TECHNICAL

BULLETIN

Wärtsilä Engine Services 2-S RT-92

Engineering Services Issue 3, 19 January 2016

Valve Control Unit

Next opportunity

Information to all Owners and Operators of Affected component

Wärtsilä RT-flex96C-B engines Valve Control Unit (VCU)
Current Situation
Reports of oil leakages and broken bolts of
the VCU were received.
Problems
Broken bolts of the valve control unit to the
servo oil rail have caused the leakages.
The leakages can cause a pressure
decrease in the servo oil rail. In the worst
case, this may lead to an automatic engine
shutdown.
Preventive action
Do a check for broken bolts and leaks on
the valve control units as soon as
possible.
Solutions
Introduction of new fitting instructions,
which must be followed after removal of
the valve control unit.
Replace the O-rings after each removal of
the valve control unit and its parts.
At the same time, new sets of elastic bolts
must be used for installation.
Validity / Issue
This Technical Bulletin remains valid from
the date of issue until further notice.
Note
This Technical Bulletin (Issue 3)
supersedes the Technical Bulletin
RT-92, Issue 2, dated 18.11.2010.
Reason:
• New repair kits and spare part code
numbers have been added.

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

PO Box 414
CH-8401 Winterthur technicalsupport.chts@wartsila.com
 TECHNICAL BULLETIN

RT-92, Issue 3, Page 2 / 12

Contents
Page
1 Introduction 2
2 Installation instructions 3
3 Broken studs and bolts 5
4 3/2 way valve leakages 8
5 Ordering of parts 10
6 Contacts 12

1 Introduction
Note:
This Technical Bulletin (Issue 3) supersedes the Technical Bulletin RT-92, Issue 2,
dated 18.11.2010. Reason:
• New repair kits and repair spare part code numbers have been added

Wärtsilä has received reports about leakages from Valve Control Units (VCU), which
are located in the rail unit. Also broken bolts were reported at two different locations as
follows:
• Between the connection piece (1, Figure 1) and the servo oil rail.
• Between the VCU and the support (11, Figure 1).

Looking at the leakage positions, the root cause are the O-rings between the 3/2-way
valve (4, Figure 1), connecting piece (1, Figure 1) and the cylinder (3, Figure 1). Some
leakages originate from the bottom of the 3/2-way valve and the lower cover.
VCU that were removed and disassembled had leaks after assembly and installation.
Insufficient compression of the O-rings caused these leakages. Incorrect assembly
sequence and misalignment of the VCU on the servo oil rail during installation caused
damage.

ATTENTION:
Check the valve control units for leakages and loose or broken bolts at the next
opportunity. Heavy leakages will cause a pressure drop in the servo oil rail, which may
result in an automatic engine shutdown in the worst case.
 TECHNICAL BULLETIN

RT-92, Issue 3, Page 3 / 12

2 Installation instructions
Install the VCU in accordance with this Technical Bulletin.

2.1 Tightening sequence and torque limits

The tightening sequence and torque limits must be followed as given in the work
procedure.

ATTENTION:
The new tightening values for the M16 and M20 bolts are only valid for the new elastic
bolt types. For details about tightening and torque limits of the original fitted bolts,
please consult the Maintenance Manual, Section 0352 “Tightening Values of Important
Screwed Connections”. The tightening value of the original M16 bolt corresponds to a
torque of 120 Nm and for the M20 bolt the tightening torque is 350 Nm.

15
4
3

7 13
5
2
10 & 14
1

12 6 11

1. Connecting piece 8. Elastic bolt M16

2. Stud M12 and hexagon nut M12 9. Hexagon nut M20
3. Cylinder 10. Shims
4. 3/2-way valve 11. Support
5. Screw M16 12. Servo oil rail
6. Elastic bolt M20 13. Shoulder
7. Screw M20 14. Positioning grooves
8. Elastic bolt M16 15. Connecting piece
Figure 1: VCU mounted on servo oil rail
 TECHNICAL BULLETIN

RT-92, Issue 3, Page 4 / 12

2.2 Work procedure

1. Put oil on the six M12 nuts and the four M16 screws (5, Figure 1).
2. Put the O-rings on the six M12 studs (2).
3. Put the connecting piece (1), in position on the servo oil rail (12).
4. Tighten with your hand the six M12 nuts. Make sure that the connecting piece (1)
fully touches the servo oil rail.
5. Put the cylinder (3) together with the 3/2-way valve (4) in position on the servo oil
rail (12).
6. Move the cylinder (3) and the 3/2-way valve (4) against the connecting piece (1).
7. Tighten with your hand, the four M16 screws (5).
8. Loosen slightly, the four M20 screws (7). Make sure that the O-rings between the
cylinder (3) and the 3/2-way valve (4) are in the correct position.
9. Put the shims (10) in position between the cylinder (3) and the servo oil rail (12).
10. Put the shims (10) in position between the servo oil rail (12) and the support (11).
11. Torque symmetrically, the six M12 nuts (2) to 60 Nm.
12. Torque the four M16 screws (5) to 170 Nm.
13. Torque the M20 elastic bolts (6) to 20 Nm.
14. Initially, torque the M20 nuts (9) to 100 Nm.
15. Torque the two M16 elastic bolts (8) to 270 Nm.
16. Torque the M20 nuts (9) to 300 Nm.
17. Torque the four M20 screws (7) to 350 Nm

