maintenance schedule for wartsila 20 b-c engines wfi 2004n007 02gb

Services, Wärtsilä Finland Oy

Engine section Engine type Ref. Date Issue Document No. Page 04 Maintenance Schedule W20 B/C WFI–S 19.12.2007 02 2004N007 1(2)+10

Wärtsilä Finland Oy P.O. Box 252 (Tarhaajantie 2) Telecop. +358 10 709 1847 Tel. +358 10 709 0000 Business ID 0773744-3 Services, Vaasa FIN-65101 Vaasa, Finland Telecop. +358 10 709 1380 Registered Office: Vaasa

Wärtsilä Finland Oy P.O. Box 50 (Stålarminkatu 45) Telecop. +358 10 709 3279 Tel. +358 10 709 0000 Services, Turku FIN-20811 Turku, Finland Telecop. +358 10 709 3410

DATA & SPECIFICATIONS

Maintenance schedule for WÄRTSILÄ® 20 B and C engines

General This document contains the latest version of the maintenance shedule for the WÄRTSILÄ® 20 B and C engines.

The new maintenance intervals are dependent on fuel type and load and are to be seen as guidelines only.

A prerequisite for the implementation of the new maintenance intervals is that all previous maintenance has been done in accordance with the instruction manual originally supplied with the engine, and that all upgrades recommended in previous service bulletins have been made.

Recommendation Replace the maintenance schedule in chapter 04 of your Instruction Manual.

Distribution Wärtsilä Service Network and owners / operators of concerned engines.

Letter validity Until further notice.

Enclosure Chapter 04 Maintenance Schedule, version 20-200747-01, 10 pages.

© 2007 Wärtsilä Finland Oy – 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 Finland Oy 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.

04. Maintenance Schedule

04.1 General

The actual operating conditions, and above all the quality ofthe fuel used, will largely determine the maintenance neces-sary for the engine. Because of the difficulty in anticipating thevarious operating conditions that may be encountered in thefield, the periods stated in the schedule should be used for guid-ance purposes only, but must not be exceeded during the war-ranty period. Where any indications are encountered that the performanceof a maintenance procedure is required in advance of the recom-mended time period, prudent industry practice dictates thatthe suggested maintenance procedure be performed. Addition-ally, where inspection or observation reveals that a part showswear or use beyond the prescribed tolerances, that part shouldbe renewed immediately. See also the instruction books of theturbocharger and the governor, separate instructions for addi-tional equipment and chapter 03.

1 Before any steps are taken, carefully read the corre-sponding item in this Manual.

2 Note the Risk Reduction in chapter 00A.

3 Note the Environmental Hazards in chapter 02A.

4 At all maintenance work, observe the utmost cleanli-ness and order.

5 Before dismantling, check that all systems concerned aredrained or the pressure is released. After dismantling,immediately cover holes for lubricating oil, fuel oil and air withtape, plugs, clean cloth or similar.

6 When exchanging a worn-out or damaged part pro-vided with an identification mark stating cylinder or bearingnumber, mark the new part with the same number on the samespot. Every exchange should be entered in the engine log andthe reason should be clearly stated.

7 Always renew all gaskets , sealing rings and O-rings at maintenance work.

8 After reassembling, check that all screws and nuts aretightened and locked, if necessary.

20-200747-01 04

WÄRTSILÄ 20 04 - 1

Warning! When overhauling the engine, make absolutely sure that theautomatic start and the priming pump are disconnected.Make also sure that the starting air shut-off valve locatedbefore main starting valve is closed. Otherwise it might causeengine damage and/or personal injury.

04.1.1 How to select application and fuel quality

There are two different types of applications defined:• Average load is above 75 % of nominal engine output.• Average load is below 75 % of nominal engine output.

Three types of fuel are defined:• HFO 1 Heavy fuel oil of normal quality.• HFO 2 Heavy fuel oil of below normal standard quality.• DO Diesel oil or light fuel oil (LFO).

