 is carried out analogously but in reverse sequence to the
removal.
Before fitting smear the running surfaces lavishly with clean bearing oil. The tensioning of the connecting rod studs
must be carried out as instructed in group 3303–1.

Remark When fitting the bearing shell, as well as the crosshead pin, pay attention not to damage the two
guide segments 15. The two white metal lined guide segments are fitted to the front sides of the
upper connecting rod head (Fig. ’K’).

K
13
8
7
12
10

11 9
15
15
3

96.7509

Attention Always fit toggle lever 2 in such a way that its curvature stands upwards.
The retaining pins 94323, the roller supports 94331 and the carrying roller 94332 must be
removed immediately after completing the work.

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3303–3/A1 Maintenance RTA48T

Inspection, Removing and Fitting of Top End Bearing

Removal of the bearing cover

The bearing cover may be inspected or removed with the working piston in situ or removed.
Inspection and removal of a bearing cover with working piston in situ:
– Loosen all four nuts 7 (Fig. ’K’) to the connecting rod studs 8 of the top end bearing with the hydraulic device as
instructed in group 3303–1, then remove the nuts.
– Remove the nuts to the four waisted studs for the connection of the crosshead pin 6 and the piston rod foot 18
(see also group 3403–1).
– Screw down both suspension straps 94333a (Fig. ’L’ and ’M’) onto the piston rod foot.
– Fit two eye bolts 94333c to the underside of the cylinder jacket.
– Turn crank of the corresponding cylinder towards T.D.C. until both wire ropes 94333b can be attached to the
eye bolts and the two suspension straps.
– Turn crankshaft slowly towards B.D.C.. Thereby the piston rod foot 18 must slide out through the waisted studs
in the crosshead pin 6 without jamming.
– The bearing cover 13 may now be inspected or if necessary removed as described under paragraph ”Inspec-
tion and removal”.
For the removal of the bearing cover 13 the toggle lever 2 must be dismantled.

Fitting the bearing cover

The fitting of the bearing cover 13 is carried out analogously but in reverse sequence to the removal, whereby the
following instructions require special attention:
 Tightening of the nuts 7 (Fig. ’K’), see group 3303–1.
 Tightening of the nuts to the four waisted studs for the connection of the crosshead pin 6 and the piston rod foot
18, see group 3403–1.

L M

94333c

94333b

94333a
I
13
18
6

98.7875

3.00 8 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 3303–3/A1

Inspection, Removing and Fitting of Top End Bearing

Removal of the bearing cover with working piston removed:

– Turn crank to B.D.C.
– Remove toggle lever 2.
– Loosen all four nuts 7 to the connecting rod studs 8 of the top end bearing (Fig. ’K’) with the hydraulic device as
instructed in group 3303–1, then remove the nuts.
– Lift out the bearing cover 13 by means of the lifting tackles a, b and c according to Fig. ’N’.
– Protect the crosshead pin against dirt and damage.

b a

94335 c 6

13

3
Brennstoffseite
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99.7688

Wärtsilä Switzerland Ltd 9 u 3.00

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 RTA48T
Maintenance 3303–4/A1

Connecting Rod
Removing and Fitting

Tools: Key to Illustrations:

1 Working platform 94142 1 Crank 8 Nuts
2 Retaining pins 94323 2 Toggle lever 9 Guide segment
2 Roller supports 94331 3 Connecting rod 10 Bearing cover for
1 Carrying roller 94332 4 Support bottom end bearing
1 Girder 94335 5 Guide way 11 Threaded hole
Hydraulic tools 6 Crosshead pin
according to group 3303–1 7 Bearing cover R Eye bolt
Various eye bolts
Various steel ropes
Lifting tackles

Remark A connecting rod can be removed from or fitted to the engine without removing the working piston
and crosshead pin.
To protect the crankpin from damage, it must be wrapped for best effect with a bandage (e.g.
thick leather) which is only removed just before the connecting rod with the bearing shell is re-
placed on the crankpin.
As regards the loosening and tensioning of the connecting rod bearing studs, as well as remov-
ing and fitting of the bearing, refer to groups 3303–1 to 3303–3 for directions.

A
Removal
– Turn crank of the respective cylinder to ap-
prox. 40 before B.D.C.
– Install the working platform 94142.
(For details see also group 3301–1).
– Loosen the screws fastening the toggle le-
ver 2 of the crosshead lubrication and piston
cooling, and separate the toggle lever from
the connecting rod 3. Suspend toggle lever
with lifting tackle inside the crankcase as
shown in Fig. ’A’.
3
– Remove the working platform.
– Turn crank to B.D.C.. 94142
– Loosen all four nuts 8 (Fig. ’B’) of connecting
rod studs of top end bearing with the hydrau-
lic device as instructed in group 3303–1,
then remove the nuts.
Brennstoffseite
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1
99.7662

Wärtsilä Switzerland Ltd 1 3.00

3303–4/A1 Maintenance RTA48T

Connecting Rod: Removing and Fitting

– Remove and mark the lateral guide segments 9 (Fig. ’B’) to the crosshead pin (lack of space).
On assembly these must be refitted in the same place as removed.

9 9

11

96.7509 3

– Remove the working platform.

– Turn crank to T.D.C. and dismantle the nuts as well as the bearing cover to the bottom end bearing according to
the details in group 3303–2.
– Fit both retaining pins 94323 on exhaust side, both roller supports 94331 with distance piece, as well as the
carrying roller 94332 in the same manner as described for the inspection and dismantling of the connecting rod
top end bearings, group 3303–3.

Attention Should the working piston have been removed prior to the removal of the connecting rod then
suspension device 94324 for the crosshead pin (see group 3326–2) must be installed or the
bearing cover secured by steel ropes. In this way the bearing cover 7 of the top end bearing is
prevented from turning around and dropping down after lowering the connecting rod.

7
C 6
a
94323
R
2
– Turn crankshaft carefully max. 60 after
T.D.C. towards exhaust side. Follow
5
instructions in group 3303–3.
– Screw eye bolt ’R’ into the threaded hole 94331
11 (Fig. ’B’) of the upper connecting rod
head and connect it with rope ’a’ (Fig. 94332
’C’). Tighten rope ‘a’ with a lifting tackle
until the carrying roller 94332 is slightly
lifted off the roller support 94331.
– Dismantle the carrying roller 94332.

10 99.7663

3.00 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 3303–4/A1

Connecting Rod: Removing and Fitting

a
– Lower connecting rod by rope ’a’ (Fig. ’D’) to b
c
the opening of the crankcase (by about 80).
Pay careful attention that the fillet of the
crankpin is not damaged by the connecting
rod collar.
– Sling rope ’b’ around the connecting rod head.
Attach rope ‘c’ to the eye bolt ’R’ screwed into
the connecting rod head, and tighten rope ’c’.

99.7665

E
4

– Attach the girder 94335 on the corresponding

supports 4.
(For details see also group 3303–3).
c – Remove rope ’a’.
94335 d
– Turn crankshaft slowly after T.D.C. (Fig. ’E’)
b until the connecting rod head protrudes from
R
the crankcase, while stretching ropes ’b’ and
’c’ correspondingly.
– Connect eye bolt ’R’ screwed into the con-
necting rod head to rope ’d’ with support
94335 outside the crankcase.

99.7666

Wärtsilä Switzerland Ltd 3 3.00

3303–4/A1 Maintenance RTA48T

Connecting Rod: Removing and Fitting

– Remove rope ’b’.

– Slowly turn crankshaft to about 50 before
T.D.C. (Fig. ’F’).
d
– Tighten ropes ’c’ and ’d’ correspondingly.

c – With the aid of the engine crane remove

connecting rod completely from crankcase
as shown in Fig. ’F’.

Attention Load the ropes with the

weight of the connecting rod
only, and not with the force
resulting from the turning
gear.

99.7667

Fitting
Fitting the connecting rod is carried out analogously to the removal but in reverse sequence, whereby attention must
be paid to groups 3303–1 to 3303–3.
For the assembly bearings and bearing pins must be in perfect condition. They must be smeared lavishly with fresh
bearing oil.

Remark When fitting the crosshead pin, pay attention not to damage the two guide segments 9 to the
crosshead pin (Fig. ’B’) if they are already fitted. The two white metal lined guide segments are
fitted to the front sides of the connecting rod head.

Always fit toggle lever 2 in such a way that its curvature stands upwards.
After completing the work the retaining pins 94323, roller support 94331 and carrying
roller 94332 must be removed immediately.

3.00 4 u Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 3326–1/A1

Crosshead
Checking the Clearances and Fitting the Guide Shoes

Tools: Key to Illustrations:

1 Feeler gauge 94238 1 Crosshead pin 5 Top end bearing
2 Guide shoe 6 Guide rail
2a Guide shoe 7 Middle part
3 Retaining cover 8 Screw
4 Guide way in engine column 9 Screw

A
5 1 e

2
2a

c1
3

8
2a
2
b1

9
4
6

Brennstoffseite 95.7814
d1 4
FUEL SIDE

On the occasion of an overhaul or when a crosshead has been removed measure the various running clearances
and compare them with the values found in the clearance table group 0330–1.

Wärtsilä Switzerland Ltd 1 7.03

3326–1/A1 Maintenance RTA48T

Checking the Clearances and Fitting the Guide Shoes

Checking the clearances

Clearance b1 Clearances between guide shoes and guide ways:
The corresponding crankpin must stand in such a position that guide shoes 2/2a lie on guide
ways 4 on fuel or exhaust side.
Clearance b1 is valid for the whole guide way length and is measured according to the posi-
tion as shown in Fig. ’B’.

Clearance c1 Radial clearance between crosshead pin and middle part:

This clearance is very difficult to establish inside the engine. It is therefore best to measure
and calculate this clearance on the removed crosshead. For this the pin diameter and the
bore in the middle part 7 have to be measured with micrometers.

Clearance d1 Lateral clearance of crosshead between the columns:

The clearance is measured in every position of the crosshead. The complete crosshead
must be pressed axially to a side with suitable hardwood wedges or similar aids. The pres-
sure must be exerted onto the guide shoe or middle part 7 and not onto the crosshead pin 1.

Clearance e Lateral clearance between middle part and crosshead pin:

Push the corresponding middle part to the stop of retaining cover 3 in the above mentioned
position of the crosshead.

4
2/2a

b1 90° BEFORE / AFTER T.D.C.

013.784/06

2.06 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 3326–1/A1

Checking the Clearances and Fitting the Guide Shoes

Fitting a guide shoe

Pay attention that the lubricating oil bores in the guide shoes 2 and 2a are different in design. Therefore, guide shoe
2 must not be replaced with guide shoe 2a and vice versa nor exchanged!
The guide rails 6 are screwed on fuel side only!

Remark Attention must be paid when mounting a guide shoe 2 onto the middle part 7 so that the middle
part bears the guide shoe with no clearance whatsoever. For this purpose, the screws 8 are first
to be tightened slightly. Then the screws 9 are to be tightened slightly by hand and subsequently
tightened and secured with 440 Nm or to an angle of 50.
Tighten and secure screws 8.
Check with the feeler gauge 94238 that there is no clearance between the surfaces of the guide
shoe 2 and middle part 7.

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 RTA48T
Maintenance 3326–2/A1

Crosshead
Removal and Fitting of a Crosshead Pin

Tools: Key to Illustrations:

2 Working platform 94142 1 Crank 6 Middle piece
1 Cover and lifting plate 94324 2 Connecting rod 7 Support
2 Holders 94325 3 Crosshead pin 8 Guide way
1 Girder 94335 4 Guide shoe 9 Bearing cover
Various lifting tackles 5 Column plate 10 End cover
and ropes

If a crosshead pin is to be removed, the piston of the cylinder concerned must be dismantled beforehand, see Gr.
3403–1. The toggle (articulated) lever for crosshead lubrication and piston cooling must be removed as well.

Removal A
– Turn crank 1 of the cylinder concerned to
B.D.C.
– Loosen and remove all four nuts for the
upper connecting rod studs according to
the instructions given in group 3303–1.
– Dismantle bearing cover 9 according to
Fig. ’A’, see group 3303–3.
94335 3
9
2
Brennstoffseite
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Maschinenkran 1
ENGINE CRANE
B

99.7677

94324

– Screw in eye bolts ’R’ on either side

3 of the connecting rod head, and
connect them with lifting tackles ’a’
a b and ’b’.
R R
– Fasten lifting plate 94324 with
screws to the crosshead pin.
– Lift crosshead pin 3 with the crane
1 2 until it is completely retracted from
the connecting rod top end bearing.

99.7678

Wärtsilä Switzerland Ltd 1 3.00

3326–2/A1 Maintenance RTA48T

Removal and Fitting of a Crosshead Pin

– Connect eye bolt ’R’ with lifting tackle ’c’ on

the fuel side of the connecting rod head.
Protect the edge of the connecting rod head!
– Hold connecting rod 2 in position using lifting
tackles ’a’ and ’c’, and remove lifting tackle ’b’.

c
a
R b
Brennstoffseite

2
FUEL SIDE

99.7679

The crankshaft must now be turned in such a manner that the crank of the neighbouring cylinder – listed in the table
below – ends up in an angle of 90° or 270° after T.D.C.
On 8 cylinder engines the details given for the neighbouring cylinder and crank angle change depending on the firing
order.
This position (ideal position) of the neighbouring cylinder is necessary to ensure the accessibility to the crosshead
pin to be removed.
While turning follow up with the lifting tackles ’a’ and ’c’, and move the connecting rod head towards the exhaust side
(Fig. ’D’).
5 Zyl. 7 Zyl.
Motor Nachbarzylinder Kurbelwinkel nach OTP Motor Nachbarzylinder Kurbelwinkel nach OTP
ENGINE NEIGHBOURING CYL. CRANK ANGLE AFTER TDC ENGINE NEIGHBOURING CYL. CRANK ANGLE AFTER TDC
1 2 270 1 2 270
2 1 90 2 1 90
3 2 90 3 2 90
4 3 90 4 5 90
5 4 90 5 4 270
6 5 90
7 6 90
6 Zyl. 8 Zyl.
Motor Nachbarzylinder Kurbelwinkel nach OTP Motor Nachbarzylinder Kurbelwinkel nach OTP
ENGINE NEIGHBOURING CYL. CRANK ANGLE AFTER TDC ENGINE NEIGHBOURING CYL. CRANK ANGLE AFTER TDC
1 2 270 1 * 2 ** 2 * 90 ** 270
2 1 90 2 3 1 90 90
3 2 90 3 4 2 270 90
4 3 270 4 3 5 90 90
5 4 90 5 4 6 90 90
6 5 90 6 7 5 90 270
7 8 6 90 90
8 7 7 270 90

* Zündfolge / FIRING ORDER 1–6–5–2–7–4–3–8

** Zündfolge / FIRING ORDER 1–8–3–4–7–2–5–6

3.00 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 3326–2/A1

Removal and Fitting of a Crosshead Pin

8
D
94325

5
In order to prevent the connecting
f d e rod studs from touching the column
10
plate 5, a piece of wood (protection)
g 6 is to be stuck between connecting
4 rod head and column plate.
Remove lifting tackle ’a’.
4 Schutz
PRETECTION
Removal of the guide shoes:
2 – Fasten two holders 94325 to the
1
guide ways 8 facing the neigh-
bouring cylinder.
Brennstoffseite
FUEL SIDE

– Screw an eye bolt M10 each in

the ends of the guide shoes 4,
and connect them to the holders
94325 by means of the lifting
tackles ’d’ and ’e’.
– Unscrew the guide shoes 4 from
the middle piece 6, and lower
them with the lifting tackles ’d’
and ’e’.
4 – Remove the guide shoes 4 with
the lifting tackle ’f’ and ’g’.

3 99.7680

Nachbarzylinder
NEIGHBOURING CYL.

Wärtsilä Switzerland Ltd 3 3.00

3326–2/A1 Maintenance RTA48T

Removal and Fitting of a Crosshead Pin

Removal of the middle piece facing the

neighbouring cylinder:
– Lower the crosshead till all the screws of
the end cover 10 (see group 3326–1) are
d e accessible.
– Attach middle piece 6 to lifting tackles ’d’
and ’e’ as shown in Fig. ’E’, then dismantle
the end cover 10.
10 – Retract the middle piece from the cross-
6 head pin according to Fig. ’E’, and lower it.
If necessary dismantle the guide bar
mounted on the guide shoe on fuel side
(see group 3326–1).
– Lift the crosshead pin until it has reached
the initial position, then remove middle
piece 6 by means of lifting tackles ’d’, ’e’,
and ’g’ (Fig. ’F’).

99.7681
F

e
d

99.7077

6
99.7682

Nachbarzylinder
NEIGHBOURING CYL.

3.00 4 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 3326–2/A1

Removal and Fitting of a Crosshead Pin

Removal of the crosshead:

G
– Lower the crosshead until the screws of the
end cover are accessible.

8 – Move both holders 94325 and the lifting

tackles ’d’ and ’e’ to the opposite guide ways
94325 8.
d e – Connect the middle piece 6 with lifting tackles
’d’ and ’e’.
6 – Remove end cover from the corresponding
middle piece.
– As shown in Fig. ’G’, retract crosshead pin 3
from the middle piece; then pull up the middle
3 piece as far as possible with lifting tackles ’d’
and ’e’.
– Lower the crosshead (Fig. ’G’).
– Turn crosshead pin 3 as shown in Fig. ’H’. At-
tach lifting tackles ’f’ and ’h’ according to Fig.
’H’, and connect them to the lifting plate
94324.
– Disconnect the crane, and retract the cross-
head from the crankcase by means of lifting
tackles ’f’, ’h’, and ’g’ (Fig. ’H’).
99.7683

d e h
f
94324
g

99.7078

Nachbarzylinder
NEIGHBOURING CYL. 99.7684

Wärtsilä Switzerland Ltd 5 3.00

3326–2/A1 Maintenance RTA48T

Removal and Fitting of a Crosshead Pin

Fitting
Fitting procedure is analogous to the removal, but in reverse sequence.
 Fit only crosshead pins which have a perfect, undamaged running surface.
 If guide shoes have been dismantled, see instructions in group 3326–1 prior to fitting them.
 Before fitting the crosshead pin clean all guide and bearing surfaces carefully and smear them lavishly with
bearing oil. Always fit toggle lever to crosshead lubrication and piston cooling in such a way that its
curvature stands upwards.
 After completing the work check that all tools and foreign bodies are removed from the crankcase, and that all
the screwed fastenings are tightened to specification and locked accordingly.
 Check crosshead clearances according to Clearance Table in group 0330–1.
 Check with lubricating oil pump running that crosshead and connecting rod bottom end bearings are lavishly
supplied with oil.

3.00 6 u Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 3403–1/A1

Piston
Removal and Fitting

Tools: Key to Illustrations:

1 Piston ring expander 94338 1 Piston rod 15 Compression shim
2 Pre-tensioning jacks 94340 2 Crosshead pin 16 Securing screw
1 Suspension device 94341 3 Waisted stud 17 Locking element
1 Insertion funnel 94342a 4 Nut 18 Waisted screw
2 Distance holders 94345 5 Vent screw 19 Piston skirt
1 Cover plate 94345d 6 Pin 20 Cylinder liner
1 Tap 94348 7 Piston 21 Holder
1 Piston supporting device 94350 8 Platform support
1 HP oil pump 94931 9 Support
1 Pressure gauge 94932 10 Hinged cover
1 Pressure gauge 94932a 11 Piston rod gland K Slot
1 Connection piece 94934a 12 Straps R Round bar
1 HP hose 94935 13 Screw connection S Gap
2 HP hoses 94935a 14 Centring pin V Relief valve

Remark We strongly recommend to follow the instructions in group 9403–4 referring to the application of
hydraulic pre-tensioning jacks to screwed connections.
Regarding draining cylinder cooling water and removal of a cylinder cover refer to group 2708–1.

Working sequence for the removal

– Turn crank to B.D.C.
– Remove wear ridge in the cylinder liner (see group 2124–3).

Brennstoffseite
FUEL SIDE

99.7093

Wärtsilä Switzerland Ltd 1 2.06

3403–1/A1 Maintenance RTA48T

Piston: Removal and Fitting

Loosening the waisted studs of the piston rod foot fastening

– Clean the threads of waisted studs 3 and the area around the nuts 4 (Fig. ’B’).
– Place both pre-tensioning jacks 94340 crosswise on the waisted studs 3 to be loosened, and completely screw
them on (arrangement according to Fig. ’B’) with opened vent screw 5 (Fig. ’C’).
– Both pre-tensioning jacks are to be loosened by about ½ turn (gap ’S’ in Fig. ’C’).
– Connect both pre-tensioning jacks to the HP oil pump 94931 with the HP hoses 94935, 94935a and the connec-
tion piece 94934a as shown in Fig. ’B’.
– Start up HP oil pump 94931 with
closed relief valve ’V’ and at the same
B
time open the vent screws 5 of the
pre-tensioning jacks till oil flows out I 94340
bubble-free. Close vent screws.
– At a pressure of 1020 bar unscrew
the nuts 4 by one turn with a round bar
’R’. Attention should be paid to en-
sure that the pins 6 always protrude 14
slightly compared with the pistons 7
on the pre-tensiioning jacks!
– Release pressure to zero with the aid
of relief valve ’V’ at the HP oil pump I
and then remove pre-tensioning
jacks and the nuts.
– The same procedure is to be applied
for loosening the other two waisted
studs.
94340
3
4
94935a
2
15
94932 94932a

94931 V 94935 94934a

99.7094a

94935a

7.03 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 3403–1/A1

Piston: Removal and Fitting

Vorspannpresse Vorspannpresse
C aufgeschraubt zum Spannen aufgeschraubt zum Lösen
PRE-TENSIONING JACK PRE-TENSIONING JACK
PLACED FOR TENSIONING PLACED FOR LOOSENING

5
6
7
x

3
4
R
K S

99.7095

Tensioning the waisted studs of the piston rod foot fastening

– Clean the threads of the waisted studs 3 and the area around the nuts 4 (Fig. ’B’).
– Apply oil to the threads of the waisted studs 3 and screw on the nuts 4.
– Tighten the nuts with a round bar ’R’ (Fig. ’C’) by hand with a smart jerk.
– Using a feeler gauge, check whether the nuts rest flush on the connecting rod foot.
– Mark position of nuts to seating surface with a felt tipped pen (Fig.’a’).
– Completely screw the pre-tensioning jacks diagonally onto the waisted studs 3 (Fig. ’B’). Moreover, the vent
screws 5 are to be opened slightly so that the pistons 7 can slide back to their initial position i.e. there is no or
very little clearance at ’x’ (Fig. ’C’).
– Connect both pre-tensioning jacks to the HP oil pump 94931 with the HP hoses 94935, 94935a and the connec-
tion piece 94934a as shown in Fig. ’B’.
– Shut the relief valve ’V’ and start up HP oil pump 94931 till bubble-free oil flows out through the vent screws 5.
Shut the vent screws.
– Slowly raise the pressure to 600 bar (1st step). Attention should be paid to ensure that the pins 6 always pro-
trude slightly compared with the pistons 7 on the pre-tensiioning jacks! Keep the pressure of 600 bar constant
and tighten the nuts 4 with a round bar ’R’ till firmly seated.
– Release pressure to zero with the aid of relief valve ’V’ at the HP oil pump and then screw the pre-tensioning
jacks onto the other two waisted studs. These are to be tensioned in the same sequence as described above.

– Subsequently the waisted studs are to Fig. ’a’ Fig. ’b’

be tensioned again diagonally with 1000
bar (2nd step). After tensioning the nuts
check their seatings with a feeler gauge
through the slot ’K’.
– After tightening the nuts check again if y
these have been turned by about the
same angle i.e. about 55, compared
with the marks previously made (Fig. ’b’).
y 98.7700

x x
Tightening angle

Wärtsilä Switzerland Ltd 3 3.00

3403–1/A1 Maintenance RTA48T

Piston: Removal and Fitting

Removal of the piston

Brennstoffseite Loosen and remove all screws
Attention
FUEL SIDE for the screwing gland box /
cylinder jacket (see group
2303–1).
– Screw fasten both distance holders 94345 to
the piston rod foot (Fig. ’D’).

94345

E
94341

99.7096a

11
94345

– Turn crank to T.D.C. whereby the gland is

pushed out of its seating in the cylinder jacket
by the distance holders 94345 (Fig. ’E’).
– Use tap 94348 to clean threaded holes of com-
bustion residue in the piston crown.
– Mount suspension device 94341 to piston
crown.
Before pulling the piston out, the
Remark
crosshead pin and the top end
bearing must be protected, so
that entry of dirt into the top end
bearing is absolutely prevented.

3.00 4 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 3403–1/A1

Piston: Removal and Fitting

– Fasten piston supporting device 94350 to

the platform supports 8 designed for this F
on the middle platform (Fig. ’F’ and ’G’).
– The antipolishing ring provided at the top
of the collar in the cylinder liner must be re-
moved as described in group 2124–2.
– Pull piston by crane out of cylinder liner.
– Loosen the screw connection 13 and push
the supports 9 of the piston supporting de-
vice 94350 completely outwards and turn
up the hinged covers 10 (Fig. ’G’).
– Lower piston on crane into the supporting 94350 94345d
device until the piston rod foot protrudes
below the supporting device (Fig. ’F’). 8
– Place the cover plate 94345d over the
gland bore in the cylinder jacket and fasten
it provisionally with several screws.

94341
99.7730

12

9
13

11 – Turn the two hinged covers 10 down and

lower the piston until the piston rod gland
10 11 rests on the two hinged covers. Push the
10
94350 two supports 9 together and firmly tighten
screwed connection 13.

94345

1
99.7690

Wärtsilä Switzerland Ltd 5 2.06

3403–1/A1 Maintenance RTA48T

Piston: Removal and Fitting

If the piston has to be dismantled, then it must be secured against turning when loosening the waisted studs 18,
whereby the procedure is as follows:
– Lower the piston until access is obtained to the securing screws 16.
– In place of the straps 12 which are fixed to the piston as shown in Fig. ’H’, loosen and remove the securing
screws 16 together with their locking plates and locking elements 17.
– Fully lower the piston and fit the straps by means of the securing screws.

94341

H 12

18

I-I

12 18 17 I I

16
Brennstoffseite
FUEL SIDE

19
94350

12

99.7691

3.00 6 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 3403–1/A1

Piston: Removal and Fitting

Fitting preliminaries
 Remove piston rings with ring expander 94338 and clean piston exterior thoroughly. (Use no tool which could
scratch or otherwise damage the surface!)
 Establish the height of the piston ring grooves (refer to Clearance Table group 0330–1).
 Clean piston rings and measure them. When re-fitting used piston rings be sure to fit them in the same
grooves as before. For the re-fitting of used as well new piston rings, follow strictly the instruction in group
3425–1.
 Fit the piston rings such that their TOP marking is on top.
 Check the piston top surface (see group 3403–4).
 Measure bore of cylinder liner (see group 2124–1) and carry out any needed reconditioning to scavenge ports
and lubricating grooves (see group 2124–3).
 Actuate the cylinder lubrication until oil flows from the respective lubricating points.
 Piston rod gland and both distance holders 94345 must be mounted on the piston rod (see group 2303–1).
 The insertion funnel 94342a must be fitted to the cylinder liner as shown in Fig. ’I’.
 The suspension device 94341 must be fastened to the top of the piston crown.
 Smear piston rings, piston skirt, piston rod and running surface in cylinder liner lavishly with bearing oil.
 Remove the securing screws 16 which were perhaps used to secure the piston in the piston supporting device,
and screw (and lock) them again into the piston rod for locking of the waisted studs 18.

94342a

21

20

99.7451

Wärtsilä Switzerland Ltd 7 2.06

3403–1/A1 Maintenance RTA48T

Piston: Removal and Fitting

Working sequence for the fitting

– Slightly lift piston by crane. Loosen screw connection 13 K
of supports 9 (Fig. ’G’) and push both supports outwards.
Then lift the piston including piston rod gland 11 so far that
the two hinged covers 10 can be turned up. 94342a
– Lift piston out of supporting device and bring it above the
cylinder liner, lower it slowly into it (Fig. ’K’).
– When the piston is lowered into the cylinder liner until the
lowest piston ring is at the upper level of the fitting funnel,
arrange the piston rings so that their gaps alternate by
180 to each other.
See instructions in group 3425–1.
– Slowly lower the piston further till its piston rod foot has
arrived just above the crosshead pin. While one person
directs the further lowering of the piston from the top,
another directs the piston rod progress from the engine
interior and how it must be turned to guide the piston rod 94345
foot, without jamming, into the centring pins 14 (Fig. ’B’) in
the crosshead pin.
– Turn crank to B.D.C. (loosen crane correspondingly) and
direct the insertion of the piston rod gland into its seating
bore in the cylinder jacket (see group 2303–1).
– Loosen and remove both distance holders from the piston
rod foot.
– Firmly tighten all screws fastening the gland housing.
– Turn crank to T.D.C. (follow up with crane correspond-
ingly) and remove the suspension device.
– Turn crank to B.D.C. and tension the waisted studs for the
piston rod foot fastening as described.
– The antipolishing ring must be fitted as described in group 013.777/06

2124–2.

Leak test
A leak test must be carried out after every fitting of a piston in the cylinder. For this, start the bearing lubrication pump
and set the bearing lubricating pressure. Check through the scavenge space on the fuel side in the cylinder jacket
(piston underside) whether cylinder liner running surface and piston rod remain dry.
Any increase in the dirty oil level in the scavenge air space may be caused by a faulty O-ring in the piston.

2.06 8 u Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 3403–2/A1

Piston
Changing the Compression Shims

Tools: Key to Illustrations:

1 Propping device 94347 1 Gland housing, 2-part
(consisting of 2 segments 2 Piston rod
for changing compression shim) 3 Piston rod foot
2 Eye bolts 4 Crosshead pin
1 Spanner 5 Piston
6 Compression shim
A Slot

Working sequence for fitting and

5
removing compression shim
94347 Loosen the nuts of the waisted studs
for the screwing of the piston rod foot 3
A and crosshead pin 4, as described in
I I group 3403–1.

1 Open the door to the piston underside

of the corresponding cylinder on fuel
side.

2 Place both supporting sheets of prop-

ping device 94347 – with the slots ’A’
provided for the screw heads pointing
downwards – onto the flange of the
gland housing 1, and push these as far
as possible to the piston rod.
Turn the respective piston downwards
until it rests fully on both supporting
sheets. Check!
3 Carefully turn crank forward and take
care that the two centring pins in the
crosshead pin 4 do not jam in the piston
6 rod foot.
Loosen the two screws fastening the
4 compression shim 6 and remove them.
Remove the compression shim with
the aid of the two eye bolts.
For fitting the new compression shim
proceed in reverse sequence to the re-
I-I moval.
If the new compres-
94347 Remark sion shim is thicker
than the old one, it
must absolutely
2 be remembered to
grind off the wear
1 ridge in the cylinder
liner (see group
2124–3).

99.7106

Wärtsilä Switzerland Ltd 1 u 3.00

This page is intentionally left blank
 RTA48T
Maintenance 3403–3/A1

Piston
Dismantling and Assembling

Tools: Key to Illustrations:

1 Suspension device 94341 1 Piston crown 8 Centring pin
1 Piston supporting device 94350 2 Spraying plate with oil pipe 9 Screw
2 Jacking screws 94363 2a Nozzle to spraying plate 10 Locating pin
2 Jacking screws 94364 3 Locking element 11 Strap
1 Impact ring spanner AF36 4 Screw with locking plate 12 Screw
1 Torque wrench 5 Waisted bolt 13 O-ring
6 Piston rod 14 O-ring
7 Piston skirt 15 Locating pin

Should the dismantling of a piston become necessary (cleaning the cooling chamber, reconditioning the ring
grooves etc.), then this can be carried out as described below. For this purpose the piston is to be placed in the piston
resting device. The latter must firstly be mounted on a platform support that has been determined for this purpose
(see group 3403–1).

Dismantling of a piston
– Remove locking elements 3 with screw and locking plate 4 from all waisted bolts 5 (Fig. ’A’).
– Loosen and remove all waisted bolts 5.
– Insert both jacking screws 94363 into the two opposite bores for locking screws 4 in the piston rod head (Fig.
’A’), and drive them in till they press against centring pin 8 (Fig. ’C’). Equally tighten the two jacking screws in
small steps, till the piston crown is separated from the piston rod. When raising piston crown 1 take particular
care not to damage the nozzles 2a of the spraying plate 2.
– Remove both jacking screws from piston rod head.
Following the removal of piston crown separate piston skirt 7 from piston rod 6 as described below:
– Loosen and remove both screws 9 (Fig. ’A’).
– Using two jacking screws 94364 (see Fig. ’D’) the piston skirt can be separated from the piston crown.
While raising the piston skirt pay attention that locating pin 10 does not jam.
For the removal of spraying plate with oil pipe 2 (Fig. ’A’) loosen and remove first screws 12 with locking plates. The
spraying plate with oil pipe can then be pulled as a complete unit from piston rod 6. Attention! Do not damage the
nozzles of the spraying plate 2a.

Remark When fitting and removing the waisted bolts 5 the piston rod must be steadied against rotation
with the two straps 11 of the supporting device and two locking screws 4.
When dismantling or assembling a piston take particular care that the nozzles to the
spraying plate 2a are not damaged.

Wärtsilä Switzerland Ltd 1 1998

3403–3/A1 Maintenance RTA48T

Piston: Dismantling and Assembling

Assembling
For assembling the piston the following points must be observed:
 Any damaged nozzle to spraying plate 2a may under no circumstances be re-fitted.
 Whenever possible always use new O-rings, they must conform in dimensions and quality to our specifications
(also refer to group 0370–1).
 All cylindrical guide portions as well as O-rings, screw head seatings and threads must be smeared with
MOLYKOTE paste before fitting.
 The screws 12 to the spraying plate with oil pipe 2 are to be pre-tightened with 10 Nm using a torque wrench,
then tightened to an angle of 25 and finally secure with a locking plate. Apply only lube oil to all threads of
screws 12 before fitting.
Attention must be paid to the locating pin 10 when assembling a piston skirt with a piston rod.
Insert and tighten both screws 9.
For the assembly of piston crown 1 to piston rod 6 make sure that the two centring pins 8 (Fig. ’A’), serving also as
guides, mate with the corresponding bores in the piston skirt 7 and the piston rod.
Screw all waisted bolts 5 into the well cleaned threaded holes till fully seated; tighten these carefully crosswise in
small steps with an impact ring spanner.
Mark position of screw heads against piston rod flange with felt-tip pen (= initial position).
Using an impact ring spanner and a hammer, alternately tighten the waisted bolts in small steps until these have
been turned by an angle of 75 compared with the initial position (see group 0352–1).
Lock all the waisted bolts 5 with their locking elements 3. For fitting a locking element a screw may under no circum-
stances be turned back; it must instead be tightened further (by max. 5).

