WORK

INSTRUCTION

Wärtsilä low-speed engines I-19

Services 2-stroke Issue 2, 04.12.2012

Instruction for replacement of Next opportunity

ICU fuel valve assembly Concerned components

Information and instruction for the replacement of the
ICU fuel valve assembly.
Applicable to Wärtsilä RT-flex82C, RT-flex82T and
RT-flex68-D engines
Injection Control Units (ICU) of Wärtsilä
RT-flex82C and RT-flex82T engines in
service and in production between
February 2009 and June 2011. Also
concerned are some ICU types as initially
installed in RT-flex68-D engines. Details to
concerned ICUs in RT-flex68-D engines
are given in the Introduction part.

Problems
Wear at the valve seat of the ICU affects
the thermodynamic behaviour of the
engine in operation.

Preventive action
Replacement of the ICU fuel valve
assembly with an improved matching of
valve seat and spindle.

Solution
The concerned mounted ICU fuel valve
assembly must be exchanged with the one
having an improved matching of valve seat
and spindle.

Note
This Issue 2 supersedes Work Instruction
I-19 Issue 1, dated 30.05.2012.
New inspection chapters “Check the drain
bores and piping” have been added.

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

PO Box 414 Fax: +41 52 262 07 31
CH-8401 Winterthur technicalsupport.chts@wartsila.com
 WORK INSTRUCTION I-19
Issue 2, Page 2 / 15

1 Table of contents
1  Table of contents 2 
2  Introduction 2 
3  References 3 
4  Skills and manpower 3 
5  Required material and tools 4 
6  Tightening torques 4 
7  Brief work description 6 
7.1  Removing of the ICU pre-control device 6 
7.2  Checking/Removing of the shim 6 
7.3  Removing of ICU fuel valve assembly 7 
7.4  Check the valve clearance 7 
7.5  Check the drain bores 9 
7.6  Check the piping for clogging 10 
7.7  Assembly of the fuel valve assembly to the measuring device 11 
7.8  Assembly of the pre-control device to the fuel valve assembly 12 
7.9  Venting of the ICU and checking the injection curves 12 
8  Maintenance and cleaning 13 
8.1  Check and clean the quantity piston rod 13 
8.2  Work procedure 13 
9  Appendix 14 
10  Contacts 15 
10.1  How to contact Wärtsilä 15 
10.2  Contact details for emergency issues 15 

2 Introduction

Note:
This Issue 2 supersedes Work Instruction I-19 Issue 1, dated 30.05.2012. New
inspection chapters “Check the drain bores and piping” have been added.

Unexpected wear at the valve seats on the Injection Control Unit (ICU) was found
during follow up inspections on RT-flex82C and RT-flex82T engines in service.

Beside concerned ICUs of RT-flex82C and RT-flex82T engines, the same indices
were found on ICUs of RT-flex68-D engines, but depending on the ICU types
installed.
 WORK INSTRUCTION I-19
Issue 2, Page 3 / 15

For the determination of concerned RT-flex68-D ICUs, please check the 3D

drawings in Figure 1 and compare with the actually installed ICUs in the rail unit.
The ICUs (1) are not concerned only the ICUs (2) which are built to the same
concept as the ICUs in the RT-flex82C and RT-flex82T engines.

Determination of concerned ICUs of RT-flex68-D engines

1 2

1. Not concerned generation of ICUs, 2. Concerned ICUs

Fig. 1

With the replacement of the fuel valve assembly (2) with an improved one, the
wear at the valve seat will be minimised, see Figure 2.

3 References

Document type Doc. Number Description

Order Drawing 107.395.622 Injection Control Unit (ICU) for RT-flex82C
Order Drawing 107.404.791 Injection Control Unit (ICU) for RT-flex82T
Order Drawing DAAD015194 Injection Control Unit (ICU) for RT-flex68-D
Maintenance Section 5564–1
Injection Control Unit: Removal and Fitting
Manual (latest edition)

Table 1

4 Skills and manpower

Required skills and manpower for the replacement of the Injection Control Unit
(ICU) fuel valve assembly.
Depending on the ICU condition the work scope may vary.

