INSTRUCTIONS

DAAD044709 / PAAD143811

Wärtsilä 2-stroke I-26

Technical Services Issue 1, 14 March 2014

ICU onboard repair kit:

Fuel quantity piston kit & Fuel quantity sensor kit At your convenience

Information to all Owners and Operators of Concerned components

Wärtsilä RT-flex and W-X engines.
NOTE:
This Instructions bulletin is only delivered with the
ordered repair kit to the customers.
This instruction concerns Injection Control
Units (ICU) of Wärtsilä RT-flex82C and
RT-flex82T engines in service and the new
Wärtsilä X82 engines.
Concerned are as well some ICU types
which are installed on the RT-flex68-D
engines. Further details regarding the
concerned ICUs on RT-flex68-D engines
are given in the introduction.

Current situation
With the General Information bulletin
RT-137 “Repair concepts for RT-flex
components” Wärtsilä offers some
“onboard repair kits” for ICUs.

Solution
This Instructions bulletin is a supporting
document for the ICU onboard repair kits
to assist in the maintenance of ICUs.

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

PO Box 414
CH-8401 Winterthur technicalsupport.chts@wartsila.com
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Contents
Page
1 Introduction 2
2 References 3
3 Skills and manpower 3
4 Required tools and material 3
5 Tightening torques 4
6 Main parts of ICU onboard repair kits 4
7 Preparation work 5
8 Removal and fitting of the ICU 5
9 Work procedure 6
10 Contacts 11

1 Introduction
This Instructions bulletin is intended to support the repair work on the Injection Control
Unit (ICU) for the ordered onboard repair kit as explained in the General Information
bulletin RT-137.

In particular this Instructions bulletin is for carrying out the exchange of the fuel valve
block assembly and/or servo oil valve unit.

The work described is valid for size 3 Injection Control Units. This type of ICU is
installed on most RT-flex82C and RT-flex82T engines. Also concerned are some ICU
types installed on RT-flex68-D and W-X82 engines.

Please consult the 3D drawings in Figure 1 for the identification of concerned

RT-flex68-D ICUs. Compare the drawings with the actually installed ICUs on the rail
unit to determine the ICU generation. The ICUs (1) are not concerned but the ICUs (2)
which are built on a similar concept as the ICUs in the RT-flex82C and RT-flex82T
engines.

1 2

1. Not concerned ICUs 2. Concerned generation of ICUs

Figure 1, Determination of concerned ICUs of RT-flex68-D engines
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NOTE:
The drawings, illustrations and pictures used in this Instructions bulletin are based on
RT-flex82C and RT-flex82T engines. These engines have Injection Control Units size 3.
ICUs of RT-flex68D_V1 and W-X82 engine might look in certain details different but
irrespective of the visual view, the given instructions are valid for all listed types of
ICUs. Any significant differences will be pointed out in this instruction.

2 References
Table 1

Document type Doc. Number Description

Group 0 Changing Over from Diesel Oil to Heavy Fuel Oil and
Operating Manual
Chapter 0270–1 Vice Versa
Group 0 Operation under Abnormal Conditions:
Operating Manual
Chapter 0510–1 Operation with Injection Cut Out
Group 5 Injection Control Unit:
Maintenance Manual
Chapter 5564–1 Removal and Fitting

3 Skills and manpower

The following skills and manpower are required for the replacement of the Injection
Control Unit (ICU) and fuel valve assembly. Depending on the ICU condition the work
scope may vary.

Table 2

Skills Required Min time [h] Max time [h]

Supervisor or
1 2 3
Service Engineer
Mechanic 1 2 3
Estimated work duration per unit 2.5 3.5

4 Required tools and material

The following Material is required in addition to the “onboard repair kit”.

