RT-87 Intermediate Fuel Accumulator (Issue 1, 03-03-2010)

TECHNICAL
BULLETIN
Wärtsilä low-speed engines RT-87

Services 2-stroke Issue 1, 03.03.2010
Intermediate Fuel Accumulator For immediate attention
Concerned products:
Wärtsilä RT-flex96C-B and RT-flex84T-D
engines
Information to all Owners and Operators of
Wärtsilä RT-flex96C-B or RT-flex84T-D engines Summary and main topics:
This Technical Bulletin advises to remove
the non-return valve in the intermediate
fuel accumulator.
Main emphasis is given to fast localisation

of a defective fuel pump with an
emergency procedure for quick resolving
the problem.
It serves also as a guide for fast leakage

detection in the fuel system, especially in
the intermediate fuel accumulator and
rising pipes.
An assembly guideline helps to refit

removed parts in order to avoid damage to
sensitive parts and prevent leakages
during operation.
In case of wrong or old pressure settings

of the fuel pressure control valve, a setting
sequence guides through the various
steps for correct adjustment.
Wärtsilä recommends to distribute this

document immediately to all installations
where the above listed engines are
installed.
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
TECHNICAL BULLETIN RT-87
Issue 1, Page 2 / 18
1 Content
1 Content 2
2 Introduction 2
3 Removal of Non-return Valve and Compression Spring 3
4 Localisation of Defective NRV in Fuel Pump and Emergency Operation 4
5 Improvements at Intermediate Fuel Accumulator 6
6 Fuel Leakage in IFA and Rising Pipes 9
7 Assembly Guideline 13
8 New Setting of Fuel Pressure Control Valve 17
2 Introduction
This Technical Bulletin supersedes Service Bulletin RT-flex-10, named “Non-
Return Valves of Intermediate Fuel Accumulator”.
The presence of the intermediate fuel accumulator acts to damp and reduce
pressure pulsations generated by the fuel pumps in the system, thereby
delivering fuel at constant pressure to the rail.
In case of failure of the fuel pump regulation, matching of the observed pressure
to that of the set point is achieved by the functioning of the fuel pressure control
valve. The relief valve is an additional overpressure safety device.
The aim of this Technical Bulletin is to promote reliable engine operation with a
properly functioning intermediate fuel accumulator. Should leakage be observed,
advice is provided for measures to be taken to quickly locate and counteract the
problem.
Intermediate fuel accumulator and fuel pumps
1 3 4
1. Intermediate fuel accumulator, 2. Pressure control valve, 3. Relief valve, 4. Non-return

valve in IFA, 5. Fuel pump, 6. Non-return valve in fuel pump
Fig.1
3 Removal of Non-return Valve and Compression Spring

The high pressure fuel system includes a number of Non-Return Valves (NRV);
one in each fuel pump cover and one in each flange that connects the high
pressure fuel pipe to the Intermediate Fuel Accumulator (IFA), see Figure 2.
The NRV in the fuel pump cover is essential for correct functioning of the pump,
the NRV in the IFA inlet serves as a back-up for the NRV in the fuel pump cover.
Service experience has shown very few failures of the NRV in the fuel pump
cover, but quite a high number of damaged NRVs in the IFA inlet. This is mainly
caused by the hydraulic interaction between the two NRVs connected in series.
Depending on the operating speed of the engine, this interaction could cause
pressure fluctuations in the high pressure pipe between the fuel pump and IFA,
which could result in high stresses in the NRV located in the IFA and
consequently a reduced lifetime. It also has been recognised that in case of a
NRV failure in the fuel pump, the NRV in the IFA can lead to other fuel pump
damage.
Note:
Until further notice Wärtsilä recommends to remove the Non-Return Valves
(NRV), comprising valve body and compression spring, in the Intermediate Fuel
Accumulator (IFA) inlet.
The purpose is to reduce the pressure fluctuations in the high pressure pipe
between fuel pump and the IFA, which is causing damage to the NRV in the IFA
inlet. A damaged NRV in the IFA inlet will not be fulfilling its intended back-up
function, so its removal will have no detrimental effect and will not contaminate
the fuel system.
Location of non-return valves
1 2
1. NRV with valve body and spring in IFA flange, 2. IFA flange without NRV, 3. NRV in
fuel pump
Fig. 2
After the NRV has been removed from the IFA, another device must ensure the
fuel rail pressure in case of a defective NRV in the fuel pump. This is ensured by
the pump regulation.
The following chapters describe how to localise the defective NRV in the fuel
pump. An emergency procedure is also given for safe engine operation.
4 Localisation of Defective NRV in Fuel Pump and Emergency Operation

