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94877302-Wartsila-38 Fds
94877302-Wartsila-38 Fds
INTRODUCTION
The Management of the Service Department of Wärtsilä NSD Nederland B.V. offers you
this Field Service Data Book to support you in your world wide Service activities for W38
engines.
This book must be considered as a supplement to the W38 Engine manual and is intented
to be used by W38 engine trained personnel only.
Validity
Address:
Edition 01
Zwolle
April 1998
FIELD SERVICE
DATA BOOK W38
Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 0.0 Introduction April ‘98
Edition 01
Zwolle
April 1998
FIELD SERVICE
DATA BOOK W38
Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 0.0 Introduction April ‘98
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 owner.
Edition 01
Zwolle
April 1998
FIELD SERVICE
DATA BOOK W38
TABLE OF CONTENTS
ENCLOSURES:
Engine definitions
Operating side
The longitudinal side of the engine where the operating controls are located.
Non–operating side
The longitudinal side opposite of the operating side.
Driving end
The end of the engine where the flywheel is located.
Free end
The end opposite the driving end.
Designation of cylinders
The designation of cylinders begins at the driving end.
Clockwise rotating
Looking against the driving end of the engine the shaft rotates clockwise.
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Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 1.0 Main data April ‘98
Counter–clockwise rotating
Looking against the driving end of the engine the shaft rotates counter–clockwise.
Cylinder numbering
The cylinders are progressively numbered from the flywheel. The cylinder next to the flywheel
has the lowest number.
Combustion sequence
W38-6L : 1-4-2-6-3-5
W38-8L : 1-3-2-5-8-7-6-4
W38-9L : 1-7-4-2-8-6-3-9-5
W38-V12 : A-Bank : 1-2-4-6-5-3
B-Bank : 5-3-1-2-4-6
W38-V16 : A-Bank : 1-3-2-5-8-6-7-4
B-Bank : 8-6-7-4-1-3-2-5
W38-V18 : A-Bank : 1-7-4-2-8-6-3-9-5
B-Bank : 8-6-3-9-5-1-7-4-2
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Engine type Chapter Subject Issue date
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W38-6L : 1-5-3-6-2-4
W38-8L : 1-4-7-6-8-5-2-3
W38-9L : 1-5-9-3-6-8-2-4-7
W38-V12 : A-Bank : 1-3-5-6-4-2
B-Bank : 5-6-4-2-1-3
W38-V16 : A-Bank : 1-4-7-6-8-5-2-3
B-Bank : 8-5-2-3-1-4-7-6
W38-V18 : A-Bank : 1-5-9-3-6-8-2-4-7
B-Bank : 6-8-2-4-7-1-5-9-3
P
p me =
(n * 0,044898)
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DATA BOOK W38
Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 1.0 Main data April ‘98
Derating conditions
Standard conditions :
Nom. Min.
Air temperature engine inlet [°C] 25
Site elevation above sea level [m] 0 -
Barometric pressure [mbar] 1000 -
Charge air cooling :
- Water - Water x
- Water - Air -
- Air -
Temperature of coolant before aircooler [°C] 25 -
Pressure loss before the compressor of the [mbar] 10 -
turbocharger
Relative pressure loss in the aircooler related to [mbar/bar] 40 -
the absolute charge air pressure
Pressure loss exhaust gas after the [mbar] 30 -
turbocharger
1. In case the conditions deviate from the values mentioned in the above table (!!), reduce the
output to prevent overload :
• 1,5 % per °C that inlet air temperature is above the maximum
• 0,5 % per °C that inlet air temperature is below the minimum
• 0,8 % per °C that receiver temperature is above the maximum
• 0,4 % per mbar that resistance in inlet or exhaust system is above nominal
• 0,4 % per ‰ relative pressure loss in the air cooler.
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Engine type Chapter Subject Issue date
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2. Reduce engine load if operating temperatures of lubricating oil, cooling water or exhaust
gas tend o exceed the maximum values.
CAUTION!
2)
The stated specific fuel oil consumption applies to engines at constant
speed without engine driven pumps, operating at ambient reference
conditions ; tolerance +5%
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DATA BOOK W38
Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 1.0 Main data April ‘98
Following values are valid for HFO, MDO, LFO, 600 rpm. For specific engine values see
testbed protocol.
[°C]
Air temperature before air cooler 195
after air cooler 50
Lub. oil temperature before engine 63
after engine 72
HT cooling water temperature before engine
after engine 75
93
LT cooling water temperature
before engine 35
after engine 40
Main bearings Max.
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DATA BOOK W38
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Engine type Chapter Subject Issue date
W38 1.0 Main data April ‘98
[bar]
Charge air pressure 3
Air intake, pressure drop 40
Exhaust gas back pressure 30 mbar max.
Fuel oil pressure before engine 6 nom.
6.5 max.
5 min.
Lubrication oil pressure before engine (after 4 nom.
filter)
Including running-in filter 4.3
High temperature cooling water pressure before 4.6 max.
engine
HT cooling water pressure drop over engine 0.8
Low temperature cooling water pressure before 5 max.
engine
LT cooling water pressure drop over engine 0.4
Heat balance
HFO
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DATA BOOK W38
Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 1.0 Main data April ‘98
Pump data
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DATA BOOK W38
Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 1.0 Main data April ‘98
Valve clearance
For adjusting method and -values, see chapter 09 of the particular Engine Manual.
MDO/LFO contains fewer lubricating particles than HFO. When an HFO-engine is running on
MDO/LFO the valve seat lubrication will be inferior to running on HFO. Therefore the valve
rotator (High speed turnomat) should be replaced (by low speed turnomat) when running more
than 250 hours on MDO/LFO (HFO engine). The only difference between the two valve
rotators is the lower rotation speed of the modified valve rotator.
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Engine type Chapter Subject Issue date
W38 1.0 Main data April ‘98
Attention:
If it is necessary that an engine can run on all fuel qualities without overhaul, It is
recommended to use Nimonic80A exhaust valves and Low speed turnomats
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Engine type Chapter Subject Issue date
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Engine type Chapter Subject Issue date
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Engine dimensions
9604DT642
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Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 1.0 Main data April ‘98
9604DT642
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Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 1.0 Main data April ‘98
turbo charger
E
B E
D C
D C
Engine version A B C D E
6L38 1650 1105 969 610 810
8L38 2075 1387 1065 636 810
9L38 2075 1387 1065 636 810
12V38 1650 1105 860 600 2200
16V38 2075 1387 860 600 2200
18V38 MARINE 2075 1387 860 600 2200
18V38 DPP 2075 1378 1065 636 810
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DATA BOOK W38
Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 1.0 Main data April ‘98
Crankshaft
Crankshaft dimensions
Engine 6L38 8L38 9L38 12V38 16V38 18V38
F 4555 5755 6355 5155 6555 7255
Counter weight
G counter weight
H I
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DATA BOOK W38
Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 1.0 Main data April ‘98
main bearing
450
695
160
Oil sump
Oil sump
6L38 8L38 9L38 12V38 16V38 18V38
J 1120 1120 1120 1370 1370 1370
K 736.5 736.5 736.5 820 820 820
L 4643 5843 6443 5315 6739 7450
L K
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Engine type Chapter Subject Issue date
W38 1.0 Main data April ‘98
Cylinder block
Cylinder block
6L38 8L38 9L38 12V38 16V38 18V38
Length 4455 5655 6255 5210 - 7650
Fly wheel
Fly wheel
6L38 8L38 9L38 12V38 16V38 18V38
Q 1336 1336 1336 1752 1752 1752
R 120 120 120 120 120 120
number of teeth 165 217
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DATA BOOK W38
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Engine type Chapter Subject Issue date
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FIELD SERVICE
DATA BOOK
Wärtsilä NSD Nederland B.V.