Fuel characteristics, maximum limitsHFO 1 HFO 2

Sulphur % mass 1.5 1.5 - 4.5

Ash % mass 0.05 0.05 - 0.15

Vanadium mg/kg 100 100 - 600

Sodium mg/kg 50 50

Sodium, before engine mg/kg 30 30

Aluminium + silicon mg/kg 30 30 - 80

Aluminium + silicon, bef. eng. mg/kg 15 15

Conradson Carbon residue % mass 15 15 - 22

Asphaltenes % mass 8 8 - 14

CCAI 850 850 - 870

Note! If any of specified fuel properties exceed HFO 1 maximumvalue the fuel should be classified as HFO 2.

04.2 Every second day, irrespective of the engine being in operation or not

Automatic prelubrication Check operation 03.1.218.10

Crankshaft Marine engine: In a stopped engine, turn the crankshaft into anew position.

04.

04.3 Once a week irrespective of the engine being in operation or not

Start process Test start (if the engine on stand-by). 03.1

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04 - 2 WÄRTSILÄ 20

04.4 Interval: 50 operating hoursAir cooler Check draining of air cooler 15.2.1

Check that the draining pipe is open, check if any leakage. 03.3.1

Cooling system Check water level in cooling system 19.1.3

Check the water level in the expansion tank(s) and/or the staticpressure in the engine cooling circuits.

Connecting rod Check tightening of the connecting rod screws 11.4.5

Check the tightening of the connecting rod screws after the first 50operating hours on a new engine and after overhaul, those screwsthat have been opened.

07.

Fuel and lub. oil filters Check pressure drop indicators 17.2

Change filter cartridges if high pressure drop is indicated. 03.3.123.1.4

Gauges and indicators Take readings 03.3.1

Read and record (use form No. WV98V089) all temperature andpressure gauges, and at the same time the load of the engine.

Governor, actuator Check oil level in governor, and look for leaks

Injection and fuel system Check leak fuel quantity 03.3.1

Check the amount of leak fuel from the injection pumps andinjection nozzles.

17.

Injection pipes Check tightening of injection pipe connections 16.207.1

Check the tightening of injection pipe connections on a hotengine after the first 50 operating hours on a new engine and,after overhaul, those connections that have been opened.

Lubricating oil sump Check oil level in sump 18.2

Check oil level by means of the dip stick, compensate forconsumption.

02.2

Main bearings Check tightening of main bearing screws 10.4

Check the tightening of main bearing screws after the first 50operating hours on a new engine and after overhaul, those screwsthat have been opened.

07.

Turbocharger Check turbocharger oil level 15.1.2

VTR-chargers Check oil level, and look for leaks 02.2

Turbocharger Water cleaning of compressorClean the compressor by injecting water. 15.1.5

Check the turbine side V-clamp ring tightening on TPS charger, ifspecified, after the first 50 operating hours on a new engine and,after overhaul. See turbocharger makers manual.

Check fastening bolts at feet, tighten housing bolts and pipingjoints. Once after commissioning or overhaul; then every 4000 hrs.See turbocharger makers manual.

Valve mechanism Check valve clearances 12.2.4

Check the valve clearances after 50 hours’ running in new andoverhauled engines. Check tightening of rocker arm screws andvalve/yoke adjusting screw nuts.

06.1

Multiduct Check tightening of the multiduct screws 07.1

Check the tightening of the multiduct screws after the first 50operating hours on a new engine and, after overhaul, thosescrews that have been opened. The engine should be in normaloperating temperature.

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04.5 Interval: 100 operating hoursTurbocharger Water cleaning of turbine 15.1.3

Clean the turbine by injecting water; adjusted acc. to operation.

04.6 Interval: 250 operating hoursCentrifugal filter Clean centrifugal filter 18.9

Clean more often if necessary. Remember to open the valvebefore the filter after cleaning. Check the condition of bearingsand shaft journals.

Control mechanism Maintenance of control mechanism 22.2

Check for free movement, clean and lubricate.