NOTE:
• When tightening the VCU parts, check with a feeler gauge that the parts are
aligned evenly. This feeler gauge check has to be performed between all facing
surfaces of the valve control unit and between the VCU and the servo oil rail.
• The clearances between the shoulder (13) of the partition device
(3) and the positioning grooves (14) of the servo oil rail
(12) have to be filled with shims (10), see Figure 1
 TECHNICAL BULLETIN

RT-92, Issue 3, Page 5 / 12

3 Broken studs and bolts

The reports showed three different types of broken studs or bolts. The M20 stud
(6), that attaches the cylinder to the servo oil rail and the M16 bolt (8) that attaches the
support to the rail unit. An incorrect sequence and an incorrect torque value, will
overload the M20 studs and M16 bolts and cause them to break, see Figure 1 and
Figure 2.

1 2

1. Broken stud M20 2. Broken bolt M16

Figure 2: Broken stud M20 and bolt M16

The third reported failure are six M12 studs (2) of the connecting piece (1), which is a
part of the VCU, see Figure 1 and Figure 3. These M12 studs break only rarely. The
M12 studs break if the instructions to torque the M12 studs were not obeyed, or the
sequence to torque them was incorrect.
Also, the studs will be over-stressed if the connecting piece is not correctly aligned with
the servo oil rail (i.e. not perpendicular). Fretting, because of long operation time with
insufficient contact pressure between the surfaces, will cause uneven surfaces if not
found at an early stage.

1. Broken studs M12 2. Fretting

Figure 3: Broken M12 studs and fretting
 TECHNICAL BULLETIN

RT-92, Issue 3, Page 6 / 12

3.1 Solutions
When ordering a replacement for a broken M20 stud, a new elastic bolt (1, Figure 4)
will be delivered. The new elastic bolt has a higher tensile strength than the studs used
before.
Two different types of studs and/or bolts must not be used. A set of new elastic bolts
will always be delivered.
Installation instructions are included with the delivery of new elastic bolts. Read and
obey the installation instructions to make sure of safe operation.

1
2

1. Elastic bolt M20 3. Elastic bolt M16

2. Rolled threads M20
Figure 4: New elastic bolt M20 and elastic bolt M16 to support

If an M16 elastic bolt (3, Figure 4) is broken, new elastic bolts must be ordered. The
new M16 elastic bolts have a higher tensile strength and they will be delivered as a set
together with the installation instructions.

ATTENTION:
Irrespective of a broken M20 stud or M16 bolt, both parts must be replaced at the same
time by the new elastic bolts and this applies to all mounting points of the VCU. When
ordering the new elastic bolts, a complete set will always be delivered together with the
installation instructions.
 TECHNICAL BULLETIN

RT-92, Issue 3, Page 7 / 12

If a broken M12 stud is found, the problem must be repaired and the broken stud
replaced with a standard M12 as soon as possible.
When broken M12 studs are replaced, refer to the procedure given in paragraph 2.3.
If the M12 thread in the servo oil rail is damaged, Wärtsilä Services must be contacted.
To solve the problem, it is possible to fit an oversized M12 elastic bolt with an M16
thread at the lower end. Thus also an M16 thread must be cut into the servo oil rail.
The new retrofit M12/M16 elastic bolt must be ordered through Wärtsilä Services.
Because of the relative movement between the servo oil rail and the connecting piece,
some fretting might occur. Regardless of which types of studs are used, the installation
instructions must be followed.

ATTENTION:
If damaged M12 threads are discovered in the servo oil rail, Wärtsilä Services must be
contacted.

1. Retrofit elastic bolt M12/M16

Figure 5: Retrofit elastic bolt M12/M16
 TECHNICAL BULLETIN

RT-92, Issue 3, Page 8 / 12

4 3/2 way valve leakages

4.1 Lower Cover
Reports were received about leakages between the 3/2-way valve and the lower cover.
This is related to O-ring grooves, which were out of the machining tolerances. A new
type of cover will stop leakages. When new cover is ordered, a new O-ring is also
supplied.

