TECHNICAL

BULLETIN

Wärtsilä low-speed engines RT-110

Services 2-stroke Issue 1, 31.05.2011

CLU4 pulse lubricating module: For immediate attention

Pressure check and maintenance Concerned components

Accumulators of CLU4 pulse lubricating
module of Wärtsilä RTA and RT-flex
Information to all Owners and Operators of engines.
Wärtsilä RTA or RT-flex engines
Current situation
Reports have been received of pressure
loss from accumulators on the CLU4
cylinder lubricating module.

Problem
Pressure loss in the accumulator leads to
damage of the accumulator membrane,
which in turn might influence the
performance of the cylinder lubrication.

Solutions
Check regularly the pre-charge pressure
of the accumulator.
Introduction of a new filling device.

Note
The lubricating system with the CLU4-C
pulse lubricating module is excluded from
this bulletin, except point 3.2. For details
on the CLU4-C lubricating module, please
consult the Operating and Maintenance
Manuals, Group 7, Chapter 7218-1.

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 accumulator filling device 4
3 Lubricating module and accumulator maintenance 4
4 Ordering of spare parts 13
5 Abbreviations 14

1 Introduction
On several engines with the CLU4 Pulse Lubricating System – see Figure 1 – a
significant loss of nitrogen was detected in the accumulator. This pressure loss
might result in a damaged accumulator membrane, irrespectively of the Pulse
Lubricating System (PLS) or the retrofit version (RPLS).
The pulse lubricating module CLU4-C, with the smaller type of accumulator, is
not affected and thus is not part of the improvements as described hereafter.
For the identification of the pulse lubricating module, please refer to Figure 2.

Pulse Lubricating System

2 1

3 6 4 3

1. Cylinder lubricating system, 2. CLU4 lubricating module, 3. Accumulator,

volume 0.75 l, 4. Membrane, 5. Gas filling port, 6. Servo oil port
Fig. 1
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A correctly pre-charged accumulator is necessary to obtain a good performance

of the lubricating module and the lubricating system in general. It ensures the
correct injection time, and further it reduces pressure fluctuations in the servo oil
system.

Wärtsilä utilises two modules on their Pulse Lubricating Systems:

• Module CLU4:
On the first generation of the lubricating module, the accumulator is mounted
horizontally.

• Module CLU4-C:
The second generation of the lubricating module is more compact. The
accumulator is mounted vertically and is smaller compared to the previous
CLU4 module.

Design of cylinder lubricating modules CLU4 and CLU4-C

1 4

2 3 5 6

1. Lubricating module CLU4, 2. Accumulator, volume 0.75 litre, 3. Filling

connector, 4. Lubricating module CLU4-C, 5. Accumulator, volume 0.32 litre,
6. Filling connector
Fig. 2
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2 New accumulator filling device

For the horizontally-positioned accumulator used on the CLU4 lubricating
module, Wärtsilä has introduced a new gas filling device. This device is
maintenance-friendly and the risk of losing gas pressure during the pressure
check and later in operation is eliminated.

Note:
Wärtsilä recommends replacing the former accumulators with the accumulator
incorporating the new filling valve.
The new accumulator can only be filled with the tool 94720c – see chapter 3.3 –
or with the adapter 94720a-R to the former filling tool – see chapter 3.6. For
ordering the parts please refer to chapter 4.

Improved accumulator with filling valve

2 1

1. Accumulator, 2. Filling device, 3. Protection cap

Fig. 3

3 Lubricating module and accumulator maintenance

In order to ensure trouble-free operation, the pre-charge pressure has to be
periodically checked. Checks and maintenance are only to be carried out when
the engine is at standstill.
For additional details please consult also the Operating Manual Group 7,
Chapter 7218–1 or the RPLS Instruction Manual if it is a RPLS installation.
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3.1 Determine the accumulator membrane condition

An accumulator membrane gets damaged due to no back pressure from the gas
side. The pulsation from the oil side without gas back pressure causes the
membrane to bend over the limit and finally cracks arise or brakes completely.
The membrane is damaged when no remaining gas pressure is present in the
accumulator or when oil leaks from the gas filling port. The concerned
accumulator must be replaced with a new improved one.

For ordering the parts please refer to chapter 4 in this bulletin.