1998 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 3403–3/A1

Piston: Dismantling and Assembling

I-I II - II
A
1
2a
12
2

II II

13 10
14 IV
I I
15 7 IV V

5 6
V
Brennstoffpumpenseite
FUEL PUMP SIDE

IV - IV

V
III
1
III 9

5
3
4

95.7845
4

Wärtsilä Switzerland Ltd 3 1998

3403–3/A1 Maintenance RTA48T

Piston: Dismantling and Assembling

94341 C
1 Abdrücken des Kolbenoberteils
SEPARATING THE PISTON CROWN

1
2a 2

7
8
6
7
5
11 6
94363

D
Abdrücken des Kolbenunterteils
SEPARATING THE PISTON SKIRT

94350 94364
2

98.7410

3.00 4 u Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 3403–4/A1

Piston
Checking Piston Top Surface

Tools:
1 Feeler gauge 94122
1 Template 94366
1 Template 94366a

Every time a piston is pulled the piston top surface contour must be checked with the checking template 94366 con-
tained in the tool set and with feeler gauge 94122. The template is placed on the topmost piston ring and rotated
around the piston axis (see Fig. ’A’).
Where burn scars are only slight it is sufficient to grind over them and to smooth sharp edged zones with emery cloth.
Where, however, burn scars exceed x = 10 mm the original material thickness must be restored by surface welding.
This entails the removal of the piston crown.
Before re-starting the engine, the reason for such heavy burns should be established. The causes must be reme-
died.

Causes of heavy burn scars may be:

Poor combustion, worn nozzles, heavy local carbon deposits on top of the piston crown etc.

94366

Kolbenring
PISTON RING

94366a

95.7848a

The template 94366a should be used if the shape of the crown top of a piston in situ has to be checked.
As shown in Fig. ’B’, the template is to be pushed through one of the scavenge ports of the cylinder liner and placed
on top of the piston crown.

Wärtsilä Switzerland Ltd 1 u 1998

This page is intentionally left blank
 RTA48T
Maintenance 3425–1/A1

Piston Rings
Checking Piston Ring Wear

Tools:
1 Inside micrometer 94101
1 Feeler gauge 94122
1 Piston ring expander 94338
1 Insertion funnel 94342
1 Micrometer (0–30 mm)
1 Wire brush
Various cleaning liquids

94338

93.7166

In the course of a piston overhaul the following work has to be done depending on the requirement.

Removing piston rings

Always use piston ring expander 94338 to remove rings from piston ring grooves. Expand the rings only sufficiently
to allow removal over the piston crown. Avoid unnecessary strain (overstrain, while fitting or removing).
Thoroughly clean piston, piston rings and piston ring grooves.
Use a steel wire brush to remove carbon and lacquer residue, then wipe clean all the parts with a cloth and suitable
cleaning agent.

Measuring piston rings and piston

Check all dimensions with the clearance table (group 0330–1) and record them. These records are important for
later evaluation of the running gear. They should encompass all dimensions, the date of overhaul and operating
hours of the various components and of the engine itself.

Piston rings

Ring gap:
The current piston ring wear can roughly be determined – without having to dismantle the piston – by means of the
ring gap.
When the piston is assembled after an overhaul the piston rings must be fitted in such a manner that the ring gaps of
all or at least the two topmost piston rings point in the direction of a scavenge port.
After assembling the piston it must be moved until the piston rings appear at the level of the scavenge ports. In this
position the ring gap (S1) can be measured and recorded.

Determining the wear of the piston rings:

In order to determine the piston ring wear, some time or other – perhaps 3000 running hours after the last piston
overhaul – the ring gaps (S2) are measured where accessible and recorded.
S2 * S1
The piston ring wear can then be calculated with the formula
2 3.14

Wärtsilä Switzerland Ltd 1 3.00

3425–1/A1 Maintenance RTA48T

Working Piston: Checking Piston Ring Wear

Later regular optical checking of the piston rings through the scavenge ports provides a reliable judgement of the
piston ring condition. Depending on the position of the topmost piston ring, its ring gap can be measured through the
ports.
The ring gap measured during such an inspection also permits a determination of the next piston overhaul.
Should the gap of the topmost piston ring be in an inconvenient position, do not try turning it by using any sort of tool.
In such cases it is recommended to measure the ring gap at a later opportunity.

Piston ring grooves

Measure the vertical clearance j1 and k1 with fitted piston rings and feeler gauge 94122. At the measuring point
press the piston ring right into the groove (see Fig. ’A’).

Reuse of piston rings

It is recommended to pull one piston after about 2’000 operating hours, to establish the wear rate of the cylinder liner
and the piston rings.
With the aid of the diagram in group 0330–1 the approximate service life of a piston ring can be estimated.
At the same time the replacement date for the piston ring can be estimated.

Examples: (consult also the diagram)

Case one: New cylinder liner, new piston rings
Piston pulled after 2’000 operating hours. Wear was established as:
Cylinder liner . . . . . . . . . . . . 0.10 mm = 0.05 mm / 1000hrs. point 1
Piston ring . . . . . . . . . . . . . . 0.60 mm = 0.30 mm / 1000hrs. point 1
If all piston rings are otherwise in good condition they can be refitted. One must, however, take into
consideration that refitted piston rings may only be used till the limiting line I min.
Case two: First piston overhaul after total 9’000 operating hours
Total wear of cylinder liner 0.45 mm = 0.05 mm / 1000 hrs. point 2
Total wear of piston ring . . 2.70 mm = 0.30 mm / 1000 hrs. point 2
Point 2 lies between the line I min. and I min. N, therefore the piston ring must be replaced by a
new one.
Case three: Second piston overhaul after total 19’000 operating hours of the engine
Wear of cylinder liner . . . . . 0.95 mm since the first overhaul = 0.05 mm / 1000hrs. point 4
Wear of piston ring . . . . . . . 3.00 mm since the first overhaul = 0.30 mm / 1000hrs. point 4
Point 4 lies between the line I min. and I min. N, i.e. the piston ring can not be reused.

Remark Line I min . . . . . . . = for old reused piston rings

Line I min N . . . . . = for new piston rings
1. When fitting piston rings, note down whether they are new ones or used ones.
2. To ensure good sealing of the whole piston ring set, the diagram must be followed without fail. When piston rings
are worn too much, an optimum seal of the piston ring set is no longer ensured.
3. Experience has shown that used and refitted piston rings seal rather less well in operation than newly fitted
ones. For this reason the limit for total wear of old reused piston rings (I min) has been set somewhat higher than
for new piston rings (I min N).

8.98 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 3425–1/A1

Working Piston: Checking Piston Ring Wear

Fitting of used piston rings

When reusing old piston rings, only such rings may be fitted which are in undamaged, good condition. The piston
rings must be fitted with the marking TOP upwards.
Reused old piston rings with sharp edges must be rounded off with radii according to Fig. ’B’ (with the exception of
SCP1CC piston ring).
The edges of the ring gap must be rounded off with a radius of 0.50 mm (with the exception of SCP1CC piston ring).
Reused piston rings must be refitted in the same ring grooves and in the same position (TOP) as removed. Before
fitting used piston rings, measure them in view of a later judgement, as mentioned.

Fitting of new piston rings

The marking TOP stamped into the piston ring must, without fail, be facing upwards. Before fitting new piston
rings, measure them in view of a later judgement, as mentioned.
Newly fitted piston rings have to be run-in according to the relevant indications in the Operating Manual.

Piston ring equipment for cylinder liner without antipolishing ring

Ring type Coating / material Application

Uppermost piston ring ’a’

1 x SCP1CC 15 or chrome-ceramic for new and used cylinder liners

1 x SCP1RC 15 with running-in coating for new and used cylinder liners
as an alternative

Piston rings ’b’ – ’d’

3 x SCP1RC 15 with running-in coating for new and used cylinder liners

Piston ring equipment for cylinder liner with antipolishing ring

Ring type Coating / material Application

Uppermost piston ring ’a’

1 x SCP1CC 15 chrome-ceramic for new and used cylinder liners

Piston rings ’b’ – ’d’

3 x SCP1RC 15 with running-in coating for new and used cylinder liners

Reconditioning of worn piston ring grooves

If an inspection reveals much wear of the chrome layers (Fig. ’A’), then a new chrome plating is indicated.
Instructions for reconditioning work of piston ring grooves can be requested from the engine maker.

Wärtsilä Switzerland Ltd 3 11.02

3425–1/A1 Maintenance RTA48T

Working Piston: Checking Piston Ring Wear

Ringausrüstung
A RING ARRANGEMENT B

CR TOP
j1 r 1.75

a
CR
TOP r 1.75
CR j1

b
CR
TOP r 1.75
k1

c
CR
TOP r 1.75
k1

d
CR
96.7141 r 1.75

CR (Chromschicht) = 0.40–0.45 mm
(CHROMIUM PLATING)

Original Ringbreite = 16 mm
ORIGINAL RING WIDTH = 16 mm
l [mm]
Radiale Ringabnützung [mm]

16 3 0
RADIAL RING WEAR [mm]

lmin
1
15 1

14 2
l
2 min N
13 3
4
12 4
480 481 482 483 484 [mm]

Max. Zyl. Abnützung = 483,36 mm

MAX. LINER WEAR = 483,36 mm

3.00 4 u Wärtsilä Switzerland Ltd

 RTA48T
Betrieb Group4

Camshaft and Control Elements Group 4

 Camshaft Driving Wheels

– Checking the Running and Backlash Clearances and Condition of the Teeth . . . . . . . . . . . . . . 4103–1/A1
– Removal and Fitting of Intermediate Gear Wheels, Replacing a Toothed Rim . . . . . . . . . . . . . 4103–2/A1
– Replacing the Gear Wheel on the Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4103–3/A1

 Camshaft
– Removing and Fitting a Camshaft Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4203–1/A1
– Removing and Fitting of Hydraulic Locking Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4203–2/A1
– Removing and Fitting of Hydraulic Locking Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4203–3/A1
– Removing and Fitting of an SKF Shaft Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4203–4/A1
– Removing and Fitting the Gear Wheel on the Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4203–5/A1

 Starting Air Distributor

– Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4303–1/A1

 Shut-off Valve for Starting Air

– Cleaning and Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4325–1/A1

 Rotating Direction Safeguard

– Inspection and Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4506–1/A1

Wärtsilä Switzerland Ltd 1 RTA48T / MM / 1998

This page is intentionally left blank
 RTA48T
Maintenance 4103–1/A1

Camshaft Driving Wheels

Checking the Running and Backlash Clearances and Condition of the Teeth

Tools: Key to Illustrations:

1 Feeler gauge 94122 0–6 Tooth profile
1 Micrometer a,b,c Lead wires
1 Dial gauge TF Driving flanks
1 Lead wire Ø 1.5 mm
Oil resisting marking blue (ink)

Gear wheels of new engines have to be checked visually during the running-in period after about 1–2 operating
hours. The same applies to old engines which have been equipped with new gear wheels. For this the respective
casings have to be removed. Rotate crankshaft with the turning gear until all the teeth have been inspected. Follow-
ing this, check with running lubricating oil pump, whether all the spray nozzles are delivering oil freely. Further, check
whether all the screws are correctly locked, and whether any irregularities can be detected. After the running-in
period we recommend checking the gear wheels periodically every 3 months in the manner described above.
Should in this time any faults appear, then these can in certain cases be remedied by an experienced engineer.
Should noises be heard in the region of the gear train, these should be investigated and remedied as quickly as
possible. Replace defective gear wheels as soon as ever possible, to prevent damage to the mating gear wheels.
When the gear wheels have run well for an initial running period of 6000–8000 hours the above-mentioned inspec-
tion may be carried out annually.
For the checking of clearances and tooth impressions the tie rods and the waisted studs of the main bearings must
be tightened.

Checking the gear tooth backlash

Information concerning the correct gear tooth backlash values can be found in the table of clearances (see group
0330–1). The backlash can be determined in several ways. Depending on the possibilities, the following methods of
measurement can be used:

With feeler gauge 94122:

The gap between the teeth flanks can be measured by using the different thicknesses of feelers in the feeler gauge.
Repeat the measurement at a minimum of four points on the circumference of the gear wheel.

With dial gauge:

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

Measuring tooth backlash with lead wire:

Use a fresh piece of lead wire Pb 99.9 fine of 1.5 mm diameter for each measurement.
If several measurements are being carried out, lead wires of the same diameter and quality must be used.
Place three lead wire pieces a, b, c of about 200 mm length by hand around the tooth profile and attach them with
scotch tape (see Fig. ’A’ and ’B’).
Number the tooth profiles in accordance with Fig. ’B’.
The middle lead wire ’c’ (Fig. ’A’) serves to verify the total tooth backlash ’f’ (Fig. ’C’). With the two outer lead wires ’a’
and ’b’ (Fig. ’A’) the tooth profile parallelity is checked.
The lead wires are turned only once through the teeth meshing, by rotation of the engine crankshaft.
For the calculation of the total tooth backlash ’f’ see Fig. ’C’.
The obliquity ’Df’ is calculated from the difference in thickness of the squashed lead wires along the driving flanks TF
(Fig. ’A’):
Df = a1–b1 or a3–b3 etc.
The admissible deviation of tooth profile parallelity amounts to 0.03 mm across the width of the gear wheel.
For admissible tooth backlash please refer to group 0330–1.

Wärtsilä Switzerland Ltd 1 1998

4103–1/A1 Maintenance RTA48T

Checking the Running and Backlash Clearances and Condition of the Teeth

A B

z = 15mm Bleidraht Ø 1,5 mm

z LEAD WIRE Ø 1,5 mm
=
=
z b1 0
1
b3 2
3
7
4
5
a1
6
b
a3 ...
c
a ...
...

f’

f”

The total tooth backlash is composed

of the sum of backlash f’ and f”.
TF Measurement is done with lead wire.
c

f = f’ + f”
93.7201

Checking the running performance with ink

To enable judging the running performance of the gear train after re-commissioning, three teeth each of the gear
wheels are smeared with a thin coat of oil resisting marking blue (ink) equally spread. This check of the mating ap-
pearance of the teeth is necessary although the re-alignment of the gear train has been made with utmost care, by
the use of lead wire. One brand of oil resisting marking blue is, for example, Dykem Layout Red Dx-296.

1998 2 u Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 4103–2/A1

Camshaft Driving Wheels

Removal and Fitting of Intermediate Gear Wheels, Replacing a Toothed Rim

Tools: Key to Illustrations:

1 Feeler gauge 94122 1 Lower intermediate wheel 13 Bearing
6 Adjusting devices 94410 2 Upper intermediate wheel 14 Bearing journal
Withdrawing device 3 Gear wheel on camshaft 15 Locking strap
for taper pins 4 Gear wheel on crankshaft 16 Double column
Various lifting tackles 5 Casing cover 17 Wheel hub
6 Casing cover 18 Toothed rim
7 Casing cover 19 Screw plug
8 Hood
9 Bearing housing
10 Waisted screws H Lifting tackle
11 Cover M Marking lines
12 Taper pins U Vertical outer edge

Removal and fitting of intermediate gear wheels 1 and 2 (Fig. ’A’) are carried out on the fuel pump side of the engine.

Attention On engines of five and six cylinders, which in addition to the integrated balancer might also be
equipped with a balancer on the free end, driven off the camshaft, the balance weights must
point downwards prior to the removal of an intermediate gear wheel.
To prevent an unexpected rotation of the camshaft while the removal of the intermediate gear
wheel is in progress, it is recommended to remove the first camshaft coupling by the gear wheel 3
from the camshaft, before working on the removal of the intermediate gear wheels (see group
4203–4).

Removal
The turning gear must be engaged. Precautions must be taken that, while removal work is in progress, the running
gear can on no account be put into motion.
– Remove casing covers 5 and 7 (one each on fuel pump side and exhaust side) as well as casing cover 6.
– Remove hood 8 over gear wheel 3 on the camshaft. Check whether marking lines ’M’ on the camshaft gear
wheel correspond with the vertical outer edge ’U’ of bearing housing 9, when the crank of the first cylinder is at
T.D.C.
– As shown in Fig. ’B’, the upper intermediate gear wheel 2 must be attached to the board crane by wire rope ’c’
through the bearing housing 9. In order to prevent damage when lifting the upper intermediate gear wheel, it is
recommended to mount lifting tackle ’H’ between board crane and wire rope ’c’. With this arrangement the up-
per intermediate gear wheel can be lifted off with the lifting tackle without risk.
– Pull wire rope ’c’ taut with lifting tackle ’H’.
– Remove screw plugs 19 of taper pins 12 (Fig. ’F’) and then loosen taper pins 12 for the bearing location from the
double column using a withdrawing device.
– Loosen all waisted screws 10 (Fig. ’F’) of the upper intermediate gear wheel and remove them together with
cover 11.
– Carefully lift the upper intermediate gear wheel with the lifting tackle attached to the board crane. For this place
a protection as shown in Fig. ’B’ between gear wheel and bearing housing.
– The upper intermediate gear wheel has to be lifted at least as much as it no longer meshes with lower gear
wheel 1.
– With the help of two lifting tackles ’a’ and ’b’ fasten the lower intermediate gear wheel as shown in Fig. ’B’.
– Tauten both lifting tackles.
– Remove taper pins 12, the waisted screws 10 and the covers 11 using the same procedure as mentioned
above.
– The lower intermediate gear wheel, which now rests on the gear wheel 4 of the crankshaft, can now slowly be
turned out from the double column while guiding it simultaneously with lifting tackles ’a’ and ’b’ (Fig. ’C’). For this
process the teeth of both gear wheels must be absolutely clean and slightly smeared with oil.

Wärtsilä Switzerland Ltd 1 3.00

4103–2/A1 Maintenance RTA48T

Removal and Fitting of Intermediate Gear Wheels, Replacing a Toothed Rim

– Secure the lower intermediate gear wheel to the board crane with wire rope ’c’ and lift it completely out of the
double column (Fig. ’D’). So that the board crane is free for this process, fasten the upper intermediate gear
wheel temporarily with two waisted screws in its bearing unit.
– For lowering upper intermediate gear wheel 2 (Fig. ’E’) the two temporarily fitted waisted screws must be re-
moved. Using the board crane lower the upper intermediate gear wheel till it comes to rest on gear wheel 4 of
the crankshaft. The further removal procedure is the same as for the lower intermediate gear wheel.
Bearings 13 (Fig. ’F’) can be pulled off bearing journal 14, after having removed locking straps 15 with screws and
locking plates.

Fitting
Fitting the intermediate gear wheels is carried out analogously to the removal but in reverse sequence, whereby the
following points must be specially taken care of:
 When fitting bearings 13 they must first be lavishly smeared with bearing oil. Both bearings are basically equal,
they may, however, only be refitted in their original place, as their position has been dowelled with taper pins 12
when building the engine (pay attention to part numbers).
 Fit the intermediate gear wheels so that the marking ’DRIVING END’ appears when viewed from the driving end
of the engine. The lettering is stamped on the rim of the gear wheels.
 The intermediate gear wheels may be fitted arbitrarily with respect to the tooth position. After fitting the inter-
mediate gear wheels the installation position has to be checked, i.e. when the crank of the first cylinder stands at
T.D.C. the marking lines ’M’ (Fig. ’A’) on gear wheel 3 on the camshaft must correspond with the vertical outer
edge ’U’ of bearing housing 9 (hood 8 removed).
 Smear a non-hardening sealing compound on the sealing surfaces between cover 11 and double column 16 at
the driving end.
 Prior to the final fitting of an intermediate gear wheel it must be fixed firstly with the cover 11 and by two waisted
screws 10 in the approximate end position in the double column. For this tighten the waisted screws only to such
an extent that both bearings 13 can still be slightly shifted when the taper dowel pins are driven in.
 On both bearings 13 drive in taper pins 12 with a copper punch. Subsequently coat the threads of screw plugs
19 (Fig. ’F’) with LOCTITE type A and screw them in until they lay on the taper pins 12.
 Tighten waisted screws 10 equally with a hand spanner. In this position mark the waisted screws with a line,
then tighten them diagonally by stages till an angle of 40 is attained.
 As a safeguard check the tooth backlash between the gear wheels (compare with the Clearance Table group
0330–1).
 Lock all waisted screws in pairs with locking wire.

Remark Should it be necessary to replace one bearing, the opposite bearing must be replaced at the
same time, as new bearings are always manufactured in pairs. When fitting them an exact ad-
justment of the intermediate gear wheels is essential.

For a new adjustment of the intermediate gear wheels the adjusting devices 94410 must be used
as shown in Fig. ’G’. After adjustment the bores provided for the adjusting devices are to be
closed again by the screw plugs 19 whereby their threads are to be coated with LOCTITE type A.
After a new adjustment of the intermediate gear wheels the tooth backlash (see Clearance Table
group 0330–1), as well as the tooth flank contact pattern have to be checked (see group
4103–1).
If a new dowelling of the bearings is required e.g. due to the replacement of a gear train, then the
pin holes pre-bored in the column must be used.
Such work is best carried out by an experienced erector who possesses the required instructions
from the engine manufacturer’s.

1998 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 4103–2/A1

Removal and Fitting of Intermediate Gear Wheels, Replacing a Toothed Rim

M U 9
A Gezeichnet für RTA58T
DRAWN FOR RTA58T

6
3
Gezeichnet für 5–6 Zyl. Motor
DRAWN FOR 5–6 CYL. ENGINE

8
M 2

U
16

1
Brennstoffpumpenseite Abgasseite
FUEL PUMP SIDE EXHAUST SIDE

5
7

96.7346

Rechtsmotor – rechtsdrehend : voraus

Rechtsmotor – linksdrehend : zurück
RIGHT HAND ENGINE CLOCKWISE ROTATION: AHEAD
RIGHT HAND ENGINE COUNTER-CLOCKWISE ROTATION: ASTERN

Wärtsilä Switzerland Ltd 3 1998

4103–2/A1 Maintenance RTA48T

Removal and Fitting of Intermediate Gear Wheels, Replacing a Toothed Rim

Bordkran
B C
BOARD CRANE

H
c c

3 9

Schutz
2 PROTECTION 2

1 a b
b
a
1
4
4

D E

c
c

2
1

a b
b
2

00.7042

3.00 4 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 4103–2/A1

Removal and Fitting of Intermediate Gear Wheels, Replacing a Toothed Rim

Replacement of a split design gear rim (2-part intermediate gear wheel)

 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 mounted condition at the
maker’s works and guarantees the required perfect true running of the complete gear wheel. For this reason a
split design gear wheel may only be installed if the final machining of the teeth had been carried out
with assembled hub/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 reused, provided a new rim, on
which the teeth are not finish-machined, is fitted to the hub, screw-fastened and dowelled. Then its teeth can be
finish-machined.
II - II
F
18 III - III 10
11
19
17 19

12
15

16 16 I II

10 10
11 11
I
14

19
III III
II
II - II
G
13 13 15
I
II

10

I
11
94410
II

94410

96.7497

Wärtsilä Switzerland Ltd 5 u 1998

This page is intentionally left blank
 RTA48T
Maintenance 4103–3/A1

Camshaft Driving Wheels

Replacing the Gear Wheel on the Crankshaft

Tools: Key to Illustrations:

1 Feeler gauge 94122 1 Gear wheel 8 Self-locking nut
1 Hydraulic tightening device 94412 2 Crankshaft flange 9 Dowel pin
consisting of: 3 Waisted stud 10 Column
1 Clamping fork with extension 94412a 4 Castle nut
1 Impact ring spanner 94412b 5 Base
1 Forked piece 94412c 6 Flange screw P Closing piece
1 Hydraulic ram 94412d 7 Distance sleeve V Relief valve
1 Retaining wrench 94412e
1 HP oil pump 94931
1 Pressure gauge 94932
1 Pressure gauge 94932a
1 Connection piece 94934a
1 HP hose 94935
1 HP hose 94935a

6
1

4
5
3
9 9

5
4

97.7726

Usually, the gear wheel on the crankshaft (from now on referred to as gear wheel) is executed in one part and fitted
as such on the crankshaft. If a damaged gear wheel in the engine is to be replaced, it must be separated into two
halves for dismantling. In order to avoid damages, especially to the crankshaft, please obtain the necessary
instructions and recommendations for executing such dismantling work from the engine supplier or from Wärtsilä
Switzerland Ltd.

Wärtsilä Switzerland Ltd 1 3.00

4103–3/A1 Maintenance RTA48T

Replacing the Gear Wheel on the Crankshaft

For dismantling as well as for assembling a new gear wheel, dismount the lower intermediate wheel of the camshaft
drive (group 4103–2) and the compensating shafts of the possibly provided integrated balancer (group 7722–1).
The spare gear wheel is executed in two parts and must be fitted as described below.

Remark When ordering a two-part spare wheel, please indicate the engine type, the engine No., as well
as the engine supplier. This data is necessary because the centring diameter of the crankshaft is
registered for mounting the gear wheel, and the center hole of the two-part spare wheel is
manufactured according to these dimensions.

Preparing the assembly of the gear wheel

 The undersize of the center hole ‘d’ (Fig. ‘A’) on the two-part gear wheel 1 with regard to the corresponding
centring diameter of the crankshaft has to be checked and recorded beforehand. For measuring, the crank-
shaft, the gear wheel, and the measuring instrument must have the same temperature.
The undersize of the center hole with respect to the centring diameter must be 0.05–0.12 mm.
 If the undersize is not within the mentioned tolerance, the gear wheel must not be assembled, but the center
hole of the gear wheel has to be given an appropriate aftertreatment (remachine / possibly bore and flame-
spray, and machine to obtain the correct diameter).
 Check whether there is a mark on the crankshaft flange 2 for fitting the gear wheel. For the assembly, the gear
wheel partition must coincide with this mark.
The designation DRIVING END, which is located on the front of the gear wheel, must be on the side of the
flywheel!
 Before assembling, the centring diameter of the crankshaft flange as well as the centre hole of the gear wheel
with the corresponding flange faces must be well cleaned and degreased (Fig. ‘B’). Do not use neither oil nor
MOLYKOTE. All surfaces must be in faultless condition.

Antriebsseite
DRIVING END

2
entfetten
DEGREASE

97.7728

Remark The assembly of the gear wheel must be carried out carefully, since relatively small faults could
have a negative influence on the operating performance of all gear wheels of the camshaft drive.

1998 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 4103–3/A1

Replacing the Gear Wheel on the Crankshaft

Assembly of the two-part gear wheel

The connection consists of four waisted studs 3, each of them comprising two castle nuts 4 and bases 5 (Fig. ‘C’).
Before assembling the gear wheel halves, two waisted studs must be fitted crosswise into each half. A base 5 and a
castle nut 4 are to be fastened on either side of each waisted stud.
The projection ‘X’ of the waisted stud with respect to the castle nut must be 2 mm.
Before fitting the castle nut, degrease the thread and apply LOCTITE 262 to it.
In addition, the castle nut has to be secured with a split pin to prevent it from slipping when tightening the waisted
studs afterwards. Please wait one or two days before tightening the waisted studs in order to ensure thorough curing
of the LOCTITE.

Attention The castle nut secured with LOCTITE and a split pin must be fitted in such a way that the waisted
stud can be tensioned together with the castle nut opposite, as showed in Fig. ‘I’ and ‘K’.

C
4
5
MOLYKOTE

9
LOCTITE 262 1
entfetten / DEGREASE 3
Splint / SPLINT PIN

5
X

97.7731

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

D E
3
6
6
1
1
3
97.7732

Wärtsilä Switzerland Ltd 3 1998

4103–3/A1 Maintenance RTA48T

Replacing the Gear Wheel on the Crankshaft

– Turn the gear wheel half to the bottom (Fig. ‘E’) and place the second gear wheel half, which is also provided
with two pre-assembled waisted studs 3, on the top (Fig. ‘G’).
– Check the correct diameter tolerance by measuring the size of the gap between both gear wheel halves. For
that the gap must be closed on the opposite side (Fig. ‘F’).

F G
6

Spalt 0
GAP 0
1
j

97.7733

– The gap ‘j’ must be 0.16 mm–0.38 mm. If the dimension is not within the mentioned tolerance, the gear wheel
must not be assembled, but the center hole has to be given an appropriate aftertreatment (see preparing the
assembly of the gear wheel).
– After measuring, align the gaps between the wheel halves and slightly tighten the castle nuts 4 of the waisted
studs 3 (Fig. ‘C’).
– Also insert a flange screw 6 in the centre of the upper gear wheel half and tighten it temporarily (Fig. ‘G’).
– Remove the flange screws 6 from each end of the lower gear wheel half so that there are now only two flange
screws 6, each of them tightened temporarily in the centres of the upper and the lower gear wheel half (Fig. ‘H’).

3
1

6
97.7733

– There must be no clearance on the seating surfaces between the gear wheel and the crankshaft flange –
please check!
– For fitting the four remaining castle nuts 4 belonging to the waisted studs 3 (Fig. ‘C’), apply MOLYKOTE paste to
the threads and the seating surfaces. Tighten only the castle nuts treated with MOLYKOTE paste. Use the
retaining wrench 94412e (Fig. ‘K’) for holding up the castle nuts opposite which have already been fitted and
secured with LOCTITE and a split pin.
– Tighten the four castle nuts 4 of the waisted studs 3 crosswise by means of the hydraulic tightening device
94412 (Fig. ‘I’ and ‘K’), measuring and recording the length of the waisted studs beforehand.

1998 4 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 4103–3/A1

Replacing the Gear Wheel on the Crankshaft

– Fit the clamping fork with extension 94412a as shown on Fig. ‘I’ and ‘K’, and connect the hydraulic ram 94412d
to the forked piece 94412c and the impact ring spanner 94412b.
– For tightening, connect the hydraulic ram together with both HP hoses 94935a and 94935 and the connection
piece 94934a to the HP oil pump 94931, plugging one of the openings at the connection piece with a closing
piece ‘P’ (Fig. ’K’).
– Close the relief valve ‘V’ on the HP oil pump and actuate the HP oil pump.
– All the waisted studs are correctly pretensioned if an extension of L 1.20
±
0.06 mm is measured.
Check: there must be no gap in the gear wheel partition.
– If the split pin for securing the castle nut cannot be fitted, turn the castle nut only so far as to allow the split pin to
be fitted.
– After the check mentioned above has been carried out, dismantle both flange screws 6 which have been tem-
porarily fitted beforehand (Fig. ‘H’).
– Degrease the threads of all flange screws 6 and their self-locking nuts 8 and then apply LOCTITE 262 to them;
do not use MOLYKOTE!
– Fit all flange screws 6 with the distance sleeves 7 and the self-locking nuts 8 (Fig. ‘I’).
Afterwards, tighten them crosswise and evenly distributed over the circumference with an angle of twist of 65°.
After fitting the gear wheel on the crankshaft and assembling the intermediate wheels of the camshaft drive, check
the correct positioning of the camshaft driving wheels (see group 4103–2).
Furthermore, reassemble the compensating shafts of the integrated balancer which have possibly been dismantled
beforehand, following the instructions given in group 7722–1.
Check all camshaft driving wheels as specified in group 4103–1 after assembling them.

Wärtsilä Switzerland Ltd 5 3.00

4103–3/A1 Maintenance RTA48T

Replacing the Gear Wheel on the Crankshaft

10

94412a

94412d

94412b
94412c

98.7144

8 7 2 6

1998 6 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 4103–3/A1

Replacing the Gear Wheel on the Crankshaft

10

I-I 94412a

1
3

94935a I
94412d 3

94412c
LOCTITE 262
94412e 4 2
MOLYKOTE 1

I
94932a
P

94934a
94935

98.7487

94932 V 94931

Wärtsilä Switzerland Ltd 7 u 3.00

This page is intentionally left blank
 RTA48T
Maintenance 4203–1/A1

Camshaft
Removing and Fitting a Camshaft Section

Tools: Key to Illustrations:

2 Supports 94413 1 Oil trough
1 Prop 94413a 2 Oil connections
1 Base support 94413b 3 Reversing servomotor
1 Guide 94413c 4 Screwed connections
1 Cross beam 94414 5 Slide ring
2 Thread studs with nuts 94414a 6 Platform support beam
2 Distance sleeves 94414b 7 Bearing cover
2 Pre-tensioning jacks 94415 8 Waisted stud
1 Side member 94416 9 Nut
2 Supports 94417 10 Vent screw
1 Support 94417a 11 Pin
1 Clamp screw 94419 12 Piston
1 Beam 94422 13 Pump housing
1 Beam 94422a 14 Vibration damper
(for 5 and 7 cyl. engines only) 15 Screw
1 Set of tools for cutting 94430 15a Screw
out an actuator pump 16 O-rings
1 HP oil pump 94931 17 Nut
1 Pressure gauge 94932 18 Screw
1 Pressure gauge 94932a 19 Support
1 Connection piece 94934a 20 Camshaft
1 HP hose 94935 21 Ring
2 HP hoses 94935a 22 O-ring
23 V-ring
24 Tension spring
25 Oil baffle (2-part)

K Slot
R Round bar
V Relief valve

The complete camshaft, consisting of several sections, should never be installed or removed as a unit. The ar-
rangement and application of the devices and tools for individual sections is slightly different dependent on the num-
ber of cylinders. For certain camshaft sections, dependent on number of cylinders, flange couplings are used
instead of shaft couplings.

Attention Engines with five or six cylinders might also be equipped with a balancer at the free end that is
driven by the camshaft in addition to the integrated balancer. Prior to loosening the camshaft
coupling, these balance weights must be in a vertically downward position.

Removing a camshaft section

– Turn the engine with the turning gear and simultaneously lift off the rollers and their guides above their cams of
all injection and actuator pumps (see also Operating Manual). The cut-out devices (one tool 94430 per ac-
tuator pump) should be made ready for cutting off the actuator pumps.
– Loosen the shaft couplings which connect the camshaft to be removed with the neighbouring units, according
to the instructions given in groups 4203–2 and 4203–4. The existing markings (check) on the shafts and cou-
plings enable precise positioning of the components for re-assembly.
– Slide the loosened couplings onto the camshaft couplings that are not to be removed. For camshaft sections
with flange couplings, remove the coupling bolts.

