V.No. BookNo. / ..New Sulzer Diesel NewSulzerDieselAG Winterthur,Schweiz MaintenanceManual for Sulzer - DieselEngines RTA76 InstallationIVessel: Type: EngineNo.: Mailingaddress: NewSulzerDieselAG POBoxTelephone0522624922 CH-8401WinterthurTelex89606070szch SwitzerlandTelefax052224917 1990NewSulzerDieselLtd.Switzerland- PrintedinSwitzerland 000 ForparticularAttention Thismanual isput at thedisposal of the recipient solelyforuseinconnection withcorresponding DIESEL ENGINES. It hasalwaystobetreatedasconfidential. Theintellectualpropertyregardinganyandallofthecontentsofthismanual,particularlythecopyright, remainswithNEW SULZER DIESELLIMITED,WINTERTHUR,SWITZERLAND.Thisdocument and partsthereof mustnotbereproducedorcopiedwithouttheirwrittenpermission,and thecontents thereof mustnotbeimpartedtoathirdpartynorbeusedforanyunauthorizedpurpose. Beforethe operator attempts tousetheengineor before maintenancework willbe undertaken,therespectivemanualistobereadcarefully. To ensurethebest efficiency,reliabilityandlifetimeof theengineand itscomponents,onlyoriginalspare partsshouldbeused. It istobeensuredaswellthatallequipmentandtoolsformaintenanceareingoodcondition. ",---,.Theextentofanysuppliesandservicesisdeterminedexclusivelybytherelevantsupplycontract. Theparticulars.data.presentationsetc.inthismanualcorrespondtothesituationexistingat thetimeof goingtopressandtheyarebasedondrawingsmadebyNEWSULZERDIESEL.It mustberecognized that such particulars.data.presentationsetc.may be subject to later modificationsdue tofurther developments.experienceoranyotherreason. Thismanualisprimarilyintendedforusebytheengineoperatingandmaintenancepersonnel.Itisassumed that it willa ~ w a y s be at the disposalof such personnel forthe operation of theengines and/orfor the requiredmaintenancework. Thismanualhasbeenpreparedontheassumptionthatoperationandmaintenanceof theenginesconcerned willalwaysbecarried out by personnel having the specialknowledgeand skill needed to handle in a workman-like manner dieselengines of thecorresponding size.the pertaining auxiliary equipment.aswell asfuelandotheroperatingmedia. Therefore.generallyapplicablerules.whichmay alsoconcern such items asprotection against danger.are specifiedinthismanualinexceptionalcasesonly.It isgenerallyassumedthattheoperatingandmaintenancepersonnelarefamiliarwiththerulesconcerned. Thismanualhasbeenpreparedtothebestknowledgeandabilityof itsauthors.However,neither NEW SULZER DIESEL nor their employees assume any liability under any legaltheorywhateverincludingnegligenceforclaimsforanydamageswhatsoeveror claimsofanyothernaturesuchasregardingadditionalsuppliesorservicesorother demands,withregard tothismanual and itscontentsor toanymodificationtheretoor inconnectionwithanyusethereof. NEWSULZERDIESELLIMITED WINTERTHUR SWITZERLAND New Sui... Diesel 10.91 ,'---" ' Pi ston rodnut Informaton Theenginecanbeequippedwith"long"or"short"pistonrods. Withthelongversion,therodofthepistonisledthrough thecrossheadfromaboveandsecuredatthebottomwithasuitabl enut. Inthecaseofshortpistonrods,connectioniseffectedby meansofastrongbolt,whichisinsertedatthebottomso thatitpassesthroughthecrossheadandintothepistonrod. Toruleofthepossibilityofmistakes,thedatarelevantto enginesequippedwithshortpistonrodsareprintedongreencolouredpaper. Customersarerequestedtoremovethepagesofthemanual thatdonotapplytotheirparticularengines. "Long D pistonrod Pi stonrod bolt ."Short"pi ston !rod SULZER Group:001 RTPREFACE Sheet:1 Preface The aim of the"M a in ten a n c eMan u a1"is to help to ensure thatthemaintenancewhichhastobecarriedoutatspecificintervalsisdone correct1 y. Itisassumedthatthestaffchargedwithsuchworkpossesthenecessaryknowhow. Informationcoveringengineoperationaswellasthedescriptionofthefunctioningofspecificsystemsiscontainedinaseparatebook"Descriptionand OperatingInstructions". The"MaintenanceManual"isdividedintothefollowingmainchapters: GeneralGuideLinesforMaintenance MaintenanceSchedule TablesofWeights,ClearancesandValuesforBoltedConnections WorkSheets Too1sList Thefollowingareafewexplanationstotheaboveitems: The"GeneralGuideLinesforMaintenance"contain- inadditiontoindications regardingprecautionarymeasurestobetaken- recommendationsonhowtocarry outthework. Inthe"MaintenanceSchedule"theintervalsarespecifiedatwhichthevarious maintenanceoperationsaretobecarriedout. The"TablesofWeights.ClearancesandTighteningValuesforBoltedConnections" dealwithweightsofindividualenginecomponents,normalandmaximumpermissible clearancesaswellasthepropertighteningofcertainimportantboltedconnections. The"standardclearances"mentionedintheTableofClearances012/1&fcorrespond tothosepartlyresultingfrommanufacturingtolerancesorthoseadjustedonthe~engine. Themaximumclearancesormax./min.dimensionsstatedarethosevalueswhichmay resultfromwearafteraprolongedperiodofoperationandwhichareneithertobe exceedednorgoneblow.Inpartswheretheclearancecanbecorrectedbyachange inthethicknessofshims,discs,distancepiecesetc.theoriginalstandardclearanceshouldalwaysbeaimedat,andadjusted.Whereverthisisnotpossible,theworn partsmustbereplacedorreconditionedbybuildingup(chromeplating,welding build-upormetalspray. Shouldduringanoverhaul,clearancesordimensionsbefoundclosetothepermissible limits,ithastobelefttotheengineerinchargeoftheenginetodecidewhether ornotthepartshavetobereplaced.Thisdependsforexampleonthetimeofoperationuntilthenextoverhaulandontheweartobeexpectedfromexperiencemadeover acertaintimespan. Detailedinstructionsaregiveninthe"WorkSheets"ontheprocedureofmaintenance