TECHNICAL

BULLETIN

Wärtsilä low-speed engines RT-110

Services 2-stroke Issue 2, 02.04.2013

CLU4 pulse lubricating module: For immediate attention

Pressure check and maintenance Concerned components

CLU4 pulse lubricating module of Wärtsilä
RTA and RT-flex engines and the
Information to all Owners and Operators of accumulator of the pressure reducing
Wärtsilä RTA or RT-flex engines valve on RT-flex engines.

Current situation
Reports have been received of pressure
loss from accumulators on the CLU4
cylinder lubricating module.

Problem
Pressure loss in the accumulator leads to
damage of the accumulator membrane,
which in turn might influence the
performance of the cylinder lubrication.

Solutions
Check regularly the pre-charge pressure
of the accumulator.
Introduction of a new filling device.

Note 1
The lubricating system with the CLU4-C
pulse lubricating module is excluded from
this bulletin, except point 3.2. For details
on the CLU4-C lubricating module, please
consult the Operating and Maintenance
Manuals, Group 7, Chapter 7218-1.

Note 2
This Technical Bulletin Issue 2 supersedes
Technical Bulletin RT-110 Issue 1, dated
31.05.2011.
Chapter 3.3 and 3.4 were updated to
include also checking of old type
accumulators and the accumulator on the
pressure reducing valve, if applicable.
In addition, a new chapter was added, i.e.
3.10 “CLU4 lubricating module – screw
plug and non-return valve”.

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 accumulator filling device 4 
3 Lubricating module and accumulator maintenance 4 
4 Ordering of spare parts 19 
5 Abbreviations 21 
6 Appendix 21 
7 Contacts 21 

1 Introduction
Note:
This Technical Bulletin supersedes Technical Bulletin RT-110, Issue 1, dated
31.05.2011. Chapter 3.3 and 3.4 were updated to include also information about
checking of old type accumulators and the accumulator on the pressure reducing
valve. In addition, a new chapter was added, i.e. 3.10 “CLU4 lubricating module –
screw plug and non-return valve”.

On several engines with the CLU4 Pulse Lubricating System – see Figure 1 – a
significant loss of nitrogen was detected in the accumulator. This pressure loss
may result in a damaged accumulator membrane, irrespectively of the Pulse
Lubricating System (PLS) or the retrofit version (RPLS).
The pulse lubricating module CLU4-C, with the smaller type of accumulator, is
not affected and thus is not part of the improvements as described hereafter.
For the identification of the pulse lubricating module, please refer to Figure 2.

Pulse Lubricating System

2 1

3 6 4 3

1. Cylinder lubricating system, 2. CLU4 lubricating module, 3. Accumulator,

volume 0.75 l, 4. Membrane, 5. Gas filling port, 6. Servo oil port
Fig. 1
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A correctly pre-charged accumulator is necessary to obtain a good performance

of the lubricating module and the lubricating system in general. It ensures the
correct injection time, and further it reduces pressure fluctuations in the servo oil
system.

Wärtsilä utilises two modules on their Pulse Lubricating Systems:

• Module CLU4:
On the first generation of the lubricating module, the accumulator is mounted
horizontally.

• Module CLU4-C:
The second generation of the lubricating module is more compact. The
accumulator is mounted vertically and is smaller compared to the previous
CLU4 module.

Design of cylinder lubricating modules CLU4 and CLU4-C

1 4

2 3 5 6

1. Lubricating module CLU4, 2. Accumulator, volume 0.75 litre, 3. Filling

connector, 4. Lubricating module CLU4-C, 5. Accumulator, volume 0.32 litre,
6. Filling connector
Fig. 2
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2 New accumulator filling device

For the horizontally-positioned accumulator used on the CLU4 lubricating
module, Wärtsilä has introduced a new gas filling device. This device is
maintenance-friendly and the risk of losing gas pressure during the pressure
check and later in operation is eliminated.

Note:
Wärtsilä recommends replacing the former accumulators with the accumulator
incorporating the new filling valve.
The new accumulator can only be filled with the tool 94720c – see chapter 3.3 –
or with the coupling & short hose 94720a-R to the former filling tool – see
chapter 3.6. For ordering the parts please refer to chapter 4.

Improved accumulator with filling valve

2 1

1. Accumulator, 2. Filling device, 3. Protection cap

Fig. 3

3 Lubricating module and accumulator maintenance

In order to ensure trouble-free operation, the pre-charge pressure has to be
periodically checked. Checks and maintenance are only to be carried out when
the engine is at standstill.
For additional details please consult also the Operating Manual Group 7,
Chapter 7218–1 or the RPLS Instruction Manual if it is a RPLS installation.
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3.1 Determine the accumulator membrane condition

An accumulator membrane gets damaged due to no back pressure from the gas
side. The pulsation from the oil side without gas back pressure causes the
membrane to bend over the limit and finally cracks arise or brakes completely.
The membrane is damaged when no remaining gas pressure is present in the
accumulator or when oil leaks from the gas filling port. The concerned
accumulator must be replaced with a new improved one.

