Service Letter RT-flex-01/07

22.03.2007
Technical Information to all Owners / Operators Updated version
of Sulzer RT-flex96C Engines
previously issued
26.01.2007

Fretting on Exhaust Valve

Actuator Pipe

Contents: Page

1. Introduction 1

2. Inspection and Actions 1

3. Temporary Repair 3

4. Inspection Checklist 4

Wärtsilä Switzerland Ltd PO Box 414 Tel. +41 52 262 23 30

Wärtsilä Schweiz AG CH-8401 Winterthur Fax +41 52 212 71 03
Wärtsilä Suisse SA Switzerland E-mail: techservice.ch@wartsila.com
1 INTRODUCTION
This Service Letter applies to all RT-flex96C engines. Please note additional instructions for
the 7-cylinder version on page 2.
Recent inspections have shown fretting taking place between the Joint Disc and the Exhaust
Valve Hydraulic Pipe, see fig.1. This is caused by:
1. The Joint Discs not properly tightened.
2. The Joint Discs being subjected to tension from the Horizontal Pipe Holders due to
incorrect fitting.
3. Application of wrong size Joint Disc relative to Actuator Pipe diameter.
4. Joint Disc fitted on rubber protecting sleeve of Actuator Pipe.

2 INSPECTION AND ACTIONS

We recommend inspection of the Hydraulic Pipes by disconnecting the Metal Hose Flanges
and check the pipe for fretting at the position of the Joint Disc.

Horizontal Pipe Protective Metal Hose Upper

Holders and Lower Section

Joint Disc Old Design

Points where fretting takes place

Fig. 1

1/4 Service Letter RT-flex-01/07

Depending on the findings the following actions should be taken:

A No wear observed Horizontal Pipe Holders (see fig. 1) to be permanently removed to

eliminate tension on the Joint Discs 1).
B Wear is observed, but is Horizontal Pipe Holders to be permanently removed 1).
within limits 2)
Joint Disc to be exchanged for latest design. Install the new disc
180° turned so that the contact faces touch an unaffected part of
the Hydraulic Pipe (see also temporary repair section 3)
Alternatively the two-piece Metal Hose can be inverted (short
section at the actuator side, long section at the valve side) so that
the new Joint Disc will be fitted on an unaffected part of the
Hydraulic Pipe, see fig.3.
C Wear is observed and is Horizontal Pipe Holders to be permanently removed 1).
exceeding the limit 2)
Hydraulic Pipe to be exchanged.
Metal Hose to be fitted with new design Joint Disc.
1)
With the exception of the 7 cylinder version. To prevent possible excessive vibration of the
hydraulic pipes on this engine the horizontal Pipe Holders have to stay on. The Pipe Holders
have to be fitted without tension on Joint Discs and Hydraulic Pipes. If necessary use washers
between Pipe Holder Flange and Joint Disc for tension-free alignment.
2)
There are two hydraulic pipe sizes in operation: 71 x 10.5 mm and 75 x 15 mm (outside
diameter x wall thickness). The radial wear limits for these pipes are as follows:
71 x 10.5 mm pipe : 1 mm
75 x 15 mm pipe : 5 mm
All newly delivered hydraulic pipes will be of size 75 x 15 mm and are fully interchangeable
with the previous 71 x 10.5 mm pipes.
Fig. 2 shows the Joint Disc new design. The Tightening Torque of the M16 Bolts of the new
Joint Disc is 70 Nm.

Tightening
Torque 70 Nm
Standard position
of Joint Disc

Alternative position of
Joint Disc with inverted
two-piece metal hose

Fig. 2 Joint Disc New Design Fig.3, Hydraulic Pipe

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3 TEMPORARY MEASURES
In case of a loosened joint disc and when new parts are not available at short notice,
temporary measures can be taken. The disc can simply be turned round 180° so that the three
contact faces of the disc touch an unworn part of the Hydraulic Pipe, see fig. 4. Longer bolts
with sleeves should be applied to prevent the bolts getting loose due to loss of tension. It is
possible that due to wear of the contact faces the gap between parts A and B is fully closed
while the Joint Disc still does not hold onto the Hydraulic Pipe. In that case Part A should be
adapted as shown in fig.4.

Apply sleeve according to drawing.

Apply 8.8 M16 bolts. Length approx 115
mm.
70
Pay attention the bolt extends sufficiently
Turn Joint Disc180° deep in the thread hole without getting stuck
in the bottom.
Tightening Torque M16 bolts: 170 Nm

Elongate the bolt holes to compensate for

the more inward position of part B.
B Alternatively, use M12 bolts instead of M16

Gap min. 2 mm

File approx. 5 mm off the faces of part A to enable part B to

slide further inward. After tightening, the gap between A and
B should be at least 2 mm.

Fig. 4 Joint Disc old design

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4 INSPECTION CHECKLIST

Ship Name: Engine Type: Running Hours:

Date: Unit No. Parts Order

Condition of Hydraulic

Total
Pipes
1 2 3 4 5 6 7 8 9 10 11 12 13 14 Part No.

A No wear
-- --

Joint Disc 71 mm
B Pipe size 71 mm. DF 84656
Wear less than 1 mm DF 84657
Replace Joint Disc and fit Bolts 2x
180° turned. DF 84661

C Joint Disc 75 mm
Pipe size 71 mm. DF 84666
Wear more than 1 DF 84667
mm Bolts 2x
DF 84661
Replace Hydraulic Pipe*) Hydraulic Pipe 75 mm
Replace Joint Disc DF 84665

Joint Disc 75 mm
D Pipe size 75 mm. DF 84666
Wear less than 5 mm DF 84667
Replace Joint Disc and fit Bolts 2x
180° turned. DF 84661

E Joint Disc 75 mm
Pipe size 75 mm. DF 84666
Wear more than 5 DF 84667
mm Bolts 2x
DF 84661
Replace Hydraulic Pipe*) Hydraulic Pipe 75 mm
Replace Joint Disc DF 84665

Pipe diameter [mm]

)
Joint Disc size Y*
Was Shrink Sleeve of
pipe removed? yes/no

*) Joint Disc execution:

Joint Disc old design, Pipe dia 71 mm: Y = 82 mm
Joint Disc old design, Pipe dia 75 mm: Y = 87 mm
Joint Disc new design, Pipe dia 75 mm: Y = 79 mm

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