Skills Required Min time [h] Max time [h]

Supervisor or 1 2 3
Service Engineer
Mechanic 1 2 3
Estimated work duration per unit 2.5 3.5

Table 2
 WORK INSTRUCTION I-19
Issue 2, Page 4 / 15

5 Required material and tools

Material No. Description Quantity Unit

107.389.792.001 Fuel valve assembly for RT-flex82C 1 Per ICU
107.405.360.001 Fuel valve assembly for RT-flex82T 1 Per ICU
107.381.835.200 Lip seal 1 Per ICU
O-ring size 171.04x 3.53 (connection Fuel
021.702.017.005 1 Per ICU
valve assembly to Intermediate casing)
O-ring size 44.04x3.53(connection Pre-
021.702.004.305 3 Per ICU
control block to Intermediate casing)
021.501.000.507 O-ring size 5.28x1.78 (to Rail valves) 9 Per ICU
021.702.004.105 O-ring size 40.87x3.53 1 Per ICU
Tools & Material Description Quantity Unit
Torque spanner: 1 to 6 Nm 1 —
Torque spanner: up to 60 Nm 1 —
Allen keys for: M4, M6, M10 and M12 4 —
Depth gauge (depth micrometer, dial
1 —
indicator – Resolution 0.01 mm)
Never-Seez Regular Grade, NSBT-8 —
Material for Scotch–Brite™ 1 —
maintenance Brake cleaner or similar cleaning solvent
and cleaning
purposes only WD40 or similar available solvent

Table 3

Note:
The tools have to be brought on board by the Service Engineer.

6 Tightening torques

Screw Tightening torque with lubricant

Location
dimension Never-Seez NSBT-8 Oil
M4x16
Rail valve 4.0 Nm 4.0 Nm
(4 pieces)
M6x45 Intermediate casing &
7.0 Nm 10.0 Nm
(2 pieces) Pre-control block
M10x60 Sensor housing & ICU
30.0 Nm 40.0 Nm
(4 pieces) measuring device
M10x130 Pre-control device &
30.0 Nm 40.0 Nm
(12 pieces) Fuel valve assembly
M10x120 Fuel valve assembly &
30.0 Nm 40.0 Nm
(4 pieces) Measuring device
M12x120 Fuel valve assembly &
55.0 Nm 70.0 Nm
(6 pieces) Measuring device

Table 4
 WORK INSTRUCTION I-19
Issue 2, Page 5 / 15

When the lubricant Never-Seez NSBT-8 is not available, the alternative lubricant
“Oil” can be used. But be aware that the torque of the bolts is different, see
Table 4.

For a more efficient, reliable and safe work, the engine should be operated on
Diesel Oil (MDO) for the last 1 to 2 hours.

Note:
Make sure that the fuel and servo rail pressures are completely released.

It is not necessary to remove the whole ICU from the fuel rail. Only the ICU pre-
control device, consisting of the pre-control block (4) and intermediate casing (3),
as well as the fuel valve assembly (2) has to be removed from the measuring
device (1), see Figure 2.

Main parts of the ICU (drawn for RT-flex82C)

4 3

1. Measuring device, 2. Fuel valve assembly, 3. Intermediate casing, 4. Pre-

control block, 5. Rail valve, 6. Housing with fuel quantity sensor
Fig. 2
 WORK INSTRUCTION I-19
Issue 2, Page 6 / 15

7 Brief work description

7.1 Removing of the ICU pre-control device

The two parts, i.e. the pre-control block (4) and the intermediate casing (3) form
together the pre-control device, see Figure 2 and 3.