For ordering the parts please refer to chapter 4 in this bulletin.

3.2 Inspection interval of the pre-charge pressure at the accumulator

Check the pre-charge pressure directly after the installation of a new
accumulator, then at least once in the first week after start-up. Afterwards, check
the pre-charge pressure every three months.

3.3 Required tools for pre-charge pressure checking or filling

Wärtsilä has introduced a tool kit (1) for easy checking or filling the accumulator.
The toolbox includes all equipment needed to do the job, including a pressure
reducing valve (4) for the nitrogen bottle, see Figure 4.

Note:
For checking or filling the pre-charge pressure of the accumulator Wärtsilä
strongly advises to use the tool kit No. 94720c.

Accumulator testing and filling equipment, tool No. 94720c

2 3 4

1. Complete tool kit No. 94720c, 2. Control unit, 3. Hose – length 1 m and 4 m,
4. Pressure reducing valve
Fig. 4
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In case of using the filling equipment No. 94720c (as shown in Figure 4) for
checking and/or filling an accumulator of the former design with an M28x1.5
connection, Wärtsilä provides an adapter for this set-up, see Figure 5.
The adapter has to be mounted permanently at each accumulator filling
connection, which means for each accumulator one adapter is required.

Adapter to accumulator, tool No. 94720b-R

1. Adapter, tool No. 94720b-R, 2. Adapter piece connection with AF 19,

3. Adapter piece connection with AF 32
Fig. 5

Before connecting the adapter No. 94720b-R, release the pressure of the
complete system. Afterwards release the nitrogen pressure of the accumulator.
To release the nitrogen pressure, slowly loosen the hexagon screw at the
nitrogen filling connection (filling screw) by two to three turns until the pressure is
fully released.
After the nitrogen pressure is fully released, the hexagon screw (filling screw) has
to be removed. The hexagon screw must not be reinstalled because the adapter
includes a check valve.

Warning:
Before starting with any maintenance work on pressurised systems, the pressure
must be completely released, see Maintenance Manual Group 0,
Chapter 0011-1, “Safety measures and warnings”.
Risk of injury: Always wear gloves when working on hot components and safety
goggles when working with hot fluids and compressed air.
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3.4 Preparation before checking or refilling

Before starting any maintenance work, ensure that the servo oil supply unit is
switched off and the servo oil pressure is completely released.
In any case, when the accumulator has been removed the lubricating pump has
to be vented, see chapter 3.9 “Venting the lubricating pump” in this bulletin.

In order to release the remaining servo oil pressure, please follow the below
preparation either for RTA or RT-flex engines with the CLU4 cylinder lubricating
system.

Preparation on RTA engines

• Stop the servo oil supply.
• Interrupt the main bearing oil supply by closing the 3-way valve (3).
• Drain the servo oil system by opening shut-off valve SV2 one turn, see
Figure 6.

Note:
Shut-off valve SV2 must remain open during the entire checking and/or refilling
procedure.

Servo oil supply unit of RTA engine

2 3 1

1. Servo oil pump, 2. Shut-off valve SV2, 3. 3-way valve

Fig. 6
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Preparation on RT-flex engines

• Stop the servo oil supply.
• Close the stop valve 4.30–5 on the servo oil rail 4.11, see Figure 7.
• Drain the servo oil system at screw plug (13) of the pressure reducing
valve 8.11–1, see Figure 7.

Note:
Screw plug (13) must remain open during the entire checking and/or refilling
procedure.

Control diagram of servo oil supply for RT-flex engine

8.06

4.11

4.30–5 PI2041L
13
8.11–1

1 2

1. Stop valve: 4.30–5, 2. Servo oil rail: 4.11, 3. Pressure reducing valve: 8.11–1,
13. Screw plug
Fig. 7

Remark:
Quoted numbers in the control diagram Figure 7 correspond with the numbers as
used in the Maintenance Manual Group 7, Chapter 7218-1 and in the Operating
Manual Group 4, Chapter 4003-2 as well as in Group 7, Chapter 7218-1.
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Pressure reducing valve with accumulator

When doing maintenance on the CLU4 lubricating module and checking the pre-
charge pressure of the accumulator, check also the gas pre-charge pressure on
the accumulator (4) of the pressure reducing valve (3), see Figure 8.

The pre-charge pressure of the accumulator located on the pressure reducing

valve shall be checked on RT-flex engines if an accumulator is installed.

Depending on the engine type and cylinder configuration one or two pressure
reducing valves with respective accumulators are installed. The location of the
pressure reducing valve depends again on the engine type, see example in
Figure 8.

The filling procedure is described in Chapter 3.5.

Note:
The pre-charge pressure is the same as on the accumulator of the lubricating
module CLU4, i.e. 25 bar.