Wärtsilä Switzerland Ltd 1 10.00

4203–1/A1 Maintenance RTA48T

Removing and Fitting a Camshaft Section

00.7644

20
20

21

22 23 24 23 25

Special measures
 If the first camshaft section is to be removed, then the 2-part guide ring to the oil baffle and the 2-part oil baffle at
the bearing housing should be dismantled so that the shaft coupling can be pushed to the right side in the bear-
ing housing.
 For removal of a camshaft section that is bound with a mechanical balancer, the six coupling bolts M30 and the
four positioning pins in the coupling flange should be dismantled. The camshaft section can only be lowered
when the drive shaft of the mechanical balancer has been pushed away axially by X 20 mm from the free end.
 Before detaching the last shaft coupling, the prop 94413a with the base support 94413b and the guide 94413c
are always to be mounted under the last camshaft section. By this measure tilting of the camshaft section with
the mounted vibration damper 14 is avoided. To also avoid tilting of the prop 94413a, guide 94413c must be
fixed to the support 19 with screw 18.

Removing oil trough 1:

– Remove all oil pipes of the oil trough 1 (Fig. ’A’).
– After detaching the flange connections, pull out the oil connections 2 of the reversing servomotor 3 downwards.
– Screw in an eye bolt at each of the front faces of the oil trough.
– Depending on the number of cylinders and the camshaft section that has to be removed, remove the floor plates
of the cylinder cover platform and place side member 94416 for attaching the hoists (Fig. ’F’ and ’G’).
– As shown in Fig. ’B’, both supports 94413 are to be placed at the upper column face and on the appropriate floor
plate of the injection pump platform.
– The appropriate platform support 6 (Fig. ’L’ and ’M’) should be removed to provide space for dismantling the oil
trough and subsequently the camshaft section.

Attention The cylinder cover platform should not be loaded additionally after the platform support beam 6
has been removed. Never remove more than one platform support beam at a time.

10.00 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 4203–1/A1

Removing and Fitting a Camshaft Section

– Attach two hoists on the side member 94416 and connect the oil trough with the help of both eye bolts. Pull
hoists taut.
– Undo the screwed connection 4 of the oil trough 1.
– Using both hoists simultaneously, lower the oil trough on to the support 94413 (Fig. ’B’) and pull it out.

Removing bearing cover 7 (Fig. ’C’):

The instructions given in group 9403–4 on the application of the hydraulic pre-tensioning jacks for screwed connec-
tions are to be observed.
– Clean the threads of both waisted studs 8 which have to be loosened as well as the area around the seating
surfaces of the stud nuts 9.
– Place pre-tensioning jacks 94415 on the two waisted studs 8 and completely screw them on with opened vent
screws 10 (arrangement according to Fig. ’D’).
– Then both pre-tensioning jacks are to be loosened by about ½ turn.
– Connect both pre-tensioning jacks to the HP oil pump 94931 with HP hoses 94935a and the connection piece
94934a as shown in Fig. ’D’.
– Start up HP oil pump 94931 with closed relief valve ’V’ and at the same time open the vent screws 10 of the
pre-tensioning jacks till oil flows out bubble-free. Close vent screws.
– At a pressure of 1020 bar unscrew the nuts 9 by one turn with a round bar ’R’. Attention should be paid to ensure
that the pins 11 always protrude slightly compared with the pistons 12 on the pre-tensioning jacks!
– Release pressure to zero with the aid of relief valve ’V’ at the HP oil pump and then remove both pre-tensioning
jacks.
– Lay the cross beam 94414 (Fig. ’E’) on the supports 94413 such that the recesses of the cross beam engage in
the supports.
– Attach two hoists, or one hoist and the engine crane to the camshaft section to be removed as shown in Fig. ’F’
and ’G’. Pull the ropes taut.
– Drive in both thread studs 94414a in the front face of the waisted stud 8 (Fig. ’E’) and counter tighten strongly
with the two upper nuts 17.
– Remove one nut 9 (Fig. ’C’) and instead tighten a distance sleeve 94414b with the help of the lower nut 17 to the
limit stop on the bearing cover 7 (Fig. ’E’). The same procedure is to be carried out for the second nut.
– The bearing cover can now be lowered to the support of the cross beam 94414 with the help of both lower nuts
17.
– After removal of distance sleeves 94414b and thread studs 94414a, the bearing cover resting on the cross
beam 94414 can be pulled out for transportation.

Removing a camshaft section:

For dismantling a camshaft section, the cross beam 94414, the supports 94413 and perhaps a mounted prop
94413a with base support 94413b are to be detached.
To locate the slide ring 5 (Fig. ’C’) screw on the clamp screw 94419 through the middle bore for the oil connections 2
in the slide ring 5 of the reversing servomotor 3.
Place beam 94422 or 94422a before lowering a camshaft section.
Mount the corresponding supports 94417 or 94417a, depending on the camshaft section that has to be removed, as
shown in the Fig. ’F’ to ’M’.
To avoid tilting of the supports 94417a and 94417 they must be fixed with screws 15 and 15a as shown in Fig. ’H’ and
’M’.
The camshaft section can now be lowered, without tilting, using hoists and crane. For further transport roll out onto
supports.

Wärtsilä Switzerland Ltd 3 10.00

4203–1/A1 Maintenance RTA48T

Removing and Fitting a Camshaft Section

Mounting a camshaft section

The mounting follows analogously to the removal, but in the reverse sequence. Moreover, attention should be paid
to the following points:
 The numbering of the relevant components must correspond.
 The bearing surfaces of the supports on which the camshaft section is placed before mounting and also the
camshaft bearing and bearing journal should be clean.
 Prior to fitting a coupling, the tension spring 24, the V-ring 23 and ring 21 together with O-ring 22 must be placed
on the camshaft 20 according to Fig. ’A’.
 A check should be carried out whether the locating marks on the shaft ends to be connected correspond with
one another when sliding and positioning the couplings. Concerning pressing-on of the shaft coupling, see
groups 4203–2 and 4203–4. After fitting screw down both locking plates, whereby the screws must be locked by
means of spring washers (see group 4203–4).
 The coupling bolts of the flange couplings and the damper connection are to be tightened to the corresponding
angle without additional lubricants (see group 0352–1 “Tightening Values of Important Screwed Connections”).

Attention The clamp screw 94419 must be removed from the reversing servomotor so as to insert and
tighten the three oil connections 2 in the slide ring 5 before the couplings are pressed on the
shaft connections, or the flange couplings are bolted together.

Replacing of V-rings
Should it be necessary to replace a V-ring without the camshaft being removed, then cut the new V-ring with a
smooth cut. Afterwards, place the V-ring around the shaft, moisten both ends with LOCTITE 406, and join them
carefully.
Joining the ends of the V-ring requires skill and strength since the ring has to be extended by almost 20%.
The following procedure may be of help: attach a string approx. 100 mm behind both ends in order to stretch the
V-ring, then join the ends as described above.

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 RTA48T
Maintenance 4203–1/A1

Removing and Fitting a Camshaft Section

Tensioning waisted studs 8:

After mounting the bearing cover 7 (Fig. ’C’) the stud nuts 9 are to be tightened with the round bar ’R’ (Fig. ’D’) till the
bearing cover lies without any clearance on the pump housing 13.
Subsequently the waisted bolts 8 for the bearing cover are to be tensioned as follows:
– Mark position of the nuts against the bearing cover 7 with a felt-tip pen (Fig. ’a’).
– Screw both pre-tensioning jacks 94415 onto the waisted studs 8 completely (Fig. ’D’). Moreover, the vent
screws 10 are to be opened slightly so that the pistons 12 can slide back to their initial positions i.e. there is no or
very little clearance at ’x’.
– Connect both pre-tensioning jacks by HP hoses 94935a and connection piece 94934a with the HP oil pump
94931 as shown in Fig. ’D’.
– Shut the relief valve ’V’ and start up HP oil pump till bubble-free oil flows out through the vent screws 10. Shut
the vent screws.
– Slowly raise the pressure to 1000 bar and keep it constant until both nuts 9 have been tightened with a round
bar ’R’ till firmly seated. Attention should be paid to ensure that the pins 11 always protrude slightly compared
with the pistons 12 on the pre-tensioning jacks! Using a feeler gauge inserted through the slot ’K’, check if there
is no clearance between the nuts and the bearing cover. After tightening the nuts check that these have been
turned by about an angle of 60 (Fig. ’b’).
– Release pressure to zero with the aid of relief valve ’V’ at the HP oil pump and then remove both pre-tensioning
jacks.

Fig. ’a’ Fig. ’b’

y 98.7700

x x
Tightening angle

Remark After re-assembling camshaft sections, the correct positions of the actuator and the fuel cams of
the removed cylinder and the following cylinder should be checked (see setting table).
Concerning the inspection of a vibration damper on a camshaft, see group 3130–1.

Wärtsilä Switzerland Ltd 5 10.00

4203–1/A1 Maintenance RTA48T

Removing and Fitting a Camshaft Section

Motoren mit gerader

B Zylinderzahl
ENGINES WITH EVEN
CYL. NUMBERS

1
94413a
94413b

94413

Motoren mit ungerader

Zylinderzahl
ENGINES WITH ODD
I CYL. NUMBERS
I

14

1
94413a
94413b

94413

94413a

94413

96.7626

94413b 94413c 18 19

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 RTA48T
Maintenance 4203–1/A1

Removing and Fitting a Camshaft Section

94419

13
I I-I

16 4
1
9
7 5
8 2
9
8

5 3 2

D
8
8
7
7

9 9
K
R
94415

x 12 12

94935a
10 11 10 11

94932a
94934a 94932 V 94931
94935

98.7416

Wärtsilä Switzerland Ltd 7 10.00

4203–1/A1 Maintenance RTA48T

Removing and Fitting a Camshaft Section

Motoren mit gerader

E Zylinderzahl
ENGINES WITH EVEN
CYL. NUMBERS

94413 94414 94413

Motoren mit ungerader

Zylinderzahl
ENGINES WITH ODD
CYL. NUMBERS
I

8
17
94414a 94413 94414 94413
7

94414b
17
94414 94413

96.7627

10.00 8 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 4203–1/A1

Removing and Fitting a Camshaft Section

Motor mit gerader Zylinderzahl

F ENGINE WITH EVEN CYL. NUMBERS 94416
ENGINE CRANE

H I
Maschinenkran

13

14 94417a 94417 94422 94417 94422

G Motor mit ungerader Zylinderzahl

ENGINE WITH ODD CYL. NUMBERS 94416
ENGINE CRANE
Maschinenkran

96.7628

14 94417a 94422a 94417 94422 94422 94417

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4203–1/A1 Maintenance RTA48T

Removing and Fitting a Camshaft Section

H I

94416 94416
ENGINE CRANE
Maschinenkran

L M

15a
15a

15a 15a

14 94417a 94417 94422 94416 94422 94417

K
ENGINE CRANE
Maschinenkran

15a

15a

96.7629

14 94417a 94422a 94417

10.00 10 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 4203–1/A1

Removing and Fitting a Camshaft Section

94416
L

94417a
I
I
15a 15

96.7631

94416
M

94417
II
II
15

Wärtsilä Switzerland Ltd 11 u 10.00

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 RTA48T
Maintenance 4203–2/A1

Camshaft
Removing and Fitting of Hydraulic Locking Elements

Camshaft couplings (Fig. ’A’) must be removed according to the instructions in group 4203–4. Already fitted cou-
pling flanges (Fig. ’B’ and ’C’) as well as actuator and fuel cams (Fig. ’D’ and ’E’) have to be fitted, aligned (set) as well
as removed with hydraulic tool (see group 4203–3).

A
Removing
Turn engine and lift rollers. Couplings to
be loosened and slid in axial direction
(Fig. ’A’). If flange couplings are installed,
coupling screws must be removed. Re-
move reversing servomotor oil connec-
tions and lower oil trough.

B
Camshaft section to be lowered onto re-
moval supports. If a flange coupling is
installed, dismantle it with the aid of hy-
draulic tool (Fig. ’B’).

HYDR. TOOL
C
If a vibration damper is fitted to the cam-
shaft, dismantle it. Afterwards with the
aid of hydraulic tool dismantle coupling
flange to the vibration damper (Fig. ’C’).

HYDR. TOOL

D
Hydraulic tool to be fixed to actuator cam
and actuator cam to be taken off (Fig.
’D’).

HYDR. TOOL

E
Hydraulic tool to be fixed to fuel cam and
fuel cam to be taken off (Fig. ’E’).
93.7191

Fitting
Same as dismantling but in reverse se- HYDR. TOOL
quence.

Wärtsilä Switzerland Ltd 1 u 1998

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 RTA48T
Maintenance 4203–3/A1

Camshaft
Removing and Fitting of Hydraulic Locking Elements

Tools: Key to Illustrations:

1 Hydr. jacking tool 94424 1 Fuel cam
1 Intermediate ring 94424a 2 Actuator cam
1 Guide ring 94424b 3 Ring piece
1 Connecting branch 94426 4 Screw
1 Connecting branch 94427 4a Washer
1 Centring disc 94428 5 Piston (total 8 pieces)
1 Suspension strap 94431 6 Camshaft
1 Cam setting template 94432 7 Sleeve E Vent
1 Round bar 94432a 8 Bush H Connection from hydraulic
2 Plug spanners 94432b 9 Bush unit 94942
1 Side stop 94432c 10 Guide plate M Mark
1 HP oil pump 94931 11 Pump housing P Closing piece
1 Pressure gauge 94932 12 Flange coupling V Relief valve
1 Pressure gauge 94932a 13 Damper coupling W Connection from oil pump
1 Connection piece 94934a 14 Bush 94931
2 HP hoses 94935 15 Bush For details of jacks and
1 HP hose 94935a 16 Oil trough hydraulic pumps see groups
1 Hydraulic unit 94942 17 Screw 9403–2 to 9403–4

High pressure oil pump 94931 and hydraulic unit 94942 must be filled with engine oil having a
Remark viscosity of SAE30 to SAE40 before starting them up.
In exceptional cases hydraulic unit 94942 may be filled with cylinder lubricating oil.
Attention Risk of accident! Cut out the corresponding injection pumps when working on the injection
pump drive or on the fuel cam (i. e. adjusting) with the camshaft section in situ.
Keep the control oil system under pressure and local manoeuvring lever 5.03 must be in position
RUN AHEAD or ASTERN to prevent an unexpected turning of the reversing servomotor together
with their fuel cams.
Removing the cams for the fuel pump and actuator pump (Fig. ’A’)
Working sequence:
– Place the camshaft section at an easily accessible clean location.
– Remove the guide plates 10 (Fig. ’C’) to the fuel cam.
– Push hydr. jacking tool 94424 over the shaft against the cam. (For removing the fuel cam first fit the intermediate
ring 94424a).
– Screw in and tighten connecting branch 94426 (M16 x 1.5) as shown in Fig. ’A’.
– Screw in by hand equally, but do not tighten, all screws 4 with washers 4a (6 pieces) for fastening the hydr.
jacking tool 94424 to sleeve 7 of the reversing servomotor, or to the actuator cam respectively.
– Connect the HP oil pump 94931 by high pressure hoses 94935, as well as the connection piece 94934a by HP
hoses 94935a to connection ’W’ and hydraulic unit 94942 to connections ’H’ by HP hose 94935 as shown in Fig.
’A’. The free connection must be plugged with closing piece ’P’ on the connection piece 94934a.
– Open vent screw ’E’ on hydr. jacking tool 94424, and actuate HP oil pump 94931 until the oil flows out bubble-
free. Shut vent screw.
– Draw out pistons and equally tighten all screws 4.
– Only after the oil pressure in the hydr. jacking tool (connection ’W’) has risen to about 90 bar, may oil pressure be
fed to connection ’H’.

Attention Risk of accident!! Pressure may only be raised on the connection ’H’ when hydr. jacking tool
94424 has been correctly mounted and pressurized.
The oil pressure in the hydr. jacking tool 94424 may not exceed 250 bar.
– When oil squeezes out all around the circumferences of the press seats the oil pressure in the hydr. jacking tool
94424 may slowly and carefully be reduced with the relief valve ’V’ at the HP oil pump whereupon the cam will
loosen. Dismantle the hydr. jacking tool.
– Attach suspension strap 94431 to fuel cam or actuator cam as shown in the illustration on the last page in this
group. Lift cams with the aid of a hoist from the sleeve 7 or the camshaft 6 together with the bushes 8 and 9.

Wärtsilä Switzerland Ltd 1 7.03

4203–3/A1 Maintenance RTA48T

Removing and Fitting of Hydraulic Locking Elements

A 94424a Brennstoffnocken
FUEL CAM

1 E

94426
6

4
(M16x165)
7
W

94424 3 8

5 Hubgebernocken
ACTUATOR CAM
E
4a

4
(M16x165)

3 9

W
94424 94426

94935a

H
94935
94932a

94932 94934a

94935

98.7473

94942 94931 V

3.00 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 4203–3/A1

Removing and Fitting of Hydraulic Locking Elements

Fitting the fuel cam and actuator cam

Brennstoffnocken 2 Hubgebernocken
B FUEL CAM ACTUATOR CAM
9

5 94424a 5

4a
4
7

4 9

8 3

1 95.7950

94424 3 94424 2

Concerning arrangement and use of hydraulic connections consult the paragraph ’Removing the cams for the fuel
pump and actuator pump’ (Fig. ’A’).
– Clean all setting surfaces before the fitting.
– Slide fuel cam 1 with its bush 8 onto sleeve 7 of the reversing servomotor. Make sure fuel cam and bush are
flush. Fit intermediate ring 94424a
– When fitting the actuator cam, slide bush 9 and cam 2 onto camshaft and position them (watch the recess).
– Equally tighten by hand the screws 4 (6 pieces) for fixation of hydr. jacking tool 94424. Connect HP oil pump
94931 to connection ’W’ and hydraulic unit 94942 to connection ’H’.
– Open vent screw ’E’ at the hydr. jacking tool 94424 (see Fig. ’A’) and actuate HP oil pump 94931 till oil flows out
bubble-free. Shut vent screw.
– Actuate hydraulic unit 94942, pressurizing taper through connection ’H’ till oil squeezes out on both sides of the
cam around the whole circumference.
– Slowly increase the pressure in the hydr. jacking tool whereby the cam is slowly moved axially. The pressure
continually rises to about 1100 bar for the fuel cam and about 900 bar for the actuator cam at connection ’H’.
During the whole fitting procedure oil must be squeezing out on both sides of the cam.
– The end position is reached when the cam is flush with the sleeve 7 and bush 9. Now first release oil pressure at
connection ’H’ and only about 30 seconds later the pressure at hydr. jacking tool.
– Dismantle the hydr. jacking tool and store back in its tool box.
– Fit guide plate 10 to fuel cam and lock screws 17 (Fig. ’C’).

Remark When replacing an actuator cam 2, its bush 9 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.

Wärtsilä Switzerland Ltd 3 3.00

4203–3/A1 Maintenance RTA48T

Removing and Fitting of Hydraulic Locking Elements

Adjusting the fuel cam and the actuator cam

C
I II

94432a 94432 11 1 M 94432 94432b 11 6 2 11 94432

I II
7

10
17

94427
94427

94432c M
Brennstoffnocken 16 94432c
FUEL CAM Hubgebernocken
1 ACTUATOR CAM
2
8
7 9
6

94427 94935

94427

H
94942
95.7951a

Attention Before pressurizing the fuel cam (view I) or actuator cam (view II), check carefully whether the
guide plates 10 (two pieces) are screwed to the side of the sleeve 7 or the side stop 94432c to the
actuator cam is fitted to the oil trough 16. They prevent sideways slipping of the fuel cam or the
actuator cam during the cam shifting. Their presence is therefore essential for safety reasons.
After cam shifting the side stop to the actuator cam is to be removed immediately.
For adjusting the actuator cam connecting branch 94427 screwed into the camshaft 6 is always
to be used.

3.00 4 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 4203–3/A1

Removing and Fitting of Hydraulic Locking Elements

Adjusting the fuel cam and the actuator cam (Fig. ‘C’)
If a cam has to be adjusted (turned), the corresponding roller guide above the cam must be lifted.

Adjustment of the fuel cam 1:

– As shown in Fig. ‘C’ (view I), screw the connecting branch 94427 into the fuel cam 1, and connect the hydraulic
unit 94942 to connection ‘H’, using the HP hose 94935.
– Check whether the guide plates 10 (two pieces) are laterally screwed on the sleeve 7.
– Screw the cam setting template 94432 on the corresponding inspection hole of the pump housing 11.
– Slowly increase the pressure in the hydraulic unit 94942.
The approximate pressure for turning a fuel cam is 1100 bar. By means of the round bar 94432a the fuel cam 1
can be adjusted to the desired value.
– After turning a fuel cam, check the adjustment of the corresponding injection pump timing as described in group
5512–1.

Adjustment of an actuator cam 2:

– Bring the piston of the cylinder concerned to T.D.C. (the peak of the actuator cam is orientated towards the
bottom).
– As shown in Fig. ‘C’ (view II), screw the connecting branch 94427 into the camshaft 6 to the actuator cam 2
concerned, then connect the hydraulic unit 94942 to connection ‘H’, using the HP hose 94935.
– Fit the side stop 94432c for the actuator cam to the oil trough 16.
– Screw the cam setting template 94432 on the corresponding inspection hole of the pump housing 11.
– Fit the plug spanner 94432b to the actuator cam 2.
– Using the mark on the plug spanner as a reference, the present position of the cam centre with regard to the
B.D.C. of the actuator cam can be read off the scale of the cam setting template. If the mark ‘M’ on the plug
spanner 94432b (Fig. ‘C’) is above the 0° mark (‘retard’ direction) of the cam setting template 94432, it means
that the cam centre is after B.D.C.. If, however, the mark ‘M’ on the plug spanner is below the 0° mark (‘advance’
direction), the cam centre consequently is before B.D.C..
If the plug spanner indicates precisely zero, then the actuator cam is in ‘zero position’, where both marks ‘M’ at
the actuator cam must be horizontal (= check).
– For a correct exhaust valve timing adjustment, the actuator cam must correspond to the position specified by
the engine manufacturer (see setting table). The setting table normally describes the piston position of the cyl-
inder concerned with the expression “before/after T.D.C.”, where the cam actuator is in the ‘zero position’ men-
tioned above. Accordingly, the drive gear of the engine is to be turned to the recorded position, the actuator cam
being shifted until the ‘zero position’ is reached.
– For adjusting (turning) an actuator cam 2 slowly increase the pressure in the hydraulic unit 94942.
The approximate pressure is 900 bar.

Wärtsilä Switzerland Ltd 5 3.00

4203–3/A1 Maintenance RTA48T

Removing and Fitting of Hydraulic Locking Elements

Removing the flange and damper coupling

Flanschkupplung
D FLANGE COUPLING
E 4 14
(M20x160)
5
6
94428
94424b
3 12
94424
W 94426

Anschlüsse ’W’ siehe Seite 2 94935

CONNECTIONS ’W’ SEE SHEET 2 H
94426
Dämpferkupplung
DAMPER COUPLING

E 5
4
(M20x160) 15
94942

3 13
94424
96.7618
W
– For removal of the flange coupling 12 insert centring disc 94428 on the shaft butt.
– Fasten hydr. jacking tool 94424 to flange and damper coupling with screws 4 (eight pieces) but tighten screws
only slightly by hand. Thereby the guide ring 94424b must be screwed onto the hydr. jacking tool 94424 (only for
removal of a flange coupling).
– Join hydraulic unit 94942 to connection ’H’ and HP oil pump 94931 to connection ’W’ (Fig. ’A’).
– Open the vent screw ’E’ on hydr. jacking tool 94424 and actuate HP hydraulic unit 94942 till oil flows out bubble-
free. Shut vent screw.
– Draw out pistons 5 and equally tighten all screws 4.
– Bring pressure in hydr. jacking tool 94424 (connection ’W’) to about 160 bar for the flange coupling and about
180 bar for the damper coupling. After these pressures have been applied, connection ’H’ may be pressurized.

Attention Risk of accident! At connection ’H’ pressure may only be raised when hydr. jacking tool 94424
is correctly fastened and pressurized.
The oil pressure in the hydr. jacking tool 94424 may not exceed 250 bar.
– When oil squeezes out around the whole circumferences, the oil pressure in the hydr. jacking tool may slowly
and carefully be reduced with the relief valve ’V’ at the HP oil pump 94931 (Fig. ’A’), whereupon the flange or the
damper coupling will loosen.
– Remove hydr. jacking tool, remove centring disc.

3.00 6 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 4203–3/A1

Removing and Fitting of Hydraulic Locking Elements

Fitting the flange and damper coupling

E Flanschkupplung Dämpferkupplung
FLANGE COUPLING DAMPER COUPLING

4 5 4 5

14 15

94428

6
6

12 13
3
94424

95.7955

x
3 94424 94424b

Concerning arrangement and use of hydraulic connections consult the paragraph ’Removing the flange and
damper coupling’.
– Clean all seating surfaces before the fitting.
– Position flange and damper coupling with bush onto camshaft. Pay attention to the marks on bush, coupling
and camshaft. The damper coupling at the camshaft end must be positioned from the camshaft front end in
accordance with distance ’x’ (Fig. ’E’). It amounts to 55 mm for a heavy damper and a distance of 44 mm is
provided for a light damper or balance disc.
– For fitting flange coupling 12, insert centring disc 94428 at the camshaft butt and screw guide ring 94424b onto
the hydr. jacking tool 94424.
– Fasten hydr. jacking tool 94424, by tightening all screws 4 equally by hand. Join HP oil pump 94931 to connec-
tion ’W’ and hydraulic unit 94942 to connection ’H’.
– Open the vent screw ’E’ on hydr. jacking tool 94424 and actuate HP oil pump 94931 till oil flows out bubble-free.
Shut vent screw.
– Actuate hydraulic unit 94942 pressurizing the taper through ’H’, till oil squeezes out on both sides on the whole
circumference.
– By slowly raising the oil pressure in the hydr. jacking tool at ’W’ the flange moves slowly towards the shaft end.
The pressure rises continually during this procedure till about 1900 bar for the flange coupling and about 1600
bar for the damper coupling at connection ’H’. During the whole fitting process oil must squeeze out on both
sides of the flange.
– When the end position is reached i.e. flange coupling 12 or damper coupling 13 is flush with the bush, release
first the oil pressure at connection ’H’ and only about 30 seconds later release the pressure in the hydr. jacking
tool.
– Remove the hydr. jacking tool and the centring disc 94428.

Wärtsilä Switzerland Ltd 7 1998

4203–3/A1 Maintenance RTA48T

Removing and Fitting of Hydraulic Locking Elements

Aufhängelasche für Brennstoff- und Hubgebernocken-Transport

LIFTING LUG FOR FUEL AND EXHAUST CAM TRANSPORT

94431

99.7015

1998 8 u Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 4203–4/A1

Camshaft
Removing and Fitting of SKF Shaft Coupling

Tools: Key to Illustrations:

1 HP oil pump 94931 1 Camshaft 11 Spring washer
1 SKF hand oil pump 94931a 2 Inner bush
1 Pressure gauge 94932 3 Coupling sleeve F Fit gap
1 Pressure gauge 94932a 4 Locking plate P Closing piece
1 Connection piece 94934a 5 Valve screw R Annular space
2 HP hoses 94935 6 Screw V Relief valve
1 HP hose 94935a 7 Nut HPC High Pressure
1 Hydraulic unit 94942 8 Seal ring Connection
9 Connection piece LPC Low Pressure
10 Adapter Connection

A
94935
94942

94932a 94935a 94931a

P 5
94934a

94932 10mm
94935

94931 V 105mm

10 9
Marken
MARKS

4 6 3

7 F 1 2 F 3 99.7129

11 7 8 R 2 Anschluss
G 3/4” HPC
CONNECTION

G 1/4” Anschluss LPC

CONNECTION

Wärtsilä Switzerland Ltd 1 3.00

4203–4/A1 Maintenance RTA48T

Removing and Fitting of SKF Shaft Coupling

Removing an SKF shaft coupling

Working sequence:
– Loosen screws 6 and remove locking plates 4.
– Connect the connection piece 9 together with adapter 10 which are screwed into ’LPC’ to the HP oil pump
94931 as shown in Fig. ’A’. Plug one side of the connection piece 94934a with closing piece ’P’.
– Connect the hydraulic unit 94942 to connection ’HPC’ by HP hose 94935. In the place of the hydraulic unit, the
SKF hand oil pump 94931a, which is screwed directly into the coupling sleeve 3 at connection ’HPC’, may also
be used.
– With HP oil pump 94931 raise an oil pressure of about 200 bar (20 MPa) in the annular space at connection
’LPC’ and keep this constant. The pressure in this annular space must not exceed 250 bar (25 MPa) under
any circumstances.
– Actuate hydraulic unit 94942 or SKF hand oil pump 94931a and press oil into connection ’HPC’ until it squeezes
out all around the circumference (’F’) between coupling sleeve and inner bush. This can take several minutes
on large couplings.
– Should the coupling be cold and the oil difficult to press in, then warming up the coupling will help (approx. tem-
perature 20–30C). As a rule, the HP oil pump 94931, the hydraulic unit 94942, and SKF hand oil pump 94931a
have to be filled with engine oil of a viscosity SAE 30 to SAE 40. In exceptional cases cylinder lubricating oil may
be used.
– Open the relief valve ’V’ at HP oil pump 94931 until the coupling sleeve 3 slowly slides off the inner bush 2.
Should the coupling sleeve not loosen continue pressing oil into fit gap ’F’ between the sleeve and the bush with
hydraulic unit 94942 or SKF hand oil pump 94931a. A slight tap on the inner bush can also start the loosening of
the coupling sleeve.
– Clean the shaft surfaces on either side of the coupling. Shut connection and vent bores to the annular space,
then push the coupling completely onto one camshaft end. Shutting connection and vent openings is necessary
to ensure that the pushing force is transmitted only through the oil enclosed in the annular space, thereby pre-
venting the jamming of seal ring 8.

Fitting an SKF shaft coupling

Working sequence:
– Clean coupling seats on shaft and bore of inner bush. Slightly smear coupling seats with clean low viscosity oil.
– The marks on the shaft ends must coincide (Fig. ’A’).
– When joining the two shaft pieces the axial gap between them must not be more than 1 mm. Therefore, the two
shaft ends must first exactly be lined up. Check: Roller to fuel cam aligned.
– Push shaft coupling onto the camshaft. Place inner bush 2 according to Fig. ’A’.
– Connect the HP oil pump 94931 to connection ’LPC’ (for annular space ’R’) of the coupling sleeve 3. Open vent
bore near to the connection ’LPC’ which is closed by an Allen screw.
– Connect the hydraulic unit 94942 to connection ’HPC’ by HP hose 94935. In the place of the hydraulic unit, the
SKF hand oil pump 94931a, which is screwed directly into the coupling sleeve 3 at connection ’HPC’ can also be
used.
– Press oil into the fit gap ’F’ (connection ’HPC’) until it squeezes out at the thicker end of the inner bush 2. With the
HP oil pump 94931 press now oil into the annular space ’R’ (connection ’LPC’) until it flows bubble-free from the
vent hole.
– Plug vent bore and drive the outer coupling sleeve by further pumping onto the inner bush, whereby care must
be taken that the pressure gauge 94932 never shows more that 250 bar (25 MPa). During fitting keep pumping
oil into the fit gap to maintain the oil film. Fitting is completed when the inner bush still protrudes by 10 mm (Fig.
’A’).

3.00 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 4203–4/A1

Removing and Fitting of SKF Shaft Coupling

– After ’driving on’ outer sleeve 3, release pressure on the hydraulic unit or open valve screw 5 of the SKF hand oil
pump 94931a to allow the oil flowing back from the fit gap. Only then release the pressure in the annular space
’R’.
– Remove HP hose to annular space ’R’ and the connections. Plug the connecting bore with the threaded plug
provided. The remaining oil from the annular space must not be drained any more.
– Fit locking plates 4 with screw 6.

Remark After the first fitting of the coupling the nut 7 must be retightened. Then fit locking plates 4 with
screws 6.

Wärtsilä Switzerland Ltd 3 u 3.00

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 RTA48T
Maintenance 4203–5/A1

Camshaft
Removing and Fitting the Gear Wheel on the Camshaft

Tools: Key to Illustrations:

2 Pre-tensioning jacks 94315 1 Bearing housing 16 Shims
1 Removing device 94421 2 Camshaft 17 Shims
2 Adjusting devices 94421a 3 SKF shaft coupling 18 Gear wheel
1 Pin 94421b 4 Revolution counter 19 Rotation direction
1 Rod with two locking 94421c 5 Driving shaft safeguard
features 6 Locating pins 20 Tacho generator
2 Guides 94421d 7 Bearing 21 Cover
1 HP oil pump 94931 8 Waisted stud 22 Flange
1 Pressure gauge 94932 9 Nut 23 Screw plug
1 Connection piece 94934a 10 Vent screw 24 Starting air distributor
1 HP hose 94935 11 Pin 25 Gear wheel
2 HP hoses 94935a 12 Piston
13 Setscrew M24x100 K Slot
14 Gear rim R Round bar
15 Hub V Relief valve

Removal
Should the gear wheel on the camshaft (camshaft wheel) have to be removed, proceed as follows:
– Turn crank of first cylinder to T.D.C. (first cylinder near flywheel). Remove casing over the camshaft wheel from
bearing housing 1. The marking lines on the gear rim 14 must be flush with the outer edge of the bearing hous-
ing (see group 4103–2).
– Remove 2-part closing cover of the bearing housing at the free end.
– Remove SKF shaft coupling 3 as described in group 4203–4.
– Push the loose SKF shaft coupling onto the camshaft 2 of the gear wheel to be removed. After uncoupling check
whether the two markings on the uncoupled shaft ends coincide with each other.
– For safety reasons, measures must be taken that during the work in progress the turning gear remains engaged
but cannot be put in motion.

