INSTRUCTIONS

DAAD044419 / PAAD142907

Wärtsilä 2-stroke I-24

Technical Services Issue 1, 30 September 2013

Emergency on board repair kit:

At your convenience
Injection control valve
Information to all Owners and Operators of Concerned components
Wärtsilä RT-flex engines. Injection Control Units (ICU) of most
NOTE: Wärtsilä RT-flex engines in service. Not
This Instruction is only delivered with the ordered concerned are RT-flex82C and RT-flex82T
repair kit to the customers. engines. Also not concerned are some
ICU types as installed in RT-flex68-D
engines. Details to concerned ICUs in RT-
flex68-D engines are given in the
Introduction part.

Current situation
With the General Information bulletin
RT-137 “Repair concepts for RT-flex
components” Wärtsilä offers some
emergency on board repair kits.

Solution
In order to handle the repair work for the
ordered emergency on board repair kit
without fail, this Instructions bulletin shall
give all needed information.

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 3
3 Skills and manpower 3
4 Required tools and material 3
5 Tightening torques 4
6 Main parts of ICU and content of the ICV emergency on board repair kits 4
7 Preparation work 5
8 Removal and fitting of the ICU 5
9 Work procedure, ICV replacement 6
10 Contacts 10

1 Introduction
This Instructions bulletin is intended to carry out the repair work on the Injection Control
Unit (ICU) for the ordered emergency on board repair kit as explained in the General
Information bulletin RT-137.

In particular this Instructions bulletin is for carrying out the exchange of the Injection
Control Valve (ICV).

The work described is valid for Injection Control Units of size 0, 1, 2 and 4. These types
of ICUs are installed in most RT-flex engines. The repair instructions are not valid for
RT-flex82C and RT-flex82T engines. Also not concerned are some ICU types as
installed in RT-flex68-D engines.

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 concerned but not the ICUs (2) which are built to the same concept as the ICUs in
the RT-flex82C and RT-flex82T engines.

1 2

1. Concerned ICUs
2. Not concerned generation of ICUs
Figure 1, Determination of concerned ICUs of RT-flex68-D engines
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NOTE:
The drawings, illustrations and pictures as used in this Instructions bulletin are based
on RT-flex96C and RT-flex84T-D engines. These engines have Injection Control Units
of size 4.
ICUs of size 0, 1 and 2 might look in certain details different but irrespective of the
visual view, the given instructions are valid for all listed types of ICUs. And finally, if
there is a significant difference it is pointed out in the instructions.

2 References
Table 1

Document type Doc. Number Description

Group 0 Changing Over from Diesel Oil to Heavy Fuel Oil and
Operating Manual
Chapter 0270–1 Vice Versa
Group 0 Operation under Abnormal Conditions:
Operating Manual
Chapter 0510–1 Operation with Injection Cut Out
Group 5 Injection Control Unit:
Maintenance Manual
Chapter 5564–1 Removal and Fitting

3 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.

Table 2

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

4 Required tools and material

Required material in addition to the ordered emergency on board repair kit.

Table 3

Tools & Material Description Quantity Unit

Torque spanner: up to 200 Nm 1 —
Allen key for M14 2 —
Allen key for M12 2
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
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NOTE:
• No tools are delivered with the respective emergency on board repair kit.
• The required tools and material for cleaning must be available from the on board
workshop store.
• Material and tools for the removal of the ICU are not listed here, see Maintenance
Manual Group 5, Chapter 5564–1.

5 Tightening torques
Table 4

Screw Tightening torque with lubricant

Location
dimension Never-Seez NSBT-8
M14x300 Flange of ICV
170 Nm
(8 pieces per ICV flange) Size 4
M12x240 Flange of ICV
130 Nm
(8 pieces per ICV flange) Size 0, 1 and 2

6 Main parts of ICU and content of the ICV emergency on board repair kits

1. Injection control valve kit 4. Rail valve

2. Injection control piston 5. Injection control block
3. Fuel quantity sensor
Figure 2, Main parts of ICU and location of ICV emergency on board repair kit
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Table 5, Injection control valve kit by engine type and ICU size

Engine type ICU size Kit order Kit contents Quantity

number
RT-flex96C-B DF 55657
4
RT-flex84T-D BF 55754
RT-flex68-B
2 MF 55602
RT-flex68-D • Injection control valve (006) 3 sets
RT-flex60C • Spring carrier (008) 3 pieces
NF 55602 • Lip seal (014) 1 piece
RT-flex60C-B
RT-flex58T-B • Compression spring (023) 3 pieces
1
RT-flex58T-D OF 55602
RT-flex58T-D_V1
RT-flex58T-D_V2 GF 55602
RT-flex50 • Injection control valve (006) 2 sets
RT-flex50-B IF 55655 • Spring carrier (008) 2 pieces
0
RT-flex50-D • Lip seal (014) 1 piece
RT-flex48T-D EF 55655 • Compression spring (023) 2 pieces

7 Preparation work
For the replacement of the injection control valve the injection control unit must be
removed from the fuel rail.