3.2 Inspection interval of the pre-charge pressure at the accumulator

Check the pre-charge pressure directly after the installation of a new
accumulator, then at least once in the first week after start-up. Afterwards, check
the pre-charge pressure every three months.

3.3 Required tools for pre-charge pressure checking or filling

Wärtsilä has introduced a tool kit (1) for easy checking or filling the accumulator.
The toolbox includes all equipment needed to do the job, including a pressure
reducing valve (4) for the nitrogen bottle, see Figure 4.

Note:
For checking or filling the pre-charge pressure of the accumulator Wärtsilä
strongly advises to use the tool kit No. 94720c.

Accumulator testing and filling equipment, tool No. 94720c

2 3 4

1. Complete tool kit No. 94720c, 2. Control unit, 3. Hose – length 1 m and 4 m,
4. Pressure reducing valve
Fig. 4
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3.4 Preparation before checking or refilling

Before starting any maintenance work, ensure that the servo oil supply unit is
switched off and the servo oil pressure is completely released.
In any case, when the accumulator has been removed the lubricating pump has
to be vented, see chapter 3.9 “Venting the lubricating pump” in this bulletin.

In order to release the remaining servo oil pressure, please follow the below
preparation either for RTA or RT-flex engines with the CLU4 cylinder lubricating
system.

Preparation on RTA engines

• Stop the servo oil supply.
• Interrupt the main bearing oil supply by closing the 3-way valve (3).
• Drain the servo oil system by opening shut-off valve SV2 one turn, see
Figure 5.

Note:
Shut-off valve SV2 must remain open during the entire checking and/or refilling
procedure.

Servo oil supply unit of RTA engine

2 3 1

1. Servo oil pump, 2. Shut-off valve SV2, 3. 3-way valve

Fig. 5
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Preparation on RT-flex engines

• Stop the servo oil supply.
• Close the stop valve 4.30–5 on the servo oil rail 4.11, see Figure 6.
• Drain the servo oil system at screw plug (13) of the pressure reducing
valve 8.11–1, see Figure 6.

Note:
Screw plug (13) must remain open during the entire checking and/or refilling
procedure.

Control diagram of servo oil supply for RT-flex engine

8.11–1

13

4.11
PI2041L
4.30–5

1 2

1. Stop valve: 4.30–5, 2. Servo oil rail: 4.11, 3. Pressure reducing valve: 8.11–1,
13. Screw plug
Fig. 6

Remark:
Quoted numbers in the control diagram Figure 6 correspond with the numbers as
used in the Maintenance Manual Group 7, Chapter 7218-1 and in the Operating
Manual Group 4, Chapter 4003-2 as well as in Group 7, Chapter 7218-1.
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3.5 Checking the pre-charge pressure on a new-type accumulator

Setting-up the equippment

14

4a C 5 B A 4

1. Accumulator, 2. Protection cap, 3. Pressure reducing valve, 4. Hose – length

1 m, 4a. Hose – length 4 m, 5. Control unit with three valves, 7. Pressure gauge
0 to 60 bar, 14. Nitrogen bottle, A. Valve, B. Valve, C. Valve
Fig. 7

For the below work procedure, the accumulator does not have to be
disconnected from the lubricating module.

Note:
During every check a small amount of gas may be lost to atmosphere. Therefore,
in order to make up possible losses make sure a nitrogen bottle is available
before a pre-charge pressure check is made.

Procedure for checking/refilling the gas pre-charge pressure

1. Close the three valves (A), (B) and (C) on the control unit (5), see Figure 7.
2. Connect accumulator (1) to the valve (A) on the control unit (5), using short
hose (4).
3. Open valve (A) and read the pressure on gauge (7).
Required pre-charge pressure: min. 20 bar / max 25 bar.
4. If pre-charge pressure is within the given limit, close valve (A) and vent
remaining pressure in control unit (5) by opening valve (B). Disconnect the
short hose (4) from accumulator (1) and refit protection cap (2).
5. If it is required to refill the accumulator, please continue to point 6.
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Remark:
The accumulator may only be filled with super-clean, Class 4.0 nitrogen,
99.99% N2 by volume.