W38
Engine type Chapter Subject Issue date
W38 1.1 Fuel and injection system April ‘98
General
For the general descriptions and principle outlines we refer to the maintenance manual W38.
Fuel characteristics
(DM = Distillate marine)
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DATA BOOK
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W38
Engine type Chapter Subject Issue date
W38 1.1 Fuel and injection system April ‘98
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W38
Engine type Chapter Subject Issue date
W38 1.1 Fuel and injection system April ‘98
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W38
Engine type Chapter Subject Issue date
W38 1.1 Fuel and injection system April ‘98
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W38
Engine type Chapter Subject Issue date
W38 1.1 Fuel and injection system April ‘98
Fuel System
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DATA BOOK
Wärtsilä NSD Nederland B.V.
W38
Engine type Chapter Subject Issue date
W38 1.1 Fuel and injection system April ‘98
Viscosity table
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DATA BOOK
Wärtsilä NSD Nederland B.V.
W38
Engine type Chapter Subject Issue date
W38 1.1 Fuel and injection system April ‘98
HP-fuel pumps often give pressure surging in the low pressure fuel lines.
Extra attention is given to the low pressure system of the W38 engine.
Orifices are installed between fuel pump and the low pressure fuel supply lines. To insure that
the surge pressure does not exeed the maximum, you should measure the pressure at the
begin of fuel supply line near the connection with the installation line. In general: the maximum
pressure surge, measured on the W38, should not exceed 21 bar.
The tightness of main delivery valve and constant pressure valve can be checked by means of
the injector test pump. This pump is connected to the high pressure fuel pump by a flexible
hose and check valve. Increase the pressure to 100 bar. Observe the time of the pressure drop
to 70 bar. If this takes less than 5 seconds, the constant pressure valve and/or main delivery
valve have to be renewed.
After the tightness tests, the opening pressure of the constant pressure valve can be checked.
(see picture next page)
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FIELD SERVICE
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W38
Engine type Chapter Subject Issue date
W38 1.1 Fuel and injection system April ‘98
- (1) bracket 5 4
- (2) nut
- (3) testing device
- (4) pressure gauge device
- (5) dial indicator 3
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W38
Engine type Chapter Subject Issue date
W38 1.1 Fuel and injection system April ‘98
Remove the pump connection piece and lift out delivery valve and constant pressure relief
valve. Remove one erosion plug form the pump.
Fasten the bracket.
In this position the condition of the element and the plunger is defined as a secondary pressure
indicating the air leakage by the edges of the plunger.
The commencement of delivery check must only be performed on pumps with acceptable
element condition. The fuel control rack has to be set on full load and the plunger should not be
lifted.
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FIELD SERVICE
DATA BOOK W38
Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 1.2 Lubricating oil system April ‘98
For the general descriptions and pineapple outlines, we refer to the maintenance Manual
W38.
requirements
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FIELD SERVICE
DATA BOOK W38
Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 1.2 Lubricating oil system April ‘98
Requirements (continuation)
Optional box
D1 Without engine driven oil pumps
D2 Engine driven oil pumps
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FIELD SERVICE
DATA BOOK W38
Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 1.2 Lubricating oil system April ‘98
The desired control pressure is adjusted by means of spindle (1). For this purpose the
protective cap has to be removed and the hexagon seal nut unscrewed. The desired control
pressure is set by turning the adjusting spindle ( clockwise turning to increase the pressure,
counter-clockwise turning to reduce the pressure).
With running in filters the pressure should be 4.3 bar and without running in filters 4 bar.
clamping rings
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FIELD SERVICE
DATA BOOK W38
Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 1.2 Lubricating oil system April ‘98
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FIELD SERVICE
DATA BOOK W38
Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 1.3 Starting air system April ‘98
adjustments
13
13 05
05 03
03
07
07 0606 04
04 0101
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FIELD SERVICE
DATA BOOK W38
Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 1.3 Starting air system April ‘98
14 01 02
Adjustable cam
05 03 12 06
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FIELD SERVICE
DATA BOOK W38
Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 1.3 Starting air system April ‘98
Maintenance.
1 For maintenance remove the complete distributor from the engine.
2 In case of a sticking plunger, use a pipe with M8 thread inside to draw the plunger out of
the liner, if necessary.
3 It is recommended not to interchange the positions of the plungers in the distributors.
4 Clean parts and check for wear.
5 If a pilot liner is worn out, press it out it may be necessary to heat the distributor up to
about 200 °C as Loctite is used for fixing and sealing.
6 Clean the bore carefully.
7 Use Loctite 242 for mounting of the liner. The liner openings must correspond to those in
the housing.
8 Check that no Loctite has been left on the inside of the liner.
9 Apply Molykote Past G to the plunger Sliding surface before reassembling. Wipe off the
surplus. Check that the plungers after mounting do not stick.
10 Apply silicon sealant to both sides of the intermediate plate (33). Do not use too much
as the surplus sealant will be forced into the system during tightening.
Starting distributor
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FIELD SERVICE
DATA BOOK W38
Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 1.3 Starting air system April ‘98
Starting valve
MAINTENANCE
1 Remove the holding plate and pull out the valve with control piston.
2 Take off the self locking nut (9) and take off the piston (2).
3 Clean all components.
4 Clean the seat condition of valve and valve housing. If necessary, lap the seats by hand.
See also the instructions for the cylinder head valves in chapter12. Keep the piston on
the valve spindle mounted for support during grinding.
5 Check that the vent holes (04) in the valve housing are open.
6 Lubricate piston and liner with lubricating oil.
7 After reassembling the valve, check that the valve spindle with piston moves smoothly
and closes completely.
8 Check that the O-ring (3) of the valve housing is intact. Lubricate with oil.
9 Renew the copper ring (5) between starting air valve housing and cylinder head.
10 Tighten the bolts (07) to the torque setting (see .......)
7
2
1
9
3
Starting air valve
4 5
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FIELD SERVICE
DATA BOOK W38
Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 1.3 Starting air system April ‘98
System components
01 Main starting valve
02 Flame arrester
03 Starting air valve
04 Starting air distributor
05 Booster for speed governor
06 Air filter
07 Air receiver
08 Pneumatic stop cylinder
09 Blocking valve, when turning gear engaged
10 Valve for automatic draining
12 Drain valve
13 Non return valve
15 Ball valve
17 Stopping valve fuel injection pumps
18 Safety valve
20 Starting valve
21 Emergency stop valve
24 Drain valve
Pipe connections
301 Starting air inlet
302 Control air inlet
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FIELD SERVICE
DATA BOOK W38
Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 1.3 Starting air system April ‘98
Engines which are remotely started after a stand still period of a certain time, can be
provided with a slow turning device. This system turns the crankshaft automatically two
revolutions prior to the actual starting procedure. The intention of this device is to protect the
engine if there is water, oil or fuel in a cylinder, at remote starting.