– Dismantle the tacho generator 20 (Fig. ’A’). A

– Dismantle the rotation direction safeguard 19.
– Remove the revolution counter 4 (Fig. ’A’),
then screw off and remove the cover 21 (Fig.
’D’).
– Screw driving shaft 5 off the camshaft 2 and 24
remove it (Fig. ’D’).
4
– Remove the locking plate above the locating
pin 6 for the bearings 7 (Fig. ’D’), then disman- 20
tle the locating pin by means of a threaded rod 19
M10 and the corresponding nut.

22

23 98.7744

Wärtsilä Switzerland Ltd 1 3.00

4203–5/A1 Maintenance RTA48T

Removing and Fitting the Gear Wheel on the Camshaft

Loosening the nuts 9:

The instructions given in group 9403–4 on the application of the hydraulic pre-tensioning jacks for screwed connec-
tions are to be observed.
10 R K 8 7
– Clean threads of both waisted studs 8 as well as B
X
the area around the nuts 9.
– Place the pre-tensioning jacks 94315 on the
waisted studs which belong to the same bearing
7, and with opened vent screws 10 screw them
fully down to the bearing (Fig. ’B’ and ’C’).
– Both pre-tensioning jacks are to be loosened by
about ½ turn (gap ’S’) according to Fig. ’C’.
– Connect both pre-tensioning jacks to the HP oil
pump 94931 according to Fig. ’B’. 94935a
– Shut the relief valve and start up HP oil pump till
bubble-free oil flows out through the vent screws
10. 94934a
Shut the vent screws.
11 12 94315 9

– Pump till a pressure of 1020 bar is reached, and

10 12 94315 9 7 8
unscrew the nuts 9 by one turn with a round bar
’R’.
Attention should be paid to ensure that the pins
11 always protrude slightly with regard to the pis-
tons 12!
– Release the pump pressure and remove the
pre-tensioning jacks.

99.7133

94935a 11

94931 ’V’ 94932 94935

9 K
X
C

Vorspannpresse aufgeschraubt zum Spannen

PRE-TENSIONING JACK PLACED FOR TENSIONING

Vorspannpresse aufgeschraubt zum Lösen

PRE-TENSIONING JACK PLACED FOR LOOSENING

10 12 S

3.00 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 4203–5/A1

Removing and Fitting the Gear Wheel on the Camshaft

D Removing the gear wheel from the camshaft:

– Screw off both lateral flanges 22 (Fig. ’A’), and,
from the driving end, push pin 94421b (Fig. ’D’)
94421d a little into the resulting opening.
1
– Push the removing device 94421 under the
94421a
gear rim 14 of the camshaft wheel, then push
9 pin 94421b through the bore in the removing
8 device (Fig. ’D’).
– Screw down pin 94421b.
I – To prevent the camshaft wheel from rolling out,
fit the rod 94421c and secure it with the two
locking features (Fig. ’D’).
Moreover, fasten both guides 94421d with
screws to the top of the bearing housing (Fig.
7 ’D’).
14 – Screw off screw plug 23 (Fig. ’A’) and screw in
setscrew 13 instead, till the removing device
94421 pushes against the gear rim.
– Remove nut 9 and the rod 94421c.
– The camshaft wheel lying on the removing de-
vice 94421 can now be rolled out of the bearing
housing together with the two bearings 7 and
the SKF shaft coupling 3.
Lock the gear wheel with the engine crane!
17 94421b 13 94421c 94421
Attention Danger of accident! Before
I transporting the camshaft wheel,
either remove the SKF shaft cou-
pling 3 and the bearings 7, or se-
cure them against sliding off.

94421a
18
II
6
18

II
3 7
5
16 21
2
94421c 98.7394

94421b
13

Wärtsilä Switzerland Ltd 3 3.00

4203–5/A1 Maintenance RTA48T

Removing and Fitting the Gear Wheel on the Camshaft

Fitting
The fitting of the gear wheel with its shaft section is effected in reverse sequence to the removal, whereby the follow-
ing points must be paid attention to:
 The markings (numbering) of the individual parts must coincide.
 All parts must be clean and undamaged, they must be slightly oiled before assembling.
 Crank of cylinder number one must be at T.D.C.
 The V-ring must be positioned on the camshaft according to group 4203–1, Fig. ’A’.

Remark When fitting the gear wheel with the camshaft, take care that the marking DRIVING END on the
gear rim 14 points to the driving end. On the same side the marks are stamped in for the correct
camshaft drive wheel setting (see Fig. ’F’).
The adjusting devices 94421a (Fig. ’D’) are only to be used for aligning the gear wheel on the
camshaft together with the shims 16 for corrections. After usage, the tool 94421a is to be re-
moved immediately. Under no circumstances should the shims 16 and 17 be interchanged;
they should, therefore, be marked prior to removal.

The following is to be checked after the gear wheel

together with the mounted bearing 7 and the SKF
shaft coupling 3, or the coupling halves have been
slid into the bearing housing 1 and the nuts 9 have E 25 24
been tightened by hand:
1. That the bearings 7 lies on the shims 16, 17
without clearance and the bearing housing
respectively and that there is no clearance
between the bearing and the nuts 9 (Fig. ’D’).
2. That the location mark on the gear rim 14 (Fig.
’F’) coincides with the vertical outer edge of
Marke
the bearing housing 1 (see group 4103–2). MARK

3. That the gear wheel 18 for the starting air dis-

tributor drive is in the correct position i.e. the
mark on the gear wheel 18 coincides with the
gear wheel mark (25) on the starting air dis-
tributor (Fig. ’E’).
After the above-mentioned check, the bearings
are to be pinned and secured with locating pins 6 2
and the waisted studs 8 must be tensioned hy-
draulically.
18

98.7395

10.00 4 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 4203–5/A1

Removing and Fitting the Gear Wheel on the Camshaft

Tensioning the waisted studs 8:

– Mark position of nuts 9 on a corner and their position on the bearing 7 with a felt-tip pen (Fig. ’a’).
– Screw the pre-tensioning jacks 94315 onto the waisted studs 8 completely (Fig. ’B’). Moreover, the vent screws
10 are to be opened slightly so that the pistons 12 can slide back to their initial position, i.e. that there is no or
very little clearance at ’x’.
– Connect both pre-tensioning jacks to the HP oil pump 94931 according to Fig. ’B’.
– Shut the relief valve ’V’ and start up HP oil pump 94931 till bubble-free oil flows out through the vent screws 10.
Shut the vent screws.
– Slowly raise the pressure to 1000 bar. Attention should be paid to ensure that the pins 11 always protrude
slightly with regard to the pistons 12! Keep this pressure constant and tighten the nuts 9 with a round bar ’R’ till
firmly seated on bearing 7 (check seating with a feeler gauge through the slot ’K’). After tightening the nuts
ascertain that these have been turned by about an angle of 75 (Fig. ’b’).
– Release pressure to zero with the aid of relief valve ’V’ at the HP oil pump and then remove hydr. pre-tensioning
jacks.

Fig. ’a’ Fig. ’b’

y 98.7700

x x
Tightening angle

Couple of the camshaft:

Before pushing on the SKF shaft coupling, check whether the marks coincide at the shaft ends. For tensioning of the
SKF shaft coupling see group 4203–4. After fitting screw down both locking plates, whereby the screws must be
locked by means of spring washers.

Oil check:
Before finally fitting the hood, check with running oil pump whether the oil supply to the bearings functions.

Wärtsilä Switzerland Ltd 5 3.00

4203–5/A1 Maintenance RTA48T

Removing and Fitting the Gear Wheel on the Camshaft

Dismantling of the camshaft wheel:

Should the gear rim 14 with hub 15 have to be removed from the camshaft 2 (Fig. ’F’) for further dismantling, all parts
must be marked prior to removal.

F Remarks for the replacement of a split design

gear wheel on the camshaft
The replacement of a damaged split design gear

DRIVING END
Antriebsseite wheel on the camshaft may only be done in ex-
change for a complete gear wheel i.e. the gear rim
must be screw fastened to the gear wheel hub and
the camshaft 2. This is necessary as the final ma-
chining of the gear teeth has been carried out in this
mounted condition at the maker’s works and guaran-
tees 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 has been carried out with assembled
hub/toothed gear rim.
After the final machining of the teeth the rim must not
be separated from the hub.
Should the damage be limited to the toothing (gear
rim), then the hub may be reused, provided a new
2
rim, on which the teeth are not finish-machined, is
15 fitted to the existing hub. Then its teeth can be finish-
machined.

14
96.7310

Assembly of the camshaft wheel:

When fitting the gear wheel with the camshaft, take care that the marking DRIVING END on the gear rim 14 points to
the driving end (Fig. ’F’).
The marks made on the parts before dismantling must coincide.

3.00 6 u Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 4303–1/A1

Starting Air Distributor

Dismantling and Assembling

Tools: Key to Illustrations:

1 Grip screw M5 1 Control valve 20 Bearing housing
2 Roller pin 21 Gear wheel
3 Screws 22 Driving wheel
4 Protection pipe 23 Rod seal ring
5 Housing 24 Piston seal ring
6 Screws 25 Bearing bush
7 Guide flange 26 Bearing bush ’DU’
8 Cover 27 Screws
9, 9a Thrust washer 28 Closing cover
10 Cylinder 29 Intermediate piece
11 Piston 30 Spring dowel pin
12 Cam 31 Valve unit
13 Allen screws 32 Starting air distributor
14 Flange 33 Inspection cover
15 Spring 34 O-ring
16 Roller 35 O-ring
17 Shaft 36 O-ring
18 Taper pin 37 O-ring
19 Screws

The starting air distributor generally requires no maintenance. However, it is recommended to dismantle, clean and
inspect the starting air distributor every four years during a general overhaul.

Attention Before starting work on a starting air distributor 32 it is essential to manually close the stop valves
on the starting air receivers, and the shut-off valve for starting air (group 4325–1). The turning
gear must be engaged without fail, by which it is ensured that the starting air and control air
piping to the starting air distributor are devoid of air pressure.

Remark The control valves 1 can be removed only after removing the roller pins 2.

31
A
32

Dismantling
– Turn crank of first cylinder to T.D.C.
– Unscrew all air pipes between starting
air distributor 32 and valve unit 31.

99.7701

Wärtsilä Switzerland Ltd 1 3.00

4303–1/A1 Maintenance RTA48T

Starting Air Distributor: Dismantling and Assembling

– Unscrew protection pipe 4, and keep cylinder 10 temporarily in position by means of two screws 3.
– Remove the locking wire for the screws 6, and dismantle the screws together with cover 8 and thrust washer 9a.
– Transfer the mark engraved on the front of cam 12 to cylinder 10.
– Unscrew both screws 3 which have been temporarily screwed in before, then remove the unit consisting of
cylinder 10, guide flange 7, piston 11, and thrust washer 9 from the housing 5.
– Withdraw cam 12 from the toothing of shaft 17.
– Screw off flange 14.
– Screw the grip screw M5 in the roller pin 2, press the control valve 1 a little inwards, withdraw the roller pin, and
remove the roller 16.
– Remove the control valve together with spring 15.
I-I 37 1 14 15 5 13 36
B

28
19

21
29
20 10
24 11
35 23

25 9a
8
17
6
4

Marken
MARKS

16 9 27 7 23 26 12 3

99.7703

22 30 18 34 2

3.00 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 4303–1/A1

Starting Air Distributor: Dismantling and Assembling

Dismantling of the complete starting air distributor:

– Turn crank of first cylinder to T.D.C.
– Unscrew the inspection cover 33 (Fig. ‘C’) and check if
the mark on gear wheel 21 and that on driving wheel 22
coincide (Fig. ‘B’).
33 – Screw off all air pipes and valve unit 31 (dismantling of
the valve unit see ‘dismantling of starting air distribu-
tor’).
– Remove the taper pins 18 (Fig. ‘B’).
– Unscrew the screws 19 while holding the starting air dis-
tributor in place with a lifting tackle.
– Dismantle the starting air distributor carefully.

99.7705

Assembling

General fitting directions:

The crank of cylinder No. 1 must be in T.D.C.
Apply a non-hardening jointing agent on metal-to-metal joint faces.
Replace damaged piston rings and rod joint rings, as well as O-rings, and lubricate them at assembly.
Control valves must be greased a little with MOLYKOTE before assembly.
Do not interchange control air pipes. The corresponding cylinder numbers are stamped on the housing 5.

Assembling after dismantling the starting air distributor (Fig. ’B’):

– Fit the control valve 1 in housing 5 together with spring 15.
– Fit the roller 16 by pressing the control valve slightly inwards, until the roller pin 2 can be pushed in. Be careful
that the roller pin does not protrude with regard to the housing 5.
Check the control valve for ease of movement.
– Fit the cam 12, taking care that the engraved mark on the cam front coincides with the centre of the control
valve 1 for cylinder No. 1 (Fig. ’A’).
The cylinder number is stamped on housing 5.
– Fit piston 11 in cylinder 10, then fasten the guide flange 7 on the cylinder with screws.
– Slide the assembled cylinder 10 on the cam together with the thrust washer 9 and adjust it with regard to hous-
ing 5.
The position of the cam can now be checked again with the mark made on the cylinder beforehand.
– Fit the flange 14 together with O-ring 37, and screw it down.
– Fit the thrust washer 9 together with cover 8 and screws 6; tighten the screws and secure them.
– Fit the protection pipe 4 and tighten the screws 3.

Wärtsilä Switzerland Ltd 3 3.00

4303–1/A1 Maintenance RTA48T

Starting Air Distributor: Dismantling and Assembling

Mounting of the complete starting air distributor:

– Attach the starting air distributor to the lifting tackle and turn gear wheel 21 until its mark points downwards in
vertical direction.
– Fit the starting air distributor and fasten it with the taper pins 18 (Fig. ‘B’).
– Check if the mark on the gear wheel 21 coincides with that on driving wheel 22 (Fig. ‘B’).
– Screw in the screws 19 and tighten them.
– Fit the valve unit 31.
– Mount all air pipes.

3.00 4 u Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 4325–1/A1

Shut-off Valve for Starting Air

Cleaning and Function Check

Key to Illustration:
1 Valve seat 14 Screw plug
2 Cover 15 Spring
3 Spring 16 Screw plug
4 Valve body 17 Bush
5 Valve seat 18 O-ring
6 Valve guide 19 O-ring
7 Spring 20 O-ring
8 Valve body 21 Spindle
9 Control valve 22 Spindle guide
10 Piston seal ring 23 Handwheel
11 Equalizing bores 24 Locking lever
12 Piston 25 Stopper
13 Valve body

A* To test valve 2.06

B* From pneumatic logic unit connection E3
C* To vent valve 2.21
D* To pressure gauge panel and pressure transmitter PT 4301C
* Refer also to ’Engine Control Diagram’ in the Operating Manual group 4003–2

Attention Risk of accident! Before starting work on the shut-off valve for starting air it is essential to manu-
ally close the stop valves on the starting air receivers. The venting valve 2.21 to connection ’C’ as
well as the venting valve 2.27 must be opened for venting and draining the main starting air pip-
ing on the engine (see Operating Manual group 4003–2).
The turning gear must be engaged.

Shut-off valve for starting air

The shut-off valve must be dismantled, cleaned and inspected from time to time. If necessary the valve seats of the
non-return valve as well as of the shut-off valve must be slightly ground in. For grinding in of valve seat 1, firstly
loosen the screwing for cover 2. Subsequently the cover including spring 3 and valve body 4 with spindle 21 are to be
removed as a whole. After the spindle guide 22 has been screwed out, the valve seat can be lifted from the spindle.
If valve seat 5 of the non-return valve needs grinding-in, then the shut-off valve must be completely dismantled.
After removing valve guide 6, stopper 25 and spring 7 valve body 8 of the non-return valve can be removed.
When the above mentioned items are being checked, control valve 9 has also to be dismantled and cleaned.
Before reassembling all above items replace any corroded springs by new ones.
Damaged or much worn piston seal ring 10 has to be replaced.
Check equalizing bores 11 for free passage.
Before reassembling the spindle 21, the threads in the valve body 4 and spindle guide 22 are to be thoroughly de-
greased and then smeared with LOCTITE HV77. Insert the spindle and fully tighten the spindle guide.
For the assembly smear all the parts lightly with MOLYKOTE paste. Check to ascertain that the clearance ’S’ be-
tween piston 12 and valve body 13 of control valve 9 amounts to about 1 mm.
After completing the assembly carry out a function check, for which the following precautions have to be taken:

Initial position
 The shut-off valving of the starting air receiver must still be closed.
 Screw plug 14 of the shut-off valve has to be removed.
 Shut-off valve for starting air is in position CLOSED (closed by hand).
 Drain valve to connection ’C’ must be closed.
 The engine has to be completely assembled, ready to start and the turning gear must be in the disen-
gaged position.
 The area of flywheel, propeller shaft and propeller must be free of persons or objects.
 During the functional check the reversing lever in the control desk must remain in the position STOP and the
starting button may not be actuated under any circumstances.

Wärtsilä Switzerland Ltd 1 7.03

4325–1/A1 Maintenance RTA48T

Shut-off Valve for Starting Air: Cleaning and Function Check

Checking
a) Tightness:
Open the shut-off valve of a starting air receiver slowly to check whether the automatic shut-off valve is airtight,
i.e. verify that no air escapes from the bore of screw plug 14.
b) Manual opening:
Open the shut-off valve slowly with the help of the handwheel 23 till the locking lever 24 is in the position
OPENED (by hand). The discharging air at the bore for the screw plug 14 indicates that the valve bodies 4 and 8
of both the shut-off valve and the non-return valve are open.

Attention Great care must be taken for this operation. To prevent accidents from compressed air suddenly
escaping out of the bore for screw plug 14 a sufficient distance has to be kept.

c) Automatic closing:
Turn the handwheel 23 in the closing direction till the locking lever 24 engages in position AUTOMATIC. In this
position the shut-off valve should, through the spring resistance, be automatically closed. No more air should
come out at the bore for the screw plug 14.
In this position, the valve closes positively only if there is a clearance ’S1’ between spindle 21 and spindle guide
22 (in new condition min. 2 mm – max. 5 mm).
By turning the spindle carefully in opening direction, the contact with the spindle guide 22 can be felt. The clear-
ance ’S1’ can thus be determined externally and it shall be min. 2 mm corresponding to 1/3 turn of the spindle.
Should virtually no clearance exist after frequent reconditioning of valve seat and valve body, these parts will
have to be replaced during the next overhaul.
d) Automatic opening (locking lever 24 in position AUTOMATIC):
By opening test valve 2.06, which is fitted in piping ’A’, the same effect is obtained as when actuating control
valve 9. Upon opening test valve 2.06 the shut-off valve opens automatically. The air now escaping at the bore
for screw plug 14 indicates that the two valve bodies 4 and 8 of the shut-off valve and of the non-return valve
have opened.

Attention Great care must be taken for this operation. To prevent accidents from compressed air suddenly
escaping out of the bore for screw plug 14 a sufficient distance has to be kept away from the
shut-off valve.

– After shutting (control valve) test valve 2.06 no air must escape from the bore for screw plug 14.
– After completing these checks fit and tighten screw plug 14, and the shut-off valve is to be closed with the hand-
wheel to position CLOSED (by hand).

Remark To avoid accumulation of water in the main starting air piping open for a short time water drain
pipe on the main starting air piping after each starting operation.

7.03 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 4325–1/A1

Shut-off Valve for Starting Air

20
6
19
25
7

8
14

5
1

C
S1

11
D

10
22
4
17
3

16
18
15
9 2
13
S

12

B
21

24

23

010.958//03

Wärtsilä Switzerland Ltd 3 u 7.03

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 RTA48T
Maintenance 4506–1/A1

Rotation Direction Safeguard

Inspection and Function Check

Key to Illustration:
1 Special bolt 16 Castellated nut
2 Driving disc 17 Gasket
3 Driving wheel 18 Stop pin
4 Coupling element 19 Screw
5 Housing 20 Dowel pin
6, 6a Ball bearings 21 Key
7 Sleeve 22 Dowel pin
8 Rotary valve 23 Heavy type dowel pin
9 Screw 24 Closing cover to bearing housing
10 Spring plate (inner) 25 Gear wheel
11 Cover
12 Compression spring
13 Spring plate (outer) F Sliding faces
14 Pointer S Sealing face
15 Split pin Y Air gap

The rotation direction safeguard does not need any maintenance in service. However, we recommend that it be
dismantled during a major overhaul (every 4 years). The components should be cleaned and checked for wear, in
particular the sliding faces ’F’ (Fig. ’B’).
Roughened sliding faces can possibly be reconditioned by careful polishing.

Dismantling
– Loosen oil pipes and screws 19 and then remove the complete rotation direction safeguard.
– Remove the pointer 14 after first knocking out the heavy type dowel pin.
– Unscrew screws 9 and remove the cover 11 together with the gasket 17 (Fig. ’B’).
– Pull out the split pin 15, loosen the castellated nut 16 and remove the spring plates 10 and 13 together with the
compression spring 12 (Fig. ’B’).
– Knock out and remove the special bolt 1.
– Driving disc 2 and coupling element 4 as well as the driving wheel 3 in between can now be pushed down from
the rotary valve 8.
If the ball bearings 6 or 6a must be replaced, the rotary valve 8 can now be knocked out from the sleeve 7 towards the
side of the ball bearing 6.

A IV I-I
19
25 II
5 20 9 10 20
3
2 I
4
III III

II
22
6
1 13 14 23 14 98.7752
24
50
8 7 6a 11
IV I

Wärtsilä Switzerland Ltd 1 3.00

4506–1/A1 Maintenance RTA48T

Rotation Direction Safeguard: Inspection and Function Check

III - III IV - IV
S B
1 21 F 7 11 9 10 12 13 16 27

4
3

98.7397

x=63 mm
18 22 21
Y 2 3 4 18 8 17 15

Assembly
The assembly is carried out analogously to the dismantling procedure but in reverse sequence.
The parts prepared for reassembling should be oiled slightly, in particular the faces marked with ’F’. The sealing
surface ’S’ is to be smeared with a non-hardening sealing compound.
With sliding faces overhauled and any sharp edges removed, proceed for reassembling as for dismantling, but in
reverse order. The air gap ’Y’ must not be less that 2 mm. If it is less, the driving disc 2 and the coupling element 4
must be machined to restore the original air gap of 4 mm.
The spring plates 13 and 10 are not identical, therefore, first insert the inner spring plate 10. After fitting the compres-
sion spring 12 and the outer spring plate 13 adjust the dimension ’x’ to 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. According to Fig. ’A’ the 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 14 must coincide with the marks on the cover in ’Forward’ and ’Reverse’ during the function
check.

Function check
After refitting of the rotation direction safeguard on the engine its function should be checked as described in group
4003–1 of the Operating Manual.

3.00 2 u Wärtsilä Switzerland Ltd

 RTA48T
Betrieb Group5

Governor, Injection Pump and Actuator Pump Group 5

 WOODWARD Governor PGA 200

– Installing, Removing and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5103–1/A1

 Safety Cut-out Device

– Maintenance and Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5307–1/A1

 Fuel Injection Pump

– Adjusting and Checking the Control with Load-dependent V.I.T. (Variable Injection Timing) . 5512–1/A1
– Lapping the Sealing Faces for the Covers of the Suction, Delivery and Spill Valves . . . . . . . . 5512–2/A1
– Checking and Setting of the Relief Valve with L’ORANGE Test Stand . . . . . . . . . . . . . . . . . . . . 5512–3/A1
– Removing and Fitting of a Pump Plunger and Plunger Bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5512–4/A1

 Actuator Pump
– Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5513–1/A1

 Regulating Linkage and Roller Guide of Injection Pump

– Fitting and Removal of Eccentric Shafts and Roller Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5520–1/A1

Wärtsilä Switzerland Ltd 1 RTA48T / MM / 2.99

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 RTA48T
Maintenance 5103–1/A1

WOODWARD Governor PGA 200

Installing, Removing and Maintenance

Key to Illustrations:
1 Governor cover 10 Dip stick for checking oil level
2 Connection for pneumatic speed control 11 Governor output shaft
3 Accumulator 12 Oil filter
4 Governor drive shaft 13 Oil drain plug
5 Oil drain plug 14 Oil filling connection
6 Adjusting screw for needle valve 15 Connection ’1’/oil from starting booster
7 Connection ’2’/oil from starting booster 16 Connection/oil to starting booster
8 Knob for manual speed setting 17 Connection ’3’/oil from starting booster
9 Connection for charge air

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 do not get damaged. Furthermore, it must be possible to insert the shaft without it
jamming when fitting the governor onto the drive.
Pipes and linkages must be connected up without stressing them.
When the governor and booster are separated from each other, care has to be taken to prevent any dirt from enter-
ing 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 gover-
nor; they must absolutely correspond to the positions on the control plate on the fuel injection pump, the V.I.T. indica-
tor must then stand in position ’0’.

Maintenance
Information about maintenance work, maintenance intervals and repairs can be gained from the WOODWARD bul-
letin 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
allows 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 adjustment records which are included in the accep-
tance records of the engine, be handed to the agency as the governor will have to be re-adjusted according to these
records.

Oil change
Under favourable 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 13 with the engine
stopped. The oil in the starting booster must also be drained.
Where an oil filter is fitted (governor with charging protection), remove the screw on top of the housing 12 and with-
draw the filter element. This should be shaken 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.
Thereafter, make ready the same amount of clean flushing oil, of which approx 6 litres are poured in at oil filling
connection 14.
Now run the engine for 5–10 minutes at low speed. Since the oil can only reach the starting booster when the gover-
nor is working, the oil level will sink shortly after the engine has been started. The remaining oil must therefore be
added in stages.

Wärtsilä Switzerland Ltd 1 1998

5103–1/A1 Maintenance RTA48T

Installing, Removing and Maintenance

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
than necessary.
During the short running time, the speed of the engine is to be changed frequently so that the governor is working.
Afterwards drain off the flushing oil in the same way as the old oil from the governor and starting booster.
After flushing has been completed, fill the system with new, filtered oil (for oil specification, see WOODWARD bulle-
tin 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 unscrew the adjusting screw of needle valve 6 anti-
clockwise by a few turns. This should cause the engine to hunt and thus force the governor to work.
– Should opening the needle valve not cause the engine to hunt, this must be done by moving 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 cor-
rect 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 circumstances may the needle valve be screwed com-
pletely tight; the governor could never work satisfactorily in this condition.

Maintenance of the spare governor

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 oil to the mark on the dip stick.

1998 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 5103–1/A1

Installing, Removing and Maintenance

I
A 14

II 2 9 III
17
6
10

15

16

II III

8
9
7 12

11
5

13
95.7981
4

Wärtsilä Switzerland Ltd 3 u 1998

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 RTA48T
Maintenance 5307–1/A1

Safety Cut-out Device

Maintenance and Function Check

Key to Illustrations:
1 Side guide of cut-out stirrup 12 3/2 way solenoid valve
2 O-ring 13 Valve plate
3 Piston 14 Screws with locking plate
3a O-ring* 15 Allen screws
3b Slide ring* 16 Cover plate
3c O-ring** 17 Threaded stud
3d Slide ring** 18 O-ring
4 Compression spring 19 Cut-out yoke
5 Crown nut with split pin 20 Intermediate piece
6 Cover 21 Bush
7 Lower cylinder pipe
8 Upper cylinder pipe L Air supply space
9 O-ring St Control air pipe
10 Guide bush * To piston seal
11 Tie rod ** To rod seal

As 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 O-rings, piston or rod sealing
rings must be replaced by new ones. As opposed to the other parts of the air cylinder, the tie rod 11 can only be
removed 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 sys-
tem 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 assembly. A function check has to be carried out after assembly and after putting
the control air system under pressure. Operate the electrical emergency stop button 126HB (see also group 4003–2
of the Operating Manual). As a result, the cut-out yoke will be pulled up to the stop on the underside of the fuel pump
block.

Attention Risk of accident! Never press the emergency stop button as long as work is being done either
manually or with tools on the underside of the fuel pump block.

Wärtsilä Switzerland Ltd 1 1998

5307–1/A1 Maintenance RTA48T

Safety Cut-out Device

17 9 6 16

3a 8
3b 4
K
5
12
3 18
13
2
21 15

2
3d
3c 7
L
18 St
20
2

11

10

14

19

95.7979

1998 2 u Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 5512–1/A1

Fuel Injection Pump

Adjusting and Checking of the Control with Load-dependent V.I.T. (Variable Injection Timing)

Tools: Key to Illustrations:

1 Device for measuring 94552 1 Spill valve 39 Spacer
2 Devices for measuring 94554 2 Delivery valve 40 Spacer
2 Fork spanners 94555 3 Suction valve 41 Nut
2 Special spanners 94555a 4 Relief valve 42 Withdrawing rod
2 Fork spanners 94557 5 Safety cut-out device 43 Disc
1 Withdrawing device 94561 6 Pressure bush 44 Locking pin
1 Socket insert wrench 94571 7 Pressure bush 45 Setting screw
1 Torque wrench 8 Push rod 46 Positioning unit
1 Grease gun 9 Cover 47 Distance sleeve
10 Pin (short) 48 Lever
11 Pin (long) 49 Support
12 Compression spring 50 Setting screw
13 Compression spring 51 Setting screw
14 Plunger 52 Eccentric pin
14a Plunger bush 53 Roller guide
15 Cap screws 54 Lever to regulating
16 Casing linkage
17 Orifice 55 Shut-off valve (suction pipe)
18 Screw plug 55a Shut-off valve (spill pipe)
18a Drain screw 56 Fuel channel
19 Fuel injection pump block 57 Shut-off valve housing
20 Screw plug 58 Vent screw
21 Screw plug 59 Spindle guide
22 Regulating tappet 60 Valve spindle
23 Shut-off valve 61 O-ring
24 Vent valve 62 O-ring
25 Air cylinder 63 O-ring
26 V.I.T. indicator 64 O-ring
27 Pointer to setting shield 65 O-ring
28 Setting shield
29 Load indicator 3.12 Fuel lever
30 Speed governor E Fuel inlet
31 Eccentric shaft to D to the injection valves
suction valve K Check bore
32 Eccentric shaft to R Fuel return
spill valve U1 Spill valve to pump 1
33 Valve housing U2 Spill valve to pump 2
34 Valve body D1 Delivery valve to pump 1
35 Pressure spring D2 Delivery valve to pump 2
36 Stop sleeve S1 Suction valve to pump 1
37 Disc S2 Suction valve to pump 2
38 Screw plug

Remark The fuel pump control can only be correctly adjusted, provided the regulating linkage bores are
not worn!
Before starting preliminary measures to carry out checking and adjusting work on the fuel injec-
tion pumps, the engine must be changed over to diesel oil before shutting it down!
A) Directions and permissible deviations
The correct adjustment of the fuel injection pump control is extremely important. Changes to the effective plunger
(delivery) strokes may only be attempted when, on the occasion of checks, inadmissible deviations from the re-
corded data of the setting table are established.
The setting table which will be often mentioned in this description is handed over to the customer together with the
shop trial documents.

Wärtsilä Switzerland Ltd 1 3.00

5512–1/A1 Maintenance RTA48T

Adjusting and Checking of the Control with Load-dependent V.I.T. (Variable Injection Timing)

a) Replacement of parts:
When parts of the fuel injection pumps (f.i. pumps for short) are replaced which influence the fuel injection control in
any way then the f.i. pump controls must be checked and if necessary re-adjusted in compliance with the values of
the setting table.
b) Cut-out checks:
In order to ensure that the engine can be shut-down at any time and can never overspeed, the various cut-out
checks must be carried out after the fuel injection pumps have been newly adjusted (see section F).
c) Adjusting data in the setting table:
The decisive adjusting data of the fuel injection pumps and fuel cams is established for a specified load indicator
position and entered in the fuel pump setting table.
These are:  Idle stroke, begin of injection, total stroke, end of injection.
 The effective plunger stroke is arrived at by subtraction of idle stroke from total stroke.
d) Effective plunger (delivery) stroke in mm:
The effective plunger stroke is adjusted by modifying the length of the regulating tappet for the suction and spill
valves.
In this manner shortening the regulating tappet produces an increase in the effective plunger stroke, and lengthen-
ing the regulating tappet produces a reduction in the effective plunger stroke.

Attention Adjusting the regulating tappet during operation is forbidden!

Equal effective plunger strokes on all f.i. pumps are necessary to obtain balanced power outputs on all the cylinders.
For this reason the measured values of the individual f.i. pumps have to be compared with each other.
The maximum admissible deviation between the biggest and the smallest effective plunger stroke on individ-
ual cylinders is 0.20 mm, and the deviation of the effective plunger stroke from the values in the setting table should
not exceed ± 0.10 mm.
e) Begin of injection:
The begin of injection (° T.D.C.) of a fuel injection pump may only be altered by turning the fuel cams and not by
re-adjusting the regulating tappet of the suction valve.
The deviation from the setting table shall not exceed ± 0.3.
f) Equalizing the maximum cylinder (firing) pressures:
The equalizing of the maximum cylinder pressures may only be brought about by turning the fuel cam and not by
changing the lengths of the regulating tappets of suction and spill valves (on condition that the compression pres-
sures are equal). Directions for the turning of fuel cams are given in group 4203–3.
g) Spacers for fuel delivery reduction:
While adjusting and checking the f.i. pumps no spacers may be inserted for delivery reduction. Directions to this
effect are given under group 5512–1 in the Operating Manual.

B) Preparations (see also group 4003–2 of the Operating Manual)

1. Close shut-off valve for starting air with the handwheel to position CLOSED (closed by hand).
2. Start lubricating oil pumps for bearings and crossheads and set pressures for normal operation.
3. Disengage the turning gear, bring reversing lever on the local manoeuvring stand to AHEAD (RUN AHEAD),
and stop lever 5.07 to RUN.
4. All pressure indicators (end position indication) of the valve groups D , located under the housings for the fuel
injection pumps and actuator pumps, must be actuated. Check whether the reversing valve 5.02 is also in posi-
tion AHEAD (see Engine Control Diagram sheet 4003–2 in the Operating Manual) and that its position indicator
is not protruding.
5. Engage turning gear.

