TECHNICAL

BULLETIN

Wärtsilä low-speed engines RT-127

Services 2-stroke Issue 1, 23.04.2012

Crank Angle Sensor (CAS) belt For immediate attention

replacement Concerned products/components

Information to all Owners and Operators of
Wärtsilä RTA and RT-flex engines
All RT-flex engines and all RTA engines
with the Pulse Lubricating System (PLS)
which have a CAS type “AC58 encoder”
installed are concerned.
In addition some RTA96C and RTA96C-B
engines with the Retrofit Pulse Lubricating
System (RPLS) which have the same type
“AC58 encoder” installed are also
concerned.

Current situation
Insufficient lifetime of the Crank Angle
Sensors (CAS) has been reported.
Investigation showed that during engine
operation high dynamic peak forces can
occur excited by the toothed belt.

Solution
The new belt is made of a softer material
which helps to reduce the dynamic radial
forces on the sensor internal shaft bearing.
In addition the pre-tension value of the
toothed belt is slightly reduced.

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 belt version 2 
3 CAS drive condition and installation 3 
4 Replacement and repair kits 9 
5 Updated Maintenance Manual 11 
6 Contacts 12 

1 Introduction
Wärtsilä received reports mentioning insufficient lifetime of Crank Angle Sensors
(CAS). Analysing the reports showed that in some cases wear on the shaft and
the internal bearing of the CAS occurred. Concerned is the CAS type “AC58
encoder”.

Investigations showed that high dynamic peak forces can occur at the toothed
belt during engine operation. This can lead to the above mentioned damage of
the CAS unit. Consequently this mechanical failure results in disturbed and
unusable signals to the WECS and thus will trigger an alarm. As a result, the
CAS must be replaced.

2 New belt version

In order to reduce the dynamic peak forces caused by the toothed belt which is
the main cause of CAS mechanical failures, the belt material has been changed.
The new belt version is made of different material, is more elastic and reinforced.
This leads to reduced forces compared to the previous belt. In addition the
installation pre-tension value has been reduced.

Comparison of the two CAS toothed belts

1 2
1. Old version, 2. New version (black colour)
Fig. 1
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3 CAS drive condition and installation

3.1 Checking the condition of the CAS drive

Note:
Checks and replacement of CAS parts can only be carried out if the engine is at
standstill. For additional details of the CAS drive, refer to the Maintenance
Manual Group 9, Chapter 9223–1.

3.1.1 Checking the shaft eccentricity

High shaft eccentricity of the CAS drive can also generate additional dynamic
peak forces to the CAS. Wärtsilä recommends checking the shaft eccentricity in
case of CAS exchange. It is essential to perform the eccentricity check also
according to the maintenance intervals as listed in Chapter 5, entitled “Updated
Maintenance Manual”.
Eccentricity check:
1. Remove the protection hood of the CAS drive.
2. Install a magnetic base dial gauge as shown in Figure 2.

Illustration

1 3 4 5

1. Shaft with gear wheel of CAS drive, 2. Gear wheel of CAS drive, 3. Toothed
belt, 4. Magnetic base, 5. Dial gauge
Fig. 2

Note:
The measuring point must be horizontally adjacent to the gear wheel.

3. Read the deviation of the dial gauge while turning the crank shaft with the
turning gear.
4. According to gained experience, the average shaft eccentricity under normal
working and proper assembly condition should be less than 0.15 mm.
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In case the measured value is out of the stated average eccentricity value,
Wärtsilä recommends replacing the CAS drive with a new one. A new CAS drive
is available as a standard spare part on board. The replacement shall be done
according to the Maintenance Manual Group 9, Chapter 9223–1 “4. Removal of
crank angle sensor drive” and “7. Fitting the crank angle sensor drive”.

The replaced doubtful or defective CAS drive shall be overhauled and/or repaired
as soon as possible. The overhaul job can be done by the ship’s crew according
to the Maintenance Manual Group 9, Chapter 9223–1 or it can be done through
Wärtsilä Services.
An overhaul kit is under preparation and will later be available from Wärtsilä
Services. Please refer to Chapter 4.3 “Repair kit for CAS drive”.

3.1.2 Checking the clearance between shaft and internal bearing of the CAS
If the CAS is over 5 years in service or has more than 48,000 running hours,
Wärtsilä recommends checking the condition of the CAS before a new belt
version is installed. The CAS condition is checked by measuring the clearance
between the shaft and internal CAS bearing.