workoncertainengineparts. Thetoolsanddevicesarespecifiedinthe"ToolsList"whichareneededformaintenanceworkandwhicharenormallysuppliedwiththeengine. Alltheinformationcontainedinthetextandtheillustrationsofthisbookare validatthetimeofgoingtopress. Modificationswillbeincorporatedinthenextedition. SULZER Group:002TABLEOFCONTENTS RT forMaintenanceManual Sheet: 1 FORPARTICULARATTENTION PREFACE TableofcontentsforMaintenanceManual Enginecross- andlongitudinalsection Numberingofbearingsandcylindersaswellasdefinitionof enginesides 000 001 002 004 008 G E ~ E R A L GUIDELINESFORMAINTENANCE Precautionarymeasuresformaintenancework Recommendationsforcarryingoutthework 011 TABLEOFCLEARANCES - Crankshaftandthrustbearings - Crossheadguides - Cylinderliners - Pistonrodglands - Crosshead- andcrankpinbearings - Crossheadlubrication - Workingpistonandpistonrings - Pistontelescopicpipeglands - GearwheelsforcamshaftdriveandPTOgearbox - PTOgearbox - Camshaftandreversingservomotor - Ancillarygeardrives - Ancillaryandstartingairdistributordrive - Intermediateshaftforancillarygeardrives - Rollerguidesforfuelinjectionandactuatingpumps - Driveforcylinderlubricators - Overspeed,pick-upandremotetachometertransmitter - Balancerdriveelements(2ndorder4to6cyl.engines) - Balancerdriveelements(1stand2ndorder,4cyl.engines) 012/1 012/2(2aRTA58) 012/3 012/4 012/5 012/6 012/7 012/8 012/9 012/9a 012/10 012/11 012/11a 012/11b 012/12 012/13 012/14 012/15 012/15a(RT68,RT76) lNFORMATIONONTHETIGHTENINGOFIMPORTANTSCREWEDCONNECTIONS MASSESOFINDIVIDUALCOMPONENTS(perunitinkg) DIMENSIONSANDMATERIALSPECIFICATIONSOFTHERUBBERRINGS MAINTENANCESCHEDULE(Tableofintervals) 013 014 015 021 WORKSHEETS Checkingthelubricatingoilbythespottestmethod Takingofoilsamplesfor1aboratoryanalysi s - Looseningandtighteningthebearingthrustbolts117/2 - Removalandfittingofabearingcoverandanupper117/3 beari ngshell - Removalandfittingofthebearingcoverandstopper117/4 bridgeinthethrustbearingassembly - Removalandfittingofalowermainbearingshell117/5 Bedplate Mainbearings - Checkingthefoundationbolts 042/1 042/2 110/1 I R1Qh 002/1a RT ~r---/' Thrustbearing- Checkingtheaxialclearance - RemovalandfitHingofthrustbearingpads Tierods- Checkingthepre-tensionandtensioningthetierods Cylinderjacket- Transportingacyl inder1inerwithfi Hedcylinderjacket - Removalandfittingofthewaterguidering Cylinderliner- Measuringborewear - Removalandfitting - Removalofwearridge,rectifying1ubricating groovesandedgesofscavengeports Lubricatingquills- Functioncheck Pistonrodgland- Removalandfittingandmeasurementofwear Cylinderhead- Removalandfitting - Hydrauliclooseningandtensioningofcylinderheadstuds - Mechanicallooseningandtensioningofcylinderheadstuds - Manualrectifyingtheseal ingfaceforthefuelinjectorin thecylinderhead Fuelinjectorvalve- Checking,dismantling,assemblingandsetting - Cleaningandoverhaulinginjectornozzle - Lappingofinjectorbodysealingface - Checkingacirculatingvalves Startingvalve- Cleaningandchecking Reliefvalve- Dismantling,assemblingandchecking ExhaustvalveRemovingandfittingtheexhaustvalvesinthecylinderhead - Dismantlingandassembling - EKchangingandgrindingthevalveseat - Grindingtheseatfaceonthevalvespindle Crankshaft- Measuringthecrankdeflection Torsionalvibration- Takingasiliconfluidsample damper(oncrankshaftandcamshaft) Axialdamper Turninggear Cftnneetingrodand Cllnnlllctingrod bearings -,Dismantlingandassembling - Oilchangeandcheckingwormgearwheels Checkingrunningclearances - Looseningandtensioningconnectingrodbolts Separatingthecrankpinbearingbodyfromthe connectingrodshank Inspectingthecrankpinbearings - Inspectingandifnecessaryreplacingcrosshead bearingshell s - Removingandfittingaconnectingrod 120/1 120/2 190/1 211/1 211/2 214/1 214/2 214/4 215/1 231/1 270/1 270/2 270/3 270/4 272/1 272/2 272/3 272/4 273/1 274/1 275/1 275/2 275/3 275/4 310/1 313/2 314/1 320/1 330/1 330/2 330/3 330/4 330/5 330/6 I P '--" V V C . / ~ U332 i 1Crosshead - Checkingtheclearances _Removingandfittingacrossheadwithworkingpistonremoved337/3 340/1Workingpiston - Removingaworkingpiston 340/2- Fittingaworkingpiston _Looseningandtighteningthepistonrodnut(resp.bolt) 34J/3withasped alspanner 340/4- Checkingthepistontopsurface 340/5- Dismantlingandassembling _Pressuretestingcoolingspace(leaktightnesstest) 340/6 342/1Exchangingpi stoncoolingtel escopicpipes 34212Pistonrings Checkingpistonringwear 360/1Pistoncooling- Checkingthestandpipes 362/1Maintenanceofglandsforthetelescopicpipes Camshaftdrivegear- Checkingofrunningclearances,backlashesandconditionof 410/1teeth 410/2_Removingandfittingtheintermediategearwheel 410/3- Replacingthesplitgearwheelonthecrankshaft 420/2Cam sha ft - Removingandfittingacamshaftsection Dismantlingandassemblingofhydraulicallyfitted components421/0 - Removingthefuelinjectionandtheactuatorcam 421/1 42l/lb- Pressingonthefuelinjectioncam 42l/lc- Pressingontheactuatorcam - Adjustingthefuel- andtheactuatorcam 42l/ld 42l/le- Removingand 42l/lfFittingtheflangecoupling 42l1lg- Removi ngand 421/1 hFittingthecamshaftcoupling - Removingandfittingthegearwheelonthecamshaft 421/4 430/1Startingcontrolair- Removingandfittingthepilotvalves di stri butor )Startingairshut- Cleaningandfunctionchecking 432/1 offvalve 453/1Runningdirection- Inspectingandfunctionchecking safeguard 455/1Shut-downservo- - Oismantlingandassembling motor 510/1WOODWARDgovernorInstalling,removingandmaintenance 530/1Safetycut-outde- - Maintenance,fundi oncheck vice aD2/lc RT Fuelinjection - Adjustingandcheckingthetiming - Lappingthesealingfacesofthecoversofthesuction, deliveryandspillvalves - Checkingandsettingthereliefvalve - Checkingandsettingthestaticpressureregulating valve - Tightenofnippleforplungerbush 551/1 551/2 551/3 551/4 551/5

