09.01 ICU Rail Valve Leakages
09.01 ICU Rail Valve Leakages
09.01 ICU Rail Valve Leakages
BULLETIN
Concerned components
Rail valves installed on the Injection
Control Units (ICU) and the Exhaust Valve
Information to all Owners and Operators of Control Units (VCU) of Wärtsilä RT-flex
Wärtsilä RT-flex engines engines.
Problem
Leakage of control oil.
Solution
Replacement of the O-rings between the
ICU/VCU block and the rail valve
assembly
Contents
Page
Introduction 2
Problem description 3
Consequences 3
Recommendations and measures for improvements 6
Work description 6
Contacts 11
Introduction
The rail valves are used for pre-controlling the Injection Control Units (ICU) and
Exhaust Valve Control Units (VCU) on Wärtsilä RT-flex engines.
The location of the O-rings sealing the connections to the ICU or VCU is shown
in Figure 1. Depending on the engine type an intermediate orifice plate is
mounted between the rail valve assembly (valve body) and the ICU or VCU.
Note:
The information given in this Technical Bulletin applies for the rail valves installed
on both – Injection Control Units and Valve Control Units.
Rail valve
7 1 2 3 4 5 6
Remark:
Two different mounting executions of the rail valve assemblies were applied in
the past. One is with an intermediate orifice plate and the other is directly fixed to
the ICU or VCU. Today’s common execution is the one directly fixed to the ICU or
VCU.
If an intermediate orifice plate is installed, three additional identical O-rings (6)
are applied.
Problem description
Service experience has shown cases, where a leakage from the rail valves
installed on Injection Control Units (ICU) and Valve Control Units (VCU) is
observed.
2 1
1. Control oil accumulated at the rail valve plugs, 2. Servo oil leakage – a high
amount of oil accumulated on the bottom plate of the common rail unit
Fig. 2
Consequences
The oil collected at the rail valve socket can leak through the exposed bayonet
groves in the socket into the electrical plug’s connector.
Additionally, control oil and fuel oil content on the socket can be caused by not
well protected plugs during maintenance.
As a result, oil traces are observed at different locations in these cabinets, i.e. in
the cable trays, terminals, cables, etc.
1 2
3 4
1. Oil collected in E95.XX cabinet, 2. Oil traces on FCM-20 module –
WECS 9520, 3. Oil collected at the cable trays – WECS 9500, 4. Oil running
along the wires – original cable colour “white” now “yellow”
Fig. 5
Work description
*) If an intermediate plate is installed between the rail valve and ICU / VCU,
six (6) O-rings are required.
Table 1
Note:
If ordering O-rings for ICU and VCU with the order numbers listed in Table 4
and 5, the required number of O-rings has to be stated. Wärtsilä recommends
ordering at least 3 O-rings per rail valve or at least 6 O-rings if an intermediate
orifice plate is mounted.
TECHNICAL BULLETIN RT-146
Issue 1, Page 7 / 11
Table 2
Table 3
TECHNICAL BULLETIN RT-146
Issue 1, Page 8 / 11
1.78
NF 55759
RT-flex60C-B
RT-flex58T-B QF 55759
RT-flex58T-B
RT-flex58T-D OF 55759
RT-flex58T-D_V1
RT-flex58T-D_V2 GF 55759
RT-flex50 Note, minimum quantities:
RT-flex50-B IF 55759 3 O-rings per rail valve
RT-flex50-D 6 O-rings with intermediate orifice plate
RT-flex48T-D EF 55759
Table 4
NF 56162
RT-flex60C-B
RT-flex58T-B QF 56162
RT-flex58T-B
RT-flex58T-D OF 56162
RT-flex58T-D_V1
RT-flex58T-D_V2 GF 56162
RT-flex50
RT-flex50-B IF 56145 Note, minimum quantities:
RT-flex50-D 3 O-rings per rail valve
RT-flex48T-D EF 56168
Table 5
TECHNICAL BULLETIN RT-146
Issue 1, Page 9 / 11
2 1
5 3 4 4 1
1. Rail valves, 2. Screws – tighten with 4 Nm, 3. O-rings, 4. Part of ICU, 5. Rail
valve with intermediate orifice plate, O-rings and screws
Fig. 6
Note:
The leakages described under point 1 and 2 can lead to a similar distribution of
lubricating oil. Therefore, carefully check the origin of the leakage before
replacing the rail valve.
TECHNICAL BULLETIN RT-146
Issue 1, Page 10 / 11
Leakage location between ICU and rail valve (drawn for RT-flex82C)
1 3
1. ICU, 2. Fuel rail, 3. Rail valve, 4. Leakage location between rail valve and ICU,
5. Screws, 6. O-rings
Fig. 7
Note:
Tightening of the four screws must be done with 4 Nm and not with 2.5 Nm as
specified in the instructions delivered with the spare rail valves.
TECHNICAL BULLETIN RT-146
Issue 1, Page 11 / 11
Contacts
Field service
If you need Wärtsilä Field Service, please send your enquiry to:
[email protected]
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:
[email protected]
or phone 24hrs support: +41 52 262 24 02