W38

INFORMATIVE COPY OF THE FIELD SERVICE DATA BOOK

For Informative use only For engine related data please contact our Service Department

FIELD SERVICE DATA BOOK W38
Wärtsilä NSD Nederland B.V. Engine type W38 Chapter 0.0 Subject Introduction Issue date April ‘98

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 In case any technical data differs from those of the engine manual or parts catalogue, the engine related engine manual or parts catalogue is normative. In case of doubt or if you have any questions, please contact the Technical Service Group of the NSD NL Service Department in Zwolle, The Netherlands

Address: Wärtsilä NSD Nederland BV, Office: Hanzelaan 95, 8017 JE Zwolle, P.o. box 10608 8000 GB Zwolle, The Netherlands. Tel. :(+31) (0)38 4253253, Fax :(+31) (0)38 4223564 E-mail : martin.swart@zwolle.wartsila.infonet.com

Edition 01 Zwolle April 1998

FIELD SERVICE DATA BOOK W38
Wärtsilä NSD Nederland B.V. Engine type W38 Chapter 0.0 Subject Introduction Issue date April ‘98

A BRIEF HISTORY OF THE
The W38 is a medium speed 4stroke diesel engine with turbocharger, inter-cooler, trunk pistons and direct fuel injection. Every cylinder head is equipped with two inlet and two exhaust valves. This engine type is built in 6, 8 and 9 cylinders in-line and 12, 16 and 18 in vee. Main design goals for the W38 were made in the late eighties. Required in the engine program was a design with a output range of 660 kW per cylinder, medium speed of 600 rpm and bore/stroke 380/475 mm. Fuel is specified as gas, dual fual, marine and heavy fuel. All versions are built in clockwise or anti-clockwise rotating execu-tion. Applications are: main propulsion engine, base load generator and industrial operation.

W38 ENGINE

Edition 01 Zwolle April 1998

taping or other information retrieval systems) without the prior written permission of the copyright owner. THIS PUBLICATION IS DESIGNED TO PROVIDE AN ACCURATE AND AUTHORITATIVE INFORMATION WITH REGARD TO THE SUBJECT-MATTER COVERED AS WAS AVAILABLE AT THE TIME OF PRINTING. mechanical. recording. THE PUBLISHER AND COPYRIGHT HOLDER SHALL UNDER NO CIRCUMSTANCES BE HELD LIABLE FOR ANY FINANCIAL CONSEQUENTIAL DAMAGES OR OTHER LOSS. THE PUBLISHER AND COPYRIGHT OWNER OF THIS PUBLICATION CAN NOT ACCEPT ANY RESPONSIBILITY OR LIABILITY FOR ANY EVENTUAL ERRORS OR OMISSIONS IN THIS BOOKLET OR FOR DISCREPANCIES ARISING FROM THE FEATURES OF ANY ACTUAL ITEM IN THE RESPECTIVE PRODUCT BEING DIFFERENT FROM THOSE SHOWN IN THIS PUBLICATION. Edition 01 Zwolle April 1998 . graphic. OR ANY OTHER DAMAGE OR INJURY.0 Subject Introduction Issue date April ‘98 © Copyright 1998 by Wärtsilä NSD Nederland B.V. CONSEQUENTLY. Engine type W38 Chapter 0. THE PUBLICATION DEALS WITH COMPLICATED TECHNICAL MATTERS SUITED ONLY FOR SPECIALISTS IN THE AREA AND THE DESIGN OF THE SUBJECT-PRODUCTS IS SUBJECT TO REGULAR IMPROVEMENTS. MODIFICATIONS AND CHANGES. photocopying.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.V. No part of this publication may be reproduced or copied in any form or by any means (electronic. All rights reserved. HOWEVER. SUFFERED BY ANY PARTY MAKING USE OF THIS PUBLICATION OR THE INFORMATION CONTAINED HEREIN.

LFO : AIR CONSUMPTION AND GASFLOWS MAIN OPERATING TEMPERATURES AND PRESSURES HEAT BALANCE PUMP DATA STANDARD VALVE TIMING VALVE CLEARANCE ENGINE CONFIGURATION AT VARIOUS USE OF FUEL WEIGHTS OF ENGINE PARTS ENGINE DIMENSIONS DIMENSIONS OF MAIN PARTS DIMENSIONS AND WEIGHTS OF SPARE PARTS 1. MDO/LFO) DERATING CONDITIONS FUEL CONSUMPTION AT HFO. BRANDS 1 1 2 2 7 8 8 8 10 11 12 13 13 14 15 16 16 16 17 19 21 25 26 26 26 30 30 31 32 32 34 35 35 36 37 38 38 .0 GENERAL DATA TABLE OF CONTENTS SYMBOLS FOR DRAWINGS AND DIAGRAMS SYMBOLS FOR UNITS VISCOSITY TORQUES FOR BOLTS AND NUTS (GENERAL) 1.0 MAIN DATA CHARACTERISTICS ENGINE DEFINITIONS CYLINDER OUTPUT AND MEAN EFFECTIVE PRESSURE (AT HFO.2 LUBRICATING OIL SYSTEM REQUIREMENTS INTERNAL LUBRICATING OIL SYSTEM.1 FUEL AND INJECTION SYSTEM FUEL REQUIREMENTS (ISO) FUEL CHARACTERISTICS FUEL SYSTEM INTERNAL FUEL SYSTEM VISCOSITY TABLE PRESSURE SURGES IN LOW PRESSURE FUEL SYSTEM TESTING THE DELIVERY VALVE AND THE CONSTANT PRESSURE VALVE FUEL PUMP CONDITION CHECK 1. DIAGRAM ADJUSTMENT OF LUBRICATING OIL PUMP POSITIONING OF THE LUBRICATING OIL PUMP LUBRICATING OIL.FIELD SERVICE DATA BOOK W38 TABLE OF CONTENTS 0.MDO.

5 CILINDER LINER SPECIFICATION ANTI POLISHING RING 2.6 CONTROL SYSTEM HANDLING THE 721 HAND HELD PROGRAMMER CHECKING THE PGA IN THE ENGINE 721 SOFTWARE SETTINGS FOR DIESEL POWER PLANTS SOFTWARE SETTINGS MARINE ENGINES MENU FUEL LIMITERS EXPLANATIONS ON 721 SOFTWARE SETTINGS TROUBLESHOOTING COMMUNICATION PROCESSOR 2.FIELD SERVICE DATA BOOK W38 1.CHARGE AIR SYSTEM REQUIREMENTS CHARGE AIR SYSTEM SCHEDULE SPECIFICATION OF EXHAUST GAS LUBRICATING THE TURBOCHARGER WATER WASHING THE TURBOCHARGER VTR 354/454 1.3 OPERATION RUNNING-IN PROGRAM W38 (COMPLETE OVERHAUL) 2.4 COOLING WATER SYSTEM REQUIREMENTS COOLING WATER CONTROL COOLING WATER CONTENTS COOLING WATER SYSTEM SCHEDULE PUMP PRESSURES DROPS COOLER CLEANING APPROVED COOLING WATER ADDITIVES POSITIONING COOLING WATER PUMPS COOLING WATER PUMPS.4 MAINTENANCE BEARINGS(OVERSIZE UNDERSIZE) TIGHTENING TORQUE’S FOR THE VARIOUS ENGINE PART CONNECTIONS TIGHTENING PROCEDURE AND HYDRAULIC JACK PRESSURES 2. CHARACTERISTICS 1. SCHEDULE SLOW TURNING DEVICE 1.6 PISTON GENERAL DATA TIGHTENING OF PISTON CROWN 39 39 40 41 42 43 44 45 45 46 46 47 47 48 49 50 51 52 52 52 53 53 53 55 55 55 55 59 61 62 69 80 84 84 86 86 88 91 92 92 93 94 94 94 .5.3 STARTING AIR SYSTEM ADJUSTMENTS ADJUSTMENT STARTING CAM STARTING AIR DISTRIBUTOR STARTING VALVE STARTING AIR SYSTEM.

9. Measurement record for main bearing shell. 8. Measurement record for Operating data (Dutch. 4. 3. Measurement record for cylinder liner. Measurement record for injection valve test. Measurement record for piston ring grooves. 12.0 NO . Measurement record for big-end bearing bore. 11. English not available) 2.0 MOUNTING INSTRUCTION FOR FLEXIBLE MOUNTED ENGINE 95 95 96 97 101 101 105 107 107 109 109 110 113 114 114 115 116 117 118 120 122 124 125 127 128 ENCLOSURES: 1. .FIELD SERVICE DATA BOOK W38 CONNECTING ROD DISASSEMBLY OF SMALL EYE BEARING ASSEMBLY OF SMALL EYE BEARING CRANKSHAFT SPECIFICATION 2. Measurement record for cylinder heads.7 CYLINDER HEAD WITH VALVES GRINDING INLET AND EXHAUST VALVES GRINDING THE VALVE SEATS 2. Measurement record for piston crown. 7. Measurement record for big-end bearing shell. Measurement record for valve guides. CRANKSHAFT DEFLECTION TOLERANCE ALUMINIUM PLAIN BEARINGS WEAR LIMITS 4. Measurement record for gudgeon pin. Measurement record for camshaft bearing. 5.8 CAMSHAFT AND VALVE DRIVE CAMSHAFT DIAGRAM CAMSHAFT PART MOUNTING OF CAMSHAFT GEARWHEEL GEARWHEEL CLEARANCES AND DIMENSIONS GENERAL ROUNDNESS CHECK FOR GEARWHEELS 3. 6. 10.GO CRITERIA FOR ENGINE PARTS PISTON AND PISTON RING WEAR LIMITS PISTON GUDGEON PIN WEAR LIMITS CONNECTING ROD WEAR LIMITS CYLINDER LINER WEAR LIMITS EXHAUST VALVE AND SEAT WEAR LIMITS INLET VALVE AND SEAT WEAR LIMITS VALVE DRIVE MECHANISM WEAR LIMITS EXHAUST AND INLET VALVE SPRING.

16.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.9 l/cyl. 8 . 9 cylinders in line 12. 8.0 Subject Main data Issue date April ‘98 1. Clockwise rotating Looking against the driving end of the engine the shaft rotates clockwise. Engine type W38 Chapter 1. Non–operating side The longitudinal side opposite of the operating side. Designation of cylinders The designation of cylinders begins at the driving end. 18 cylinders in Vee Vee-angle : 50° Maximum cylinder pressure :180 (210) bar Pressure charging air : 3 bar Engine definitions Operating side The longitudinal side of the engine where the operating controls are located.0 MAIN DATA Characteristics (main data) Type Cylinder bore Stroke Swept volume Configuration : Four stroke with direct injection : 380 mm : 475 mm : 53. : 6. Driving end The end of the engine where the flywheel is located.V. Free end The end opposite the driving end.

The cylinder next to the flywheel has the lowest number.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. Cylinder numbering The cylinders are progressively numbered from the flywheel.V. Engine type W38 Chapter 1. W38-6L W38-8L W38-9L W38-V12 W38-V16 W38-V18 : : : : : : : : : 1-4-2-6-3-5 1-3-2-5-8-7-6-4 1-7-4-2-8-6-3-9-5 1-2-4-6-5-3 5-3-1-2-4-6 1-3-2-5-8-6-7-4 8-6-7-4-1-3-2-5 1-7-4-2-8-6-3-9-5 8-6-3-9-5-1-7-4-2 : : : A-Bank B-Bank A-Bank B-Bank A-Bank B-Bank 9 . Combustion sequence Normal rotating engine: (Clockwise as viewed from the flywheel side).0 Subject Main data Issue date April ‘98 Engine definitions (continuation) Counter–clockwise rotating Looking against the driving end of the engine the shaft rotates counter–clockwise.

(Counter clockwise as viewed from the flywheel side).V.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.044898) = = Output per cylinder [kW] Engine speed [rpm] 10 .0 Subject Main data Issue date April ‘98 Engine definitions (continuation) Reverse rotation. Engine type W38 Chapter 1.5 The Break Mean Effective Pressure can be calculated as follows : p me = P n P (n * 0. W38-6L W38-8L W38-9L W38-V12 W38-V16 W38-V18 : : : : : : : : : 1-5-3-6-2-4 1-4-7-6-8-5-2-3 1-5-9-3-6-8-2-4-7 1-3-5-6-4-2 5-6-4-2-1-3 1-4-7-6-8-5-2-3 8-5-2-3-1-4-7-6 1-5-9-3-6-8-2-4-7 6-8-2-4-7-1-5-9-3 : : : A-Bank B-Bank A-Bank B-Bank A-Bank B-Bank NOTE : Interval between A1 and B1 = 360° (Crankshaft) + 50° (Vee-angle) Cylinder output and Mean effective pressure (at HFO. MDO/LFO) Engine speed [rpm] 600 Fuel type HFO/MDO/LFO Cylinder output (MCR) [kW] 660 Mean effective pressure [bar] 24.

5 % per °C that inlet air temperature is above the maximum • 0.Air . 25 0 1000 x 25 10 40 30 Min. Relative pressure loss = pressure loss air cooler in mbar [‰] absolute charge air pressure 11 . reduce the output to prevent overload : • 1. - Air temperature engine inlet Site elevation above sea level Barometric pressure Charge air cooling : .0 Subject Main data Issue date April ‘98 Derating conditions Standard conditions : Nom.Air Temperature of coolant before aircooler Pressure loss before the compressor of the turbocharger Relative pressure loss in the aircooler related to the absolute charge air pressure Pressure loss exhaust gas after the turbocharger [°C] [m] [mbar] [°C] [mbar] [mbar/bar] [mbar] - 1.Water .8 % per °C that receiver temperature is above the maximum • 0.V.5 % per °C that inlet air temperature is below the minimum • 0. In case the conditions deviate from the values mentioned in the above table (!!).Water .4 % per mbar that resistance in inlet or exhaust system is above nominal • 0.4 % per ‰ relative pressure loss in the air cooler. Engine type W38 Chapter 1.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.Water .

tolerance +5% 12 .reduction of charge air pressure by 5% : -contamination of the turbocharger compressor and/or turbine -contamination of the air side of the cooler -contamination of the air in take filter -too much wear of the turbine. Thermal overload may be caused by .Too high engine load . Engine type W38 Chapter 1.deviation of setting of (individual) high pressure fuel pumps .FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.Too high aspirated air temperature .MDO. cooling water or exhaust gas tend o exceed the maximum values. operating at ambient reference conditions . Reduce engine load if operating temperatures of lubricating oil. .0 Subject Main data Issue date April ‘98 Derating conditions (continuation) 2.V.LFO : 6L38 [g/kWh] Fuel oil(2) 100 % 75 % 2) 8L38 [g/kWh] 178 179 9L38 [g/kWh] 178 179 12V38 [g/kWh] 177 178 16V38 [g/kWh] 177 178 18V38 [g/kWh] 177 178 178 179 The stated specific fuel oil consumption applies to engines at constant speed without engine driven pumps.Too high charge temperature due to contaminated charge air cooler CAUTION! NEVER CHANGE THE INDIVIDUAL FUEL RACK SETTINGS TO REDUCE THE EXHAUST GAS TEMPERATURE ! Fuel consumption at HFO.Worn high pressure fuel pumps .

3 Combustion air flow at 100% load 7.7 18.6 HFO Exhaust gas [kg/s] quantity 8. Unit [kg/s] 6L38 8L38 9L38 12V38 16V38 20. For specific engine values see testbed protocol. Engine type W38 Chapter 1.5 1. 21.5 consumption will Main operating temperatures and pressuresError! Bookmark not defined.7 15.3 23.0 Subject Main data Issue date April ‘98 Air consumption and gasflows All values are for an engine speed of 600 rpm.8 2. MDO.V. [°C] 195 50 63 72 75 93 35 40 Air temperature before air cooler after air cooler Lub. LFO. Following values are valid for HFO.9 16.2 2.MDO.4 9.0 16. In case of the slow turning option the increase.LFO *Starting conditions 30 bar.0 at 100% load HFO Exhaust gas [kg/s] quantity 6.8 10. 13 . oil temperature before engine after engine HT cooling water temperature before engine after engine LT cooling water temperature before engine after engine Main bearings Max.7 18V38 23.4 11.7 12.7 HFO. 600 rpm.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.3 1. 20° C.5 8.7 12.9 at 75% load HFO Air consumption [Nm3] per start 1.0 1.0 10.

4 Charge air pressure Air intake.8 5 max.0 Subject Main data Issue date April ‘98 Main operating temperatures and pressures: (continuation) [bar] 3 40 30 mbar max. 5 min. 6 nom.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. 6.V. 0.3 4.6 max. 0.5 max. Engine type W38 Chapter 1. 4. 4 nom. pressure drop Exhaust gas back pressure Fuel oil pressure before engine Lubrication oil pressure before engine (after filter) Including running-in filter High temperature cooling water pressure before engine HT cooling water pressure drop over engine Low temperature cooling water pressure before engine LT cooling water pressure drop over engine Heat balance All values are stated in Kilowatts (kW) Engine type Engine speed [rpm] HFO Engine output High temperature cooling water Jacket cooling Charge air cooler Low temperature cooling water Charge air cooler Lubricating oil Radiation engine only 3960 1475 750 780 5280 1970 1000 1040 5940 2215 1125 1170 7920 2950 1270 1300 10560 3930 1700 1730 11880 4430 1910 1950 6W38 600 8W38 600 9W38 600 12W38 600 16W38 600 18W38 600 430 405 72 570 540 96 625 610 108 830 1065 120 1105 1420 160 1245 1600 180 14 .