ScavengeairreceiverMaintenanceofvalve airreceiver - Maintenanceofwater groupsandcleaning separatorelements thescavenge640/1 640/2 Auxili aryblower- Maintenance654/1 ScavengeaircoolerCleaning(airsideJwithengineatstandstill - Cleaning(waterside)withengineatstandstill - Removingandfittingthecoolerstack 650/1 660/2 660/3 Cylinderlubricators- Cleaning721/1 Drivingshafttothe flowcontrolvalveof thecylinderlubrication - Dismantlingandassembling722/1 '-..../ p. l.O.-Gearbox- Checki ngthetoo thprofi 1eandtoothbackl ash,realigningthegearboxhousing,checkingtherunning performance - Removingandfittinggearboxcomponentsaswellasthe intermediategearwheel. - Geislingercoup1ing,externalcheckforoil1eaksand constantventing 740/1 740/2 740/3 Efficiency-Booster- Removingandfittingthehydrauliccouplingaswellas theflexiblepacketcoupling.Checkingtheoillevel ofthehydrocouplingandthealignmentofthepower turbine. - Funcioncheckingandmaintenanceoftheshut-offflap andthecornervalve 750/i 750/2 Balancer- Fitting,Removing,TensioningtheRollerChain - Fitting,RemovingtheFlexibleCouplingandaCamshaft section resp.lf 710/1 770/1eand1f(2nd order and1g(l st+2ndorder) Exhaustpi peAdjustingtheBellevillewasher exhaustpipemounts springpacksonthe811/1 Hydraulic valvedrive to - Overhaulingthepipesealfaces846-1 TOOLS- Explanation940 Hydr.Jacksandpumps- Arrangementandapplication940/0&Oa Hydr.pre-tensioning jack s - Storage,careandsparesstock - Generalapplicationinstructions 940/0b&Dc 940/Dd-Oh(Oi,RT84) Toolslist- Standardtools - Recommendedtools - Toolsobtainableonloan 940/1;41 940/48;51 960/60 12.89 CJ04/1 RTA76 RTA76 846/1 811/1 660/1+3 551/1+5--_....,... 231/1 'C , 1,21/1 +I, 110/1 10.86 001,/2 RTA76

