TECHNICAL

BULLETIN

Wärtsilä low-speed engines RT-127

Services 2-stroke Issue 3, 13.05.2013

Crank Angle Sensor (CAS) For immediate attention

toothed belt replacement Concerned products/components

Information to all Owners and Operators of
Wärtsilä RTA and RT-flex engines
All RT-flex engines and all RTA engines
with the Pulse Lubricating System (PLS)
which have a CAS type “AC58 encoder”
installed.
In addition some RTA96C and RTA96C-B
engines with the Retrofit Pulse Lubricating
System (RPLS) which have the same type
“AC58 encoder” installed.

Current situation
Insufficient lifetime of the Crank Angle
Sensors (CAS) has been reported.
Investigation showed that during engine
operation high dynamic peak forces can
occur excited by the toothed belt.

Solution
The new version of the toothed belt is
made of a softer material which helps to
reduce the dynamic radial forces on the
sensor internal shaft bearing. In addition
the pre-tension value of the new version of
toothed belt is slightly reduced.

Note
Issue 2 of Technical Bulletin RT-127 had
to be revised. Besides the code numbers
for the belt package, a new spare kit for
the CAS drive was prepared. The code
numbers for the belt package and spare kit
are listed in Table 1 on Page 10.

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
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Contents
Page
1 Introduction 2 
2 New version of toothed belt 2 
3 CAS drive condition and installation 3 
4 Replacement and spare kits 9 
5 Ordering of parts and spare kits 10 
6 Updated Maintenance Manual 11 
7 Contacts 12 

1 Introduction
Note:
This Technical Bulletin supersedes Technical Bulletin RT-127, Issue 2,
dated 05.06.2012, entitled “Crank Angle Sensor (CAS) belt replacement”.

Wärtsilä received reports mentioning insufficient lifetime of Crank Angle Sensors

(CAS). Analysing the reports showed that in some cases wear on the shaft and
the internal bearing of the CAS had occurred on the CAS type “AC58 encoder”.
Investigations showed that high dynamic peak forces can occur at the toothed
belt during engine operation. This can lead to the above-mentioned damage of
the CAS unit. Consequently this mechanical failure results in disturbed and
unusable signals to the WECS and thus will trigger an alarm. As a result, the
CAS must be replaced.

2 New version of toothed belt

In order to reduce the dynamic peak forces caused by the toothed belt, which is
the main cause of CAS mechanical failures, the belt material has been changed.
The new version of the toothed belt is made of different material, is more elastic
and is reinforced. This leads to reduced forces compared to the previous belt. In
addition, when fitting a new version of the toothed belt, the pre-tension value has
been reduced.

Comparison of the two CAS toothed belts

1 2
1. Old version of toothed belt, 2. New version of toothed belt (black colour)
Fig. 1
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3 CAS drive condition and installation

3.1 Checking the condition of the CAS drive

Note:
Checks and replacement of CAS parts can only be carried out if the engine is at
standstill. For additional details of the CAS drive, refer to the Maintenance
Manual Group 9, Chapter 9223–1.

3.1.1 Checking the shaft eccentricity

High shaft eccentricity of the CAS drive can generate additional dynamic peak
forces to the CAS. Wärtsilä recommends checking the shaft eccentricity in case
of CAS exchange. In addition, it is essential to perform the eccentricity check
according to the maintenance intervals as listed in Chapter 6, entitled “Updated
Maintenance Manual”.
Eccentricity check:
1. Remove the protection hood of the CAS drive.
2. Install a magnetic base dial gauge as shown in Figure 2.

Illustration

1 3 4 5

1. Shaft with gear wheel of CAS drive, 2. Gear wheel of CAS drive, 3. Toothed
belt, 4. Magnetic base, 5. Dial gauge
Fig. 2

Note:
The measuring point must be horizontally adjacent to the gear wheel.

3. Read the deviation of the dial gauge while turning the crank shaft with the
turning gear.
4. The average shaft eccentricity under normal working and proper assembly
condition must be less than 0.15 mm.
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In case the measured value is out of the stated average eccentricity value,
Wärtsilä recommends replacing the CAS drive with a new one. A new CAS drive
is available as a standard spare part on board. The replacement shall be done
according to the Maintenance Manual Group 9, Chapter 9223–1 “4. Removal of
crank angle sensor drive” and “7. Fitting the crank angle sensor drive”.

The replaced doubtful or defective CAS drive shall be overhauled and/or repaired
as soon as possible. The overhaul job can be done by the ship’s crew according
to the Maintenance Manual Group 9, Chapter 9223–1 or it can be done through
Wärtsilä Services.
An overhaul kit is available from Wärtsilä Services. Please refer to Chapter 4.3
“Spare kit for CAS drive”.