Procedure for measuring the clearance:

1. Remove the protection hood of the CAS drive.
2. Remove the protection plate.
3. After loosening the fixation screws, remove first the toothed belt of the outer
CAS and then the belt of the inner CAS.
4. After removing the belt, tighten the fixation screws again.
5. Install the magnetic base dial gauge as shown in Figure 3.
6. Push the gear wheel of the CAS to left and right direction.
The measurement has to be done in fixed condition of the inner and outer
CAS but without the toothed belts.
7. Read the deviation of the dial gauge while pushing the gear wheel of the CAS.
8. According to gained experience, the average CAS clearance under normal
working and in proper assembly conditions should be less than 0.05 mm.

Measuring of clearance

2 1 3
1. Magnetic base dial gauge, 2. Measurement on inner CAS, 3. Measurement on
outer CAS
Fig. 3
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3.1.3 Checking the toothed belt condition

As recommended in the “Inspection and Overhaul Intervals (Guidelines)”, the
toothed belt has to be checked every 3000 operating hours for its pre-tension. In
addition a visual inspection of the belt has to be performed, which means
checking for possible cracks and worn-out tooth areas.

3.1.4 Experience with the new belt version

The toothed belt example in Figure 4 shows the new version in normal working
condition. Wear down particles or debris of the toothed belt surface, which
appear on the cover of the CAS drive, is a normal appearance.
Small particles or debris from the new version may be found also inside the cover
from the initial running of the new belt version. The particles found after initial
running of a new belt will not disturb the function of the CAS.

New toothed belt

3 4

1. New toothed belt before installation, 2. New belt with some operating hours,
3. Belt with little wear on tooth surface, 4. Some particles from new belt surface
located on CAS cover
Fig. 4
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An old version toothed belt with wear and material loss at the tooth tip is shown in
Figure 5.
A belt in this condition shall be considered to be replaced in the near future. In
addition, the time for a replacement of the belt depends also on the visual
inspection result at every 3000 operating hours.

Old belt showing some wear (after approximately 18,000 operating hours)

1. Worn tooth tip area

Fig. 5

The pictures shown in Figure 6 are examples of toothed belts with severe
material loss. Worn-out toothed belts in such condition must be replaced
immediately.

Damaged belts (after approximately 45,000 operating hours)

1
2 3
1. Lost teeth of belt, 2. Damaged belt structure, 3. Damaged belt structure and
lost teeth
Fig. 6
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3.2 Tightening instructions and adjustment of CAS

3.2.1 New tightening instruction for toothed belts
When replacing the toothed belt, it must tensioned to 30 N. The correct tension
has to be adjusted with the spring balance which is located in the Shaft Encoder
Package box.

Note:
According to IACS regulations, at least one Shaft Encoder Package box
containing the spring balance is part of the standard spare parts supply per ship.

Adjusting the tension of the toothed belt

2 3 4

1. Gear wheel of CAS drive, 2. Toothed belt, 3. Shaft encoder, 4. Spring balance
Fig. 7

Note 1:
It is recommended to do this installation by two skilled workers to ensure correct
pre-tensioning of the belt.

Note 2:
To prevent toothed belt tightening with the old value of 40 to 45 N, which is
currently described in Maintenance Manual Group 9, Chapter 9223–1 “3.2 Fitting
the toothed belt”, Wärtsilä recommends updating the corresponding page
manually to 30 N.
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3.2.2 Adjustment of the crank angle offsets in WECS

After the mechanical work on the CAS and CAS drive, the crank angle offsets
must be adjusted.

1. Turn the engine with the turning gear until the flywheel marks show TDC,
cylinder number one = 0.0°.
− Marks (1) and (2) should be aligned as indicated in Figure 8.
− TDC of cylinder number one can be cross checked from the crank case.
But safety measures must be taken accordingly before opening of the
crankcase – see “Warning labels” located near the crank case doors on the
engine.

2. Start the flexView programme and go to the ADJUST card.

3. With the flywheel position as described in the first point, read the crank angle
values displayed in the fields “Crank angle 1/2". If they are different from
0.0° CA, enter the displayed values as offsets in the fields "CA 1/2 Offs.".

Note:
For negative deviations, e.g. 359.8<°, use negative values, e.g. -0.2<°, see
Figure 8.

