80 RT-flex Service-Operation

RT-flex Training
Service Aspects
Chapter 80
© Wärtsilä Land & Seal Academy Page 1 Chapter 80

RT-flex, Operation and Service
Goals of chapter “Operation and Service”:
Trainees will know to operate their RT-flex engine in a safe

and economical way
Trainees will be able to perform trouble shooting and basic
maintenance work on the RT-flex engine
© Wärtsilä Land & Sea Academy Page 2 Chapter 80

RT-flex, Operation and Service General remarks
Things to consider during normal operation:

The flex parts of the engine requires different treatment than used on
conventional engines.
However, for the mechanical parts in general refer to the manuals, your
knowledge as an engineer and to common sense.
On the following pages some important hints and tricks are listed but is
not limited to.

RT-flex, Operation and Service General remarks
Please note that the tips, hints and remarks mentioned hereafter are just
some possibilities to solve a problem based on experiences with real
situations
However, the manuals delivered with the RT-flex engine and on-site
given instructions from engine maker prevails these chapters.
Remember that even at engine standstill, there is probably pressure

remaining in the rails.
Depressurise the rails and pipes before starting to work on them !

RT-flex, Operation and Service Visual Checks
Visual checks on daily rounds

The top covers of the rail unit lift up easily, so look inside daily and
check for leaks, etc.
Regularly inspect the fuel pump regulating racks. Does it move freely on
all pumps ? The rod can be push to a lower position, the other pumps
will automatically compensate.
Fuel-, Servo- und Control oil pumps, valves, distribution blocks, pipe
connections, etc. have to be checked daily for possible leaks.

RT-flex, Operation and Service Safety
Working on Pumps, valves and rail unit

Before starting any work on pumps, valves or rail unit make sure that
there is no remaining pressure

RT-flex, Operation and Service After Overhaul
After overhaul works in or around the rail unit and/or supply unit
Make use of the simulation possibilities of WECS-9520 and flexView.
Once the control oil pumps are running, the exhaust valves can be
manually open and closed. This proves that they work properly and
leakages can be detected.
To check the fuel pipes and injectors, the function "Injection venting"
which will trigger all injection rail valves on-off for a minute. Oil will flow
through them and warm them up. Possible leaks can be seen.

RT-flex, Operation and Service Electronic Units
Do not use water washing devices anywhere near any

electronic unit !
No welding work within 2 meters around a switched-on

electronic units !

RT-flex, Operation and Service FCM-20
FCM-20 modules
The FCM-20 installed in E90 as “Online-Spare” can be installed in any
E95 box. A new FCM-20 from the store has to be installed in the E90
box first for synchronisation.
Make sure that ALL FCM-20’s in the store have the same software
version loaded than the ones used on the engine.

RT-flex, Operation and Service WECS
WECS-9520
The electronic units of the WECS-9520 system shall always be kept on,
there is no need to switch it off the electronic units in port. But it is
recommended to turn off power when unplugging sockets from
modules, disconnecting sockets of the crank angle sensors and during
welding works on the engine.
Power supply to a single cylinder can be cut off even with running
engine, after switching back on the cylinder it will boot and start
working.

RT-flex, Operation and Service Protection Guards
Protection guards
The E95 boxes have to be protected against damage by using the
protection guards (if available).

RT-flex, Operation and Service Protection
Protection against unexpected alarms

To avoid a slow-down / shut-down released by accidentally pushed
lever, protect it with a cover.

RT-flex, Operation and Service Trace Heating
Trace heating of rail unit, supply unit and rising pipes (all fuel parts):
To avoid sticking HFO, the trace heating shall be on at all times, also in
port. The fuel inside rising pipes and rail does not circulate and must be
kept warm.
To avoid starting difficulties, it is recommended to turn on the heating at
least 4 hours before engine starting.
All rail unit covers shall be kept close.
WARNING: When changing over from bunker to MDO, the trace

heating must by all means be stopped early enough to avoid
overheating of the diesel oil.

RT-flex, Operation and Service Oil Treatment
Oil treatment
Some of the hydraulic components are very sensitive and require clean
oil. It avoids operational troubles and prolongs their lifetime.
The automatic filter is a good and efficient provider of clean oil. Should
the filter indicate high differential pressure all the time, this can be an
indicator for a problem with the main bearing oil treatment.
Only in real emergency cases the automatic filter must be switched over
to its by-pass side.

RT-flex, Operation and Service Main Starting Valve
Function test of main starting valve

The two solenoid valves are normally
activated together for high availability.
From time to time a function test

should be carried out by disabling
one of the valves, starting the engine
and repeating using the other valve.
The valves can be disabled by pulling their plugs or via the “User” page
of the flexView.
Instead of starting the engine, a “slow turning” or “air run” can be done.