Lubricating oil Take oil sampleIn a new installation or after change to use of a new lubricating oilbrand, take samples for analysing.

02.2.3

04.7 Interval: 500 operating hoursCirculating water Check water quality

Check content of additives. 2.3.3

Cylinder pressure Check cylinder pressure 03.3.3

Record firing pressures of all cylinders.

Lubricating oil Take oil sample 18.2

Take oil sample for analysis. Use of lubricating oil can be prolongedas long as the analysis results are within the specified limits set bythe engine manufacturer. For a new installation, see the interval: 1000 hours.

Turbocharger Change lubricating oil in turbocharger 15.1.2

VTR-chargers Change lubricating oil in the turbocharger. Take care that theturbine oil is not mixed with the engine lubricating oil.

02.2

Turbochargers Wash filter mat on filter silencer 15.1.2

After being washed five times or fulfilling 3000 operating hours,replace by new one. See turbocharger makers manual.

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04.8 Interval: 1000 operating hoursAutomation Functional check of automation 23.1.5

Check function of the alarm and automatic stop devices. 01.2

Fuel filter Replace fuel oil filter cartridgesClean the wire gauze and filter housing. Replace the filter cartridges.(The cartridges are to be replaced when the pressure differenceindicator shows too high pressure drop).

17.117.2

Lubricating oil Change lubricating oil 18.2

Change oil in a new installation (wet sump installations). Take samplesfor analysing. Use of lubricating oil can be prolonged, in steps of 500operating hours, as long as the analysis results are within the specifiedlimits set by the oil supplier or the engine manufacturer.Change oil in an installation (wet sump installations) that is notpurifying regularly the lubricating oil, independently of oil analysisresult.Clean all oil spaces with a high quality fibre-free / lint free cloth whenchanging lubricating oil.

02.2.3

Lubricating oil filter Replace lubricating oil filter cartridges 18.8

Drain the filter housings. Clean the wire gauze and filter housing.Replace the filter cartridges. (The cartridges are to be replacedsooner if the pressure difference indicator shows too high pressuredrop.)

Valves Check of valve condition 12.2.4

Check valve clearances.Check cylinder tightness (valves, piston rings) with a pneumatic test.Check that the inlet and exhaust valves move freely in their guides.This should preferably be done when the engine has been out ofoperation for a couple of hours.

06.1

04.9 Interval: 2000 operating hoursCharge air cooler Check water side of charge air cooler 15.2.1

The first time check and possible cleaning of the waterside. If ingood condition and deposits unsignificant: future intervals 4000running hours.

Measuring instruments Checking of gaugesCheck pressure and temperature gauges. Replace faulty ones. 23.

Governor Change oil in governor 02.2.4

Change lubricating oil. 22.4

Injection valves Inspect injection valves 16.4.3

Test the opening pressure. Dismantle and clean nozzles. Check theeffective needle lift. Check the springs. Replace the O-rings.

Overspeed trip device Check function of overspeed trip 22.3.3

Check function and tripping speed.

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04.10 Interval: 4000 operating hoursAir cooler Clean the charge air cooler 15.2.1

Clean the air and water side of the charge air cooler and pressuretest it. Look carefully for corrosion.

Camshaft Inspect contact faces of camshaftCheck the contact faces of the cams and tappet rollers. Check thatthe rollers rotate. Rotate the engine with the turning gear.

Control mechanism Check control mechanism 22.2

Check for wear in all connecting links between the governor and allinjection pumps.

Crankshaft Check crankshaft alignment 11.1.3

Check alignment, use form No. WV98V036. Alignment check hasto be performed on a warm engine.

Flexible coupling If specifiedCheck anignment, use form WV98V041. Check condition ofcoupling. See manufactures instructions.

Resilient mounts Inspect the buffer clearance,reset if necessary. Inspections to be made at least once a year.