Table 3

Tools & Material Description Quantity Unit

Torque spanner: up to 200 Nm 1 —
Spanner for M5 nut 1 —
Allen keys for M8 and M10 Each 1 —
Allen key for M12 2 —
Never-Seez Regular Grade, NSBT-8 —
Material for Scotch–Brite™ 1 —
maintenance Brake cleaner or similar cleaning solvent
and cleaning
purposes only WD40 or similar available solvent
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NOTE:
• There are no tools delivered with the “onboard repair kit”.
• The required tools and material for cleaning must be available from the on board
workshop store.
• Material and tools for the removal of the ICU are not listed in this document. Refer
to Maintenance Manual Group 5, Chapter 5564–1.

5 Tightening torques
Table 4

Screw Tightening torque with lubricant

Location
dimension Never-Seez NSBT-8
M12x70 Flange with Piston rod 55 Nm

M10x60 Housing 30 Nm
M8x50
Fuel quantity sensor 20 Nm
M8x35
M5 clamping nut Measurement tube 2 Nm

6 Main parts of ICU onboard repair kits

5 6

1. Fuel valve block assembly kit 4. Fuel quantity sensor kit

2. Measuring block 5. Servo oil valve unit kit
3. Fuel quantity piston kit 6. Rail valve
Figure 2, Main parts of ICU and location onboard repair kit
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Table 5, ICU onboard repair kit by engine type and ICU size

Fuel quantity piston kit

Engine type ICU Kit order Kit contents Quantity
size number
RT-flex82C, Tier 1 LF 55410
• Piston (002) 1 piece
RT-flex82C, Tier 2 LF 55414 • Flange with Piston rod (004) 1 set
RT-flex82T, Tier 1 & 2 3 VF 55414 • Lip seal (007) 1 piece
RT-flex68-D_V1 PF 55414 • Lip seal (009) 1 piece
W-X82 CX 55414 • O-ring (012) 1 piece

Fuel quantity sensor kit

Engine type ICU Kit order Kit contents Quantity
size number
RT-flex82C, Tier 1 LF 55762
RT-flex82C, Tier 2 LF 55762
RT-flex82T, Tier 1 & 2 3 VF 55762 • Fuel quantity sensor kit (006) 1 set
RT-flex68-D_V1 PF 55762
W-X82 N/A

7 Preparation work
For the replacement of the injection control valve the injection control unit must be
removed from the fuel rail.

Before the replacement of an injection control unit, the engine must operate for a
minimum of 1.5 hours with Marine Diesel Oil (MDO). Further information is available in
Operation Manual Group 0, Chapter 0270−1.

For any work on an injection control unit, the engine has to be stopped and the fuel
booster and bearing oil pumps have to be switched off.

ATTENTION:
Make sure that the fuel and servo rail pressures are completely released.

The corresponding drain screws and respectively valves must be opened as described
in the Operating Manual Group 0, Chapter 0510–1.

8 Removal and fitting of the ICU

Please read and follow the information in the Maintenance Manual, Group 5, Chapter
5564–1 “Injection Control Unit, Removal and Fitting”. Make sure that the mentioned
tools and material are ready to use.

WARNING:
Pay attention to the general guidelines for lifting tools in the Maintenance Manual
Group 0, Chapter 0012-1.
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NOTE:
During dismantling and assembling of the ICU make sure that the activity area is clean
and free from dust. Grinding in the nearby work area must be stopped.

Electric welding near or on the engine must be absolutely omitted.

When mounting the ICU back to the fuel rail, the lip seal (007) must be replaced with
the new one from the delivered “onboard repair kit”.

ATTENTION:
Repairs of RT-flex parts onboard or at customer’s workshops are beside any quality
control by Wärtsilä. No warranty can be granted on these parts after such work has
been done.