RT-flex, Operation and Service ICU
Special measures in emergency cases:

In case of a heavy internal or external fuel
leakage of the ICU, which cannot be fixed
immediately, the fuel supply from fuel rail to the
corresponding ICU can be shut off. The screw
plug tool (Nr. 94585) can be installed instead of
the venting plug shown in the sketch. The
control oil supply and return can be shut in a
similar way.
If for any other reason the injection of a unit

needs to be stopped, this can be done
manually through the WECS-9520 user
interface (user parameter).
The ICU itself MUST NOT be opened since without it can not be
reassembled without special tools.
RT-flex, Operation and Service ICU
Injection unit, “quantity piston stuck in end position”

“Sticking” does not always mean that the piston got physically seized,
the rail valve failed, an FCM failure, cold control oil, etc.
Very often the piston starts working again after a while with warm oil or
after depressurizing the fuel rail.
Normally replacing the ICU is NOT need.
Remind the very high fuel pressure before working on the ICU or
fuel rail unit !!

RT-flex, Operation and Service Injection
Venting of fuel oil rail:

After a major overhaul or to fill up an empty fuel oil system, venting has
to be done.
The venting plug in one ICU per rail must be slackened. Running the
booster pump fills the rail with fuel while air and foam escapes from the
plug.
Some engine types have the possibility to fill the fuel rail via servo oil
system.
Venting can also be done via flexView under “User”.

RT-flex, Operation and Service Fuel Leakages
Detection of leakages:
Internal leakages of ICU’s and high pressure
injection pipes (on each rail unit half) are
monitored by one leakage sensor. In order to
find out whether the leakage actually comes
from the ICU or an injection pipe, the plugs
on the connection flanges can be slightly
unscrewed.
In order to locate a probable leaking ICU,
observe the injection time on all units,
observe exhaust gas temperatures after
Screw plug for
cylinders, or run the engine with reduced
leakage checking load (i.e. < slow down speed) and cut off the
injection of all units (one by one). If the
leakage stops after a certain unit was cut off,
this ICU can be suspected.
Only Wärtsilä approved workshops are
allowed to overhaul ICU’s !
RT-flex, Operation and Service Fuel press. regulating valve
Accumulator
Main bearing oil
pressure at norm.
Emergency operation:
operation
In case of fuel pressure
Knurled screw regulation failure (e.g. actuator
and shims
failure), resulting in a constantly
too high fuel pressure, the max.
Piston
opening pressure can be
reduced in order to remove load
from fuel pump etc.
Valve
A good value will be between
seat and Fuel 600-700 bar.
needle pressure
increase/
decrease
Fuel
inlet
Drain to return pipe

RT-flex, Operation and Service VCU
Exhaust Valve Drive

If the injection of a certain cylinder is cut off, the

exhaust valve has to remain operational.
In case of a heavy leakage of exhaust valve actuator,

actuator pipe or valve drive, the servo oil supply can
be shut off by installing plug (Tool Nr. 94586). The
main bearing oil supply can easily be interrupted by a
shut-off valve as well. In such a case, the engine is
operated with a closed exhaust valve and cut-off
injection.
Additionally, you can disconnect the exhaust valve
sensor plug from the cylinder cover to prevent alarms
from exhaust valve monitoring system.

RT-flex, Operation and Service Exhaust Valve
Blocking of exhaust valve:

If a cylinder cooling water leakage into combustion
space occurs, the engine shall be operated with an
open exhaust valve. Therefore the valve is moved
open manually by user parameter (will close by itself
after a short time!), and pins Nr. 94259 can be
inserted.
Of course the injection has to be cut off as well !

RT-flex, Operation and Service Exhaust Valve
Non-closing of Exhaust Valves

According to the manual, prior to starting the oil pumps, spring air has
to be supplied. If the engine is at standstill for a while with pumps
running but without air, there is a possibility to block the exhaust valves
in open position.
To release the exhaust valves
the jammed oil in the pipe has
to be drained via the venting
screws.

RT-flex, Operation and Service Fuel Pump
Lifting a fuel pump: Exocentric shaft

Roller guide Tool Nr: 94430
In normal operation, all fuel pumps deliver

roughly the same quantity. If a pump is
defective, it will be detected by the Alarm
System (temperature reduction at HP-outlet
pipe). The regulating linkage position will
be higher than normal at a given fuel
command.
In such cases, the affected pumps need to
be cut out mechanically by lifting the roller
from the cam by eccentric shaft tool. This
can only be done at engine standstill.
With one pump cut out, the engine can still

be operated at high load and regular
service speed. The more pumps are cut
out, the more the maximal load is limited.

RT-flex, Operation and Service Fuel Pumps Lifting

RT-flex, Operation and Service Fuel Pump
Spacer
In case of one or all electronic actuator fail, the
corresponding linkage stays in position or Regulating rack
moves to full output position. The remaining
working actuators will compensate the
regulation for the failed one.
A torsional spring on each regulating shaft will

pull the linkage to full output, if the affected
actuator has no torque force anymore (electric
power loss).
In addition, spacers can be installed on
regulating rack of affected pump. Depending
on, how many pumps are fixed in max. position,
the fuel rail pressure cannot be regulated
properly anymore. A constantly higher fuel rail
pressure will result. The emergency
overpressure regulating valve will limit the max.
pressure accordingly. For long term operation, When internal actuator faults occur, the
the opening pressure of that one must be position is kept on actual position.
reduced.

RT-flex, Operation and Service CA
The crank angle signal is absolutely indispensable for engine operation.

At least one of the sensors must be working. If one fails, WECS-9520
can detect the failure and will keep working with the healthy signal
(plausibility check). In case both sensors fail, the engine will stop
without delay.
There is no emergency operation possible without at least one CA
sensor!