The slow turning procedure, which controlled by the LCS, should take place every two hours
with a maximum speed of 20 rpm.
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FIELD SERVICE
DATA BOOK W38
Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 1.4 Cooling water system April ‘98
The engine cooling water system consists of cylinder liner, cylinder head, turbo charger and
charge air cooler.
For further general description and principle outlines of the cooling water system, see the
Maintenance Manual W38.
Requirements
The make-up water should be free of any foreign particles and gases. Supplied to the engine
cooling water system it must at least meet the following requirements :
To prevent the formation of rust and scale in the cooling water system, an inhibitor on
nitrate/borate basis should be added to the system through a dosing tank. The use of inhibitors
does not permit zinc in piping, fittings and instrument sensors.
In case of emergency, water up to 500 mg/l (Cl+S) may be used. This water has to be replaced
as soon as possible by required water quality.
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FIELD SERVICE
DATA BOOK W38
Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 1.4 Cooling water system April ‘98
Most suppliers of cooling water additives can provide a test kit for cooling water quality control.
For removing, dismantling, assembling and replacing the cooling water pump, see the
Engine Manual, chapter 1.4 - 17.
Engine type
W38-6L W38-8L W38-9L
LT HT LT HT LT HT
100 300 150 400 200 450
Engine type
W38-12V W38-16V W38-18V
LT HT LT HT LT HT
100 600 150 600 200 900
Flow pressure suction height difference head pump in m- head in acc. with
m 3/h(l/min) bar pressure pressure gauge water column “Johnson” curve
bar in respect to heart
pump
84 / 1400 3.07 -0.04 1 32.7 32.9
100 / 1666 2.74 -0.06 1 29.6 30.0
120 / 2000 2.24 -0.08 1 24.7 25.0
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FIELD SERVICE
DATA BOOK W38
Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 1.4 Cooling water system April ‘98
System components
01 LT section charge air cooler
02 HT section charge air cooler
03 Turbocharger
05 Non-return valve
06 LT cooling water pump, engine driven, (D1/3)
07 HT cooling water pump, engine driven, (D2/3)
Pipe connections
401 HT cooling water inlet
402 HT cooling water outlet
404 HT cooling water vent
405 HT cooling water to preheater
406 HT cooling water from preheater
451 LT cooling water inlet
452 LT cooling water outlet
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FIELD SERVICE
DATA BOOK W38
Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 1.4 Cooling water system April ‘98
Cooler cleaning
The cooler consist of two sections, a water section and an air section.
To clean the film plates in the air section, immerse the stack in a tank containing a solution
made from de-greasing power.
The powder must be non-toxic and free form fire risk. It is most effective when used as a
solution as near boiling point as possible.
Either steam or electric immersion heater may be used to heat the water.
The de-greasing powder should be added to the boiling water, NEVER vice versa, and
agitation of the solution, either by raising and lowering the stack or by means of a jet of steam
or air, will accelerate the washing process.
To clean the tubes in the water section internally use special nylon brushes connected to a rod.
If the scale is hard and too stubborn to remove with these brushes, we recommend the use of
an inhibited acid solvent.
Add the acid to the water solution. Heat the diluted acid to 49°C and immerse the cooler stack
in the tank, observing the effervescence which indicates that the scale is dissolving. If the
effervescence ceases before all the scale is removed it will be necessary to repeat the
process.
This should remove any scale remaining.
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W38 1.4 Cooling water system April ‘98
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W38 1.4 Cooling water system April ‘98
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Engine type Chapter Subject Issue date
W38 1.4 Cooling water system April ‘98
Line engine
Vee engine
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DATA BOOK W38
Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 1.5 Charge air system April ‘98
requirements
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DATA BOOK W38
Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 1.5 Charge air system April ‘98
The Napier EGT turbocharger and the ABB TPL turbocharger are both lubricated with engine
oil. The ABB VTR turbochargers have there own lubricating system.
The compressor section must be cleaned daily by filling the water container with clean water
and flushing during service load.
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DATA BOOK W38
Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 1.5 Charge air system April ‘98
5: Open needle valves on the turbo inlet pipes one by one to check gas coming out with
disconnected supply line, in order to verify free flow.
11: Continue flushing for 5 to 10 minutes. Drain water, if any, must be clean then.
12: Close the needle valves slowly.
13: Close the water valve. Disconnect water supply line!
14: Leave the engine at same load for 5 minutes.
15: Close drain valve of gas outlet casing.
16: Slowly increase engine load and operate engine at service load for about 30
minutes.
17: Check engine parameters to verify cleaning effect.
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Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 1.6 Control system April ‘98
1) Connect the Hand Held Programmer and press any button. Now there will be
shown “Wärtsilä programme” or something like that.
2) By pressing the button 1 and 2 you can go up and down the menu (pressing
escape will always bring you back to the beginning). By pressing the buttons 3 and 4 you can
go to a different menu.
In co-operation with the bridge it is better to reduce the pitch to 0, than turn the speed control
knob two turns to the direction min.revs and remove the wire plug from the 721. you now have
the situation that the back-up is in operation. Bring the speed back to 600 rpm and check the
situation.
Bring the engine to approximate 625 rpm and mark the position, bring the engine to 600 rpm
and place the wire-plug back and turn the speed setting knob to the marked position.
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Engine type Chapter Subject Issue date
W38 1.6 Control system April ‘98
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Engine type Chapter Subject Issue date
W38 1.6 Control system April ‘98
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Engine type Chapter Subject Issue date
W38 1.6 Control system April ‘98
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W38 1.6 Control system April ‘98
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Engine type Chapter Subject Issue date
W38 1.6 Control system April ‘98
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Engine type Chapter Subject Issue date
W38 1.6 Control system April ‘98
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Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 1.6 Control system April ‘98
Menu Dynamics 1
Proportional gain 1
This value represents the P value on the PID. Increasing the gain will increase the P values. This
will affect the response on a transient. If the value is too high it will result in an oscillation.
If the value is too low it will result in high offspeeds on transients.
Integrator rate 1
This value represents the I value on the PID. Increasing the integrator will increase the I value. This
will affect the recovery rate after a transient. If the value is too low the speed will take a long time to
return to its setpoint after a transient, giving an overdamped response.
Derivative ratio 1
This value represents the D value on the PID. Increasing the derivative will increase the D value.
This will affect the load action of the control.
High settings will decrease the derivative function giving the control a PI action.
If the value is too high it will make the system less responsive.
If the value is too low it will make the system oscillate and can not be compensated for with gain or
integrator rate.
Fast proportional gain 1
Fast gain works in conjunction with the window width to provide higher control gain for load
transients outside the window, and lower control gain inside the window at steady state. The base
gain set point defines the control gain inside the window. Outside this window the fast gain is
activated.