2.99 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 5512–1/A1

Adjusting and Checking of the Control with Load-dependent V.I.T. (Variable Injection Timing)

6. Drain the fuel injection pump block 19. Thereby proceed as follows:
– Shut off the fuel feed pumps.
– Close the corresponding shut-off valves 55(a) in the fuel channel 56, and loosen their vent screws 58 by
several turns.
– Loosen carefully the drain screw 18a marked with red colour (Fig. ’A’ and ’H’) by several turns in the fuel
injection pump block 19 on the corresponding spill valve side which points away from the engine (possibil-
ity of hot fuel!).

Remark The screw plugs 18 and 21 (Fig. ’A’ and ’H’) are secured with LOCTITE No. 243 and should not be
loosened for draining the fuel injection pump block.

Attention Danger of accident! Always loosen first the vent screws 58, prior to loosening the correspond-
ing drain screw 18a.

A
55 I 55a I

56 56

19 19
21 21
18a 21 18a
18

18 21
I

59 62 61 57 58 64

60
65
99.7718

Wärtsilä Switzerland Ltd 3 3.00

5512–1/A1 Maintenance RTA48T

Adjusting and Checking of the Control with Load-dependent V.I.T. (Variable Injection Timing)

7. Remove all covers 9, valve housings 33 and the corresponding internal parts (Fig. ’G’ and ’H’).
8. Wash suction and spill valves as well as their valve seats with clean diesel oil. Check that the valves slide easily
in their bodys and that the valve seats are undamaged. If necessary recondition the seat faces by careful grind-
ing-in or replace the valves. Refit suction and spill valves (without their springs), apply MOLYKOTE G to the
pressure bushs 6, and tighten these to a tightening angle of 30° by means of the socket wrench insert 94571.
9. Check whether the spacers 39 and 40 of the dial gauge holders slide well and the dial gauge functions properly.
If so, mount the dial gauge holders and screw them tight (see Fig. ’F1’ and ’F2’).
10. Draw fuel lever 3.12 out of position REMOTE CONTROL and engage it with the lever to the regulating linkage
54 (Fig. ’R’). This move vents the air cylinder 25 (see also group 4003–2 of the Operating Manual). Set fuel lever
together with lever 54 to position ’8’.
11. Close shut-off valves 23 in the console to the control air supply. Open and actuate both vents 24 to drain the air
bottles till they are without any air pressure (see Fig. ’B’).
12. Distance sleeve 47 must be fitted between the lever 48 and strap of support 49 as shown in Fig. ’C1’. By this, the
eccentric shafts 31 for the suction valves are locked i.e. the V.I.T. indicator 26 is forced to be in position ’0’. If
necessary move the lever 48 correspondingly by means of the setting screws 50 and 51 in order to facilitate the
fitting of the distance sleeve 47. Their positions should be marked beforehand!
13. The V.I.T. indicator 26 must point to zero (Fig. ’C’).

Remark  After completing the checking, the spacer sleeve 47 must again be disconnected, and for
storing be mounted as shown in Fig. ’C’. Turn back to the original position and lock the set-
ting screws 50 and 51 if they have been adjusted.
 The linkage joints of the regulating linkage between the governor and the f.i. pumps are
equipped with grease nipples. They must be lubricated weekly with MOLYKOTE paste G by
a grease gun which is supplied with the tools.
 Tighten the drain screws 18a. Tighten the vent screws 58 and open the shut-off valves 55(a)
in the fuel channel.

23

Steuerluftversorgung
CONTROL AIR SUPPLY

24
99.7029

10.08 4 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 5512–1/A1

Adjusting and Checking of the Control with Load-dependent V.I.T. (Variable Injection Timing)

C
31 26 32 27 28

47
50

Gezeichnet für RTA58T

I I DRAWN FOR RTA58T

48 49 46

C1
I-I

48 47 49 48 25 49 51 50 29

D
3.12

30

31 54
26
96.7009

32 27 28
48 46

Wärtsilä Switzerland Ltd 5 2.99

5512–1/A1 Maintenance RTA48T

Adjusting and Checking of the Control with Load-dependent V.I.T. (Variable Injection Timing)

E
44
94561 44
94561 41
41
43
43

42
42

19 2
19

3 1

F1
F2

For removal of the valve seats use

the withdrawing device 94561
(see Fig. ’E’).
It is used as follows:
Push the withdrawing rod 42 with-
15 94552 94554 15
out any accessories right down
through the valve body and pull it
back until the spread forward end
comes against the front end of the
valve body.
Mount disc 43 and screw on nut 41
but not right down yet.
19 Lead the locking pin 44 through
the withdrawing rod until its ring
6 enters the slot at the upper end.

40 By tightening the nut 41 the valve

body can now be pulled out of the
pump block.
F1 = Arrangement of the dial
gauge above the plunger
(delivery valve)
39
F2 = Arrangement of the dial
gauge above the suction
3 (1) and spill valves.
14a

14

96.7317

3.00 6 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 5512–1/A1

Adjusting and Checking of the Control with Load-dependent V.I.T. (Variable Injection Timing)

G I

D U1

S1 D1

V R

V
II D2
S2
D

II
III III
E U2
III - III
38
18 20
15 V-V
33
34 16
17
35 63

36 19
37

99.7716

Wärtsilä Switzerland Ltd 7 3.00

5512–1/A1 Maintenance RTA48T

Adjusting and Checking of the Control with Load-dependent V.I.T. (Variable Injection Timing)

H
II - II

5
15 9 15 9

6
6 11
7
11 10
13
12
12
2
1
3
IV IV

4 19
21

8 8

14a 14

IV - IV 18a
18 K 18a

21

19
21

99.7717

3.00 8 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 5512–1/A1

Adjusting and Checking of the Control with Load-dependent V.I.T. (Variable Injection Timing)

C) Mounting the dial gauge for adjustment and

checking of fuel injection pump timing

J
Suction valve
(S) closed
Dial gauge set to ’0’
Adjusting the dial gauge above the suc- Spill valve
tion valve: (U)
 Turn the engine till the roller reaches the
highest position (cam peak).

Clearance
 Install the dial gauge above the suction
valve (S), now closed, providing an initial
tension and set to zero.

Roller on
cam peak

K Dial gauges set to ’0’

Adjusting the dial gauges above the spill Suction valve Spill valve
valve and plunger: (S) (U)

 Turn the engine ASTERN till the roller lies

on the base circle of the cam.
Clearance

 Install a dial gauge above the spill valve (U)

which is now closed, and above the
plunger providing an initial tension and set Plunger
to zero.

Roller on cam
base circle

96.7322

Wärtsilä Switzerland Ltd 9 2.99

5512–1/A1 Maintenance RTA48T

Adjusting and Checking of the Control with Load-dependent V.I.T. (Variable Injection Timing)

D) Adjustment of fuel injection pump timing

– Carry out the preparations according to the sections A) and B).
– All checking data may neither exceed nor fall bellow the deviations mentioned in section A).
– The required data below is to be taken from the fuel pump setting table.

1. Adjusting positions . . . . . . . . . . . . . . . . . . ⇒ Setting shield, normal position 8 (F.Q.S. + V.I.T. position ’0’)
2. Idle stroke ’a’ in mm . . . . . . . . . . . . . . . . . ⇒ Suction valve closes at a plunger stroke of ’a’
3. Begin of injection before T.D.C. in ° . . . ⇒ Suction valve closes before T.D.C. in °
4. Total stroke ’b’ in mm . . . . . . . . . . . . . . . . ⇒ Spill valve opens at a plunger stroke of ’b’
5. End of injection after T.D.C. in ° . . . . . . ⇒ Spill valve opens after T.D.C. in °
6. Effective plunger (delivery) stroke . . . . . ⇒ Total stroke – idle stroke (’b’–’a’ in mm)

Plunger stroke ’a’

Adjusting the begin of injection:
L (idle stroke)
0.02 mm 0.00 mm
 Turn the engine AHEAD till the dial gauge
Suction valve
above the plunger shows the value of the
(S)
idle stroke ’a’.
Spill valve
 Adjust the regulating tappet 22 with the (U)
special spanners (Fig. ’M’) so that the dial

Clearance
0.02 mm

gauge above the suction valve (S) shows

0.02 mm (Fig. ’L’).
(When taking the reading the locking nut of
the push rod in question must already have
been tightened).
This position signifies:
Suction valve closes = Begin of injection
 On the flywheel graduation check the crank
angle before T.D.C. in ° and record it.
 If necessary the fuel cam must be turned
appropriately (see group 4203–3).
’a’

S 94557 S
M 98.7132

8
45
94557

94555

94555a

22
96.7407

U 94555 U
94555a

3.00 10 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 5512–1/A1

Adjusting and Checking of the Control with Load-dependent V.I.T. (Variable Injection Timing)

N Plunger stroke ’b’

(total stroke)
0.00 mm 0.02 mm

Suction valve Spill valve

Adjusting the end of injection: (S) (U)
 Turn the engine AHEAD till the dial gauge
above the plunger shows the value of the

Clearance
total stroke ’b’.
 Adjust the regulating tappet 22 with the
special spanners (Fig. ’O’) so that the dial

0.02 mm
gauge above the spill valve (U) shows 0.02
mm (Fig. ’N’).
(When taking the reading the locking nut of
the push rod in question must already have
been tightened).
This position signifies:
Spill valve opens = End of injection
 On the flywheel graduation check the
’b’

crank angle after T.D.C. in ° and record it.

96.7322

O
S S

8
45
94557

94555

94555a

96.7134 22

U 94557 U

94555
94555a

Wärtsilä Switzerland Ltd 11 2.99

5512–1/A1 Maintenance RTA48T

Adjusting and Checking of the Control with Load-dependent V.I.T. (Variable Injection Timing)

E) Checking of fuel injection pump timing

– All checking data must be compared with the fuel pump setting table, and may neither exceed nor fall bellow the
deviations mentioned in section A).

P Plunger stroke
(idle stroke)
Checking the begin of injection: 0.02 mm 0.00 mm
 Turn the engine AHEAD till the dial gauge
above the suction valve (S) shows 0.02 Suction valve Spill valve
mm. (S) (U)
This position signifies:
Suction valve closes = Begin of injection

Clearance
 On the dial gauge above the plunger check
the idle stroke ’a’ and record it.

0.02 mm
 On the flywheel graduation check the crank
angle before T.D.C. in ° and record it.

’a’

Plunger stroke ’b’

Q (total stroke)
Checking the end of injection:
0.00 mm 0.02 mm
 Turn the engine AHEAD till the dial gauge
above the spill valve (U) shows 0.02 mm.
Suction valve Spill valve
This position signifies: (S) (U)
Spill valve opens = End of injection
 On the dial gauge above the plunger check
Clearance

the total stroke ’b’ and record it.

The effective plunger stroke is arrived at by
subtraction of ’b’–’a’.
0.02 mm

 On the flywheel graduation check the

crank angle after T.D.C. in ° and record it.
’b’

96.7322

2.99 12 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 5512–1/A1

Adjusting and Checking of the Control with Load-dependent V.I.T. (Variable Injection Timing)

F) Cut-out checks
The cut-out checks of the f.i. pumps are of major importance and must therefore be carried out after every re-adjust-
ing of the f.i. pumps. We further recommend that these checks also be made after every major overhaul of the f.i.
pumps. Thereby the following checks must be carried out:
1. Checking the fuel cut-out with the fuel lever 3.12:
This check has to be performed best subsequently to the adjustment and checking of the fuel injection pump
timing, whereby proceeding as follows:
 Turn the engine AHEAD till the dial gauge above the suction valve shows 0.02 mm, i.e. begin of injection (Fig.
’L’).
 Set the fuel lever 3.12 together with the lever to the regulating linkage 54 to position zero (Fig. ’R’).
 Check the stroke on the dial gauge above the spill valve.
(This amount must be compared with the value quoted in the fuel pump setting table; only a little discrepancy is
allowed and it should be never less than 0.8 mm.)
 Check whether the zero positions on the load indicator 29 and the setting shield 28 of the f.i. pumps coincide
(Fig. ’R’).

R 29

30 3.12

54
31 26

32 27 28
48
98.7136

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5512–1/A1 Maintenance RTA48T

Adjusting and Checking of the Control with Load-dependent V.I.T. (Variable Injection Timing)

S 53 52

2. Checking the manual cut-out on the f.i.

pump:
 Cut out the drive of the fuel injection pump
(see Operating Manual group 5512–2).
 There must be a visible clearance of about
2 mm between the roller and the fuel cam
peak after cutting off.

~2 mm

98.7137

3. Checking the safety cut-out device:

The instructions in the Operating Manual group 4003–1 must be strictly followed.
As the suction valve tappets are suddenly lifted with a jerk during this test, the suction valve units should be com-
pletely installed or at least secured by means of a cover.

G) Installing the valves after a check

The following points must be observed when fitting the valves:
 All the valves and springs must be dipped in clean diesel oil before fitting them.
 If the pressure bushes 6 and 7 were once more removed after the resetting, their threads and seating surfaces
must also be coated with MOLYKOTE paste G; then tighten the pressure bushes to an angle of 30° by means of
the socket wrench insert 94571 (see Fig. ’H’).
 During the assembly, tighten the screws 15 carefully crosswise and in small steps with 60 Nm. Use MOLYKOTE
paste G as lubricant (see Fig. ’H’).

10.08 14 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 5512–1/A1

Adjusting and Checking of the Control with Load-dependent V.I.T. (Variable Injection Timing)

H) Checking of stagnation pressure control valve

During a check-up on the fuel injection pumps, at the same time also the stagnation pressure control valves (Fig. ’T’)
are to be removed, cleaned and examined. Slight damage to the seating surface of the valve body 34 and of the
valve housing 33 can be remedied by lapping-in with fine lapping paste.
The parts of the stagnation pressure control valves may not be interchanged.
The valve stroke ’X1’ must be checked and if necessary readjusted, if the valve body 34, the seating surface ’A’ (Fig.
’T’) on the fuel injection pump block 19 or on the valve housing 33 have been remachined or lapped in.

34
33

X1
36
19

Checking and adjusting the valve stroke: ’A’ 35 37

U – Insert valve body 34 into the valve housing 33.

33
Measure and record the distance ’X’ using a
depth gauge (Fig. ’U’).
34
V
X

36
Y

37

19
– Fit the disc 37 and the stop sleeve 36 in the
corresponding bore of the fuel injection pump
block 19 (Fig. ’V’).
98.7220
– Measure and record the distance ’Y’.
The difference X–Y results in the measured valve stroke.
The calculated valve stroke is 1.40 ± 0.15 mm.
 If the valve stroke is below 1.25 mm it can be adjusted by remachining the small landing surface (touching disc
37) of the stop sleeve 36.
 If the valve stroke is more than 1.65 mm the valve body 34 and the valve housing must be checked and if neces-
sary replaced.

Attention The engine must under no circumstances be operated with the valve body 34 or the pressure
spring 35 removed.

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 RTA48T
Maintenance 5512–2/A1

Fuel Injection Pump

Lapping the Sealing Faces for the Covers of the Suction, Delivery and Spill Valves

Tools: Key to Illustrations:

1 Lapping mandrel 94566 1 Pressure bush A Fitted cover
1 Lapping mandrel 94567 2 Covers for the valves B Lapping the sealing face
1 Torque wrench with 3 Fuel injection pump on the pump block
socket spanner block C Lapping the sealing face
4 Cap screws on the cover
SF Flat sealing face
SF1 Sealing face with
a slope of 0 15’

In case of leakage between cover 2 and pump block 3, although the cap screws 4 have been tightened to the pre-
scribed torque of 60 Nm, it may be that the sealing faces are no longer in perfect condition.
Additional tightening of the screws will not solve the problem; the sealing faces will have to be dressed.
Slight damage can be rectified with the lapping mandrels 94566 and 94567.
For lapping the flat sealing faces on the pump block, the lapping mandrel 94566 is to be used as shown in Fig. ’B’.
The cover sealing face and the corresponding lapping mandrel 94567 are tapered by 015’ (see Fig. ’C’).
The lapping mandrel 94567 for lapping of the cover sealing face (Fig. ’C’) as well as the lapping mandrel 94566 for
lapping of the flat sealing face on the pump block are to be rotated around their axis.
In case of a rectification of the lapping faces of the lapping mandrels, these are to be machined accordingly.
Very fine lapping paste must be used for lapping.

Attention Under all circumstances, prevent lapping paste from getting into the pump block!

The threads of the cap screws must be coated with MOLYKOTE paste G before being screwed in. The screws must
be tightened crosswise and in even stages to 60 Nm.

A B C

4 2 60 Nm 94566 94567

LAPPING TOOL
LAPPING TOOL SF FOR VALVE
FOR INJECTION
COVER SF1 94567
PUMP BLOCK
15’

96.7264

1 3 3 2 2

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 RTA48T
Maintenance 5512–3/A1

Fuel Injection Pump

Checking and Setting of the Relief Valve with L’ORANGE Test Stand

Tools: Key to Illustrations:

1 L’ORANGE valve 94272 1 Valve housing 11 Ball Ø 12 mm
test stand 2 Valve needle 12 Flushing valve
1 Holding angle 94273 3 Stop ring 12a Spindle for item 12
1 HP hose line 94275 4 Distance ring
1 Testing device 94277 5 O-ring A Delivery pipe connection
1 Special spanner 94556 6 Disc spring (11 pieces) D Drain bore
1 Slide gauge 7 Thrust washer DA Diesel oil outlet
8 Circlip H Pump lever
9 Spring plate MA Pressure gauge
10 Closing plug (0–1600 bar)

Y X
A

10

11

94.7240

1 2 D

3 4 5 6 7 8 9

Remark Before dismantling a relief valve for overhaul (grinding in of the valve needle), the distance ’X’
must be accurately measured and the figure recorded as ’X’. For this purpose, the distance ring 4
must be pressed against the stop ring 3 by the closing plug 10.
After grinding the valve needle 2 into the seat of the valve housing 1, all the parts must be thoroughly cleaned, the
valve needle 2 lightly oiled and parts 6, 7, 9 and 11 sprayed with MOLYBDENUM DISULPHIDE.
During assembly, care must be taken that the disc springs 6 are correctly positioned (see Fig. ’A’). The distance ring
4 should not yet be fitted. Tighten the closing plug 10 until the distance ’X’ is about the same as before dismantling.

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5512–3/A1 Maintenance RTA48T

Checking and Setting of the Relief Valve with L’ORANGE Test Stand

For testing and setting a relief valve for the fuel injection pump, use the L’ORANGE valve test stand tool 94272 which
belongs to the standard tools.
Use connection ’A’ (see Fig. ’B’) for this together with the right hand pump lever ’H’ and pressure gauge ’MA’ (0–1600
bar).

Adjusting the opening pressure B

– Bolt down the testing device 94277 on the
holding angle 94273 (Fig. ’B’).
A
– Place the relief valve into the testing device
(without joint) and tighten it with special span- 94273 94275
ner 94556 as shown in Fig. ’C’.
– Connect high pressure hose 94275 to con- 94277 H
nection ’A’ and lead it to the testing device
94272
(Fig. ’B’).

MA

98.7759

12a
– Open the flushing valve 12 a little by spindle
12a (Fig. ’C’).
12
– Operate pump lever ’H’ until diesel oil es-
94277 capes bubble-free.
Close spindle 12a.
94273
– Operate the pump lever and at the same time
observe the pressure gauge ’MA’ to see at
what pressure the relief valve opens. Correct
opening pressure = 1150 bar.
94275 – The prescribed pressure can be set by mov-
DA ing the closing plug 10. Measure the distance
1 ’X’ and note it as ’X1’ (Fig. ’A’).
10 – Now reduce the height ’Y’ of the distance ring
4 by the difference between the distances ’X1’
94556
and ’X’.
– Reassemble the relief valve (this time with
distance ring 4), tighten the closing plug 10
and finally carry out another check of the
98.7759 opening pressure.

Remark Before screwing the relief valve into the fuel injection pump block, check that the sealing faces of
the relief valve and the fuel injection pump block are clean since the sealing of these faces is
metallic i.e. without sealing ring! Use the special spanner 94556 to tighten the relief valve (see
Fig. ’B’). Furthermore check the respective drain bore ’D’ for free passage in the valve housing 1
as well as in the fuel injection pump block.

3.00 2 u Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 5512–4/A1

Fuel Injection Pump

Removing and Fitting of a Pump Plunger and Pump Bush

Tools: Key to Illustrations:

1 Torque wrench 1 Fuel injection pump block 7 Compression spring
with extension 2 Intermediate piece 8 Drain screw
1 Socket spanner 3 Pump plunger 9 Safety cut-out device
2 Grip screws M8 4 Pump bush
5 Pressure ring S Sealing face
6 Allen screw H Lifting tackle

Remark Take care of scrupulous cleanliness when working on the fuel injection pump!

If pump plunger 3 and pump bush 4, or the compression spring 7 are to be removed, first separate the fuel injection
pump block 1 from the intermediate piece 2, proceeding as follows:
– Close the fuel supply and return pipes for the fuel injection pump concerned, and drain off the fuel injection
pump block by unscrewing drain screws 8 (painted with red colour).

Attention Risk of accident! The instructions given in group 5512–1 must be followed for draining the fuel
injection pump blocks.

– Loosen the control air pipe and the electric cables for the safety cut-out device 9.
– Remove the supply and return pipes and loosen the fuel pressure pipes for the fuel injection pump concerned.

’H’
A

Dismantling of the fuel injection pump block:

– Separate the fuel injection pump block 1 from
1 the intermediate piece 2, and lift it a bit by
means of the lifting tackle.
Draht – Fasten the pump plunger 3 in the pump bush
WIRE 4 using a strong wire (Fig. ‘A’).
8 – Remove the fuel injection pump block by
4 means of the lifting tackle ‘H’.

7 Attention Be careful when putting down

3 or turning the fuel injection
pump block, to prevent the tap-
pets and the safety cut-out de-
vice from being damaged!

99.7715

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5512–4/A1 Maintenance RTA48T

Removing and Fitting of a Pump Plunger and Pump Bush

B
’S’
Removing of the pump bush:
1
– Remove the wire (Fig. ‘A’), taking care that the
3 pump plunger 3 does not fall out.

4 – Dismantle the pump plunger and the com-

pression spring 7.

5 – Unscrew the Allen screw 6 and screw two grip

screws M8 in the pressure ring 5.

6 – Remove the pressure ring.

– Dismantle the pump bush.
7

98.7182

Checking and repairing of the sealing face:

First check the sealing faces of the pump bush and the fuel injection pump block before fitting an old or a new pump
bush. Proceed as follows:
Apply a thin layer of blue ink to the sealing face ’S’ of the pump bush. The pressure ring 5 must be placed upon so that
the pump bush is guided during the checking.
A good sealing face of the pump bush is characterized by only a narrow ring area – but not the whole width of the
sealing face – being formed, starting from the inner diameter. Furthermore, the ring area must not be interrupted in
the cross direction.
If the sealing face of the pump bush does not meet these requirements, it may be that it is leaky and that fuel is
coming out of the check bore during operation (see Operating Manual, group 5512–1).
Since the sealing face of the pump bush is hardened and showing a slight slope, it cannot be ground with the usual
tools. Therefore, it must be replaced together with the corresponding pump plunger.
The sealing face in the fuel injection pump block, however, is plan, allowing to be ground in with a self-made cylinder
of grey cast iron.
If only a minor improvement of the sealing faces ‘S’ is necessary, they can be lapped a bit using a very fine grinding
compound and centering them with the pump bush and the pressure ring.

The designations for pump bush and pump

plunger are stamped in pairs, i.e. the parts belong-
Kennzeichen ing together must have the same stampings.
STAMPING
Never interchange pump bush and pump
plunger!

98.7240

2.99 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 5512–4/A1

Removing and Fitting of a Pump Plunger and Pump Bush

Fitting of pump bush and pump plunger:

– Clean all parts and wipe the sealing faces ‘S’ with a dry cloth.
– Fit the pump plunger together with the pressure ring.
– Grease the threads and the seating surfaces of the Allen screws 6 with MOLYKOTE paste G, then tighten them
evenly and crosswise in several steps with the torque wrench, until a torque of 40 Nm has been reached.
– Secure the pump plunger with a wire.

Final assembly of the fuel injection pump block:

– Lower the fuel injection pump block above the intermediate piece as far as the locking wire can be removed
without the pump plunger falling out of the pump bush.
– Place the fuel injection pump block on the intermediate piece and tighten it.
– Connect the electric cables, the control air pipe, and the fuel pipes. For fitting of the fuel pressure piping see also
group 8733–1.
– Screw in the drain screws and tighten them.
– Open the fuel supply and return pipes.
– Set the fuel booster pump working and check if there are no leakages.

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 RTA48T
Maintenance 5513–1/A1

Actuator Pump
Dismantling and Assembling

Key to Illustrations:
1 Screw plug 18 Bush
2 Hydraulic piping 19 Shim (distance ring)
3 Oil inlet pipe 20 Pressure limiting valve
4 Nut with thread protection 21 Two-way valve
5 Nut 22 Support ring
6 Actuator housing 23 Spring guide
7 Spring 24 Actuator cam
8 Pump housing 25 Piston ring
9 Piston 26 Screw plug
10 Locking ring 27 Pin
11 Roller guide 28 O-ring
12 Twist stop 29 O-ring
13 Cover 30 O-ring
14 Screw
15 Head screw
16 Plate L Leak-oil bore
17 Allen screws G Thread hole
The actuator pumps generally need no maintenance. However, it is recommended to inspect at random two actua-
tor pumps in the course of a general overhaul or every four years. Depending on the condition as found, the overhaul
interval of the remaining actuator pumps has to be decided.
Should, however, troubles be experienced on an actuator pump, it must be checked and dismantled at the earliest
opportunity.
I I-I
A 2

3
6
4
9
5
6

8
I

13 Dismantling

Removing the actuator housing:

– Remove hydraulic piping 2 (see group 8460–1) and oil
inlet pipe 3.
– Rotate camshaft till the apex of the respective actuator
cam 24 points vertically downwards.
– Remove the nuts with thread protection 4.
24
– Gradually loosen the nuts 5 of the corresponding actua-
tor housing 6. The actuator housing is thereby pressed
out of pump housing 8 by spring 7. Remove the nuts.
– Fit two eye bolts into the actuator housing and pull it off
by means of a lifting tackle. Piston 9 remains in the ac-
98.7474 tuator housing, retained by locking ring 10 (Fig. ’C’).

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5513–1/A1 Maintenance RTA48T

Actuator Pump: Dismantling and Assembling

B
Removing the roller guide:
11
– Loosen screws 14 and remove them together with
7 the cover 13.
8 – Loosen head screws 15 and remove them together
witht the plate 16.
14
– Withdraw the twist stop 12.
II – Dismantle spring 7 and remove roller guide 11 by
means of a lifting tackle.
III II

13 III

15 16 14 12 30
When inspecting the actuator pump it is recommended to remove the pressure limiting valve 20 and the two-way
valve 21 for cleaning.
C
22
Removing the two-way valve:
– Remove the screw plug 26. 21 23
– Withdraw pin 27 using a screw M4.
– Withdraw support ring 22 using a screw M16.
26

27
20

Removing the piston and the bush: 22

– Take off locking ring 10 and remove the piston 1
9. ’L’
– Loosen and remove the Allen screws 17.
– Screw two Allen screws 17 into the thread 6
holes ’G’ of the bush 18 till the latter can be re- 18
moved from the actuator housing 6.
25

Attention The shim 19 must never be inter-

9
changed with one of another ac-
tuator pump, as each one has
been exactly machined individu-
ally to suit the respective cylin-
’S’

der. The thickness ’S’ of the shim

is recorded in the setting table.
98.7475

17 10 19 ’G’

2.99 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 5513–1/A1

Actuator Pump: Dismantling and Assembling

Checking
Should any parts of the actuator drive have been replaced during overhaul, the thickness ’S’ of the shim 19 must be
re-determined.

Determining the shim thickness: D

– Turn the camshaft so that the highest position
(cam peak) of the actuator cam concerned 9
points downwards.
– Fit the roller guide 11 (pay attention to the fol-

A
lowing paragraph “Assembling”).
– Place the piston 9 onto the roller guide (Fig.
’D’). 8
– Measure distance ’A’ from the piston upper 11
side to the seating of the actuator housing 6 in
the pump housing 8.
– The shim thickness ’S’ is calculated by the for-
mula: S = 158 mm – A
The actual thickness of the shim 19 may differ
by $ 0.20 mm from the calculated value.
E
Assembling
Assembling is to be carried out analogously to the 2
removal but in reverse sequence, while observing
the following:
– Turn the camshaft so that the highest position
(cam peak) of the actuator cam concerned
3
points downwards.
20
– Lubricate all the parts prior to assembling.
1
– Place the roller guide carefully onto the actua-
tor cam, and subsequently install the twist stop ’L’
12 (Fig. ’B’). 6
– The piston rings 25 must be fitted with the 25
marking TOP upwards.
– Expand the piston ring only sufficiently to allow
fitting in the piston.
– After replacing the O-ring 28, and after bringing
the actuator housing to its seating on the pump 28
housing 8 by alternative equal tightening of the
nuts 5 (Fig. ’A’), tighten the nuts diagonally
across by the specified tightening angle of 60°. 8

98.7476

Remark After the overhaul work has been completed, check on the running engine whether the pressure
limiting valve 20 and the connections of the hydraulic piping 2 are leakproof.
This is done by carefully removing screw plug 1, for a leakage check. When the above-men-
tioned parts are tight, then no oil can flow into leak-oil bore ’L’.

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 RTA48T
Maintenance 5520–1/A1

Regulating Shafts and Roller Guide of Fuel Injection Pump

Removal and Fitting of Eccentric Shafts and Roller Guide

Tools: Key to Illustrations:

Blocking device 94560 1 Eccentric shaft to suction valve 14 Intermediate piece
Blocking device 94560a 2 Connecting shaft 15 Screw
Dismantling and assembling tool 94582 3 Eccentric shaft to spill valve 16 Threaded rod
4 Outer coupling 17 Bearing
4a Internal coupling 18 Locating pin
5 Coupling screws 19 Spring link
6 Bearing cover 20 Screw
7 Control lever to spill valve 21 Cover
8 Control lever to suction valve 22 Head screw
9 Roller guide 23 Plate
10 Bearing 24 Eccentric pin
11 Spherical bearing 25 Spring
12 Snap ring 26 Sleeve
13 Double fuel injection 27 O-ring
pump housing 28 O-ring
13a Single fuel injection 29 O-ring
pump housing

Removal of the eccentric shaft

If the eccentric shafts must be removed, first lift off the fuel injection pump block concerned (see group 5512–4), and
subsequently the intermediate piece 14 and the casing above the corresponding eccentric and intermediate shafts.
Prior to displacement of the couplings 4, the blocking device must be fitted!

Fitting of the blocking devices:

 Blocking devices 94560 are bolted to the double fuel injection pump housing 13 (Fig. ’A’).
 Blocking devices 94560 and 94560a are bolted to the single fuel injection pump housing 13a (Fig. ’B’).

A 14
14

1 94560 4 2

94560
3

13

1 94560 4

94560
3
94560a
94560a

99.7019
13a

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5520–1/A1 Maintenance RTA48T

Removal and Fitting of Eccentric Shafts and Roller Guide

The blocking device must be distributed and fastened in such a way that a lateral displacement of the eccentric
shafts not to be removed is also prevented (see example Fig. ’C’).

C
4 4a 4 2 4 4a 4

13a 94560a 94560 13 19 94560 13

auszubauende Exzenterwellen
ECCENTRIC SHAFTS TO BE REMOVED

Dismantling of the eccentric shaft:

kein Spiel – Loosen the clamp screws of the cou-

plings 4.
NO CLEARANCE
D – Push the coupling on to the neighbour-
29 6 8 8 6 29 1 ing shaft, except for the eccentric
shafts to the single fuel injection pump
housing.

Attention The eccentric shafts which

are not to be dismantled
must not be turned by
more than 60 ° beyond
the standard position,
otherwise the control lev-
ers 7 and 8 may slide off
the eccentric.

– Remove the control levers 7 and 8.

– Mark and remove the bearing cover 6.
99.7021
– Lift off the eccentric shafts.
(If there are several eccentric shafts to
be removed, these and the connecting
3 7 6 4a 6 7 shafts 2 must be marked beforehand).

2.99 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 5520–1/A1

Removal and Fitting of Eccentric Shafts and Roller Guide

Assembly
The assembly is carried out analogously to the dismantling procedure but in reverse sequence. Thereby pay atten-
tion to the following:
– For mounting the coupling 4, the blocking devices 94560(a) must be mounted as described under ”Removal”.
– The clearance between the outer shaft ends at the couplings 4 shall be about 5 mm (Fig. ’E’).
– No clearance shall be at the internal couplings 4a between the internal shaft ends (Fig. ’D’).
– The coupling screws for all internal couplings 4a (Fig. ’D’) must be locked with liquid securing agent LOCTITE
type B!
– The clearance on both sides of the control levers 7 and 8 shall be about 4 mm (Fig. ’E’).
– The screws to the bearing covers 6 must be secured with lock washers.
– Check the eccentric shafts for free movement after tightening the bearing cover.
– Push the outer couplings 4 on to the shaft ends.
– The screws 5 of all the couplings must be fitted from above (Fig. ’E’).
– After tightening of the couplings check the eccentric shafts again for free movement.
– Clearance must be at hand on both sides of the O-rings 29 (Fig. D’)!

E 4 4a 8
4mm
6 1 4
5mm 4mm 5mm

5 5

5mm 4mm 5mm

4 3 4a 6 7 4mm 4 19

F 8 ’S’ 7

Check clearance ’S’ (see group 0330–1)

before mounting the intermediate piece 14.

99.7026

Wärtsilä Switzerland Ltd 3 2.99

5520–1/A1 Maintenance RTA48T

Removal and Fitting of Eccentric Shafts and Roller Guide

Removal of the roller guide

After the eccentric shafts have been removed, proceed as follows:
– Cutting in the relevant fuel injection pump as shown in Fig. ’G’ (see also Operating Manual group 5512–2).
– Turn the camshaft till the roller guide to be removed lies on the base circle of the cam.
– Dismantle the screws 20.
– Draw cover 21 together with the eccentric pin 24 and the spring 25 out of the sleeve 26.
– Loosen screw 22 and remove it together with the plate 23 and withdraw the sleeve 26.

