Service Bulletin

RT-flex-06

Technical Information to all Owners / Operators

of Sulzer RT-flex Engines
08.02.2008

Reconditioning of Injection Control Unit

Contents:

1. Introduction

2. Repair Criteria

3. Reconditioning Criteria

4. Reconditioning Process

3. Delivery / Return Procedure

Attachments: Shipping Form

Proforma Invoice

Wrtsil Switzerland Ltd

Wrtsil Schweiz AG
Wrtsil Suisse SA

PO Box 414
CH-8401 Winterthur
Switzerland

Page

Tel. +41 52 262 23 30

Fax +41 52 212 71 03
E-mail: techservice.ch@wartsila.com

INTRODUCTION

This Service Bulletin offers information on repair and reconditioning of the Injection Control
Unit (ICU) as part of the RT-flex Component Reconditioning Program. This Bulletin is
applicable to all RT-flex engines.
The life expectancy of ICU components depends entirely on operational conditions. In case of
ICU malfunction, the options for on-board problem solving are normally limited to
replacement of the Rail Valves, Fuel Quantity Sensor and Fuel Quantity Piston. If further
measures are required, the complete ICU, including Rail Valves and Fuel Quantity
Sensor/Piston, should be sent for repair or reconditioning.

The ICU test bench in Winterthur, Switzerland.

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Service Bulletin RT-flex-06

2 REPAIR CRITERIA
After long-term operation the internal drain bores of the Injection Control Block may become
clogged with carbon deposits. Due to pressure building up in these drain bores, this may
ultimately result in external leakages. The ICU will then have to be sent for repair.
The repair procedure includes:
-

Dismantling of the ICU.

Cleaning of the internal drain bores with special equipment and cleaning agents.
Modification of the internal drain bores to improve draining of leakage fuel.
Replacement of all o-rings and seals.
Assembly and testing of the ICU

3 RECONDITIONING CRITERIA
An ICU is due for reconditioning when the Injection Control Valves reach a certain wear
limit, or in case of Control Oil Valve malfunctioning.
3.1

Injection Control Valve wear

In case of Injection Control Valve wear the following alarms will be activated:
- INJ BEG DEADT n HI ( n = unit number)
This is an early indication of wear. WECS is adjusting the injection timing to compensate for
wear. The performance data and indicator diagrams should be checked for correct injection
timing, combustion temperatures and pressures.
- INJ BEG DEADT n VERY HI
The wear has reached the limit and the ICU has to be reconditioned.
3.2

Control Oil Valve malfunction

In case of Control Oil Valve malfunctioning, the following alarms will be activated:
WECS-9500:
- INJ QTY PISTON n, NO MOVEMENT
- INJ QUANTITY PISTON n STUCK IN MAX. POS.
- INJ n INJ TIME TOO LONG
WECS-9520:
-

INJ n INJ TIME TOO LONG

INJ QTY PISTON n NO MOVEMENT
INJ QTY PISTON n STUCK IN MAX POS DELAYED
INJ QTY PISTON n FAIL: Check LEDs on FCM for details.

Check the ON-times of the Rail Valves:

- WECS-9500: maximum 2.5 ms
- WECS-9520: maximum 2 ms

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Service Bulletin RT-flex-06

The above mentioned alarms are not uncommon during start-up of the engine, but should
clear when the fuel system and engine components are at their normal operational
temperature.
The ICU is due for reconditioning if the alarms cannot be reset and re-appear repeatedly while
the ON-times of the Rail Valves are found within limits, and replacement of the Fuel Quantity
Sensor and Fuel Quantity Piston do not resolve the problem.

4 RECONDITIONING PROCESS
The engine has to be stopped on MDO in order to prevent extensive and time consuming
cleaning of the ICU in the reconditioning shop.
Reconditioning of the ICU includes:
-

Dismantling of the complete unit

Cleaning of the Injection Control Block internal galleries
Replacement of the Fuel Quantity Sensor and Fuel Quantity Piston
Replacement of the Injection Control Valves and relevant parts
Replacement of the Control Oil Valve Block
Replacement of Rail Valves
Replacement of all o-rings and seals
Assembly and Testing

2
4

1. Fuel Quantity Sensor

2. Fuel Quantity Piston
5

3. Rail Valves
4. Injection Control Valves
5. Injection Control Block
6. Control Oil Valve Block
6

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Service Bulletin RT-flex-06

5 Delivery / Return Procedure

The ICU must be packed and shipped in a
special transport box to protect from damage
and prevent any remaining fuel oil from
leaking out. This box will be provided by
Wrtsil as part of the reconditioning
program. If required, additional boxes can
be obtained through your Wrtsil Sales
contact.
Approved ICU Transport Box

For collecting and forwarding arrangements please contact your Wrtsil Service Network
Representative.
The attached Shipping Form to be completed and distributed as follows:
1) Ships file
2) Shipment
3) Wrtsil Service Network Representative

Attachments:

Shipping Form
Proforma Invoice

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Service Bulletin RT-flex-06

RT-flex COMPONENT RECONDITIONING PROGRAM

Shipping Form for RT-flex components
Component:

Name:

Spare Part Code:

Running hours:
Serial Number:
Ship Name:

Company Name:

Engine Type:

Engine Running Hours:

Order / Reference No.:

Reason for Overhaul, Description of Failure

Return Address:

Customer Contact Person:

Wrtsil Contact Person:
Remarks:

Place:

Date:

Signature:

Distribution: 1) Ships file

2) Shipment
3) Wrtsil Service Network Representative

Date: 29.08.2007

Page : 1 / 1

Delivery of ships spares for reconditioning

Proforma Invoice
No.
Consignee

Shipper

Name
Address

Vessel Name
Company
Address

Tel.
Fax.

Tel.
Fax.

VAT No.:
Place of dispatch:
Dispatched by: Courier / Air Freight / Sea / Land Transport
Order No.:

Ref.:
Date:

Ships spares in transit:

Pos.

Part No. / Description / Engine Type

001
002
003
004

Transport Box:
Size: 1070x640x320
Size: 990x540x240
Size: 850x540xx240

Net Weight:
Gross Weight:
Remarks:
VALUE FOR CUSTOMS PURPOSE ONLY

Account No.

Qty

Price in EUR