Fast gain window width 1
The fast gain window width 1 is in conjunction with the fast proportional gain as described above.
fast gain window is not absolute, but an anticipated value. When the control senses a change in
speed that will cause a speed error exceeding the window width, the control gain is set to the value
determined by the fast proportional gain. This allows the control to act quickly on a transient. When
speed error is returning to zero after a disturbance the control notices the error entering the window
width and automatically reduces control gain to the value determined by proportional gain.
Gain Breakpoint 1 Sets the percent actuator output above which the gain slope becomes
effective.
Gain Slope 1 Gain Slope changes gain as a function of actuator output. Gain slope
operates in conjunction with the gain breakpoint adjustment to increase
or decrease gain when percent actuator output is greater than the
breakpoint.
Speed Filter 1 Speed filter adjusts the cut-off frequency of a low pass filter used on the
speed sensing input.
Torsional Filter 1 Torsional filter is a filter which filters away the torsionals over the clutch.
In this way the control tries to stabilise the torsionals in case they occur.
This is only effective when one speed probe is mounted before the clutch
and one speed probe mounted after the clutch.
Droop 1 This value represents the amount of droop.
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Engine type Chapter Subject Issue date
W38 1.6 Control system April ‘98
Menu Dynamics 2
Two sets of dynamics are available. Switching between both is done by the clutch feedback
discrete input. For further explanation of dynamics 2 please refer to dynamics 1.
Raise Speed Limit The maximum sped reference that is possible during operation.
Lower Speed Limit The maximum speed reference that is possible during operation.
Rated Speed The rated speed reference setpoint.
Idle Speed The idle speed reference setpoint.
Accel Rate rpm/sec Acceleration rate when ramping from idle to rated speed
reference.
Decel Rate rpm/sec Deceleration rate when ramping from rated to idle speed
reference.
Speed Raise Rate Rate in which the speed reference will change in case of giving a
raise speed command. Also the remote speed reference will be
increased with this rate.
Speed Lower Rate Rate in which the speed reference will change in case of giving a
lower speed command. Also the remote speed reference will be
decreased with this rate
4mA Remote Reference The speed reference setpoint when remote speed reference is
enabled at 4 mA input signal.
20mA Remote Reference The speed reference setpoint when remote speed reference is
enabled at 20 mA input signal.
Tach at 4 mA output Speed indication at 4mA output for Tachometer.
Tach at 20 mA output Speed indication at 20 mA output for Tachometer.
Speed Fault Override Indicates the maximum amount of actuator output. In this way you
Time can limit the maximum amount of fuel to the engine.
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Engine type Chapter Subject Issue date
W38 1.6 Control system April ‘98
Start Fuel Limit The start fuel limit sets the maximum actuator output during
start.
Maximum Fuel Limit Indicates the maximum amount of actuator output. In this
way you can limit the maximum amount of fuel to the
engine.
The external fuel limiter allows to set up the fuel limiter schedule as a function of a 4 - 20 mA
signal, the schedule has 5 setpoints.
Fuel Limit Breakpoint A mA input at first setpoint.
Fuel Limit at Breakpoint A Maximum actuator output at first setpoint.
Fuel Limit Breakpoint B mA input at second setpoint.
Fuel Limit at Breakpoint B Maximum actuator output at second setpoint.
Fuel Limit Breakpoint C mA input at third setpoint.
Fuel Limit at Breakpoint C Maximum actuator output at third setpoint.
Fuel Limit Breakpoint D mA input at fourth setpoint.
Fuel Limit at Breakpoint D Maximum actuator output at fourth setpoint.
Fuel Limit Breakpoint E mA input at fifth setpoint.
Fuel Limit at Breakpoint E Maximum actuator output at fifth setpoint.
The torque fuel limiter allows to set up a fuel limit schedule as a function of the actual speed.
The schedule has 5 setpoints.
Torque Lim P1, rpm Speed input at first setpoint.
Torque Lim P1, act (%) Maximum actuator output at first setpoint.
Torque Lim P2, rpm Speed input at second setpoint.
Torque Lim P2, act (%) Maximum actuator output at second setpoint.
Torque Lim P3, rpm Speed input at third setpoint.
Torque Lim P3, act (%) Maximum actuator output at third setpoint.
Torque Lim P4, rpm Speed input at fourth setpoint.
Torque Lim P4, act (%) Maximum actuator output at fourth setpoint.
Torque Lim P5, rpm Speed input at fifth setpoint.
Torque Lim P5, act (%) Maximum actuator output at fifth setpoint.
PID (%) at 4 mA output PID value when 4 mA are given to the PID output signal (for
CPP systems).
PID (%) at 20 mA output PID value when 20 mA are given to the PID output signal
(for CPP systems).
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Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 1.6 Control system April ‘98
Menu display
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Engine type Chapter Subject Issue date
W38 1.6 Control system April ‘98
Menu calibration
Speed #1 (rpm) Displays the speed probe #1 input signal
Speed #2 (rpm) Displays the speed probe #2 input signal
Remote ref. input (mA) Displays the remote speed reference input signal in mA
Charge air input (mA) Displays the charge air input signal in mA
Rack sensor input (mA) Displays the rack sensor input signal in mA
Master/slave input (mA) Displays the master/slave input signal in mA
Menu display 2
Display 2 menu is a true/false monitor. It represents the status of the subject. A TRUE
indicates that the status is true.
For example, minor alarm = true indicates that a minor alarm is present.
Stop/run contact True: run mode selected.
False: stop mode selected.
Idle/rated contact True: rated speed reference selected.
False: idle speed reference selected.
Lower contact True: lower speed reference contact is on.
False: lower speed reference contact is off.
Raise contact True: raise speed reference contact is on.
False: raise speed reference contact is off.
Failsafe override contact True: Failsafe function is on.
False: Failsafe function is off.
M/S Select contact True: Control selected as slave.
False: control selected as master or automatic master/slave
selection. This input has no function if auto master slave
selection is enabled.
Unload contact True: unload sequence is enabled.
False: unload sequence is disabled.
Clutch closed contact True: Clutch is closed (feedback signal) dynamics 2 is
active.
False: clutch is open (feedback signal) dynamics 1 is
active.
Major alarm relay True: relay is on (major alarm present).
False: relay is off.
Minor alarm relay True: relay is on (minor alarm present).
False: relay is off.
Unloaded relay True: relay is on (engine is unloaded to triplevel. Can be
used for clutch open signal).
False: relay is off.
MPU no.1 LED status True: LED is on (indicates speed probe fall).
False: relay if off.
MPU no.2 LED status True: Led is on (indicates speed probe fail).
False: LED is off.
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Engine type Chapter Subject Issue date
W38 1.6 Control system April ‘98
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Engine type Chapter Subject Issue date
W38 1.6 Control system April ‘98
Troubleshooting
The LCS diagnostic package monitors the correct functioning of the I/O boards, engine
sensors/contacts, LCS power supply and communication tasks.
• Set the Local Operator Panel to FULL display mode to show all channel parameters in
GROUP PAGE and ALARM PAGE. CHANNEL PAGE is shown only in full display mode.
• If prompted; check the channel statuses or parameters in either of these pages. However if
the channel number is known; best use the CHANNEL PAGE.