21 I-I 26 25 27 21 28
G I

20

23
22

24

I
96.7014

H 16 15 15 16

Dismantling of the bearings to the eccentric

shafts:
– Mark the bearings.
– Re-bend the lock washers of the screws 15
and dismantle the screws.
– Equally unscrew the nuts on the threaded
rods 16 till the bearing 10 is no longer under
spring tension.
– Remove the nuts and the bearings.
The roller guides can now be removed by means
of a lifting tackle.
99.7020

18 15 16 10 16 15 18

2.99 4 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 5520–1/A1

Removal and Fitting of Eccentric Shafts and Roller Guide

Fitting of the roller guide

– Clean and oil all parts.
– Carefully place the roller guide on the fuel cam by means of a lifting tackle.
– Turn the engine till the roller guide lies on the base circle of the cam.
– Fit the cut-out device in reverse sequence to the removal (check and if necessary replace O-rings 27 and 28).

Fitting of the bearings

– Place the pressure spring on the roller guide.
– Place the bearing and screw it fully onto the pump housing, turning equally the nuts on the threaded rods 16.
Thereby pay attention that the bearing is positioned by the locating pin 18 (Fig. ’H’).
– Mount, tighten and lock the screws 15 together with the lock washers.
For the final assembly, refer to paragraph ”Assembly”.

Removal and fitting of the spherical bearing

To remove the spherical bearings 11, proceed as follows:
– Remove the snap rings 12 with a screwdriver.
– Mount device 94582 and press the bearing out.
The fitting of the spherical bearings is done in reverse sequence.
The spherical connections of the regulating linkage between governor and fuel fuel injection pumps are equipped
with lubricating nipples. These have to be lubricated weekly with MOLYKOTE paste G using the grease gun con-
tained in the tool kit.

12 I 94582 11

93.7242

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 RTA48T
Betrieb Group6

Scavenge Air Receiver and Auxiliary Blower Group 6

 Scavenge Air Receiver

– Checking the Air Flaps and Cleaning the Scavenge Air Receiver . . . . . . . . . . . . . . . . . . . . . . . . 6420–1/A1

 Auxiliary Blower
– Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6545–1/A1

 Scavenge Air Cooler

– Cleaning (Water Side) on Engine at Standstill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6606–1/A1
– Removing and Fitting a Cooler Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6606–2/A1

 Scavenge Air Receiver

– Maintenance of Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6708–1/A1

Wärtsilä Switzerland Ltd 1 RTA48T / MM / 1998

This page is intentionally left blank
 RTA48T
Maintenance 6420–1/A1

Scavenge Air Receiver

Checking the Air Flaps and Cleaning the Scavenge Air Receiver

Key to Illustrations:
1 Hinged cover 8 Air flap
2 Scavenge air cooler 9 Relief valve
3 Cover 10 Water drainage piping
4 Inspection cover 11 Spring sheet
5 Inspection cover 12 Screws
6 Fixed support (suction space) 13 Screws
7 Auxiliary blower

Inspection of the air flaps

The air flaps 8 arranged in the scavenge air receiver and in the fixed support 6 (Fig. ’A’) must be checked for damage,
movability as well as fouling, in the course of the periodic cleaning of the scavenge air receiver.
The air flaps 8 in the receiver (Fig. ’A’) are reached through an opening in the scavenge air receiver, which is closed
with an inspection cover 4.
To check the air flaps 8 for the auxiliary blower 7, both inspection covers 5 at the fixed support 6 are to be opened.

A
5 5
I
6
7 7
II

9 9

4 4

3 2

96.7632
1
I

Wärtsilä Switzerland Ltd 1 3.00

6420–1/A1 Maintenance RTA48T

Checking the Air Flaps and Cleaning the Scavenge Air Receiver

I-I
5 Should it be necessary to remove any air flaps from
6 the scavenge air cooler and fixed support 6, first
unscrew and remove the screws 12 and 13.
Subsequently the air flaps can be removed as sin-
gle unit.

96.7025
II 12 III 12

11 13

II 8

III
8

10
96.7025

96.7632

Cleaning the scavenge air receiver

The scavenge air receiver 2 should be checked for cleanliness at regular intervals (see group 0380–1), however,
always after a piston overhaul or after regular maintenance in the piston underside.
In particular check whether water drain piping 10 from the scavenge air receiver is not clogged, so that a perma-
nent drainage is assured during operation.
At the time of a major overhaul the relief valves 9 (Fig. ’B’) fitted on the front side of the scavenge air receiver must
be checked. The relief valves are set to an opening pressure of 3.4–3.8 bar.

B 9

96.7025

3.00 2 u Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 6545–1/A1

Auxiliary Blower
Maintenance

Tools: Key to Illustrations:

1 Spur-geared chain block 94650 1 Electric motor 15 Screw
1 Dismantling device 94651 2 Motor plate 16 Countersunk screw
consisting of: 3 Spiral casing 17 Flow ring
1 Carrier 94651a 4 Impeller 18 Screw
1 Carrier 94651b 4a Hub to item 4 19 Jacking yoke
1 Trolley 94651c 5 Screw 20 Screw
2 Centring studs 94652 6 Locking plate 21 Thrust piece
Various jacking screws 7 Impeller cap 22 Fixed support (suction space)
Various spanners 8 Motor shaft 23 Scavenge air receiver
9 Threaded pin 24 Screw M16x160
10 Locking wire 25 Screw
11 Screw 26 Screw
12 Labyrinth ring 27 Exhaust manifold
13 Screw
14 Locking plate K Control bush

The following instructions apply to the auxiliary blowers of SCHMID make.

Proceed as follows to dismantle an auxiliary blower for cleaning or repairing :
– Separate the electrical connections from the electric motor.
– Depending on the auxiliary blower to be dismantled, fasten one of the two carriers 94651a(b) to the exhaust
manifold with screws 25 (Fig. ‘A’).
– Push the trolley 94651c onto the carrier, and secure it with screw 24.

Attention Risk of accident! It is imperative that the screw 24 be fitted at the end of the carrier.

– Suspend the spur-geared chain block 94650 on the trolley and connect it to the sprial casing 3 by means of
ropes. Slightly tighten the ropes.
– Loosen and remove all pins and screws connecting the spiral casing 3 to the fixed support 22 and the scavenge
air receiver 23.
– Slightly lift the spiral casing with the spur-geared chain block, turn it in the direction of the carrier, place it on the
scavenge air receiver, and fasten it with a screw 26 (Fig. ‘A’).
94651a 25 26 94651b 3
A

24
24

25

98.7114

22 23

Wärtsilä Switzerland Ltd 1 1998

6545–1/A1 Maintenance RTA48T

Auxiliary Blower: Maintenance

24

II
25
98.7115 24

II
– Disconnect the spiral casing 3 from the
25 94651a 27 24 spur-geared chain block 94650.
– Hang the electric motor 1 on the chain
block (Fig. ‘B’).
– Among the screws 15 fastening the
motor plate 2 to the spiral casing 3 (Fig.
94650 ‘C’), unscrew two screws facing each
other horizontally, then screw in both
centring studs 94652 instead (Fig. ‘B’).
– Remove all other screws 15 from the
motor plate.
– Separate the motor plate 2 from the
spiral casing 3 by means of two jacking
screws.
26
– Together with the motor plate and im-
peller 4, horizontally draw out the elec-
tric motor 1 from the spiral casing (Fig.
‘B’).

23 3 4 94652 2 1 – Lay down the entire group on an even

underlay, taking care that the impeller
is at the top.

Attention When upending the group from the horizontal position to the vertical, take great care not to knock
the impeller against anything or damage it in any way.

1998 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 6545–1/A1

Auxiliary Blower: Maintenance

3 C
3
16 2
1

17
Dismantling
– Loosen screw 5 and remove it together 4
with the locking plate and the impeller
cap 7.
– Mark together impeller 4 and hub 4a.
– Place a tool according to Fig. ‘D’ and
pull the hub 4a off the motor shaft 8 by
tightening the screw 18.
– If the labyrinth ring 12 is to be replaced, 3
it can be removed after loosening the
screws 11. 4 15
– For maintenance of the rolling bear-
ings in the electric motor please com-
ply with the instructions of the
manufacturer. 2

14
D
18 (M20) 13 1
80

4a
19
~20

10
20 (M12) 11
~20

12
21 ( Ø ~30)
9
7
5
x

6
8 4a 8 K
98.7116

19
~36

98.7117

~120

Wärtsilä Switzerland Ltd 3 1998

6545–1/A1 Maintenance RTA48T

Auxiliary Blower: Maintenance

Assembling

Remark Note that the impeller 4 is statically and dynamically balanced, and therefore must in no way suf-
fer deformation or other damage. The impeller must be rebalanced in case of any damaged or
replaced parts turning together with the motor shaft.

The assembly is done in the following sequence:

– Check clearance of labyrinth ring 12: ’x’ = 0.12–0.19 mm.
– This clearance can be checked by a control bush ’K’ (Fig. ’C’ and ’E’) by pushing the bush, prior to fitting of the
hub 4a, over the motor shaft 8 (see Fig. ’C’).

Kontroll-Büchse
E CONTROL BUSH

– 0.05
Ø 100 – 0.10 + 0.5
16 0
15 
5

59.3
~80

98.7118
5

+ 0.03
Ø 55 + 0.05

– After measuring clearance ’x’ remove the control bush and fit the labyrinth ring 12, tighten and lock it.
– Smear motor shaft lightly with MOLYKOTE and push hub with impeller onto motor shaft 8 (pay attention to key
position). By use of a threaded bar (screwed in at the motor shaft end) and of a strong disc and a nut, press hub
with impeller onto motor shaft till the stop. Then remove the tool.
– Fit impeller cap 7, tighten and lock it.
– Fit centring stud 94652.
– With the aid of dismantling device 94651 fit electric motor 1 including impeller 4 into spiral casing 3 and firmly
tighten screws 15.
– Remove centring stud and replace it by screws.
– Connect electric motor to mains and check direction of rotation.

Remark Auxiliary blowers which are out of service for a longer period should be started up for a short time
twice a month. Where this is not feasible, the impeller should be turned by hand by several turns.
This is necessary to protect the bearings from corrosion damage.

1998 4 u Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 6606–1/A1

Scavenge Air Cooler

Cleaning (Water Side) on Engine at Standstill

Tools: Key to Illustrations:

Tube brushes 1 Cover 6 Cooler casing
Various spanners 2 Air duct before cooler 7 Hinged cover
3 Cooling tubes 8 Water separator
4 Cooling fins 9 Drain
5 Tubeplate

Depending on the cleanliness of the utilized cooling water a cleaning of the cooler tubes is required after a shorter or
longer operating period. The necessity to clean becomes evident by measuring the temperature difference between
cooling water inlet and outlet, and comparing this with the values recorded in the acceptance trials.
When using clean, neutral cooling water, cooling tube cleaning will be only rarely necessary.

2
I
7

96.7637

8 1 9

Cleaning methods
The cooling tubes can be cleaned by mechanical, by hydraulic or by chemical means.
a) Mechanical cleaning in fitted condition:
After removing both covers 1 (Fig. ’A’), the dirt accumulated in the tubes is removed by means of special tube
brushes and then flushed away with water.

Wärtsilä Switzerland Ltd 1 3.00

6606–1/A1 Maintenance RTA48T

Scavenge Air Cooler: Cleaning (Water Side) on Engine at Standstill

b) Hydraulic cleaning in fitted condition:

Firmly adhering sediment which is not removed by the brush can be removed with high pressure water jets. Spray
devices with special nozzles are used, which can be ordered from the cooler manufacturers.
c) Cleaning by chemical solvents in removed condition (removal see group 6606–2):
Should the above mentioned methods not be successful then chemical means must be utilized. By this the tube
stack is immersed in a chemical cleansing bath for a time depending on the degree of fouling, then flushed through
with a strong water jet. During the cleansing process the effectiveness can be increased by circulating the chemical
through the tubes, whereby the immersion time can be reduced.
For this type of cleaning the instructions of the cleaning agent makers must be strictly followed.
When choosing the cleaning agent we recommend using only products of renowned firms of this line such as:
DREW, VECOM, GAMLEN, HENKEL, etc.

5 6 6

4 4

3 3
1 I 1

1 1

Feste Seite Ausdehnungsseite

FIXED END EXPANSION END

98.7769

Locating and sealing of leaking cooler tubes in service

Due to corrosion or mechanical damage tube leakages may occur. This causes cooling water to enter the air duct 2
and the scavenge air receiver.
The following procedure permits locating leaking cooler tubes 3 and sealing them:
– Reduce engine power, until the air temperature after the blower reaches about 65 to 70 C, then shut off the
water valves before and after the defective cooler and drain the cooler at connection 9.
– Remove the side covers 1 (see also group 6606–2) and seal the cooler tubes on one side of the cooler with
cardboard or similar.
– On the opposite end brush soapy water over the cooler tubes; leaking tubes will be revealed by bubbles.

3.00 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 6606–1/A1

Scavenge Air Cooler: Cleaning (Water Side) on Engine at Standstill

– Defective tubes are sealed up by hammering in slightly tapered plugs of hardwood, copper etc.
– Cooler tubes sealed in this manner must be replaced at the next opportunity in accordance with maker’s
instructions.

Transportation of cooler tubestacks

Always utilize specially provided suspension straps ’T’ (see group 6606–2) which can be swung sideways. Where
only holes are provided, use suitable shackles for transportation.
It is recommended to cover the finned surfaces, protecting the cooling fins and preventing the entrance of foreign
particles during transportation and storage.

Wärtsilä Switzerland Ltd 3 u 3.00

This page is intentionally left blank
 RTA48T
Maintenance 6606–2/A1

Scavenge Air Cooler

Removing and Fitting a Cooler Insert

Tools: Key to Illustrations:

1 Device complete 94661 1 Cover 11a Screw
consisting of: 2 Gasket 12 Gasket
1 Roller plate 94662, 94662a 3 Round rubber ring 13 Gasket
1 Dismantling and 4 Screw 14 Rail
assembling device 94663a,b 5 Sealing flange 15 Screw
1 Pulley support 94664 6 Cooler casing 16 Cooler insert
7 Side wall 17 Hinged cover
8, 8a Screw to cover
9 Cooler tubes K Stop lever
10 Cooling fins S Setscrews
11 Tube plate T Transport straps

The water connections may be installed both on the fixed side and at the expansion side.
When a cooler insert (tube stack) should be removed, the roller plates 94662 and 94662a have to be fastened to the
side, where the tube plate 11 is screwed into the cooler casing 6. This side is designated as ’fixed side’. On the
central platform the rails are bolted, on which the cooler insert can be pulled out. For this the device 94661, con-
tained in the tools collection of the engine, is to be used. The cooling water pumps to the scavenge air cooler must be
stopped and the cooler drained. After this proceed as follows:

A
11 13 6 6 5 4

11a
3
8a 2
7
8
12 10 1
9

Feste Seite Dehnungs Seite

FIXED END EXPANSION END

Ausbaurichtung
DISMANTLING DIRECTION 98.7769

Wärtsilä Switzerland Ltd 1 7.03

6606–2/A1 Maintenance RTA48T

Removing and Fitting a Cooler Insert

Removal
– Remove screws 15 from cooler casing 6.
– By coolers with cooling water connections arranged on the expansion side, loosen and remove all the
screws fastening the cooling water inlet/outlet pipes to the cover 1 of the cooling element (Fig. ’A’).
– By coolers with cooling water connections arranged on the fixed side, then the inlet and outlet pipes of the
cooler to the valves must be loosened and removed.
– Unscrew all the screws 4 and remove sealing flange 5 with round rubber ring 3 on the expansion side (Fig. ’A’).
– Unscrew all the screws 11a on the fixed side (Fig. ’A’).
– Fix roller plate 94662(a) at the cover of the fixed side. The rollers must rest on rails 14, which can be adjusted by
setscrews ’S’ (Fig. ’C’).
– Loosen the cooler insert with the aid of jack screws from cooler casing. As soon as the insert is free i.e. the
gasket 13 come off, lift cooler insert a little off cooler casing by tightening setscrews ’S’.
– Fasten pulley support 94664 to the platform support which is near the fixed side. Attach rope of pulling tackle on
roller plate and pull the cooler insert out of the cooler casing till arrester stop (see Fig. ’C’).
– Cover the cooling ribs of the elements.
– Connect the four transport straps ’T’ (Fig. ’C’) of the cooler insert with wire ropes and attach them to the engine
room crane. Tighten wire ropes.
– Lift stop lever ’K’ (Fig. ’C’) on roller plate upwards and pull cooler insert out of the cooler casing. Draw with the
engine room crane at the same time, thereby the wire ropes should always be tensioned!
– Lift cooler insert and remove roller plate.
– Move the cooler insert with the engine room crane out of engine room.

Feste Seite
I
FIXED END

011.103/03
15 6

011.104/03

7.03 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 6606–2/A1

Removing and Fitting a Cooler Insert

C Ausbau
DISMANTLING
T

002.532/96

14 Anschlag 94664
S STOPPER

Anschlag
STOPPER
I
14

Feste Seite
FIXED
END

94662(a)

002.532/96

Wärtsilä Switzerland Ltd 3 7.03

6606–2/A1 Maintenance RTA48T

Removing and Fitting a Cooler Insert

Fitting
– Mount pulley support 94664 on the platform support opposite to the fixed side (Fig. ’D’).
– Apply gasket 13.
– With the help of the engine room crane, lower cooler insert on a level with the cooler casing and fasten roller
plate 94662 (a).
– If necessary remove cover from the cooling ribs.
– Together with the engine room crane and pulling rope, pull cooler insert into the cooler casing till the arrester
stop.
– Remove wire ropes and transport straps.
– Raise stop lever ’K’ (Fig. ’C’) on the roller plate and pull cooler insert completely into the casing. Take care that
the cooler insert is slightly raised from cooler casing bottom by setscrews ’S’.

T
D Einbau
ASSEMBLING

002.531/96

94664

14 Anschlag 94662(a)
STOPPER

I I

Kühler GEA 150/38/24/6 Kühler GEA 120/30/24/6

COOLER GEA 150/38/24/6 COOLER GEA 120/30/24/6

002.531/96

002.531/96

94663b 94663a

7.03 4 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 6606–2/A1

Removing and Fitting a Cooler Insert

E
– Screw in all screws 11a (Fig. A).
– Push / pull the cooler insert 6 towards
the air side by means of screws 15.
– Remove pulley plate 94662(a). Feste Seite
– Tighten all screws 11a. FIXED END

II
II
94662(a)

S
011.105/03
15 6

011.106/03

– Remove assembling device 94663a,b fit rubber ring 3 as well as sealing flange 5 and tighten-up with screws 4
(FIg. ’A’).
– Connect piping, close drain cock on the cooler and open vent.
– Start cooling water pump to the scavenge air cooler and check cooler for possible leaks.

Remark The connection of the cooling water outlet is arranged in such a way that it is always near to the
cooler inlet of the scavenge air.

Sealing cooler insert for scavenge air receiver

The gap between the cooler casing 6 and the cool-
F
er insert 16 should be airtight so that the scavenge
air passes through the cooler insert. Therefore, a
high-temperature (about 300 °C) silicone jointing
compound e.g. COLTOGUN must be applied.
The gap is reached through the opening by loosen-
ing the hinged cover 17 and tilting it down.
On completion of the work screw up the hinged
cover.

Dichtmasse III
JOINT
COMPOUND
16 17

III
6

002.256/00
011.107/03

Wärtsilä Switzerland Ltd 5 u 7.03

This page is intentionally left blank
 RTA48T
Maintenance 6708–1/A1

Scavenge Air Receiver

Maintenance of Water Separator

Key to Illustrations:
1 Water separator 10 Upper carrier
2 Air flaps 11 Strap
3 Screw 12 Door
4 Spring washer 13 Supporting plate
5 Screw 14 Coupling
6 Rail
7 Lower carrier
8 Hinged cover R Eye bolts
9 Water drain S Wire rope

The water separator 1 should be inspected after completing the first operating year. The cleaning interval for future
servicing should be established on the basis of the degree of contamination found. If the air suction filter of the ex-
haust gas turbocharger is well maintained, the degree of contamination of the water separators should not be con-
siderable.

Inspection
– Open the inspection cover on the scavenge air receiver (see group 6420–1).
– Enter the scavenge air receiver, tilting up the air flaps 2, and check the water separator 1 for damage and foul-
ing.
– Unscrew and push the couplings 14 upwards on the water drains 9.
– Unscrew hinged cover 8, tilt it down and check the space below the water separator for cleanliness.
On this occasion check also the water drains for free passage.

99.7692
8 9 14

Wärtsilä Switzerland Ltd 1 7.03

6708–1/A1 Maintenance RTA48T

Maintenance of Water Separator

Removal
– Open hinged cover 8 and door 12.
– Remove the screws 3 and 5 with spring washer 4 together with the rail 6 and the lower carrier 7 (Fig. ’B’).
In order to lower the water separator 1, it must be connected with two wire ropes ’S’ which are led into the scavenge
air receiver through the air flap openings (Fig. ’B’).
The wire ropes are fastened at the water separator by means of shackles, and drawn through two eye bolts (Fig. ’B’).
– Tighten wire ropes ’S’, press together both supporting plates 13 (Fig. ’B’), and then lower the water separator by
means of the ropes.

Attention Risk of accident! To prevent injury to hands during lowering, the supporting plates must never
be pressed together without any appropriate tool!

Cleaning
– The water separator should be cleaned with the same media as used for cleaning the scavenge air cooler in
operation.
Do not use any sharp tools for cleaning.

Fitting
Before fitting the water separator, its location in the scavenge air receiver should be thoroughly cleaned and the
water drains checked for free flow.
The fitting of a water separator ensues analogously to the removal, but in the reverse sequence, however, the sup-
porting plates 13 must not be pressed together.
Attention should be paid that when inserting the water separator it is fully pushed into the upper carrier 10, and that it
rests on both lateral supporting plates 13.

3.00 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 6708–1/A1

Maintenance of Water Separator

I-I
B I

R R
R
III

S
1 S S

IV II

002.869/03

I
002.869/03
13 8 13
III

10

II

002.868/03
1 1 IV

13

002.868/03

3 002.868/03
4
7 13
5 4 6

Wärtsilä Switzerland Ltd 3 u 7.03

This page is intentionally left blank
 RTA48T
Betrieb Group7

Balancer Group 7

 Integrated Balancer of 2nd Order

– Removal and Fitting of Compensating Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7722–1/A1

 ELBA (ELectrical BAlancer)

– Checking, Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7734–1/A1

Wärtsilä Switzerland Ltd 1 RTA48T / MM / 3.00

This page is intentionally left blank
 RTA48T
Maintenance 7722–1/A1

Integrated Balancer of 2nd Order

Removal and Fitting of Compensating Shafts

Tools: Key to Illustrations:

3 Adjusting devices 94410 1 Upper compensating shaft 9 Screw
for alignment of compen- 2 Lower compensating shaft 10 Locking strap
sating shaft (driving end) 3 Waisted screw 11 Locking screw
3 Adjusting devices 94721 4 End cover 12 Locking plate
for alignment of compen- 5 Taper pin 13 Locking wire
sating shaft (free end) 6 Screw plug 14 Oil connection
Various lifting tackles 7, 7a Bearing pair 15 Screw
8 Balance weight

According to requirements, five and six cylinder engines can be equipped with an integrated balancer on the driving
end.
Before starting any work on an integrated balancer, the upper and lower compensating shafts have to be rotated in
such a way that their balance weights 8 come to the B.D.C. position. This is absolutely necessary to prevent
accidents. The correct crankshaft position for permitting the removal of the compensating shafts differs with the
number of cylinders and the engine’s direction of rotation. The respective crankshaft position is shown in table il-
lustration ’A’. After turning the crankshaft to the correct position, the electric fuse must be removed from the fuse box
of the turning gear for safety reasons. This is to prevent with all certainty that the engine be set into motion.

Motor rechtsdrehend
A ENGINE CLOCKWISE ROTATION
5 Zyl.
Kurbelstellung Zyl. 1
theoretisch 9 n. O.T.P.
5 CYL.
CYL. 1 CRANK POSITION
THEORETICAL . . . . . . . . . . . . . . 9 AFTER T.D.C.

6 Zyl.
Kurbelstellung Zyl. 1
theoretisch 15 n. O.T.P.
6 CYL.
CYL. 1 CRANK POSITION
THEORETICAL . . . . . . . . . . . . . . 15 AFTER T.D.C.
Zulässige Abweichung ± 1 Zahn
ALLOWABLE DEVIATION . . . . . ± 1 TOOTH

8
Linksdrehender Motor
COUNTER-CLOCKWISE
2
ROTATING ENGINE
5 Zyl.
8 Kurbelstellung Zyl. 1
theoretisch 351 n. O.T.P.
5 CYL.
CYL. 1 CRANK POSITION
THEORETICAL . . . . . . . . . . . . . . 351 AFTER T.D.C.

6 Zyl.
96.7109 Kurbelstellung Zyl. 1
theoretisch 345 n. O.T.P.
6 CYL.
CYL. 1 CRANK POSITION
THEORETICAL . . . . . . . . . . . . . . 345 AFTER T.D.C.
Zulässige Abweichung ± 1 Zahn
ALLOWABLE DEVIATION . . . . . ± 1 TOOTH

Wärtsilä Switzerland Ltd 1 1998

7722–1/A1 Maintenance RTA48T

Removal and Fitting of Compensating Shafts

Removal of the compensating shafts

– Remove casing cover of the camshaft drive and inspection cover to the bearing housing of the camshaft drive
on the exhaust side.
– Mark gear wheels on both sides (see Fig. ’B’).
– Lead rope ’a’ through the opening for the inspection cover to the bearing housing of the camshaft drive and sling
it around the compensating shaft. Pull rope ’a’ taut with engine crane (Fig. ’B’). Apply a protection (e.g. leather)
to the indicated positions.
– Pull rope ’b’ taut with lifting tackle as shown in Fig. ’B’ on the platform at the exhaust side.
– Remove locking wires 13 to the waisted screws 3 and screws 9.
– Remove all screw plugs 6 and withdraw all taper pins 5 using a withdrawing device.
– Dismantle oil connection 14.
– Loosen and remove waisted screws 3 and screws 9.
– With the aid of the engine crane and lifting tackle, the upper compensating shaft 1 can be removed.
– The same procedure is to be followed as described above for the removal of lower compensating shaft 2.

B
Schutz
PROTECTION

a b

Markierung
MARKING

96.7117

1998 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 7722–1/A1

Removal and Fitting of Compensating Shafts

IV - IV V
C 5
6
4
3
9 4

6
5 I
II III
IV V
I-I
13 13
9 3
UPPER COMPENSATING SHAFT
Obere Ausgleichswelle

IV V
I
4 11 10 12

14
II III
LOWER COMPENSATING SHAFT

3
Untere Ausgleichswelle

DRIVING END
Antriebsseite

7
9 7a
15 8

8
96.7118

Fitting the compensating shafts

The fitting of the compensating shafts is done analogously to their removal but in reverse sequence. The following
points must be specially taken care of:
 Should the two bearing pairs 7 and 7a have been removed after taking off locking strap 10 (Fig. ’C’) then liberally
smear bearing journals of the compensating shaft with oil before fitting them. Both bearings are generally equal,
nevertheless they must be refitted in the same initial place, where they have been exactly located during erec-
tion of the engine, with taper dowels 5.
 Fit the compensating shafts in such a way that the marking DRIVING END appears when viewed from the driv-
ing end. The writing is punch marked on the face of the gear rim.

Wärtsilä Switzerland Ltd 3 1998

7722–1/A1 Maintenance RTA48T

Removal and Fitting of Compensating Shafts

 For correct fitting of the balancer shafts their balance weights 8 must be in the exact downward position
(B.D.C.). The correct position of the crankshaft with respect to the location of these masses differs depending
on number of cylinders and engine direction of rotation. The corresponding crank position is shown in the table
Fig. ’A’ and determined by marks.
 Fix both bearings 7 and 7a with waisted screws 3 and screws 9 which are to be tightened lightly at the approxi-
mate fitting position in the double column, whereby a sealing compound is to be applied to the sealing face of
end cover 4 at the driving end.
 Mount adjusting device 94410 or 94721 (Fig. ’D’) and align the compensating shafts to bring the taper pin bores
in line so that the taper pins can be driven in with light strokes of a copper punch.
 Tighten waisted screws 3 and screws 9 evenly but lightly with a spanner.
 Starting from this initial position tighten the waisted screws and the screws diagonally across in stages with a
tightening angle of 45 (see group 0352–1).
 Check tooth backlash (see group 0330–1).
 Fit all screw plugs 6 with LOCTITE type ’A’, whereby the screws plugs are to be turned in until they rest on the
taper pins 5. Be sure the threads are clean (free of grease) before applying LOCTITE.
 Lock waisted screw 3 and screws 9 with locking wire 13 (Fig. ’C’).

I-I
D
I

I
96.7119

94721 7a 7 94410

Remark
1. If new balance weights 8 are fitted, lock screws 15 with LOCTITE type ’B’.
2. Should it become necessary to replace a bearing, then its pair must also be exchanged, as new bearings are
manufactured in pairs. For their fitting an exact setting of the balancer shaft is essential, for which adjusting
tools 94410 and 94721 (Fig. ’D’) are to be utilized.
3. Regarding tooth backlash and distance between axes, see Clearance Table group 0330–1.
After a replacement of a gear wheel or of a bearing pair of the balancer shaft the tooth contact must be checked
(see group 4103–1).
Should it become necessary to re-dowel the bearing flanges, e.g. following the fitting of a new gear wheel set
etc., then the pre-drilled pin holes in the column must be used.

1998 4 u Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 7734–1/A1

ELBA (ELectrical BAlancer)

Checking, Dismantling and Assembling

Tools: Key to Illustrations:

1 Bush 94750 1 Electric motor 33 Gear wheel
2 Threaded rods 94750a 2 Oil pipe 34 Spherical roller bearing
1 Disc 94751 3 Screw 35 Oil baffle
1 Bush 94752 4 Screw 36 Screw
2 Threaded rods 94752a 5 Screw 37 Screw
1 Thrust bearing 94752b 6 Cover 38 Disc
1 Distance piece 94753 7 Screw 39 Distance sleeve
1 Screw 94753a 8 Cover 39a Distance sleeve
2 Threaded rods 94753b 9 Distance bush 40 Driving gear wheel
1 Bush 94754 10 Annular spring 41 Motor shaft
2 Set screws 94755 11 Lock washer 42 Distance sleeve
1 Sleeve 94756 12 Screw 43 Flat bar (sensor)
1 Sleeve 94757 13 Taper pin 44 Screw
1 Bush 94758 14 Screw 45 Joint
2 Screws 94758a 15 Sleeve 46 Key
2 Distance plates 94759 16a(b) Balancer weight 47 Screw plug
2 Distance plates 94760 17 Screw 48 Screw plug
1 Bush 94761 18 Gear wheel 49 Screw plug
2 Screws 94762 19 Distance bush 50 Screw
20 Shaft 51 Cover
21(a) Spherical roller bearing 52 Taper pin
22 Screw 53 Screw
23 Cover 54 Sleeve
24 Screw 55 Screw plug
25 Disc 56 Screw
26 Screw 57 Flat bar
27 Cover 58 End casing
28 Housing 59 Cover
29 Grooved ball bearing
29a Circlip BK Pedestal
30 Intermediate shaft DF Sealing face
31 Distance sleeve OB Oil bore
32 Gear wheel RS Eye bolt M24

Description
An ELBA as it is called (ELectrical BAlancer) is fitted on the engine column at the free end.
An electric motor drives two compensating shafts via a gear (balancer weight with gear wheel) in order to compen-
sate the free second order moments.
The lubricating oil system is connected to the low pressure lube oil system of the engine.
Lube oil is distributed onto the gear wheels through spray nozzles, and to the bearings through the shafts.
The electric motor is controlled by a converter which is arranged in a special box located in the control room.

Remark The listed tools are not supplied. However, if required they are available on a loan basis and can
be ordered from the technical service department of Wärtsilä Switzerland Ltd.

Wärtsilä Switzerland Ltd 1 1998

7734–1/A1 Maintenance RTA48T

ELBA: Checking, Dismantling and Assembling

Additional Key to Illustation ’A’:

AL Suspension strap OE Oil inlet
DG Speed transmitter OF Oil filter
DW Pressure switch RV Control valve
KK Terminal box SD1–SD4 Spray nozzle
MA Pressure gauge SK Control cable
OA Oil drain pipe

AL
A
SD2 II

SD2 6

SD1
II 55
23 I SD4
2
SD3 5
I
55
MA

DW III SK
RV

OE
58
OF
III 98.7497

OA KK

I-I II - II III - III

52
54
2mm

43
53
55 DG
56
57
SK

1998 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 7734–1/A1

ELBA: Checking, Dismantling and Assembling

In order to ensure the reliability of the ELBA, the following inspections must be carried out (see also Maintenance
Manual group 0380–1 and Operating Manual group 7722–1).

Checking of the oil flow, cleanliness of the housing, and condition of the gear wheels:
The oil flow must be checked with the lubricating oil pump in operation and removed cover 23 (Fig. ’A’). Thereby
observe whether oil flows out at the spray nozzles SD2 and SD3 (Fig. ’A’). The gear wheels 18 and 33 can also be
examined (Fig. ’B’). Depending on their conditions found, it is possible to determine the conditions of the remaining
gear wheels.
Screw down cover 23 and its joint after termination of the checks.

B
Transport-Sicherung
13 LOCK FOR TRANSPORT
18
33
I-I
I

94762 8 16a(b)

98.7499

Checking of the screws to the compensating shafts:

– Check the required tightening torque of 65 Nm for the screws 5 to the covers 6 (Fig. ’A’ and ’E’) of the annular
spring packets (Fig. ’F’) with a torque wrench.
– Check the screws 14 for correct tightening (Fig. ’G’) by means of a ring spanner. In order not to damage the
LOCTITE bonding, check with a small torque of about 50 Nm whether the screws are not loose!

Checking of the screwed connection housing – engine column:

– Check the screws 53 for correct tightening by means of a ring spanner.

Wärtsilä Switzerland Ltd 3 1998

7734–1/A1 Maintenance RTA48T

ELBA: Checking, Dismantling and Assembling

Attention The ELBA must not be opened at the engine, it must be removed from the engine for repair
works.