Crank angle sensors and –drive

The crank angle sensor drive has to be checked for proper lubrication.
Check daily if the lube oil pipe feels warm. If not, the fine orifice at the
inlet to the housing may be clogged.
Open the cover every few months and look inside.

• Are the belts OK and with correct tension ?
• Is there any dirt or oil ?
• Do sensor wheels have play ?

The sensor can be exchanged easily. With the flywheel at 0.0°, the two
red lines on the sensor must be flush. If not, the toothed belt is one or
more teeth off its position and has to be slackened again, so the sensor
wheel can be turned freely until the two red lines are flush. Then the
belt has to be pre-tensioned with a given force of approx. 3.5 kg (35 N),
max. 4.5 kg. Also the complete sensor drive can be exchanged, a
complete drive is a standard spare.
Standard spare parts: 2 Sensors; 1 complete drive unit assembled, 2
belts; coupling parts.
The belts have to be exchanged after a while (estimated lifetime 3 ~ 5
years).
The belts must be free of oil!

Correct assembly of the crank

angle sensors and -drive is
indispensable for the operational
safety.
Dropped gear wheel
Sensor pulley, dropped off side ring: Worn face
Consequence of over tightened belt. Gear wheel

Fitting of shaft encoder

1. Turn crank shaft to TDC of cylinder 1
2. Insert shaft encoder into the guide of the
bearing housing. Fasten screws slightly.
3. Push shaft encoder (with black holder
plate!) inwards
4. Check whether the holder plate moves
freely in the bearing housing
Apply Molykote to
sliding surface!

Cylinder No 1 must be at its actual, physical TDC during the whole

installation process! (This is NOT necessarily corresponding with
the TDC signal "tooth"….!)
Fitting of toothed belt
1. Lay toothed belt onto the gear wheels in the position where the two red
marks of the gear wheels are flush. (The wheel of the sensor is freely
movable….)
2. Push shaft encoder outwards till belt is slightly tensioned. Slightly
tighten the screws. Re-check if red marks are flush!
3. Align toothed belt in running direction and
apply spring balance
4. Tension the belt slightly with the balance,
loosen the screws and apply approx. 3.5 kg
(35 N), max. 4.5 kg.
Tighten the screws.

5. Turn the crankshaft for several turns to let the toothed belt find its
running track.
6. If the belt tension has slackened, repeat the tensioning procedure.
Check the belt tension according the figure below.
7. Adjust and bend locking plates.
8. Tighten all screws and lock them.
It is important to re-check tension after several engine revs. It will

mostly become a bit slack as consequence of alignment on the
wheels.
Visual check for belt tension see sketch: Belt teeth in TDC and BDC of
wheel must rest in ground.

They are separated from the crankshaft by a special coupling. They create
an exact digital signal of the actual crankshaft position (0….360°) The CA
sensors have a resolution of 0.1°
The spring loaded coupling absorbs all longitudinal and axial movement of
the crankshaft. It drives a shaft which is supported by two ball bearings. The
bearings are oil lubricated. From the shaft a toothed belt drives each sensor.
Shielded BUS cables transmit the
signals to the WECS-9520 control.
CA-Sensor, complete with holder

and cable.
The two red lines must be in

line when cylinder 1 is in TDC.

RT-flex, Operation and Service Trouble Shooting
The four most important tools for trouble shooting on flex problems are:
Control Diagram
Alarm-log, indications of actual values
Wiring diagrams of WECS-9520 (E87, E85, E90, E95, E94, E96,
etc.)
Signal List of DENIS/WECS-9520
With flexView trend lines can be used to find out if a value is unstable.
The journal of the flexView shows directly the cause of the alarm.

Combination of Alarms
Some situations create not one but a series of alarms. Since this can be
confusing, the first one that came up is probably the root cause.
Logical sense may still be required to pinpoint the exact source of

trouble. The current situation has to be analyzed. Has somebody done
some work on the engine or the auxiliaries ? Switched on or off some
equipment ?

Replacing parts
It is NOT recommended just to replace parts with unclear status with new
ones (used but probably OK). Try to find out the status by e.g.
exchanging an FCM-20 module with one from an other cylinder
exchanging a rail valve with one from an other cylinder
Exchanging components with one from an other cylinders makes it very

clear if a component is faulty or not. But check first that else is controlled
by these components.

Sensor fail alarms that go on and off

Power supply to sensor and the cable connections to be checked
Faulty sensors to be changed at next opportunity.
If a faulty sensor can not be changed immediately, it is better to
disconnect it, otherwise it might disturb the function of the control
system.
The following sensors can be disconnected:

• fuel quantity sensors
• exhaust valve stroke sensors
• rail pressure transmitters
• crank angle sensor (the other one has to be operational !)