To replace an injection control unit, the engine must operate for a minimum of
1.5 hours with marine diesel oil (MDO). For more data see Operation Manual Group 0,
Chapter 0270−1.

When working on an injection control unit in principle the engine has to be stopped and
the fuel booster and bearing oil pumps switched off.

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

The corresponding drain screws and respectively valves must be opened as described
in the Operating Manual Group 0, Chapter 0510–1.
Follow the detailed instruction without fail.

8 Removal and fitting of the ICU

Please read and follow the information in the Maintenance Manual, Group 5, Chapter
5564–1 “Injection Control Unit, Removal and Fitting”. Make sure that the mentioned
tools and material is ready to use.
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NOTE:
During dismantling and assembling of the ICU the activity area has to be clean and free
from dust. Grinding in the nearby work area must be stopped.

Electric welding near or on the engine must be absolutely omitted.

When mounting the ICU back to the fuel rail, the lip seal (014) must be replaced with
the new one from the delivered emergency on board repair kit.

WARNING:
Pay attention to the lifting tools safety operation when removing and remounting the
ICU.

ATTENTION:
As the emergency repair of RT-flex parts onboard vessels or customers workshops will
be outside of any possibilities for quality control by Wärtsilä, no warranties can be
granted on these parts after such work has been done.

9 Work procedure, ICV replacement

9.1 Removal of the injection control valve

006. Injection control valve 016. Hexagon socket head cap screw
007. Flange 023. Compression spring
008. Spring carrier
Figure 3, Injection control valve replacement

• Remove the hexagon socket head cap screws (016).

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• Remove following parts:

− Flange (007)
− Compression spring (023)
− Spring carrier (008)
− Injection Control Valve (006)
from the injection control block (002, 012)
• Clean the metal touching surface between the injection control valve (006) and the
injection control block (002, 012).

9.2 Reassembly the injection control valve

Table 6

Procedure Pictures
1. Apply grease to prevent the distance pin
falling out.

2. Place the new injection control valve

(006) on the injection control block (002,
012).

3. The positioning pins should be aligned.

4. Place the spring carrier (008) with the 008 023

compression spring (023) on the injection
control valve (006).
006
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Table 6, continued

Procedure Pictures

Spring carrier (008)

Compression spring (023)

Injection control valve (006)

5. Put the flange (007) over the compression 007

spring (023).
023
6. Fix the flange (007) with two hexagon 016
head cap screws (016) on the injection
control block (002, 012). 008

006
7. Tighten alternatively using the two
hexagon socket head cap screws (016)
until the flange (007) and the injection
control valve (006) make contact.
The easiest way to install the two hexagon
head cap screws is by using two Allen
002, 012
keys (1) and (2) simultaneously.

NOTE:
Apply lubricant Never-Seez NSBT-8 on
the threads.
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Table 6, continued

Procedure Pictures
1. Insert and tighten the hexagon socket
head cap screws (016) in steps.

Eight hexagon head cap screws are

required per each flange (007).

The tightening sequence is shown in the

picture to the right.

2. Tightening steps and final torque

for Size 4 ICUs:
60, 100, 130 and finally 170 Nm.

3. Tightening steps and final torque 016 007

for Size 0, 1 and 2 ICUs:
60, 100 and finally 130 Nm.

NOTE:
Apply lubricant Never-Seez NSBT-8 on Tightening torque for
the threads. Size 4 ICU:
170 Nm

Tightening torque for

Size 0, 1 and 2 ICUs:
130 Nm

9.3 Mounting of ICU on fuel rail

After successful ICV replacement the ICU must be mounted back to the fuel rail.
Make sure that the new lip seal (014) is used which is part of the ICV kit delivery, see
Figure 4.
Follow the description in the Maintenance Manual Group 5, Chapter 5564–1 how to
mount the ICU back onto the fuel rail.

1
014

1. Injection control unit 014. Lip seal to fuel rail

2. Fuel rail
Figure 4, Injection control unit showing location of lip seal
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10 Contacts
10.1 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 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 your enquiry to:
ch.spareparts.wgls@wartsila.com
or phone 24hrs support: +41 52 262 24 02

© 2013 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 repair 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.