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t,, 1t 332/1+2 ""- ' +t: ,... --::."0/3 330/1f' 330/6

117/3 117/5 120/1 190/1 120/2310/1330/2330/3 9 -1O'Z198.411 5.87 (j) Exhaustside counter-clockwise GruppeNumerierungvonLagernundZylindernSULZER GroupsowieBezeichnungderMotorseiten BlattRT Numberingsofbearingsandcylindersandnominationofenginesides Sheet 1 Antriebseite FreiesEnde DrivingendFreeend ZylinderNumberingofmain bearings of cylinders SchubstangenNumerierung Numberingof connectionrods KurbelwellenlagerNumerierung r-+-t--...Drucklager Thrustbearing 3 - 107156.218 LinksmotorRechtsmotor Left-handengineRight-handengine Numerierung Exhaustside Brenns.toffpumpenseite Fuel pump.side rechtsdrehend clockwise AnsichtvonAntriebseite Viewfromdrivingend L.B. Table of Contents Maintenance Instructions Clearance Tables Tightening Values for Bolt Connection.s Weights Maintenance Schedule WorkSheets ToolUsts '-/ SULZER Group:011 GENERALGUIDELINESFORMAINTENANCERT Sheet:1 Themaintenanceworktobecarriedoutontheengineatspecificintervalsisdescribedinthe"MaintenanceSchedule ll ofthisbookandistobeunderstoodasa~Experiencewillshowwhethertheintervalsmaybeextendedorhavetobeshortenedasmodeandconditi onsofoperati on,quali tyoffueland1ubri ca ti ngoilused,aswellasmanyotherfactorsi nfluence theconditionoftheenginetoagreatdegree. PrecautionaryMeasuresforMaintenanceWork Priortocarryingoutanymaintenanceworkontheengine(especiallyontherunninggear),the followingprecautionshavetobetaken: Closetheautomaticshut-offvalveforstartingairaswellastheshut-offvalvesonthestarting airreceivers Closealltheshut-offvalvesinthecontrolairpressure-reducingunitandthedraincocksinthe twoairreceiversarrangedaboveit Openthedrainvalvesplacedinthepipesbeforeandaftertheautomaticstartingairshut-off valveandleaveinthispositionuntilmaintenanceworkisc o ~ p l e t e d Openallindicatorcocksonthecylinderheadsandleaveinthispositionuntilmaintenanceworkis comp1eted Engageturninggear(gearpinionmustbeinengagedposition)andlockthelever Wheretheenginehasbeenstoppedduetooverheatedrunninggearorbearings,waitat1east10minutesbeforeopeningthecrankcasedoors Thecrankcasedoorsmustalwaysbelockedwithalltheclosingdogswhenevertheengineisrunning evenifthisisonlyforashorttimeinordertomaketemperaturechecksleg.afterchangingbearingsduringanoverhaul,etc.) InthecaseofafireintheenginehavingbeenextinguishedbymeansofC02,thespaceseffected mustbewellventilatedbeforeworkcanbecarriedoutwithinthem. Recommendationsforcarryingoutthework - Priortoturningthecrankshaftwiththeturninggear,makesurethatnobodyisinsidetheengine andthatnolooseparts,toolsordevicescangetjammed.Alsoensurethatthecoupledpropeller turnstoo(dangerinsurroundings). - Whencarryingoutmaintenancework,usethetoolsanddevicesintendedfortheworkinquestion which,asarule,aresuppliedwiththeengine(see"ToolsList ll attheendofthisbook). - Toolsanddevicesshouldbereadypriortouseandbeinperfectcondition. - Hydraulictoolsaretobecheckedfromtimetotimefortightnessandfaultlessfunctioning(see alsosheet940/0a). - Allworkmustbecarriedoutwiththenecessarycare,observingutmostcleanliness. - Duringmaintenance,openingsofpipes,openoilbores,etc.mustbetemperarilyclosedtoavoid theentryofanydirt. - Allpartsoverhauledduringthecourseofmaintenancehavetobecheckedforperfectfunctioning priortostartingtheengine.Pipeswhichwereremovedhavetobecheckedfortightnessafterrefitting. -.J RTOllila Clearancesofmovingpartsbecl,eckedperiodically.Shouldthe perrr-issit,ll" J;'Jes (seeclearancetabl es)havebeer orhaveevenbeer,exceeded,thesepartsn us:12 