Cut through the ICU (drawn for RT-flex82C)

2 3 4 5 8 9

7 10

1. Measuring device, 2. Fuel valve assembly, 3. Intermediate casing, 4. Pre-

control block, 5. Rail valve, 6. Screw M4x16, 7. Screw M10x130, 8. Screw
M10x120, 9. Screw M12x120, 10. Lip seal
Fig. 3

• Disconnect all rail valve plugs from the rail valve (5); mark them if necessary
to avoid any misconnection afterwards.
• Disconnect all pipes and hoses to the pre-control block (4).
Use an eye bolt M10 to secure and lift the pre-control device, weight of part:
− 24 kg for RT-flex82C
− 26 kg for RT-flex82T and RT-flex68-D
• Loosen and remove all twelve M10x130 screws (7), see Figure 3.
• Carefully remove the ICU pre-control device from the fuel valve assembly (2).

Attention:
Handle the pre control device with care to avoid a high load on the plugs of the
rail valves.

7.2 Checking/Removing of the shim

Check if a shim (1) is visible in the gap (2) between the pre-control block (4) and
the intermediate casing (3). The shim has a thickness of 0.15 to 0.25 mm.
In case a shim is installed, remove it according to the below given procedure.
 WORK INSTRUCTION I-19
Issue 2, Page 7 / 15

Location of distance shim (drawn for RT-flex82C)

8 3 7 4 5

6 2 1

1. Distance shim, 2. Location of distance shim, 3. Intermediate casing, 4. Pre-

control block, 5. Rail valve, 6. Screw M6x45, 7. O-ring, 8. O-ring
Fig. 4

• Loose and remove the two M6x45 screws (6).

• Remove the intermediate casing (3) from the pre-control block (4).
• Remove the shim (1), thickness 0.15 mm or 0.25 mm.
• Clean both surfaces.
• Replace all three O-rings (7) between the intermediate casing (3) and the pre-
control block (4) with new ones and grease them.
• Fit the intermediate casing (3) with the pre-control block (4) together and tight
the two M6x45 screws (6) according to the given torque value in Table 4.

7.3 Removing of ICU fuel valve assembly

• Disconnect all pipes from the fuel valve assembly (2), see Figure 3.
• Use eye bolts to secure and lift the fuel valve assembly (2).
− 2 eye bolts M10 for RT-flex82C,
− 2 eye bolts M12 for RT-flex82T and RT-flex68-D.
Weight of part for all mentioned engines: 26 kg.
• Loosen and remove all six M12x120 screws (9) and the M10x120 screws (8):
− four M10x120 screws for RT-flex82C,
− three M10x120 screws for RT-flex82T and RT-flex68-D.
• Remove carefully the fuel valve assembly (2) from the ICU measuring
device (1).

7.4 Check the valve clearance

Note:
Carry out this measurement with the pre-control device (without shim) and with
the new delivered fuel valve assembly.
 WORK INSTRUCTION I-19
Issue 2, Page 8 / 15

• Lay the ICU pre-control device carefully on the rail valves.

• Remove the O-ring (8) from the intermediate casing (3), see Figure 4.
• Clean both parts, clean the three tappets on the intermediate casing (part of
pre-control device) and press them down to ensure a correct measurement.
• Clean the spindles of the fuel valve assembly.

Measurement points

1. Measuring surface of intermediate casing, 2. Tappet, 3. Depth micrometer,

4. Measuring surface of fuel valve assembly, 5. Valve spindle, 6. Dial gauge
Fig. 5

Measure the depth on all three tappets and measure also the protrusion of all
three spindles. Note results in the measuring protocol, see Appendix 1.

• The fuel valves are numbered with #1 to #3. Please not that number #1 is on
the driving end side.
• The clearance is defined as follows:

Depth minus Protrusion = Valve clearance

• The clearance should be between 0.15 and 0.30 mm.

