GENERAL

INFORMATION

Wärtsilä 2-stroke RT-119

Technical Services Issue 2, 24 July 2014

Remanufacturing services
At your convenience

Information to all Owners and Operators of Related products and components

Wärtsilä RTA and RT-flex engines Selected components of Wärtsilä RT-flex
and RTA engines. For details to the
available components see Table 1 and
Table 2.
The range of components will be
continuously extended.

Introduction
This General Information bulletin provides
continuous optimisation of maintenance
concepts to reduce the operating cost for
selected components.

Solution
This document should be consulted when
planning maintenance for those
components listed in Table 1 and Table 2.
Fault-finding and repair of the components
are dealt with in separate Technical
Bulletins.

Note
This General Information Issue 2
supersedes General Information RT-119,
Issue 1, dated 17.01.2012. Reasons and
details see extended comments in the
Introduction part.

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

PO Box 414
CH-8401 Winterthur technicalsupport.chts@wartsila.com
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Contents
Page
1 Introduction 2
2 The remanufacturing exchange concept 3
3 Available remanufactured RT-flex components on an exchange basis 3
4 The standard ordering process for components on an exchange basis 4
5 Optional process – Remanufacturing of own components 6
6 Non RT-flex related remanufactured components 6
7 Logistics 7
8 Remanufacturing and quality of components 8
9 Appendix 8
10 Contacts 9

1 Introduction
NOTE:
This General Information bulletin Issue 2 supersedes General Information RT-119,
Issue 1, dated 17.01.2012, entitled “Component remanufacturing services”. Reasons:
• Additional remanufactured components added
• Appendix 2 new: Remanufactured part code numbers
Ship owners and operators put continuous efforts into reducing vessels’ operating
costs. To support the optimisation of total cost of ownership by reduction of the main
engine’s operating costs the Component Remanufacturing Services have been
developed and introduced as one of Wärtsilä’s maintenance cost-down solutions.
This service was developed for specific components, which in future can be returned to
Wärtsilä for remanufacturing at the recommended overhaul intervals.
Remanufacturing substantially reduces the costs of maintenance compared to a
replacement by new components. Remanufacturing will always be carried out to the
latest standards and specifications to ensure or even improve the component
functionality and lifetime expectancy.
As a result of this initiative, Wärtsilä customers can enjoy reduced operating costs of
their main engines.
Component Remanufacturing Services are available in two ways:
• Exchange Component Services
Obtain a remanufactured component ex stock, returning the old component and
receive a refund  this is the recommended and preferred way.
• Remanufacturing of the customer’s own component(s)
Send used component to Wärtsilä workshop for remanufacturing and receive the
same component back  optional on request, with lead time.
Wärtsilä Remanufacturing Services use the latest industrial processes specifically
developed for this task, which ensures the best quality and economy for the customers.
Therefore, remanufacturing is the Wärtsilä chosen concept for the components as
listed in Table 1. This means that new components are not kept in stock for
maintenance purposes. New components remain available for supply of initial or
additional components for onboard stock. New components are delivered with lead
time. In case of ordering new components, please clearly indicate “order for onboard
stock”.
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2 The remanufacturing exchange concept

The remanufactured components are available ex stock and sold at a reduced cost to
the customer. To enable this service, Wärtsilä created a pool of components in
Wärtsilä’s warehouses in Kampen (the Netherlands) and Singapore. The pool enables
that customer orders can be delivered while the used components, to be taken into the
process, are returned to Wärtsilä or are in the remanufacturing process, see Figure 1.
The used components are remanufactured in dedicated and specialised Wärtsilä
workshops and put back in stock.

For the long-term sustainability of this service and continual replenishment of stock, it is
essential that in all cases used components are returned to Wärtsilä for processing on
exchange basis. Upon receipt of the used components, Wärtsilä issues a refund in the
form of a Credit Note. The net costs (remanufactured part price minus refund) enable a
substantial maintenance cost reduction for customers.

2 1 4 3

1. Material flow 1st step 3. Material flow within Wärtsilä

2. Material flow 2nd step 4. Wärtsilä pool stock
Figure 1: Exchange components services process

3 Available remanufactured RT-flex components on an exchange basis

The Exchange Components Service is currently valid for selected components of
Wärtsilä two-stroke RT-flex engines. The remanufactured components as listed in
Table 1 are already available.