acedbyeitherneworrenovatedsnes,exceptwheretheclearancecarbereadjustedby of sh i ms. - Partstakenfromthesparesstockaretobereplaced.Whenorderingnewpartsonlythecodenumbers ofthecodebookmustbeusedandenginenumber,typeofengineandnameofinstallationmustbe mentioned. - Whentighteningstuds,nutsorbolts,theutmostcaremustbetakennottodamagetheirthreads andthattheycanbescrewedinbyhanduntilmetal-to-metalcontactisobtained.Thespecified lubricantsaretobeused. - Wheretighteningvaluesarestated,thesemustbestrictlyadheredto(seetable"tighteningvalues forboltedconnections013). - Lockingdevicesofbolts,nuts,etc.mustbefittedcorrectlyandsecuredproperly. _ Usedrubberringsmustalwaysbereplacedbynewoneswhenanoverhaulofanyenginecomponenttakesplace;theylustconformindimensionandqualitytothespecificationsinthelistgroup015. Thefittingofpistonsealringsandrodsealringsrequiresthegreatestofcaretopreventslidingringsbeingdamaged,overexpandedordistorted.RECOMMENDATION:Beforefittingthesliding ringofapistonsealringheatitfirstinboilingwater. Table of Contents Maintenance Instructions Clearance Tables Tightening Values for Bolt Connectior]s Weights Maintenance Schedule WorkSheets ToolUsts 1 SULZER Gruppe:012Kurbetwellen - undDrucklagerSpiele Group: Blatt RT76 Crankshaft- andThrustBearingsGearances Sheet Kurbellllellenlager CRANKSHAFTBEARINGd u Differenzaj- a2=max.0,1mm beigespanntenBruckbolzen Differenceal- a2= max.0,1mm withthrustboltstensioned v.4 - 107. 197.046 0 / o dDrucklager THRUSTBEARING o 2'-101.198 :812 ff '1 NennmassSpielneu NominaldimensionClearancenelll b = 790 0,68B= 790+0,58 +0,48 c= 0,48 e = 20 maximumNennmassSpielneumaximum durchAbnutzungdurchAbnutzung duetolIIearNominaldimensionClearancenellldue.tolIIear o f= 100_0 03 0,82,5 ~d = 375dl+ d2= 15 g = 225 1983 2 SULZER J.C"p,'ele KreuzkopffiJhrung 1--====----+---------------1 Group:RT76 rJCROSSHEADGUIDANCEBlattLLearanCesBrennstoffpumpenseite ..... o FUELPUMPSIDE 2- 107.198.414 .. *WenndieGleitschuheaufderBrennstoffpumpenseiteanliegen,mussdieKo'ibenstangenachsezurZylinderachse umdashalbeSpiel'bl'gegendieBrennstoffpumpenseiteverschobensein, *WHENTHEGUIDESHOESLIEAGAINSTTHEFUELPUMPSIDE,THEPISTONRODAXISMUSTBEDISPLACEDBYHALFTHE CLEARANCE'bl'TOTHEFUELPUMPSIDERELATIVETOTHECYLINDERAXIS. **DasSpiel'bl'giltnurfurkaltenMotorohneangezogeneZugankerundDruckbolzen. DurchdasAnziehenvonZugankerundDruckbo1zenvergrossertsichdasSpielimBereichdesU.T.P. DieseSpielveranderungenbleibenfurdasBetriebsverhaltendesMotorsohneBedeutung. **THECLEARANCE'bl'ISONLYVALIDFORCOLDENGINEONWHICHTHETIERODSANDJACKBOLTSARENOTTIGHTENED. TIGHTENINGOFTHETIERODSANDJACKBOLTSINCREASESTHECLEARANCEMAINLYINTHEREGIONOFB.D.C. THEFLUCTUATIONOFTHISCLEARANCEDOESNOTAFFECTTHEDPERATIONOFTHEENGINE. Nominaldimension Nennmass Clearancenew Spielneumaximum durchAbnutzung duetowear Nennmass Nominaldimension Spi e1 neu Clearancenew maximum durchAbnutzung duetowear a= 370B = 924 b] 0,5** = ,2 0,6 A = 370 -0,2b =924_0,25 0,0903 0,15 cl c2 =0,15 = 15 .. .. 0,2525 0,44 5.84 3 SULZER .,Gruppe:012SJ----_===p=l=e=e_---I-_zy_It_"nd_e_re_in_s_a_tz~ Group: RT76rJB/attLLearanCesCylinderLinerSheet -A I I '/ I 1- 107.197. 095 NennnTlss Nominaldimension A = 1094,5 B= 1100,5 C = 760 Spielneu Clearancenelll 1, 1 al + a2 = 0 7 , bb1, 1 1+2=07, maximum durchAbniHzung duetowear max.= 765,3 Nennmass Nominaldimension F = 1020 G = 945 H= 935 Spielneu Clearancenew f0,6fl +2= 0 2 , 1,3 gl+ g2= 09 , h0,8 hI+2= 0.5 maximum durchAbniltzung due..:towear E = 1030 5.84 SULZER RT76 Spiele Clearances Kolbenstangen- StopfbiJchse PistonRodGlandBox 012 4

