INSTRUCTIONS

DAAD044710 / PAAD143812

Wärtsilä 2-stroke I-27

Technical Services Issue 1, 14 March 2014

ICU onboard repair kit:

Fuel valve block assembly kit & Servo oil valve unit kit At your convenience

Information to all Owners and Operators of Concerned components

Wärtsilä RT-flex and W-X engines.
NOTE:
This Instructions bulletin is only delivered with the
ordered repair kit to the customers.
This instruction concerns Injection Control
Units (ICU) of Wärtsilä RT-flex82C and
RT-flex82T engines in service and the new
Wärtsilä X82 engines.
Concerned are as well some ICU types
which are installed on the RT-flex68-D
engines. Further details regarding the
concerned ICUs on RT-flex68-D engines
are given in the introduction.

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

Solution
This Instructions bulletin is a supporting
document for the ICU onboard repair kits
to assist in the maintenance of ICUs.

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

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

I-27, Issue 1, Page 2 / 11

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 onboard repair kits 4
7 Preparation work 6
8 Removal and fitting of the ICU 6
9 Work procedure 7
10 Contacts 11

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

In particular this Instructions bulletin is for carrying out the exchange of the fuel valve
block assembly and/or servo oil valve unit.

The work described is valid for size 3 Injection Control Units. This type of ICU is
installed on most RT-flex82C and RT-flex82T engines. Also concerned are some ICU
types installed on RT-flex68-D and W-X82 engines.

Please consult the 3D drawings in Figure 1 for the identification of concerned

RT-flex68-D ICUs. Compare the drawings with the actually installed ICUs on the rail
unit to determine the ICU generation. The ICUs (1) are not concerned but the ICUs (2)
which are built on a similar concept as the ICUs in the RT-flex82C and RT-flex82T
engines.

1 2

1. Not concerned ICUs 2. Concerned generation of ICUs

Figure 1, Determination of concerned ICUs of RT-flex68-D engines
 INSTRUCTIONS

I-27, Issue 1, Page 3 / 11

NOTE:
The drawings, illustrations and pictures used in this Instructions bulletin are based on
RT-flex82C and RT-flex82T engines. These engines have Injection Control Units size 3.

ICUs of RT-flex68D_V1 and W-X82 engines might look different in certain details but
irrespective of the visual view, the given instructions are valid for all listed types of
ICUs. Any significant differences will be pointed out in this instruction.

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

The following skills and manpower are required for the replacement of the Injection
Control Unit (ICU) and 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

The following Material is required in addition to the “onboard repair kit”.

Table 3

Tools & Material Description Quantity Unit

Torque spanner: up to 200 Nm 1 —
Allen key for M4 1 —
Allen keys for M10 and M12 Each 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
 INSTRUCTIONS

I-27, Issue 1, Page 4 / 11

NOTE:
• There are no tools delivered with the “onboard repair kit”.
• The required tools and material for cleaning must be available from the onboard
workshop store.
• Material and tools for the removal of the ICU are not listed in this document. Refer to
Maintenance Manual Group 5, Chapter 5564–1.

5 Tightening torques
Table 4

Screw Tightening torque with lubricant

Location
dimension Never-Seez NSBT-8
M12x120 Fuel valve block assembly 55 Nm

M10x120 Fuel valve block assembly 30 Nm

M10x140 Servo oil valve unit 30 Nm
M10x130 Servo oil valve unit 20 Nm
M4x16 Rail valve 4 Nm

6 Main parts of ICU onboard repair kits

5 6

1. Fuel valve block assembly kit 4. Fuel quantity sensor kit

2. Measuring block 5. Servo oil valve unit kit
3. Fuel quantity piston kit 6. Rail valve
Figure 2, Main parts of ICU and location onboard repair kit
 INSTRUCTIONS

I-27, Issue 1, Page 5 / 11

Table 5, ICU onboard repair kit by engine type and ICU size

Fuel valve block assembly kit

Engine type ICU Kit order Kit contents Quantity
size number
RT-flex82C, Tier 1 LF 55411
RT-flex82C, Tier 2 LF 55415 • Fuel valve block (005) 1 set
RT-flex82T, Tier 1 & 2 3 VF 55415 • Lip seal (007) 2 pieces
RT-flex68-D_V1 PF 55415 • O-ring (015) 1 piece

W-X82 CX 55415
Servo oil valve unit kit
Engine type ICU Kit order Kit contents Quantity
size number
• Servo oil valve unit (003) 1 set
• O-ring (015) 1 piece
RT-flex82C, Tier 1 LF 55412 • Throttle screw (A003) 3 pieces
• O-ring (A007) 9 pieces
• Lip seal (007) 1 piece
3
RT-flex82C, Tier 2 LF 55416 • Servo oil valve unit ( 004) 1 set
RT-flex82T, Tier 1 & 2 VF 55416 • O-ring (015) 1 piece
• Throttle screw (A003) 3 pieces
RT-flex68-D_V1 PF 55416 • O-ring (A007) 9 pieces
W-X82 CX 55416 • Lip seal (007) 1 piece

1 2

1. Servo oil valve unit (003): 2. Servo oil valve unit (004):
RT-flex82C, Tier 1 RT-flex82C, Tier 2
RT-flex82T, Tier 1 & 2
RT-flex68D_V1
W-X82
Figure 3, Determination of servo oil valve units depending on engine types
 INSTRUCTIONS

I-27, Issue 1, Page 6 / 11

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

Before the replacement of an injection control unit, the engine must operate for a
minimum of 1.5 hours with Marine Diesel Oil (MDO). Further information is available in
Operation Manual Group 0, Chapter 0270−1.