Location of pressure reducing valve with accumulator, drawn for RT-flex96C-B

4 3

FREE
END

Servo oil pipe to

lubricating module

1. Stop valve: 4.30–5, 2. Servo oil rail: 4.11, 3. Pressure reducing valve: 8.11–1,
4. Accumulator
Fig. 8
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3.5 Checking the pre-charge pressure on a new-type accumulator

Setting-up the equippment

14

4a C 5 B A 4

1. Accumulator, 2. Protection cap, 3. Pressure reducing valve, 4. Hose – length

1 m, 4a. Hose – length 4 m, 5. Control unit with three valves, 7. Pressure gauge
0 to 60 bar, 14. Nitrogen bottle, A. Valve, B. Valve, C. Valve
Fig. 9

For the below work procedure, the accumulator does not have to be
disconnected from the lubricating module.

Note:
During every check a small amount of gas may be lost to atmosphere. Therefore,
in order to make up possible losses make sure a nitrogen bottle is available
before a pre-charge pressure check is made.

Procedure for checking/refilling the gas pre-charge pressure

1. Close the three valves (A), (B) and (C) on the control unit (5), see Figure 9.
2. Connect accumulator (1) to the valve (A) on the control unit (5), using short
hose (4).
3. Open valve (A) and read the pressure on gauge (7).
Required pre-charge pressure: min. 20 bar / max 25 bar.
4. If pre-charge pressure is within the given limit, close valve (A) and vent
remaining pressure in control unit (5) by opening valve (B). Disconnect the
short hose (4) from accumulator (1) and refit protection cap (2).
5. If it is required to refill the accumulator, please continue to point 6.
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Remark:
The accumulator may only be filled with super-clean, Class 4.0 nitrogen,
99.99% N2 by volume.

6. Connect pressure reducing valve (3) to nitrogen bottle (14), see Figure 9.
7. Connect pressure reducing valve (3) to the control unit (5) at valve (C) using
long hose (4a) and adjust the outlet pressure to approx. 30 bar.
8. Close the three valves (A), (B) and (C) on the control unit (5).
9. Open valve (A) and read pressure from gauge (7).
10. Slowly open valve (C) and refill the accumulator (1) to the required pressure
of 25 bar.
11. Close valve (A) and (C) and vent the remaining pressure in control unit (5) by
opening valve (B).
12. Disconnect the hoses (4) and (4a), remove the tools and refit all protection
caps.
13. Perform the final assembly, please refer to chapter 3.8.

3.6 Checking and refilling the gas pre-charge pressure with former filling tool
This instruction for checking and refilling with the former filling tool No. 94720 is
an alternative method to the procedure described in chapter 3.5. However, the
use of the tool No. 94720 directly from the gas bottle without a pressure reducing
valve is not recommended.

Note:
Wärtsilä does not recommend checking and refilling the accumulator without a
pressure reducing valve.

For checking and refilling the pre-charge pressure using the former tool, a
coupling with a short hose is needed. Please refer to chapter 4 for ordering the
coupling & short hose.

Setting-up the equipment of former filling tool No. 94720

3
8
1

9 4 7 5 5

1. Accumulator, 2. Protection cap, 3. Filling and testing valve with pressure

gauge, 4. Connecting hose, 5. Short hose, 6. Coupling with filling plug, 7. Relief
valve, 8. Connector to accumulator, 9. Nitrogen bottle
Fig. 10
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For the below work procedure, the accumulator does not have to be
disconnected from the lubricating module.

Note:
During every check a small amount of gas may be lost to atmosphere. Therefore,
in order to make up possible losses make sure a nitrogen bottle is available
before a pre-charge pressure check is made.

Procedure for checking/refilling the gas pre-charge pressure

1. Connect the coupling with the filling plug (6) to the filling and testing
valve (3). Tighten the connection by hand, see Figure 10.
2. Fit the hose (4) to the filling and testing valve (3) and connect to the nitrogen
bottle (9).
3. Make sure that both the relief valve (7) at the filling tool (3) and the nitrogen
bottle (9) are closed.
4. Remove the protection cap (2) from the accumulator (1); connect the short
hose (5) from the filling and testing valve (3) to the filling plug on the
accumulator. Tighten the coupling nut (8) by hand.
5. Read the pressure on the gauge (3) which must be between 20 and 25 bar.
If the pre-charge pressure is within limits, carefully remove the connector (8)
from the accumulator (1), remove the filling equipment and refit the protection
cap (2) to the accumulator.
6. If the accumulator requires to be refilled, please continue to point 7.

Remark:
The accumulator may only be filled with super-clean, Class 4.0 nitrogen,
99.99% N2 by volume.