Table 1: Available components of RT-flex engines

Components Engine bore sizes (values in cm)

Injection Control Unit (ICU) All bore sizes
Fuel Oil Pump (FOP) All bore sizes
Servo Oil Pump (SOP) from DYNEX All bore sizes
Pressure Control Valve (PCV) All bore sizes
Intermediate Fuel Accumulator (IFA) 96 and 84 bores
Pulse Lubricating Module CLU4 & CLU4-C All bore sizes
Camshaft 96 and 84 bores

The components as listed in Table 1 can be supplied from one of Wärtsilä’s

warehouses in Kampen (the Netherlands) or Singapore.
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4 The standard ordering process for components on an exchange basis

To place an order, make contact with your Wärtsilä representative for the required
remanufactured component. Wärtsilä will then send an offer with the price and delivery
time for the required component. The net cost will be the price of the remanufactured
component minus the refund value for the returned used component.
The detailed ordering flow process is shown in Figure2.
It is important that the steps are followed, but special attention is to be given to the
Return sheet (1) that has to be filled out, see example in Appendix 1.

Upon receipt of
Order Customer will receive
Send order for instructions for return the used
confirmation,
remanufactured delivery components,
delivery of (incl. return delivery
component to Wärtsilä will issue
remanufactured sheet). Please provide
your normal ALL necessary a Credit Note for
component and component information
sales contact: returned
invoicing. (existing markings).
components.

• When ordering a
remanufactured
component, please send
information about vessel
name, engine type
& number, required
delivery time and place.

• When returning used 1

components, please send
information about where
you intend to land or
deliver to, and the
running hours of the
component.

1. Return sheet, see Appendix 1

Figure 2: Process flow

Wärtsilä will send the remanufactured component from the nearest Wärtsilä warehouse
to the requested delivery address.

Most components are transported in a special box. For the return delivery of the used
components, the same box should be used, see Figure 3. The special boxes are the
property of Wärtsilä.
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Once the used component is received in the Wärtsilä warehouse together with the
respective transportation box, a Credit Note will be generated as the refund for a pre-
determined amount.

NOTE:
For efficient Credit Note processing, ensure quick return of the used component to a
Wärtsilä warehouse. Fill in the return sheet and include the Wärtsilä return order
number provided, see Appendix 1. Without the Wärtsilä Return Order Number, the
components cannot be processed and therefore a Credit Note cannot be created.

1 3

2
3

1. Component placed in box with shipping 3. Box closed and secured by catches for
documents easy opening and closing without
2. Box size and appearance depending destroying the box and cover
on component
Figure 3: Wooden transportation box

NOTE:
Used components shall be returned in the specially designed wooden box only. The
wooden boxes are the property of Wärtsilä.
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5 Optional process – Remanufacturing of own components

In some cases Customers may require their own components to be returned after
remanufacturing. Although this is not the standard process, Wärtsilä can also offer the
remanufacturing of customers’ own components on an optional basis. Here the
customer’s own component is sent to one of the dedicated Wärtsilä remanufacturing
workshops, and after remanufacturing, the same component is received back.

To cover the additional costs for the special handling of the components a small
additional fee is charged. The lead time for these components is longer due to the
remanufacturing process. In this case the customer has to keep his own “pool” of
components to cover this lead time period.

To proceed with an order in this case, contact should be made as usual with your local
Wärtsilä representative.

1. Material flow
Figure 4: Remanufacturing process of own components

6 Non RT-flex related remanufactured components

The exchange components process has also been extended to selected non RT-flex
related components which can also be supplied from Wärtsilä’s warehouse in Kampen
(the Netherlands). The available components are listed in Table 2.

Table 2: Available components for Wärtsilä 2-stroke engines on an exchange basis

Components Engine bore sizes (values in cm)

Cylinder cover 52, 58, 62, 72, 84, 96
Piston crown 52, 58, 62, 72, 84, 96
Exhaust valve spindle 48, 58, 62, 72, 84, 96

In case exchange components are not available for a particular engine type, a much
broader range of remanufacturing services for components is offered by Wärtsilä. The
components are available for almost any 2-stroke main engine type. Remanufacturing
services are offered through a worldwide network of approved remanufacturing
workshops.
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Remanufacturing Services on non RT-flex related components

Kruiningen
Netherlands

Vancouver
Canada
Shanghai
China

Genoa
Italy

Singapore
Wärtsilä network Dubai
Remanufacturing Workshop Arab. Emirates

Following major locations offering remanufacturing services on non RT-flex related

2-stroke components:
Dubai, Genoa, Kruiningen, Shanghai, Singapore and Vancouver.
Wärtsilä also has other remanufacturing facilities globally; please contact your local
Wärtsilä representative for more details.
Figure 5: Locations offering remanufacturing services

7 Logistics
Wärtsilä maintains an exchange pool of remanufactured components within its’ own
logistics centres from which the customer’s orders are served.

The used components should preferably be returned directly to one of the Wärtsilä
logistics centres.