RT-flex, Operation and Service Bosch Pump
Bosch-Rexroth servo oil pump

controller card LED indication:
Inputs:
DI1 Shows engine running direction (lit when astern)
DI2 Unused
DI3 Unused
DI4 Unused
DI5 Unused
DI6 Enable (should always be lit)
DI7 Unused
DI8 Unused
Outputs:
DO1 Swivel angle control is active
DO2 Pressure control is active. Should be active when engine is running
DO3 Power control active
DO4 Unused
DO5 No external fault (e.g. cable break detected somewhere). Lit when no fault (low active)
DO6 Lit when pressure is greater than 10 bar
DO7 Lit when Swivel angle is greater then 10%

RT-flex, Operation and Service Control Pumps
Control oil pumps (some engine types only)

The software that controls these pumps makes them run BOTH when
engine is stopped. If required, one or both of them can be stopped in
port by switching off the main breakers.
Do NOT forget to switch them on again when on stand-by.

RT-flex, Operation and Service Woodward Actuators
Internal hard stops allow 75°travel!

Electrical stops (BIAS) at 3°and 73°
Effective travel = 70°
External hard stops at ~0.5°and ~74.5 !
Inertia = 19 for size IV; 15 for size I !
At 0% position demand, pump rack must be in
zero position with little (~1mm) clearance !
Adjust connecting rod length accordingly !

RT-flex, Operation and Service Rail Valve
Rail valve
Since rail valves are very sensitive to dirt, the contact surface MUST
NEVER be wiped off !
They have to be mounted that the nameplate is not upside down.
The plugs are coded and do not fit to the wrong socket.

RT-flex, Operation and Service Level Switches
Level switches
Horizontally installed level switches of “tuning fork” type have to have
the oscillating blades in vertical position.

RT-flex, Operation and Service Parts
Parts which need regular inspection, overhaul or have to be exchanged (1):
• Fuel pumps: plunger Exchange

• Fuel pumps regulating rack: bearings Exchange
• Servo oil pumps: roller bearings, plungers, regulating valve, Overhaul
sealing
• Control oil pumps: plunger units Exchange
• Camshaft: cam surface and fuel pump rollers Overhaul
• Automatic filter Overhaul
• Fuel pressure regulating valve, shutdown valve Overhaul

RT-flex, Operation and Service Parts
Parts which need regular inspection, overhaul or have to be exchanged (2):
• Injection control unit: inspection and overhaul Overhaul *)

• Hydraulic hoses Inspection &
exchange
• Crank angle sensor and drive: belts, shaft sealing, sensor Inspection &
exchange
• FCM-20 modules Exchange
*) To be done by Wärtsilä Switzerland or authorized workshop only !

Wärtsilä has established an exchange based service for complete ICU’s,
in case an ICU is considered to be malfunctioning or damaged, or if it is
time for an regular overhaul (~24’000 - 36’000 running hrs).

RT-flex, Operation and Service Disassembly of Parts
ICU, VCU and FCM-20 MUST NOT be opened by non-authorized

persons !! Any warranty would be void ! Overhaul of ICU and VCU
requires special tools and must be
carried to at Wärtsilä Switzerland
or authorized repairers only.
Servo oil pumps (Bosch/Rexroth or

Dynex) can partly be opened,
following the respective makers'
instructions.
It is strongly recommended to leave such overhaul works to shore

workshops where absolutely clean conditions are given.

RT-flex, Operation and Service Electronic Hardware
FCM-20 Electronic Modules:

These modules are fully cast and therefore not maintainable.
FCM-20 modules have a MTBF of more than 10 years. They can not be
repaired but exchanged very easy:
Reduce engine power to half, switch off power supply to the concerned
unit (a slow-down will be initiated), remove all attached plugs, unscrew
the holding bolts and take the module out. Replace it only with the
online-spare module from E90 box.
Don not bend the cables more than necessary, do not disconnect
cables from their plugs.
Fitting in a new one goes visa-versa. After switching the power back on,
the cylinder it will start working after a few seconds.

RT-flex, Operation and Service Sensors
Sensors:
Crank angle,
b) Sensors are quiterail
easypressure
to exchange.PT,
They injection quantity
are so designed piston,
that a failure of one exhaust
sensor doesvalve
not
position, etc. can be exchanged easily.
harm engine operation.

RT-flex, Operation and Service Wiring
Wiring:
Loose or broken cables can stop a cylinder or simply cause a sensor-
alarm.
Defects on the wiring can not be detected easily and the following
points have to be observed:
Wires have to be laid in a cable duct, secured with cable
retainers to avoid faults by vibrations
Wires must not be criss-crossed but running in parallel, not
scouring on other elements

Regularly check and retighten terminals in all boxes

For wirings marked as shielded in the diagrams, shielded cable MUST
be used. The shield must be connected to the mass only on the end
defined in the diagram
For data transmission, special shielded Bus-cables must be used
“L” (low-power/sensitive) and “H” (high-power) wires have to kept
separate and always guided separately with a distance of about 25 cm
to avoid interference to signals.

Bus cabling:
Check regularly all terminal bars for loose connections.
In general only class approved, shielded cables must be used.
For any of the bus systems, only special 120Ω bus cables must be used !
(Bus- or Data cables with 110Ω to 130Ω)
At each end of a bus cable there MUST be a terminator resistor of 120Ω !
Bus cables MUST NEVER be connected as “star-connection” (parallel)
but only in serial ! Not even for an emergency repair !