For any work on an injection control unit, the engine has to be stopped and the fuel
booster and bearing oil pumps have to be 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.

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 are ready to use.

WARNING:
Pay attention to the general guidelines for lifting tools in the Maintenance Manual
Group 0, Chapter 0012-1.

NOTE:
During dismantling and assembling of the ICU make sure that the activity area is 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 (007) must be replaced with
the new one from the delivered “onboard repair kit”.

ATTENTION:
Repairs of RT-flex parts onboard or at customer’s workshops are beside any quality
control by Wärtsilä. No warranty can be granted on these parts after such work has
been done.
 INSTRUCTIONS

I-27, Issue 1, Page 7 / 11

9 Work procedure
9.1 Removal of the fuel valve block assembly (005) and
Servo oil valve unit (003, 004)

012

011
009

005
003,
004
007 015

001,
002

001., 002. Measuring block 011. M10x140 or M10x130 hexagon

003., 004. Servo oil valve unit
005. Fuel valve block assembly
007. Lip seal
009. M12x120 hexagon socket head cap
screw
Figure 4, Injection control valve replacement
socket head cap screw (screw
length depending on engine type)
012. M10x120 hexagon socket head cap
screw
015. O-ring

• Remove the M10x140 or M10x130 hexagon socket head cap screws (011) and
disconnect servo oil valve unit (003 or 004) from fuel valve block assembly (005)
(Screw length depending on engine type)
• Remove the M12x120 and M10x120 hexagon socket head cap screws (009 & 012)
and disconnect fuel valve block assembly (005) from measuring block (001,002)
• Clean the touching surface for lip seal (007) and O-ring (015)
 INSTRUCTIONS

I-27, Issue 1, Page 8 / 11

9.2 Reassembly of the fuel valve block assembly (005) and

Servo oil valve unit (003, 004)

Table 6

Procedure Pictures
1. Place lip seal (007) between the
measuring device (001, 002) and fuel
valve block assembly (005).

Assemble the fuel valve block assembly

(005) on the measuring device (001,
005
002).
007

001, 002
2a Concerned engine types:
RT-flex82C, Tier 1 3 7 9 6 2

Tighten M12x120 screws (1, 3, 5, 7, 9, 10),

i.e. screws (009) according to Figure 4,
apply Never-Seez NSBT-8.
Tightening torque: 55 Nm.

Tighten M10x120 screws (2, 4, 6, 8) i.e.

screws (012) according to Figure 4,
apply Never-Seez NSBT-8.
Tightening torque: 30 Nm. 1 5 10 8 4
NOTE:
Tighten screws (009) and (012) according
to the sequence in the picture.

2b Concerned engine types:

RT-flex82C, Tier 2 3 7 9 6 2
RT-flex82T, Tier 1 & 2
RT-flex68D_V1
W-X82

Tighten M12x120 screws (1, 3, 5, 7, 8, 9),

i.e. screws (009) according to Figure 4,
apply Never-Seez NSBT-8.
Tightening torque: 55 Nm.

Tighten M10x120 screws (2, 4, 6) i.e.

screws (012) according to Figure 4,
apply Never-Seez NSBT-8. 1 5 8 4
Tightening torque: 30 Nm.
NOTE:
Tighten screws (009) and (012) according
to the sequence in the picture.
 INSTRUCTIONS

I-27, Issue 1, Page 9 / 11

Table 6, continued

Procedure Pictures
3. Throttle screw (A003) should have been
inserted into the correct position as shown
in the picture.

If not, the throttle screw (A003) has to be

screwed in until to the end stop.
Apply Never-Seez NSBT-8 on thread.
Tightening torque: 1.2 Nm.

The M4x16 hexagon socket head cap

screws (A005) need to be crosswise
tightened.
Apply Never-Seez NSBT-8 on threads.
Tightening torque: 4 Nm.

4. Apply silicone grease and insert the O-ring

(015) into the O-ring groove.
003, 004
Assemble the servo oil valve unit (003 or
004) on the fuel valve block assembly
(005). 015

005

5. Tighten the M10x140 or M10x130 screws

9 8 2 3 6 11
(011) – see also Figure 4 for their location
on the overall picture.
(Screw length depending on engine type).

Apply Never-Seez NSBT-8 on threads.

Tighten screws according to the sequence

in the picture.

Tightening torques:
M10x140 with 30 Nm. 12 5 4 1 7 10
M10x130 with 20 Nm
 INSTRUCTIONS

I-27, Issue 1, Page 10 / 11

9.3 Mounting of ICU on fuel rail

After the successful ICV replacement, the ICU must be mounted back to the fuel rail.
Make sure that the new lip seal (007) is used which is delivered as a part of the ICV kit,
see Figure 5.
Follow the description in the Maintenance Manual Group 5, Chapter 5564–1 “How to
mount the ICU back onto the fuel rail”.

1
007

1. Injection control unit 007. Lip seal to fuel rail

2. Fuel rail
Figure 5, Injection control unit showing location of lip seal
 INSTRUCTIONS

I-27, Issue 1, Page 11 / 11

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 contact your nearest Wärtsilä
representative or your key account manager.

© 2014 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 Switzerland Ltd.
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.