INSTRUCTIONS

DAAD053845 / PAAD169691

Wärtsilä 2-stroke I-35

Technical Services Issue 1, 21 August 2014

Upside-down test of main

At your convenience
bearings
Information to all Owners and Operators of Concerned components
Wärtsilä RTA96C, RTA96C-B and RT-flex96C-B Main bearing shells of Wärtsilä RTA96C,
engines RTA96C-B and RT-flex96C-B engines in
service.

Introduction
This Instructions bulletin describes the
upside-down test procedure and explains
possible countermeasures.

This test should be carried out in order to

check the running surface of the bearing
shell and cover to maintain a smooth
transition between those two parts.

The main bearing upside-down test must

be carried out on all main bearing shells
and covers before fitting them at the first
time into the engine.

Wärtsilä Switzerland Ltd. Tel (24h): +41 52 262 80 10

PO Box 414
CH-8401 Winterthur technicalsupport.chts@wartsila.com
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Contents
Page
1 Introduction 2
2 References 2
3 Work scope, skills and manpower 3
4 Required tools and material 3
5 Main bearing upside-down flow chart 4
6 Main bearing upside-down test 4
6.1 Main bearing upside-down test set-up 5
6.2 Main bearing outside diameter check 6
6.3 Main bearing outside diameter correction 7
6.4 Check for a step between main bearing shell and bearing cover 8
6.5 Pass conditions for the main bearing upside-down test 9
6.6 Protrusion of the outer cover surface 9
6.7 Common turning if the inner shell surface protrudes beyond the cover 10
6.8 Scraping the main bearing cover 11
6.9 Common turning if inner cover surface protrudes beyond the shell 12
7 Contacts 13
7.1 How to contact Wärtsilä 13
7.2 Contact details for emergency issues 13

1 Introduction
The aim of the upside-down test is to check if the geometry of the shell and the cover
match before fitting the two parts into the engine. It is essential to maintain a smooth
transition between the main bearing shell and the bearing cover. Furthermore, the
outside diameter of the main bearing shell must be measured. The correct outside
diameter helps to prevent fretting on the backside of the main bearing shell.

2 References
Table 1

Document type Doc. Number Description

Spare part code Group 1
Main bearing with Slot/Key Execution
book Chapter 1132-1/A2
Group 1
Operating Manual Main bearing
Chapter 1132-1/A2
Group 0
Maintenance Manual Safety measures and warnings for maintenance
Chapter 011-1/A1
Group 0
Maintenance Manual Clearance table crankshaft and main bearing
Chapter 0330-1/A1
Group 0 Tightening values of important screwed
Maintenance Manual
Chapter 0352-1/A1 connections
Group 1
Maintenance Manual Main bearing
Chapter 1132
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3 Work scope, skills and manpower

Required skills and manpower for the upside-down test and for measuring the bearing
shell and cover after they are removed and placed outside of the crank case.
Depending on the main bearing and cover condition the work scope varies.

Table 2

Work scope Min time [h] Max time [h]

Estimated work duration per unit
Skills
Service Engineer or
qualified Crew member
Technician
1 3
Required Duration
1 For the whole work period
1 For the whole work period

4 Required tools and material

Required material for the upside-down test.

Table 3

Tools & Material Description Quantity Unit

94113 Measuring device for outside diameter 1 —
94113a Template for gap measurement 1 —
94122 Feeler gauge 1 —
— Scraper for white metal of bearing cover 1 —
Scotch–Brite™ pade 1 —
Material for cleaning
Brake cleaner or similar cleaning solvent
purposes only
WD40 or similar available solvent

NOTE:
The required tools and material for cleaning must be available from the on board
workshop store.
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5 Main bearing upside-down flow chart

The steps as described in Chapter 6 are summarised in the flow chart, see Figure 1.

START

Yes Shell outside No

diameter:
OK?

Yes Shell outside No

diameter:
too small?