Removing of the ELBA

– Turn the balancer weights 16a(b) to B.D.C. Loosen the screw plugs 55 (Fig. ’A’), and fit screws 94762 (lock for
transport) in their positions (Fig. ’B’).
– Loosen electric cables at the electric motor 1. 1 3
– Connect electric motor with the crane. *)
C
– Loosen and remove screws 3 and 4. *)
– Remove the electric motor. *)

*) As an alternative it is possible to dismantle the

electric motor after removing the ELBA.

98.7052

4 ’DF’ 28
– Loosen and remove all control cables ’SK’ (Fig. ’A’).
– Loosen connection after the oil filter ’OF’, disconnect and remove the oil pipe to the spray nozzle SD1 (Fig. ’A’).
– Unscrew oil drain pipe ’OA’ (Fig. ’A’).
– Dismantle the platform above the ELBA.
– Loosen screws 56 and remove these together with the flat bar 57. Subsequently remove taper pins 52 (Fig. ’A’)
by means of a withdrawing device.
– Connect ELBA on its suspension straps ’AL’ (Fig. ’A’) with the crane by means of wire ropes, and tighten these
lightly (weight of ELBA = 2000 kg).
– Loosen and remove screws 53 together with sleeves 54 (Fig. A’).
– Remove the ELBA from the engine.
– Re-bend the lock washers 11, loosen screws 12 and remove these together with oil pipes 2 (Fig. ’D’). Cover the
openings of the oil pipes!

II - II D
11 12

2
45

SD2–SD4 II II

I-I I

45 I
12
11

2 98.7052

1998 4 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 7734–1/A1

ELBA: Checking, Dismantling and Assembling

Remove the ELBA as illustrated in Fig. ’E’ and place it on two pedestals ’BK’ with the cover 8 pointing upwards.
Carrying capacity per pedestal = 1000 kg.
Dismantling of the ELBA

Removal of the balancer weights and their components:

8 5 94762 6 7 – Remove screws 94762.

E
– Loosen screws 5 and remove these
together with the covers 6.
– Loosen and remove screws 7.
28
– Loosen cover 8 from the housing 28
using jacking screws M16.
– Fit eye bolts M16 into the cover, con-
nect it with the crane and lift off the
cover carefully.
BK

F
8

– Remove distance bushes 9 and an-

nular springs 10 from the cover 8
(Fig. ’F’).

10 9

G
16b 16a ’RS’ 19
– Remove distance bushes 19.
– Loosen screws 14 and remove
these together with the sleeves 15.
28
– Fit eye bolts ’RS’ into the balancer
weight 16a and connect it with the
crane.
– Remove the balancer weight. Pay
attention that it is suspended hori-
zontally!

14 15 – Place the balancer weights accord-

ing to Fig. ’H’.
98.7323

Wärtsilä Switzerland Ltd 5 1998

7734–1/A1 Maintenance RTA48T

ELBA: Checking, Dismantling and Assembling

H
18

17

– Connect gear wheel 18 with the crane.

– Loosen screws 17 and remove these to-
gether with the gear wheel.

16a(b)

I 21a 20 21 94750

– Dismantle shaft 20 using bush 94750 and

threaded rod 94750a.
94750a

16a(b)

K
94750 94751

– Withdraw spherical roller bearing 21a out

94750a 21a of the balancer weight by means of bush
94750, disc 94751, and threaded rod
16a(b) 94750a.

98.7324

1998 6 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 7734–1/A1

ELBA: Checking, Dismantling and Assembling

– Screw two threaded rods 94752a into the flange of the shaft 20.
– Push the bush 94752 over the threaded rods.
– Screw nuts onto the threaded rods till the spherical roller bearing 21 can be removed from the shaft (Fig. ’L’).
94752a 94752 21 20
L

Removal of the intermediate shaft and its components:

To remove the intermediate shaft, it is advantageous to turn the housing laying on the pedestals in such a way that
the cover 27 is pointing upwards (Fig. ’M’).
– Loosen screws 22 and remove these together with the cover 59 (Fig. ’M’).
– Loosen screws 24 and remove these together with the disc 25 (Fig. ’M’).
– Knock intermediate shaft 30 off the grooved ball bearing 29 by means of a copper mandrel and a hammer.
– Loosen and remove screws 26 to the cover 27 (Fig. ’M’).
– Loosen cover 27 from the housing 28 using jacking screws M10.
– Knock grooved ball bearing 29 off the cover 27 by means of a copper mandrel and a hammer.
30 29 29a

31
27 35 22 29 24 59 25
32

26

28

98.7325
31

32 36
33 30 34

Wärtsilä Switzerland Ltd 7 1998

7734–1/A1 Maintenance RTA48T

ELBA: Checking, Dismantling and Assembling

N
94753b – Screw down distance piece 94753 on the
94753a
intermediate shaft 30 with the screw
94753 94753a.
– Screw threaded rod 94753b into the gear
30 32 wheel 32 and tighten the nuts till the gear
wheel can be removed from the inter-
mediate shaft.
– Remove tool.
– Knock intermediate shaft off the housing
by means of a lead hammer.

Radabziehvorrichtung
WHEEL PULLER

– After removing of the key to the intermediate

wheel, the spherical roller bearing 34 and the
gear wheel 33 are withdrawn from the inter-
mediate shaft 30, using a wheel puller as
shown in Fig. ’O’. 31
34
30
33

P Dismantling of the driving gear wheel

40 41 from the electric motor:
– Loosen screws 37 and remove
them together with the disc 38.
94755 – Screw both set screws 94755 into
the driving gear wheel 40 till the stop
37 at the housing of the electric motor.
38
– Tighten the jacking screws cross-
wise and equally till the driving gear
wheel can be removed from the
electric motor shaft.

98.7326

39a 39

1998 8 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 7734–1/A1

ELBA: Checking, Dismantling and Assembling

Assembling of the ELBA

Remark The threads of the screwed connections which are locked with LOCTITE must be clean and free
of oil and grease!
Heating of the spherical roller bearing and of the gear wheel can be carried out on a special heat-
ing plate, in an oil bath, or in a furnace.

Assembly of the driving gear wheel:

– Clean the motor shaft 41 and check it for damages.
– Place the key in the motor shaft.
– Slightly grease the motor shaft with MOLYKOTE.
– Push the distance sleeve 39a over the motor shaft till the stop (Fig. ‘Q’). (It should be possible to fit it without any
big effort, otherwise remachine the motor shaft and the key with a smooth emery paper.)

Q 39a 40 94754 – Align the keyway of the driving gear wheel 40

with the key on the motor shaft, and slide the
driving gear wheel not far onto the motor
shaft.
– Place the bush 94754 and screw the set
screw 94755 with the screwed-on nut in the
motor shaft 41.
– Screw on the nut until the driving gear wheel
40 stops at the distance sleeve 39a.

41 94755

R X
– Remove the tool.
– Fit the distance sleeve 39 and the disc 38 to-
gether with the screw 37.
40
39 – Tighten the screw 37 with a 170 Nm torque by
means of a torque wrench.
38
37 – Measure the reference dimension ‘X’ (nomi-
nal size 59.5"
0.5 mm), and correct if neces-
sary.
– If the reference dimension is right, remove the
screw 37 to apply LOCTITE No. 262 on its
thread.
98.7327
39a – Screw down screw 37 again and tighten it with
a torque of 170 Nm.

Wärtsilä Switzerland Ltd 9 1998

7734–1/A1 Maintenance RTA48T

ELBA: Checking, Dismantling and Assembling

Completing the intermediate shaft:

33 – Carry the gear wheel 33 to a temperature of 200 °C.

– According to Fig. ‘S’ place the gear wheel on the sleeve
94756, and slide the lubricated intermediate shaft 30 on
the gear wheel until it stops. (It should normally be pos-
30
sible to do it without any effort, possibly with a light blow
from a lead hammer.)

94756

30
– Let the intermediate shaft 30 cool down and lubricate it.
– Carry the spherical roller bearing 34 to a temperature of 94757
200 °C, then push it over the intermediate shaft 30 till
34
the stop (see Fig. ‘T’). (Possibly blow as far as the stop
by means of sleeve 94757 and hammer.)
– Remove sleeve 94757 and place the key in the inter- 33
mediate shaft.

20
Completing the balancer weights:
– Clean the shaft 20 and check it for damages.
– Carry the spherical roller bearing 21 to a temperature of
200 °C. 21
– Turn the shaft in the upright position, lubricate it, then
slide the spherical roller bearing on the shaft until it
stops.

98.7328

1998 10 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 7734–1/A1

ELBA: Checking, Dismantling and Assembling

21a 94752b
V
– Clean the bearing seats in balancer
weights 16a(b) and check them for
damages.
– Lubricate the bearing seat con-
cerned.
– Press the spherical roller bearing
21 into the balancer weight by
means of bush 94750, threaded
rod 94752a, thrust bearing 94752b,
disc 94751, and nuts, until it stops. 94750 94751 94752a
Be careful to select the right fitting
side! 16a(b)

W
42 20
– Fasten the bush 94758 to the shaft 20 with screws
94758a.
– Important! Clean the distance sleeve 42 and
check if both oil bores ‘OB’ are not clogged.
– Lubricate the distance sleeve and push it over the
shaft until it stops.
94758a 94758 21 ’OB’

– Screw the threaded rod 94752a in X 20 94750 94752b

shaft 20.
– Introduce the shaft which has been
pre-assembled as shown in Fig. ‘W’
into the balancer weight, using the
crane and the screwed-in threaded
rod.
– Place bush 94750 and thrust bear-
ing 94752b, and press in the shaft
with the nut until the spherical roller
bearing 21 stops in the balancer
94758 21 16a(b) 94752a
weight.
98.7329

Wärtsilä Switzerland Ltd 11 1998

7734–1/A1 Maintenance RTA48T

ELBA: Checking, Dismantling and Assembling

Y TOP

18
– Lubricate the spherical roller bearing
17 21(a).
– Check gear wheel 18 for damages.
– Apply MOLYKOTE to the threads of the
screws 17.
– With screws 17 fasten the gear wheel to
the balancer weight, the TOP mark
pointing upwards.
– Tighten the screws gradually and cross-
wise up to an angle of twist of 45°.
– Fit the flat bar 43 with the screws 44.
16a(b) The screws 44 must be locked with
LOCTITE No. 262.

98.7330

44 43

1998 12 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 7734–1/A1

ELBA: Checking, Dismantling and Assembling

Assembling of the compensating shafts (completed balancer weights):

– Put the housing 28 on two pedestals ‘BK’ as shown in Fig. ‘E’.
– Clean the housing and blow through the spray nozzles SD1–SD4 for cleaning them (Fig. ‘A’).
– Screw an eye bolt M24 in the bottom balancer weight 16b and hang it on the crane. Be careful that the balancer
weight is suspended horizontally!
– Clean all seating surfaces of shaft 20, and apply a liquid jointing agent to the sealing face ‘DF’ (Fig. ‘Z’, view I).
– Lower the balancer weight 16b into the housing 28, taking care that the position of the tapped holes in the flange
of shaft 20 coincides with those in the connection of the oil pipes (Fig. ‘Z’, view II)!
– Grease the seating surfaces of the sleeves 15 with MOLYKOTE. Apply LOCTITE No. 262 to the screws 14 and
screw them down together with the sleeves 15.
Tighten the screws gradually and crosswise up to an angle of twist of 30° (200 Nm).
– Turn the balancer weight “downwards” until the centre of shaft 20 and the centre of the tapped hole for eye bolt
M24 are lined up with the centre line of the housing 28. This can be checked with a straightedge as shown in
Fig. ‘A1’ on the following page.
– Fit the balancer weight 16a analogously to lower balancer weight 16b. Remove the eye bolt.
16b 16a 19 28
Z

98.7331

I II

II

20
’DF’ 20
15

14

Wärtsilä Switzerland Ltd 13 1998

7734–1/A1 Maintenance RTA48T

ELBA: Checking, Dismantling and Assembling

Lineal
A1 STRAIGHTEDGE

– Check with a straightedge if the centres

28 of the tapped holes for the eye bolts M24
in the balancer weights and of the shafts
16a 20 are lined up with the centre line (Fig.
‘A1’).
– Turn the balancer weights completely,
checking if they turn without any hin-
20 drance.

16b

Fitting of the pre-assembled intermediate shaft:

– If the oil baffles 35 in cover 27 and the housing 28 have been removed (Fig. ‘M’), they must now be screwed
down. The screws 36 are to be locked with LOCTITE No. 262.
– Lubricate the intermediate shaft 30, which has been pre-assembled in Fig. ‘T’.
– Push the distance plates 94759 between the gear wheel 33 and the spherical roller bearing 34, and place two
distance plates 94760 between gear wheel 33 and housing 28 (Fig. ‘B1’).
– Working from the balancer weight space and with light blows from a lead hammer, fit the intermediate shaft 30
in the housing 28 (Fig. ‘B1’).
– Remove distance plates 94759.

B1
94760 33 30

94760 36 28

98.7332

18 35 34 94759

1998 14 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 7734–1/A1

ELBA: Checking, Dismantling and Assembling

– Apply a large amount of MOLYKOTE to distance sleeve 31, then slide it on the intermediate shaft (Fig. ‘C1’).
– Clean the gear wheel 32, check it for damages, and grease the bore with MOLYKOTE (Fig. ‘C1’).
– Align gear wheel 32 and keyway with key 46, and push it not far over the intermediate shaft 30 (Fig. ‘C1’).
– Place bush 94761 on gear wheel 32, and screw the set screw 94755 with the screwed-on nut in the intermediate
shaft (Fig. ‘C1’).
– Screw on the nut until the gear wheel stops at the distance sleeve 31 (Fig. ‘D1’).

C1

94760

31 46

30 28
94761
32
94755

– Apply a liquid jointing agent to the seating surface of cover 27, then fasten the cover to the housing 28 with
screws 26 (Fig. ‘D1’).
– Remove set screw 94755 and bush 94761.

D1
94760

32

94761 98.7333
26 27
94755

Wärtsilä Switzerland Ltd 15 1998

7734–1/A1 Maintenance RTA48T

ELBA: Checking, Dismantling and Assembling

– Grease the distance sleeve 31 with MOLYKOTE and push it over the intermediate shaft 30.
– Lubricate the grooved ball bearing 29 and press it onto the intermediate shaft by means of bush 94761 and set
screw 94755, until the circlip 29a stops at the cover 27 (Fig. ‘E1’).

E1

94760 28

29a
27 31 29 94761
94755

– Remove the set screw, the bush, and both distance plates 94760.
– Apply LOCTITE No. 262 to the screw 24 and fit it on the intermediate shaft together with disc 25 (Fig. ‘F1’).
– Tighten the screw 24 with a torque of 70 Nm.
– Clean the joint faces for cover 59 and apply a liquid jointing agent (Fig. ‘F1’).
– Apply LOCTITE No. 222 to the screws 22, then fit them together with cover 59 and tighten them (Fig. ‘F1’). Take
care that, when fitting the cover, the keyway opposite the spring dowel pin is pointing vertically downwards (with
ELBA fitted).

F1

98.7334

22 24 25 59 49

1998 16 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 7734–1/A1

ELBA: Checking, Dismantling and Assembling

– Clean the bores in cover 8 for the annular springs (Fig. ‘F’) and check them for damages.
– Clean the joint faces for cover 8 and apply a liquid jointing agent.
– Place the distance bushes 19.
– Place cover 8 on housing 28 so that the screw plug 47 (Fig. ‘G1’) for the speed transmitter ‘DG’ is at the bottom
(Fig. ‘A’, section III–III).
– Place the taper pins 13 (Fig. ‘B’).
– Tighten the cover with screws 7 (Fig. ‘G1’).

G1 47 8 19 7

28

48

98.7335

– Put together the annular spring packets according to Fig. ‘F’, lubricate them, and place them in the cover.
– Lubricate the screws 5 and fit them together with covers 6 (Fig. ‘E’).
– Tighten the screws 5 crosswise in two steps (40 Nm and 65 Nm). Tighten with torque 65 Nm crosswise until it is
certain that all screws are tightened with 65 Nm.

Checking of the backlash:

– Remove cover 23 (Fig. ‘A’) and screw plug 48 with copper sealing ring (Fig. ‘G1’).
– Using a feeler gauge measure the backlash every 90° at positions 1 and 3 (see Clearance Table, group
0330–1), while moving the gear wheels by turning the gear wheel 32 (Fig. ‘M’).
– After measuring, screw down the screw plug 48 in the housing together with the copper sealing ring.

Wärtsilä Switzerland Ltd 17 1998

7734–1/A1 Maintenance RTA48T

ELBA: Checking, Dismantling and Assembling

Mounting of the electric motor:

– Clean the seating surfaces of the electric motor flange and of the housing 28, then apply a liquid jointing agent.
– Screw down the electric motor on housing 28 with screws 3 and 4 (Fig. ‘C’).

Checking the backlash at the driving gear wheel:

– Loosen screws 50 and remove them together with cover 51.
– Loosen screw plug 49 and remove it together with the copper sealing ring.
– By means of an open-end wrench turn the screw 37 at the driving gear wheel while measuring every 90° the
backlash between driving gear wheel 40 and gear wheel 32 (see Clearance Table, group 0330–1).
– After checking turn the balancer weights 16a(b) to B.D.C., loosen and remove the screw plugs 55 (Fig. ‘A’), and
screw down the screws 94762 (lock for transport) instead (Fig. ‘B’).
– Clean the joint faces for cover 51, then apply a liquid jointing agent.
– Apply LOCTITE No. 222 to screws 50, then fit them together with cover 51 and tighten them (Fig. ‘H1’).
– Fit the screw plug 49 together with the copper sealing ring and tighten it.

H1

98.7336

32 49 50 37 51 40

1998 18 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 7734–1/A1

ELBA: Checking, Dismantling and Assembling

Mounting the ELBA on the engine

– Hang the ELBA on the crane on its suspension straps ’AL’ (Fig. ‘A’).
– Clean the joint faces of the oil pipes; then fit them together with the new joints 45, tighten them with screws 12
and finally secure them with the necessary lock washers 11 (Fig. ‘D’).
– Clean the seating surfaces of ELBA and engine column, then apply the jointing agent LOCTITE No. 640.
– Position the ELBA on the engine column using the crane.
– Place the taper pins 52 (Fig. ‘A’).
– Apply MOLYKOTE to the threads of the screws 53, then fit and tighten them together with sleeves 54 (Fig. ‘A’),
up to an angle of twist of 85°.
– Secure the taper pins by means of flat bars 57 and screws 56 (Fig. ‘A’).
– Remove the screws 94762 (lock for transport resp.) (Fig. ‘B’) and screw in the screw plugs 55 (Fig. ‘A’) together
with the copper sealing rings instead, then tighten them.
– Connect all oil pipes, control cables, and electric cables.
– Activate the oil pump and check through the opening for cover 23 if oil is coming out at the spray nozzles SD2
and SD4 (Fig. ‘A’).
– Fit cover 23 together with the joint and screw it down.
– Check the distance 2 mm between the speed transmitter ‘DG’ and the flat bar 43 (Fig. ‘A’).
– Disconnect the crane and reassemble the platform.

Remark Should the engine be operated with dismantled ELBA, the oil supply before oil filter ’OF’ and the
opening of the oil drain ’OA’ at the end casing 58 (Fig. ’A’) must be closed!

Wärtsilä Switzerland Ltd 19 u 1998

This page is intentionally left blank
 RTA48T
Betrieb Group8

Piping Group 8

 Hydraulic Piping for the Exhaust Valve Drive

– Removing and Fitting the Pipes and Re-facing the Sealing Faces . . . . . . . . . . . . . . . . . . . . . . . 8460–1/A1

 Fuel Pressure Piping

– Fitting and Dismantling, Re-conditioning the Sealing Faces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8733–1/A1

Wärtsilä Switzerland Ltd 1 RTA48T / MM / 1998

This page is intentionally left blank
 RTA48T
Maintenance 8460–1/A1

Hydraulic Piping for the Exhaust Valve Drive

Removing and Fitting the Pipes and Re-facing the Sealing Faces

Tools: Key to Illustrations:

1 Milling/grinding device 94834 1(a, b) Sealing ring 15 Shoulder
1 Grease gun 2(a) HP pipe section 16 Grease nipple
Allen wrench 3 Pipe clip 17 Bearing bush
Hoist/rope 4(a) Casing 18 Simmer ring
Carborundum grinding paste 5(a) Casing 19 Cover
(No. 200 and 500) 6(a) Screws 20 Screw
7 Screws 21 Screw
8 Cladding 22 Actuator housing
9 O-rings
10 Spindle OA Oil drain
11 Grinding head OE Opening
12 Milling cutter S Sealing face
13 Special nut ST Rod ∅ 15 mm
14 Grip bar X Clearance about 3 mm

Removal of hydraulic piping

Please observe the following:
 The sealing faces ’S’ of the pipe ends must not be damaged under any circumstances.
 If any of the HP pipe sections, 2 or 2a, is to be removed shortly after switching off the lubricating pump, then
loosen screws 6a and 7 as well as pipe clip 3 in order to drain the HP pipe. Afterwards, insert two rods ’ST’ into
the lateral bores of the casing 5 as shown in Fig. ’C’, and then, according to Fig. ’A’, lift off HP pipe section 2a a bit
from sealing ring 1b.
Afterwards, for removing either the hydraulic actuator or the HP pipe section 2a, screw back the casing 4a, and
turn HP pipe section 2a aside.
 For removing HP pipe section 2 first loosen
the screws 7, remove the screws 6, screw A 6
back casing 4, then withdraw the HP pipe sec-
tion from sealing ring 1 in axial direction (Fig.
’B’, ’C’), and turn it aside.
 Take care that no dirt enters the pipes which
have been removed and that the pipe ends
are not damaged. 8

2 7

ST
3

2a
6a
8
8
2a
4a
6a
1b

22
OA
98.7786

Wärtsilä Switzerland Ltd 1 3.00

8460–1/A1 Maintenance RTA48T

Removing and Fitting the Pipes and Re-facing the Sealing Faces

Fitting hydraulic pipes

The following points must be noted:
 Check carefully that the inside of the tubes and the sealing faces ’S’ at the pipe ends as well as the landing faces
of the sealing rings 1(a, b) are clean and undamaged.
 The joining up of the pipes to their connectors must be done axially i.e. the pipes may not be joined sideways
so that any damage to the sealing faces ’S’ is prevented.
 The casing 4 or 4a (Fig. ’B’, ’D’) shall be screwed to the pressure pipe 2 or 2a in such a way that after tightening
screws 6 and 6a the clearance ’X’ amounts to about 3 mm.
 The two casings 5 and 5a of the connections (Fig. ’C’) must be screwed onto the hydraulic pipes during assem-
bling in such a way that each protrudes the sealing ring 1a by a little less than half. After tightening the screws 7
together make sure that a clearance ’X’ of about 3 mm exists in the separation face of the two casings 5 and 5a.
Should this not be the case, loosen the screws 7 again and remove them. Then turn both casings 5 and 5a back
by the same amount, till the above clearance ’X’ exists after re-tightening the screws 7.

9
B 6 4

S
1
x 8

C
8
7 S 2
ST 9 C
1a
ST
x

5
3
S
3 5a
21
2a
8

D S
6a
4a
9 1b
98.7789
x

3.00 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 8460–1/A1

Removing and Fitting the Pipes and Re-facing the Sealing Faces

Re-facing the sealing faces ’S’

Should it become necessary to recondition the sealing faces ’S’ (Fig. ’B’, ’C’ or ’D’), then utilize tool 94834 (see Fig.
’E’ and ’F’).
Unscrew casings 4, 4a, 5, 5a of the respective pressure pipes and push cladding 8 back until the pressure pipe can
be held in the vice and tool 94834 can be screwed on.
Tool 94834 shall bind with its shoulder 15 (Fig. ’E’ and ’F’) fast against the pressure pipe.
To prevent dirt from entering the piping during the grinding or milling, plug the bore with a piece of rag.
After grinding or milling rinse the pressure piping and blow it through with compressed air.

Grinding the sealing faces:

Should the spherical sealing faces be only slightly rough or only very lightly damaged re-grinding can be done.
For this use tool 94834 assembled according to Fig. ’E’ with grinding head 11, however, without cover 19 (Fig. ’F’).
While turning the spindle 10 slowly by hand with the tap wrench, apply from time to time some CARBORUNDUM
grinding paste through the opening ’OE’. During this grinding operation withdraw the grinding head 11 axially by the
spindle 10 in short intervals to unload the surface to be ground. For roughing, paste No. 200 is used, and for finishing
paste No. 500.

Remark Use the tool in such a position that dropping grinding paste can fall through the opening ’OE’
without assistance.
Before each use of the tool press some grease through the grease nipples 16.
After grinding rinse the pressure piping and blow it through with compressed air.

13 14 18 15 2(a)

98.7791

10 16 17 16 11 OE

Wärtsilä Switzerland Ltd 3 3.00

8460–1/A1 Maintenance RTA48T

Removing and Fitting the Pipes and Re-facing the Sealing Faces

Milling of sealing faces:

In case of bad damages the sealing faces of the pipe ends must be re-faced by milling them slightly with the tool
assembled according to Fig. ’F’. For that fit milling cutter 12 and screw cover 19 onto special nut 13.
Turn spindle 10 slowly by hand, using a tap wrench and applying drilling oil through the opening ’OE’ to the sealing
face. The pressure should be very moderate and is to be effected by accordingly turning special nut 13 with the aid of
grip bar 14.

Remark Use the tool in such a position that dropping milling chips can fall through the opening ’OE’ with-
out assistance.
Before each use of the tool press some grease through the grease nipples 16.
After milling rinse the pressure piping and blow it through with compressed air.

20 13 14 18 15 2(a)

98.7790

10 19 16 17 16 12 OE

3.00 4 u Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 8733–1/A1

Fuel Pressure Piping

Fitting and Dismantling, Re-conditioning the Sealing Faces

Tools: Key to Illustrations:

Re-grinding device 94872(a) 1 Cylinder cover 10 Cap nut
Torque wrench 2 Injection valve 11 Cap nut
3 Metal hose 12 Casing
4 Fuel distributor 13 Casing
5 Fuel pressure pipe 14(a) Bush for 94872(a)
5a Claw 15(a) Lapping body for 94872(a)
6 Fuel pressure pipe 16 Priming valve
6a Claw 17 Pipe bracket
7 Connecting piece
7a Connecting piece
8 Cap nut DF Metallic sealing face
9 Cap nut G Collar

After dismantling the fuel pressure piping check the condition of the sealing faces ’DF’ and if necessary re-condition
them by lapping.

Dismantling of the fuel pressure piping to the injection valve (Fig. ’A’)
– Remove front halves of the casings 12 and 13 for the fuel distributor 4.
– Completely loosen cap nut 10 of metal hose 3.
– Unscrew pipe bracket 17.
– Loosen cap nut 8 on the injection valve as well as cap nut 9 on the fuel distributor (section II–II), whereby it may
be necessary to prevent connecting pieces 7 and 7a from turning, with a spanner.
– Remove fuel pressure pipe including metal hose.

A II-II
3
1 5

10
8

5a

2
II
7a
17 DF
2

II 1

99.7719

I I
12

Wärtsilä Switzerland Ltd 1 3.00

8733–1/A1 Maintenance RTA48T

Fitting and Dismantling, Re-conditioning the Sealing Faces

Fitting
Before fitting the fuel pressure pipe check whether its claws 5a or 6a are screwed on properly, i.e. collar ’G’ of the
claw must be flush with the threaded end of the fuel pressure pipe.

Adjusting the claws:

All claws should jam slightly in the thread of the pressure pipe and should just not allow to be turned by hand (without
spanner). If necessary slightly open collar ’G’ on the claw with a chisel, in order to obtain the necessary clamping
effect.

Remark All claws are provided with left-hand threads!

The claw can be adjusted to the correct position by means of an open end wrench, whereby the corresponding cap
nuts must be pushed back.

Tightening the cap nut:

– Oil the threads of the cap nuts. Never use MOLYKOTE!
– Tighten the cap nuts 8 and 9 to the fuel pressure pipe 5 with a torque of 140 Nm.
Tighten the cap nut 11 to the fuel pressure pipe 6 with a torque of 180 Nm.

I-I
3
B
5
12

5 9
13
5a
5a
9 G
DF

16 7
7

11

6a
6
99.7720

3.00 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 8733–1/A1

Fitting and Dismantling, Re-conditioning the Sealing Faces

Re-conditioning the sealing faces ’DF’ on the fuel pressure piping

The following points must be noted:
 Completely unscrew the respective cap nut .
 To prevent any traces of carborundum paste from entering the bores of the fuel pressure piping, plug the same
with a piece of rag.
 For the sealing faces ’DF’ on the fuel pressure pipes 5 with a radius of 25 mm, use re-grinding device 94872
whereby the bush 14 has to be screwed on lapping body 15 and pushed over the claw 5a (Fig. ’C’).
 For the sealing faces ’DF’ on the fuel pressure pipes 6 with a radius of 35 mm, use re-grinding device 94872a
whereby the bush 14a has to be screwed on lapping body 15a and pushed over the claw 6a (Fig. ’D’).
 The sealing faces have to be lapped first with carborundum paste grain No. 200, and subsequently for the final
lapping apply carborundum paste grain No. 500.
 After the lapping process rinse fuel pressure piping with clean diesel oil, then thoroughly blow through with com-
pressed air.

C D

15 15a
94872 94872a
14 14a

5a
6a
5

6
98.7800

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 RTA48T
Betrieb Group9

Tools Group 9

 Tools
– Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403–1/A1

 Hydraulic Jacks and Pumps

– Arrangement and Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403–2/A1

 Hydraulic Pre-Tensioning Jacks

– Storing, Servicing and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403–3/A1
– General Application Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403–4/A1

 Tool List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9403–5/A1

– Standard Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1–36
– Recommended Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 37–39
– Special Tools Obtainable on Loan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 40

Wärtsilä Switzerland Ltd 1 RTA48T / MM / 1998

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 RTA48T
Maintenance 9403–1/A1

Tools
Explanation

The tools required for erection and maintenance of the engine are divided into three groups as per the following
’Tool List’:
 Standard tools
 Recommended special tools
 Special tools available on loan
Standard tools are tools and devices required for normal maintenance work on the engine. In this respect take into
consideration that, depending on the design execution of the engine, certain tools and devices which are mentioned
in the above sheets are not required for specific maintenance work, and are therefore not part of the engine tools
supply.
Recommended special tools are tools and devices which allow certain maintenance work to be done with more
ease, and in a shorter time, than with the standard tools.
These tools can be ordered separately either with the engine or at a later date.
Special tools available on loan are such tools and devices which are loaned for transportation and for erection of the
engine. They are to be returned to the engine manufacturer after completion of engine erection.
A separate set of tools is issued for certain components from sub-suppliers, which should also be stored separately
from the engine tools.
When ordering additional tools or replacements, the tool No. as well as the tool description including engine type
must be indicated (see tool list).
Detailed instructions on the arrangement and application, storing, servicing and maintenance of the hydraulic pre-
tensioning jacks are given in the groups 9403–2 to 9403–4.
When oil must be added to the hydraulic pumps, the specification regarding oil quality issued by the pump manufac-
turers must be followed. Utilize generally an engine lub. oil having viscosities SAE 30 to SAE 40.
A cylinder lubricating oil also can be used in exceptional cases.

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 RTA48T
Maintenance 9403–2/A1

Hydraulic Jacks and Pumps

Arrangement and Application

13 12 11 8 9 12 11 13

3 4 15 12 11 13 10 14

F
18 17 16
2

7 13
16 17 18 20 12 18 17 16
11 E
10
D D

1 1
17 18 13 5 6 19 20
18
B B
A

C C

98.7740

A= Tensioning / loosening of tie rods, waisted studs to valve cages, connecting rod top end and bottom end
bearings, piston rod screwing, waisted studs to camshaft bearings, and waisted studs to camshaft bearing
housing.
B= Tensioning / loosening of waisted studs to main bearing.
C= Tensioning / loosening of waisted studs to cylinder cover.
D= Removing and fitting of main bearing shells, as well as jacking out of cylinder liners.
E= Tensioning / loosening of foundation bolts and of engine stays.
F= Tightening / loosening of split gear wheel on the crankshaft
(only to be applied when replacing a gear wheel on the crankshaft).
Arrangement of the hydraulic jacking tools for work
on the camshaft see groups 4203–3 and 4203–4

Wärtsilä Switzerland Ltd 1 3.00

9403–2/A1 Maintenance RTA48T

Hydraulic Jacks and Pumps: Arrangement and Application

Key to the arrangement of the hydraulic jacks

and pumps see also groups 4203–3 and 4203–4

Tool

1 Hydr. jack 230 kN (23 t) . . . . . . . . . . . . . . . . 94936

2 Hydr. jack 44.8 kN (4.48 t) . . . . . . . . . . . . . . 94412d . . . . . . ENERPAC RC-57

3 HP oil pump 2’500 bar . . . . . . . . . . . . . . . . . 94931

4 Hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . 94942 . . . . . . . HASKEL HF-B300

Hand oil pump SKF 226400 . . . . . . . . . . . . 94931a

(see group 4203–4)

5 Connection piece . . . . . . . . . . . . . . . . . . . . . . 94934a

6 Pressure gauge (0–1’600 bar) . . . . . . . . . . 94932a

7 Closing piece

8 Pressure gaue (0–2’500 bar) . . . . . . . . . . . . 94932

9 Hydr. distributor

10 Adapter

11 Closing valve

12 Coupling socket

13 Adapter

14 High pressure hose max. 2’700 bar . . . . . . 94935

15 Adapter

16 Adapter

17 Nipple

18 Coupling socket

19 Safety valve 1’100 bar

20 High pressure hose max. 1’760 bar . . . . . . 94935a

3.00 2 u Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 9403–3/A1

Hydraulic Pre-tensioning Jacks

Storing, Servicing and Maintenance

The hydraulic pre-tensioning jacks forming part of the engine tool kit are to be stored carefully in their tool boxes
when not in use, in a clean place, where they are protected from damage (after greasing them and closing the con-
nections with dust plugs). After lengthy storage or frequent use, the O-rings may become hard, thus not sealing well
any longer. Therefore, we recommend to always keep in stock a sufficient number of new O-rings, supporting rings,
piston seal rings and rod seal rings of the specified quality and dimensions, in order to ensure efficient work at any
time. When fitting new supporting rings, piston seal rings and rod seal rings proceed with extreme care, to
avoid their damage, over expansion or deformation; do not use any sharp edged utensils for assistance.
Heat unslit supporting and sealing rings which are used as piston seal rings in boiling water before fitting
them.
Tool 94114 Pre-tensioning jacks for waisted studs to main bearing
Tool 94145 Pre-tensioning jacks for foundation bolts and engine stays
Tool 94180 Pre-tensioning jacks for tie rod
Tool 94252 Pre-tensioning jacks for waisted studs to exhaust valve
Tool 94314 Pre-tensioning jacks for waisted studs to lower connecting rod bearing
Tool 94315 Pre-tensioning jacks for waisted studs to upper connecting rod bearing and camshaft bearing
housing
Tool 94340 Pre-tensioning jacks for waisted studs to piston rod screw connection
Tool 94415 Pre-tensioning jacks for waisted studs to camshaft bearing

1 Piston 8 Supporting ring

2 Cylinder 9 O-ring Sealing ring
3 Vent screw 10 Hexagon socket head cap screw
4 Adapter 11 Pin
5 Connection piece
6 Supporting ring
Sealing ring
7 O-ring

10
3
4
11
6
7

2 9
8

003.902/96

Wärtsilä Switzerland Ltd 1 3.00

9403–3/A1 Maintenance RTA48T

Hydraulic Pre-tensioning Jacks: Storing, Servicing and Maintenance

Tool 94215a Pre-tensioning jack for waisted studs to cylinder cover

1 Piston 8 Supporting ring Sealing ring

2 Cylinder 9 O-ring
3 Vent screw 10 Nut
4 Adapter 11 Pin
5 Connection piece
6 Supporting ring
Sealing ring
7 O-ring

5 10

3
4 11
6
7
1

2
9
8

96.7659

3.00 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 9403–3/A1

Hydraulic Pre-tensioning Jacks: Storing, Servicing and Maintenance

Tool 94424 Hydr. jacking tool to camshaft

1 Piston supporting plate 8 Sealing ring

Piston seal ring
2 Piston 9 O-ring
3 Ring piece 10 Hexagon socket head cap screw
4 Adapter 11 Ball
5 Connection piece 12 Screw
6 Sealing ring 13 Screw plug
Rod seal ring
7 O-ring

11 10

12
I-I

1 3
2

I 13

6
I 9
8 96.7516

7
5 4

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 RTA48T
Maintenance 9403–4/A1

Hydraulic Pre-tensioning Jacks

General Application Instructions

For distinct screwed connections different designs and sizes of waisted bolts or waisted studs (bolts/studs) are
used, which are pretensioned by hydraulic pre-tensioning jacks. The bolts/studs have threads which extend over
the nut. The pre-tensioning jack is mounted on this thread end. For each thread of the various bolts/studs a suitable
pre-tensioning jack is supplied. Since the bolts/studs are pretensioned with the pre-tensioning jacks, the nuts are
threaded-on only manually until seated.
Prior to the mounting of the pre-tensioning jacks, depending on the design execution, their inside threads or else the
inside thread of the round nut as well as the thread of the waisted bolts/studs which are to be tightened/loosened
must be carefully cleaned. The thread must be undamaged and freely working. It has to be smeared with MOLY-
KOTE grease.

