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RT-flex-06
Contents:
1. Introduction
2. Repair Criteria
3. Reconditioning Criteria
4. Reconditioning Process
PO Box 414
CH-8401 Winterthur
Switzerland
Page
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.
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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:
-
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
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
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:
-
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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:
-
2
4
3. Rail Valves
4. Injection Control Valves
5. Injection Control Block
6. Control Oil Valve Block
6
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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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Name:
Company Name:
Engine Type:
Return Address:
Place:
Date:
Signature:
Date: 29.08.2007
Page : 1 / 1
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:
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