6. Connect pressure reducing valve (3) to nitrogen bottle (14), see Figure 7.
7. Connect pressure reducing valve (3) to the control unit (5) at valve (C) using
long hose (4a) and adjust the outlet pressure to approx. 30 bar.
8. Close the three valves (A), (B) and (C) on the control unit (5).
9. Open valve (A) and read pressure from gauge (7).
10. Slowly open valve (C) and refill the accumulator (1) to the required pressure
of 25 bar.
11. Close valve (A) and (C) and vent the remaining pressure in control unit (5) by
opening valve (B).
12. Disconnect the hoses (4) and (4a), remove the tools and refit all protection
caps.
13. Perform the final assembly, please refer to chapter 3.8.

3.6 Checking and refilling the gas pre-charge pressure with former filling tool
This instruction for checking and refilling with the former filling tool No. 94720 is
an alternative method to the procedure described in chapter 3.5. However, the
use of the tool No. 94720 directly from the gas bottle without a pressure reducing
valve is not recommended.

Note:
Wärtsilä does not recommend checking and refilling the accumulator without a
pressure reducing valve.

For checking and refilling the pre-charge pressure using the former tool, an
adapter with a short hose is needed. Please refer to chapter 4 for ordering the
adapter.

Setting-up the equipment of former filling tool No. 94720

3
8
1

9 4 7 5 5

1. Accumulator, 2. Protection cap, 3. Filling and testing valve with pressure

gauge, 4. Connecting hose, 5. Short hose, 6. Coupling with filling plug, 7. Relief
valve, 8. Connector to accumulator, 9. Nitrogen bottle
Fig. 8
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For the below work procedure, the accumulator does not have to be
disconnected from the lubricating module.

Note:
During every check a small amount of gas may be lost to atmosphere. Therefore,
in order to make up possible losses make sure a nitrogen bottle is available
before a pre-charge pressure check is made.

Procedure for checking/refilling the gas pre-charge pressure

1. Connect the coupling with the filling plug (6) to the filling and testing
valve (3). Tighten the connection by hand, see Figure 8.
2. Fit the hose (4) to the filling and testing valve (3) and connect to the nitrogen
bottle (9).
3. Make sure that both the relief valve (7) at the filling tool (3) and the nitrogen
bottle (9) are closed.
4. Remove the protection cap (2) from the accumulator (1); connect the short
hose (5) from the filling and testing valve (3) to the filling plug on the
accumulator. Tighten the coupling nut (8) by hand.
5. Read the pressure on the gauge (3) which must be between 20 and 25 bar.
If the pre-charge pressure is within limits, carefully remove the connector (8)
from the accumulator (1), remove the filling equipment and refit the protection
cap (2) to the accumulator.
6. If the accumulator requires to be refilled, please continue to point 7.

Remark:
The accumulator may only be filled with super-clean, Class 4.0 nitrogen,
99.99% N2 by volume.

7. Very slowly open the valve on the nitrogen bottle and quickly close it again
as soon as the gauge shows a pressure between 25 and 30 bar. The
complete system, including the gas chamber of the accumulator, is now
pressurised with the specified pressure.
8. If the maximum filling pressure is exceeded, it can be adjusted to 25 bar by
means of the relief valve (7) at the filling and testing valve (3), see Figure 8.
9. Firmly close the valve on the nitrogen bottle and carefully remove the
connector (8) from the accumulator (1). The filling plug closes automatically
when removing the connector (8).
10. Refit the protection cap (2) to the filling port on the accumulator (1).
11. Release the remaining pressure from the hose by opening the relief
valve (7).
12. Remove the complete pressure equipment and perform the final assembly.
Please refer also to chapter 3.8.
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3.7 Cable connections of solenoid and pressure sensor

The purpose of the regular maintenance of the cable connections is to prolong
the lifetime of electrical contact surfaces and to provide proper electrical
connection under all conditions. This prolongs the working life and maintains full
availability of the Pulse Lubricating System.

Note:
The maintenance of electrical connections should be performed every six
months.

The maintenance is carried out by applying contact lubricants to electrical contact

surfaces and retightening the screw connections. For best result the contact
surface should be cleaned with an aerosol electrical contact cleaner before
applying the lubricant.
Contact lubricants are specially formulated greases and oils that reduce friction
and enhance the electrical performance of current carrying metal interfaces in
switches and connectors. They also have a neutral pH value, thereby avoiding
surface corrosion.