9 Work procedure

001. Measuring block 013. M12x70 hexagon socket head cap

002. Fuel quantity piston screw
004. Flange with Piston rod 014. M10x60 hexagon socket head cap
005. Housing screw
006. Fuel quantity sensor kit 015. M8x50 hexagon socket head cap
009. Lip seal screw
010. M5 clamping nut 016. M8x35 hexagon socket head cap
012. O-ring screw
019. and 020. Pin 018. Washer
Figure 3, Fuel quantity piston and Fuel quantity sensor
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9.1 Fuel quantity piston replacement

• Remove the M12x70 and M10x60 hexagon socket head cap screws (013 and 014)
and disconnect the housing (005).
• Remove the flange with piston rod (004), lip seal (009) and fuel quantity piston
(002) from the measuring block (001).
• Clean the touching surface for the lip seal (009) and the measuring block (001).

Table 6

Procedure Pictures
1. Clean the centre bore of the flange and
insert the piston rod into the cleaned
bore.

Make sure the thread of the piston rod

does not get damaged.

2. Replace the fuel quantity piston (002)

and lip seal (009) on the measuring
block (001). 002

Connect the piston (002) with the piston 001

rod and insert them into the measuring
block (001).

009
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Table 6, continued

Procedure Pictures
3. Insert the M12x70 screws (013) and apply 5
Never-Seez NSBT-8 on thread and 15
contact surface. 12 1
013 9
Tighten screws according to the sequence 13
in the picture.
4
Tightening torques: 8 7
st
1 step: 5 Nm
nd
2 step: 20 Nm
rd
3 step: 55 Nm 14
10 3
11
6
2
4. Check the running behaviour of the fuel
quantity piston (002) and piston rod (004)
for an easy reciprocating movement.

004

9.2 Fuel quantity sensor replacement

• Remove the M10x60 hexagon socket head cap screws (014).
• Remove housing (005), fuel quantity sensor (006) from the flange with piston
rod (004).
• Clean the touching surface between housing (005) and flange (004).

Table 7

Procedure Pictures
1. Apply Never-Seez NSBT-8 to the thread
of the piston rod. Piston rod
Tighten the measurement tube with
5 Nm.

Insert the M5 clamping nut (010) and

tighten it with 2 Nm.

010 Measurement tube

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Table 7, continued

Procedure Pictures
NOTE:
The aluminium measurement tube is very
sensitive. You have to be extremely careful
during tightening.

The tightening torques for the tube and

the M5 clamping nut are mentioned in this
procedure step 1.

2. Place O-ring (012) on the “Intermediate

flange” and fit it into the housing (005).

Intermediate flange O-ring (012)

3. Apply the M10x60 hexagon socket head 1
cap screw (014) and mount the housing 4
(005) on the “Intermediate flange”.

Apply Never-Seez NSBT-8 on thread and 3

contact surface of the screws.
2
Tighten screws according to the
sequence in the picture.

Tightening torque has to be 30 Nm.

014 005
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Table 7, continued

Procedure Pictures
4. Place O-ring (012) on the fuel quantity
sensor.

012

5. Apply Never-Seez NSBT-8 on the thread

of the M8x50 screws (015) and also on 016
the M8x35 screws (016).
015
Tightening torque has to be 20 Nm.

012

9.3 Mounting of ICU on fuel rail

After the successful replacement of the ICV, the ICU must be mounted back to the fuel
rail.
Make sure that the new lip seal (007) is used. The lip seal is part of the ICV kit delivery,
see Figure 4.
Follow the description in the Maintenance Manual Group 5, Chapter 5564–1 how to
mount the ICU back on the fuel rail.

1
007

1. Injection control unit 007. Lip seal to fuel rail

2. Fuel rail
Figure 4, Injection control unit showing location of lip seal
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10 Contacts
10.1 How to contact Wärtsilä
For questions about the content of this Instructions 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

10.2 Contact details for emergency issues

10.2.1 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.

10.2.2 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.

10.2.3 Spare parts

If you need Wärtsilä spare parts and/or tools, please contact your nearest Wärtsilä
representative or your key account manager.

© 2014 Wärtsilä Switzerland Ltd. – All rights reserved

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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 of the product, but merely as an improvement of the product and/or the repair 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.