Working procedure for loosening

– Thread the pre-tensioning jack by hand onto the extending thread end of the bolts/studs to be loosened until it is
landed on the part and the piston on the cylinder without any clearance. On pre-tensioning jacks with round nuts
these have to be slightly tightened.
– Then, depending on the design of the pre-tensioning jack, turn it or the round nut back by about ½ to 1½ turns.
The clearance thus obtained between pre-tensioning jack and landing face of the part or piston and cylinder is
essential, before starting the pre-tensioning of the bolts/studs. It enables the loosening of the nut till total relax-
ation of the bolts/studs in one single working sequence.
– Connect the HP oil pump (hydraulic unit) and pre-tensioning jack with the HP hoses.
– If provided open the vent screw on top of the pre-tensioning jack a little.
– Shut relief valve at the HP oil pump and actuate it. As soon as oil flows out bubble-free close the vent screw at
the pre-tensioning jack. When tensioning attention should be paid that the pins of the pre-tensioning jacks pro-
trude slightly above the upper edges of the pistons (stroke limitation!).
– Raise the pressure about 20 bar beyond the tightening value (see group 0352–1). The nut is now slack, loosen
it with a round bar, while keeping the pressure constant.
– Release the pressure at the HP oil pump and remove the pre-tensioning jack.

Working procedure for tensioning

– Use a felt pen and mark the positions of the nuts, which already have been firmly seated against their landings
on the part. The marks are later a reference for judging the correct pre-tensioning.
– Thread on by hand the pre-tensioning jack onto the protruding thread end of the bolts/studs until it is fully seated
without any clearance between the jack and the part or the piston is seated on the cylinder without any clear-
ance. On a pre-tensioning jack with round nut tighten it lightly.
– It may be necessary to turn the jack back a little to gain easy access through the slot in the jack cylinder for
manipulating a round bar to tighten the nut.
– Connect HP oil pump (hydraulic unit) and pre-tensioning jack by the HP hoses.
– If provided open the vent screw on top of the pre-tensioning jack a little.
– Shut relief valve at the HP oil pump and actuate it. As soon as oil flows out bubble-free close the vent screw at
the pre-tensioning jack. When tensioning attention should be paid that the pins of the pre-tensioning jacks pro-
trude slightly above the upper edges of the pistons (stroke limitation!).
– Raise the pressure with the HP oil pump, in accordance with the indication on the tightening of important
screwed connections (see group 0352–1).
– Maintain the oil pressure constant at the adjusted value and use the round bar to tighten the nut onto its seating
surface until firmly seated. Check with the feeler gauge whether actually no clearance remains between nut and
seating.
– Release the pressure at the HP oil pump and remove the pre-tensioning jacks.
– Check with the referenced markings, whether all the nuts of a screwed connection have been turned by the
same value as mentioned in group 0352–1. If big differences are noted their causes have to be investigated and
the tensioning procedure must be repeated.
For operation and maintenance of the HP oil pump we also refer to the manufacturer’s documentation.

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 RTA48T
Maintenance 9403–5/A1

Tool List
Standard Tools

Open end ring spanner

2 Pieces . . . . AF 36
2 Pieces . . . . AF 41
2 Pieces . . . . AF 46
2 Pieces . . . . AF 50 93.7461

2 Pieces . . . . AF 55
2 Pieces . . . . AF 60

Open end spanner

1 Piece . . . . . AF 65
1 Piece . . . . . AF 70
1 Piece . . . . . AF 75
1 Piece . . . . . AF 80 93.7462
1 Piece . . . . . AF 85
1 Piece . . . . . AF 105

Open end impact spanner

1 Piece . . . . . AF 105

93.7463

Wärtsilä Switzerland Ltd 1 1998

9403–5/A1 Maintenance RTA48T

Standard Tools

Impact ring spanner

1 Piece . . . . . AF 27
1 Piece . . . . . AF 30
1 Piece . . . . . AF 32
1 Piece . . . . . AF 36
1 Piece . . . . . AF 41
1 Piece . . . . . AF 46
1 Piece . . . . . AF 50 93.7464

1 Piece . . . . . AF 55
1 Piece . . . . . AF 60
1 Piece . . . . . AF 65
1 Piece . . . . . AF 70
1 Piece . . . . . AF 75
1 Piece . . . . . AF 85
1 Piece . . . . . AF 95
1 Piece . . . . . AF 105

Allen wrench
1 Piece . . . . . AF 5
1 Piece . . . . . AF 6
1 Piece . . . . . AF 8
1 Piece . . . . . AF 10
93.7465
1 Piece . . . . . AF 12
1 Piece . . . . . AF 14
1 Piece . . . . . AF 17
1 Piece . . . . . AF 19
1 Piece . . . . . AF 22
1 Piece . . . . . AF 24
1 Piece . . . . . AF 27

Right angle screwdriver

1 Piece . . . . . b = 10 mm
1 Piece . . . . . b = 12 mm
1 Piece . . . . . b = 25 mm

93.7466

1998 2 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 9403–5/A1

Standard Tools

3 Rods
for pre-tensioning jacks
(each diameter)
Ø 7 mm
Ø 7.5 mm
Ø 9 mm
Ø 15 mm

93.7467

Eye bolt
6 PiecesM12 x 125

93.7468

Hexagon plug spanner

1 Piece . . . . . AF 11
1 Piece . . . . . AF 12
1 Piece . . . . . AF 14
1 Piece . . . . . AF 17
1 Piece . . . . . AF 19
1 Piece . . . . . AF 22
1 Piece . . . . . AF 27 93.7469

Wärtsilä Switzerland Ltd 3 1998

9403–5/A1 Maintenance RTA48T

Standard Tools

Snap ring tongs

1 Piece . . . . . Type C8
1 Piece . . . . . Type C19
1 Piece . . . . . Type C40

93.7470

1 Piece . . . . . Type A10

1 Piece . . . . . Type A19
1 Piece . . . . . Type A40

93.7471

Eye bolt
8 Pieces . . . . . . . . . . M10
8 Pieces . . . . . . . . . . M12
8 Pieces . . . . . . . . . . M16
8 Pieces . . . . . . . . . . M20
8 Pieces . . . . . . . . . . M24
8 Pieces . . . . . . . . . . M30
8 Pieces . . . . . . . . . . M36
8 Pieces . . . . . . . . . . M42
4 Pieces . . . . . . . . . . M48
93.7472

1998 4 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 9403–5/A1

Standard Tools

Grip screw
2 Pieces . . . . . . M4x150
2 Pieces . . . . . . M5x150
2 Pieces . . . . . . M6x150 93.7474
2 Pieces . . . . . . M8x150
2 Pieces . . . . . M10x150

Puller
for taper and cylindrical dowels and
pins
1 Piece . . . . . . . . . . . . M4
1 Piece . . . . . . . . . . . . M6
1 Piece . . . . . . . . . . . . M8
1 Piece . . . . . . . . . . . M10
1 Piece . . . . . . . . . . . M12
1 Piece . . . . . . . . . . . M16

93.7475

High pressure grease gun

for lubricating grease nipples on fuel
injection pump regulating linkage

93.7476

1 Torque wrench
with open end spanner inserts
99.7495
AF 36, 41, 50
Tightening range 140–620 Nm

Wärtsilä Switzerland Ltd 5 5.01

9403–5/A1 Maintenance RTA48T

Standard Tools

2 Torque wrench 3/8” and ½”

with extension and socket
93.7477
spanner 3/8” AF10

96.7614

1 Tool box
with socket wrench set ½”
(only supplied upon customer’s 93.7478
specific order)

Set hex head drivers ½”

(only supplied upon customer’s
specific order)
1 Piece . . . . . AF 4
1 Piece . . . . . AF 5
1 Piece . . . . . AF 6
1 Piece . . . . . AF 8 93.7479
1 Piece . . . . . AF 10
1 Piece . . . . . AF 12
1 Piece . . . . . AF 14
1 Piece . . . . . AF 17
1 Piece . . . . . AF 19
b d
c c f g
1 Testing device
for pneumatic elements
a Air pump
b Pressure gauge 0–4 bar
c Pressure gauge 0–6 bar
d Pressure gauge 0–16 bar
e HP hoses
f Setting tool
g Measuring connection M12x1
h Measuring connection M14x1

h a e 98.7122

1998 6 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 9403–5/A1

Standard Tools

94101 1 Inside micrometer

with case
(Measuring range 50–1010 mm) 93.7480

94101a 1 Extension
Length of 240 mm 93.7481

94107 1 Assembly template

00.7016
for positioning the locating dowel pins
in the main bearing shell X
X = 140 mm
X

94114 2 Pre-tensioning jacks

for tensioning the waisted studs
to the main bearing,
including a metal box
X = 110 mm

7056–03/F101168

94117 1 Wire rope

for removal of the main bearing cover 96.7484
X = 1500 mm X

94118 1 Device
for removal of the main bearing shell
X = 198 mm

93.7483

94119 2 Wire ropes

for removal of the main bearing shell 96.7484
X = 4000 mm X

Wärtsilä Switzerland Ltd 7 1998

9403–5/A1 Maintenance RTA48T

Standard Tools

94122 1 Feeler gauge

93.7485

94123 1 Special feeler gauge

for main bearing 93.7486
X = 625 mm
X

94124 1 Depth gauge

measuring range 250 mm

98.7543

X
94141 1 Support
for removal of the main bearing shells
X = 725 mm

7056–03/F101170

3.00 8 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 9403–5/A1

Standard Tools

94142 2 Working platforms

consisting of two grids each
X = 625 mm

7056–03/F101172b

94143 2 Working supports

X = 450–550 mm

X
009.323/01

94145 1 Pre-tensioning jack

for foundation bolts,
including a metal box
X = 128 mm

7056–03/F101168

94155 1 Turning-out device

with screws
for removal of thrust bearing pads
(with one-part gear wheel)
X = 147 mm

96.7521

94155a 1 Turning-out device

with screws
for removal of thrust bearing pads
(with two-part gear wheel)
X = 147 mm

96.7676

Wärtsilä Switzerland Ltd 9 7.03

9403–5/A1 Maintenance RTA48T

Standard Tools

94180 2 Hydraulic pre-tensioning jacks

for tie rods,
including a metal box
X = 246 mm

7056–03/F101168

94201 1 Device
for fitting & transporting a cylinder liner
consisting of:
94202
94202 1 Lifting gear
X = 230 mm
X

94202d 2 Distance plates 94202d

with screws M12x40 and nuts 013.765/06

94206 2 Suspension straps 94206

with 2 screws each 94207
X = 205 mm
X

94207 2 Special screws M30

96.7522
M12

94208 4 Suspension straps

for removal and fitting of the
X

antipolishing ring
X = 100 mm
00.7167

2.06 10 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 9403–5/A1

Standard Tools

f
d e

94215 1 Hydraulic tensioning device

with connecting elements b
for tensioning the cylinder cover studs,
consisting of:
a = 8 pre-tensioning jacks
including a metal box
b = 8 high pressure hoses,
600 mm long
d = 2 piston reset devices
98.7545
e = 2 holders
a
f = 2 round bars

X
94225 1 Measuring gauge
for measuring cylinder liner bore
X = 2340 mm
93.7498

94226 1 Measuring tool

for measuring the cylinder liner bore
X = about 1500 mm
Y = 480 mm
X

97.7497

94227 1 Setting gauge

for measuring tool of cylinder liner bore
X = 520 mm

97.7498
X

94238 1 Feeler gauge

(10-part) 93.7499
for checking bearing clearances
Leaf length = 600 mm

Wärtsilä Switzerland Ltd 11 3.00

9403–5/A1 Maintenance RTA48T

Standard Tools

94252 2 Pre-tensioning jacks

for exhaust valve cage
X = 195 mm

00.7014

94259 1 Thrust pin

for exhaust valve
X = 437 mm

93.7501

94261 1 Valve seat fitting and extracting device

X = 487 mm

93.7502

3.00 12 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 9403–5/A1

Standard Tools

94262 1 Valve protector

(only to be applied for transporting
a complete exhaust valve)
X = 435 mm

93.7503

94263 1 Jack screw to guide bush

for exhaust valve
M10x120
93.7504

94265 1 Suspension device

for cylinder cover and
exhaust valve cage
X = 570 mm
further:
a = 2 special eye nuts
X = 195 mm
b = 3 protection caps
X = 56 mm

b
X

a a
96.7523

Wärtsilä Switzerland Ltd 13 1998

9403–5/A1 Maintenance RTA48T

Standard Tools

94269 1 Hydraulic tightening device

for the cap nut of the fuel injection
valve
c
consisting of:
a 1 special spanner
b 1 hydraulic jack a
(e.g. ENERPAC type CRC-55)
c 1 high pressure hand oil pump
(e.g. ENERPAC type P-14)
(accessory to L’ ORANGE b
test stand tool 94272)

7056–03/F100920b

94270 1 Device
for overhauling the fuel injection
valve seat in the cylinder cover
X = 300 mm X

94271 1 Protection cap

for fuel nozzle 99.7687
(1 piece per nozzle)
X = 85 mm X

7056–03/F101167d

94272 1 L’ ORANGE test stand

(GXO-G004)
for setting and testing of:
S fuel injection valves,
X

S relief valves of cylinder covers,

S relief valves of fuel injection pumps
X = 1100 mm

7056–03/F100671b

3.00 14 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 9403–5/A1

Standard Tools

X
94273 1 Holding angle
for fastening of:
S fuel injection valve,
S relief valve of fuel injection pump,
S relief valve of cylinder cover
onto L’ ORANGE test stand
X = 150 mm
a 1 Support for fastening
fuel injection valve

94274 1 Connection piece

a
with closing nipple for setting and
testing fuel injection valves 96.7525

X = 41 mm

94.7100

94275 1 HP hose line

with quick release coupling
length = 1400 mm (1500 bar)
for testing of:
7056–03/F100921c
S fuel injection valve,
S relief valve of fuel injection pump,
S relief valve of cylinder cover

94276 1 Device
for testing relief valve of the cylinder
cover
X = 57 mm
X

X
7056–03/F100921d

94277 1 Device
for testing relief valves of
fuel injection pump block
X = 135 mm

97.7192

Wärtsilä Switzerland Ltd 15 1998

9403–5/A1 Maintenance RTA48T

Standard Tools

94278 1 Valve seat grinding machine complete

with pneumatic drive

94278c 1 Milling cutter

for cleaning pilot receiving cone in the
valve guide bush
96.7556

93.7615

94279 1 Gauge
for checking wear and burn scar on the
exhaust valve seat
X

X = 162 mm

98.7096

94290 1 Rotation device

for valve cage (to be used on fitting,
dismantling and grinding operations)
X = 1300 mm

96.7526

1998 16 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 9403–5/A1

Standard Tools

94292 1 Gauge
for checking wear on disc of the ex-
haust valve spindle
X = 123 mm

96.7817

94305 1 Crank web deflection checking set

(in wooden box)
X = 364 mm

93.7505

94309 1 Wire rope X

with two shackles for removal of
two-part cylinder of the axial detuner
(only for engines with integrated
7056–03/F101189
axial detuner)
X = 5000 mm

X
94310 1 Roller support
for assembling and dismantling
two-part cylinder
(only for engines with integrated
axial detuner)
X = 290 mm

98.7470

94314 2 Pre-tensioning jacks

for tensioning connecting rod studs
to bottom end bearing,
including a metal box
X = 160 mm

94315 2 Pre-tensioning jacks

for tensioning studs to connecting rod
top end bearing and waisted studs to
bearing housing of the camshaft drive,
including a metal box
7056–03/F101168
X = 127 mm

Wärtsilä Switzerland Ltd 17 3.00

9403–5/A1 Maintenance RTA48T

Standard Tools

94316a 1 Spanner
for intermediate shaft
X = 485 mm

X
94316b 1 Box spanner
for intermediate shaft with
heavy flywheel, AF 105 mm
X = 385 mm 96.7709

96.7708

94316c 1 Socket wrench insert

for screw connection flywheel /
intermediate shaft, AF 85 mm
X = 123 mm

X
94316d 1 Impact ring spanner

X
for screw connection flywheel /
intermediate shaft, AF 85 mm 96.7576
X = 382 mm

96.7710

94323 4 Retaining pins

to prop up crosshead guide shoes

X
when removing or fitting a connecting
rod or a crosshead
X = 100 mm
93.7508

94324 1 Cover and lifting plate

to the crosshead
X = 215 mm

93.7509

94325 2 Holders
for removal of a crosshead guide shoe
X = 60 mm

98.7547

3.00 18 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 9403–5/A1

Standard Tools

94331 2 Roller supports

for removal and fitting of a connecting

X
rod, as well as for inspection of the
bearing shell for the top end bearing
X = 1135 mm

98.7548

94332 1 Carrying roller

for removal and fitting of a connecting
rod, as well as for inspection of the
bearing shell for the top end bearing
X = 674 mm

97.7314

94333 1 Lifting device

to the working piston for the removal
of the top end bearing cover,
consisting of:

94333a 2 Suspension straps

with four screws
X = 128 mm
X

94333b 2 Wire ropes with hooks

X
X = 780 mm

94333c 2 Eye bolts M16

98.7549

Wärtsilä Switzerland Ltd 19 3.00

9403–5/A1 Maintenance RTA48T

Standard Tools

94335 1 Girder
for removal of heavy engine compo-
nents
(for engines with 6 and 8 cylinders)
X = 1558 mm

2 Girders
of different lengths
(for engines with 5 and 7 cylinders) 7056–03/F101194
X = 1558 mm
X = 724 mm

94338 1 Piston ring expander

X = 324 mm

93.7510
X

94340 2 Pre-tensioning jacks

for piston rod screw connection,
including a metal box
X = 89 mm

7056–03/F101168

94341 1 Piston suspension device

X = 390 mm
7056–03/F101197

3.00 20 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 9403–5/A1

Standard Tools

94342a 1 Insertion funnel

for fitting the working piston
X = 610 mm
including:
2 Holders
Y = 283 mm Y
2 Screws M12 x 20
2 Screws M30 x 45
X 005.923/00

94345 1 Distance holder

for removal and fitting of a piston rod
gland
and working piston
X = 476 mm
X

7056–03/F101181

94345b 1 Clamp ring

X

X = 46 mm

93.7515

94345c 2 Gauges
for fitting the scraper rings
X = 333 mm
X

012.158/04

Wärtsilä Switzerland Ltd 21 2.06

9403–5/A1 Maintenance RTA48T

Standard Tools

X
94345d 1 Cover plate
for covering bore of gland in the cylin-
der block (when working piston and
gland are removed)
X = 410 mm 93.7517

94345e 2 Assembly tools

for tensioning springs to
piston rod gland

X
X = 160 mm

004.284/98

94345f 6 Distance pieces X

for fitting rings in the
piston rod gland
2 pieces each 10, 11 and 16 mm
X = 267 mm
005.655/99

94347 1 Propping device

consisting of two segments for
changing the compression shims
X

X = 410 mm

93.7518

94348 1 Tap M16

for cleaning carbon deposits
in threaded holes of the piston crown
X

X = 102 mm

93.7519

2.06 22 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 9403–5/A1

Standard Tools

94350 1 Device
for supporting working piston and
removal of the piston rod gland
X = 500 mm

7056–03/F101196

94363 2 Jacking screws 7056–03/F101198

for separating piston crown from piston

X
skirt
X = M10

94364 2 Jacking screws

for separating piston skirt from piston
7056–03/F101198
rod
X = M16
X

X
94366 1 Template
for shape of top of piston crown
X = 534 mm

7056–03/F101213

X
94366a 1 Template
for shape of top of piston crown
(for use with working piston in situ)
X = 530 mm
7056–03/F101214

Wärtsilä Switzerland Ltd 23 2.06

9403–5/A1 Maintenance RTA48T

Standard Tools

94410 6 Adjusting devices

for alignment of intermediate gear
wheels
to the camshaft drive and compen-
7056–03/F101217
sating shafts of the integrated balancer
X = 184 mm X

94412 1 Tightening device

for two-part gear wheel on crankshaft 94412a
(supplied only for engine equipped
with
two-part gear wheel on crankshaft)
X = 150 mm
consisting of:

94412a 1 Clamping fork with holder 94412d 94412e

94412b 1 Impact ring spanner AF 46

94412c 94412b
94412c 1 Forked piece

94412d 1 Hydraulic ram 44.8 kN

ENERPAC RC-57

96.7552
94412e 1 Holding wrench
AF 46

94413 2 Supports
for removal of a oil trough
X = 1000 mm

94413a 1 Prop
X

96.7716
X = 777 mm

7056–03/F110110

94413b 1 Base support

7056–03/F110110
X = 120 mm
X

94413c 1 Guide 96.7717

X = 80 mm X

3.00 24 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 9403–5/A1

Standard Tools

94414 1 Cross beam

for removal of the camshaft
bearing cover
X = 910 mm

96.7619

94414a 2 Thread studs

X
with four nuts Tr 22x5
for lowering of the camshaft bearing
cover
X = 490 mm 96.7677

94414b 2 Distance sleeve

X

X = 170 mm
96.7528

94415 2 Pre-tensioning jacks

for waisted studs of camshaft bearing,
including a metal box
X = 140 mm

7056–03/F101168

Wärtsilä Switzerland Ltd 25 3.00

9403–5/A1 Maintenance RTA48T

Standard Tools

94416 1 Side member

for removal of a camshaft section
X = 2170 mm 96.7711
X

94417 2 Supports
for rolling out a camshaft section
X = 1640 mm

96.7578

94417a 1 Supports
for rolling out an end camshaft section
X = 1640 mm

96.7578

94419 1 Clamp screw

for reversing servomotor
X

X = 60 mm

93.7531

3.00 26 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 9403–5/A1

Standard Tools

94421 1 Removing device

for gear wheel on camshaft
X = 1120 mm
96.7532

94421a 2 Washers
with screws
for alignment of gear wheel on cam- 96.7679

shaft
X = 50 mm

94421b 1 Pin
for fixation of removing device
X = 376 mm
96.7679

94421c 1 Rod
with two locking features
96.7679
X = 225 mm

94421d 2 Guides
for removal of the gear wheel on the
camshaft
X = 450 mm

98.7149

94422 1 Beam
for removal of a camshaft section
X = 1610 mm
96.7712

X
94422a 1 Beam
for removal of a camshaft section
(only for engines with 5 and 7 cylin-
ders) 96.7713
X = 776 mm

Wärtsilä Switzerland Ltd 27 3.00

9403–5/A1 Maintenance RTA48T

Standard Tools

94424 1 Hydr. jacking tool

for mounting all hydr. locking elements
on the camshaft, including a metal box
X = 340 mm
accessory to it:
2 Screws M10x20
6 Screws M16x165
8 Screws M20x160
6 Washers
96.7714

94424a 1 Intermediate ring

to the hydr. jacking tool 94424
X = 305 mm

96.7620

94424b 1 Guide ring

to the hydr. jacking tool 94424
X = 340 mm

96.7715

94426 1 Connecting branch

for mounting hydr. locking
X

elements on the camshaft

X = 247 mm

96.7686

94427 1 Connecting branch

for setting the cams of fuel injection
X

pump and actuator pump

X = 198 mm

96.7687

3.00 28 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 9403–5/A1

Standard Tools

94428 1 Centring disc

for positioning the hydr. jacking tool
94424
on the camshaft when mounting a

X
flange coupling
X = 160 mm

93.7541

94429 1 Hose pipe

X = 1800 mm 93.7542
X

94430 1 Device
for cutting out an exhaust valve actua-
tor pump (1 piece per pump) 7056–03/F101219

X = 206 mm

94431 1 Suspension strap

for actuator cam and fuel cam
with one screw
X = 60 mm

93.7543

94432 1 Cam setting template

for setting the cams
X = 250 mm
X

96.7538

Wärtsilä Switzerland Ltd 29 3.00

9403–5/A1 Maintenance RTA48T

Standard Tools

96.7689
94432a 1 Round bar X
for setting the fuel cam
X = 400 mm

94432b 2 Plug spanners

for setting the actuator cam
X = 548 mm

98.7150

94432c 1 Side stop

with two screws
for setting the actuator cam
X = 94 mm
96.7691

94552 1 Device
for measuring the plunger stroke
X = 594 mm
X

94554 2 Devices
for measuring the valve stroke
X = 356 mm

96.7540

94555 2 Special spanners

for setting suction and spill valves
in the fuel injection pump
X = 250 mm
AF = 27 mm 93.7462

94555a 2 Special spanners

for setting suction and spill valves 96.7692

in the fuel injection pump

X = 518 mm
AF = 27 mm

3.00 30 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 9403–5/A1

Standard Tools

94556 1 Special spanner

to relief valve of the fuel injection pump
X = 360 mm
AF = 80 mm

X 93.7617

94557 2 Special spanners

for setting suction and spill valves
in the fuel injection pump 93.7462
X = 180 mm
AF = 19 mm X

X
94558 3 Spacers
for laying under the push rod of suction
valve
93.7610
to the fuel injection pump
(fuel charge reduction)
X = 23 mm

94560 1 Blocking device

for fitting and removal of eccentric
shafts
depending on number of cylinders two
to four pieces
X = 330 mm

96.7693

X
94560a 1 Blocking device
for fitting and removal
of eccentric shafts
(for engine with 5 and 7 cylinders)
X = 330 mm

99.7028

Wärtsilä Switzerland Ltd 31 3.00

9403–5/A1 Maintenance RTA48T

Standard Tools

94561 1 Withdrawing device

for spill, suction and delivery valve
seats 96.7542

X = 234 mm
X

94566 1 Lapping pin

for lapping seal surface on fuel
injection pump block (for valve covers)
X = Ø 70 mm

94567 1 Lapping pin

for lapping seal surface on valve cov-
ers of fuel injection pump
X
X = Ø 70 mm 96.7694

94571 1 Socket wrench insert (AF 30)

for tightening and loosening the
X

pressure bush of the injection pump

X = 108 mm

98.7699

94582 1 Dismantling and assembling tool

for spherical bearing of the
regulating linkage 93.7547

X = 112 mm

3.00 32 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 9403–5/A1

Standard Tools

94651 1 Dismantling device

X
for auxiliary blower
consisting of:

94651a 1 Carrier
X = 1616 mm
1 Screw M16x160
12 Screws M12x30
with nuts
94951a 94951c
94651b 1 Carrier
X = 1311 mm
1 Screw M16x160
12 Screws M12x30 94951b
with nuts

94651c 1 Trolley

98.7124

94652 2 Centring studs

for removing and fitting flange motor 93.7549
on the auxiliary blower X
X = 340 mm

94661 Device
for dismantling and assembling
the scavenge air cooler
consisting of:
X

94662 1 Roller plate

for cooler type:
GEA 120/30/24/6
X = 490 mm
96.7695

Wärtsilä Switzerland Ltd 33 3.00

9403–5/A1 Maintenance RTA48T

Standard Tools

94662a 1 Roller plate

X
for cooler type:
GEA 150/38/24/6
X = 425 mm

96.7696

X
94663a 1 Dismantling and assembling device
for cooler type:
GEA 120/30/24/6
X = 680 mm
96.7697

94663b 1 Dismantling and assembling device

for cooler type:
GEA 150/38/24/6
X = 680 mm

96.7698

94664 1 Roller support

for dismantling and assembling
the scavenge air cooler
X = 140 mm

93.7555

3.00 34 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 9403–5/A1

Standard Tools

94721 3 Adjusting devices

for alignment of compensating shafts
to the integrated balancer
X = 274 mm
96.7548

94811 2 Lifting lugs

(including two shackles)
for removal and fitting expansion piece
to the exhaust valve cage
X = 338 mm
011.040/03

94831 1 Blind flange

for blanking off the starting air pipe
during emergency operation
X = 180 mm

96.7699

94832 1 SERTO connecting nut M14x1

1 SERTO plugging pin

for plugging starting valve control
pipe during emergency operation
X = 12 mm
96.7700

Wärtsilä Switzerland Ltd 35 7.03

9403–5/A1 Maintenance RTA48T

Standard Tools

94834 1 Milling / grinding device

for sealing surfaces on hydraulic pipe
of the exhaust valve drive
X = ca. 250 mm

X
93.7607

94837 1 Pipe hose

for turbocharger cleaning
Length = 5000 mm

98.7483

94872 2 Re-grinding devices

to fuel high pressure piping

93.7569

3.00 36 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 9403–5/A1

Standard Tools

Jacks and pumps for

removal and fitting

94936
94931 1 HP oil pump
working pressure max. 2500 bar 94935a

94932 1 Pressure gauge

Ø 100 mm
working pressure 0–2500 bar
connecting branch G½” 94932a
94934a

94932a 1 Pressure gauge

Ø 100 mm
working pressure 0–1600 bar
connecting branch G½”

94942 94935
94934a 1 Connection piece

94935 3 HP hoses
working pressure max. 2700 bar
length about 1800 mm

94935a 2 HP hoses
working pressure max. 1760 bar
length about 1800 mm 97.7184

94931 94932
94936 2 Hydraulic jacks 230 kN (23t)

94942 1 Hydraulic unit

Wärtsilä Switzerland Ltd 37 3.00

9403–5/A1 Maintenance RTA48T

Recommended Special Tools

X
94203 2 Supporting beams
for jacking out a cylinder liner
X = 500 mm

98.7123

94291 1 Valve grinding device complete

95.7550

94299 1 Grinding device

for removing a possibly built-up wear
ridge
at top of cylinder liner running surface
X

X = about 600 mm

93.7574

3.00 38 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 9403–5/A1

Recommended Special Tools

94300 1 Tool cupboard

X = 1120 mm

X
93.7602

94336 1 Connecting flange

for pre-lubrication of crosshead
and bottom end bearing
X = 115 mm
X

93.7575

94344 1 Dismantling device

for removal of the piston rod
gland downwards
X = 650 mm

95.7551

Wärtsilä Switzerland Ltd 39 3.00

9403–5/A1 Maintenance RTA48T

Recommended Special Tools

94349 1 Pressure testing device

for working piston
X = 210 mm

93.7576

94650 1 Spur-geared chain block

for removing and fitting the electric
motor to the auxiliary blower,
carrying capacity 1000 kg

93.7577

94931a 1 Hand oil pump

SKF 226 400

96.7701

3.00 40 Wärtsilä Switzerland Ltd

 RTA48T
Maintenance 9403–5/A1

Special Tools Obtainable on Loan

94105 1 Measuring apparatus

for leveling bedplate

X
consisting of:
4 Supports
4 Weights with wire
1 Measuring underlay
X = 1100 mm
93.7578

M24
94174 4 Thread protectors

X
to upper threads of tie rods, when
fitting a cylinder jacket
X = 115 mm 96.7704

94177 1 Thread protector

to lower thread of tie rod
X = 100 mm

93.7579

94211 1 Fitting device

for insulation tubes
X = 620 mm

94212 1 Extractor
for insulation tubes
X = 890 mm
X
X

97.7351

Wärtsilä Switzerland Ltd 41 3.00

9403–5/A1 Maintenance RTA48T

Special Tools Obtainable on Loan

94441 1 Securing pin

for transport and fitting of a reversing
servomotor with housing,
3 to 4 pieces depending on cylinder
numbers
X = 45 mm

97.7380

3.00 42 u Wärtsilä Switzerland Ltd