RT-flex, Operation and Service Troubleshooting WECS
Mostly malfunctions appears because of wrong or missing signals

from or to the control system, caused by :
loose cable connections, sensor targets or links

badly crimped cable-end sockets
clogged inlet ports at pressure-sensors, transmitters and switches
sensor exposed to excessive vibrations, heat, dirt, moisture or abnormal wear
earth faults
short circuits
broken wires
noisy signals (EMC)
wrong sensor type
wrong parameters or scaling of sensors
false connections
low power supply

RT-flex, Operation and Service flexView Operator Interface
flexView Operator Interface
The screen is separated in two

pages, which can be selected
individually, for convenient
access and monitoring of
failures, indications, engine
processes and parameters.
For safety reasons, access to
parameters on the ADJUST
page is locked with a password
to allow changes for authorized
persons.
In the following there are some
examples, how to use the
flexView Trends for
troubleshooting:

flexView Inject & Exhaust valve pages
These pages indicate all

related data for the
energizing times (On-Time)
of the rail valves, the
feedback currents for the
end trigger measured values
(open close inject / return)
and the measured
deadtimes between
injection/exhaust commands
and start of real executions.

flexView User & Adjust pages

The user page allows to set
FQS, select VIT and Heavy
Sea Modes, Common start
valve test modes and to switch
off the injection on single
cylinders.
Further Injection venting and
exhaust valve manual test
commands can be selected.
The Adjust page allows to
change miscellaneous para-
meters, to artificially optimize
injection timing for ICUs with
disconnected FQ sensors and
it allows the user to modify the
injection timing and the exhaust valve closing within a certain range
for balancing the cylinder loads.

RT-flex, Operation and Service Trends for Troubleshooting
flexView Using Trends for troubleshooting
In the following there are some

examples, how to use the flexView
Trends for troubleshooting:
Crank angle sensor check:
For evaluation of the crank
angle sensors you can simply
open the CA Sensor trend from
the View menu and run the
TrendView together with the
turning gear.
While both sensor curves are
matching above each other, any
drop-outs of a sensor are visible
on the screen. To see both curves, add an offset to one of the
signals to shift its curve below or above the first.

flexView Using Trends for troubleshooting
Injection quantity feedback

signals:
Some of the injection curve data
can as well be evaluated from the
indications on the Inject page:
Deadtime Injection
time
But for certain error conditions the

fast trend of the injection curve is
necessary for determining the
malfunction:

A normal signal has got a

clear curve shape and no
If a disturbed feedback signal spikes or interference.
is within the range of 4-20 mA,
the WECS can not recognize
the erratic signal condition. For
Spikes like these in the
such a failure the Injection
signal shape indicate
Curve in the Service menu is
accelerations of the fuel
used for investigating the
quantity sensor beyond
signal shape and to determine,
any physical measures, it’s
if the sensor is working
clear evidence for a
correctly:
Sensor failure.
If the feedback signal

deteriorates like this, there
is no doubt that a
damaged fuel qty. sensor
is causing wrong and
unstable injection timing of
the respective cylinder.
RT-flex, Operation and Service Passive Failures
Alarm Card Indication Countermeasures

Charge Air press 1(2), meas. fail. Check charge air transmitter 1, (transmitter 2)
Voltage supply 24V available on plug?
FCM 3(4) AI2 1x FCM-20 #3 (4) switched off? Check cabling to E95.03 (04)
Servo Oil Pressure, Sensor 1(2), Meas. Check respective signals on operator interface.
Fail. Check servo oil p- transmitter 1(2) in RU,
FCM 1(2) AI2 1x FCM-20 #1 (2) switched off? Check cabling to E95.01 (02)
Fuel Rail pressure, sensor 1(2), Meas. Fail. Check respective signals.
Check fuel p- transmitter 1 (transmitter 2) in RU:
FCM 3(4) AI1 1x Voltage supply 24V available on plug?
FCM-20 #3 (4) switched off? Check cabling to E95.03 (04)
Exh. Valve # n Position Meas. Fail. Check plug on cyl. cover box, sensor cabling and power supply.
Change sensor if necessary.
FCM n ExD / ExF 1x If failure appears intermittent, faulty sensor can provisionally be
disconnected in cyl. cover box, until repair is possible.
FCM n ExD / ExF (on) : short circuit
MODBUS FCM #n Failure If MODBUS LED is not blinking (bus traffic) on module, check plug
X23 for proper wire connections and terminating resistors.
FCM 1-4 ModBus (dark) Check wiring and unit on other end of MODBUS (Propulsion
Control, Alarm Monitoring System) for failures, power supply, bus
connection etc. Replace module if failure only on one module.