Cylinder liners Inspect jacket water spacesPull one cylinder liner. If the deposits are thicker than 1 mm, cleanall liners and engine block water space. Improve the coolingwater treatment.Replace the distance shim under liner if installed.

02.310.6

Exhaust manifold Check the expansion bellows, nuts and pipe support ofthe flange connections

20.1

Tighten loose nuts.Replace supports and bellows if necessary.

Lube oil coolers Clean the lubricating oil cooler 18.6

If the lube oil temperature before the engine is within normaloperating values (Section 01.1), the interval can be prolonged.Unnecessary opening of the cooler should be avoided. Clean thelube oil cooler before the alarm limit for the lube oil temperature isreached. Examine carefully for corrosion.

Nozzles Check the nozzle condition in a test pump 16.4.3

Recommendation: Replace the nozzles by new ones

Turbocharger Inspect and clean 15.1.2

Clean the compressor and turbine mechanically if necessary. Inspect turbocharger cooling water ducts for possible depositsand clean if the deposits are thicker than 1 mm, if VTRturbocharger.

19.2

Inspect nozzle ring 15.1.3

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04.11 Interval: 8000 operating hoursBalancing shaft Inspect balancing shaft bearing Appendix

11.4L20 Take one bush out for inspection. If in bad condition, check the

other bushes. Replace if necessary.

Camshaft driving gear Inspect camshaft driving gear 13.

Check clearances and backlash. Replace parts if necessary.

Governor driving gear Inspect governor driving gear 22.4

Replace parts if necessary.

HT-water pump Inspect HT-water pump 19.3

Dismantle and check. Replace shaft seals and worn parts. Checkbacklash.

HT-water pump driving gear Inspect HT-water pump driving gear 19.3

Replace parts if necessary. Check backlash.

HT-water thermostatic valve Clean and inspect HT-water thermostatic valve 19.4

Clean and check the thermostatic element, valve cone-casingand sealings.

LT-water thermostatic valve Clean and inspect LT-water thermostatic valve 19.4

Clean and check the thermostatic element cone-casing andreplace sealings.. Check the function of the valve.

LT-water pump Inspect LT-water pump 19.3

Dismantle and check. Replace shaft seals and worn parts. Checkbacklash.

LT-water pump driving gear Inspect LT-water pump driving gear 19.3


Lube oil pump Inspect the lubricating oil pump 18.3

Dismantle and check. Replace worn parts. Check backlash.

Oil pump driving gear Inspect oil pump driving gear 18.3


Oil thermostatic valve Clean and inspect oil thermostatic valve 18.7

Clean and check the thermostatic element, valve cone-casingand sealings.

Prelubricating oil pump Inspect the prelubricating oil pump 18.10

Replace parts if necessary.

Electrical motor for prelubricating oil pumpReplace rollerbearings on electrical motor or latest after three (3)years in use.

Fuel system Check and adjust fuel system 17.

Check the adjustment of fuel system. Check for possible leakage.Replace parts if necessary.

Starting/smoke fuel limiter Check function of starting/smoke fuel limiter 22.23.

Turbocharger Replace turbocharger bearings 15.1.2

VTR-chargers See manufacturers instructions

Air starter General overhaul of air starter motor 21.1

Air starter maintenance in connection to general enignemaintenance or latest after 3 years. Replace bearings, solenodand worn parts. See manufacturers instructions.

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FuelOverhaul interval

Average load > 75 % Average load < 75 %HFO 2 8000 10000

HFO 1 12000 14000

DO 16000 20 000

04.12 Interval: (8000 - 20000) See table aboveConnecting rod Replace big end bearings 11.4.3

Replace big end bearings. Inspect mating face and surface ofserrations. Check the small end bearing. Measure the big endbore, use form 2011V001.

Inspect small end bearings 11.4.4

Replace if necessary. 06.2

Crankshaft Check thrust bearing clearance 10.5.3

Check axial clearance

Cylinder heads Overhaul of cylinder head 12.