7. Very slowly open the valve on the nitrogen bottle and quickly close it again
as soon as the gauge shows a pressure between 25 and 30 bar. The
complete system, including the gas chamber of the accumulator, is now
pressurised with the specified pressure.
8. If the maximum filling pressure is exceeded, it can be adjusted to 25 bar by
means of the relief valve (7) at the filling and testing valve (3), see Figure 10.
9. Firmly close the valve on the nitrogen bottle and carefully remove the
connector (8) from the accumulator (1). The filling plug closes automatically
when removing the connector (8).
10. Refit the protection cap (2) to the filling port on the accumulator (1).
11. Release the remaining pressure from the hose by opening the relief
valve (7).
12. Remove the complete pressure equipment and perform the final assembly.
Please refer also to chapter 3.8.
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3.7 Cable connections of solenoid and pressure sensor

The purpose of the regular maintenance of the cable connections is to prolong
the lifetime of electrical contact surfaces and to provide proper electrical
connection under all conditions. This prolongs the working life and maintains full
availability of the Pulse Lubricating System.

Note:
The maintenance of electrical connections should be performed every six
months.

The maintenance is carried out by applying contact lubricants to electrical contact

surfaces and retightening the screw connections. For best result the contact
surface should be cleaned with an aerosol electrical contact cleaner before
applying the lubricant.
Contact lubricants are specially formulated greases and oils that reduce friction
and enhance the electrical performance of current carrying metal interfaces in
switches and connectors. They also have a neutral pH value, thereby avoiding
surface corrosion.

Attention:
To avoid electrical shock or possibility of fire, disconnect power to any system
before applying conductive lubricant. Ensure positive and negative contacts
remain isolated. Working on a “live circuit” can result in shorting, arcing, or shock.

Electrical connectors to Pulse Lubricating System

2 1

1. Lubricating module CLU4, 2. Cable connectors

Fig. 11
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3.8 Final assembly

After checking/refilling prodedure
• On RTA engines:
− Close shut-off valve SV2, see Figure 6.
− Open the main bearing oil supply by opening the 3-way valve (3), see
Figure 6.

• On RT-flex engines:
− Reopen stop valve 4.30–5 on servo oil rail 4.11, see Figure 7.
− Close screw plug (13) of pressure reducing valve 8.11–1, see Figure 7.

After checking the pressure and refilling the accumulator, ensure to run the servo
oil supply system and vent air from the system before putting the Pulse
Lubricating System into operation. See also chapter 3.9 “Venting the lubricating
pump”.

3.9 Venting the lubricating pump

H I The lubricating pump has to be vented after refitting the accumulator.

The lubricating pump contains two vent plugs:

• One plug for the cylinder lubricating oil (H).

• One plug for the servo oil (I).

The air can escape when the plugs are loosened.

Venting the lubricating oil section of the lubricating pump

• Required tools:
− Oil collection tray.
− Cloth to wipe up escaping oil.

• Proceed as follows to vent the lubricating oil section of the lubricating pump:

1. Place an oil collection tray beneath the lubricating pump.

2. Loosen the vent plug for the lubricating oil (H). For this, turn the plug
counter-clockwise a maximum of three turns.
3. Wait until bubble-free oil escapes at the vent plug.
4. Tighten the vent plug again.
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Venting the servo oil section of the lubricating pump

Attention:
Pressurised oil system.
The servo oil system is under high pressure. Oil may spurt out when you loosen
the screws. Wear safety goggles. Do not loosen the vent plug more than three
turns.

• Proceed as follows to vent the servo oil section of the lubricating pump:

1. Place an oil collection tray beneath the lubricating pump.

2. Operate the lubricating system via manual lubrication or intermediate
lubrication operation.
For additional details please consult also the Operating Manual Group 7,
Chapter 7218–1 or the RPLS Instruction Manual Chapter 4, if it is a RPLS
installation.
3. This is only possible after the servo oil priming pressure has been
achieved by starting the servo oil pumps.
4. Put on safety goggles.
5. Loosen the vent plug for the servo oil (I). For this, turn the plug counter
clockwise a maximum of three turns.
6. Wait until bubble-free oil escapes at the vent plug.
7. Tighten the vent plug again.

3.10 CLU4 lubricating module – screw plug and non-return valve

Improperly mounted or loose non-return valves (1) can lead to faulty pressure
build-up in the CLU4 lubricating module, which will result in marginal cylinder
lubrication or no lubrication at all.

CLU4 module, extract from Appendix 1 – SKF/VOGEL documentation

1 2

1. Location of non-return valve in CLU4 lubricating module, 2. Screw plug

Fig. 12
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3.10.1 Indication of improperly tightened or loose non-return valve

Any of the following criteria can be an indicator for an improperly mounted or
loose non-return valve in the CLU4 lubricating module.

1. If the non-return valve is leaking and the oil is drained back to the return line,
it could lead to following indications and/or alarms:

1.a For lubricating systems controlled by WECS-9520

Indications in the Alarm and Monitoring System (AMS):

• PT2046A “Servo Oil Leakage Pulse Lubrication Free End”
• PT2047A “Servo Oil Leakage Pulse Lubrication Drive End”

Note:
In case the pressure in the leakage line is above 10 bar.