Replace key with Replace key with

positive-offset key negative-offset key

5.3 5.3

Yes Shell surface No

protruding cover
surface?

Yes Step Z1 smaller No

than 0.05 mm?

Yes
MB #1:
No Yes MB #2 to #X: No Scrape cover 5.8
Step Z2 smaller Step Z2 smaller or
than 0.30 mm
or
than 0.20 mm do common turning
5.9

Common turning
Is the
step between
5.7 Yes shell back surface No
and cover side surface
less than
0.50 mm
Grind outer
surface of cover

OK 5.6
5.3, 5.6, 5.7, 5.8 and 5.9:
References to the respective Chapter in this Instructions bulletin
Figure 1: Main bearing upside-down flow chart

6 Main bearing upside-down test

The main bearing upside-down test is best carried out on all main bearing shells before
fitting them into the engine.

In addition, the upside-down test must be carried out when a main bearing shell and/or
a main bearing cover has been exchanged. The main bearing shell and bearing cover
should not be fitted in the engine unless it fulfils the pass conditions, see Chapter 6.5
“Pass conditions for the main bearing upside-down test”.
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If a conical shell is fitted in Main Bearing (MB) #2 with a non-matching cover (conical or
standard, new or used), then an upside-down test must be carried out before fitting the
parts into the engine.

Furthermore, the outside diameter of the main bearing shell must be measured. The
correct outside diameter helps to prevent fretting on the backside of the main bearing
shell.

6.1 Main bearing upside-down test set-up

Check that both keys have inside contact to the main bearing cover according to
following procedure:
• Put engineer’s blue on the inner key surface (4), see Figure 2.
• Put the main bearing cover (2) in an upside down position and lower the main
bearing shell (1) down onto the main bearing cover.
• Lift-off the main bearing shell and verify that the keys have contact at the inner
surface (4).

The edges of the main bearing shell and main bearing cover should be parallel across
the length of the main bearing shell.

3 4

1. Main bearing shell 3. Outer surface of key

2. Main bearing cover in upside-down 4. Inner surface of key
position
Figure 2: Illustration of upside-down test

ATTENTION:
Carefully lift-off the main bearing shell from the bearing cover so that both keys slip out
at the same time. Otherwise there is a risk of damaging the keys.
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6.2 Main bearing outside diameter check

The main bearing shell (1) is assembled upside-down and tested as described in
Chapter 6.1.
Use the template (3) with tool number 94113 to check the shell outside diameter.
For the main bearing #1 use the feeler gauge (4) with tool number 94122 in
combination with the template.

Touch point on Touch point on

bearing shell bearing shell

2
3

1. Main bearing shell 3. Template, tool 94113

2. Main bearing cover in upside-down 4. Feeler gauge, tool 94122
position
Figure 3: Main bearing assembled upside-down – diameter check

Table 4: Limits of bearing shell outside diameter

Main bearing number Limits

minimum maximum
All main bearings
1080.42 mm 1080.66 mm
except main bearing #1
Main bearing #1 1080.22 mm 1080.48 mm

The values in Table 4 represent the normal range for new parts. The outside diameter
can be lower for used bearing shells.
• If the outside diameter is not within the limits as listed in Table 4, then correct the
outside diameter by fitting offset keys. If the offset key is oversized, then machine it
to the correct size.
• It is better for the outside diameter to be between 1080.55 mm and 1080.66 mm at
the upper limit of the range, in order to reduce the risk of fretting.
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6.3 Main bearing outside diameter correction

Outside diameter corrections could be taken into account when the measures in
Chapter 6.2 “Main bearing outside diameter check” are out of the specifications.

Correction of too SMALL shell outside diameter:

Replace the original key with a POSITIVE offset key.
2
3

Centre of
Shell deformation bearing

Contact line

Offset key code number

0.1 mm offset: D 96120 / DF 96120
0.2 mm offset: D 96121 / DF 96121
1 0.3 mm offset: D 96122 / DF 96122

Correction of too LARGE shell outside diameter:

Replace the original key with a NEGATIVE offset key.