Dismantle and clean the underside, inlet and exhaust valves andports. Pull out the exhaust gas seat rings, inspect cooling spacesand clean, replace the o-ring(s). If necessary, grind the valves andEX / IN seat rings (often lapping by hand is enough). Inspect thevalve rotators.Replace the O-rings in the valve guides. Use the Cylinder HeadOvrhaul Report messurement record 2015V015.

Cylinder liners Inspect the cylinder liners 10.6

Measure the bore using form No. 2010V002, replace liner if wearlimits are exceeded. Hone the liners. Renew the antipolishing ring.

Inspect all cylinder liners water side and replace O-rings

19.2

Pull all cylinder liners. If the deposits are thicker than 1 mm, clean allliners and the engine block water space. Replace the O-rings inthe bottom part by new ones at every overhaul.

10.6

Injection pumps Overhaul of injection pumps 16.2.4

Clean and inspect injection pumps, replace worn parts. Replaceall seal rings and constant pressure valve. Check the erosion plugs,replace if necessary.

Pistons Inspect the piston 11.4.4

Dismantle one composite piston for inspection of mating surfacesbetween piston skirt and piston crown. Inspect and clean oilspaces. Repeat the procedure with other pistons if necessary.

Piston, piston rings Inspect pistons and piston rings 11.4.3

Pull, inspect and clean. Check the height of the ring grooves. Check theretainer rings of the gudgeon pins. Replace complete set of piston rings.Note the running-in program.

Main bearings Inspect the bearing shells of one main bearing 10.4.2

Replace all bearing shells, if necessary

Turbocharger Inspect the bearings of radial type charger 15.1.2

TPS-chargers Replace bearings if necessary. See manufactures instructions.

Valve mechanism Check valve mechanism bearings 14.1.3.2

Check tappets and rocker arms. Replace valve tappet rollerbearing bush, if specified.

06.2

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04.13 Interval: 16000 operating hoursFuel feed pump Inspect fuel feed pump.

General overhaul and replace shaft seals and gaskets.

Governor drive Check the governor drive bearing 22.4

Check governor driving shaft bearing clearance in situ. 06.2

Vibration damper Dismantle and check. 11.1

See manufacturers instructions.

Viscous vibration damper Take oil sample from vibration damper 11.1

Take oil sample for analysing.

Intermediate gears andbearings

Inspect gear teeth and measure backlash and axialclearance. Replace bearings at least every 32000 hrs.

Camshaft Inspect camshaft bearings 14.1.3.2

Replace if necessary. 06.2

Governor Governor general overhaul at an autorisead workshop atlatest after 5 years in use. See manufactures instructions.

Check the function and adjustments of the governor. 22.4

Replace worn parts.

04.14 A Interval: 24000 operating hoursConnecting rod Replace connecting rod screws 11.4.5

Replace connecting rod screws at the latest every 24000operating hrs with new ones.

07.

Crankshaft Inspect crankshaftInspect the crankshaft bearing surfaces. Measure the crankpindiameter and ovality.

06.2

Engine fastening bolts Check tightening of engine fastening bolts 07.3

Replace if necessary.

Overspeed trip device General overhaul of overspeed trip device 22.5

Elektro-pneumatic Check function and tripping speed. 22.5.3

Turbocharger Replace turbocharger bearings 15.1.2

See manufactures instructions.

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04.14 B Interval: 24000 operating hours/ after 5 yearsValvemechanism Rocker arm screws, yoke and adjusting screw nuts. 14.1

Replace rocker arm screws, yoke and adjusting screw nuts.

Injection valve yoke Injection valve yoke tension screws.Replace screws.

12.1

Exhaust gas piping Exhaust gas piping support plates, nuts, screws.Replace supports, nuts and screws.

20.1

Control mechanism Replace support bearing bushes and V-rings on fuelcontrol shaft.

22.2

04.15 Interval: 48000 operating hoursTurbocharger Replace rotor 15.1.2

See manufacturers instructions.

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maintenance schedule for wartsila 20 b-c engines wfi 2004n007 02gb

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