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.... . BeimKontrollierendesSpielesilmussderAbstreifringCI)auf demFuhrungsring aufliegen. WHENCHECKINGTHECLEARANCEATilTHESCRAPERRINGCDMUSTLIE ONGUIDERING(I). BeimKontrollierenderSpieleII,III 1 undkl-mUssendasSchlossCD undderAbstreifringCI)aufdemFuhrungsring(l) aufliegen. WHENCHECKINGCLEARANCESII,mlANDklCLAMPCI)AND SCRAPERRINGCI)MUSTLIEONGUIDERING(l). c kd ---TEFLON 4-107.198.444 NennmassSpielneumaximumNennmassSpielneumaximum durchAbnutzungdurchAbnuhung NominaldimensionClearancenewduetowearNominaldimensionClearancenewduetowear min.Dicke = 39 a= 45 min.thickness il= 0,080,5 min.Dicke = 15 b = 20 min.thickness kl = 0,05y0,260,8 min.Dicke = 18 c = 20 min.thickness 11= 0,10,5 e = 30 el= 0,4or0,7O,aml= Dor0,230,5 f= 35fl= 0,4or0,70,8 G= 280280,3gl= 0,056or0,1600,4 110/, 5 SULZER Sp,'e/eQ5 012

Group: RT76 rlUpperandLowerB/attLlearanCesConnectingRodBearingsSheet ObereHal He UPPERHALF d '-..-/ Spielneu Clearancenew a1+ a2= 0,32TO,50 b = 0,34..0,56 cl+ c2= 0,60TO,80 d1+ d2= 0,30TO,70 Lagerschale BEARINGSHELL '-=I====!r----+------I 4-107, Nennmass Nominaldimension a= 65_0,08d = 284 e= 790 maximum durchAbnutzung duetowear 0,6 Nennmass Nominaldimension E = 790+0,58 +0,48 = 13 13 g = 335 Spielneu Clearancenew f= 0,48T 0,66 gl+ g2=15 0,5 maximum durchAbnutzung duetowear 0,7 5,84 SULZER 6 c,c ) / RT76 maximumNennmassSpielneu NennmassSpielneu durchAbnutzung duetowearNominaldimensionClearancenew NominaldimensionClearancenew 1,2 0,09 0,2c= 65 c1 +c2= 6a= 60al = 0 03 b = 95 bl +b2= 4~ ~ - ~ ~ ~ + - - - + - - - r - - - I - - l"---./ maximum durchAbnutzung duetowear 1983 / ArbeitskolbenSULZER (jruppe: 011"Spiele undKolbenringeGroup:L-WorkingPiston Blatt7 RT76 Clearances andPistonRings Sheet a b c mJ c mJ 4040f mI K FuerdieWiederverwendungvongebrauchtenKolbenringenistdieRingbreiteandenStellenA, BundC massgebend.GebrauchteKolbenringekoennenweiterverwendetwerden,wennbiszurnaechsten RevisiondieminimaIeRingbreitenichtunterschrittenwird(sieheBlatt34212b) TheringwidthatthepositionsA,BandCisthedecisivecriterionforrefittingofusedpistonrings. Usedpistonringsmybyrefitted,iftheywillkeepwithintheirmin.ringwidthtillthenextrevision (seegroupe342,sheet2b). I[mm]24 -rT'TTT1T'I= 23-IHlffiI33: Kolbenringbreite'I' Pistonring width'I' 2122111111120 19....LLJ..L.U.U... 760761762763764765766[mm] Zylindereinsatz-Durchmesser'a'ICylinderlinerbore'a' Spiel normal. neumaximumdurchNennmass NennmassSpiel normal, neumaxmumdurch Normalclearance.AbniltzungNormalclearance,Abniltzung NominaldimensionnewmaxduetowearNominal dimensionnewmax.duetowear 765,32g= 2BO a= 760 5,0.;.5,45H=25 b = 755 14+ 0,33 j= 0,4353,0.;.3,450,65 J = c= 757 17 14+ 0, 1B + 029 k= 0,285dmin .75B,2 1,3.;.1,7 d = 75B,70,55 K= 1 sieheDiagramm + 014 0,9.;.1,2 f= 759,11 =24 seediaram 0 m= 13,92-0025 .r--. "--"" aufdemFuhrungsri ng WHEN LIEON WHEN ANDSCRAPERRING CD MUST Nennmass Nominal a50= A50 = d39= 0 = 39 SULZERKolbenkiihlrohr- StopfbiichsenSpiele Group 012 RT76Blaff PistonCoolingPipeGlandsClearances Sheet 8'.-

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HJ 2-107."1.061 .. a1002 A BeimKontro11ierendesSpie1esb]mussderAbstreifring CD 0 aufl iegen. CHECKINGTHECLEARANCEAT b1 THESCRAPERRING CD MUST GUIDERING 0 Bei mKontrol1ierenderSpiele fl,gl und clmussdasSchloss CDundderAbstre ifri ng CD aufdemFuhrungsring 0 aufliegen CHECKINGTHECLEARANCES fl,gl AND cl THECLAMPRING CD LIEONTHEGUIDERING(1).

D d1dd2 .,

-1 I tr-e :fWl !t-Ir.I Ur. -41

, dimension Spielneu Clearance al+a2 0,08bl = 0,23cl= 0 05 dld2 + new 0,114 = 0,050 - 0,050,40 = - 0,30,05 maximum durchAbnutzung duetoweardimension max.=5J max.diam. 0,5 Nennmass Nominal h = 9,5 i = 7,5 Spielneu Clearance 0,08

f] 0 0,25gj= 0 02 0,15ml= 0,05 '-..-/'-1Ul. 198."7 maximum durchAbnutzung newduetowear min.Mass = 7,5 min.dimension min.Mass=6 min.dimension 0,5 1.85 I 9 SULZER RT76 ''"-../ Spiele Clearances maximum Spielneu Nennmass NominaldimensionClearancenew durchAbnutzung duetowear A= 270 a= 270 b = 290 al bl 0,234 = 0 142 1,1 +b2= 6, 0,35 1,5 C= 340 c= 340 d = 290 C] 0,348 0,252 1,1 d1 +d2 = 0,6 0.45 1,8 Rader zumSteuerwellenantrieb undP T.O.- Getriebe WheelsforCamshGftDriveand DriveforPT.D.-GearBox 1- 107197 322 Nennmass Nominaldimension Group: Blatt