− If the clearance is greater than allowed, check if a shim is installed.
− If the clearance is less than allowed, make sure that the tappets sticking
out of the intermediate casing are pressed completely back to the end
position in the pre-control device.
Make also sure that the valve spindles located in the fuel valve assembly
are in fully closed position.
• Please refer to the table below in order to identify the correct measuring
position.
 WORK INSTRUCTION I-19
Issue 2, Page 9 / 15

Measuring positions (drawn for RT-flex82C)

1. Protrusion of valve spindle, 2. Depth of tapped, 3. Total axial clearance

Fig. 6

7.5 Check the drain bores

• Check the condition of the ICU drain bores, i.e. the fuel and control oil drain
bores for any sludge formation (clogging), see Figure 7 and 8.
• Take pictures and describe the condition of the drain bores. Fill in the findings
into the measuring protocol as indicated in the example, see Appendix 1.
• In case the darin bores are clogged, clean them thoroughly and check the
connection piping to the drain bores, see next chapter.

ICU clogged drain bore

1. Clogged drain bore

Fig. 7
 WORK INSTRUCTION I-19
Issue 2, Page 10 / 15

Locations of ICU drain bores (drawn for RT-flex82C)

1. Control oil drain, 2. Fuel oil drain

Fig. 8

7.6 Check the piping for clogging

Check the fuel and control oil piping including the pipe connections for clogging,
see Figure 9.

7.6.1 Fuel leakage pipe

• Check the pipe connection on the ICU including the common leakage pipe.
• Check the pipe itself.

7.6.2 Control oil leakage pipe

• Check the pipe connection on the ICU including the common leakage pipe.
• Check the pipe itself.

Clean the fuel and control oil piping including the pipe connections if necessary.

ICU piping (drawn for RT-flex82C)

1. Control oil leakage pipe, 2. Fuel oil leakage pipe

Fig. 9
 WORK INSTRUCTION I-19
Issue 2, Page 11 / 15

7.7 Assembly of the fuel valve assembly to the measuring device

Cut through the ICU with main parts (drawn for RT-flex82C)

2 3 4 5 8 9

7 10

1. Measuring device, 2. Fuel valve assembly, 3. Intermediate casing, 4. Pre-

control block, 5. Rail valve, 6. Screw M4x16, 7. Screw M10x130, 8. Screw
M10x120, 9. Screw M12x120, 10. Lip seal
Fig. 10

• Clean the connection surfaces between the measuring device (1) and the fuel
valve assembly (2).
Both surfaces have to be free of any dirt and oil.
• Check the visible side of the installed lip seal (10) for any damages and
scratched.
Note: Removing of the lip seal is not necessary for the inspection.
• If any damage is detected, replace the lip seal (10) with a new one.
• Lubricate the six M12x120 screws (9) and the M10x120 screws (8) with
Never-Seez NSBT-8:
− four M10x120 screws for RT-flex82C,
− three M10x120 screws for RT-flex82T and RT-flex68-D.
Assemble the parts and tighten the screws crosswise by hand.
Note: The block is self-aligning over the dowel pins.
• Tighten the six M12x120 screws (9) crosswise to the end torque as specified
in Table 4.
• Tighten the M10x120 screws (8) crosswise to the end torque as specified in
Table 4. Note:
− four M10x120 screws for RT-flex82C,
− three M10x120 screws for RT-flex82T and RT-flex68-D.

Note:
Depending on the used lubricant the tightening torque is different, therefore
please consult Table 4 for details.
 WORK INSTRUCTION I-19
Issue 2, Page 12 / 15

7.8 Assembly of the pre-control device to the fuel valve assembly

The pre-control device consists of the two parts Intermediate casing (3) and the
pre-control block (4), see Figure 11.
• Clean the connection surfaces between the fuel valve assembly (2) and the
pre-control device.
Both surfaces have to be free of any dirt and oil.
• Slightly grease the new O-ring (8) and install it. Make sure that the O-ring
remains in the groove during the assembly.
• Lubricate the twelve M10x130 screws (7) with Never-Seez NSBT-8, assemble
it and tighten the screws crosswise by hand.
Note: The block is self-aligning over the dowel pins.
• Tighten the twelve M10x130 screws (7) crosswise to the end torque as
specified in Table 4.
• Connect all rail valve plugs (6) to the rail valves (5).
• Re-connect all removed pipes and hoses.