In case of an unexpected pressure drop in the fuel rail or impossibility to build up
the fuel rail pressure during engine start, this guideline localises a defective NRV
or NRV-spring in a fuel pump quickly (delimitation method). It also shows how the
engine can be operated in such an emergency case without any delay.
In case a NRV in the fuel pump fails, fuel from all other fuel pumps can escape
via the defective pump to the low pressure system (when that plunger is in its
lower position, around BDC). This can be avoided if the regulating rack of this
pump is pulled to the zero position.
Emergency procedure
1. Check if there is an indication of leakage in the alarm system.
2. To rule out that a leakage in the high pressure fuel system is causing the
pressure drop, check:
– High pressure pipes
– IFA
– Pressure relief valve
– High pressure fuel rising pipes
– Fuel rail
3. Switch off the power supply in the E85 box of the fuel pump actuators of one
fuel pump bank (A or B).
In case of engines with 6 fuel pumps, switch off – in addition – the actuator
that is connected to the fuel pump bank A and B.
4. With power supply in switched off position, force the regulating linkage to the
zero position.
5. Block the pump’s regulating rack in this position with spacer tool as shown in
Figure 3.
6. Try to restart the engine.
7. If pressure is building up in the fuel rail and the engine can be started, the
defective fuel pump is in the bank whose regulating linkage is in zero
position.
8. When the engine is not able to start, repeat steps 3 to 6 on the opposite
bank.
Attention:
Depending on the engine and installed WECS-9520 or WECS-9500 system, the
power switch is located either in the E85 or E85.1 box.
No leakage alarm will be released for the fuel pressure regulating valve. The
return line of the fuel pressure regulating valve is not connected to a leakage
sensor and is going directly to the fuel return line.
Application of spacer
1. Spacer, tool 94555
Fig. 3
Note:
References to tool numbers are to be found in the respective Maintenance
Manual.
Further fault localisation

In the short steps as described above, it is possible to run the engine with limited
load, due to the reduced fuel pump capacity.
The following steps describe the activation of the pumps, where the regulating
rack was forced to the zero position in order to identify the defective fuel pump.
1. Engine remains in operation.

2. Power supply is still switched off.
3. Remove the spacer (1) from the regulating rod of the pumps which are
connected to one actuator.
4. Try to push the regulating rack to a delivery position.
5. If this is possible, both pumps are working fine and can be enabled again.
– Switch on power supply to the related actuator.
6. If it is not possible to push the rack on one of the pumps,
this is the defective fuel pump.
– Block the regulating rod of this pump with a spacer (1).
– Bring back the remaining pumps into operation.
7. If point 5 was positive, both pumps are working fine, repeat point 3 and 4 to
identify which of the remaining fuel pumps is defective.
Counter measures
After the localisation of the defective fuel pump, there are two possibilities to run
the engine.
• In case the circumstances do not allow to stop the engine:
Pull the regulating linkage of the defective fuel pump to zero position and
block it with the spacer (1) as shown in Figure 3.
• In case the engine can be temporarily stopped:
After the localisation of the defective fuel pump, cut out this pump. The
procedure to cut out a pump is given in the Operation Manual delivered with
the engine, Group 5 “Cutting out and cutting in of the fuel pump”. Now you
can start the engine again and continue the voyage. Running the engine
under this constellation, you might have higher system oil consumption. Thus
we advise to replace the defective fuel pump at the next opportunity.
5 Improvements at Intermediate Fuel Accumulator

Wärtsilä made several design changes since the implementation of the first RT-
flex96C-B engine. The design changes improved the reliability of the RT-flex
system.
The below mentioned improved parts are available through our Wärtsilä Service
Sales channels.
Intermediate fuel accumulator (drawn for RT-flex96C-B)
1 2 3 4 5 6
1. Pressure control valve, 2. Flange to pressure control valve, 3. Flange to IFA and high
pressure fuel pipe, 4. Flange with insert bush, 5. Relief valve, 6. End flange to high
pressure rising pipes
Fig. 4
Hardened insert bush in the connection of IFA to flange