RT-flex, Operation and Service Passive Failures

CAN M (Module-) Bus #n Fail. Check plug X22 for proper wire connections and terminating
resistors. Check wiring and unit on other end of CAN M-bus
FCM n CAN M (on) (Propulsion Control, Manual Control Panel, Bosch pumps) for
failures, power supply, bus connection etc. Can appear on FCM
#03, if operator flexView SW is connected and fails to read all data
(e.g. too many trends running).
Module FCM #00 Fail Engine can be operated with this failure condition. Check plugs X22
and X23 for proper wire connections. Can appear if operator
FCM 0 Fail (on) flexView SW is connected and fails to read all data (e.g. too many
trends running). Try cycling the el. power supply to module.
If required, replace online spare module.
CAN S (System-) Bus Fail, FCM Check plugs X22 and X23 for proper wire connections. Replace
WECS CAN/SSI BUS Conn.
#n module if failure only on one module. If more modules show this

FCM n CAN S1/2 failure, check the CAN S-Bus wiring in all E95 boxes and
terminating resistors.
FAIL #n
Crank Angle #1(2) Failure Active, if crank angle sensor is failing or FCM-20 # (last and last-1)
are switched off.
FCM n SSI CA1/2 If failure appears on all active modules, check CA-sensor 1(2) and
replace if necessary. Else check SSI-bus terminating resistors on
X22 /23 in E95.01.
If failure on single modules, check plugs X22 and X23 for proper
wire connections. Replace module if required.
Any FCM-20 Module, Cylinder remains in operation, but after any new restarting
Cyl. Identification lost (powering up) of the FCM-20 module the cylinder is cut-off.
FCM n ID Check address wiring in corresponding E95 box on plug X25.

RT-flex, Operation and Service Common Failures

Charge Air pressure 1&2, Meas. Fail Check charge air transmitter 1 and 2,
FCM 3+4 AI2 1x Check wiring in E12 junction box.
Check cabling on X27 and “Analog In” LEDs on FCM-20 #3 and 4.
Charge Air pressure, Meas. Fail diff hi Compare both charge air pressure indications
with charge air gauge pressure indication to determine erratic
FCM 3+4 AI2 2x sensor.
Check wiring in E12 junction box.
Replace or rescale sensor if necessary.
Control Oil Pressure, Meas. Fail Check wiring on FCM-20 #5, X25 plug and on sensor in rail unit.
Sensor or sensor cable defective?
FCM 5 AI1 1x
nd
Control Oil Pressure Low At least 1 pump running? (2 should start in case of low pressure)
Main oil supply and pressure after automatic filter OK?
FCM 5 AI1 4x Leakage or shut-off cock for oil drain open?
Retaining valves 3.73 properly adjusted? El. power to pump drives
ok?


Control oil pump 1(2), fail. Check on main switchboard: Breaker on? Overload trip?
Current sensing relays in starter box ok (Bosch Pump only)? Is
FCM 3(4) Bin Out 1x pump hot?
Check cables from ctrl. oil pump starter box to E90 SIB
and FCM-20 #3 (4) X15. If pumps are running but no pressure,
check control oil block and components, see co-alarms.
Start Pilot valve #n loop fail. Check plugs on interconnection at cylinder cover and on solenoid
valve. Replace solenoid valve or cabling to interconnection box if
FCM n Start V/v (on) required.
Servo Oil press. 1+2 Meas. Fail Check servo-oil rail pressure transmitter 1 and 2,
FCM 1+2 AI2 1x Voltage supply 24V available on plugs?
Servo Oil pressure, meas. Fail. Diff. hi Compare both servo-oil rail pressure indications, if possible
change engine load through a wider range and verify which sensor
FCM 1+2 AI2 2x does not follow up linearly to the changing servo oil pressure.
Replace sensor if necessary.


Servo Oil Pressure hi DYNEX pump: Controller valve on pump not adjusted (after
overhaul). Wrong Parameters set in flexView software.
FCM 1+2 AI2 3x BOSCH pumps: Check electronic controller card indications for
troubleshooting.
Servo Oil Pressure lo Oil pressure after automatic filter OK?

Control signal and cables to DYNEX / Bosch pumps OK?
FCM 1+2 AI2 4x Check BOSCH controller card indications for troubleshooting.
Safety valve 4.23 open? Ctrl oil supply to Bosch pumps OK?
Drain from collector block open or inlet valves for servo oil rail
closed?
Can appear shortly during engine start, if more than one pump /
control fails or switched off.
Can also indicate severe failure in hydr. exhaust control parts.
If a servo oil pump is much cooler than the others while engine is
running, carrier sleeve on drive shaft is broken.
Servo Oil pump #n, No flow Pipe crack? Flow sensor failing (Dynex pumps only)
Check local swash plate indication (Bosch Rexroth only)
FCM 3,4…8 PWM 2x Refer also to co-alarms for troubleshooting( e.g. servo oil pressure
low).


Servo Oil pump #n, Failure Check indication on corresponding BOSCH controller card
Power Supply 24Vdc ok?
FCM 3,4…8 PWM 1x Any of FCM-20 #3 - #8, CAN M-Bus failing or switched off?
Check pump feedback signals and proportional valve.
Analyze LED indications on card. If required, exchange Bosch card
with neighbour card to determine, if card is defective.
Injection Quantity #n, Meas. Fail Check feedback of quantity sensor, check plug for tight fit.
Make sure measuring sleeve is properly mounted on fuel quantity
FCM n InjQ 1x piston.
Check cabling between E95 and injection quantity sensor, if “InQ”
FCM n InjQ (on): Short circuit LED on corresponding FCM-20 shows red failure indication.
Replace sensor or disconnect plug temporarily, if feedback is
instable and no spares available.
Inj. #n timing fail. Injection time on cylinder deviates from other cylinders.
Cracked, seized or stuck injection nozzles?
FCM n InjQ 5x (time too short) Injector pipe leakage? (co-alarm inj. pipe leakage?)
FCM n InjQ 6x (time too long) Too low opening pressure of injector valve?
Rail valve failure (see on times for inject valves)
Can occur when operating with temp. disconnected inj. quantity
sensor.


