DATA &

SPECIFICATIONS
2 Stroke Engine Services
Engine section Engine type Ref. Date Issue Document no. Page
RT-flex engines 2-stroke 29.11.2016 3 RT-123_A3 1(7)
Bore sizes in cm: Appendix 3
82, 84 and 96

Inspection and overhaul intervals

Table 1

Inspection or Estimated
Overhaul interval1) lifetime 1), 2) Maintenance
Component Comments
[RH: Running [RH: Running methods
Hours] Hours]
System Oil 3,000 Lube. Oil sample laboratory analysis.
Check filter elements - in particular for
Main lubricating oil
white metal particles (clean or replace
filters 3,000
filter if required).
(plant side)
Follow manufacturer’s instructions.
Bedplate foundation Check pre-tension according to the
12,000 Engine lifetime
bolts Maintenance Manual.
Visual examination, search for white
Crankcase 1,500 – 3,000 metal particles from bearings and for
abnormalities in general.
6,000 Bearing clearance measurements.
6,000 Bearing edge check by wire 3).
Bearing shell open-up inspection is
Main bearing 90,000
At indications of only necessary if bearing clearance,
excessive wear or crankshaft deflection, wire check, oil
Replacement if
damage analysis or crankcase inspection
required
indicates excessive wear or damage.
6,000 Bearing clearance measurements.
6,000 Check bottom drain for free passage.
Thrust Bearing pads open-up Replacement if
Thrust bearing Engine Life Time
At indications of inspection is only necessary if bearing required
excessive wear or clearance, oil analysis or crankcase
Replacement if
damage inspection indicates excessive wear or
required
damage.
Check pre-tension:
First time
after one year
Check pre-tension according to the
Tie rods Successive Engine lifetime
Maintenance Manual.
inspections:
Random check at
major overhauls or
all every 30,000
At each piston Inspect liner & establish wear in bore
Cylinder liner 4) Up to 90,000
removal at every piston removal.

Wärtsilä Services Switzerland Ltd PO Box 414 Tel (24h): +41 52 262 80 10
CH-8401 Winterthur
Engineering Services, 2-stroke engines Switzerland technicalsupport.chts@wartsila.com
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RT-123_A3, Issue3, Page 2 / 7

Table 1, continued

Inspection or Estimated
Overhaul interval1) lifetime 1), 2) Maintenance
Component Comments
[RH: Running [RH: Running methods
Hours] Hours]
Check non-return
Lubricating quill valves: Check function and tightness. Replacement if
(Pulse lubrication) At each piston Check function of non-return valves. required
removal
Check non-return
valves: Check function and tightness.
Lubricating quill At each liner Check function of non-return valves. Replacement if
(CLU-3) removal required
Accumulator Check diaphragm for oil leakages and
diaphragm: 6,000 replace if required.
Clean rings & establish wear at every
At each piston 36,000
Piston rod gland piston removal. Overhaul on board
removal (refers to rings)
Replace rings if required.
Check for cracks and dirty or damaged
at every piston
Cylinder cover Engine lifetime seat sealing faces of injection valves. Remanufacturing
removal
Remanufacture if required.
Before starting
engine after a Check externally for tightness
Standard injector and longer engine stop
FAST injector 1,000 RH after
replacement of Re-confirmation of opening pressure.
injector parts
Function check (opening pressure).
Visual inspection of all parts. Replace
6,000
parts if required.
Replace the nozzle tip.
Standard injector
Condition on board
Replace or recondition the nozzle is influenced by fuel
Up to 24,000 5)
body. quality and
treatment.
Function check (opening pressure). Replace the parts if
6,000
FAST Injector Visual inspection of all parts. required
18,000 Replace the nozzle tip & nozzle body.
Check pipe upstream of the valve
weekly during operation, if pipes are too hot,
disassemble starting valve.
Make sure that the nut on the solenoid
monthly
is tight, if necessary tighten the nut.
Solenoid valve; random functional
Starting valve 6,000
check.
Remove and disassemble one starting
12,000 valve, from the condition, calculate the
time of overhaul for remaining valves.
18,000 Solenoid valve. Overhaul on board
engine lifetime Starting valve.
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Table 1, continued