3.1.2 Checking the clearance between shaft and internal bearing of the CAS
If the CAS is over 5 years in service or has more than 48,000 running hours,
Wärtsilä recommends checking the condition of the CAS before a new version of
the toothed belt is installed. The CAS condition is checked by measuring the
clearance between the shaft and internal CAS bearing.

Procedure for measuring the clearance:

1. Remove the protection hood of the CAS drive.
2. Remove the protection plate.
3. After loosening the fixation screws, remove first the toothed belt of the outer
CAS and then the belt of the inner CAS.
4. After removing the belt, tighten the fixation screws again.
5. Install the magnetic base dial gauge as shown in Figure 3.
6. Push the gear wheel of the CAS to left and right direction.
The measurement has to be done in fixed condition of the inner and outer
CAS but without the toothed belts.
7. Read the deviation of the dial gauge while pushing the gear wheel of the CAS.
8. According to gained experience, the average CAS clearance under normal
working and in proper assembly conditions should be less than 0.05 mm.

Measuring of clearance

2 1 3
1. Magnetic base dial gauge, 2. Measurement on inner CAS, 3. Measurement on
outer CAS
Fig. 3
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3.1.3 Checking the toothed belt condition

The toothed belt has to be checked every 3000 operating hours for its pre-
tension. In addition a visual inspection of the belt has to be performed, which
includes checking for possible cracks in the belt areas of the teeth that may be
worn out. See also the information in Chapter 6 about “Inspection and Overhaul
Intervals (Guidelines)”.

3.1.4 Experience with the new version of toothed belt

The example in Figure 4 shows the new version of toothed belt in normal working
condition. Small quantity of wear particles or debris of the toothed belt surface,
which appear on the cover of the CAS drive, is normal.
Small particles or debris may be found also inside the cover from the initial
running-in. However, the particles found after initial running-in of a new version of
toothed belt will not disturb the function of the CAS.

New version of toothed belt

3 4

1. New version of toothed belt before installation, 2. Toothed belt with some
operating hours, 3. Toothed belt with little wear on tooth surface, 4. Some
particles from new version of toothed belt surface located on CAS cover
Fig. 4
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An old version toothed belt with wear and material loss at the tooth tip is shown in
Figure 5.
A belt in this condition should be replaced. In addition, the time interval for
replacing the belt depends also on the condition found during the visual
inspection every 3000 operating hours.

Old belt showing some wear (after approximately 18,000 operating hours)

1. Worn tooth tip area

Fig. 5

The pictures shown in Figure 6 are examples of toothed belts with severe
material loss. Worn-out toothed belts in such condition must be replaced
immediately.

Damaged belts (after approximately 45,000 operating hours)

1
2 3
1. Lost teeth of belt, 2. Damaged belt structure, 3. Damaged belt structure and
lost teeth
Fig. 6
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3.2 Tightening instructions and adjustment of CAS

3.2.1 New tightening instruction for toothed belts
When replacing the toothed belt, it must tensioned to 30 N. The correct tension
has to be set with the spring balance which is located in the box “Shaft encoder,
complete”.

Note:
According to IACS regulations, at least one box “Shaft encoder, complete”
containing the spring balance is part of the standard spare parts supply per ship.

Adjusting the tension of the toothed belt

2 3 4

1. Gear wheel of CAS drive, 2. Toothed belt, 3. Shaft encoder, 4. Spring balance
Fig. 7

Note 1:
It is recommended that two skilled technicians carry out this installation to ensure
correct tensioning of the belt.

Note 2:
To prevent the toothed belt from being tightening to the old value of 40 to 45 N,
as currently described in Maintenance Manual Group 9, Chapter 9223–1 “3.2
Fitting the toothed belt”, Wärtsilä recommends amending the corresponding page
manually to 30 N.
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3.2.2 Adjustment of the crank angle offsets in WECS

After the mechanical work on the CAS and CAS drive, the crank angle offsets
must be adjusted.

1. Turn the engine with the turning gear until the flywheel marks show TDC,
cylinder number one = 0.0°.
− Marks (1) and (2) should be aligned as indicated in Figure 8.
− TDC of cylinder number one can be cross checked from the crank case.
But safety measures must be taken accordingly before opening of the
crankcase – see “Warning labels” located near the crank case doors on the
engine.

2. Start the flexView programme and go to the ADJUST card.

3. With the flywheel position as described in the first point, read the crank angle
values displayed in the fields “Crank angle 1/2". If they are different from
0.0° CA, enter the displayed values as offsets in the fields "CA 1/2 Offs.".

Note:
For negative deviations, e.g. 359.8<°, use negative values, e.g. -0.2<°, see
Figure 8.

Adjustment of the crank angle offsets

2 1 2

T.D.C. 1

1. Mark on gear wheel, 2. Marks on shaft encoder and holder

Fig. 8
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4 Replacement and spare kits

4.1 Replacement of belt

Wärtsilä will provide the new version of toothed belt to the concerned vessels in
operation. Once they are received on board, the old toothed belts shall be
replaced by the new version of toothed belt at the first opportunity. The exchange
must be done according to the instruction in Chapter 3.2 “Tightening instructions
and adjustment of CAS”.