Adjustment of the crank angle offsets

2 1 2

T.D.C. 1

1. Mark on gear wheel, 2. Marks on shaft encoder and holder

Fig. 8
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4 Replacement and repair kits

4.1 Replacement of belt

Wärtsilä will provide the new belt version to the concerned vessels in operation.
Once they are received on board, the old toothed belts at the running CAS shall
be replaced by the new version at the next convenient opportunity. The exchange
must be done according to the instruction in Chapter 3.2 “Tightening instructions
and adjustment of CAS”.

The old toothed belts in the CAS spare package, i.e. “Shaft Encoder Package
box” must also be replaced by the new version. These CAS spare packages are
part of the IACS spare parts on board.

Note:
Do not use the old toothed belts anymore. All of them must be scrapped once the
new toothed belts are available on board and have been fitted as described
above.

The new toothed belt version can be ordered separately as a single part.
Information about ordering of parts or how to contact Wärtsilä is listed in
Chapter 6 “Contacts”.

List of engine types with respective code numbers of new belt package

Code number Code number

RT-flex RTA
for new belt for new belt
engine types engine types
package package
RT-flex50
RT-flex50-B IF 92266 – –
RT-flex50-D
RT-flex58T-B
OF 92266 – –
RT-flex58T-D
RT-flex60C
NF 92266 – –
RT-flex60C-B
RT-flex68-B
MF 92266 – –
RT-flex68-D
RT-flex68-D_V1 PF 92266 – –
RT-flex82C LF 92266 RTA82C L 92266
RT-flex82T VF 92266 RTA82T V 92266
RT-flex84T-D BF 92266 RTA84T-D B 92266
RTA96C and RTA96C-B
RT-flex96C-B DF 92266 D 92266
with RPLS 1)

1)
RPLS: Retrofit Pulse Lubricating System
Table 1
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4.2 Reasons for CAS drive replacement

There are two reasons for a CAS drive overhaul:
• High shaft eccentricity
Refer to chapter “Checking the shaft eccentricity” to verify the eccentricity.
• Maintenance Schedule
Work to be carried out at 48,000 Op.h (Operating hours)

Before carrying out the replacement of a CAS drive which is available as

standard spare parts on board, a new CAS drive must be ordered unless a repair
kit is available on board, see also next chapter.
The spare parts order number is to be found in the Spare Parts Code Book
Group 9, Chapter 9601–1, within Item “Crank Angle Sensor Unit” and named
“Shaft encoder drive, complete” or “Shaft encoder, complete (box)”.

4.3 Repair kit for CAS drive

The replaced doubtful or defective CAS drive shall be overhauled and/or repaired
as soon as possible. With a Repair kit, the overhaul job can be done by the ship’s
crew according to the Maintenance Manual Group 9, Chapter 9223–1 or it can be
done through Wärtsilä Services.

Note 1:
The repair kit for the CAS drive is under preparation. The kit will contain all
needed parts to overhaul the CAS drive on board. As soon as the repair kit is
available a new issue of this Technical Bulletin or a separate Work Instruction will
be released with information about code number for ordering etc.

Note 2:
Damaged CAS shall only be sent back to Wärtsilä if specially requested. The
return shipment, if requested, will be handled individually case by case.
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5 Updated Maintenance Manual

Updated information is added to the Maintenance Manual Group 9, Chapter
0380–1 “Inspection and Overhaul Intervals (Guidelines)”. The update of the
respective Manual page is illustrated in Figure 9 as an example.

Example of Inspection and Overhaul Intervals (Guidelines)

stroke Maintenance 0380–1/A1

Inspection and Overhaul Intervals (Guidelines)

Group Component Work to be carried out Intervals

9
9223–1 Crank angle – Check tension visually acc. to MM 3000 Op.h
sensor unit Check cracks and wear of toothed belt visually.
Visual lubricating oil check.

– Replace toothed belt 24 000 Op.h

– Overhaul drive (ball-bearing, sealing ring etc.) 48 000 Op.h

and check shaft eccentricity of CAS drive

– Check shaft eccentricity of CAS drive At every CAS exchange

for any reason

– Replace crank angle sensor 48 000 Op.h

(Only if new soft belt
is applied from
the beginning)

1 1

1. New entries in Maintenance Manual for inspection

Fig. 9
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6 Contacts

6.1 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

6.2 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

© 2012 Wärtsilä Switzerland Ltd. – All rights reserved

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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 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.