Fuel Rail Pressure 1+2, Meas fail Check fuel rail pressure transmitter 1 and 2,
FCM 3+4 AI1 1x Voltage supply 24V available on plugs?
Fuel Rail Pressure, Meas. Fail diff Hi Compare both fuel rail pressure indications, if possible change
engine load to range, where fuel rail pressure varies with load (e.g.
FCM 3+4 AI1 2x 15-20% or 70-80%) and verify which sensor does not follow up
linearly.
Replace sensor if necessary.
Fuel Rail pressure Hi Check fuel pressure regulating linkage for free movement.
Check if fuel pressure actuators (Woodward) are switched on and
FCM 3+4 AI1 3x working.
Assembly mistake of fuel pump? (After overhaul).
Check for fuel actuator alarms in alarm monitoring system.
Can appear during short nervous manoeuvring, if engine is
repeatedly started and stopped without having any fuel release in
between.


Fuel Rail pressure lo Check fuel pressure regulating linkage for free movement.
Check if fuel pressure actuators (Woodward) are switched on and
FCM 3+4 AI1 4x working.
Check for fuel actuator alarms in alarm monitoring system.
Is fuel supply pressure ok (7-10bar)?
Is there a leakage alarm pending?
Em. regulating valve releases fuel (=> bearing oil supply to valve
not ok or valve seat seized)?
Size4: Temp monitoring alarm from fuel pump?
Check non return valves in intermediate accumulator and fuel
pumps
Check safety valves in supply unit or rail unit (size0 &1)
Crank Angle, Difference Drive belt shifted or slack?

When flywheel is at TDC#1, both sensors must show 0°CA.
FCM n SSI CA1 + CA/2 1x Adjust sensor offset parameter or belt position, if required.
If only on one cylinder: Check SSI bus wiring on FCM-20 plugs X22
and X23. Replace FCM-20, if necessary;
If on a successive group of FCMs: Check SSI bus wiring from
highest failing cyl. number to next higher cylinder without alarm.


TDC signal, fail Check TDC-Pickup for correct cabling and correct distance to
flywheel tooth . Measure voltage supply and signal. Replace sensor
FCM 5 BI1 1x if necessary.
Check wiring in E95.05 on X27 and LED indication on FCM-20 #5.
Crank Angle, TDC lo shift CA sensor drive shaft or belts shifted?

TDC offset wrongly adjusted?
FCM 5 BI1 2x CA1 lo shift Possibility of shifted crankshaft?
FCM 5 BI1 4x CA2 lo shift
Crank Angle, TDC hi shift CA sensor drive shaft or belts shifted?

FCM 5 BI1 3x CA1 hi shift Possibility of shifted crankshaft?
FCM 5 BI1 5x CA2 hi shift

RT-flex, Operation and Service Cylinder Failures

Module FCM #n Fail. Check CAN S Bus LEDs on module. If red indication, check plugs
X22 and X23 for proper wire connections.
FCM n Fail (on) Replace module if module doesn’t recover after power cycling .
Exh valve #n fail. Exhaust rail valve failure (on time >3 ms)?
Air spring pressure too high or too low?
FCM n ExD 2x Late / not opening For common rails without mono-block VCU=>RT-flex96C, old
FCM n ExD 3x Early closing design 60C, 58T-B: Check non-return valve of bearing oil supply to
actuator pipe (early closing);
FCM n ExD 4x Late / not closing
FCM n ExD 5x Clos. deadtime too long
Check non-return valve in air supply to air spring (Late / not
closing).
Mechanical failure of exh. control v/v or partition device?
Injection qty piston #n fail Rail valve failure (on time >3 ms)? Check injection on-times on
user interface.
FCM n InjQ 2x Late / no return Check feedback of quantity sensor, check plug for tight fit.
FCM n InjQ 3x No movement Make sure measuring sleeve is properly mounted on fuel quantity
piston.
FCM n InjQ 4x Stuck in max. position Replace sensor or disconnect plug temporarily, if feedback is
instable and no spares available.
Fuel viscosity too high? Steam trace heating off?
If not recovering:
Try short manual opening of fuel SHD-valve with red solenoid lever.
Ultimately: Can also hint on seized quantity piston, ICU needs to be
replaced.

RT-flex, Operation and Service Cylinder Failures

Injection #n Cut-off Manual (user-) cut-off or automatic cut-off indication
Refer to co-alarms in case of automatic cut-off.
No LED code
Control Oil Pressure Very Low At least 1 pump running? (2nd should start in case of low pressure)
Main oil supply and pressure after automatic filter OK?
FCM 5 AI1 5x Leakage or shut-off cock for oil drain open?
El. power to pump drives ok?
Servo Oil Pressure Very Low Oil pressure after automatic filter OK?
Control signal and cables to DYNEX / Bosch pumps OK?
FCM 1+2 AI2 5x Check BOSCH controller card indications for troubleshooting.
Safety valve 4.23 open? Ctrl oil supply to Bosch pumps OK?
Drain from collector block open or inlet valves for servo oil rail
closed?
Can appear shortly during engine start, if more than one pump /
control fails or switched off. Can also indicate severe failure in
hydr. exhaust control parts.
If a servo oil pump is much cooler than the others while engine is
running, carrier sleeve on drive shaft is broken.