5
1

2 3 4

1. Connecting piece 4. New O-ring groove

2. 3/2-way valve 5. O-ring
3. New lower cover
Figure 6: Lower cover

4.2 Sealing face of ports

In some cases, VCU leakages were reported between the sealing faces of the 3/2-way
valve (1) and the connecting piece (1) on one side, and the cylinder (3) on the other
side. To stop the leakages between the sealing faces, new O-rings must be inserted,
see Figure 7 and Figure 8.
 TECHNICAL BULLETIN

RT-92, Issue 3, Page 9 / 12

3
2

1. 3/2-way valve 3. Sealing face between 3/2-way valve

2. Sealing face between 3/2-way valve and cylinder
and connection piece
Figure 7: Sealing faces

The supplied O-ring set consists of two different types. The O-ring grooves of the 3/2-
way valve are of different size, depending on the year the VCU was built. Therefore,
the O-ring grooves on the housing of the 3/2-way valve must be measured to find the
correct O-ring type:
• O-ring type A, size 32.92 x 3.53 mm: Groove depth 2.7 mm
• O-ring type B, size 32.4 x 3.8 mm: Groove depth 3.1 mm
If new O-ring types A or B are required, they can be ordered as a kit with the part
number mentioned in chapter 5.

x x

2 3
1. 3/2-way valve 3. X= O-ring groove depth
2. O-ring grooves 4. O-ring type A or type B
Figure 8: O-ring grooves
 TECHNICAL BULLETIN

RT-92, Issue 3, Page 10 / 12

5 Ordering of parts
Depending of the checks and investigations carried out for each valve control unit,
different retrofit kits/parts can be requested from the nearest Wärtsilä representative.

Table 1: Valve control unit kits/parts

Kit name Order Items (Qty)

number
2x Elastic bolt M20 (6, Figure 1), 4x Elastic bolt M16 (8, Figure 1), 4x
Standard Shims (10, Figure 1), 4x O-ring type A (4, Figure 8),
DF 56115
kit 4x O-ring Type B (4, Figure 8), 4x Hexagon nut M20 (9, Figure 1)
and installation instructions.

4x O-ring type A (4, Figure 8), 4x O-ring Type B (4, Figure 8),
Cover
DF 56116 1x new lower Cover (3, Figure 6), 1x O-ring lower cover (5, Figure 6)
leakage kit
and installation instructions.

4x O-ring type A (4, Figure 8), 4x O-ring Type B (4, Figure 8),
Repair Kit DF 56117 6x Retrofit elastic bolt M12/M16 (1, Figure 5),
6x Hexagon nut M12 (Qty 6) and installation instructions.

4x O-ring type A (4, Figure 8), 4x O-ring Type B (4, Figure 8) and
O-ring kit DF 56118
installation instructions.

2x Elastic bolt M20 (6, Figure 1), 2x Elastic bolt M16 (8, Figure 1), 4x
Shims (10, Figure 1), 4x O-ring type A (4, Figure 8),
One unit
4x O-ring Type B (4, Figure 8), 1x new lower Cover (3, Figure 6),
per DF 56119
1x O-ring lower cover (5, Figure 6), 4x gaskets and 8x O-rings
cylinder kit
between the connecting piece and the 3/2-way valve (4,15, Figure 1)
and installation instructions.

Table 2: Additional spare parts

Part name Order number Items (Qty)

Elastic Bolt DF 56087 1x Elastic Bolt M16 (8, Figure 1)

Elastic Bolt DF 56148 1x Elastic Bolt M20 (6, Figure 1)

Hexagon Nut DF 56168 Hexagon nut for M20 elastic bolt (9, Figure 1)

The spare parts listed in Table 2 need to be ordered 2 times in order to receive the
required quantity.

NOTE:
If there are damaged M12 threads in the servo oil rail, contact the nearest Wärtsilä
Services representative.
 TECHNICAL BULLETIN

RT-92, Issue 3, Page 11 / 12

ATTENTION:
Order new O-rings before you disassemble the VCU or loosen the bolts and screws.
This will avoid prevent leakages after assembly the VCU and final mounting to the
servo oil rail. This is valid for all connections sealed with O-rings.

Make sure to request for 2 pieces of the elastic bolts (DF 56087 and DF 56148) and
the hexagon nut (DF 56168) when ordering these spare parts.

Standard O-rings for connections not described in this bulletin must be ordered
separately. Related part numbers can be found in the Spare Parts Catalogue, Group
5610 and 5612.

The O-ring between the sealing face of the connecting piece and the servo oil rail is not
part of the O-ring kit DF 56118, or one of the packages given before.

Make sure that there is an O-ring with the part number DF 56063 available on board
(refer to the Spare Parts Catalogue, Group 5, Chapter 5610-1/A1). If there is no O-ring,
you must order it separately with the standard kit (DF 56115) and / or the O-ring kit
(DF 56118)
 TECHNICAL BULLETIN

RT-92, Issue 3, Page 12 / 12

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.

6.2 Contact details in case of emergency

6.2.1 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.

6.2.2 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.

6.2.3 Spare parts

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

© 2016 Wärtsilä Services 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 Services
Switzerland Ltd 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 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.