4 2

Centre of
bearing Shell deformation

2
Contact line

Offset key code number

0.1 mm offset: D 96120 / DF 96120
0.2 mm offset: D 96121 / DF 96121
0.3 mm offset: D 96122 / DF 96122 1

1. Main bearing cover 2. Main bearing shell

3. Positive offset key 4. Negative offset key
D= Code for RTA96C & RTA96C-B engines DF= Code for RT-flex96C-B engines
Figure 4: Main bearing outside diameter correction
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6.4 Check for a step between main bearing shell and bearing cover
Procedure:
• Measure dimensions “X” and “Z” as shown in Figure 5 on both sides (port and
starboard) and in engine forward and aft positions.
• Measure dimension “Z1” at 30 mm above the contact surface between bearing cover
and main bearing shell.
• Measure dimension “Z2” at 30 mm below the contact surface between bearing cover
and main bearing shell.

5 5

4
X
10 mm

30 mm

30 mm

Z1

30 mm

3
30 mm

Z2
2

1. Main bearing shell 5. Template, Standard tool no. 94113a –

2. Main bearing cover see Maintenance Manual Group 9,
3. Key Chapter 9403–5
4. Contact line
Figure 5: Gap measurement between main bearing shell and bearing cover
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6.5 Pass conditions for the main bearing upside-down test

The main bearing shell passes the upside-down test if condition 1 and either condition
2a or 2b are met:

1 The outer surface of the main bearing cover protrudes beyond the outer surface of
the main bearing shell. The following condition is acceptable:
− The protrusion “X” should be maximum 0.50 mm.
If this condition is not fulfilled, than perform corrections according to Chapter 6.6.

2a The running surface of the main bearing shell protrudes beyond the main bearing
cover. The following condition is acceptable:
− Dimension “Z2” should be maximum 0.20 mm, except on MB #1 which should
be maximum 0.30 mm.
If condition 2a is not met, common turning has to be done (see Chapter 6.7
“Common turning if the inner shell surface protrudes beyond the cover”) or contact
Wärtsilä for further advices.

2b The main bearing cover protrudes beyond the running surface of the main bearing
shell by maximum 0.05 mm (Dimension Z1).

If condition 2b is not met and the dimension Z1 is between 0.05 mm and maximum
0.35 mm then the white metal of the main bearing cover has to be scraped by
hand, see Chapter 6.8 “Scraping the main bearing cover”.

In case Z1 is above 0.35 mm, than the cover has to be common turned, see
Chapter 6.9 “Common turning if inner cover surface protrudes beyond the shell”.

NOTE:
For cases the pass conditions are not met, Wärtsilä can provide advice about actions
to be taken for solving the problem.

6.6 Protrusion of the outer cover surface

The maximum protrusion of the outer surface of the cover beyond the outer surface of
the bearing shell is 0.50 mm. If the protrusion is greater, then grind the outer surface of
the bearing cover to bring it within the specified limit.
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6.7 Common turning if the inner shell surface protrudes beyond the cover
• Rig up the cover and shell as shown in Figure 6, holding down the shell with a belt
or wire.

NOTE:
Do not use force to tighten in order to avoid shell deformation.

• Select 3 contact points for the turning circle. One point at the top of the shell
(point A) and two points on the cover, one on each side 30 mm below the split line
between the shell and cover (points B and C).
• Do not machine at point A and D.
• Turn out the shell to remove the step between shell and cover.

ATTENTION:
Depending on the facilities and machine tools available in the on board workshop, the
common turning might not be possible. In such cases common turning has to be done
in a workshop ashore. Please contact Wärtsilä Services for assistance.