RT-flex, Operation and Service Rail Pressure Failures

Fuel Rail Pressure Very Low Check fuel pressure regulating linkage for free movement.
Fuel pressure actuators (Woodward) are switched on and working?
FCM 3+4 AI1 5x Check for fuel actuator alarms in alarm monitoring system.
Is fuel supply pressure ok (7-10bar)? Is there a leakage alarm
pending?
Regulating valve 3.06 releases fuel (=> bearing oil supply to valve
not ok, valve seat damaged)?
Shut-off cocks at intermediate accumulator or rail inlet still closed
after repair works?
Charge Air Overpressure Reduce M/E power;
Take countermeasures according to T/C manual.
FCM 3+4 AI2 3x Check waste gate control, if engine is equipped with waste heat
recovery system.

RT-flex, Operation and Service Critical Failures

Crank angle / TDC Hi shift 1+2 CA sensor drive or belts shifted?
FCM 5 BI1 [3x + 5x] Possibility of shifted crankshaft?
Crank angle 1+2, Fail. Check entire CA sensor drive and E96 box for damage.
Also active if both FCM-20 #(last) and #(last-1) are switched off
FCM n SSI CA1 + CA2 (No clock-masters!). [Last => highest cylinder number]
Check LED indication on FCM-20 modules.
If failure on all FCM-20 modules:
Check SSI-bus terminating resistors on X22 /23 in E95.01.
If failure comes up on single modules only, check wiring on plugs
X22 and X23 for proper connections. Replace module if required.
Excessive engine speed Engine was overspeeding (more than 115% nominal RPM).
Rough weather? => Reduce RPM;
No LED code Check for separate alarms from CA-sensors or FCM-20 modules.

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80 RT-flex Service-Operation

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RT-flex Training

© Wärtsilä Land & Seal Academy Page 1 Chapter 80

Goals of chapter “Operation and Service”:

Trainees will know to operate their RT-flex engine in a safe

© Wärtsilä Land & Sea Academy Page 2 Chapter 80

Things to consider during normal operation:

© Wärtsilä Land & Sea Academy Page 3 Chapter 80

Remember that even at engine standstill, there is probably pressure

© Wärtsilä Land & Sea Academy Page 4 Chapter 80

Visual checks on daily rounds

© Wärtsilä Land & Sea Academy Page 5 Chapter 80

Working on Pumps, valves and rail unit

© Wärtsilä Land & Sea Academy Page 6 Chapter 80

© Wärtsilä Land & Sea Academy Page 7 Chapter 80

Do not use water washing devices anywhere near any

No welding work within 2 meters around a switched-on

© Wärtsilä Land & Sea Academy Page 8 Chapter 80

© Wärtsilä Land & Sea Academy Page 9 Chapter 80

© Wärtsilä Land & Sea Academy Page 10 Chapter 80

© Wärtsilä Land & Sea Academy Page 11 Chapter 80

Protection against unexpected alarms

© Wärtsilä Land & Sea Academy Page 12 Chapter 80

WARNING: When changing over from bunker to MDO, the trace

© Wärtsilä Land & Sea Academy Page 13 Chapter 80

© Wärtsilä Land & Sea Academy Page 14 Chapter 80

Function test of main starting valve

From time to time a function test

© Wärtsilä Land & Sea Academy Page 15 Chapter 80

Special measures in emergency cases:

If for any other reason the injection of a unit

Injection unit, “quantity piston stuck in end position”

Normally replacing the ICU is NOT need.

© Wärtsilä Land & Sea Academy Page 17 Chapter 80

Venting of fuel oil rail:

© Wärtsilä Land & Sea Academy Page 18 Chapter 80

Drain to return pipe

© Wärtsilä Land & Sea Academy Page 20 Chapter 80

Exhaust Valve Drive

If the injection of a certain cylinder is cut off, the

In case of a heavy leakage of exhaust valve actuator,

© Wärtsilä Land & Sea Academy Page 21 Chapter 80

Blocking of exhaust valve:

Of course the injection has to be cut off as well !

© Wärtsilä Land & Sea Academy Page 22 Chapter 80

Non-closing of Exhaust Valves

© Wärtsilä Land & Sea Academy Page 23 Chapter 80

Lifting a fuel pump: Exocentric shaft

In normal operation, all fuel pumps deliver

With one pump cut out, the engine can still

© Wärtsilä Land & Sea Academy Page 24 Chapter 80

© Wärtsilä Land & Sea Academy Page 25 Chapter 80

A torsional spring on each regulating shaft will

© Wärtsilä Land & Sea Academy Page 26 Chapter 80

The crank angle signal is absolutely indispensable for engine operation.

© Wärtsilä Land & Sea Academy Page 27 Chapter 80

Crank angle sensors and –drive

Open the cover every few months and look inside.

© Wärtsilä Land & Sea Academy Page 28 Chapter 80

© Wärtsilä Land & Sea Academy Page 29 Chapter 80