• PT2041A “Servo Oil Pressure Pulse Lubrication Free End”

• PT2042A “Servo Oil Pressure Pulse Lubrication Drive End”

Note:
In case the pressure is below 40 bar with 3 second delay; this alarm is
suppressed at engine stand still.

In case of severe leakage:

• WF0020-15“ME Servo Oil Pressure low” during engine operation

Indication in the flexView Journal:

• “ME Servo Oil Pressure low” (ID 20)

1.b For lubricating systems controlled by stand-alone unit E40, valid mostly for
PLS and RPLS installations

Indication in the flexView Journal of the PLS or RPLS personal computer:

• “Servo Oil leakage” in case the pressure is above 25 bar

In case of severe leakage:

• “ME Servo Oil Pressure low” during engine operation, in case the
pressure is below 35 bar
• “Servo Oil System not ready – check Servo Oil Pumps!”, at standstill

The triggering of above mentioned indications and/or alarms might as well

depend on the extent of the leakage rate through the valve. In other words, if
the leakage is small there might not be an alarm from the low servo oil
pressure at all or any other alarm. Lack of servo oil pressure will lead to
“slow” movement of the main piston of the lubricating module and
consequently to lower the cylinder oil injection peak pressures, longer
injection duration, etc.
 TECHNICAL BULLETIN RT-110
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Respective alarms which can be triggered are:

• “Lubrication module Cylinder #[Cyl. No.] pressure low”
• “ME Cylinder Lubrication Malfunction Cyl#[Cyl. No.]”

Due to the lower servo oil pressure the “Deadtime” could as well become
quite long as the lubricating module piston moves slowly. In case the
“Deadtime” reaches 60 ms or more until 10 bar is reached, the alarm
“Lubrication Deadtime MAX Limited Module #[T]” will be shown in flexView.

2. In case the non-return valve is blocked there will be NO consequences,

except that the servo oil can NOT be drained with the spindle if it should
become required.

3. In case the non-return valve is loose (but does not rotate out of position), it
could lead as well to leakage of servo oil. As a result, this might lead to the
same indications and/or alarms as described under point 1.

4. If the non-return valve rotates out, the servo oil supply channel to the
solenoid valve might have a “flow” restriction of servo oil which can lead to
the same phenomenon as described under point 1.

5. In case debris, i.e. particles from the non-return valve spring or other parts
enter into the solenoid valve and in a worst case into the lubricating module
itself, this can lead to same alarms as described under point 1.

3.10.2 Solution
The solution to solve the problem of improperly mounted or loose non-return
valves is already available since 2007/2008. The solution was partly
communicated by SKF with the document “Vogel, 951-130-328-US”, see
Appendix 1.
 TECHNICAL BULLETIN RT-110
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Non-return valve and screw plug

1 2

3 4

1. Old non-return valve, 2. New non-return valve, 3. Old screw plug, 4. New
screw plug, 5. Ring
Fig. 13

3.10.3 Affected CLU4 lubricating modules

Affected CLU4 lubricating modules can easily be identified depending on the total
volume output and the manufacturing date of the CLU4 lubricating module. The
respective information is to be found on the name plate which is located on the
side of the lubricating module, see Figure 14.
All CLU4 lubricating modules have to be checked. The criteria for affected CLU4
lubricating modules are listed in Table 1.

Attention:
It is recommended to modify all affected CLU4 lubricating modules including the
spares. The modification with the new screw plug and non-return valve is also
part of the Wärtsilä remanufacturing service for CLU4 lubricating modules.
Please contact your Wärtsilä representative for more details about Wärtsilä
component remanufacturing services.
 TECHNICAL BULLETIN RT-110
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Location of name plate on CLU4 lubricating module

3 4

1. Location of name plate on CLU4 lubricating module, 2. Name plate, 3. Total

volume 2480 mm3, 4. Manufacturing date information – Week 17, Year 2007 –
not affected
Fig. 14

Affected CLU4 lubricating modules

Total volume output Manufacturing date, Week / Year [WW / YY]

2480 mm3 Manufactured before 14 / 07
All other volumes Manufactured before 33 / 07

Table 1

4 Ordering of spare parts

4.1 Ordering of new accumulator

• Identify the accumulator and include the information for the order.
• If possible include a picture of the pulse lubricating module with your order
which shows clearly the accumulator.

The improved accumulator can be ordered through Wärtsilä by quoting the spare
part code number, see also remark below.
Code number of accumulator:
• For RTA engines: D 96369
• For RT-flex engines: DF 96369
 TECHNICAL BULLETIN RT-110
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4.2 Ordering of new screw plug and non-return valve

• Repair kit (assembly): SP 72300

Repair kit consisting of:

− Screw plug: SP 72301
− Ring: SP 72302
− Non-return valve: SP 72303

Remark:
Designation of Spare Part Code Number: X 12345 or XF 12345.
“X” = Given letter depending on the engine bore size and type – please consult
your Spare Part Code Book.
Letter “F” is the indication for RT-flex engines.
e.g., in this Technical Bulletin spare part numbers are quoted with following
letters:
“D” for RTA96C and RTA96C-B engines
“DF” for RT-flex96C-B engines
“SP” for Service Product parts irrespective of the engine bore size and type.