The improvement of the insert bush (1) in Figure 5 is the enlarged sealing
surface (2) to the main collector. It reduces the possibility of internal leakage.
New design of IFA and flange
1. Insert bush, 2. Sealing surface
Fig. 5
Hexagon socket head cap screw for the flange

The location of the hexagon socket head cap screws (1) is shown in Figure 6.
The safety margin of the hexagon socket head cap screw has been increased by
using high-tensile material with a strength class of 12.9, whereas the former
screw had a tensile strength class of 8.8. The hexagon socket head cap screw is
now also designed as an elastic bolt (2). For fitting the flanges and tightening the
elastic bolts to the IFA, please consult chapter 7 of this Technical Bulletin.
Location and new design of elastic bolt
1 2
1. Location of hexagon socket head cap screws, 2. Elastic bolt

Fig. 6
IFA relief valve

There were several executions made of the intermediate fuel accumulator relief
valves. The current execution has two identification bores with ø 3 mm on the
hexagon face with size 80 mm across flats (AF). Both bores are on the same
face, see Figure 7. The material specification of the current IFA relief valve was
also improved to ensure a more reliable performance.
Important:
Please make sure that the IFA relief valve has at least one identification bore of
ø 3 mm on the hexagon AF 80 face.
IFA relief valve
1. Two identification bores on one face
Fig. 7
6 Fuel Leakage in IFA and Rising Pipes

A fuel leakage can become noticeable in different ways:
• Fast fuel pressure drop after shut down of the engine.
• Difficulties to build up the fuel pressure during engine start phase.
• Indication of leakage alarm.
Guideline to localise the internal fuel leakage (IFA and rising pipes)
Caution:
With high pressure leaks there are risks of accidents. It is advisable to determine
the location of high pressure leakages in safe areas when the engine is stopped,
preferably in port.
For safety precautions please refer to the respective Engine Manuals and
published Service Bulletins.
Before you start loosening and disassembling any parts, make sure that you
have all necessary tools on board. For damaged parts also the corresponding
spare parts must be available. Check also that you have enough consumable
goods on stock, such as recommended lubricants and lip seals for example.
In case you miss tools and/or spare parts, your local Wärtsilä representative can
support you.
The leakage channel of the non-return valve/flange on the IFA and leakage
channel of the rising pipes are common.
Fuel leakages on intermediate fuel accumulator or fuel high pressure rising pipes
can be detected by opening the corresponding fuel leakage cock, see Figure 8.
The position of the fuel leakage cock depends on the installation. The cocks
should be labelled as in Figure 8.
Location of fuel leakage cocks
1
1
1. Fuel leakage inspection device
Fig. 8
For components and numbers mentioned hereafter, please refer to the engine
control diagram located in the Operation Manual Group 4. For references to the
fuel pressure pipes and leakage inspection plugs, please consult the Spare Part
Code Book, Group 8 “High Pressure Pipe”. References to tool numbers are to be
found in the respective Maintenance Manual. All three mentioned manuals are
delivered with the engine.
Depressurisation of the system and IFA

1. Stop the engine, switch off the booster pumps and close the fuel inlet pipe to
the engine.
2. On the fuel pressure control valve 3.06, push the red emergency stop handle
3.08 and fix it in pushed position with tape or wire.
3. Shut-off the valve of the fuel return pipe.
4. Slightly slacken one of the relief valves 3.52-1 or 3.52-2, using spanner size
80. Release the pressure over the leakage pipe into the fuel leakage
inspection device, see Figure 8.
5. Make sure the pressure is completely released, thus check the relief valve
cock by the leakage inspection device, see Figure 8.
6. Tighten the relief valve with spanner size 41, torque 300 Nm (see also
chapter 7 assembly guideline).
Leakage inspection points
3
2
1. Leakage inspection plug in fuel rail, 2. Leakage inspection plug in intermediate piece,
3. Leakage inspection plug in IFA block, 4. Detail of high pressure pipe connection with
leakage inspection plug
Fig. 9
Procedure for leakage detection on the rising pipes