• Refer to document LOCAL OPERATOR PANEL, Operator Guide for detailed information
concerning the use of the Local Operator Panel.
• Although in the LCS documentation all data is included concerning the channels, I/O
boards, termination boards and sensors connections and there relation to each other,
when troubleshooting it is handy to understand this relationship.
For instance; if an alarm is reported, the channel number is displayed in the alarm page. This
channel number enables the trouble-shooter to locate the I/O board, the termination board
and the termination board terminals without consulting additional documentation.
For ZZ = 1-16:
Termination board/terminal number: TB-YYA / terminal ZZ
For ZZ = 17-32:
Termination board/terminal number: TB-YYB / terminal (ZZ - 16)
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Engine type Chapter Subject Issue date
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Engine type Chapter Subject Issue date
W38 1.6 Control system April ‘98
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Engine type Chapter Subject Issue date
W38 1.6 Control system April ‘98
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Engine type Chapter Subject Issue date
W38 1.6 Control system April ‘98
Digital input
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Engine type Chapter Subject Issue date
W38 1.6 Control system April ‘98
Digital input(continuation)
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Engine type Chapter Subject Issue date
W38 1.6 Control system April ‘98
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Engine type Chapter Subject Issue date
W38 1.6 Control system April ‘98
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Engine type Chapter Subject Issue date
W38 1.6 Control system April ‘98
Sensors
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Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 1.6 Control system April ‘98
Sensors(continuation)
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Engine type Chapter Subject Issue date
W38 1.6 Control system April ‘98
I/O board
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Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 1.6 Control system April ‘98
I/O board(continuation)
Communication processor
Symptom Possible cause or solution
MODBUS communication MODBUS converter
failure; ⇒ Converter (U1) power supply fuse (external) is blown.
• Converter LED (1) is off. Replace the fuse (refer to LCS documentation). If the
fuse immediate blows again; the converter is defect.
• Converter LED’s (3) or (4) ⇒ Possibly the converter is defect.
show no activity.
The MODBUS central alarm system.
• Converter LED (3) shows no ⇒ Possibly the MODBUS central alarm system is not
activity. requesting any data from the LCS. Refer to the alarm
system documentation.
• Converter LED (3) shows ⇒ The alarm system is making invalid (non protocol)
activity and; requests to the LCS. Refer to the alarm system
6001 LED documentation.
COMMUNICATION PORT
FAILURE is on.
Not During normal communication occasionally the
e: 6001 LED COMMUNICATION PORT FAILURE
flickers indicating a LCS communication time-out.
This should not result in a MODBUS
communication alarm.
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Engine type Chapter Subject Issue date
W38 1.6 Control system April ‘98
I/O board(continuation)
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Engine type Chapter Subject Issue date
W38 1.6 Control system April ‘98
Power supply
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Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 1.6 Control system April ‘98
GENERAL
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Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 2.3 Operation April ‘98
2.3 Operation
110
100
90
80
LOAD/SPEED IN %
70
60
LOAD
50
SPEED
40
30
20
10
0
135
150
175
240
255
280
310
0
30
45
70
100.2
205.2
TIME IN MIN.
Step time in Speed in Ramp time speed Step Load in % Ramp time Step
min. % in min. load in min.
30 53 1 1 10 10 1
5 100 1 1 0 0.2 -1
30 100 1 1 25 10 1
5 100 1 1 0 0.2 -1
30 100 1 1 35 10 1
5 100 1 1 0 .02 -1
30 100 1 1 50 10 1
5 100 1 1 0 0.2 -1
30 100 1 1 60 10 1
5 100 1 1 0 0.2 -1
30 100 1 1 70 10 1
5 100 1 1 0 0.2 -1
30 100 1 1 80 10 1
5 100 1 1 0 0.2 -1
30 100 1 1 90 10 1
5 100 1 1 0 0.2 -1
30 100 1 1 100 15 1
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Engine type Chapter Subject Issue date
W38 2.3 Operation April ‘98
Running in program(continuation)
The running-in process is mainly intended to wear piston rings on the liners for a properly fit and
sealing.
For a good running-in it is important to vary the load several times. The ring grooves in the piston
have a different tiling angle at each load and conse-quently the piston rings gave different
contact lines to the cylinder liner walls.
Running-in may be performed either on distillate or heavy fuel, using the lubricating oil specified
for the fuel.
After a piston overhaul the piston rings have to slid into new positions and need time to refit. If
the program cannot be followed, do not load the engine fully for at least 4 hours.
After a complete overhaul, if the running-in program cannot be followed, do not load the engine
fully for at least 10 hours.
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ärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 2.4 Maintenance April ‘98
2.4 MAINTENANCE
Bearings(oversize undersize)
1401DT101 X
1401DT102 X
1401DT127 X
1401DT128 X
1401DT129 X
1401DT130 X
1401DT131 X
1401DT132 X
1401DT133 X
1401DT134 X
1401DT135 X
1401DT136 X
1401DT137 X
1401DT138 X
1401DT139 X
1401DT140 X
Standard part
Non standard
Sales part
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ärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 2.4 Maintenance April ‘98
Axial.bearings
1102DT103 X
1102DT104 X
1102DT110 X
1102DT111 X
standard
Non standard
Sales part
Attn:
Undersized axial bearings can be made out of undersized main bearing shells in consultation
with Technical Service WNSD.NLs
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ärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 2.4 Maintenance April ‘98
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ärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 2.4 Maintenance April ‘98
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ärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 2.4 Maintenance April ‘98
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ärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 2.4 Maintenance April ‘98
ATTENTION!
When following this procedure, its very important to carry out ALL four steps!!
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Engine type Chapter Subject Issue date
W38 2.5 Cylinder liner April ‘98
Specification
Honing specification
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Engine type Chapter Subject Issue date
W38 2.5 Cylinder liner April ‘98
Material: GG 30
Attention:
Assemble the anti polishing
ring with the chamfered
side down.
anti polishing
ring
cylinder liner
93
FIELD SERVICE
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Engine type Chapter Subject Issue date
W38 2.6 piston,conn.rod,crankshaft April ‘98
2.6 PISTON
General
bolt
94
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Engine type Chapter Subject Issue date
W38 2.6 piston,conn.rod,crankshaft April ‘98
Connecting rod
95
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Engine type Chapter Subject Issue date
W38 2.6 piston,conn.rod,crankshaft April ‘98
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Engine type Chapter Subject Issue date
W38 2.6 piston,conn.rod,crankshaft April ‘98
Crankshaft specification
The crankshaft hardness may not exceed more than 10% of the average hardness, measured
on the undamaged part of the crankshaft.
Concentricity crankshaft
Maximum deviation between adjacent crank 0.08
97
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Engine type Chapter Subject Issue date
W38 2.6 piston,conn.rod,crankshaft April ‘98
Crankshaft (continuation)
98
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DATA BOOK W38
Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 2.6 piston,conn.rod,crankshaft April ‘98
Radius in way of oil hole : 10 mm, rounded off to the pin(see detail A *)
Check running pattern before start-up with Prussian blue and turning to verify that the pin is not
“barrel shaped”.