4.3 Ordering of tool kit and adapters

The required tools can be ordered from your nearest Wärtsilä representative by
stating the respective tool number as listed in Table 2.

Description Tool number

Tool kit for checking or filling the new accumulator 94720c
Coupling & short hose to former filling tool No. 94720 94720a-R
* Adapter for new filling equipment 94720c in combination with
94720b-R
former design of accumulator with an M28x1.5 connection

Table 2

* Note:
If the former design of accumulator is used with the new filling equipment 94720c
then the adapter 94720b-R must be mounted permanently to each accumulator.

4.4 Remanufacturing service for CLU4 modules

By remanufacturing used CLU4 modules to the latest technical specification and
returning to an “as new” condition with the latest specifications, remanufactured
components are available ex stock with the same warranty as new parts but sold
at a reduced cost to the customer. Please refer to the General Information
bulletin RT-119, entitled “Component remanufacturing services”.
 TECHNICAL BULLETIN RT-110
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5 Abbreviations

Abbreviation Description
CLU4 Cylinder lubricating system of fourth generation
CLU4-C Cylinder lubricating system of fourth generation, with
compact lubricating module
PLS Pulse Lubricating System
RPLS Retrofit Pulse Lubricating System

Table 3

6 Appendix
Appendix 1:
Document entitled “CLU4 Check Valve Retrofitting Instructions”.
Document issued by SKF / VOGEL with document number 951-130-328-US.

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
 TECHNICAL BULLETIN RT-110
Issue 2, Page 22 / 22

© 2013 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 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.
 APPENDIX 1 ($  ""!'DB

2;D#
2WTRZ
EP[eT
ATca^UXccX]V
8]bcadRcX^]b
Exchange of the check valve on the CLU4 cylinder lubrication pump

In the past few months we have received some complaints regarding

defective pressure build-up on the cylinder lubrication pumps. In-
depth tests at the VOGEL factory have revealed that the prescribed
starting torque for the built-in check valve was not adhered to with
the pumps in question.
The check valve's inner part "traveled" backwards and impeded the in-
ternal flow of servo oil.

The following retrofitting instructions should help to identify the error. If

the check valve is responsible for a malfunction, a modified valve part
and a new screw plug are to be mounted in accordance with the follow-
ing retrofitting instructions. In doing this, the correct starting torque is to
be observed.

Explanation of symbols and signs

You will find these symbols, which are warnings of specific dangers to
persons, material assets, or the environment, next to all safety instruc-
tions in this operating manual.
Please heed these instructions and proceed with special care in such
cases. Please forward all safety instructions to other
users.
Instructions placed directly on machines/engines must be followed
without fail and kept in fully readable condition.

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2;D#
2WTRZ
EP[eT
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8]bcadRcX^]b
Inhaltsverzeichnis
Fehlererkennung
Umbaubeschreibung der Austausch-
Hubtaktpumpe
Austausch der Hubtaktpumpe am Zylinder 4
Umbau einer defekten Hubtaktpumpe
Hubtaktpumpe entlüften
Hubtaktpumpe-Schmieröl entlüften
Hubtaktpumpe-Servoöl entlüften
Schmiersystem entlüften
Pump malfunction
Timed lubricator not working
Leakage between base plate and
Pump unit
Pressure build-up too slow
Pressure sensor does not give
any more signals although there
is a change in pressure in the
lubricating oil exit.
Pump is not supplying oil
Made in Germany
161-140-050
NG6
! ($  ""!'DB
APPENDIX 1
2
4aa^a
XST]cXUXRPcX^]
3
Note!
5 reason for the defective build-up of pressure
Faulty pressure build-up in the CLU4 cylin-
6 should be ascertained.
der lubrication pump will result in marginal
6 cylinder lubrication, or no lubrication at all.
The following checklist should serve as a guide.
6 This could imply, though not inevitably, a
7 malfunction due to an improperly-mounted If no cause is determined, even after following
check valve. the checklist, the following retroffiting action is
Thus, prior to disassembly of the pump, the to be carried out.
Cause Elimination-see operating instructions
 Servo oil pressure is insufficient  Check the servo oil pressure at the measurement
connector and reset to between 45 and 50 bar
 4/2 directional solenoid valve defect  Exchange 4/2 directional solenoid valve
 Pump unit damaged  Exchange pump unit
 One or more lubricating quills are blocked  Check the quills and replace if necessary
 Position of shutoff valve(3) (5) in the base  Control position of the valve - see operating instructions
plate is incorrect
 Seals between base plate and pump unit damaged  Exchange seals - see operating instructions
 Servo oil pressure is insufficient  Check the servo oil pressure at the measurement connector
and reset to between 45 and 50 bar
 Nitrogen pressure in the diaphragm  Refill nitrogen (max. 25 bar)
accumulator is too low
 Pressure sensor defect  Exchange pressure sensor - operating instructions
 Air in the lubrication feed line  Vent the lubrication feed line - see operating instructions
 Servo oil pressure is insufficient  Check the servo oil pressure at the measurement connector
 Oil supply is insufficient  Exchange filter element - see operating instructions
 Check position of shutoff valve
 Filter supply valve is closed  Open supply valve
 Air in the lubrication line  Vent lubrication and servo oil system
 L-shutoff valve (5) closed  Open valve
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2;D#
2WTRZ
EP[eT
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Note!
A replacement timed lubricator pump, found in the set of spare parts that is included
in the delivery, belongs to the general scope of delivery of the CLU4 timed lubricator.
The timed lubricator replacement pump is to be retrofitted prior to its mounting.