Spielneu Clearancenew maximum durchAbnutzung* duetowear Zahnflankenspiele/Backlashofteeth norma1max.*norma 1max.* 0,32 0,7854 0,43 0,78 2 0,65 0,43 0,75 3 0,66 6.87 SULZER _T._O_,-_G_et_n_eb_e--l012 RT76Blatt9-,L- ..L::G::e::Q::r:::Q::n::c:::e::s=---J_p_T._O_'-_D_r_iv_e __a--l'---"" c Nennmass Nominaldimension a=340 b =250 c=190 d=220 Spielneumaximum durchAbnuhung Clearancenewduetowear 0,348 al=a 2520.45 b_ 0,343 , 0,631 - 0,285 0,31 0,56C]=a,252 d_ 0,321 0,581 - 0,258 1,1 1,8 e= 0,6 b bl NennmassSpielneu NominaldimensionClearancenew f =1,51 1,0 0,91 9 =a,50 maximum durchAbnutzung* duetowear 2,0 1,5 Zahnflankenspiele/Backlashofteeth normal CD 0,43 0,66 CD 0,32 0,51 max. * 0,75 0,66 normal CD 0,32 0.47 max.* 0,58 "6.87 10 Steuerwelleund SULZER 012Spiele UmsteuerservomotorGroup: BlattRT76CamshaftandClearances ReversingServomotor cd

:1i , I' o4 - 107199.345 Nennmass Nominaldimension a=300 A= 300+0,200 +0,150 Spielneu Clearancenew 0,232 aj0,150 0,45 bl +b2 =,14 maximum/minimum durchAbnutzung duetowear 0,35 0,6 Nennmass Nominaldimension Spi e1neu Clearancenew 0,3 c= 0,1 O,16d1 +d2 = 0,10 maximum durchAbnutzung duetowear 0,4 0,3 5.84 11 SULZER GetriebefurHilfsantriebeSpiele RT76 GearingforAuxiliaryDrivesGearances SieheauchBl'att012/13 Seealsosheet012/13 . ~ ~ . ~ ~ ' ; ; ; : t : ~ 0----1 SieheauchBlatt012/11b ( : ; \ ~~ ~~ ""'-",\1Seealsosheet012/llb SieheauchBlatt012/14 Seealsosheet012/14 2- 101.197.010 NennmassSp ieIneu NominaldimensionClearancenew maximum durchAbnutzung* duetowear Zahnf1ankenspiele/Backlashofteeth normal CD0,12 0,26 CD0,14 0,26 0,10 0,21 max.*normalmax.* 0,47CD00'21000,34, 0,40 0,38 1983 GetriebefilrHi/fsantriebeund SULZERGruppe:Spiele Group 012Anlass - Steuerluftverteiler RT76Blatt GearingforAuxiliaryDrivesandClearances Sheet 110StartingControlAirDistributor Anlass - Steuerluftverteiler STARTINGCONTROLAIRDISTRIBUTORe0-1 , o cp I 0,175 h ;1,0b ;50 b]0,30,] 1O0,5 0,175.0,20c ;45 cl 0,30,31; ,150,1] 0,175 k ;0,22d ;50 d1 0,3 0,3 3 - 107.19'1058 NennmassSpielneu NominaldimensionClearancenew a;80 a1 0,090 0,030 0,1100,14 0,136m;60 m1 0,20,060 Zahnf1ankenspie1e/Back1ashofteeth e; 1 norma]max.*normal 0,10f; 10,3020 maximum durchAbnutzung duetowear 0,15 maximum durchAbnutzung* Nomina]dimension NennmassSpielneu Clearancenewduetowear 1,0 ,5 9 ; max.* 1Seealsosheet012/11 -==::::12-107.197.306 SULZER ZwischenwellefurHilfsantriebeSpiele Group: Blatt IntermediateShaftRT76 11b Clearances forAuxiliaryDrives J Si eheauchB1att012/11 NennmassSpielneumaximum durchAbnUtzung Nominaldimensionduetowear Clearancenew 0,106Zahnflankenspie1eBacklashofteeth0,2 a=100 a1 0,036norma1max.*normalmax.* b0,8CD0,12CD0,120,90,470,500,30,260,28 1983 12 RollenfilhrungenzuBrennstoff SULZER Gruppe:012Spiele undHubgeber- PumpenGroup: BlattRollerGuidestoFuelPump RT76 Gearances andActuatorSheet ol,) e E :: ~ : ~ : ~ : ~ : ~ : ~ : ~ : ~ : ~ : 'mfff)-:.:-:.:-:.:-:.:-: 4- 107.197.325 --C"tJt---tt-+-b2 b B b1 Nennmass Nominaldimension = 64-0,030 a-0,060 b =265-0,250 -0,300 B-265+0,052- =108-0,036 '---'c-0,058 C =108+0,052 +0,030 Spielneu Clearancenew 0,030 al= ,090 0,250 bl+ b2= 352, 0,066cl 0,110 maximum durchAbniJtzung duetowear 0,35 0,5 0,16 Nennmass Nominaldimension d =90-0,036 -0,058 o = 90+0,022 = 120-0,36 e-054 E = 120 +0,25 +015 Spielneu Clearancenew 0,036dl 080 0,5181 + e2= 79 maximum durchAbniJtzung duetowear 0,12 1,5 5.84 ZahnradpumpezumAntriebSULZER Gruppe:01.'')Spiele derZylinderschmierpumpen Group:L GearPumpfor Blatt RT76 Gearances Cyl.Lub.PumpDriveSheet 13 1 3 -107.134.605 SieheauchBlatt012/11 Seealsosheet012/11 NennmassSpielneumaximumNennmassSpielneumax i mu'm durchAbnUtzungdurchAbnUtzung NominaldimensionClearancenewduetowearNominaldimensionClearancenewduetowear 0,050 a= 38al 0,009 min.0,055b max.130 0,15 max.0,20 min.0,14 0,40CD max.0,26 min.0,06 0,20CD max.0,13 5.84 AntriebfurUberdrehzahl,Pickup Gruppe: 012Spiele undFerndrehzahl-GeberGroup: BlattOverspeed- JPickup - andRemo-Clearances teTachometer7ransmitter - 0 riveSheet 14 3 SieheauchB1att012/11 SULZER RT76 Ueberdrehzah1-Geber-Antrieb OverspeedTransmitter-Drive - -'-- -_...._-----------..-----

