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Wärtsilä Italy, Service

Subject Engine type Ref. Date Document No. DLC Issue Page

Piston Maintenance W38B WIT-S 28.02.07 I- W38B.0044.GB 114 01 1/8

Piston Maintenance and Overhaul

1 Introduction
This Technical Bulletin gives notice about changing during pistons scheduled overhaul and maintenance, and
gives additional information or updating on existing Engine Instruction Manual.

2 Application
This bulletin applies to all Wärtsilä 38B engines.

3 Instructions

3.1 Maintenance procedure

Pistons must be dismantled and inspected for maintenance every 12000 running hours, according
to the maintenance schedule and following the dismantling instructions described in chapters 2.4
and 2.6.2 of Engine Instruction Manual.
When the pistons have been dismantled, the below instructions must be carefully followed:

1) Clean accurately the piston from possible carbon deposits;

IMPORTANT: When doing the mechanical cleaning, take care neither scratching nor
scoring the metal surfaces.

2) Disassemble the connecting rod and keep the gudgeon pin off each piston;
3) Evaluate the condition of the small end bearing bush and of the gudgeon pin. Measure
their diameters filling in the Measurement Records M-W38B.0006.GB and
M-W38.0008.GB.
4) Check the piston from outside in order to evaluate its general external conditions.
5) Blow air into oil bores of the connecting rod and gudgeon pin, in order to make sure that
any bore is free from occlusions or dirt.
6) Check the gap between piston crown and skirt (fig.1, see also chapter 2.3 in this
Instruction) and measure the piston ring grooves height, filling in the Measurement Record
M-W38.0010.GB.

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Service 34018 San Dorligo Della Valle (TS) ITALY Fax : +39 040 319 5647
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Subject Engine type Ref. Date Document No. DLC Issue Page

Piston Maintenance W38B WIT-S 28.02.07 I- W38B.0044.GB 114 01 2/8

fig.1: Gap between piston crown and skirt

7) Check the piston crown for hot corrosion. If hot corrosion spots are noticed, open the
piston by disassembling the piston crown and clean the cooling galleries from under-crown
deposits (see also chapter 2.4 in this Instruction). Fig.2 shows a piston crown top surface
in normal condition; fig.3 shows typical places where under-crown deposits and hot
corrosion marks can be found.

fig.2: Piston crown top land

fig.3

NOTE: If corrosion marks on the piston crown top surface are deeper than 3 mm,
the crown has to be replaced.

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Subject Engine type Ref. Date Document No. DLC Issue Page

Piston Maintenance W38B WIT-S 28.02.07 I- W38B.0044.GB 114 01 3/8

8) When the piston needs to be disassembled (in case as per point 7 or, anyhow, at the
24000 running hours maintenance), also check for fretting at the mating surfaces between
piston crown and piston skirt.

If you need more detailed information, advice or instructions about the piston maintenance work,
please refer to the following sections and piston view, as per fig.4.
To order inner component please refer to linked Spare Parts Catalogue pages.

fig.4: Exploded view of W38B piston

3.2 Piston screws

At piston disassembly, two types of screws (SPN 1130.009, item #05 in fig.4) might be found in a
W38B piston, depending when the piston has been manufactured:
• Old type screws: stem diameter Ø 14,5 mm;
• Standard screws: stem diameter Ø13,5 mm.
Both types of screw stems are 194 0-0,2 mm long (see fig.5). If the length of your screws is found
different from this value, please contact WIT-Technical Service office.

fig.5: W38B piston screw

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Service 34018 San Dorligo Della Valle (TS) ITALY Fax : +39 040 319 5647
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Subject Engine type Ref. Date Document No. DLC Issue Page

Piston Maintenance W38B WIT-S 28.02.07 I- W38B.0044.GB 114 01 4/8

Old type screws (stem diameter Ø14,5 mm) are no more available as spare parts. If the piston
under maintenance is provided with old type screws (stem diameter Ø14,5 mm), it is suggested to
replace them with the standard ones (stem diameter Ø13,5 mm), in order to update and
standardise your machinery according latest design release. If your engine is provided with both
pistons mounting old type screws and pistons mounting standard screws, take care to re-assemble
the screws into their piston of origin and, in particular, pay attention not to mix different type screws
on the same piston.

IMPORTANT: Old type screws (stem diameter Ø14,5 mm) cannot be machined by lathe,
reducing the stem diameter to Ø13,5 mm.