6 4. Engine type W38-6L W38-8L W38-9L W38-12V W38-16V W38-18V Output HT pump [m3/h] 84 112 126 132 176 198 Output LT pump [m3/h] 84 112 126 168 168 168 Engine type W38-6L W38-8L W38-9L W38-12V W38-16V W38-18V Output main engine driven lubricatingpump [m3/h] 101 140 159 179 228 254 Prelubricating pump [m3/h] 30 40 45 54 69 77 Engine type W38-6L W38-8L W38-9L W38-12V W38-16V W38-18V Booster pump head 6 bar at 2mm2/s [m3/h] 1.8 5.6 2.4 1.9 2.6 10.2 9.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.4 7.0 Subject Main data Issue date April ‘98 Pump data All values are for an engine speed of 600 rpm.V.8 15 .3 1.9 Circulating pump head 6 bar at 2mm2/s [m3/h] 3.0 1. Engine type W38 Chapter 1.

Journals order the position of combustion configuration.V.0 mm For adjusting method and -values. Engine configuration at various use of fuel MDO/LFO contains fewer lubricating particles than HFO.between exhaust valve stem and rocker arm is : 1. Opening of the inlet valves 70° [degrees before TDC] Closing of the inlet valves 37° [degrees after BDC] Opening of the exhaust valves 69° [degrees before BDC] Closing of the exhaust valves 64° [degrees after TDC] Injection timing 12°30’ [degrees before TDC] *For valve timing. Valve clearance The nominal valve clearance for engine : . When an HFO-engine is running on MDO/LFO the valve seat lubrication will be inferior to running on HFO.between inlet valve stem and rocker arm is : 1. 16 .FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. see testbed protocol.0 Subject Main data Issue date April ‘98 Standard valve timing * Engine speed of 600 rpm The standard valve timing is the same for all cylinders. see chapter 09 of the particular Engine Manual. The only difference between the two valve rotators is the lower rotation speed of the modified valve rotator. Engine type W38 Chapter 1. The camshaft contents of several camshaft-modules. 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).0 mm .

FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.V. Engine type W38 Chapter 1. Parts Cylinder block Oil sump Crankshaft Vibrationdamper Geislinger Vibrationdamper Hasse & Wrede Vibrationdamper camshaft Fly wheel Bracket turbocharger Charge aircooler Silencer 6L38 15500 1175 5070 635 1050 1684 496 2200 8L38 18700 1725 6400 635 1050 2000 720 2350 9L38 20500 1850 7070 715 792 76 1050 2000 720 3980 12V38 19500 1555 5735 1168 750 16V38 26000 2285 7295 750 18V38 37000 2450 8070 1517 1365 76 750 1400 4700 720 4950 720 5350 17 .0 Subject Main data Issue date April ‘98 Engine configuration at various use of fuel (continuation) For HFO use (standard): Nimonic80A exhaust valve High speed turnomat For temporary LFO/MDO (>250 hours) use: Nimonic80A exhaust valve Low speed turnomat For DMC quality fuel use: Nimonic exhaust valve Low speed turnomat (There is a risk of LFO behaviour when a high quality DMC fuel is used) 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 Weights of engine parts All values are stated in kg.

Engine type W38 Chapter 1.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.0 Subject Main data Issue date April ‘98 Weights of engine parts (continuation) Parts Main bearingcap counter weight small counter weight large Cylinderhead Valve drive mechanism Piston Gudgeon pin Connecting rod lower part Connecting rod Cylinder liner Turbo ABB VTR 354 Turbo ABB VTR 454 Governor Weight 250 140 159 630 84 136 54 160 115 590 1800 3400 70 Parts Camshaft Camshaft journal small Camshaft journal large Fuel pump Fuelinjector holder Governor drive Lubrication oil pump LT Coolingwater pump HT Coolingwater pump Exhaust pipe Turbo ABB TPL 69 Turbo ABB NA 457 Weight 135 25 55 59 16 100 148 122 122 80 1300 2050 18 .V.

FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.0 Subject Main data Issue date April ‘98 Engine dimensions 9604DT642 Engine A 6L38 8L38 9L38 Dimensions [mm] B C D E F G H K L 2678 2978 2978 Mass. Engine type W38 Chapter 1.V. dry [t] M 2880 3207 3207 N 2703 2305 2305 50 67 72 6320 5010 3000 4643 1205 700 7717 6214 4200 5843 1305 800 8316 6810 4800 6443 1305 800 782 1030 856 1057 1040 936 1057 1040 936 19 .

dry [t] Overhaul dimensions [mm] R S 1980 1970 2300 2200 1950 12V38 16V38 18V38 7660 9060 9760 84 104 117 Camshaft gear wheel Intermediate gear Connecting rod caps Main bearing cap Hoisting tool main bearing jack 1980 and 1970 and 2300 or 2200 or 1950 or Remark * Subject to changes.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.0 Subject Main data Issue date April ‘98 Engine dimensions (continuation) 9604DT642 Engine Dimensions [mm] A B 6245 7645 8345 C 3500 4900 5600 L* 2930 3210 3210 Mass. 20 . Engine type W38 Chapter 1.V.

FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.V. Engine type W38 Chapter 1.0 Subject Main data Issue date April ‘98 Dimensions of main parts turbo charger B A E D C B E D Charge air cooler Marine L38 DPP L38 + 18V38 C Charge air cooler Marine V38 DPP 12V38 + 16V38 Engine version 6L38 8L38 9L38 12V38 16V38 18V38 MARINE 18V38 DPP A 1650 2075 2075 1650 2075 2075 2075 B 1105 1387 1387 1105 1387 1387 1378 C 969 1065 1065 860 860 860 1065 D 610 636 636 600 600 600 636 E 810 810 810 2200 2200 2200 810 21 .

5 100 100 100 Engine type Counter weight G H I V Big 400 990 105 G counter weight H I 22 .FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.V.5 1072. Engine type W38 Chapter 1.0 Subject Main data Issue date April ‘98 Dimensions of main parts(continuation) Crankshaft Crankshaft dimensions 8L38 9L38 12V38 5755 6355 5155 Engine F 6L38 4555 16V38 6555 18V38 7255 F Counter weight Counter weight dimensions L Small Big Small 365 365 400 760 799.

Engine type W38 Chapter 1.5 736.0 Subject Main data Issue date April ‘98 Dimensions of main parts (continuation) main bearing 450 695 160 Oil sump Oil sump 8L38 9L38 12V38 1120 1120 1370 736.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.5 820 5843 6443 5315 J K L 6L38 1120 736.5 4643 16V38 1370 820 6739 18V38 1370 820 7450 J L K 23 .V.

0 Subject Main data Issue date April ‘98 Dimensions of main parts (continuation) Cylinder block Cylinder block 9L38 12V38 6255 5210 Length 6L38 4455 8L38 5655 16V38 - 18V38 7650 Fly wheel Fly wheel 8L38 9L38 1336 1336 120 120 165 Q R number of teeth 6L38 1336 120 12V38 1752 120 16V38 1752 120 217 18V38 1752 120 Q R 24 .FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. Engine type W38 Chapter 1.V.

FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.0 Subject Main data Issue date April ‘98 Dimensions and weights of spare parts 25 . Engine type W38 Chapter 1.V.

Max.0 0.1 Subject Fuel and injection system Issue date April ‘98 1. Fuel characteristics (DM = Distillate marine) Characteristic Appearance Density at 15°C.3 0. Max. Max. % (v/v) Vanadium.8217 DMX DMA DMB DMC Visual 890 900 920 1. mg/kg Aluminium plus silicon.4 1. (micro method) % (m/m) Ash.01 -6 0 1. Engine type W38 FIELD SERVICE DATA BOOK W38 Chapter 1. [micro method 10% (v/v) distillation bottoms] %( m/m) Carbon residue. % (m/m) Sediment. Max.0 11.winter quality .1 FUEL AND INJECTION SYSTEM Fuel requirements (ISO) General For the general descriptions and principle outlines we refer to the maintenance manual W38.5 5.summer quality Cloud point.3 100 25 Max.0 43 60 60 60 -16 1.10 0.0 45 0. Max. °C Pour point (upper).3 0.3 0. °C Sulphur. 26 .01 0 6 2.V.0 14.5 40 0.3 0. Max. Max. Min.07 0. Max. kg/m3 Kinematic viscosity at 40°C. °C . Max. mg/kg Limit Category ISO . Max.05 0.0 35 0. Min. % (m/m) Cetane number Carbon residue.Wärtsilä NSD Nederland B.5 6.01 0. mm2/s Flash point. Max. % (m/m) Total existent sediment. % (m/m) Water. Min. Max. Max.3 0 6 2.

°C . % (v/v) Sulphur. Max. °C Pour point (upper). mg/kg Total sediment. kg/m3 Kinematic viscosity at 100°C. Max.V. potential.winter quality .0 200 80 0.10 0.10 24 24 14 30 30 14 0.10 22 0.0 500 80 0. Max.10 30 30 18 0.0 60 60 60 30 30 20 0. % (m/m) limit Max.20 30 30 22 0. Max. Max.20 1.0 15. Max. kg/m3 Kinematic viscosity at 100°C. % (m/m) Water. Max. % (v/v) Sulphur. Min. mg/kg Aluminium plus silicon.10 0. Max.10 1.10 300 Characteristic Density at 15°C. % (m/m) Vanadium.8 4.0 5.15 1. Max. % (m/m) Water. mg/kg Aluminium plus silicon.10 27 .summer quality Carbon residue. Min. Max.Wärtsilä NSD Nederland B.5 3. % ( m/m) Ash.winter quality . Max. % (m/m) limit Max. Category ISO .summer quality Carbon residue. Max. Max. mm2/s Flash point.15 1.0 25. Max.0 5.8217 RMA RMB RMC RMD RME 10 10 10 15 25 975 981 985 991 10.0 350 80 0.0 60 60 60 0 6 10 0. Max. °C . Engine type W38 FIELD SERVICE DATA BOOK W38 Chapter 1.0 5.1 Subject Fuel and injection system Issue date April ‘98 Fuel requirements (continuation) (RM = Residual fuels) Characteristic Density at 15°C. Max. mm2/s Flash point.0 600 80 0.0 5. % (m/m) Vanadium.0 35. °C Pour point (upper).0 300 600 80 0. mg/kg Total sediment.0 45.10 30 30 15 0.5 150 80 0. % ( m/m) Ash. Category ISO .8217 RMF RMG RMH RMK RMH 25 35 35 35 45 991 991 1010 991 25. Max. potential. Max. Max. Max.

summer quality Carbon residue. °C Pour point (upper).20 1.L) 35 RMH 45 RM (K. Max.10 22 0.0 55. Max.H) 35 RM (K. mg/kg Aluminium plus silicon.winter quality . Max. °C .0 60 60 30 30 22 0. % (m/m) Water. Max. mm2/s Flash point. % (v/v) Sulphur. kg/m3 Kinematic viscosity at 100°C.0 5.0 600 80 0. Max. mg/kg Total sediment.20 1. Max.0 600 80 0.B. Max.V. Engine type W38 FIELD SERVICE DATA BOOK W38 Chapter 1.Wärtsilä NSD Nederland B.8217 RMK RML RMH RMK RML 45 45 55 55 55 1010 991 1010 45.1 Subject Fuel and injection system Issue date April ‘98 Fuel requirements (continuation) Category ISO .F) 25 RM (G. % (m/m) Vanadium.C) 10 RMD15 RM (E. Min.L) 45 RML 55 Gasoil for emergency engines gasoil or marine gasoil Marine dieseloil or marine dieselfuel LFO LFO MDO MDO Distillate fuels Blended marine dieseloil Intermediate fueloils or thin fueloils or light marine fueloils Distillate fuels with small amount residuum Marine fuel oils or bunker C oils Residual fuels or heavy fuels (HFO) 28 . Max.10 30 30 - Characteristic Density at 15°C. % ( m/m) Ash. Max. % (m/m) limit Max.0 5. potential. DMX DMA DMB BMC RM (A. Max.

max.centrifugal separated on water and dirt . must be conditioned : . Engine requirements LFO MDO Water content max. [%vol] 0.heated or cooled to obtain the correct viscosity range during operation.2 Fineness filter back flushing filter [mm] 5 5 Viscosity min.1 Subject Fuel and injection system Issue date April ‘98 Fuel requirements (continuation) Engine requirements LFO/MDO The fuel. °C 35 65 29 . supplied to the engine. 2 2 2 [mm /s] Recommended injection temp.filtered . Engine type W38 FIELD SERVICE DATA BOOK W38 Chapter 1.Wärtsilä NSD Nederland B.V.

of holes 10 11 Diameter of holes 0. One for engines that run on HFO and one for engines that run on MDO. water and lube oil 30 . The nozzles are cooled and made of nitrated material. Internal fuel system System components 01 Fuel injection pump 02 Fuel injector Pipe connections 101 Fuel inlet 102 Fuel outlet 103 Spill fuel 153 Leak fuel. Fuel type MDO HFO nr.59 Injection angle 145° 155° insert length 42 mm 40 mm For injection timing see chapter 2. The opening pressure of both nozzles is 450 bar.63 0.Wärtsilä NSD Nederland B.1 Subject Fuel and injection system Issue date April ‘98 Fuel System Fuel injector nozzle There are two types of fuel injector nozzles being used for the W38.V.8 camshaft diagram. Engine type W38 FIELD SERVICE DATA BOOK W38 Chapter 1.

V. Engine type W38 FIELD SERVICE DATA BOOK W38 Chapter 1.1 Subject Fuel and injection system Issue date April ‘98 Fuel system (continuation) Viscosity table 31 .Wärtsilä NSD Nederland B.

Wärtsilä NSD Nederland B. Testing the delivery valve and the constant pressure valve The tightness of main delivery valve and constant pressure valve can be checked by means of the injector test pump. the opening pressure of the constant pressure valve can be checked. . After the tightness tests.Mount the pressure gauge device (4) and measuring pin on the cover. To insure that the surge pressure does not exeed the maximum. .Remove one erosion plug. Extra attention is given to the low pressure system of the W38 engine.V. you should measure the pressure at the begin of fuel supply line near the connection with the installation line. Observe the time of the pressure drop to 70 bar. the constant pressure valve and/or main delivery valve have to be renewed. . 32 .Tighten two nuts (2) for keeping the pump in position.Set the control rack to full position (100%). . If this takes less than 5 seconds. Engine type W38 FIELD SERVICE DATA BOOK W38 Chapter 1.Fit the dial indicator (5) into its position in the bracket.1 Subject Fuel and injection system Issue date April ‘98 Fuel system (continuation) Pressure surges in low pressure fuel system HP-fuel pumps often give pressure surging in the low pressure fuel lines. . measured on the W38. (see picture next page) .Mount the pump on a (1) bracked. . should not exceed 21 bar.Remove pump cover with valves. Orifices are installed between fuel pump and the low pressure fuel supply lines. Take care that locating pin fits into the recess. . Increase the pressure to 100 bar.Mount cover of testing device (3) on pump. This pump is connected to the high pressure fuel pump by a flexible hose and check valve. In general: the maximum pressure surge. .Connect the pressure regulator and its hose. .Tighten the nut lightly with a wrench.

(1) bracket .V.(2) nut .(3) testing device .(4) pressure gauge device .(5) dial indicator 5 4 3 2 1 33 .Wärtsilä NSD Nederland B.1 Subject Fuel and injection system Issue date April ‘98 Fuel system (continuation) High pressure fuel pump . Engine type W38 FIELD SERVICE DATA BOOK W38 Chapter 1.

The fuel control rack has to be set on full load and the plunger should not be lifted.Lift the plunger 12 mm what can be read on the dial gauge.5 . 5 bar The commencement of delivery check must only be performed on pumps with acceptable element condition. .Adjust the primary pressure to 2 bar. . The secondary pressure will increase now.Adjust the plunger lift by means of the screw until the dial of the secondary pressure gauge starts to move. . .Set the dial gauge exactly on zero position. Condition New element/plunger Acceptable wear Replacement element secondary pressure 2.3 bar 2. Remove one erosion plug form the pump.1.5 bar below 1. 34 .5 . Engine type W38 FIELD SERVICE DATA BOOK W38 Chapter 1. this is the commencement of delivery of the pump. . the fuel control should be on position 55. Fasten the bracket. If the pump is correctly assembled and calibrated.V.Wärtsilä NSD Nederland B. .Move the fuel control rack till the secondary pressure is 1 bar again. 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.Read the position of the fuel rack.1 Subject Fuel and injection system Issue date April ‘98 Fuel system (continuation) Fuel pump condition check Remove the pump connection piece and lift out delivery valve and constant pressure relief valve.

0.2 Subject Lubricating oil system Issue date April ‘98 1. EXAMPLE: A residual grade fuel with a 3% sulphur content requires a TBN of: 7 + 11 x 3 = 40 Remarks In case of xcessive low ambient temperatures the pour point should be at least 5°C below the lowest temperature at which the oil is expected to used.5 % >2% > 0.5 % > 0. TBN = Total base number.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.V. Engine type W38 Chapter 1. The lubricating oil must have a high demulsifying ability for cleaning by centrifugal separator.2 % <1% <6% 35 .25% sulphur content a lubricating oil with a TBN 10 is advised. requirements Bunker requirements lubricating oil General The content of additives should meet at least the requirements of US-Army-Mil-l-2104C or API Class CD Continuous The lubricating oil must be suitable for continuous cleaning cleaning by a centrifugal separator. The lubricating oil separator inlet temperature should be controlled between 80°C and 90°C. This is particular important in case of a high water content Flash point >200°C (ASTM D 93) Pour point Maximum -12 °C 1) Viscosity SAE 40 (ISO G 150) Alkalinity General relation for advised TBN2) of the lubricating oil (TBN) related to the S-content of the fuel oil:TBN = 7 + S% x 11. For light fuel oils with max.2 LUBRICATING OIL SYSTEM For the general descriptions and pineapple outlines. we refer to the maintenance Manual W38. Pentane insolubles Toluene insolubles Pentane insolubles minus toluene insolubles Water content Fuel contamination HFO MDO/LFO NO-GO ------- <180 °C ----20/+20 % ≥60% > 2.