Check running pattern after 10 minutes at 20 % load.
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Engine type Chapter Subject Issue date
W38 2.6 piston,conn.rod,crankshaft April ‘98
C
B
100
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W38
Engine type Chapter Subject Issue date
W38 2.7 Cylinder head with valves April ‘98
1) Chris-Marine valve spindle grinder type 75H for use in the lathe.
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W38
Engine type Chapter Subject Issue date
W38 2.7 Cylinder head with valves April ‘98
Direction of rotation: counter clockwise, looking against bottom side of the valve.
• Move the wheel radial to the valve and keep pressure on the stone constantly (Never leave
the wheel).
• Grind until entire seat shows a clearly ground surface (not too shiny).
• Measure valve.
Do not hand-grind valves to seat in cylinder head.
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W38
Engine type Chapter Subject Issue date
W38 2.7 Cylinder head with valves April ‘98
3 0 + 4’
- 0’
30 +4
-0
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W38
Engine type Chapter Subject Issue date
W38 2.7 Cylinder head with valves April ‘98
Inlet:
3) Fit the cooled ring carefully. The ring should be tightened of the bottom of the inlet chamber
of the cylinder head.
4) After cylinder head/seat is back on environmental temperature the seat should be grinded
on correct setting.
Exhaust:
4) After the cooling down of the seat, put slightly some oil = “Super-O-Lube” on the O-ring.
Place on the outer diameter ∅ 144 (make sure that surface is clean and free of grease etc.)
Loctite 290, whereafter fitting the new seat including the O-ring, together in cylinder head
a.s.a.p.
5) After the cooling down of the cylinder head, to environmental temperature, the seat should
be grinded.
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W38
Engine type Chapter Subject Issue date
W38 2.7 Cylinder head with valves April ‘98
- Set the grinding angle for the inlet and exhaust seats of the W38. (since the seats of
the W38 are machined straight and not curved the conversion table on the machine
based on seat diameter is not relevant).
- Adjust the handwheel(3) until the marking(1) on the setting plate is in the middle of
the two border markings(2).
- loosen the two blocking handles (4) and (5) and lower the grinding stone until it is in
the middle of the seating face.
- Fasten the handles (4) and (5)
- Move the gringing stone down towards the starting point by means of the handwheel(3).
- Feed in the grinding wheel 0.05mm.(one notch on the fine-adjustment knob will feed in
0,1mm.).This is to avoid high temperatures during machining.
- Lock the handwheel(3) with knob(7).
- Move slider(8) in “up”-position
105
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W38
Engine type Chapter Subject Issue date
W38 2.7 Cylinder head with valves April ‘98
106
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Engine type Chapter Subject Issue date
W38 2.8 Camshaft and valve drive April ‘98
Camshaft diagram
open close
Adjustment at 8 exhaust inlet exhaust inlet clearance clearance
mm lift exhaust inlet
15°30’ 72 73 61 34 11.2 4.2
14°30’ 71 82 62 35 10.6 4.8
13°30’ 70 71 63 36 10.0 5.4
12°30’ * 69 70 64 37 9.2 5.8
11°30’ 68 69 56 38 9.1 6.5
10°30’ 67 68 66 39 8.0 7.0
9°30’ 66 67 67 40 7.5 7.8
8°30’ 65 66 68 41 6.8 8.2
* Adjustment figures drawn diagram
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Engine type Chapter Subject Issue date
W38 2.8 Camshaft and valve drive April ‘98
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Engine type Chapter Subject Issue date
W38 2.8 Camshaft and valve drive April ‘98
Camshaft part
1 2 3 4
To mount the camshaft gearwheel you can use a hydraulic tool. The pressure that is set on the
tool represents a torque. Every tool is unique and therefor has its own convert table.
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Engine type Chapter Subject Issue date
W38 2.8 Camshaft and valve drive April ‘98
L38 V38
H1 440.10 440.17
H2 484.00 484.14
110
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Engine type Chapter Subject Issue date
W38 2.8 Camshaft and valve drive April ‘98
111
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Engine type Chapter Subject Issue date
W38 2.8 Camshaft and valve drive April ‘98
112
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Engine type Chapter Subject Issue date
W38 2.8 Camshaft and valve drive April ‘98
113
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Engine type Chapter Subject Issue date
W38 2.8 Camshaft and valve drive April ‘98
Place a cylindrical pin in the tooth cap as shown. Turn the shaft and use a dial indicator to obtain
indications. Repeat the procedure and take comparative indications from at least four different
locations.
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Engine type Chapter Subject Issue date
W38 3.0 No-go criteria April ‘98
1
Two piece
piston 2
3
4
Clearance
between new
piston ring and
A
groove.
A: 0.15
0.50
Groove 1. - 0.17
0.15
0.45 Note:
Groove 2. - 0.17 Measering point:
approx.5.0mm from
outer surface.
0.15
0.40
Groove 3. - 0.17
0.06
0.30
Groove 4. - 0.08
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Engine type Chapter Subject Issue date
W38 3.0 No-go criteria April ‘98
Gudgeon pin
hole.
A- 175.04
A
175.05
175.02
Gudgeon pin
10 10 10
diameter. 10 10 10
A- 175.00
174.97
174.99
A A A
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Engine type Chapter Subject Issue date
W38 3.0 No-go criteria April ‘98
Con.rod. D
0.03
Ovality D-E
C
1 2
Big end bore D
diameter 378.057
378.000
A+B+C+D Max.378.057
Min.377.980 The measurement
3
0.05 A+B+C+D
Ovality A-C
4
0.02
Conicity 1-2
should be taken at
Assembled bearing side 1 and 2 of the
360.373
bore big end.
360.40
The conicity is the difference
360.288
between
0.02
1 and 2.
Difference between
B/C
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Engine type Chapter Subject Issue date
W38 3.0 No-go criteria April ‘98
Bore 380.057 93
380.90 147
380.000 202
Conicity,
i.e. difference
in diameters 872
measured at
93 and 202 mm
from top. 0 0.60
Height A- 349.100 B
348.50
349.000
A
Height B- 79.40
79.20
79.60
Anti polisching
ring C
Height C - 81.10
80.70
80.90
wall thichness
D- 10.240 D
10.00
10.193
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Engine type Chapter Subject Issue date
W38 3.0 No-go criteria April ‘98
B- Ø 28.00 Ø 27.50
25 25
Valve guide bore.
A- Ø 30.161 A A
Ø 30.30
Ø 30.134
A- 13.00
B A
12.00 C
B-
C- 1.00
angle D - 29°50’±5’
Max.oscillation of 0.00
valve stam and 0.15
disc. 0.03
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Engine type Chapter Subject Issue date
W38 3.0 No-go criteria April ‘98
angle E - 30°±5’ E
Recess cyl.head
outer bore - Ø 144.025
D
Ø 144.000
Ø 125.000
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Engine type Chapter Subject Issue date
W38 3.0 No-go criteria April ‘98
B- Ø 28.00 Ø 27.50
25 25
Valve guide bore.