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..... b NennmassSpiel NominaldimensionClearancenew a= 22a1 = b = c= 1,0 d= 1,0 e= 22e1 = -0'\ Seealsosheet012/11 - - / \. f'rndr,hzahl-6,b'r - --+-}{+} RemoteTachometer ''i-' 12""t-'Pi ck-up-Geber-Antri ebTransmitter-Drive 4 -107.197.333 "ri- l '"-""'" r--t-"" -l\r:: j....

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4 -107.197.320 3-107.f97.321L/ ----0 Nameofscrewedconnections{g'I. 8AT ........ o o........._ - . _ ~ .._.... ~ . . . - - - . . . . - - .....__::=.,.. z.- !lIIIIIl...=. - ..Iw.IcJot. Item8& 9onlyonvalves manufacturedafter1.7.83 "T58 -84IMOUNTIIIClINSTRUCTION FLOWCONTROLVALVE RL56 90(REXROTH) SULZERIE14-107.093.727 Ge. 0... ,,_. 3/1 _.t''''""". ~1 SULZER JRIVINGSHAFTTOTHEFLOWCONTROLVALVE Group:722 OFTHECYLINDERLUBRICATIONRT Sheet: DismantlingandAssembling KeytoIII ustrati on 1Screll6Drivingshaft 2Lockingplate7Key 2aEndplate8Syntheti csball 3Spurgear9Threadedpin 4Screll10FlollControlValve 5Casing11Flollcontrolvalveshaft Shouldthetroublefreefunctioningoftheflollcontrolvalve(REXROTH)notbeassuredforanyreason,it hastobeexchangedagainstanellone.Theremovalofthevalveoffitsdrivingshaftandthefittingof thenellonerequiresparticularcare,itisthereforerecommendedtofollollcarefullytheinstructions givenherebeloll. Thecompany(REXROTH)lIilltakecareofreconditioningthedefectivevalveuponrequest. Dismantl i ng - Loosenthescrell4andgentlytrytoliftthecasing5offthevalve10.IfthisisnoteasilyachievedtheflollcontrolvalveisofthenellertypeIIhichisequippedlIithclearance-freecouplingbetlleen drivingshaftandthrottlingbush(Thevalvearemanufacturedafter1.7.83) - Onthenellvalves,thespurgear3hastoberemoved.Thefasteningofthecouplingcanbeloosenedby turningbackthethreadedpin9. Whenremovingthedrivingshaftthesmallsyntheticsball8mayfallout. - Itisrecommendedtomarkthecorrectfittingpositionforthereassemblyafterremovingthecoupling. Assembling - Incasethecorrectfittingpositionofthedrivingshafttothethrottlingbushhasnotbeenmarked, thevalvemustberemovedoffthevalveplatetocheckthethroughflollfrom.AtoB lIithcompressed ai r. Durchflusskennlinie FLOWCHARACTERISTIC(I/trin,)

SO-I-+-+--+--+--+---+---+------+-:.."e-----1 /'"S>mbolischeDorsteIlung l:I/'..2 -1-+-+--+---f---+----+--t-7fI'< ~X = 185mm(RT76) X = 205mm(RT84) 941771Threadprotectionfor X thelowerthreadofthe tierods X =150mm(RT58) X =180mm(RT68) X =205mm(RT76) X = 220mm(RT84) "'-' 941851 Leafspringforscrewingonthelowertie rodnut X=720mm(RT58)-j "X=815mm(RT68) L: XX=760mm(RT76) , X=1025mm(RT84), I I'""!" ~8.84