Centrifugal separated on water and dirt .V.Filtered . diagram System components 01 Lube oil pump engine driven 02 Safety valve 03 Non-return valve 05 Valve 06 Centrifugal filter 07 Wet sump 09 Sample valve 10 Turbocharger 13 Oil mist detector 14 Control valve Pipe connections 201 Lube oil inlet 204 Lube oil from engine driven pump 205 Lube oil to priming pump 213 Lube oil from separator and filling 214 Lube oil to separator and drain 215 Lube oil filling 223 Flushing oil from external filter 701 Crankcase ventilation 710 Discharge condensation oil Optional box D1 Without engine driven oil pumps D2 Engine driven oil pumps 36 .2 Subject Lubricating oil system Issue date April ‘98 Requirements (continuation) Engine requirements lubricating oil Lubricating oil.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. mm min. sump tank level) Max. bar 0. must be conditioned: . supplied to the engine.25 Internal lubricating oil system.Adjusted to temperature Water Fineness filter Preheated before starting Allowable suction pressure main lubricating oil pump (strainer contamination.2 10 40 0. °C Max. % vol eff. Engine type W38 Chapter 1.

V. Engine type W38 Chapter 1. 1 clamping rings The friction between shaft and gearwheel is achieved by three pairs of clamping rings. The desired control pressure is set by turning the adjusting spindle ( clockwise turning to increase the pressure. 37 . The way in which the clamping rings should be assembled is shown in the detail of the drawing above.2 Subject Lubricating oil system Issue date April ‘98 Adjustment of lubricating oil pump The desired control pressure is adjusted by means of spindle (1). With running in filters the pressure should be 4.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.3 bar and without running in filters 4 bar. counter-clockwise turning to reduce the pressure). For this purpose the protective cap has to be removed and the hexagon seal nut unscrewed.

FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. Engine type W38 Chapter 1.V.2 Subject Lubricating oil system Issue date April ‘98 Positioning of the lubricating oil pump Counter clockwise rotation Clockwise rotation Lubricating oil. brands Advised system oils for Wärtsilä 38 engines running on HFO Lubricating oil Designation (brand name) of lubricating Visc supplier oil supplier BP Energol IC-HFX 404 SAE40 Castrol TLX 404 SAE40 Caltex/Chevron Delo 3400 Marine SAE40 SAE40 Elf Lub Marine Aurelia XT4040 SAE40 Esso Exxmar 40 TP Plus 40 SAE40 Fina Stellano S 440 SAE40 Mobil Mobilguard 440 SAE40 Shell Argina X40 SAE40 Texaco Taro 40XL40 SAE40 TBN 40 40 40 40 40 40 40 40 40 38 .

1 5° before top of combustion phase. (5-10 bar) Disconnect starting air line cyl. 1. Check the position of the starting cam in pos 06 an lock the screws 05 equally. that the air just flows out of connection cyl. (turn in direction of rotation) Remove supply pipe from starting air distributor and connect the distributor to an external pressure air supply.3 Subject Starting air system Issue date April ‘98 1.V.) Connect pipes to starting air distributor. Engine type W38 Chapter 1.2 mm. Check the oscillation of the starting cam. Torque 41 NM. 13 13 Fixed cam construction 05 05 03 03 07 06 04 01 07 06 04 01 39 .3 Starting air system adjustments Adjustment starting cam (fixed cam): 1 2 3 4 5 6 7 Turn cyl. 1. Turn the starting cam in direction or rotation so.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. (The maximum allowed oscillation is 0.

Connect an hydraulic pump to the journal (oil pressure 800 . Disconnect hydraulic pump and connect both pipes again.1200 bar). Adjustable cam 14 01 02 05 03 12 06 40 . that the air just flows out of connection cyl. Engine type W38 Chapter 1. (5-10 bar) Disconnect starting air line cyl. 1.1 5° before top of combustion phase.V. 1. Turn the starting cam in direction or rotation so. Caution: Do not move starting cam in axial direction.3 Subject Starting air system Issue date April ‘98 Adjustment starting cam Adjustment starting cam (adjustable cam): 1 2 3 4 5 6 7 Turn cyl.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. (turn in direction of rotation) Remove supply pipe from starting air distributor and connect the distributor to an external pressure air supply.

Check that the plungers after mounting do not stick.3 Subject Starting air system Issue date April ‘98 Starting air distributor Maintenance. 1 2 3 4 5 6 7 For maintenance remove the complete distributor from the engine. Engine type W38 Chapter 1. 8 9 10 Starting distributor 41 . In case of a sticking plunger. Apply silicon sealant to both sides of the intermediate plate (33). Use Loctite 242 for mounting of the liner. Clean the bore carefully. press it out it may be necessary to heat the distributor up to about 200 °C as Loctite is used for fixing and sealing. Wipe off the surplus.V. If a pilot liner is worn out. Apply Molykote Past G to the plunger Sliding surface before reassembling. Clean parts and check for wear. Check that no Loctite has been left on the inside of the liner. use a pipe with M8 thread inside to draw the plunger out of the liner. It is recommended not to interchange the positions of the plungers in the distributors. The liner openings must correspond to those in the housing. Do not use too much as the surplus sealant will be forced into the system during tightening.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. if necessary.

Keep the piston on the valve spindle mounted for support during grinding. Renew the copper ring (5) between starting air valve housing and cylinder head. See also the instructions for the cylinder head valves in chapter12. Clean the seat condition of valve and valve housing.3 Subject Starting air system Issue date April ‘98 Starting valve MAINTENANCE 1 2 3 4 Remove the holding plate and pull out the valve with control piston. If necessary. Check that the O-ring (3) of the valve housing is intact. check that the valve spindle with piston moves smoothly and closes completely. Engine type W38 Chapter 1. Tighten the bolts (07) to the torque setting (see .. Take off the self locking nut (9) and take off the piston (2). Clean all components..) 5 6 7 8 9 10 7 2 1 9 Starting air valve 3 4 5 42 . lap the seats by hand..V. Lubricate piston and liner with lubricating oil. Check that the vent holes (04) in the valve housing are open..FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. After reassembling the valve... Lubricate with oil.

The minimum pressure that is needed to start an engine is 12 bar. 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 The nominal (maximum) starting air pressure in the system is 30 bar. 43 . schedule 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.3 Subject Starting air system Issue date April ‘98 Starting air system.V.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. Engine type W38 Chapter 1.

This system turns the crankshaft automatically two revolutions prior to the actual starting procedure. The slow turning procedure. Engine type W38 Chapter 1. The intention of this device is to protect the engine if there is water. should take place every two hours with a maximum speed of 20 rpm. can be provided with a slow turning device.3 Subject Starting air system Issue date April ‘98 Slow turning device Engines which are remotely started after a stand still period of a certain time. at remote starting. 44 . which controlled by the LCS.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.V. oil or fuel in a cylinder.

] pH min. cylinder head.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.4 Subject Cooling water system Issue date April ‘98 1. [°C] before starting Static pressure inlet HT and LT cooling min. fittings and instrument sensors. see the Maintenance Manual W38. an inhibitor on nitrate/borate basis should be added to the system through a dosing tank.] Sulphate content (S) max. 45 . The use of inhibitors does not permit zinc in piping. [mg/l. [bar] water pump Free of air 60 0. turbo charger and charge air cooler.25 In case of emergency. Supplied to the engine cooling water system it must at least meet the following requirements : Requirements make-up water Chloride content (Cl) max. Engine type W38 Chapter 1. [mg/l.4 COOLING WATER SYSTEM The engine cooling water system consists of cylinder liner. water up to 500 mg/l (Cl+S) may be used. Engine requirements cooling water HT cooling water system preheated min. For further general description and principle outlines of the cooling water system. This water has to be replaced as soon as possible by required water quality. Requirements The make-up water should be free of any foreign particles and gases. Hardness less than [°D] 80 150 7 10 To prevent the formation of rust and scale in the cooling water system.V.

FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.7 32. Cooling water contents (in litres without coolers) 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 m 3/h(l/min) pressure bar suction pressure bar height difference pressure gauge in respect to heart pump head pump in m.17. chapter 1. • Request the supplier of the treatment product for instructions regarding the treatment procedure.0 46 . assembling and replacing the cooling water pump.9 30.4 Subject Cooling water system Issue date April ‘98 Cooling water control Most suppliers of cooling water additives can provide a test kit for cooling water quality control. Engine type W38 Chapter 1.4 .08 1 1 1 32.7 29.07 2.24 -0.head in acc.74 2. with water column “Johnson” curve 84 / 1400 100 / 1666 120 / 2000 3.V. see the Engine Manual. • Record the results of tests in the engine log book.06 -0. dismantling. Observe the following points : • Follow thoroughly the instructions of the supplier. For removing. dosage and concentration control.6 24.0 25.04 -0.

FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. engine driven.4 Subject Cooling water system Issue date April ‘98 Cooling water system schedule 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. (D1/3) 07 HT cooling water pump.4 47 .V. Engine type W38 Chapter 1.8 Pressure drop over internal system LT [bar] 0. 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 Pump pressures drops Pressure drop over internal system HT [bar] 0.

FIELD SERVICE DATA BOOK W38
Wärtsilä NSD Nederland B.V. Engine type W38 Chapter 1.4 Subject Cooling water system Issue date 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.

48

FIELD SERVICE DATA BOOK W38
Wärtsilä NSD Nederland B.V. Engine type W38 Chapter 1.4 Subject Cooling water system Issue date April ‘98

Approved cooling water additives Manufacturer Drew Ameroid Marine Division Achland Chemical Company One Drew Plaza Boonton, NJ 07005, USA Grace Dearborn Widnes, Chesire WA8 8UD, UK Houseman Ltd The Priory, Burnham Sloutgh SL1 7LS, UK Maritech AB Box 143 S-29122 Kristianstad, Sweden Nalco Chemical Company One Nalco Centre Naperville, Illenois 60566-1024 USA Nalfleet Marine Chemicals PO Box 11 Winnington Avenue, Northwich Cheshire, CW8 4DX, UK Rohm & Haas La Tour de Lyon 185, Rue de Bercy 75579 Paris, Cedex 12, France Tampereen Prosessi-Insinöörit Sarankulmankatu 12 33900 Tampere, Finland S>A> Taxaco Belgium N.V. Technologiepark-Zwijnaarde 2 B-9052 Ghent/Zwijnaarde Belgium Unitor AS Mastermyr 1401 Kolbotn, Norway Vecom Holding BV PO Box 27 3140 AA Maassluis, Holland Additive name DEWT-NC powder Drewgard 4109 Liquidewt Maxigard Vecom CWT Diesel QC-2 Dearborn 547 Cooltreat 651

Marisol CW

Nalco 39 (L) Nalcool 2000

Nalcool 2000 Nafleet EWT 9-108 Nalfleet CWT 9-131C RD11 RD11M RD25 Ruostop XM

Texaco ETX6282

Dieselguard NB Rocor NB liquid Vecom CWT Diesel QC-2

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FIELD SERVICE DATA BOOK W38
Wärtsilä NSD Nederland B.V. Engine type W38 Chapter 1.4 Subject Cooling water system Issue date April ‘98

Positioning cooling water pumps

Clockwise turning HT coolingwater Counter clockwise turning HT pump cooling water pump

Clockwise turning LT cooling water pump

Counter clockwise turning LT cooling water pump

50

V.4 Subject Cooling water system Issue date April ‘98 cooling water pumps. engine at 600 rpm Line engine Vee engine 51 . Engine type W38 Chapter 1.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. characteristics Pump characteristic.

Engine type W38 Chapter 1.5 Subject Charge air system Issue date April ‘98 1.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. the water temperature of the LT section of the air cooler should not below 10°C • For operation the inlet air temperature should not below -5°C Charge air system schedule System components 01 Turbochargers 02 Charge air cooler 03 Cylinder head 04 Turbocgaeger cleaning system 06 Needle valve 07 Drain valve 08 Filter Components of Cleaning device (04) / washing system (05) 12 Valve for cleaning turbine 13 Valve for cleaning compressor 14 Reducer 15 Flow meter 16 Main valve 17 Non return valve 18 Valve for air injection Pipe connections 501 Exhaust gas outlet 502 Cleaning water to turbine 506 Air supply to turbine 601 Air inlet to turbocharger 711 Discharge dirty condensation water from 717 Discharge dirty water from air receiver. air receiver 52 . grit. etc) fluids exhaust gases combustion gases chemicals.CHARGE AIR SYSTEM requirements The combustion air must be free of: • • • • • • dust (sand.5. (solvents etc) to ensure starting.V.

650°C 710°C 620°C 620°C Lubricating the turbocharger The Napier EGT turbocharger and the ABB TPL turbocharger are both lubricated with engine oil. turbo rpm and exhaust gas temperature before and after turbine.C.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. fuel rack. until temperatures have stabilised. 53 . The ABB VTR turbochargers have there own lubricating system. Engine type W38 Chapter 1. Water washing the turbocharger VTR 354/454 The compressor section must be cleaned daily by filling the water container with clean water and flushing during service load.V. 2: Reduce output at full rpm to about 25% = fuel rack 22 to 25 mm (exhaust gas temperature before turbine below 430°C).5 Subject Charge air system Issue date April ‘98 Specification of exhaust gas • The exhaust gas must meet the following conditions. scavenging air pressure. Turbine cleaning should be done weekly by following the instructions: 1: Check engine parameters as: engine rpm. 3: Wait 5 to 10 minutes. before T. • The maximum resistance of the inlet system before the turbocharger amounts: 10 mbar • The maximum resistance of the exhaust system measured just after the turbocharger amounts: 30 mbar • The maximum receiver temperature is: 60°C • The maximum exhaust gas temperature: After cylinder: 340° Turbocharger Napier EGT ABB TPL 69 ABB VTR 354 ABB VTR 454 Max. 4: Open drain valve of gas outlet casing and chick gasses coming out. exhaust gas temp.

if any. (dP+scav.3 .5 Subject Charge air system Issue date April ‘98 Water washing the turbocharger VTR 354/454 (continuation) 5: Open needle valves on the turbo inlet pipes one by one to check gas coming out with disconnected supply line. the water supply must be disconnected to prevent melting of the flow meter.2 . VTR 354 354 454 454 Inlets 1 or 2 3 1 or 2 3 Nozzles 2 3 2 3 Dia.5 .8 1. Open water valve halfway only.5 . Engine type W38 Chapter 1.3 .7 2. 7: 8: 9: 11: 12: 13: 14: 15: 16: 17: Continue flushing for 5 to 10 minutes. Close the needle valves slowly.2 .5 bar.8 2. with a manometer. or use flow meter.5 .0 M3/hr 1.7 54 .9 1. see below) Check dirty water flow from the drain.4 1.1. Open the water valve half way only.1.1.0 1. Open water valve slowly further. Drain water. Close drain valve of gas outlet casing. Note: During normal operation. air pressure. If no or too little water flow decrease engine power.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.2. in order to verify free flow.2. Using water flow meter 6: Connect the water supply. till a correct flow is achieved (see below). must be clean then. Slowly increase engine load and operate engine at service load for about 30 minutes.5 dP bar 1. Check engine parameters to verify cleaning effect. mm 4.5 4.2 . Close the water valve. This should be ± 0. Open both needle valves and verify a certain rise of flow each time.2.5 3. Disconnect water supply line! Leave the engine at same load for 5 minutes.V.5 5. Open both needle valves and verify a certain pressure drop each time. with a water flow meter. Using manometer only 6: 7: 8: 9: 10 Connect the water supply.2 l /min. Open water valve future until the pressure is about 2.2.2.

revs and remove the wire plug from the 721. Checking the PGA in the engine In co-operation with the bridge it is better to reduce the pitch to 0.6 Subject Control system Issue date April ‘98 1. bring the engine to 600 rpm and place the wire-plug back and turn the speed setting knob to the marked position.0185 1.3 10 20% 1.6 CONTROL SYSTEM Handling the 721 hand held programmer 1) Connect the Hand Held Programmer and press any button.0 2) AUXILIARY DYNAMICS MENU Aux gain Aux stability Aux compensation Aux gain ratio Aux window width Aux gain slope breakpoint Aux gain slope Aux speed filter DPP 0.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. By pressing the buttons 3 and 4 you can go to a different menu. Engine type W38 Chapter 1.V.13 1.0 55 . you now have the situation that the back-up is in operation.12 1. 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). than turn the speed control knob two turns to the direction min.0201 1.00 0.3 15. Now there will be shown “Wärtsilä programme” or something like that. Bring the speed back to 600 rpm and check the situation.0 15 100 % 0 15. Bring the engine to approximate 625 rpm and mark the position.00 0. 721 Software settings for Diesel Power Plants 1) DYNAMICS MENU Gain stability Compensation Gain ratio Window width Gain slope breakpoint Gain slope Speed filter DPP 0.

0 volts 0 kw 7920 kw 800 kw 50 kw 100 sec 120 sec 1000 kw/min 1000 kw/min 0 kw 7920 kw 4% 0 kw 7920 kw 56 .FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.V.50 0% 100 % 100 % 100 % 0% 5) KW setting menu Maximum load Load gain voltage 4 mA kw load input 20 mA kw load input base load reference Unload trip level Load ramp time Unload ramp time Raise load rate Lower load rate 4 mA remote.6 Subject Control system Issue date April ‘98 3) speed setting menu Raise speed limit Lower speed limit Idle speed reference Accel ramp time Decel ramp time Raise speed rate Lower speed rate 4 mA remote reference 20 mA remote reference Tach at 4 mA output Tach at 20 mA output Low idle droop Low idle breakpoint DPP 690 rpm 320 rpm 320 rpm 60 sec 30 sec 200 rpm/min 200 rpm/min 320 rpm 600 rpm 0 rpm 700 rpm 0% 0% 4) Torsional filter menu Torsional filter Torsional level 4 mA Torsional level 20 mA Derated fuel limit Derated trip level Derated clear level DPP 0. kw reference Load droop percent Load at 4 mA output Load at 20 mA output DPP 7920 kw 6. Engine type W38 Chapter 1. kw reference 20 mA remote.

FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.V. Engine type W38 Chapter 1.0 mA 100 % 8) Configuration menu Rated speed Gear #1 teeth Gear #2 teeth Actuator sense Dynamics map MPU1 failed alarm MPU2 failed alarm Both MPU’s failed alarm Load sensor failed alarm Sequence error alarm High torsional level alarm Remote input failed alarm DPP 600 217 217 Reverse Linear Minor alarm Minor alarm Major alarm No alarm No alarm No alarm No alarm 57 .0 mA 100 % 8.6 Subject Control system Issue date April ‘98 6) Fuel limiters and control output menu Idle fuel limit Maximum fuel limit External fuel limit Fuel limit breakpoint A Fuel limit at breakpoint A Fuel limit breakpoint B Fuel limit at breakpoint B Fuel limit breakpoint C Fuel limit at breakpoint C Fuel limit breakpoint D Fuel limit at breakpoint D Fuel limit breakpoint E Fuel limit at breakpoint E DPP 60 % 100 % Disabled 6.0 mA 100 % 20.0 mA 100 % 10 mA 100 % 15.

01 0. Engine type W38 Chapter 1.00 4.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.00 0.00 3.6 Subject Control system Issue date April ‘98 9) Calibration menu Calibration key KW load input Synchroniser input Fuel limiter input Remote reference input Parallel line input Load sharing error De-droop Load sharing output Load sharing offset Torsional level KW load output Tachometer output Actuator output Analogue speed #1 Analogue speed #2 DPP 0 -0.48 0 0 rpm 0 rpm 58 .02 0.00 4.00 0.01 0 0 4.V.81 0.

76 0.00 30.90 0.50 0.30 0. Engine type W38 Chapter 1.50 0.80 10.76 0.00 1.00 12.00 12.V.6 Subject Control system Issue date April ‘98 Software settings marine engines menu dynamics 1 Proportional Gain 1 Integrator Rate 1 Derivative Ratio 1 Fast Proportional Gain 1 Fast Gain Window Width 1 Gain Breakpoint 1 Gain Slope 1 Speed filter 1 Torsional Filter 1 Droop 1 marine 0.08 0.90 10.90 0.00 menu dynamics 2 Proportional Gain 2 Integrator Rate 2 Derivative Ratio 2 Fast Proportional Gain Fast Gain Window Width 2 Gain Breakpoint 2 Gain Slope 2 Speed Filter Torsional Filter 2 Droop 2 marine 0.00 59 .FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.08 0.00 30.30 0.00 1.

00 200.00 320.00 5.00 700.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.00 15.00 60 .00 320. Engine type W38 Chapter 1.00 5.00 600.00 600.V.6 Subject Control system Issue date April ‘98 menu speed setting Raise Speed Limit Lower Speed Limit Rated Speed Idle Speed Accel Rate rpm/sec Decel Rate rpm/sec Speed Raise Rate Speed Lower Rate 4mA Remote Reference 20mA Remote Reference Tach at 4mA Output Tach at 20mA Output Speed Fault Override Time marine 600.00 5.00 0.00 320.

menu display Stop/Run contact Idle/Rated contact Lower contact Raise contact Failsafe Override contact M/S Select contact Unload contact Clutch Closed contact Major Alarm Relay Minor Alarm Relay Unloaded Relay MPU No. See also the explanation on these setting in next chapter.2 LED Status marine TRUE/FALSE TRUE/FALSE TRUE/FALSE TRUE/FALSE TRUE/FALSE TRUE/FALSE TRUE/FALSE TRUE/FALSE TRUE/FALSE TRUE/FALSE TRUE/FALSE TRUE/FALSE TRUE/FALSE menu configuration Gear #1 Teeth Gear #2 Teeth Actuator Forward Acting Auto Selection M/S Trim Function Enabled Overspeed Trip marine 165 (depends on installation) FALSE FALSE FALSE 690 menu set alarms MPU#1 Failed Alarm MPU#2 Failed Alarm Remote Input Failed Alarm Charge Air Failed Alarm Rack Sensor Failed Alarm Master/Slave Failed Alarm Stop on MAJOR Alarm 2 2 2 2 2 1 True (This goes against the philosophy of the “mechanical back-up”. If both of the signals should fail. the back-up takes over.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. On most of the ships with controllable pitch propeller the settings of these so called “smoke limiters” are not used and are set to 100%.1 LED Status MPU No.) 61 marine 1=No Alarm 2=Minor Alarm 3=Major Alarm .6 Subject Control system Issue date April ‘98 Menu fuel limiters These can differ from installation to installation.V. Engine type W38 Chapter 1.

62 .2. These option is only possible together with a reverse acting actuator. The effect will be a fuel cut off at a major alarm. the rest that follows are slaves). Calibration and trimming of separate fuel rack sensor can be done in the software.2. 1 means No Indication 2 means Minor Alarm 3 means Major Alarm If 1 is selected. True: automatic master/slave selection. Trim function enabled True: trim function enabled.6 Subject Control system Issue date April ‘98 Explanations on 721 software settings Menu Configuration Gear #1 Teeth The number of teeth on the wheel where the first speed probe is mounted on.2. gear #2 Teeth The number of teeth on the wheel where the second speed probe is mounted on Actuator forward acting True: actuator is forward acting. Engine type W38 Chapter 1. Auto selection M/S False: no automatic master/slave selection. In case a mechanical backup governor is present and a continuous transfer is requires at a major alarm.3) MPU #2 failed Alarm 2 (1. also the override of the function is activated. True: speed sensor 2 fault is overridden Menu Set alarms An integer value assigns the function of the failed indication.2. False: trim function disabled.2. Override speedsensor 2 False: speed sensor 2 fault is not overridden. The fail detection for that channel is not working.V. The control will initiate a major alarm if level is exceeded.3) Charge air input failed Alarm 2 (1. Overspeed trip engine overspeed trip level.3) Both MPU’s failed Alarm 3 (1.2. The slave selection must be done by means of the M/S select contact. False: actuator is reverse acting.3) remote input failed Alarm 2 (1.3) Rack sensor input failed Alarm 1 (1. (Normally used if mechanical backup governor is used).3) Master/slave input failed Alarm 1 (1. (First engine clutched in will be the master engine. the value of the Boolean should be set to False.3) False: Engine will not stop on major alarm. MPU #1 failed Alarm 2 (1.2. Stop on major alarm True: engine will stop on major alarm.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.

Fast gain window width 1 The fast gain window width 1 is in conjunction with the fast proportional gain as described above. 63 . fast gain window is not absolute. but an anticipated value. Gain Slope 1 Gain Slope changes gain as a function of actuator output. Outside this window the fast gain is activated.6 Subject Control system Issue date April ‘98 Menu Dynamics 1 Proportional gain 1 This value represents the P value on the PID. High settings will decrease the derivative function giving the control a PI action. Speed Filter 1 Speed filter adjusts the cut-off frequency of a low pass filter used on the speed sensing input. If the value is too low the speed will take a long time to return to its setpoint after a transient.V. Increasing the integrator will increase the I value. The base gain set point defines the control gain inside the window. If the value is too high it will make the system less responsive. This will affect the load action of the control. Derivative ratio 1 This value represents the D value on the PID. 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. If the value is too high it will result in an oscillation. Increasing the derivative will increase the D value. If the value is too low it will make the system oscillate and can not be compensated for with gain or integrator rate. In this way the control tries to stabilise the torsionals in case they occur. Droop 1 This value represents the amount of droop. 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. Increasing the gain will increase the P values.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. If the value is too low it will result in high offspeeds on transients. This will affect the response on a transient. the control gain is set to the value determined by the fast proportional gain. This allows the control to act quickly on a transient. Integrator rate 1 This value represents the I value on the PID. Torsional Filter 1 Torsional filter is a filter which filters away the torsionals over the clutch. When the control senses a change in speed that will cause a speed error exceeding the window width. This is only effective when one speed probe is mounted before the clutch and one speed probe mounted after the clutch. Gain slope operates in conjunction with the gain breakpoint adjustment to increase or decrease gain when percent actuator output is greater than the breakpoint. giving an overdamped response. This will affect the recovery rate after a transient. Engine type W38 Chapter 1. Gain Breakpoint 1 Sets the percent actuator output above which the gain slope becomes effective.

Switching between both is done by the clutch feedback discrete input. For further explanation of dynamics 2 please refer to dynamics 1.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. Also the remote speed reference will be increased with this rate. The idle speed reference setpoint. The speed reference setpoint when remote speed reference is enabled at 20 mA input signal. Rate in which the speed reference will change in case of giving a lower speed command.V.6 Subject Control system Issue date April ‘98 Menu Dynamics 2 Two sets of dynamics are available. In this way you can limit the maximum amount of fuel to the engine. Menu Speed Setting Raise Speed Limit Lower Speed Limit Rated Speed Idle Speed Accel Rate rpm/sec Decel Rate rpm/sec Speed Raise Rate The maximum sped reference that is possible during operation. Rate in which the speed reference will change in case of giving a raise speed command. The maximum speed reference that is possible during operation. Acceleration rate when ramping from idle to rated speed reference. Deceleration rate when ramping from rated to idle speed reference. Also the remote speed reference will be decreased with this rate The speed reference setpoint when remote speed reference is enabled at 4 mA input signal. The rated speed reference setpoint. Engine type W38 Chapter 1. Speed Lower Rate 4mA Remote Reference 20mA Remote Reference Tach at 4 mA output Tach at 20 mA output Speed Fault Override Time 64 . Speed indication at 20 mA output for Tachometer. Indicates the maximum amount of actuator output. Speed indication at 4mA output for Tachometer.

Fuel Limit at Breakpoint B Maximum actuator output at second setpoint. Torque Lim P3. Fuel Limit Breakpoint E mA input at fifth setpoint. Torque Lim P4. Torque Lim P5. rpm Speed input at first setpoint. act (%) Maximum actuator output at third setpoint. The schedule has 5 setpoints.20 mA signal.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. rpm Speed input at third setpoint. PID (%) at 20 mA output PID value when 20 mA are given to the PID output signal (for CPP systems). rpm Speed input at fourth setpoint. act (%) Maximum actuator output at first setpoint. the schedule has 5 setpoints.6 Subject Control system Issue date April ‘98 Menu Fuel Limiters Start Fuel Limit The start fuel limit sets the maximum actuator output during start. Torque Lim P1. rpm Speed input at fifth setpoint. Maximum Fuel Limit Indicates the maximum amount of actuator output. Torque Lim P3. PID (%) at 4 mA output PID value when 4 mA are given to the PID output signal (for CPP systems). The torque fuel limiter allows to set up a fuel limit schedule as a function of the actual speed. Torque Lim P2. Fuel Limit Breakpoint C mA input at third setpoint. Torque Lim P4. Fuel Limit at Breakpoint C Maximum actuator output at third setpoint. Torque Lim P2. Fuel Limit Breakpoint D mA input at fourth setpoint.V. Fuel Limit at Breakpoint E Maximum actuator output at fifth setpoint. act (%) Maximum actuator output at fourth setpoint. Fuel Limit Breakpoint A mA input at first setpoint. 65 . Torque Lim P5. In this way you can limit the maximum amount of fuel to the engine. rpm Speed input at second setpoint. The external fuel limiter allows to set up the fuel limiter schedule as a function of a 4 . act (%) Maximum actuator output at second setpoint. Fuel Limit at Breakpoint A Maximum actuator output at first setpoint. Fuel Limit Breakpoint B mA input at second setpoint. act (%) Maximum actuator output at fifth setpoint. Fuel Limit at Breakpoint D Maximum actuator output at fourth setpoint. Torque Lim P1. Engine type W38 Chapter 1.

. In case a fuel rack sensor is used. In case a fuel rack sensor is used. Engine type W38 Chapter 1. This is needed for calculation of droop and/or amount of load.. (Mostly set at clutched in engines.. The rate that the engine will be (un)loaded when clutch in or unload contact is given. full load) In master/slave application.6 Subject Control system Issue date April ‘98 Menu load sharing Act % at No load The actuator position at no load should be given here.kw In master/slave application. the position of the fuel rack of the slave unit can be tuned with this parameter. no load) Act % at full load mA rack sensor at no load mA rack sensor at full load Full load (kw) (Un)load rate (kw/s) Minimum trip level (kw) Slave rack gain Slave rack offset Menu display Engine speed Speed reference Actuator LSS (%) Actuator output (%) Fuel limit LSS (%) Function as slave Indicates the actual engine speed Indicates the actual speed reference with droop and bias Indicates the status of the actuator low signal select bus 100% is full fuel.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. The 100% load level (in kw) of the engine must be given here.kw/s The load level at which the clutch open contact is given. It is calculated as follows: ((full load act pos-no load act pos)/full load) *minimum trip level =.. Indicates the actuator output in % Indicates the actual value on the limiter low signal select bus.V. It is calculated as follows: ((full load act pos-no load act pos)/full load)*un-load rate = . Indicates if control is in slave mode. the feedback signal of that sensor at full load must be set here. This signal is needed when run in master/slave applications. (mostly set at clutched in engines... the position of the fuel rack of the slave unit can be tuned with this parameter. The actuator position at full load should be given here. True: Slave mode False: Master mode or not clutched in 66 . This is needed for calculation of droop and/or amount of load. the feedback signal of that sensor at no load must be set here.

False: clutch is open (feedback signal) dynamics 1 is active. False: idle speed reference selected. Can be used for clutch open signal). Failsafe override contact True: Failsafe function is on. False: relay is off. M/S Select contact True: Control selected as slave.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. Major alarm relay True: relay is on (major alarm present). MPU no. False: lower speed reference contact is off. Clutch closed contact True: Clutch is closed (feedback signal) dynamics 2 is active. Stop/run contact True: run mode selected. False: relay is off. This input has no function if auto master slave selection is enabled. False: stop mode selected. False: relay if off. Unloaded relay True: relay is on (engine is unloaded to triplevel. Engine type W38 Chapter 1. A TRUE indicates that the status is true. It represents the status of the subject. Unload contact True: unload sequence is enabled. 67 .V. Raise contact True: raise speed reference contact is on. False: unload sequence is disabled.1 LED status True: LED is on (indicates speed probe fall). input (mA) Charge air input (mA) Rack sensor input (mA) Master/slave input (mA) Displays the speed probe #1 input signal Displays the speed probe #2 input signal Displays the remote speed reference input signal in mA Displays the charge air input signal in mA Displays the rack sensor input signal in mA Displays the master/slave input signal in mA Menu display 2 Display 2 menu is a true/false monitor.6 Subject Control system Issue date April ‘98 Menu calibration Speed #1 (rpm) Speed #2 (rpm) Remote ref. Minor alarm relay True: relay is on (minor alarm present). MPU no. Idle/rated contact True: rated speed reference selected.2 LED status True: Led is on (indicates speed probe fail). For example. Lower contact True: lower speed reference contact is on. False: control selected as master or automatic master/slave selection. False: LED is off. False: relay is off. False: raise speed reference contact is off. minor alarm = true indicates that a minor alarm is present. False: Failsafe function is off.

False:MPU #1 has not failed MPU #2 failed True: MPU #2 has failed. False:MPU #2 has not failed Both MPU’s failed True: both MPU #1 have failed. Engine type W38 Chapter 1. (signal < 2 mA or signal > 22 mA) False: Charge air input signal has not failed. 68 . (signal<2mA or signal> 22 mA) False: rack sensor input signal has not failed. A TRUE indicates that the status is true. remote input failed True: remote input signal has failed. It represents the status of the subject. Master/slave input failed True: master/slave input signal has failed. (signal<2mA or signal> 22 mA) False: master/slave input signal has not failed. (signal<2mA or signal> 22 mA) False: Charge air input signal has not failed. False: both MPU #1 have not failed. For example: MPU #1 failed = true indicates that speed probe 1 has failed MPU #1 failed True: MPU #1 has failed.V. Rack sensor input failed True: rack sensor input signal has failed. Charge air input failed True: Charge air input signal has failed.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.6 Subject Control system Issue date April ‘98 Menu monitor alarms Monitor alarms menu is true false monitor.

However if the channel number is known. Channel number: XYYZZ ⇒ X means: YY means: ZZ means: LCS unit number I/O board number I/O board channel number For ZZ = 1-16: Termination board/terminal number: For ZZ = 17-32: Termination board/terminal number: TB-YYA / terminal ZZ TB-YYB / terminal (ZZ . For instance.6 Subject Control system Issue date April ‘98 Troubleshooting The LCS diagnostic package monitors the correct functioning of the I/O boards. General guidelines/tips using the following troubleshooting lists: • Set the Local Operator Panel to FULL display mode to show all channel parameters in GROUP PAGE and ALARM PAGE. • If prompted. termination boards and sensors connections and there relation to each other.16) 69 . when troubleshooting it is handy to understand this relationship. the channel number is displayed in the alarm page. best use the CHANNEL PAGE. check the channel statuses or parameters in either of these pages. Engine type W38 Chapter 1. CHANNEL PAGE is shown only in full display mode. Operator Guide for detailed information concerning the use of the Local Operator Panel.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.V. This channel number enables the trouble-shooter to locate the I/O board. engine sensors/contacts. • Refer to document LOCAL OPERATOR PANEL. I/O boards. if an alarm is reported. the termination board and the termination board terminals without consulting additional documentation. LCS power supply and communication tasks. • Although in the LCS documentation all data is included concerning the channels.