Retrofitting instructions for the timed lubricator

replacement
 For a better overview, as well as to facilitate the retrofitting action, a clean surface
area should be set up in the vicinity of the mounted timed lubricator pump. The individual
components of the retrofitting set are to be placed on this surface.

 Inspect the retrofitting set to ensure that it is complete

ATca^UXccX]V
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Pos. Description Quantity Part number

"








2WTRZ
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24-2103-2258

!
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#
Screw plug

!
44-1855-2150

$

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!
95-1631-7603

 Fig. 1 If the mounting plate (1) is available, loosen up mounting plate screws (1) (4x), 5XV

Rh[X]STa
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remove the mounting plate
1
 Loosen up and remove the screw plugs(2) using a hexagon socket screw key (SW8)

 Loosen up and carefully remove the check valve (3) from the pump housing, using a
hexagon socket screw key (SW10)

 Screw in the new check valve (3) to the pump housing, and tighten with a hexagon socket
R

Made in Germany

screw key (SW10) using a torque of 50 Nm

 Screw in the newscrew plug (2) with seal (5) in the pump housing, and tighten
with a torque of 50 Nm, using a hexagon socket screw key (SW8) 161-140-050
R

A B

NG6 P T

 Loosen up and remove the screw plug(4) using a hexagon socket screw key (SW8) 2/5

 Screw in the newscrew plug (4(identical to 2)) with seal (5) in the pump housing 4/5
and tighten with a torque of 50 Nm using a hexagon socket screw key (SW8)

 If mounting plate (1) is available, please place it on the pump housing

 Tighten the mounting plate screws (1) (4x) with a tightening torque of 50 Nm

" ($  ""!'DB
2;D#
2WTRZ
EP[eT
ATca^UXccX]V
8]bcadRcX^]b APPENDIX 1

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Disassembly of the timed lubricator

 Turn off the engine

5XV
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 Replacement pump is prepared - see page 3 1

 Close the lubricating oil outlet (if present) - see engine manufacturer's operating
instructions

 Close and release pressure on servo oil circulation - see engine manufacturer's operating R

instructions Made in Germany

 Place the oil tray under the timed lubricator

R

161-140-050

 Fig. 2 Slightly loosen the lubricating line screw unions (1) (up to the lubricating quills)
A B

NG6 P T

 When the screw unions (1) are loosened up, back-flowing lubricating oil will discharge.
Only when no more lubricating oil escapes at the screw unions (1) should these be fully
loosened up

 Fully loosen up the screw unions (1) of the lubricating lines (up to the lubricating quills)

 Fig. 3 Loosen up the screw unions (2) (2x) for the servo oil circulation, the pump inlet,
and the pump outlet "P". 5XV
"
5
 Loosen up the screw union (3) for lubricating oil inlet "L" 6

 Loosen up the screw union (4) for the tank return "T" 3

 drain off the lubricating oil and servo oil found in the timed lubricator
L

4
T

 Loosen up the screws (4x) for mounting plate (5), carefully remove the mounting plate
operation

valve
drain

with timed lubricator from the lubricating and control lines 2

shut-off
valve (P)
service

 Loosen up the screws (4x) found on the back side of the mounting plate (5), that are used
to affix the timed lubricator (6), and remove together with the mounting plate

 Set aside the mounting plate (5) with the old timed lubricator (6), affix the mounting plate
to the new replacement pump if needed, and tighten with a torque of 50 Nm

Mount the replacement pump

 Place the mounting plate (5) (with timed lubricator) in the earlier mounting position and
affix with screws (4x)

 Position the lubricating line's screws (1) on the timed lubricator and sturdily tighten
without a tool

 Position and tighten the screw unions (2) (2x) for the servo oil circulation, pump inlet "P"
and pump outlet "P" on the timed lubricator

 Position and tighten the screw union (3) for lubricating oil inlet "L" and (4) for tank return
"T" at the timed lubricator

 Retrofit disassembled pump according to the instructions on page 3 and, if necessary,

exchange additional pumps according to the instructions provided above.