Inspection or Estimated
Overhaul interval1) lifetime 1), 2) Maintenance
Component Comments
[RH: Running [RH: Running methods
Hours] Hours]
Check condition and wear of valve
spindle (if necessary regrind seat by
machining). Valve plates with
Inspection at
corrosion layer deeper than the limit
18,000RH,
Exhaust valve spindle 108,000 6) given in the Maintenance Manual or Remanufacturing
36,000RH and
seating surface ground back more
72,000RH
than 3 mm can be remanufactured.
Nimonic 80A spindles can be
remanufactured up to 2 times.
Check condition and wear of valve
seat (if necessary regrind seat by
Inspection at machining). Valves with seat surface
18,000RH, ground back more than 3 mm or with
Exhaust valve seat 72,000 Remanufacturing
36,000RH and burn scars on the inside of the seat
72,000RH that exceed the limit given in the
Maintenance Manual must be
remanufactured.
Check condition of piston seal ring, air
Exhaust valve drive Inspection at
spring, rod seal ring and guide bush.
18,000RH,
Replace parts as needed. Overhaul on board
36,000RH and
Check condition of exhaust valve
72,000RH
hydraulic drive parts.
For old designed dampers, replace
with new designed damper at
Exhaust valve 20,000RH (Refer to RT-120) Replacement if
18,000
damper 6) required
For new designed dampers, random
check every 18,000RH.
Measure crank deflection, always after
Crankshaft 6,000 Engine lifetime the ship grounded and after each
docking
6,000 Bearing clearance measurements
6,000 Wire check on all bearing edges 3)
Connecting rod 70,000 8) Random open-up inspection.

Top end bearing and Bearing shell open-up inspection is

90,000
Bottom end bearing only necessary if bearing clearance,
wire check, oil analysis or crankcase
Replacement if
inspection indicates excessive wear or
required
damage.

Ring grooves: Inspect condition of chromium plating

18,000 - 36,000 and measure ring groove clearance.
Condition based Overhaul on board.
Piston head Check condition of piston top surface
18,000 – 36,000 Remanufacturing
Crown surface: and clean oil cooling bores if needed.
72,000 Recondition/rechrome if required.
Measure thickness of chrome-ceramic
1,500 – 2,000
layer.
Piston rings Replacement
Condition based Replace piston rings based on
18,000 – 36,000 remaining coating thickness.
Starting air shut-off Clean and check seat, springs and
30,000 – 36,000 Engine lifetime Overhaul on board
valve seal rings.
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RT-123_A3, Issue3, Page 4 / 7

Table 1, continued

Inspection or Estimated
Overhaul interval1) lifetime 1), 2) Maintenance
Component Comments
[RH: Running [RH: Running methods
Hours] Hours]
– Pumps with serial number <
147899: remanufacture initially at
24,000 hours. Thereafter the higher
interval of 42,000 hours applies.
Initial: – Pumps with serial number ≥ 147899: Remanufacturing
Servo oil pumps 24,000 only exchange of pump cover on
(Dynex) board at 24,000 hours.
Remanufacture initially at 42,000
hours. Thereafter the interval of
42,000 hours applies.
Successive: Pumps with serial number ≥ 160686:
42,000 remanufacture only at 42,000 hours.
Servo oil pump
60,000 Remanufacturing
(Bosch)
Supply unit pinion Replacement if
42,000 90,000 Visual inspection.
bearing bushes required
Inspect condition & check bearing
Supply unit camshaft clearances. Check for white metal Replacement if
6,000 90,000
bearings pieces coming out of the bearings or required
in the casing.
Inspect fuel drain system to find
Supply unit fuel drain
6,000 Engine lifetime clogged drain pipes. Cleaning on board.
pipes
Refer to technical bulletin RT-102.
Check the oil leakage on FOP top
weekly Replace
cover caused NRV O-ring brittle.
Cam surface can be
3,000 FOP Roller running surface check.
checked together.
Fuel pump
Random flow check of lubricating oil
6,000 at every 6,000 RH according to RT-
180.
18,000 Remanufacturing at every 18,000 RH. Remanufacturing
Heinzmann electrical Check condition of the carbon
actuator StG-16 & 6,000 – 12,000 brushes and replace if required Overhaul on board
StG-30 for FOP Only RT-flex82C/T & W-X82 engine.
Only ICUs on 84 and 96 bore engines
24,000 built before 2010, which have not Remanufacturing
been remanufactured.
Applies to ICUs on engines built from
2010 onwards and to the already
36,000 Remanufacturing
Injection control unit remanufactured ICUs on engines built
(ICU) 9) before 2010.
Filter: Clean and check filter condition.
Replacement
18,000 Replace only if required.
Check “on-time” of rail valves
Rail valve:
through flexView and replace Replacement
Monitored
if “on-time” > 2.6 ms.
Control oil pump
60,000 Replace with a new pump. Replacement
(Bucher)
Control oil pump Replace ball bearings and
60,000 Replacement
electric motor bearings overhaul motor.
Check condition and replace if
Servo oil rail hoses 30,000 Replacement
required.
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Table 1, continued