The sensor is defect. ⇒ This is indicated by the flashing I/O board LED SYSTEM OK.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. Analog value is The channel is not used and therefor skipped. and channel status reads SKIP. ⇒ See paragraph SENSORS. The channel alarms are inhibited by other system functions. ⇒ Check the LCS documentation for the type of sensor adapter to place. cables and connectors.V. On the termination board the corresponding sensor adapter is defect. The channel is used but skipped. ⇒ This is indicated by the channel status INHIB. ⇒ Check the channel setup and LCS documentation. 70 . Refer to the LCS documentation. When the flashing of this LED stops the analog value will be restored. ⇒ Check the channel parameter DT for the delay time. ⇒ Check the LCS documentation for the type of sensor adapter to replace. See paragraph SENSORS. Refer to the LCS not updated documentation. On the termination board the corresponding sensor adapter is removed.6 Subject Control system Issue date April ‘98 Analogue/pulse input channels Symptom Analog value reads ‘---’ and channel status reads SENSFA. change skip in channel setup to NO. A (long) delay time has been set. The channel is not an alarm channel and therefore set as status channel. ⇒ Check on the channel terminals if the sensor signal is measured. Alarm is not activated passing the alarm limits. If not. Loose wire(s). Possible cause or solution On the termination board one (or more) of the corresponding sensor isolation switches is OPEN. The corresponding I/O board is downloading (or waiting to download) it’s setup data. check the system wiring. Engine type W38 Chapter 1. If necessary. ⇒ Close the three sensor switches.

The sensor is faulty. 71 . The channel setup parameters do not correspond with the sensor type. Possible cause or solution The channel status is inhibited by other system functions. ⇒ This is indicated by the channel status INHIB. The channel alarm/status limit’s dead band is not yet passed. Alarm/status does not return to normal repassing the limits.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. ⇒ Check the sensor characteristics. ⇒ Check the channel parameter DT for the delay time. ⇒ See paragraph SENSORS.V. On the termination board the corresponding sensor adapter is not correct. Analog value does not correspond with the actual (process) value. ⇒ Check the channel parameter DB for the dead band. the LCS documentation and in the channel setup: SENSOR TYPE and ENGINEERING UNITS. ⇒ Check the LCS documentation for the type of sensor adapter. Engine type W38 Chapter 1. A (long) delay time has been set.6 Subject Control system Issue date April ‘98 Analogue/pulse input channels(continuation) Symptom Status does not change passing the limits.

FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. Multiple failing inputs. switch off all sensor isolation switches on the termination board and replace the fuse. mA or pulse inputs. Earth failure on corresponding I/O board. ⇒ Check if green power LED on the termination board is lit.g. 72 . • PT100. replace fuse.6 Subject Control system Issue date April ‘98 Analogue/pulse input channels(continuation) Symptom Alarm/status limits are not correct due to vessel dependent parameters. Possible cause or solution ⇒ Change the alarm/status limits in the channel setup. static pressure compensations for the cooling water circuits. If the fuse immediately blows again. • mA or pulse inputs: Common fuse on termination board blown. If not. If the fuse immediately blows again. Switch off the sensor isolation switches on the termination boards one by one to determine the sensor causing the failure. Engine type W38 Chapter 1. E. the termination board is defective. ⇒ This is indicated by the I/O board LED EARTH FAILURE.V. switch on the sensor isolation switches one by one to determine the sensor causing the failure. If not.

O. ⇔ N. ⇒ Refer to sensor and LCS documentation. The channel alarm is inhibited by other system functions. change connection at sensor. ⇒ Refer to sensor and LCS documentation. cables and connectors. If necessary. ⇒ Close the three isolation switches. Wrong sensor contact connected (N.C. Loose wire(s). If no contact change is measured. Refer to the LCS documentation.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. Possible cause or solution On the termination board one (or more) of the corresponding sensor contact isolation switches is OPEN. ⇒ Test the contact at the sensor with changing process conditions. ⇒ This is indicated by the channel status INHIB. ⇒ Check the channel parameter DT for the delay time. A (long) delay time has been set. A (long) delay time has been set. ⇒ Check the channel parameter DT for the delay time.: OPEN ⇔ CLOSED 73 . Sensor is defect. The channel setup parameters do not correspond with the sensor type. COND. The channel is not an alarm channel and therefor set as status channel. No alarm at input alarm condition (connections tested).6 Subject Control system Issue date April ‘98 Digital input Symptom No alarm or status change at changing process conditions. ⇒ Check on the channel terminals A and B if contact is measured. Engine type W38 Chapter 1.V.). Alarm/status is inverted in relation to the input. change in the channel setup: NORM. The channel statuses are inhibited by other system functions. If not. replace sensor. check the system wiring. If necessary. No status change at input changes (connections tested). ⇒ This is indicated by the channel status INHIB.

The channel is not used and therefor skipped. ⇒ Check on the channel terminals A and B if contact is measured.C. 74 . When the flashing of this LED stops the digital status is restored. ⇒ Check the channel setup and LCS documentation. the termination board is defective. Common fuse on termination board blown. Refer to the LCS documentation. The corresponding I/O board is downloading (or waiting to download) it’s setup data. switch off all sensor isolation switches on the termination board and replace the fuse. Multiple failing digital input channels. Engine type W38 Chapter 1. Note: This only applies to digital contacts connected to 6004 or 6018 I/O boards.V. If the fuse immediately blows again. cables and connectors. change skip in channel setup to NO. If not. Loose wire(s). ⇒ Check the placement of the 10 kOHM resistor over the contact in case of a normally open contact (N. The termination resistor is removed from the contact unit.O. ⇒ Close the three isolation switches. ⇒ Check the placement of the 10 kOHM resistor in series with the contact in case of a normally closed contact (N.6 Subject Control system Issue date April ‘98 Digital input(continuation) Symptom No alarm/status change at changing process conditions and channel status reads WIREFA. On the termination board the corresponding sensor adapter is removed. ⇒ Check if green power LED on the termination board is lit.). Possible cause or solution On the termination board one or more of the corresponding contact isolation switches is OPEN. The channel is used but skipped. Digital status does not change according to input and channel status reads SKIP.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. ⇒ This is indicated by the flashing I/O board LED SYSTEM OK. ⇒ Check the LCS documentation for the type of sensor adapter to place.). If necessary. If now the fuse immediately blows again. switch on the sensor isolation switches one by one to determine the sensor causing the failure. If not. If not. check the system wiring. replace fuse.

FIELD SERVICE DATA BOOK W38
Wärtsilä NSD Nederland B.V.

Engine type W38

Chapter 1.6

Subject Control system

Issue date April ‘98

Analogue output channels Symptom Possible cause or solution ⇒ Disconnect component wiring and measure signal on (cable) wires. If signal measured; replace component. Loose wire(s) or short-circuit in output wiring. ⇒ Disconnect output wiring on termination board terminals. Test output voltage signal on the termination board terminals: A(+) - B(-).Test output current signal on the termination board terminals: C(+) - B(-). If signal measured; check system wiring, cables and connectors. Defect analog output adapter. ⇒ Disconnect output wiring on termination board terminals. Test output voltage signal on the termination board terminals: A(+) - B(-).Test output current signal on the termination board terminals: C(+) - B(-). If no signal measured; replace analog output adapter. Refer to the LCS documentation for the adapter type. (Minor) output voltage/current deviation in relation to displayed channel value. For instance due to external cable length (voltage output) a minor re-calibration of the analog output adapter can be required. ⇒ Minimum (zero) adjustment; Verify minimum channel value (E.g. 0%, 0 Degr etc.) . Adjust output signal with P1 on analog output adapter. ⇒ Maximum (span) adjustment; Verify maximum channel value (E.g. 100%) . Adjust output signal with P2 on analog output adapter. Multiple failing mA-output channels. Common fuse on termination board blown. ⇒ Check if green power LED on the termination board is lit. If not; replace fuse. If the fuse immediately blows again remove the analog output adapters on the termination board and replace the fuse. If now the fuse immediately blows again; the termination board is defective. If not; mount the analog output adapters on the termination board one by one to determine the adapter causing the failure.

Analog actuator not responding. Short-circuit in analog actuator.

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Engine type W38

Chapter 1.6

Subject Control system

Issue date April ‘98

Relay output channels Symptom Multiple actuators not responding. Possible cause or solution Common fuse on termination board blown. ⇒ Results in the malfunctioning of all 16 relay outputs. Check if green power LED on the termination board is lit. If not; replace fuse. If the fuse immediately blows the termination board is defect. ⇒ Check the channel status and if it changes under the correct conditions (e.g. ON⇔OFF). Refer to LCS documentation. ⇒ Check the on/off status of the relay indication LED to correspond with the channel status. If not corresponding; the I/O board is defect. See paragraph I/O BOARD. • while corresponding relay indication LED is lit. Relay output fuse on the termination board is blown. ⇒ Test the relay output fuse; replace if blown. If blown again; check system wiring and actuator for short-circuit. Loose wire(s) or short-circuit in output wiring. ⇒ Disconnect output wiring on termination board terminals. After testing the relay output fuse; test relay output contact (ohm) on the output terminals A and C. If contact measured; check system wiring, cables and connectors. Actuator is defect. ⇒ Disconnect the (cable) wiring at the actuator. After testing the relay output fuse; test the actuating signal (ohm/volt) on the (cable) wires. If a signal is measured on the (cable) wires; replace actuator.

Actuator not responding; • General

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Engine type W38

Chapter 1.6

Subject Control system

Issue date April ‘98

Sensors Symptom • PT100 Possible cause or solution Test PT100 sensor checking the displayed channel value. ⇒ Heat the sensor in an oven and verify the channel reading. Test PT100 sensor with DMM on LCS terminals. ⇒ Disconnect sensor from the LCS by means of the termination board sensor isolation switches. ⇒ Measure on termination board terminals (partial table) : A⇔B 0 Degr 50 Degr 100 Degr 150 Degr • Thermocouple type K (TC-K) Test TC-K sensor checking the displayed channel value. ⇒ Heat the sensor in an oven and verify the channel reading. Test TC-K sensor with DMM on LCS terminals. ⇒ Measure on termination board terminals (partial table) and add cold junction temperature (e.g. ambient temperature 20 Degr; + 8mV) A⇔B 0 Degr 100 Degr 200 Degr 500 Degr 1000 Degr 4.1 mVDC 8.1 mVDC 20.6 mVDC 41.2 mVDC B⇔C 0 mVDC 100 Ω 119.4 Ω 138.5 Ω 157.3 Ω B⇔C ± 0-5 Ω ± 0-5 Ω ± 0-5 Ω ± 0-5 Ω

77

2 VDC 24 VDC 0. stroboscope) and verify with the channel reading. Test volt-transmitter with DMM on LCS terminals.g.V. replace sensor adapter. Engine type W38 Chapter 1. If applicable. ⇒ Measure on termination board terminals (partial table) : A⇔B 0 mA 4 mA 12 mA 20 mA Not es: 0 VDC B⇔C (P602) B ⇔ C (P604) - 0. Otherwise. ⇒ Simulate volt-transmitter output value and measure on termination board terminals A (+) and B(-). Pressurize the transmitter with a hand pump and verify the channel reading. Refer to transmitter manufacturers documentation. ⇒ Simulate volt-transmitter output value and verify the channel reading.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. ⇒ In case of a pressure transmitter. If in column ‘B ⇔ C (P602)’ no 24 VDC is measured.6 VDC 24 VDC 1 VDC 24 VDC 24 VDC Pxxx indicates the sensor adapter type. ⇒ Measure pulse-transmitter frequency on termination board terminals A (+) and B(-) and verify the calculated RPM with the channel reading. Check channel setup parameters and refer to LCS documentation and transmitter manufacturers documentation • Pulse-transmitter Test pulse-transmitter checking the displayed channel value. replace sensor adapter. check transmitter manufacturers documentation. If no 24 VDC is measured.6 Subject Control system Issue date April ‘98 Sensors(continuation) Symptom • mA-transmitter Possible cause or solution Test mA-transmitter checking the displayed channel value. 78 . Refer to LCS documentation. test pulse-transmitter supply voltage (sensor adapter P607) on terminals C (+) and B(-). Test mA-transmitter with DMM on LCS terminals. • Volt-transmitter Test volt-transmitter checking the displayed channel value. ⇒ Measure engine speed in alternative fashion (e.

Remove defect I/O board from the system rack. 79 . IMPORTANT Inserting an I/O board in a powered system rack may cause the board to start-up incorrectly and/or can shutdown the engine! During initialization it is possible for the I/O boards to go temporarily into an undefined status which can result in multiple alarms and consequently in possible control actions! For this reason observe the following rules for absolute safety. Turn off and purge the engine starting air supply. If engine running. To replace an I/O board. follow these steps: I. IV.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.6 Subject Control system Issue date April ‘98 I/O board Symptom I/O board indication I/O BOARD FAILURE is lit or I/O board indication SYSTEM ON is off or I/O board concluded defect in other tests.Move the front text sheet to the new board (front-top access). • never perform these following actions with a running engine. Engine type W38 Chapter 1. • turn off and purge the starting air supply. Possible cause or solution Replace I/O board. II. VI. Wait until I/O board is ready for operation (after LED test pattern) and the LED SYSTEM ON is lit.V. III. Place new I/O board in the system rack. stop the engine. • switch off system power before inserting an I/O board. V.

Refer to the alarm system documentation. Possible cause or solution I.V. After about 30 seconds the 6001 starts (up)loading the I/O boards one by one. • Converter LED (3) shows no activity. This is indicated by the flashing of the SYSTEM OK LED on the appropriate I/O board. Communication processor Symptom MODBUS communication failure. The MODBUS central alarm system. If the fuse immediate blows again.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. • Converter LED (1) is off. II. • Converter LED (3) shows activity and. the converter is defect.6 Subject Control system Issue date April ‘98 I/O board(continuation) Symptom I/O board indication I/O BOARD FAILURE is lit or I/O board indication SYSTEM ON is off or I/O board concluded defect in other tests. Replace the fuse (refer to LCS documentation). 6001 LED COMMUNICATION PORT FAILURE is on. Refer to the alarm system documentation. This should not result in a MODBUS communication alarm. Reset the communication processor board 6001 by means of the reset button ‘hidden’ in the front. ⇒ Possibly the MODBUS central alarm system is not requesting any data from the LCS. 80 . Turn the starting air supply back on. Simultaneously activate the 6001 pushbuttons ACK and STOP HORN during the start of the run-time program. ⇒ The alarm system is making invalid (non protocol) requests to the LCS. When after several minutes all I/O board SYSTEM OK LED’s stopped flashing the LCS is ready for operation. Not e: During normal communication occasionally the 6001 LED COMMUNICATION PORT FAILURE flickers indicating a LCS communication time-out. Possible cause or solution MODBUS converter ⇒ Converter (U1) power supply fuse (external) is blown. Release these buttons when the 6001 LED SYSTEM ON is lit. • Converter LED’s (3) or (4) show no activity. Engine type W38 Chapter 1. (Up)load the I/O board setup data. ⇒ Possibly the converter is defect.

This solidstate disk can be recognized by the text DiskOnChip. PROCESSOR BOARD ⇒ If this situation remains. Otherwise. try if resetting the communication FAILURE is on. 81 .6 Subject Control system Issue date April ‘98 I/O board(continuation) Symptom • Converter LED (3) shows activity and. Converter LED (4) shows no activity and. ⇒ If this situation remains. Carefully note the placement before removing both chips. Next: ⇒ (Up)load the I/O board data following the steps described in paragraph I/O BOARDS (ignore steps 3. Otherwise. 6001 LED COMMUNICATION PORT FAILURE is off. ⇒ The communication processor is defect. After replacing communication processor most or all channel statuses read SKIP. The communication processor solid-state disk (containing the system setup data) is not confirm the latest LCS setup. Communication processor LED The LCS run-time program is crashed. The LCS run-time program is not yet started after a powerup or a reset. try if resetting the communication processor solves this problem. 5 and 6). Engine type W38 Chapter 1. processor solves this problem. replace communication processor . Communication processor LED SYSTEM ON is off. replace communication processor . Possible cause or solution Communication processor 6001.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.V. ⇒ Replace the solid-state disk on the processor board with the one on the removed processor board. 4.

Circuit-breaker F2 off: 230VAC power supply. Allowed voltage spread: 24VDC -5VDC/+6VDC 230VAC ± 4% Power supply short-circuit.before switching on the power supply. Power fail alarm. ⇒ Measure LCS external power supplies on the field terminals. Otherwise. ⇒ Check if circuit breaker F1 is switched on. ⇒ Check if circuit breaker F2 is switched on. No short-circuit (0 Ohm) may be measured otherwise: One by one disconnect the +24V supplied field wires (see document W38X-001.). ⇒ Check on common termination board TB0 if both red LED’s are off. 82 . External power supply absent or to low. colomn Conn. Refer to LCS documentation. check for short-circuit and switch F1 on. Circuit-breaker F1off: 24VDC power supply. Otherwise.V.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. supplies fail (without safeties!) switching on one or both power supplies will shutdown the engine! ⇒ Stop the engine -at the stop valve. check for short-circuit and replace fuse(s). Refer to LCS documentation. Otherwise. ⇒ Measure the resistance between the fail-safe power supply (right door) terminals 6(+) and 7(-). check for short-circuit and switch F2 on. System rack fuse(s) blown. Engine type W38 Chapter 1.6 Subject Control system Issue date April ‘98 Power supply Symptom Possible cause or solution IMPORTANT Both power supplies have failed Although the engine keeps on running when both power while the engine is running.

push ACK. push local RESET SAFETIES ⇒ On communication processor board front. Front SAFETY indication is flashing. Possible cause or solution ⇒ See paragraphs I/O BOARDS.6 Subject Control system Issue date April ‘98 GENERAL Symptom Front indication SYSTEM OK is off LCS system failure alarm (central alarm system). ⇒ In remote control mode. ⇒ See SYSTEM OK ⇒ This indicates the safety override of an existing safety stop condition. push remote RESET SAFETIES. COMMUNICATION PROCESSOR and POWER SUPPLY. 83 . push local RESET SAFETIES ⇒ On communication processor board front. ⇒ In local control mode. push STOP HORN.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. ⇒ In remote control mode. How to acknowledge LCS alarms. ⇒ In local control mode. push remote RESET SAFETIES. ⇒ Send the defect communication processor with the fault description to the nearest support address. What to do with defect components. Engine type W38 Chapter 1. ⇒ Write a note describing the diagnosed fault. How to acknowledge MODBUS backup alarms.V.