A- Ø 30.161 A A
Ø 30.30
Ø 30.134
A- 13.00
B A
12.00 C
B-
C- 1.00
angle D - 29°50’±5’
Max.oscillation of 0.00
valve stam and 0.15
disc. 0.03
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Engine type Chapter Subject Issue date
W38 3.0 No-go criteria April ‘98
Valve drive
A
mechanism. Ø 114.928
Ø 114.75
Valve tappet 1 - Ø 114.893
Ø 115.035
Ø 114,95
Guide diam. 2 - Ø 115.000 A
Ø 50.016
Roller pin bore in Ø 50.05
tappet. 4 - Ø 50.000
Ø 50.105
Ø 50.20
Roller bore 5 - Ø 50.080
Ø 50.000
Ø 49.95
Tappet pin 6 - Ø 49.989
Rocker arm
Ø 85.102
bearing sleeve Ø 85.30
diam.in situ. 9 - Ø 85.050
Ø 85.000
Bearing journal Ø 84.95
diameter 10 - Ø 84.989
122
FIELD SERVICE
DATA BOOK W38
Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 3.0 No-go criteria April ‘98
Yoke
Ø 34.050
Pin diam. 11 - Ø 33.95
Ø 34.034
Ø 34.119
Yoke bore 12 - Ø 34.20
Ø 34.080
123
FIELD SERVICE
DATA BOOK W38
Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 3.0 No-go criteria April ‘98
Copyed from
Length of spring
(Dismantled)
L= 203.00 L
201.50
207.00
124
FIELD SERVICE
DATA BOOK W38
Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 3.0 No-go criteria April ‘98
Max. No – Go
Crankshaft deflection tolerance mm mm
After alignment of the crankshaft, the crankweb deflection limit is : 0.04 0.05
Alignment must be carried out =No – Go.
If power is taken from the free end, the crankweb deflection limit
for the first crank is : 0.08 0.10
Note:
The bending moment in the crankshaft caused by extra weights is
limited as well as the corresponding deflections. In case of extra
weights contact Wärtsilä NSD nederland B.V..
(*)
125
FIELD SERVICE
DATA BOOK W38
Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 3.0 No-go criteria April ‘98
126
FIELD SERVICE
DATA BOOK W38
Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 3.0 No-go criteria April ‘98
Max. No – Go
Aluminium plain bearings wear limits mm mm
The engine bearings consist of a steel back onto which a very tiny
bonding of almost pure Aluminium. On this bonding is a running layer of
Aluminium alloy.
It concerns the bearings for crankshaft, connecting rod big end, and
camshaft.
- Camshaft 7.395
7315
7.375
– the inside diameter is within the given tolerances, until the next Ø 380.447
inspection. - Main bearing Ø 380.30
Ø 380.361
127
FIELD SERVICE
DATA BOOK W38
Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 4.0 mounting instruction April ‘98
1. Lift the engine on the right location, control with foundation screws or with the drillings for
flexible mountings.
2. See fig. 1.
Location of the rubber element and tools
Place the engine on the tools H=100 mm.
Level the engine.
Figure 1
128
FIELD SERVICE
DATA BOOK W38
Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 4.0 mounting instruction April ‘98
3. See fig.2.
Assembly foundation rubber element controlling that the element height difference
x(+s) between the elements will be within 1mm.
Figure 2
129
FIELD SERVICE
DATA BOOK W38
Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 4.0 mounting instruction April ‘98
Figure 3
See fig. 4:assembly of the double foundation rubber elements. Place no. 2,8,13,17 and
20.
NOTE!
Place no. 1 and 4 will be empty.
5. See fig. 3.
Adjust mechanical height limiter on all single foundation rubber elements to 10 mm.
130
FIELD SERVICE
DATA BOOK W38
Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 4.0 mounting instruction April ‘98
Figure 4
6. See fig. 4.
Adjust mechanical height limiter on all double foundation rubber elements to 2 mm.
7. See fig. 5. Install the generator to the engine taking into account that the engine
should be situated 0.7 +−00. 25 mm higher .
8. Check regularly the clearance at the marked places.
When the checked clearance has become 1 mm. less that the recorded clearance ,
then adjust the checked clearance with shims to the recorded clearance .
131
FIELD SERVICE
DATA BOOK W38
Wärtsilä NSD Nederland B.V.
Engine type Chapter Subject Issue date
W38 4.0 mounting instruction April ‘98
Figure 5
132
Service, SWD Engines
Engine section Engine type Ref. Date Issue Document No. Page
1000 General W38 WNL 03.12.1997 00 mr38/1000/01 1(2)
Engine section Engine type Ref. Date Issue Document No. Page
1102 Main Bearing W38 WNL–S 07.03.1997 00 mr38/1102/01 1(2)
25 25
Lower half Upper half
MAIN BEARING SHELL C A C B A
15 15
45° 1 80 45°
1
Main bearing shell nominal thickness: 2 145 145 2
9.835 - 9.810 [mm] code nr. code nr.
3 3
Max. 9.750
4 3
5 5
Bearing number
0 1 2 3 4 5 6 7 8 9
1
Upper A 2
Half 3
4
5
1
B 2
3
4
5
1
C 2
3
4
5
Remarks/Manufact. No.
1
A 2
Lower 3
half 4
5
1
C 2
3
4
5
Remarks/Manufact. No.
Wärtsilä Netherlands b.v. P.O. Box 10608 (hanzelaan 95) Telecop. +31-38-4253538 Tel. +31-38-4253253
Service, Zwolle NL-8000 GB Zwolle Telecop. +31-38-4223564 Telex 42116 swdz nl
Service, WNL Engines
Engine section Engine type Ref. Date Issue Document No. Page
1302 Cylinder liner W38 WNL–S 07.03.1997 00 mr38/1302/01 1(1)
X
Cylinder liner 1
Code number: A
B
40
Component running hours before measurement: 70
4 2
Measured: o Mounted
o Free Temperature (°C): I
92
3 II 147
Nominal diameter = 380.000 – 380.057 [mm] View X 1
III 202
Wear limits: I = 380.9 [mm], II = 380.6 [mm], III, IV +V= 380.3 [mm]
Ovality = 0.1 [mm] (Difference between dmax and d min measured on any level).
Reference diameter (or V/1):
2 IV 568
Antipolishing ring, wall thickness
Nominal thickness = 10.24 – 10.19 [mm], Wear limit = 10.10 [mm]
Measure with a ball-shaped micrometer on level A and level B. V 872
mark “X”
Component running hours before measurement:
I 1
2
II 1
2
III 1
2
IV 1
2
V 1
2
Remarkss/Manufact No.
Antipolishing ring, wall thickness([mm]
Level A 1
2
3
4
Level B 1
2
3
4
Remarks/Manufact No.
Wärtsilä Netherlands b.v. P.O. Box 10608 (hanzelaan 95) Telecop. +31-38-4253538 Tel. +31-38-4253253
Service, Zwolle NL-8000 GB Zwolle Telecop. +31-38-4223564 Telex 42116 swdz nl
Service, WNL Engines
Engine section Engine type Ref. Date Issue Document No. Page
1401 Connecting rod W38 WNL–S 07.03.1997 00 mr38/1401/01 1(1)
D1 L
D2 L
D3 L
D4 L
D5 L
Max. deviation
Remarks/Manufact. No.