3.3 Checking the clearance between piston crown and skirt

Check the clearance between piston crown and skirt (see fig.1), in cold condition, in different
circumferential places by means of a feeler gauge. Such measurements have to be taken on 4
positions, each one spaced 90° by the adjacent, as shown in the Measurement Record
M-W38.0017.GB. In new pistons, the nominal clearance is between 0,14 and 0,18 mm.
Measurement method is explained in chapter 2.6.
When checking pistons with long operating period, bigger clearance can be accepted, even on
single circumferential sectors. This clearance can be due either to the piston crown slight
deformation (especially on heavy duty installations, where thermal load is significant), or to wear
caused by relative micro-displacements of crown and skirt (occurrence of fretting between crown
and skirt mating surfaces).
If the measured clearance exceeds No-Go limit (>0,5 mm) in cold condition, it is strongly
advisable to replace the whole piston with a new one. The pistons that could have been rejected by
these criteria should be sent to Wärtsilä to check for reconditioning possibility.

IMPORTANT: If the piston has been dismantled, after inspection the same original pair of
crown and skirt must be reassembled together again, and sealing ring
(SPN 1130.008, item #03 in fig.4) must be replaced.

3.4 Internal deposits

Normal under-crown deposits become critical for cooling efficiency if built up layer is more than
0,5 mm thick. These deposits may retain the oil which can bake on, creating an insulation layer,
and thus leading to a considerable increase of the piston temperatures (hot spots), especially on
the piston top land. Such an increase of the material temperatures, combined with inferior and/or
aggressive fuel qualities, might cause hot corrosion on the top side of the piston crown.
It is recommended to use the new formulation lubricating oils with improved fuel/lube oil
compatibility properties in installations operating on heavy fuel, especially on high sulfur, high
sodium and/or high vanadium content. Please refer to the updated list of lubricating oils approved
by Wärtsilä, as per Technical Bulletin T-W38B.0020.GB: Lubricating Oil Requirements for W38B
Engines.

Wärtsilä Italia SpA Bagnoli della Rosandra, 334 Telephone : +39 040 319 5000
Service 34018 San Dorligo Della Valle (TS) ITALY Fax : +39 040 319 5647
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Subject Engine type Ref. Date Document No. DLC Issue Page

Piston Maintenance W38B WIT-S 28.02.07 I- W38B.0044.GB 114 01 5/8

3.5 Fretting
In some cases, disassembling the piston, it has been noticed that fretting can occur in some areas
of the piston crown and skirt mating surfaces. However, it should be pointed out that relative micro-
displacement, and thus spots of fretting, in a running component can never be completely
eliminated. The limitation of such relative movements depends above all on the specific surface
pressure between the mating surfaces, which correctness is ensured by a careful and accurate
tightening of the piston screws.
Fretting can occur with some slight build-up material stuck on one side of the mating interface
(usually on the crown side) removed from the other side. In this case proceed removing locally any
fretting mark by hand polishing by means of fine flat oilstone only. Be aware that grinding and/or
scrapping away large areas affected by fretting is strictly forbidden, since the mating surfaces could
be altered from their original geometry, thus changing the specific mating pressure as a
consequence when the screws are retightened.

NOTE: Piston crown and skirt showing mating surfaces affected by severe signs of fretting
must be replaced by new ones.

Fretting marks Fretting marks

fig.6: Fretting on piston crown fig.7: Fretting on piston skirt

Check the thread of the screw holes bolts for fretting and/or wear. Check also the contact surfaces
for the bolt head. If fretting or wear on the thread is noticed, the piston crown should be rejected.

3.6 Tightening instructions

Once the required maintenance works on the piston components have been performed, it is
recommended to put the piston crown upside down and to fix it to the ground using an apposite
clamping tool before re-assembling the piston. In this way the piston crown is kept locked, making
the assembly of the skirt to the crown easier and ensuring an adequate tightening accuracy.

If the adequate mentioned tool is not available, please contact nearest Wärtsilä workshop.

Wärtsilä Italia SpA Bagnoli della Rosandra, 334 Telephone : +39 040 319 5000
Service 34018 San Dorligo Della Valle (TS) ITALY Fax : +39 040 319 5647
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Subject Engine type Ref. Date Document No. DLC Issue Page

Piston Maintenance W38B WIT-S 28.02.07 I- W38B.0044.GB 114 01 6/8

NOTE: It is strongly recommended to apply Molikote Paste G-N-Plus on the thread and on
the under-collar contact surface of the screws. Anyway, only if the standard screws
(stem diameter Ø13,5 mm) are used and Molikote Paste G-N-Plus is not available in
situ, engine lube oil can be used for tightening the screws, carrying out a different
procedure explained below.

o Procedure for standard screws (stem diameter Ø13.5 mm) using Molikote
Paste G-N-Plus:

1. Apply a new “O” ring (SPN 1130.008) into the proper groove on the piston skirt and
lubricate it with vaseline or engine oil;
2. Carefully clean and blow by compressed air the for threaded holes on the piston crown;
3. Put the piston skirt onto the piston crown, taking care to place it in the right position by
centring the positioning pin;
4. Coat the thread and the contact surface of each screw with Molikote Paste G-N-Plus;
5. Tighten the screws cross wise applying a 140 Nm torque;
6. Loosen the screws;
7. Check the gap between skirt and piston crown (nominal value: 0,14 ÷ 0,18 mm in new
pistons) by means of a feeler gauge. No-Go limit: >0,5 mm;
8. Tighten the screws cross wise at 15 Nm;
9. Turn the screws cross wise another 120°;

10. CONTROL: Applying a 95 Nm control torque, the screws should not turn any
further.

o Procedure for standard screws (stem diameter Ø13.5 mm) using engine
lubricating oil:

1. Apply a new “O” ring (SPN 1130.008) into the proper groove on the piston skirt and
lubricate it with vaseline or engine oil;
2. Carefully clean and blow by compressed air the for threaded holes on the piston crown;
3. Put the piston skirt onto the piston crown, taking care to place it in the right position by
centring the positioning pin;
4. Coat the thread and the contact surface of each screw with engine oil;
5. Tighten bolts cross wise applying a 240 Nm torque;
6. Loosen the screws;
7. Check the gap between skirt and piston crown (nominal value: 0,14 ÷ 0,18 mm in new
pistons) by means of a feeler gauge. No-Go limit: >0,5 mm;
8. Tighten the screws cross wise at 30 Nm;
9. Turn the screws cross wise another 120°;

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Service 34018 San Dorligo Della Valle (TS) ITALY Fax : +39 040 319 5647
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Piston Maintenance W38B WIT-S 28.02.07 I- W38B.0044.GB 114 01 7/8

10. CONTROL: Applying a 195 Nm control torque, the screws should not turn any
further. Depending on the oil characteristics and on the operative parameters, an
additional, small rotation (max 10°) can be accepted.

o Procedure for old type screws (stem diameter Ø14.5 mm):

1. Apply a new “O” ring (SPN 1130.008) into the proper groove on the piston skirt and
lubricate it with vaseline or engine oil;
2. Carefully clean and blow by compressed air the for threaded holes on the piston crown;
3. Put the piston skirt onto the piston crown, taking care to place it in the right position by
centring the positioning pin;
4. Coat the thread and the contact surface of each screw with Molikote Paste G-N-Plus;
5. Tighten the screws cross wise applying a 130 Nm torque;
6. Loosen the screws;
7. Check the gap between skirt and piston crown (nominal value: 0,14 ÷ 0,18 mm in new
pistons) by means of a feeler gauge. No-Go limit: >0,5 mm;
8. Tighten the screws cross wise at 15 Nm;
9. Turn the screws cross wise another 120°;

10. CONTROL: Applying a 105 Nm control torque, the screws should not turn any
further.

3.7 Re-assembling into cylinder unit

Once the maintenance work is finished, piston can be fitted to connecting rod and re-assembled
into the cylinder unit of origin, according the instructions described in chapter 2.6.2.4 of Engine
Instruction Manual. Each piston can be arranged into the cylinder liner oriented it in both possible
ways, even if it is preferable to keep the same direction found when it has been taken out.

4 Tools
- Torque wrench 250 Nm;
- Extensions and sockets for torque wrench;
- Torque wrench pluggable angle indicator;
- Feeler gauge set;
- Oil stone (if fretting is noticed);
- Fixing tool for piston;
- Molikote Paste G-N-Plus.

5 Documentation
Torque list and Maintenance manual have to be updated.

Wärtsilä Italia SpA Bagnoli della Rosandra, 334 Telephone : +39 040 319 5000
Service 34018 San Dorligo Della Valle (TS) ITALY Fax : +39 040 319 5647
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Subject Engine type Ref. Date Document No. DLC Issue Page

Piston Maintenance W38B WIT-S 28.02.07 I- W38B.0044.GB 114 01 8/8

6 Distribution
Wärtsilä Italy Service Wärtsilä Service Network Owners of engines concerned

7 Liability
NO LIABILITY WHETHER DIRECT, INDIRECT, SPECIAL INCIDENTAL OR CONSEQUENTIAL, IS
ASSUMED WITH RESPECT TO THE INFORMATION CONTAINED HEREIN. THIS PUBLICATION IS
CONFIDENTIAL AND INTENDED FOR INFORMATION PURPOSES ONLY.

8 Validity
This general instruction is valid until further notice.

Wärtsilä Italia SpA Bagnoli della Rosandra, 334 Telephone : +39 040 319 5000
Service 34018 San Dorligo Della Valle (TS) ITALY Fax : +39 040 319 5647