3 Subject Operation Issue date April ‘98 2. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Step 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Load in % 10 0 25 0 35 0 50 0 60 0 70 0 80 0 90 0 100 Ramp time load in min. Engine type W38 Chapter 2.2 10 0.2 310 30 45 70 0 LOAD SPEED TIME IN MIN.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.2 10 0. 30 5 30 5 30 5 30 5 30 5 30 5 30 5 30 5 30 Speed in % 53 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 Ramp time speed in min.2 10 0.2 10 0.2 10 0.02 10 0. 10 0.3 Operation Running-in program W38 (complete overhaul) 110 100 90 LOAD/SPEED IN % 80 70 60 50 40 30 20 10 0 135 150 175 240 255 280 100.2 10 .2 205.V. Step time in min.2 15 Step 1 -1 1 -1 1 -1 1 -1 1 -1 1 -1 1 -1 1 -1 1 84 .

using the lubricating oil specified for the fuel. 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. After a complete overhaul.3 Subject Operation Issue date 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. Engine type W38 Chapter 2. If the program cannot be followed.V. if the running-in program cannot be followed.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. Running-in may be performed either on distillate or heavy fuel. do not load the engine fully for at least 10 hours. For a good running-in it is important to vary the load several times. After a piston overhaul the piston rings have to slid into new positions and need time to refit. do not load the engine fully for at least 4 hours. 85 .

nr. 1401DT101 1401DT102 1401DT127 1401DT128 1401DT129 1401DT130 1401DT131 1401DT132 1401DT133 1401DT134 1401DT135 1401DT136 1401DT137 1401DT138 1401DT139 1401DT140 Up Down X X X X X X X X X X X X X X X X -10 -8 -6 -4 -2 -1 360 shaft STD.5 1 Standard part Non standard Sales part 86 .4 Subject Maintenance Issue date April ‘98 2.FIELD SERVICE DATA BOOK W38 ärtsilä NSD Nederland B.V.4 MAINTENANCE Bearings(oversize undersize) Big-end bearings Part. 378 rod STD. Engine type W38 Chapter 2. 0.

FIELD SERVICE DATA BOOK W38 ärtsilä NSD Nederland B.NLs 87 .V. 1102DT101 1102DT102 1102DT106 1102DT107 1102DT108 1102DT109 1102DT112 1102DT113 1102DT114 1102DT115 1102DT116 1102DT117 1102DT118 1102DT119 Up X X X X X X X X X X X X X Downe X -4 -2 -1 380 400 shaft block STD STD 0.4 Subject Maintenance Issue date April ‘98 Main bearings Part.5 1 Axial. Engine type W38 Chapter 2.nr.bearings 1102DT103 1102DT104 1102DT110 1102DT111 standard Non standard Sales part X X X X Attn: Undersized axial bearings can be made out of undersized main bearing shells in consultation with Technical Service WNSD.

8 M20 8. Airsys.8 M16 8.9 M14 12.9 M20 10.5 M12 8.5 TORQUE [Nm] 300 400 then 20 back 200 600 540 540 25 145 28 330 500 85 79 220 79 68 125 450 3850 550 195 5100 550 195 550 390 79 215 40 195 20 150 195 9.V.8 M20 x 1.Damper start.8 M12 8.8 M20 M16 8.8 M16 M16 8.8 M24 x 1.9 M20 M16 8.4 Subject Maintenance Issue date April ‘98 Tightening torque’s for the various engine part connections CONNECTION Counter weight Main bearing below Main bearing side Connection rod complete Cylinder head Split gear on crankshaft (split) Split gear on crankshaft (flang???) Safety valve on cyl. HP Fuel pump HP Fuel pump cover HP Fuel pump cover HP Fuel pump locking bolt Tappet housing Control device coupling part Fitted bolt control device Governor drive housing Gear wheel on governor drive Nut driving shaft governor SIZE AND CLASS M42 x 3 M72 x 4 M48 x 3 M36 x 3 M64 x4 M20 12.8 M10 10.8 M30 x 2 M16 8.9 M16 8.8 M10 8.8 M42 x 3 12.8 M42 x 3 8.8 M6 8.9 M16 8.8 M8 8.Vibr.block cover Cylinder liner clamp Starting valve spindle Rocker arm bracket Locking nut valve clearance Cylinder head safety valve Starting valve Locking nut bridge piece guide Bridge piece guide Flange for exhaust gas pipe Gland injector Injector L’orange Vibration damper Double gear wheel Shaft with intermediate gear PTO-Vibration damper Camshaft flange Camshaft gear flange Fast.9 M10 8.8 M10 12.FIELD SERVICE DATA BOOK W38 ärtsilä NSD Nederland B.5 100 88 .9 M8 12. Engine type W38 Chapter 2.8 M20 M20 8.

FIELD SERVICE DATA BOOK W38
ärtsilä NSD Nederland B.V. Engine type W38 Chapter 2.4 Subject Maintenance Issue date April ‘98

Tightening torque’s (continuation) CONNECTION Locking bearing governor drive Turning wheel L38 Turning wheel 18V38 Fly wheel on turning wheel Gear wheel on lub. oil pump Gear wheel on cool.water pump Exhaust V-clamp Exhaust gas pipe Insulation box insulation metal Air cooler trunk 6/8/9 cylinder Air cooler trunk 18 cylinder Turbo charger 6 cylinder Turbocharger 6 cylinder Turbocharger 8/9/18 cylinder Support exhaust gas pipe Compensator exhaust gas pipe T-Support exhaust gas pipe 18v Receiver Connection piece to injector Locking flange HP Fuel pipe to cylinder head HP Fuel pipe to fuel pump Input piece delivery pipe Rubber compensator Bracket flexible mounting SIZE AND CLASS M6 12.9 12 x M48 4 x M48 M48 x 3 M24 8.8 M10 12.9 M10 8.8 M12 M12 M8 8.8 M16 8.8 M24 8.8 M20 8.8 M24 8.8 M20 8.8 M24 8.8 M24 8.8 M30 8.8 M24 8.8 M16 M16 8.8 M20 8.8 M20 12.9 M18 x 1,5 M10 8.8 M33 x 3 M39 x 2 M28 x 2 M20 8.8 M36 8.8 TORQUE [Nm] 10 4000 2000 4300 570 79 46 85 85 15 195 670 390 670 390 670 670 1350 670 195 160 390 650 150 12 180 210 210 60 2000

89

FIELD SERVICE DATA BOOK W38
ärtsilä NSD Nederland B.V. Engine type W38 Chapter 2.4 Subject Maintenance Issue date April ‘98

Tightening torque’s (continuation) CONNECTION Turbocharger 6 cylinder Turbocharger 6 cylinder Turbocharger 8/9/18 cylinder Support exhaust gas pipe Compensator exhaust gas pipe T-Support exhaust gas pipe 18v Receiver Connection piece to injector Locking flange HP Fuel pipe to cylinder head HP Fuel pipe to fuel pump Input piece delivery pipe Rubber compensator Bracket flexible mounting SIZE AND CLASS M20 M24 M24 M30 M24 M16 M16 TORQUE [Nm] 390 670 670 1350 670 195 160 390 650 150 12 180 210 210 60 2000

8.8 8.8 8.8 8.8 8.8

8.8

M20 8.8 M20 12.9 M18 x 1,5 M10 M33 x 3 M39 x 2 M28 x 2 M20 M36 8.8

8.8 8.8

90

FIELD SERVICE DATA BOOK W38
ärtsilä NSD Nederland B.V. Engine type W38 Chapter 2.4 Subject Maintenance Issue date April ‘98

Tightening procedure and hydraulic jack pressures Step 1: Positioning of engine components Step 2: Setting of materials Step 3: Obtaining the correct prestress Step 4: Checking step

ATTENTION! When following this procedure, its very important to carry out ALL four steps!! CONNECTION Main bearing stud Side stud Big end stud Connecting rod stud Counter weight stud Cylinder head stud STEP 1 [bar] 200 200 300 300 100 100 STEP 2/3/4 [bar] 770 750 870 870 760 600 NUT SHIFTING Tight firmly 4.0 - 4.5 holes Tight firmly 2.6 - 3.0 holes Tight firmly 2.6 - 3.0 holes Tight firmly 1.1 - 1.4 holes Tight firmly 1.6 - 2.0 holes Tight firmly holes

91

bar test .5 Subject Cylinder liner Issue date April ‘98 2.V.293 HB cylinder liner Honing specification 92 .5 CYLINDER LINER Specification Material: GG 30 (DIN 1691) Centrifugally cast Mechanical values in the wall of the liner .Hardness : 275 N/mm2 : 223 .FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. Engine type W38 Chapter 2.Tensile strength.

V. anti polishing ring cylinder liner 93 .5 Subject Cylinder liner Issue date April ‘98 Anti polishing ring Material: GG 30 Attention: Assemble the anti polishing ring with the chamfered side down.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. Engine type W38 Chapter 2.

6) Check at 85 Nm. bolts should not turn tighter! bolt bolt 94 .conn.6 Subject piston. 4) Tighten bolts cross wise at 20 Nm. 2) Tighten bolts cross wise at 100 Nm. 5) Turn bolts cross wise 100 degrees tight.rod. 3) Loosen bolts.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. Engine type W38 Chapter 2.crankshaft Issue date April ‘98 2.6 PISTON General Material of piston: GGG 70 Material of piston crown: 42 CrMo 4 V Tightening of piston crown 1) Lubricate threat with Molykote Gn plus.V.

∅ 4 mm Smitweld with a transformer setting of 200 Ampere).V. upper part lower part Disassembly of small eye bearing Place the connecting rod in a level position. After 10 to 25 minutes at positions 3 and 4. 1 5 3 6 4 7 2 95 . (See chapter 2.6 Subject piston. Make two welds on the small part of the bearing according to the drawing.conn.crankshaft Issue date April ‘98 Connecting rod Assembly of the connecting rod Assembly of the connecting rod upper part and connecting rod lower part should be done following the hydraulic tightening procedure.rod.4-3). (welding with resistance 100. Place a protection strip in the oil groove to prevent welding drops from entering the oil channel.6 and 7.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. First at positions 1 and 2. Now remove bearing with a copper punch. additional weldings must be made at positions 5. Engine type W38 Chapter 2. When the bearing does not come out.

x 96 .rod.conn.1 mm.4 mm ± 0.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. Engine type W38 Chapter 2.6 Subject piston.V.crankshaft Issue date April ‘98 Assembly of small eye bearing Cool the gudgeon-pin bearing bush in liquid nitrogen before fitting. Adjustment dimension X = 0.

34 max. 0.015 Ø 0.6 12. clearances and NO-GO criteria.025 GH 0.0 / 379.conn.964 1.crankshaft Issue date April ‘98 Crankshaft specification The crankshaft hardness may not exceed more than 10% of the average hardness.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.015 Concentricity crankshaft Maximum deviation between adjacent crank 0. Hardness Radius oil channels Quality surface radius Crankweb 240 Hbr R = 10 Fig I 1. The following information regard measurements.6 Subject piston.V.015 0.015 / 1000 GH 97 .0 / 400.015 0.036 min.08 Diameter main bearing Main bearing clearance Diameter crankpin Roughness crankpin Radius crankpin Straightness Roundness Paralellety Ø 400 H6 400.5 Main bearing journal . measured on the undamaged part of the crankshaft.and clearance Diameter main bearing Roughness bearing surface Radius concentricity roundness Straightness Ø 380 h6 380.rod. Engine type W38 Chapter 2.4 R21 Fig III 0.42 Ø 360 h6 0. 0.6 R 30 Fig: IV Ø 0.

95 Axial bearing with axial rings 139.109. 0.95 Axial bearing measurement crankshaft 140.02 GH 98 .20 .139. Engine type W38 Chapter 2.conn.6 Subject piston.85 .V.crankshaft Issue date April ‘98 Crankshaft (continuation) Diameter big-end bearing Ø 380 Big-end bearing clearance Axial clearance crankshaft Axial bearing without axial rings 109.05 GH Concentricity Ø 0.25 max.02 GH Flywheel flange 3.140.rod.2 Roughness Run out 0. 0.05 GH Concentricity 0.85 .40 Damper flange Runout 0.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.25 Clearance axial: min.

0. max. taperness Shape of crankpin a.349.04 mm : 0.5 .0.02 mm ( see detail C *) : 0. crankpin: 357.96 mm 10 mm U. Engine type W38 Chapter 2. see detail B *) : 0.conn.6 Subject piston.357. run-out of adjacent main bearing journals: 0.Undersize crankpin bearings available 2 mm U.S. ovality Max. *) See also Illustration on the following page 99 .3 / 1000 Max.S. Check running pattern after 10 minutes at 20 % load.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. diameter ) 3. crankpin: 349.92 . crankpin: 353.V.S: 10 mm U.rod.4 µm ( 1 µm = 40 µ inch ) Roughness of fillet : 0.S.8 µm Radius in way of the fillet Undercut to fillet Radius in way of oil hole : min.General requirements for repair of a damaged crankshaft Hardness Oscillation Cracks : nominal 240 HV. R = 17 mm ( standard: 21 mm.96 mm : 0. parallelism to centreline Roughness of crankpin: 0.92 . b.S: 1401DT131 / 132 1401DT135 / 136 1401DT139 / 140 ( = minimum admissible U.crankshaft Issue date April ‘98 1.96 mm 6 mm U.5 mm ( R = 17 mm ) : 10 mm. rounded off to the pin(see detail A *) 4. Max. Checks on actual running pattern Check running pattern before start-up with Prussian blue and turning to verify that the pin is not “barrel shaped”.353.92 .S.Geometrical requirements for repair of the crankpin by a specialised firm Diameter Diameter Diameter 2 mm U.06 mm ( dial ) : no cracks are allowed ( Magnaflux ) 2. 300 HV : max.03 mm : Convex shape ( “Barrel shape” ): absolutely not allowed : Concave shape: max.S: 6 mm U.

conn.6 Subject piston.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.crankshaft Issue date April ‘98 Illustration to be used at requirements for repair of a damaged crankshaft A C B 100 .rod.V. Engine type W38 Chapter 2.

Measure valve according instructions. clock valve spindle close to steady rest (max. • Place valve in the chuck of the lathe directly or. 0. • • • • • • Clean valve. Balance wheel. 101 . • Measure valve. • Install grinder at correct horizontal level. Engine type W38 FIELD SERVICE DATA BOOK W38 Chapter 2.02 mm) • Apply a stabilizer plate (slightly smaller diameter than valve). looking against bottom side of the valve.7 Subject Cylinder head with valves Issue date April ‘98 2. Study manual for grinding machine carefully.Wärtsilä NSD Nederland B. • Watch temperature of valve disc. speed of grinding wheel: 8000 rpm. • Dress-up the grinding wheel if necessary • Approach the wheel radial and: • Keep pressure on the stone constantly (Never leave the wheel).7 CYLINDER HEAD WITH VALVES Grinding inlet and exhaust valves 1) Chris-Marine valve spindle grinder type 75H for use in the lathe. for instance by glass blasting. • Do not hand-grind valves to seat in cylinder head. • Grind until entire seat shows a clearly ground surface (not too shiny).V. • Lubricate valve seat during the grinding with thick gear oil (sae 80 to 90). Angle of chisel holder to be set with conical template for 29° 50’ ± 5’. between valve disc and center ensure sample air supply.70 rpm • Direction of rotation: anti clockwise. Use a standard grinding wheel for NiMoNic valves. • Have valve running with the grinding wheel. if chuck is not 100% true: Use steady rest.

Dress-up the grinding wheel if necessary.V. • Use long type stabilizer. looking against bottom side of the valve. 102 .Wärtsilä NSD Nederland B. • Angle to be set at 29. Direction of rotation: counter clockwise. • Balance wheel. Turn all screws by hand and than slightly with spanner. • Use a white grinding wheel. Cooling: Water with 1-1½ % anti corrosion (5% is too much). • Standard speed of grinding wheel: 100 rpm at 50 Hz. • Fit valve. • The beveled edge of the valve spindle top should be just outside the collet. Do not hand-grind valves to seat in cylinder head. using centering collets for a 30 mm valve spindle.83° ± 0. • Study manual for grinding machine carefully. for instance by glass blasting. • Measure valve according instructions. 27/1373010). • Move the wheel radial to the valve and keep pressure on the stone constantly (Never leave the wheel). • Measure valve. 200 x 13 x 32 mm (cm part nr.7 Subject Cylinder head with valves Issue date April ‘98 Grinding inlet and exhaust valves (continuation) 2) Chris-marine valve grinding machine type bsp 1 or 3 • Clean valve.05° = 3’. • Grind until entire seat shows a clearly ground surface (not too shiny). Engine type W38 FIELD SERVICE DATA BOOK W38 Chapter 2.08° (=29° 50’ ± 5’) Nonius devisions: 0.