# ($  ""!'DB
2;D#
2WTRZ
EP[eT
ATca^UXccX]V
8]bcadRcX^]b APPENDIX 1

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5XV
#
Attention!
If a check valve (8) is damaged, the servo channels must be inspected and cleaned prior to installa-
tion of a new valve. This is to be conducted as described below.
12

 Fig. 4 Loosen up and remove the test connection (9) or, optionally, the mounted screw
plug
R

Made in Germany

 Loosen up the hexagon socket screws (4x) (SW4) (10) and remove the directional control 11
valve (11) 10
R

161-140-050

 The following inspection of the control channels is to be conducted using a piece of wire 8
A B

NG6 P T

(max. ø 2 mm). 7
13
 Inspect the control channel between the test connection and directional control valve, vi
sually and with the wire piece, for any foreign matter. If necessary, remove foreign matter 9
with the wire. After, blow some pressurized air through the control channel to clean it.

 Clean the flanging surface of the base plate (12) as well as the directional solenoid valve (11)

 Place the directional solenoid valve (11) on the base plate (12) and tighten using hexagon 5XV
$
socket screws (4x) (SW4) ((12) using a torque of 5 Nm 7

 Screw in the new check valve (8) to the pump housing, and tighten using a hexagon
socket screw key (SW8) using a torque of 50 Nm

 screw in the new screw plug (7) with seal in the pump housing, and tighten with a 6 L
hexagon socket screw key (SW8), using a torque of 50 Nm
T


operation

Remove the screw plug (13) using a hexagon socket screw key (SW8), and screw in a new 4
valve
drain

screw plug(13 (identical to 7)) with seal in the pump housing, and tighten with a hexagon
shut-off
valve (P)
service

socket screw key (SW8) using a torque of 50 Nm

 Fig. 5 if mounting plate (5) is available, place it on the pump housing

 Tighten the mounting plate screws (5) (4x) with a tightening torque of 50 Nm

 The repaired timed lubricator is now an exchange pump ready for another pump
retrofitting.

$ ($  ""!'DB
2;D#
2WTRZ
EP[eT
ATca^UXccX]V
8]bcadRcX^]b APPENDIX 1

Vent the timed lubricator

Venting of the pump is carried out through two special venting plugs with central
boreholes. Plug "A" is for lubricating oil, plug "B" is for servo oil. By loosening up the plugs, any
air present in the timed lubricator can escape. During normal operation, the pump is
self-venting.

5XV
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Control the valve positions of the timed lubricator
(see operating instructions)

 Open the lubricating oil filter outlet (if present) - see engine manufacturer's operating
instructions

 Place the oil tray under the timed lubricator

 Fig. 6 Loosen the vent plug "A" (lubricating oil) with a max. of 3 turns in
a clockwise direction

 The venting procedure has ended when bubble-free oil discharges

from the timed lubricator.

 Tighten vent plug "A" (lubricating oil), starting torque of 10 Nm

Vent the servo oil timed lubricator

 Place the oil tray under the timed lubricator

 Activate servo circulation

 Activate the CLU4 pulse lubrication system using manual lubrication, or using
the manual emergency activation

Danger- Risk of injury!

In the following venting procedure, there is a system pressure of 50 bar in venting
plug "B". Therefore, the venting plug may only be loosened by a maximum of
3 turns.

 Loosen the vent plug "B" (servo oil) a max. of 3 turns in a counterclockwise direction

 The venting procedure has ended when bubble-free oil discharges

from the timed lubricator.

 Tighten vent plug "B" (servo oil), starting torque of 10 Nm

% ($  ""!'DB
2;D#
2WTRZ
EP[eT
ATca^UXccX]V
8]bcadRcX^]b APPENDIX 1

Venting the lubrication system

After the timed lubricator has been vented, the lubrication lines to the
quills are to be vented
5XV
&
 Place the oil tray under the timed lubricator 1

 Fig. 7 Loosen the union nuts (1) in all lubricating quills by one turn

 Activate timed lubricator electrically or manually using the manual emergency (2)

 Activation of the manual emergency (2) is to be continued until bubble-free lubricating oil
discharges from the lubricating quills.

operation
Carefully tighten union nut (1) at the quill 2

valve
drain
shut-off
valve (P)
service
 Repeat these steps with the remaining quills

 Clean the pump

Prong, max. ø 3.5 mm
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Willy Vogel Aktiengesellschaft

SKF Lubrication Solutions
Hockenheim plant
2. Industriestrasse 4 · 68766 Hockenheim · Germany
Tel. +49 (0)6205 27-0 · Fax +49 (0)6205 27-101
info@vogel-berlin.de · www.vogelag.com · www.skf.com

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