The old toothed belts in the CAS spare package, i.e. in the spare parts list named
“Shaft encoder, complete (Box)” must also be replaced by the new version of
toothed belt. These CAS spare packages are part of the IACS spare parts on
board.

Note:
Do not use belts of the old type anymore. All of them must be discarded once the
new version of toothed belt is available on board and have been fitted as
described above.

The new version of the toothed belt can be ordered separately as a single part.
Information about ordering of parts or how to contact Wärtsilä is listed in
Chapter 6 “Contacts”.

4.2 Reasons for CAS drive replacement

There are two reasons for overhauling a CAS drive:
• High shaft eccentricity
Refer to chapter “Checking the shaft eccentricity” to verify the eccentricity.
• Maintenance Schedule
Work to be carried out at 48,000 Op.h (Operating hours)

Before carrying out the replacement of a CAS drive which is available as

standard spare parts on board, a new CAS drive must be ordered unless a spare
kit is available on board, see also next chapter.
The spare parts order number is to be found in the Spare Parts Code Book
Group 9, Chapter 9601–1, within Item “Crank Angle Sensor Unit” and named
“Shaft encoder drive, complete” or “Shaft encoder, complete (box)”.

4.3 Spare kit for CAS drive

The CAS drive that was removed shall be overhauled and/or repaired as soon as
possible. With a spare kit, the overhaul job can be done by the ship’s crew
according to the Maintenance Manual Group 9, Chapter 9223–1 or it can be done
through Wärtsilä Services.
The spare kit contains all parts needed to overhaul the CAS drive on board as
listed in Table 1. The replacement procedure is also described in the above-
mentioned Maintenance Manual Chapter, i.e. in Section 5 and 6.
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After the assembly, the run-out of the gear wheel should be confirmed to be
within 0.15 mm. For more details about checking the shaft eccentricity see
Chapter 3.1.1.

Note:
The damaged CAS shall only be sent back to Wärtsilä if specially requested. The
return shipment, if requested, will be handled on an individual case by case
basis.

5 Ordering of parts and spare kits

The new belt package and the spare kit for the CAS drive can be ordered through
your Wärtsilä representative by stating the Code number as listed in Table 1.

List of engine types with respective code numbers

RT-flex Code number for: RTA Code number for:

engine types engine types
New belt New belt
Spare kit Spare kit
package package
RT-flex50
RT-flex50-B IF 92366 IF 92367 – – –
RT-flex50-D
RT-flex58T-B
OF 92366 OF 92367 – – –
RT-flex58T-D
RT-flex58T-D_V2 GF 92366 GF 92367
RT-flex60C
NF 92366 NF 92367 – – –
RT-flex60C-B
RT-flex68-B
MF 92366 MF 92367 – – –
RT-flex68-D
RT-flex68-D_V1 PF 92366 PF 92367 – – –
RT-flex82C LF 92366 LF 92367 RTA82C L 92366 L 92367
RT-flex82T VF 92366 VF 92367 RTA82T V 92366 V 92367
RT-flex84T-D BF 92366 BF 92367 RTA84T-D B 92366 B 92367
RTA96C and
RT-flex96C-B DF 92366 DF 92367 RTA96C-B D 92366 D 92367
with RPLS 1)

1)
RPLS: Retrofit Pulse Lubricating System
Table 1
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6 Updated Maintenance Manual

Updated information is added to the Maintenance Manual Group 9, Chapter
0380–1 “Inspection and Overhaul Intervals (Guidelines)”. The update of the
respective page in the Manual is illustrated in Figure 9 as an example.

Example of Inspection and Overhaul Intervals (Guidelines)

stroke Maintenance 0380–1/A1

Inspection and Overhaul Intervals (Guidelines)

Group Component Work to be carried out Intervals

9
9223–1 Crank angle – Check tension visually acc. to MM 3000 Op.h
sensor unit Check cracks and wear of toothed belt visually.
Visual lubricating oil check.

– Replace toothed belt 24 000 Op.h

– Overhaul drive (ball-bearing, sealing ring etc.) 48 000 Op.h

and check shaft eccentricity of CAS drive

– Check shaft eccentricity of CAS drive At every CAS exchange

for any reason

– Replace crank angle sensor 48 000 Op.h

(Only if new soft belt
is applied from
the beginning)

1 1

1. New entries in Maintenance Manual for inspection

Fig. 9
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7 Contacts

7.1 How to contact Wärtsilä

For questions about the content of this Technical 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

7.2 Contact details for emergency issues

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.

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.

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

© 2013 Wärtsilä Switzerland Ltd. – All rights reserved

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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.