7 Subject Cylinder head with valves Issue date April ‘98 Grinding inlet and exhaust valves (continuation) Material: valve = X45CrSi 93 seat = GZ-X190CrMo12 2V Induction hardened : min.V. 50 Hrc / case depth 1. Engine type W38 FIELD SERVICE DATA BOOK W38 Chapter 2.Wärtsilä NSD Nederland B.0’ Material: valve MDO = X45CrSi93 valve HFO = NIMONIC 80A seat = GNiCr50Nb Hardness: 46 ± 3 Exhaust valve and seat 30 +4 -0 103 .5 Inlet valve and seat 3 0 + 4’ .

NOTE: It is important that the whole cylinder head should be heated up slowly and not only the seat bore. This to avoid hot spots which could result in cracks etc. which should be placed above the liquid until the right temperature should be reached. 2) Cool the new seat-ring down to -150°C with liquid nitrogen.) Loctite 290. 4) After cylinder head/seat is back on environmental temperature the seat should be grinded on correct setting.a. put slightly some oil = “Super-O-Lube” on the O-ring. Exhaust: 1) Idem as above item 1. (The cylinder head should not be headed up for fitting the inlet seat!!) 3) Fit the cooled ring carefully.7 Subject Cylinder head with valves Issue date April ‘98 Inlet and exhaust valves (continuation) Replacing the valve seat rings in cylinder head. 104 . to environmental temperature.s. the seat should be grinded. Place on the outer diameter ∅ 144 (make sure that surface is clean and free of grease etc. Preferable is to cooling down the new seat ring on a plate.p. 5) After the cooling down of the cylinder head.Wärtsilä NSD Nederland B. Inlet: 1) Remove the old seat by the welding/shrink method. 4) After the cooling down of the seat. whereafter fitting the new seat including the O-ring. 3) Heat up the cylinder head to 90°C. The ring should be tightened of the bottom of the inlet chamber of the cylinder head.V. together in cylinder head a. Clean the bore of the seat in cylinder head and check diameter bore etc. Engine type W38 FIELD SERVICE DATA BOOK W38 Chapter 2. 2) Cooling down the new seat-ring to -50°C.

Set the grinding angle for the inlet and exhaust seats of the W38.Adjust the handwheel(3) until the marking(1) on the setting plate is in the middle of the two border markings(2).1mm.loosen the two blocking handles (4) and (5) and lower the grinding stone until it is in the middle of the seating face.Move slider(8) in “up”-position 105 .(one notch on the fine-adjustment knob will feed in 0. . .7 Subject Cylinder head with valves Issue date April ‘98 Grinding the valve seats . . (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).Move the gringing stone down towards the starting point by means of the handwheel(3).Lock the handwheel(3) with knob(7).V.This is to avoid high temperatures during machining.Wärtsilä NSD Nederland B. .Fasten the handles (4) and (5) . .).Feed in the grinding wheel 0.05mm. Engine type W38 FIELD SERVICE DATA BOOK W38 Chapter 2. .

Move slider(8) in “down”-position and restart the rotation motor. .During the last-but-one movement of the grinding stone the maximum in-feed is 0.7 Subject Cylinder head with valves Issue date April ‘98 Grinding the valve seats (continuation) .V.During the last movement grind without in-feed. 106 .Start rotating movement by turning and moving down the clutch ring(9).the necessary grinding depth should be adjusted by the fine adjustment.Grind until the upper side of the valve seat is reached.and rotation motor.When more grinding cycles are required. . Then turn of the rotation motor by means of the clutch ring(9) .Start grinding. .Wärtsilä NSD Nederland B.03 mm. Engine type W38 FIELD SERVICE DATA BOOK W38 Chapter 2. . .

5 7.8 clearance inlet 4.2 10.5 6.0 7.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.valve Adjustment at 8 mm lift 15°30’ 72 73 14°30’ 71 82 13°30’ 70 71 12°30’ * 69 70 11°30’ 68 69 10°30’ 67 68 9°30’ 66 67 8°30’ 65 66 * Adjustment figures drawn diagram open exhaust inlet close exhaust inlet 61 62 63 64 56 66 67 68 34 35 36 37 38 39 40 41 clearance exhaust 11.2 9.0 7.V.4 5.1 8.2 4.8 5.8 6.8 CAMSHAFT AND VALVE DRIVE Camshaft diagram Possible adjustments Nominal valve timing at 1 mm lift Clearance piston .0 9.8 8.8 Subject Camshaft and valve drive Issue date April ‘98 2.2 107 . Engine type W38 Chapter 2.6 10.

8 Subject Camshaft and valve drive Issue date April ‘98 Camshaft and valve drive (continuation) 108 . Engine type W38 Chapter 2.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.V.

Engine type W38 Chapter 2. Every tool is unique and therefor has its own convert table.V.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. 109 . The pressure that is set on the tool represents a torque.8 Subject Camshaft and valve drive Issue date April ‘98 Camshaft part Material: Camshaft part = 17CrNiMo6 Journal = 42CrMo4 Bearing journal = C35N 1 1: Fuel injection cam 2: Exhaust cam 3: Inlet cam 4: Camshaft journal 2 3 4 Mounting of camshaft gearwheel To mount the camshaft gearwheel you can use a hydraulic tool.

00 V38 440. 6 Gear name Z M Width 50 50 50 Water pump 20 8 gearwheel 7 Pump driven 90 8 gearwheel 8 Lubricating pump 31 8 gearwheel Flankclearance with bearingcorrection L38 440.54 clearance H1 H2 6 7 8 110 . Engine type W38 Chapter 2.8 Subject Camshaft and valve drive Issue date April ‘98 Gearwheel clearances and dimensions nr.39-0.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.63-0.14 Opp. gear 7 Flank clearance 0.V.10 484.17 484.78 Assembly flank- 7 0.

8 Subject Camshaft and valve drive Issue date April ‘98 111 . Engine type W38 Chapter 2.V.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.

81 Assembly crankshaft 2 Intermediate 66 10 90 flankgearwheel large 3 Intermediate 33 10 110 0.28-0.24-0.V.71 Split gearwheel for 62 10 90 Assembly crankshaft 2 Intermediate 66 10 90 flankgearwheel large 3 Intermediate 33 10 110 4 0. 112 .68 5 Governor drive 19 10 35 5 gearwheel Operating flankclearance under given circumstances as: Shaftdistance-tolerance/bearing clearance-tolerance/teeth-tolerance/bending and thermal expansion (with operating temperature 100°c).41-0.8 Subject Camshaft and valve drive Issue date April ‘98 Gearwheel clearances and dimensions(continuation) nr. 1 Gear name Z M Width Opp gear 2 Flank clearance 0.32-0.47-0.39-0. Engine type W38 Chapter 2.45-0.59 clearance gearwheel small 4 Camshaft gearwheel 62 10 110 5 0.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.40 5 Governor drive 19 10 35 gearwheel Flankclearance where the gearwheel is the theoretical center 1 Split gearwheel for 62 10 90 2 0.61 clearance gearwheel small 4 Camshaft gearwheel 62 10 110 4 0.57-0.53 Assembly crankshaft 2 Intermediate 66 10 90 flankgearwheel large 3 Intermediate 33 10 110 4 0.59 5 Governor drive 19 10 35 gearwheel Flankclearance with bearingcorrection 1 Split gearwheel for 62 10 90 2 0.31-0.55 clearance gearwheel small 4 Camshaft gearwheel 62 10 110 5 0.

FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. Engine type W38 Chapter 2.V.8 Subject Camshaft and valve drive Issue date April ‘98 Picture for gearwheel clearances 5 4 3 2 1 113 .

Engine type W38 Chapter 2. Turn the shaft and use a dial indicator to obtain indications.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.8 Subject Camshaft and valve drive Issue date April ‘98 General roundness check for gearwheels Place a cylindrical pin in the tooth cap as shown. Repeat the procedure and take comparative indications from at least four different locations. 114 .V.

15 0.5. 0.30 Groove 4.17 Note: Measering point: approx.08 114 .0 Subject No-go criteria Issue date April ‘98 3.45 Groove 2.17 0. A: Groove 1. 1 Two piece piston 2 3 4 Clearance between new piston ring and groove.15 0.GO CRITERIA FOR ENGINE PARTS Piston and piston ring wear limits Description Design size (mm) Wear limit (mm) Two piece piston with steel crown.06 0. 0. 0.40 Groove 3.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.15 0. 0. 0.17 A 0.50 0. Engine type W38 Chapter 3.0 NO .V.0mm from outer surface.

FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.99 A 10 10 10 10 10 10 A- A A 115 . Engine type W38 Chapter 3. A175.00 174.0 Subject No-go criteria Issue date April ‘98 Piston gudgeon pin wear limits Description Design size (mm) Wear limit (mm) Piston and gudgeon pin Gudgeon pin hole.02 A Gudgeon pin diameter.97 174.05 175.V.04 175. 175.

000 359.057 378.25 175.V.000 Small end bore diameter with bearing D-E 175.02 The measurement A+B+C+D 4 should be taken at side 1 and 2 of the big end.377. Engine type W38 Chapter 3.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.373 Max.288 0.05 0. D 1 2 E 195. Assembled bearing bore 360. Small end bore diameter without bearing D-E Wear limit (mm) Connecting rod.rod.02 Difference between B/C 116 .029 195.000 A+B+C+D 3 Ovality Conicity A-C 1-2 360.378.120 0.40 360.180 175. 360.03 Ovality D-E Big end diameter.05 195. The conicity is the difference between 1 and 2.980 0.0 Subject No-go criteria Issue date April ‘98 Connecting rod wear limits Design Description size (mm) Con.057 Min.964 A B 1 2 C D Big end bore diameter 378.

90 wall thichness D- 10.03 0.00 10.70 80.50 349. Engine type W38 Chapter 3.240 10.e.193 D 117 . 872 0 0.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.20 79.40 79.90 380.100 348. i.0 Subject No-go criteria Issue date April ‘98 Cylinder liner wear limits Description Design size (mm) Wear limit (mm) Cylinder liner.000 93 147 202 Ovality 0.000 B A Height B- 79. difference in diameters measured at 93 and 202 mm from top.60 Height A- 349.V.057 380. Bore 380.10 568 Conicity.60 Anti polisching ring Height C - C 81.10 80.

V.30 Ø 30.00 D C B A 118 . AI = 66 II = 110 III = 325 BØ 30.oscillation of valve stam and disc.00 1.15 0.134 Valve disc at: ABCangle D Max.00 0.03 13. Valve stem diam. 29°50’±5’ 0.979 I II A III A B B Ø 28. Engine type W38 Chapter 3. AØ 30.161 Ø 30.000 Ø 29.00 Ø 27.90 Ø 29.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.00 12.50 25 25 A A Valve guide bore.0 Subject No-go criteria Issue date April ‘98 Exhaust valve and seat wear limits Description Design size (mm) Wear limit (mm) Exhaust Valve.

025 Ø 125.00 Ø 130.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.000 119 .80 angle E Recess cyl.V.000 D inner bore - Ø 125.head outer bore - 30°±5’ E Ø 144.025 Ø 144.0 Subject No-go criteria Issue date April ‘98 Exhaust valve and seat wear limits (continuation) Valve seat Diam.00 Ø 127. Engine type W38 Chapter 3. D- Ø 128.

FIELD SERVICE DATA BOOK W38
Wärtsilä NSD Nederland B.V. Engine type W38 Chapter 3.0 Subject No-go criteria Issue date April ‘98

Inlet valve and seat wear limits

Description

Design size (mm)

Wear limit (mm)

Inlet Valve.

Valve stem diam. AI = 66 II = 110 III = 325 BØ 30.000 Ø 29.90 Ø 29.979
I II A III A B B

Ø 28.00

Ø 27.50

25

25

Valve guide bore. AØ 30.161 Ø 30.30 Ø 30.134
A A

Valve disc at: ABCangle D Max.oscillation of valve stam and disc. 29°50’±5’ 0.00 0.15 0.03 13.00 12.00 1.00

D

C

B

A

120

FIELD SERVICE DATA BOOK W38
Wärtsilä NSD Nederland B.V. Engine type W38 Chapter 3.0 Subject No-go criteria Issue date April ‘98

Inlet valve and seat wear limits (continuation)

Valve seat Diam. D-

Ø 128.00 Ø 130.00 Ø 127.80
E

30°±5’ angle E Recess cyl.head outer bore Ø 144.025 Ø 144.000
D

121

FIELD SERVICE DATA BOOK W38
Wärtsilä NSD Nederland B.V. Engine type W38 Chapter 3.0 Subject No-go criteria Issue date April ‘98

Valve drive mechanism wear limits

Description

Design size (mm)

Wear limit (mm)

Valve drive mechanism

Valve drive mechanism. Valve tappet 1 -

Ø 114.928 Ø 114.75 Ø 114.893 Ø 115.035 Ø 114,95

A

Guide diam. 2 -

Ø 115.000

A

Ø 50.016 Roller pin bore in tappet. 4 Ø 50.05 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 diam.in situ. 9 Ø 85.30 Ø 85.050

Ø 85.000 Bearing journal diameter 10 Ø 84.95 Ø 84.989

122

034 Ø 34.95 123 .V. Engine type W38 Chapter 3.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.080 Ø 34.050 Pin diam.119 Yoke bore 12 Ø 34.20 Ø 33. 11 Ø 34.0 Subject No-go criteria Issue date April ‘98 Valve drive mechanism wear limits (continuation) Yoke Ø 34.

Description Design size (mm) Wear limit (mm) Exh. Engine type W38 Chapter 3.0 Subject No-go criteria Issue date April ‘98 Copyed from Exhaust and inlet valve spring.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.V.00 ø105 L 124 .50 207.00 201. and inlet spring Valve spring Length of spring (Dismantled) L= 203.

015 Note: The bending moment in the crankshaft caused by extra weights is limited as well as the corresponding deflections.7 X deflection limit The maximum deviation between A and E is : – Inline–engine – Vee–engine The maximum deviation between 2xC + A + E D+B ---------------. the crankweb deflection limit is : Alignment must be carried out =No – Go.08 0. So the crankshaft ends has to be free from extra loads due to for instance the weight of elastic couplings etc.V. If power is taken from the free end.V. the crankweb deflection limit for the first crank is : The maximum deviation between adjacent cranks is : 0.10 0.and -------.05 0. Engine type W38 Chapter 3.01 0.04 0. After alignment of the crankshaft. mm No – Go mm Crankshaft deflection tolerance Measuring the alignment of the engine the unloaded crankshaft is considered as a reference. (*) 125 .FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. For execution of the crankshaft deflections see chapter 11 in Manual.0 Subject No-go criteria Issue date April ‘98 Crankshaft deflection tolerance Max. In case of extra weights contact Wärtsilä NSD nederland B..is: 4 2 (for diagram : see next page) 0.02 0.

FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. Engine type W38 Chapter 3.V.0 Subject No-go criteria Issue date April ‘98 Crankshaft deflection tolerance (diagram) operating side non operating side Dial gauge position 126 .

375 Ø 380. An overloaded bearing shell can be recognized to locally melted or smeared lining.835 9.447 Ø 380.Main bearing – the bearing shell is free of any damage. mm No – Go mm 9.395 7315 7. Judgement of a Aluminium type bearing does not tell everything since.0 Subject No-go criteria Issue date April ‘98 Aluminium plain bearings wear limits The engine bearings consist of a steel back onto which a very tiny bonding of almost pure Aluminium. For determination of wear. until the next inspection.361 Big end .Main bearing Max.Camshaft – the inside diameter is within the given tolerances. engine components and measuring equipment should for some hours first be acclimated at room temperature ( 20 C° ). Engine type W38 Chapter 3.805 8. there is no copper barrier between the steel back and the run-ning layer visible. connecting rod big end.V.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. .75 9.890 8. – the wear pattern is equal. the quality of the lubricating oil cleaning should be observed more carefully.865 7. until the next inspection. It concerns the bearings for crankshaft. On this bonding is a running layer of Aluminium alloy. unlike a tri–metal bearing.30 Ø 380. . Where bearings show heavy wear grooves in the running layer. – the bearing shell is free of any corrosion.810 8. and camshaft. – the running layer is not overloaded. A bearing is suitable for further use as long as: – the shell thickness is expected to stay within the given tolerances. New bearings are treated with a corrosion protection oil that has to be removed before mounting.Note! 127 .

See fig. control with foundation screws or with the drillings for flexible mountings. Figure 1 128 . 1.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.0 MOUNTING INSTRUCTION FOR FLEXIBLE MOUNTED ENGINE 1. 2. Location of the rubber element and tools Place the engine on the tools H=100 mm.V. Lift the engine on the right location. Engine type W38 Chapter 4. Level the engine.0 Subject mounting instruction Issue date April ‘98 4.

See fig.11. Place no. See fig.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B.9.15.5.12. 129 . Engine type W38 Chapter 4.V.6.14. 3: assembly of the single foundation rubber elements.18 and 19.10. Figure 2 When necessary adjust the element height with shims.0 Subject mounting instruction Issue date April ‘98 3.16. Assembly foundation rubber element controlling that the element height difference x(+s) between the elements will be within 1mm.7.2. 3.

See fig.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. Mark the location of the tools on the engine block.17 20.V.8. Place no. 4. Adjust mechanical height limiter on all single foundation rubber elements to 10 mm. Remove the tools. 2. 1 and 4 will be empty. 4:assembly of the double foundation rubber elements. Record after at least 48 hours the clearance at the marked places. 3. NOTE! Place no.0 Subject mounting instruction Issue date April ‘98 Figure 3 See fig. and 130 .13. 5. Engine type W38 Chapter 4.

then adjust the checked clearance with shims to the recorded clearance . Engine type W38 Chapter 4. See fig. See fig. 5.V. −0 Check regularly the clearance at the marked places. 7. When the checked clearance has become 1 mm. 131 .FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. 25 mm higher . Adjust mechanical height limiter on all double foundation rubber elements to 2 mm. less that the recorded clearance .7 +0. 8. 4. Install the generator to the engine taking into account that the engine should be situated 0.0 Subject mounting instruction Issue date April ‘98 Figure 4 6.