(stamped on conrod)
Gudgeon pin bearing bush mounted [mm]
d1 L
d2 L
Remarks/Manufact. No.
Wärtsilä Netherlands b.v. P.O. Box 10608 (hanzelaan 95) Telecop. +31-38-4253538 Tel. +31-38-4253253
Service, Zwolle NL-8000 GB Zwolle Telecop. +31-38-4223564 Telex 42116 swdz nl
Service, WNL Engines
Engine section Engine type Ref. Date Issue Document No. Page
1401 Connecting rod W38 WNL–S 07.03.1997 00 mr38/1401/02 1(1)
25 25
BIG END BEARING SHELL Lower half
C B A
Upper half
C B A
15 15
Bearing shell nominal thickness: 8.890 - 8.865 [mm] 45° 1
70 70 1
125 125 45°
Max. 8.805 [mm] 2 2
codenr codenr
3 3
4 4
5 5
1
A 2
Lower 3
half 4
5
1
B 2
3
4
5
1
C 2
3
4
5
Remarks/Manufact. No.
Wärtsilä Netherlands b.v. P.O. Box 10608 (hanzelaan 95) Telecop. +31-38-4253538 Tel. +31-38-4253253
Service, Zwolle NL-8000 GB Zwolle Telecop. +31-38-4223564 Telex 42116 swdz nl
Service, WNL Engines
Engine section Engine type Ref. Date Issue Document No. Page
1421 Piston W38 WNL–S 07.03.1997 00 mr38/1421/01 1(1)
A
Piston ring groove height
1 I
Component running hours before measurement:
II
Temperature (°C):
III
IV
Nominal height Wear limit 4 2
(mm) (mm)
Cylinder number
1 2 3 4 5 6 7 8 9
1
A- I 2
Bank 3
4
1
II 2
3
4
1
III 2
3
4
1
IV 2
3
4
Remarks/Manufact. No.
1
I 2
B- 3
Bank 4
1
II 2
3
4
1
III 2
3
4
1
IV 2
3
4
Remarks/Manufact. No.
Wärtsilä Netherlands b.v. P.O. Box 10608 (hanzelaan 95) Telecop. +31-38-4253538 Tel. +31-38-4253253
Service, Zwolle NL-8000 GB Zwolle Telecop. +31-38-4223564 Telex 42116 swdz nl
Service, WNL Engines
Engine section Engine type Ref. Date Issue Document No. Page
1421 Piston W38 WNL–S 22.12.1997 00 mr38/1421/02 1(1)
Inspection method:
reduced / extensive
Wärtsilä Netherlands b.v. P.O. Box 10608 (hanzelaan 95) Telecop. +31-38-4253538 Tel. +31-38-4253253
Service, Zwolle NL-8000 GB Zwolle Telecop. +31-38-4223564 Telex 42116 swdz nl
Service, WNL Engines
Engine section Engine type Ref. Date Issue Document No. Page
1421 Gudgeon pin W38 WNL–S 22.12.1997 00 mr38/1421/03 1(1)
GUDGEON PIN
Wärtsilä Netherlands b.v. P.O. Box 10608 (hanzelaan 95) Telecop. +31-38-4253538 Tel. +31-38-4253253
Service, Zwolle NL-8000 GB Zwolle Telecop. +31-38-4223564 Telex 42116 swdz nl
Service, WNL Engines
Engine section Engine type Ref. Date Issue Document No. Page
1501 Inlet-/exhaustvalve W38 WNL–S 07.03.1997 00 mr38/1501/01 1(1)
VALVE GUIDES
25 25
I II
air in exh.out
D inlet D
exhaust
A D
B C
Valve guide nominal diameter: 30.161 - 30.134 [mm]
Wear limit: 30.30 [mm]
bottom view
Cylinder nr.
Bank:
1 2 3 4 5 6 7 8 9
A I
Inlet II
B I
II
C I
Exhaust II
D I
II
Remarks / Manufact Nr.
Wärtsilä Netherlands b.v. P.O. Box 10608 (hanzelaan 95) Telecop. +31-38-4253538 Tel. +31-38-4253253
Service, Zwolle NL-8000 GB Zwolle Telecop. +31-38-4223564 Telex 42116 swdz nl
Service, WNL Engines
Engine section Engine type Ref. Date Issue Document No. Page
1501 Injection valve W38 WNL–S 22.12.1997 00 mr38/1501/02 1(2)
........................
Wärtsilä Netherlands b.v. P.O. Box 10608 (hanzelaan 95) Telecop. +31-38-4253538 Tel. +31-38-4253253
Service, Zwolle NL-8000 GB Zwolle Telecop. +31-38-4223564 Telex 42116 swdz nl
III Bad
Service, WNL Engines
Engine section Engine type Ref. Date Issue Document No. Page
1504 Inlet-/exhaustvalve W38 WNL–S 07.03.1997 00 mr38/1504/01 1(1)
Valves
air in exh.out
I II III Z
Stampings
Y
A D
Nominal diameter: 30.000 - 29.979 mm.
B C
Wear Limit: 29.900 mm. Stem stampings Valve locations
I : 66 mm
III : 325 mm
Cylinder Nr.
1 2 3 4 5 6 7 8 9
I
II
I A III
N Z
L Y
E I
T II
B III
E II
X C III
H Z
A Y
U I
S II
T D III
Wärtsilä NSD Nederland b.v. P.O. Box 10608 (hanzelaan 95) Telecop. +31-38-4253538 Tel. +31-38-4253253
Service, Zwolle NL-8000 GB Zwolle Telecop. +31-38-4223564 Telex 42116 swdz nl
Service, WNL Engines
Engine section Engine type Ref. Date Issue Document No. Page
2103 Camshaft bearing W38 WNL–S 03.12.1997 00 mr38/2103/01 1(1)
Camshaft Bearing
Nominal diameter : D = 250,24-250,31 Towards Towards
flywheel end flywheel end
Wear limit : Dmax= 250,4 (B-bank) (in Line or A-bank)
Reference diameter : D = 250
Remarks
Wärtsilä NSD Nederland b.v. P.O. Box 10608 (hanzelaan 95) Telecop. +31-38-4253538 Tel. +31-38-4253253
Service, Zwolle NL-8000 GB Zwolle Telecop. +31-38-4223564 Telex 42116 swdz nl
FIELD SERVICE
DATA BOOK W38
P V
Piston Valve clearance, 16
general, 94 Valve seats
Power supply, 82 grinding, 105
Pressure surges valve seats
in low pressure fuel system, 32 replacing, 104
Pump data, 15 valve timing, 16
Pump pressures drops, 47
W
R Wear limit
Relay output channels, 76 exhaust and inlet valve spring, 124
repair of a damaged crankshaft, 99 Wear limits
Running-in program W38, 84 aluminium plain bearings, 127
cilinder liner, 117
S connecting rod, 116
Sensors, 77 exhaust valve and seat, 118
Slow turning device, 44 inlet valve and seat, 120
small eye bearing, assembly, 96 piston and piston rings, 114
FIELD SERVICE
DATA BOOK W38