Inspection or Estimated
Overhaul interval1) lifetime 1), 2) Maintenance
Component Comments
[RH: Running [RH: Running methods
Hours] Hours]
Piston and
Random check of piston and slide rod at
slide rod: Engine lifetime Replacement
overhaul. Replace only if required.
36,000
Exhaust valve control Filter: Clean and check filter condition.
Replacement
unit 18,000 Replace only if required.
Check “on-time” of rail valves
Rail valve:
through flexView and replace Replacement
Monitored
if “on-time” > 2.6 ms.
Accumulator: Check gas (nitrogen) pre-charge
Cylinder lubricating Overhaul on board
every 3 months pressure. Refill if required.
pump
(Pulse lubrication) Lubricating pump:
Remanufacturing
30,000
According to According to
Cylinder lubricating
instruction of pump instruction of pump Overhaul on board
pump (CLU-3)
manufacturer manufacturer
Intermediate fuel Random check for
Remanufacture IFA if required. Remanufacturing
accumulator (IFA) leakages
Overhaul only
Fuel pressure control Perform a function check once a year.
necessary when Engine lifetime Remanufacturing
valve (PCV) Remanufacture part if required.
PCV is failing
Check pre-tension,
cracks and wear of
Replace belt after 24,000 hours and
toothed belt 24,000 Replacement
measure run-out of the drive shaft.
visually:
Crank Angle Sensor 3,000
(belt driven at free
Overhaul drive: Replace ball bearings and sealing rings Replacement of
end)
48,000 at overhaul. relevant parts
Crank angle
sensor: Replace sensor at 48,000 hours. Replacement
48,000
Check and clean
CAS with LEMAG sensor lenses Replace only if required
increment wheel quarterly —
(engines with Retrofit
Pulse Lubrication) Check and clean Remove dirt, oil or other contamination
Engine lifetime
wheels quarterly from the slits of the increment wheels.
Do a visual check of the cables.
quarterly
Replace the damaged cables and wires
Replace FCM-20, ALM-20, ACM-20
WECS-9520 60,000 Replacement
modules if failing
Components
Replace Exh. Valve stroke sensor and
60,000 Replacement
TDC sensor if failing.

WECS-9500
60,000 Replace modules if failing. Replacement
Components
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Notes to inspection and overhaul table

1. Intervals for inspection or overhauls and estimated lifetimes are estimates only. They
are based on past experience and valid for engines fully according to currently
applicable Wärtsilä Switzerland Ltd specifications. They are given for information
purposes only and do not constitute any guarantee or warranty whatsoever, as the
actual service life can vary considerably due to numerous conditions and influences
such as but not limited to:
− Environmental and operating conditions;
− Heavy fuel and lubricating oil qualities;
− Engine load factor;
− Fuel, lubricating oil and cooling water treatment;
− Overhaul according to engine manuals;
− Only genuine spare parts used;
− Careful and continuous engine monitoring.
2. “Estimated lifetime” refers to the life expectancy in hours under normal operating
conditions before the component is removed for replacement or remanufacturing.
3. Use welding rod with the end flattened and bent at 90°.
4. The anti-polishing ring is recommended to be replaced at the liner replacement.
5. Lifetime can be achieved with remanufacturing provided that the clearance between
nozzle needle and nozzle body is within specified limits.
6. Spindle lifetimes can be reached with remanufacturing. Remanufacturing of spindles
must only be done at Wärtsilä workshops.
7. The current exhaust valve dampers have a tendency to suffer from cavitation and the
damper can break up over a long period of time. Consequently broken parts can enter
the valve drive and cause subsequent damage. Wartsila recommends replacing all
dampers with the new design during the next overhaul, or anyway after 20,000
operating hours. Refer to RT-120.
8. It is recommended to open for inspection one connecting rod top end bearing and one
bottom end bearing at 70,000 running hours. In case either the connecting rod top or
bottom end bearing is found damaged, it is recommended to inspect other bearings
of same type at the next opportunity.
9. For ICUs on 82 cm bore engines built before June 2011 refer to Technical
Bulletin RT-122.

NOTE:
Appendix 3 with Table 1 “Inspection and overhaul intervals” is part of the Data &
Specifications bulletin RT-123.
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