Wärtsilä logistics centres locations:

• Central Distribution Centre, Kampen (the Netherlands)
• Spare Parts Centre, Singapore

If requested by the Customer and agreed in advance with your local Wärtsilä contact,
pick-up and return of the component(s) from/to the place of landing can be arranged.
The same also applies for transportation requests for remanufacturing of customer’s
own components.

NOTE:
Always ensure the packing of used components in the special Wärtsilä wooden boxes,
including the return sheet and labelling the box with the Wärtsilä return order number.
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8 Remanufacturing and quality of components

High quality remanufacturing processes and quality control are carried out in
specialised and dedicated Wärtsilä workshops to ensure the high quality of the original
Wärtsilä components. The remanufactured components are delivered with the same
terms and conditions as new parts and components.

8.1 Remanufacturing
Remanufacturing in the workshop will include the following tasks:
• Registering of used returned components
• Disassembly
• Cleaning
• Replacement of all necessary components
• Re-assembly of complete component
• Functionality testing
• Report and certificate
• Packing

8.2 Quality
Remanufacturing of components by Wärtsilä will always be carried out according to the
latest design and specifications.

Remanufacturing of a component comprises the points as listed above including re-

machining, sub-component replacement or reconditioning and applying the latest
technical specification and standards. This results in remanufactured components
being “as new” with the same or even improved functionality and lifetime.

Before entering the Wärtsilä warehouse, the remanufactured components are tested in
specifically designed test benches. All remanufactured components are inspected and
certified by Wärtsilä Quality Control as a standard part of the remanufacturing process.

9 Appendix
• Appendix 1
“Return sheet – Example only”
• Appendix 2, RT-119_A2
Remanufactured part code numbers
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10 Contacts
10.1 How to contact Wärtsilä
For questions about the content of this General Information, or if you need Wärtsilä
assistance, services, spare parts and/or tools, please contact your nearest Wärtsilä
representative.
If you do not have the contact details at hand, please follow the link “Contact us” – “24h
Services” on the Wärtsilä webpage:
www.wartsila.com

10.2 Contact details for emergency issues

10.2.1 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.

10.2.2 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.

10.2.3 Spare parts

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

© 2014 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 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.
This page is intentionally left blank
 APPENDIX 1

Return sheet – Example only

Wärtsilä Services

A) Return to warehouse: Singapore

B) Return to warehouse: Kampen, the Netherlands
RT-flex component: Part "X" for remanufacturing

The subject part is to be sent back to the Wärtsilä warehouse as indicated on this sheet. Procedure:
• Decide where to return the component: A) to Singapore or B) to Kampen, the Netherlands
• Fill in this form. Make sure that the Wärtsilä "Return Order Number" is inserted – for crediting reasons.
• Include a copy of the completed form with the consignment.
• Additionally send an electronic copy of the completed form to the respective contact persons mentioned below under A) or B).

A) Contacts for Singapore B) Contacts for Kampen, the Netherlands

Name: Logistic Manager Name: Logistic Manager
Email: WGLS.SPCasia@wartsila.com Email: cdc-kampen.returns@wartsila.com
Phone: +65 62 67 42 17 Phone: +31 38 42 79 231
Fax: +65 62 62 17 89 Fax: +31 38 42 23 564
Name: Cc: Production Planner Name: Cc: Production Planner
Email: production.planning@wartsila.com Email: production.planning@wartsila.com

Do not disassemble the component

Wärtsilä Return Order Number: >> Number will be given by Wärtsilä to customer <<

The complete component must be returned in Wärtsilä's wooden transportation box to the selected shipping address A) or B):

A) Shipping address to Singapore B) Shipping address to Kampen, the Netherlands

Wärtsilä Singapore Pte Ltd Wärtsilä Switzerland Ltd

14 Benoi Crescent Wärtsilä Global Logistics Services
Singapore 629977 Genuakade 8 / Zuiderzeehaven
8263 CG Kampen
Contact: The Netherlands
Attn.: Logistic Manager
Phone: +65 62 67 42 17 Phone: +31 38 42 79 231
Fax: +65 62 62 17 89 Fax: +31 38 42 23 564

Name of installation:
Hull No.:
Engine type:

Order/Claim No.: Exchange programme Engine running hours:

Date of failure: Part running hours:
Part position:
Part serial number (4 digits): (S/N)

Description of damage / Sequence of damage

Text:

Predifined questions: Yes / No

Please be informed that the complete defective component must be returned to one of the above mentioned
address A) or B) – or Wärtsilä has to be informed of the port of discharge, within 30 days. Otherwise,
Wärtsilä reserves the right not to issue a Credit Note for the component.

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