ICU section (drawn for RT-flex82C)

2 8 3 4 5

7
6
1

1. Measuring device, 2. Fuel valve assembly, 3. Intermediate casing, 4. Pre-

control block, 5. Rail valve, 6. Rail valve plug, 7. Screw M10x130, 8. O-ring
Fig. 11

7.9 Venting of the ICU and checking the injection curves

Perform the below steps to ensure correct functioning of the ICU.

• Clean all sides, free surfaces from liquid fuel and oil residues.
• Turn the engine a few revolutions by pushing the “Air Run” button on the
WECS manual control panel and release the button after a short time to reach
a fuel rail pressure of 150 to 200 bar.
• Switch to the “flexView” screen and activate on the “User” tab “Injection
Venting” on all cylinders to vent the ICU together with the injection pipes.
 WORK INSTRUCTION I-19
Issue 2, Page 13 / 15

• After venting, activate in “flexView” the “Heavy Sea Mode” and start the
engine on idle speed.
• Check the ICUs for leakages.
• Switch to “flexView” screen and select (take) an injection curve plot.
− Check the injection time between the different cylinders.
The injection time between the different cylinders should vary only a little.

8 Maintenance and cleaning

8.1 Check and clean the quantity piston rod

The following procedure can be made when convenient:
During general engine operation only about 50 to 70% of the fuel quantity piston
stroke is used. As a consequence, fuel deposits will build up on the unused part
of the piston rod, see Figure 12. If a sudden increase in stroke occurs, the fuel
deposits can lead to a sticking piston in its maximum position

Contaminated piston rod

1. Fuel deposits on piston rod

Fig. 12

8.2 Work procedure

The material needed for cleaning is listed in Table 3.
• Remove the leakage pipe of the ICU sensor housing.
• Loose the four M10x60 bolts and remove the sensor housing together with the
sensor and sensor cable.

Attention:
Do not remove the Quantity piston flange. Pay attention to the coupling of the
piston rod to the measuring tube. This coupling is very sensitive.
 WORK INSTRUCTION I-19
Issue 2, Page 14 / 15

• Moisten the deposits on the piston rod with brake cleaner.

• Use Scotch–Brite™ or similar to remove deposits.
• Carefully clean the piston rod from any particles.
• Lubricate the piston rod with lubricating oil.
• Tighten the four M10x60 bolts from the sensor housing crosswise according to
the torque as specified in Table 4.

Removing of housing and cleaning of piston rod

1 2

3 4

1. Removing of housing with sensor, 2. Cleaning with Scotch–Brite™, 3. Brake

cleaner, 4. Clean piston rod with cloth
Fig. 13

9 Appendix
• Appendix 1, I-19_A1
Measuring protocol for:
RT-flex82C, RT-flex82T and RT-flex68-D ICU fuel valve assembly
replacement
 WORK INSTRUCTION I-19
Issue 2, Page 15 / 15

10 Contacts

10.1 How to contact Wärtsilä

For questions about the content of this Work Instruction, or if you need Wärtsilä
assistance, services, spare parts and/or tools, please contact your nearest
Wärtsilä representative.
If you don’t have the contact details at hand, please follow the link “Contact us” –
“24h Services” on the Wärtsilä webpage:
www.wartsila.com

10.2 Contact details for emergency issues

10.2.1 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.

10.2.2 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.

10.2.3 Spare parts

If you need Wärtsilä spare parts and/or tools, please send you enquiry to:
ch.spareparts.wgls@wartsila.com
or phone 24hrs support: +41 52 262 24 02

© 2012 Wärtsilä Switzerland Ltd. – All rights reserved

No part of this publication may be reproduced or copied in any form or by any means (electronic, mechanical,
graphic, photocopying, recording, taping or other information retrieval systems) without the prior written
permission of the copyright holder. Wärtsilä Corporation 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 in the engine, but merely as an improvement of the engine 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.