1. Make sure the system is depressurised.
2. Close the two stop valves on IFA 3.62-1 and 3.62-2.
3. Remove all leakage inspection plugs (4) at positions (1) to (3), see Figure 9.
4. Connect the control oil rail to the fuel oil rail between plug 3.39 and stop
valve 3.40. This is done with either the high pressure flexible hose or fixed
steel pipe as latest execution (tool 94583).
5. Run one control oil pump 3.72-1 or 3.72-2 and adjust the pressure retaining
valve 3.72-1 to lowest possible pressure (approx. 20 to 30 bar).
6. Increase the pressure of the control oil pump to 200 bar. If no leakage can be
detected on the inspection plugs and the pressure remains steady, the fuel
pressure rising pipes and the fuel rail do not leak.
Procedure for leakage detection on the IFA

1. Remove all leakage inspection plugs (1) from the IFA, see Figure 10. The
plugs can also be found in the Spare Part Code Book (numbers DF 87521
for RT-flex96C-B, respectively BF 87521 for RT-flex84T-D engines). Please
confirm spare part numbers with documents supplied with the engine.
2. Connect the control oil rail to the fuel oil rail between plug 3.39 and stop
valve 3.40. This is done with either the high pressure flexible hose or fixed
steel pipe as latest execution (tool 94583).
3. Close both stop valves 3.62-1 and 3.62-2 on the IFA.
4. Run one control oil pump 3.72-1 or 3.72-2 and adjust the pressure retaining
valve 3.72-1 to lowest possible pressure (approx. 20 to 30 bar).
5. Open one of the stop valves 3.62-1 or 3.62-2. During opening, another
person has to check the IFA drain bores for first symptoms of leaking fuel.
6. If no leaks are found, increase the control oil pump pressure slowly in steps.
7. Repeat these steps until leaks are detected from one of the leakage
inspection plugs.
After that you have localised the exact position of the leakage.
8. Inspect carefully the affected parts and report any findings to Wärtsilä
Switzerland, Technical Service or to your nearest Wärtsilä Service Station.
9. Check also the connections from the fuel pump to the high pressure fuel pipe
and to the IFA flange (cone connection).
10. Check also the relief valve for any leakage at the fuel leakage inspection
device, see Figure 8.
11. Replace parts which cause the leakage.
Remarks:
Since the leakage channel is common from the rising pipes and IFA itself, within
a very short time the control oil will leak from all leakage inspection bores.
Points 5 to 8 have to be repeated in order to find the leakage bores which are
leaking all the time first. These leakage bores can lead to the potentially affected
insert bush, see Figure 10.
Figure 10 shows the location of the leakage inspection plug on the IFA (1). The
sketch to the right shows also the way of leaking fuel into the leakage bore (2),
indicated by the grey areas.
Leakage inspection and way of leakage flow
1 2
1. Leakage inspection plug, 2. Way of leakage flow (grey areas)
Fig. 10
Return the engine to its normal operating condition. Make sure that the
emergency stop handle on the pressure control valve is in the operating position.
Previously applied fixation material has to be removed. All bolts have to be
tightened to the correct torque, as described in chapter 7 of this Technical
Bulletin or Section 0352 of the Maintenance Manual.
It is essential to localise fuel leakages without delay. Even if an engine is running
for a relatively short time with a heavy intermediate fuel accumulator leakage, the
fuel could cause erosion, see Figure 11. Consequently the IFA seat will get
damaged and the fuel pressure cannot build up again. In case of extreme erosion
on the IFA seat, the IFA has to be exchanged.
Intermediate fuel accumulator seat and bush
1 2
1. Erosion marks at IFA seat, 2. Erosion marks on insert bush
Fig. 11
7 Assembly Guideline
This guideline shows correct assembly for sensitive parts of the intermediate fuel
accumulator. It shall help to prevent incorrect assembly of IFA parts, which
consequently could lead to internal leakages.
For references to spare part numbers mentioned hereafter, please consult your
Spare Part Code Book delivered with the engine. Spare part numbers starting
with “DF” are related to RT-flex96C-B engines. Spare part numbers starting with
“BF” are related to RT-flex84T-D engines.
Important!
Before installation of any part on the intermediate fuel accumulator, make sure
that the parts are clean and free of any dirt.
After each removal of pipes and/or flanges, the parts must be correctly aligned
prior to assembly and final tightening.
The important comments made above are valid for all procedures described
hereafter.
Connection flanges to IFA