Touch point A

Touch point B Touch point C

Touch point D 2

1. Main bearing shell 3. Belt or wire

2. Main bearing cover in upside-down
position
Figure 6: Inner shell surface protrudes beyond the cover
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6.8 Scraping the main bearing cover

A slight protrusion of the main bearing cover beyond the main bearing shell can be
corrected by scraping the main bearing cover.

ATTENTION:
Scraping the main bearing cover is a very delicate job and should be carried out by
experienced and qualified personnel only.

• The main bearing cover should only be scraped if the scrape depth is
maximum 0.30 mm.
• Rig up the main bearing cover as shown in Figure 7.
• Scrape the main bearing cover using a run-out length depending on the scrape-
depth:
max. run-out length: 𝑠𝑐𝑟𝑎𝑝𝑒 𝑑𝑒𝑝𝑡ℎ ∗ 500 𝑚𝑚, (𝑒. 𝑔. 0.30 𝑚𝑚 ∗ 500 𝑚𝑚 = 150 𝑚𝑚)
• Scrape until dimension “Z1” is within the allowed range, see Figure 5 and previous
Chapter 6.5.

max. scrape depth

run-out
length

1. Main bearing cover

Figure 7: Main bearing cover scraping
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6.9 Common turning if inner cover surface protrudes beyond the shell
If the inner cover surface protrudes more than 0.35 mm beyond the shell, proceed as
follows:
• Rig up the cover and shell as shown in Figure 8, holding down the shell with a belt
or wire.

NOTE:
Do not use force to tighten in order to avoid shell deformation.

• Select three contact points for the turning circle. One point at the top of the shell
(point A) and two points on the side of the shell, i.e. one on each side 30 mm above
the split line between the shell and cover (points B and C).
• Do not machine at point A and D.
• Turn out the cover to remove the step between the shell and cover.

ATTENTION:
Depending on the facilities and machine tools available in the on board workshop, the
common turning might not be possible. In such cases common turning has to be done
in a workshop ashore. Please contact Wärtsilä Services for assistance.

Touch point A

Touch point B Touch point C

Touch point D 2

1. Main bearing shell 3. Belt or wire

2. Main bearing cover in upside-down
position
Figure 8: Inner cover surface protrudes beyond the shell
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7 Contacts
7.1 How to contact Wärtsilä
For questions about the content of this Instructions bulletin, or if you need Wärtsilä
assistance, services, spare parts and/or tools, please contact your nearest Wärtsilä
representative.
If you do not have the contact details at hand, please follow the link “Contact us” – “24h
Services” on the Wärtsilä webpage:
www.wartsila.com

7.2 Contact details for emergency issues

7.2.1 Operational support
For questions concerning operational issues, please send your enquiry to:
technicalsupport.chts@wartsila.com
or phone 24hrs support: +41 52 262 80 10.

7.2.2 Field service

If you need Wärtsilä Field Service, please send your enquiry to:
ch.fieldservice@wartsila.com
or phone 24hrs support: +41 79 255 68 80.

7.2.3 Spare parts

If you need Wärtsilä spare parts and/or tools, please contact your nearest Wärtsilä
representative or your key account manager.

© 2014 Wärtsilä Switzerland Ltd. – All rights reserved

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makes no representation, warranty (express or implied) in this publication and assumes no responsibility for the correctness, errors or
omissions for information contained herein. Information in this publication is subject to change without notice.

Unless otherwise expressly set forth, no recommendation contained in this document or any of its appendices is to be construed as
provided due to a defect of the product, but merely as an improvement of the product and/or the maintenance procedures relating thereto.
Any actions by the owner/operator as a result of the recommendations are not covered under any warranty provided by Wärtsilä and such
actions will thus be at the owners/operators own cost and expense.

NO LIABILITY WHETHER DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL, IS ASSUMED WITH RESPECT TO
THE INFORMATION CONTAINED HEREIN. THIS PUBLICATION IS CONFIDENTIAL AND INTENDED FOR INFORMATION
PURPOSES ONLY.