Attention:
To avoid electrical shock or possibility of fire, disconnect power to any system
before applying conductive lubricant. Ensure positive and negative contacts
remain isolated. Working on a “live circuit” can result in shorting, arcing, or shock.

Electrical connectors to Pulse Lubricating System

2 1

1. Lubricating module CLU4, 2. Cable connectors

Fig. 9
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3.8 Final assembly

After checking/refilling prodedure
• On RTA engines:
− Close shut-off valve SV2, see Figure 5.
− Open the main bearing oil supply by opening the 3-way valve (3), see
Figure 5.

• On RT-flex engines:
− Reopen stop valve 4.30–5 on servo oil rail 4.11, see Figure 6.
− Close screw plug (13) of pressure reducing valve 8.11–1, see Figure 6.

After checking the pressure and refilling the accumulator, ensure to run the servo
oil supply system and vent air from the system before putting the Pulse
Lubricating System into operation. See also chapter 3.9 “Venting the lubricating
pump”.

3.9 Venting the lubricating pump

H I The lubricating pump has to be vented after refitting the accumulator.

The lubricating pump contains two vent plugs:

• One plug for the cylinder lubricating oil (H).

• One plug for the servo oil (I).

The air can escape when the plugs are loosened.

Venting the lubricating oil section of the lubricating pump

• Required tools:
− Oil collection tray.
− Cloth to wipe up escaping oil.

• Proceed as follows to vent the lubricating oil section of the lubricating pump:

1. Place an oil collection tray beneath the lubricating pump.

2. Loosen the vent plug for the lubricating oil (H). For this, turn the plug
counter-clockwise a maximum of three turns.
3. Wait until bubble-free oil escapes at the vent plug.
4. Tighten the vent plug again.
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Venting the servo oil section of the lubricating pump

Attention:
Pressurised oil system.
The servo oil system is under high pressure. Oil may spurt out when you loosen
the screws. Wear safety goggles. Do not loosen the vent plug more than three
turns.

• Proceed as follows to vent the servo oil section of the lubricating pump:

1. Place an oil collection tray beneath the lubricating pump.

2. Operate the lubricating system via manual lubrication or intermediate
lubrication operation.
For additional details please consult also the Operating Manual Group 7,
Chapter 7218–1 or the RPLS Instruction Manual Chapter 4, if it is a RPLS
installation.
3. This is only possible after the servo oil priming pressure has been
achieved by starting the servo oil pumps.
4. Put on safety goggles.
5. Loosen the vent plug for the servo oil (I). For this, turn the plug counter
clockwise a maximum of three turns.
6. Wait until bubble-free oil escapes at the vent plug.
7. Tighten the vent plug again.

4 Ordering of spare parts

Ordering of new accumulator

• Identify the accumulator and include the information for the order.
• If possible include a picture of the pulse lubricating module with your order
which shows clearly the accumulator.

The improved accumulator can be ordered through Wärtsilä by quoting the spare
part code number, see also remark below.
Code number of accumulator:
• For RTA engines: D 96369
• For RT-flex engines: DF 96369

Remark:
Designation of Spare Part Code Number: X 12345 or XF 12345.
“X” = Given letter depending on the engine bore size – please consult your Spare
Part Code Book.
Letter “F” is the indication for RT-flex engines.
e.g., in this Technical Bulletin spare part numbers are quoted with letter “D”
where this is used for RTA96C/RTA96C-B and “DF” for RT-flex96C-B engines.
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Ordering new tool kit

The tool kit for checking or filling the new accumulator has the number 94720c. It
can be ordered from your nearest Wärtsilä representative by stating this tool
number.

Ordering adapter for the former filling tool

The adapter with the short hose has the number 94720a-R. It can be ordered
from your nearest Wärtsilä representative by stating this tool number.

5 Abbreviations

Abbreviation Description
CLU4 Cylinder lubricating system of fourth generation
CLU4-C Cylinder lubricating system of fourth generation, with
compact lubricating module
PLS Pulse Lubricating System
RPLS Retrofit Pulse Lubricating System

Tab. 1

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 or send your enquiry to:
technicalsupport.chts@wartsila.com
or phone 24hrs Support: +41 52 262 80 10.

© 2011 Wärtsilä 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 Corporation 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 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.