0 Subject mounting instruction Issue date April ‘98 Figure 5 132 .V.FIELD SERVICE DATA BOOK W38 Wärtsilä NSD Nederland B. Engine type W38 Chapter 4.

mr38/1000/01 Engine No. after turbocharger speed turbocharger Mainbearing temp Date of measurement: Wärtsilä Nederland b.tem after turbocharger Char.t1 exh.druk Brst. Service.cooler temp.1997 00 Engine type: Temperature (°C): Operating Data Record Date Time Verm. Netherland Name: Telecop.Zwolle .Service.afname Engine speed Position regulat. eng temp before air cooler temp.tem in receiv. WNL Date Issue Document No.v. +31-38-4253538 Tel. Box 10608 (hanzelaan 95) NL-8000 GB Zwolle.t2 [kW] r/s hours fuel r.cooler Brst. temp.inl. C r/s C C C C 0 1 2 3 4 5 6 7 8 9 Gem. 1 2 3 4 5 6 7 8 9 Gem. bar C C C C bar bar C C C bar C bar Place: P.12. Intake air temp Lub oil temp before engine Lub oil pressure before engine LT pressure inl. charging pressure Char. SWD Engines Engine section 1000 General Installation (ship): Fuel viscosity (cSt): Engine type Ref. after lub oil.eng.temp HTpressure. Running hours exh. +31-38-4253253 Telecop.O.: Running hours: Page 1(2) W38 03. +31-38-4223564 Telex 42116 swdz nl C C mm C C mm C C mm C C mm exh. before lub oil.

before air cooler temp. Vasa Engines Issue 01 Measurement record Document No. 00000000GB Page 2(2) temp before engine temp.Service. after air cooler C C C .

v. No. No. Box 10608 (hanzelaan 95) NL-8000 GB Zwolle Name: Telecop. +31-38-4253538 Telecop. +31-38-4253253 Telex 42116 swdz nl . +31-38-4223564 Tel.Service. WNL–S Date 07.03.O. WNL Engines Engine section 1102 Main Bearing Installation (ship): Engine type W38 Ref. 3 4 5 5 3 Bearing number 0 1 2 3 4 5 6 7 8 9 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 Upper Half A B C Remarks/Manufact. 145 code nr. 1 2 3 4 5 1 2 3 4 5 A Lower half C Remarks/Manufact. Date of measurement: Wärtsilä Netherlands b. Service.: Running hours: 25 Page 1(2) MAIN BEARING SHELL Main bearing shell nominal thickness: 9.810 [mm] Max.1997 Engine type: Temperature (°C): Issue 00 Document No. 9.9.835 . Zwolle Place: P. mr38/1102/01 Engine No.750 45° 25 Lower half C 1 A 15 Upper half C B A 15 80 145 1 45° 2 3 2 code nr.

.

mark “X” 2 IV 568 V 872 Component running hours before measurement: Bank ______ 1 2 3 4 Cylinder number 5 6 7 8 9 Cylinder liner. Reference diameter (or V/1): Antipolishing ring.000 – 380. II = 380. +31-38-4253253 Telex 42116 swdz nl .Service. +31-38-4253538 Telecop.9 [mm].: Running hours: X 1 A 40 4 2 92 147 202 B 70 Page 1(1) Cylinder liner Code number: Component running hours before measurement: Measured: o o Mounted Free Temperature (°C): View X 3 1 I II III Nominal diameter = 380.6 [mm]. wall thickness([mm] Level A 1 2 3 4 Level B 1 2 3 4 Remarks/Manufact No.1 [mm] (Difference between dmax and d min measured on any level). mr38/1302/01 Engine No. WNL Engines Engine section 1302 Cylinder liner Installation (ship): Engine type W38 Ref.057 [mm] Wear limits: I = 380. Wear limit = 10. III. wall thickness Nominal thickness = 10.03. +31-38-4223564 Tel. WNL–S Date 07.v.24 – 10. Service. IV +V= 380. Antipolishing ring.3 [mm] Ovality = 0.1997 Engine type: Temperature (°C): Issue 00 Document No.O. diameter d (deviation in 100/mm) I II III IV V 1 2 1 2 1 2 1 2 1 2 Remarkss/Manufact No.19 [mm].10 [mm] Measure with a ball-shaped micrometer on level A and level B. Date of measurement: Wärtsilä Netherlands b. Zwolle Place: P. Box 10608 (hanzelaan 95) NL-8000 GB Zwolle Name: Telecop.

057 . No. Box 10608 (hanzelaan 95) NL-8000 GB Zwolle Name: Telecop.25 [mm] Code number: Bank ______ 1 Big end bearing bore (Deviation in 100/mm) D1 L R D2 L R D3 L R D4 L R D5 L R Max. WNL Engines Engine section 1401 Connecting rod Installation (ship): Engine type W38 Ref.1 [mm] d2 1 Reference diameter [mm]: Code number: 378 Component running hours before measurement: Temperature (°C): 15 R D 15 Gudgeon pin bearing bush mounted Wear limit (d1. Date of measurement: Wärtsilä Netherlands b.rod 15 Cylinder number 5 6 7 8 9 Remarks/Manufact. deviation 2 3 4 15 L dowel pin con. d2): 175.O. No.0) [mm] Allowed minimum diameter: 377. WNL–S Date 07. +31-38-4253253 Telex 42116 swdz nl .90 [mm] Maximum allowed difference between D max and Dmin: 0.1997 Engine type: Temperature (°C): Issue 00 Document No. +31-38-4253538 Telecop.Service. Hydraulic pressure when tightening: I = 870 bar II= 870 bar d1 15 15 3 2 4 5 II I Nominal diameter without shells: (D)= 378 H7 (+ 0. mr38/1401/01 Engine No. (stamped on conrod) Gudgeon pin bearing bush mounted [mm] d1 L R d2 L R Remarks/Manufact. Service. Zwolle Place: P. +31-38-4223564 Tel.v.: Running hours: Page 1(1) Big end bearing bore Big end nuts and connecting rod must be tightened before measuring.03.

8.: Running hours: 25 Page 1(1) BIG END BEARING SHELL Bearing shell nominal thickness: 8. WNL Engines Engine section 1401 Connecting rod Installation (ship): Engine type W38 Ref.03. Date of measurement: Wärtsilä Netherlands b. No. Box 10608 (hanzelaan 95) NL-8000 GB Zwolle Name: Telecop.865 [mm] Max. Zwolle Place: P.890 .v.1997 Engine type: Temperature (°C): Issue 00 Document No.O. No. Service. +31-38-4253253 Telex 42116 swdz nl . +31-38-4223564 Tel. +31-38-4253538 Telecop. WNL–S Date 07. 8. mr38/1401/02 Engine No.805 [mm] 3 45° 25 Lower half C B A 15 70 125 codenr Upper half C B A 15 70 125 codenr 1 2 1 2 3 45° 4 5 5 4 Bank 1 2 3 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 Cylinder number 4 5 6 7 8 9 Upper Half A B C Remarks/Manufact.Service. 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 A Lower half B C Remarks/Manufact.

03.50 8.45 8. WNL–S Date 07.8.17 . Service.v.40 10. No.8.15 8. WNL Engines Engine section 1421 Piston Installation (ship): Engine type W38 Ref.Service. +31-38-4253253 Telex 42116 swdz nl .15 8. 1 I 2 3 4 1 II 2 3 4 1 III 2 3 4 1 IV 2 3 4 Remarks/Manufact.8. +31-38-4223564 Tel. Zwolle Place: P.17 .30 4 2 view A 3 notch in pistonskirt Cylinder number 1 1 2 3 4 5 6 7 8 9 ABank I 2 3 4 1 II 2 3 4 1 III 2 3 4 1 IV 2 3 4 Remarks/Manufact.10. No.O.: Running hours: A Page 1(1) Piston ring groove height Component running hours before measurement: Temperature (°C): 1 I II III IV Nominal height (mm) Ring Ring Ring Ring I II III IV 8.15 10.08 . mr38/1421/01 Engine No. Box 10608 (hanzelaan 95) NL-8000 GB Zwolle Name: Telecop. BBank Date of measurement: Wärtsilä Netherlands b. +31-38-4253538 Telecop.06 Wear limit (mm) 8.17 .1997 Engine type: Temperature (°C): Issue 00 Document No.

1997 Engine type: Temperature (°C): Issue 00 Document No.b.12.1mm Measure the values a. +31-38-4253253 Telex 42116 swdz nl . WNL–S Date 22.O. mr38/1421/02 Engine No.v.c. +31-38-4223564 Tel. Service. Box 10608 (hanzelaan 95) NL-8000 GB Zwolle Name: Telecop. WNL Engines Engine section 1421 Piston Installation (ship): Engine type W38 Ref.Service. +31-38-4253538 Telecop.d at three points on the side of the crown (see drawing 2) Inspection method: reduced / extensive Date of measurement: Wärtsilä Netherlands b.: Running hours: Page 1(1) Crown number Cylinder number Top view (1) Side view (2) Bottom view (3) a b c d A B C D E F G H I J K L M Thickness of carbon in 0. Zwolle Place: P.

WNL–S Date 22.970 [mm] Reference diameter: 175 [mm] Deviation to be given in 1/100mm Bank: -1 2 2 1 A 2 3 4 1 B 2 3 4 1 C 2 3 4 1 D 2 3 4 1 E 2 3 4 1 F 2 3 4 Cylinder number 4 5 6 7 8 9 Date of measurement: Wärtsilä Netherlands b.12. Box 10608 (hanzelaan 95) NL-8000 GB Zwolle Name: Telecop. Service.1997 Engine type: Temperature (°C): Issue 00 Document No. mr38/1421/03 Engine No. +31-38-4253538 Telecop.988-175. Zwolle Place: P.000 [mm] Wear limit: 174. +31-38-4223564 Tel. WNL Engines Engine section 1421 Gudgeon pin Installation (ship): Engine type W38 Ref.O.v. +31-38-4253253 Telex 42116 swdz nl .Service.: Running hours: Page 1(1) GUDGEON PIN Gudgeon pin nominal diameter: 174.

v.03. 1 I II I II I II I II 2 3 4 5 6 7 8 9 Date of measurement: Wärtsilä Netherlands b.1997 Engine type: Temperature (°C): Issue 00 Document No. bottom view Bank: A Inlet B C Exhaust D Remarks / Manufact Nr.Service.: Running hours: Page 1(1) VALVE GUIDES 25 I II 25 air in exh.30 [mm] Referenc diameter: 30. Box 10608 (hanzelaan 95) NL-8000 GB Zwolle Name: Telecop. +31-38-4253538 Telecop.O.161 . Cylinder nr. Zwolle Place: P. +31-38-4253253 Telex 42116 swdz nl .30.134 [mm] Wear limit: 30. +31-38-4223564 Tel. WNL Engines Engine section 1501 Inlet-/exhaustvalve Installation (ship): Engine type W38 Ref.out D inlet D exhaust A B D C Valve guide nominal diameter: 30. Service. WNL–S Date 07.00 [mm] Deviations to be given in 1/100 mm. mr38/1501/01 Engine No.

mr38/1501/02 Engine No... WNL Engines Engine section 1501 Injection valve Installation (ship): Engine type W38 Ref.. Service. 1 Opening pressure Po = 450 bar 2 Testing pressure (P o .20 bar) 3 Pressure drop range (P o .... Zwolle Place: P.12. WNL–S Date 22.....O.1997 Engine type: Temperature (°C): Issue 00 Document No.20) → (P o ...220) bar 4 I Excellent at all speeds II Good at some test speeds Date of measurement: Wärtsilä Netherlands b... Nozzle type Remarks ...: Running hours: Page 1(2) INJECTION VALVE TEST RECORD No..Service... +31-38-4253538 Telecop. Box 10608 (hanzelaan 95) NL-8000 GB Zwolle Name: Telecop. +31-38-4253253 Telex 42116 swdz nl .. +31-38-4223564 Tel.. Cyl...v.

III Bad .

29. +31-38-4223564 Tel. Stem stampings Valve locations Burn-off area: Z max = 1. WNL–S Date 07.: Running hours: Page 1(1) Valves I II III Z air in exh. Wear Limit: 29.Service. WNL Engines Engine section 1504 Inlet-/exhaustvalve Installation (ship): Engine type W38 Ref. Box 10608 (hanzelaan 95) NL-8000 GB Zwolle Name: Telecop.900 mm.O.03.out Stampings Y A B D C Nominal diameter: 30. mr38/1504/01 Engine No.979 mm.000 .v.1997 Engine type: Temperature (°C): Issue 00 Document No. Zwolle Place: P. +31-38-4253253 Telex 42116 swdz nl . Cylinder 1 I II I N L E T B A III Z Y I II III Z Y I E X H A U S T D C II III Z Y I II III Z Y Nr.5 mm Y max = 12 mm I : 66 mm bottom view II : 110 mm III : 325 mm Deviations to be given in1/100 mm. 6 7 8 9 2 3 4 5 Date of measurement: Wärtsilä NSD Nederland b. Service. +31-38-4253538 Telecop.

4 Reference diameter : D = 250 Towards flywheel end (B-bank) Towards flywheel end (in Line or A-bank) Deviation to be given in 1/100mm Bank: -D1 D2 D3 D4 E1 E2 E3 E4 0 1 2 3 Bearing number 4 5 6 7 8 9 Remarks Date of measurement: Wärtsilä NSD Nederland b. WNL Engines Engine section 2103 Camshaft bearing Installation (ship): Engine type W38 Ref. mr38/2103/01 Engine No. WNL–S Date 03.: Running hours: Page 1(1) Camshaft Bearing Nominal diameter : D = 250.24-250.Service. Box 10608 (hanzelaan 95) NL-8000 GB Zwolle Name: Telecop. +31-38-4223564 Tel. Service. +31-38-4253538 Telecop.v.12. +31-38-4253253 Telex 42116 swdz nl .O.1997 Engine type: Temperature (°C): Issue 00 Document No. Zwolle Place: P.31 Wear limit : Dmax= 250.

grinding. 79 Inlet and exhaust valves. mounting. 32 Control system troubleshooting. 97 Cylinder numbering. 52 schedule. 11 Digital input. 13 Analog output channels. 19 of main parts. 31 Fuel consumption. 113 gudgeon pin wear limits. 39 flexible mounted engine. 69 Cooling water approved additives. 93 B Bearings(oversize undersize). 110 general roundness check.FIELD SERVICE DATA BOOK W38 INDEX A Adjustable cam. 33 gasflows. 80 connecting rod. 8 Characteristics (main data). 10 definitions engine. 13 G Gearwheel clearances and dimensions. 101 Internal fuel system. 49 contents. 50 Crankshaft deflection tolerance. 26 viscosity table. 125 Crankshaft specification. 8 D Delivery valve. 48 requirements. 73 D (continuation) Dimensions of engine. 16 Exhaust gas specification. 115 H Hand held programmer(721) handling. 9 communication processor. 52 Cylinder liner specification. 75 Analog/pulse input channels. 92 Combustion sequence. 95 Constant pressure valve. 25 E Engine configuration at various use of fuel. 30 Fuel pump condition check. 45 system schedule. 21 of spare parts. 53 F Fixed cam construction. assembly. 107 Camshaft gearwheel. 12 Fuel injector nozzle. 9 Cylinder output. 26 requirements. 30 . 46 cooler cleaning. 14 Hydraulic jack pressures. 109 Characteristics. 55 Heat balance. 40 Air consumption. 34 high pressure. 32 Derating conditions. 70 Anti polishing ring. 86 C Camshaft diagram. 51 positioning. 128 Fuel characteristics. 47 Cooling water pumps characteristics. 91 I I/O board. 46 control. 8 Charge air system requirements.

37 clamping rings. 7 turbocharger VTR 354/454. 13 P Piston general. 63 Menu Dynamics 2. 62 fS(continuation) or diesel power plants. 1 for units. 76 repair of a damaged crankshaft. 68 Menu Set alarms. 15 Pump pressures drops. 32 Pump data. 55 for marine engines. 104 valve timing. 62 Menu display. disassembly. 67 Menu Dynamics. 96 small eye bearing. 124 Wear limits aluminium plain bearings. 59 Starting air distributor. 95 Software settings(721) explanations on. water washing the. 116 exhaust valve and seat. 16 W Wear limit exhaust and inlet valve spring.FIELD SERVICE DATA BOOK W38 L Lubricating oil brands. 66 Menu monitor alarms. 42 Symbols for drawing and diagrams. 43 starting air system adjustments. 62 Menu Speed Setting. 37 positioning of. 53 Turbocharger. 41 Starting air system schedule. 38 internal system. 65 Menu load sharing. 99 V Valve clearance. 36 L (continuation) requirements. 94 Power supply. 66 Menu display 2. 118 inlet valve and seat. 47 R Relay output channels. 44 small eye bearing. assembly. 10 Menu calibration. 35 lubricating oil pump adjustment of. 16 Valve seats grinding. 53 U Undersize crankpin bearings available. 91 Tightening torque’s for the various engine parts connections. 84 S Sensors. 88 Torques for bolts and nuts. 82 Pressure surges in low pressure fuel system. 105 valve seats replacing. 2 T Tightening procedure. 13 Operating temperatures. 2 for viscosity. 64 O Operating pressures. 120 piston and piston rings. 38 M Mean effective pressure. 99 Running-in program W38. lubricating the. 114 . 64 Menu Fuel Limiters. 67 Menu Configuration. 117 connecting rod. 77 Slow turning device. 127 cilinder liner. 39 Starting valve.

17 of spare parts. 25 . 122 Weights of engine parts.FIELD SERVICE DATA BOOK W38 valve drive mechanism.

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