The location of the flanges to the IFA are shown in Figure 4.
Material, designation and tightening overview for fitting flanges to IFA:
Screw: Hexagon socket head cap screw M16x100
Strength class: 12.9
Spare part number: DF 87518 / BF 87518
Lubrication: Never-Seez NSBT-8 or equivalent
Tightening torque: 190 Nm
Tightening sequence: crosswise
Tightening procedure: in steps
Assembly sequence:
1. Clean the IFA seat, insert bush and flange, make sure the parts are free of
dirt and other contaminants
2. Insert the bush and make sure it is in the correct position (should be possible
to turn the bush)
3. Put flange in correct position
4. Screw in all four bolts by hand
5. Tighten the screws carefully crosswise hand tight (use a small allen key) and
ensure that the flange is aligned correctly
6. Torque the four bolts carefully crosswise to 80 Nm
7. Torque the four bolts crosswise to 140 Nm
8. Torque the four bolts to the end torque 190 Nm
Important:
In case that any screw of the flange was loosened, it is essential to release all
four screws and retighten those according to above sequence from step 5 to 8.
This procedure is essential to avoid later leakages.
Fitting of high pressure fuel pipe to fuel pump and IFA

The location of the high pressure fuel pipes on the supply unit and their
connection points to the fuel pumps (1) respectively to the IFA (2) are shown in
Figure 12.
High pressure fuel pipe connection points
1. Connection to fuel pump, 2. Connection to IFA
Fig. 12
Material, designation and tightening overview for fitting high pressure fuel pipes
to fuel pump and IFA:
Strength class: 12.9
Tightening procedure: Step 1: Place flange into correct position
Step 2: Tighten the screw in 3 steps
(20 Nm, 40 Nm, 70 Nm)
Fuel rising pipe to IFA and fuel rail

The description below about fitting of high pressure fuel rising pipes is also valid
for the fuel rising pipe connection to the intermediate piece and finally to the rail
unit.
The location and connection point of the fuel rising pipe to IFA (1) is shown in
Figure 13. The high pressure fuel rising pipe connection to the fuel rail is shown
in Figure 9.
Location of fuel rising pipe
1. Connection to IFA
Fig. 13
Material, designation and tightening overview for fitting the fuel rising pipe to IFA:
Strength class: 8.8
Tightening procedure: in steps
Important:
For correct installation of the fuel pressure piping consult the Maintenance
Manual, Group 8 “Removing, Fitting and Regrinding” of fuel pressure piping.
Removing and tightening of relief valve

In case a relief valve has to be removed or replaced, it must be re-fitted
according to the following description.
Relief valve loosening and tightening
2 3
1. Relief valve, 2. Hexagon socket for tightening, 3. Hexagon socket for loosening
Fig. 14
Designation and tightening overview for relief valve:

Loosening: Use spanner size 80
Location of hexagon socket (3) on relief valve
Tightening: Use spanner size 41 and torque-meter
Location of hexagon socket (2) on relief valve
IFA lip seals on end flanges

Whenever an end flange on the IFA has to be removed, the lip seal has to be
replaced with a new one, to minimise the risk of IFA leakage. The location of lip
seals (1) and (2) are shown in Figure 15.
In case that the sealing surfaces in the IFA are scratched or damaged, please
contact your nearest Wärtsilä Service Station.
Location of lip seals on IFA
1 2
1. Lip seal on flange to pressure control valve, 2. Lip seal on end flange to high pressure
rising pipes
Fig. 15
Designation of lip seals in IFA:

Spare part code number: DF 87523 / BF 87523
8 New Setting of Fuel Pressure Control Valve
Attention:
Below procedure supersedes the Service Letter RT-flex-07/07, issued on
06.08.2007.
New setting of pressure control valve must be adjusted, if not already set to 950
bar. Check label (4) on pressure control valve for correct pressure setting, see
Figure 16.
Range of Application
The new setting (950 bar) of the fuel pressure control valve has to be applied to
all RT-flex96C-B and RT-flex84T-D engines which still have the old pressure
setting of 1050 bar. The fuel pressure control valve (1) is mounted on the
intermediate fuel accumulator of the supply unit. A label (4) with the actual
pressure setting is fixed on the pressure control valve, see Figure 16.
Problem Description
Pressure peaks in the fuel rail have sometimes been observed during starting of
the engine or sudden load reduction, which may have led to opening of the fuel
safety relief valves. This is caused by the slower reaction of the regulating valve
compared to the safety valves.
Solution
The opening set point of the pressure regulating valve can be adjusted to be just
above the maximum effective rail pressure in operation. Sudden pressure peaks
will then be prevented at a lower level than presently and unnecessary opening
of the safety valve can be avoided.
Implementation procedure
The set point of the valve is adjusted with the knurled screw (2) as indicated in
Figure 16. Normally the screw is turned fully down to the shims (3). The more the
screw is turned out, the lower the opening threshold.
Fuel pressure control valve
1. Pressure control valve, 2. Knurled screw, 3. Shim, 4. Label
Fig. 16
Setting sequence:
1. Determine the power range with the highest operating fuel rail pressure.
Figures can be found in the “Technical File” where the main engine tuning is
specified. Not all engines have the same pressure set points. The highest
fuel rail pressure is typically between 80 to 90% for RT-flex96C-B engines or
at highest possible load >90% for RT-flex84T-D engines.
2. Run the main engine at the load which corresponds to the fuel pressure of
800 bar. Confirm the fuel pressure.
3. Turn the knurled screw (2) of the pressure regulating valve slowly counter
clockwise (CCW), until the valve starts opening. This point can be detected
by a clearly audible whistling sound.
4. Turn the knurled screw (2) clockwise (CW) down by ONE turn. This sets the
opening pressure to about 950 bar.
5. Due to its hysteresis, the valve might now remain open and is still emitting a
whistling sound.
6. In order to close the valve, the main engine load must be reduced to ~70 to
75% or lower, where the fuel rail pressure setting is 600 bar.
7. The whistling sound of the control valve should now have disappeared
completely.
8. Secure the new screw position. Preferably make an additional shim (3) that
can be inserted below the screw to prevent accidental alterations. Every full
turn requires an additional shim of 1.25 mm thickness.
9. Secure the additional shim to prevent it from falling out.
Important:
A label with a note “Opening set point reduced, yyyy-mm-dd” shall be fitted.
If you have questions to the content of this Technical Bulletin or you need
Wärtsilä assistance, services, spare parts and/or tools, please contact your
nearest Wärtsilä representative or send your enquiry to:
technicalsupport.chts@wartsila.com
or phone 24hrs Support: +41 52 262 80 10.
© 2011 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 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.

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TECHNICAL

Wärtsilä low-speed engines RT-87

Intermediate Fuel Accumulator For immediate attention

Main emphasis is given to fast localisation

It serves also as a guide for fast leakage

An assembly guideline helps to refit

In case of wrong or old pressure settings

Wärtsilä recommends to distribute this

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

Intermediate fuel accumulator and fuel pumps

1. Intermediate fuel accumulator, 2. Pressure control valve, 3. Relief valve, 4. Non-return

3 Removal of Non-return Valve and Compression Spring

Location of non-return valves

4 Localisation of Defective NRV in Fuel Pump and Emergency Operation

1. Spacer, tool 94555

Further fault localisation

1. Engine remains in operation.

5 Improvements at Intermediate Fuel Accumulator

Intermediate fuel accumulator (drawn for RT-flex96C-B)

Hardened insert bush in the connection of IFA to flange

New design of IFA and flange

1. Insert bush, 2. Sealing surface

Hexagon socket head cap screw for the flange

Location and new design of elastic bolt

1. Location of hexagon socket head cap screws, 2. Elastic bolt

IFA relief valve

IFA relief valve

1. Two identification bores on one face

6 Fuel Leakage in IFA and Rising Pipes

Location of fuel leakage cocks

1. Fuel leakage inspection device

Depressurisation of the system and IFA

Leakage inspection points

Procedure for leakage detection on the rising pipes

Procedure for leakage detection on the IFA

Leakage inspection and way of leakage flow

Intermediate fuel accumulator seat and bush

1. Erosion marks at IFA seat, 2. Erosion marks on insert bush

Connection flanges to IFA

Fitting of high pressure fuel pipe to fuel pump and IFA

High pressure fuel pipe connection points

1. Connection to fuel pump, 2. Connection to IFA

Fuel rising pipe to IFA and fuel rail

Location of fuel rising pipe

Removing and tightening of relief valve

Relief valve loosening and tightening

Designation and tightening overview for relief valve:

IFA lip seals on end flanges

Location of lip seals on IFA

Designation of lip seals in IFA:

8 New Setting of Fuel Pressure Control Valve

Fuel pressure control valve

1. Pressure control valve, 2. Knurled screw, 3. Shim, 4. Label

© 2011 Wärtsilä Switzerland Ltd. – All rights reserved

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