W200

04
Maintenance schedule

0936 Page 1
 W200

Maintenance Schedule ..........................................................................................................................3

04.1.General Remarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

04.2.Power plant & Marine applications (1500 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

04.2.1.Engine running more than 1500 hours/year . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

04.3.Power plant & Marine applications (1200 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

04.3.1.Engine running more than 1500 hours/year . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

04.4.Power plant & Marine applications (standby mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

04.4.1.Engine running less than 1500 hours/year . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Page 2 0936
 W200 Maintenance Schedule 04.

04. Maintenance Schedule

04.1. General Remarks
The maintenance of your engine depends largely on the operating
conditions. The intervals of the time shown in this schedule should
not be exceeded during the warranty period or the warranty shall be
waived. The non-respect of schedules may lead to serious break-
downs and hazardous operating conditions for which Wärtsilä shall
not be liable. Moreover, the time between the different mainte-
nance operations can vary, depending on the application and the
duty of your engine. Wärtsilä worldwide service organisation is
available to supply original spare parts, qualified field service engi-
neers and dedicated training programs to perform all maintenance
activities.

Note : The maintenance schedules below are for normal operating

conditions :
- All specifications (see chapter 02)
- Back-pressure : 5 kPa Max.

1 Before performing any maintenance activity, read the

paragraphs relating to one or more specific questions.
2 When doing maintenance work, keep the working area
perfectly clean and tidied.
3 Before removing any items, check that the systems con-
cerned have been drained and are not under pressure or electrical
power. After removal, immediately stop up the oil, gas and air in-
lets and outlets with tapes or plugs.
4 When replacing a damaged component, note down each
replacement and location in the engine log book and state the rea-
sons for the replacement.
5 After refitting, make sure that all nuts and bolts are pro-
perly tightened and locked, see chapter 07.

Note : Wärtsilä France may change the quantities, parts and periodi-
cities depending on product development or engine operating
conditions.

Warning : Before working on the engine, make sure that all pressure
lines are released. The engine is locked out and tagged out.

0936 Page 3
 04. Maintenance Schedule W200

04.2. Power plant & Marine applications (1500 rpm)

04.2.1. Engine running more than 1500 hours/year
X° Engine with Paulstra couplings - X°° If engine equiped with
X°°° Check the date on the hose, in accordance with chapter 07
XX means operation to do only one time on new component or after overhaul
Servicing checks and maintenance operations
M1 M2 M3 M4 M5 M6
M
W
D o 1500 3000 6000 12000 24000 48000
e
To do every : a n
e
y t hours hours hours hours hours hours
k
h
01. GENERAL DESCRIPTION
Clean engine X
Look for leaks or other defects X
Record all engine parameters X
10. ENGINE BLOCK, CYLINDER LINERS
Check cylinder liners
X
(Boroscop inspection)
Replace main bearings X X
Replace liners X X
Replace Piston-rings X X X
Replace antipolishing ring X X X
Replace cover gaskets X X X
11. CRANKSHAFT, CONNECTING ROD, PISTON, DAMPER
Check the crankshaft alignment XX X X X
Check elastic mounting (under en-
X X X
gine) status and compression
Replace elastic mounting X°° X°°
Check engine coupling (replace if
X° X° X
necessary)
Replace connecting rod
X X X
(bearings, studs & nuts)
Check engine pistons X X
Take Damper silicone samples
X X X X
(12V-16V )
Replace Damper (only 12V-16V) X X
12. CYLINDER HEAD & VALVES
Check rocker arm
X X X
And replace if needed
Check and adjust valve clearances XX X X X X
Overhaul of cylinder heads X X X
13. CAMSHAFT DRIVE
Check camshafts X X X
Replace camshaft bushing X
Check camshaft gears X X
Check roller tappet X X
Replace roller tappet X

Page 4 0936
 W200 Maintenance Schedule 04.

X° Engine with Paulstra couplings - X°° If engine equiped with

X°°° Check the date on the hose, in accordance with chapter 07
XX means operation to do only one time on new component or after overhaul
Servicing checks and maintenance operations
M1 M2 M3 M4 M5 M6
M
W
D o 1500 3000 6000 12000 24000 48000
e
To do every : a n
e
y t hours hours hours hours hours hours
k
h
15. TURBOCHARGING & INTERCOOLING
Check turbochargers clearances XX X X X X X
Clean compressor X X X X X
Replace turbochargers
X X X
bearings & clean T/C
Clean filtering cover around T/C si-
lencer X°°
(replace if necessary)
Replace filtering cover around T/C
X°° X°° X°° X°° X°° X°°
silencer
Clean T/C silencer
X°° X°° X°° X°° X°° X°°
(replace if necessary)
Replace T/C silencer (if equipped) X°° X°°
Tighten the V clamps on T/C X°° X°° X°° X°° X°° X°°
Replace the V clamps on T/C X°° X°° X°° X°°
Overhaul charge air cooler X X X X
Replace the charge air cooler X X
16. INJECTION SYSTEM
Drain the fuel oil prefilter X
Clean the fuel oil prefilter X X X
Replace fuel prefilter element X X X X
Replace fuel oil cartridges X X X X X X
Lubricate fuel rack & fuel rack
X X X X X X
linkage
Check injectors X
Replace injectors X X X X
Replace fuel feed pump coupling
X X X X
spider
Clean fuel cooler X X X
Overhaul fuel feed pump X X
Replace injection pump head valve X
Overhaul injection pump X X X
Check mechanical state of flexible
hoses on fuel circuit (replace if X°°°
damaged)
Replace fuel hoses X X X
18. LUBRICATING OIL SYSTEM
Check Lube-oil level
X
(adjust level if necessary)
Take oil samples for analysis X X X X X X
Change lube oil X X X X X X

0936 Page 5
 04. Maintenance Schedule W200

X° Engine with Paulstra couplings - X°° If engine equiped with

X°°° Check the date on the hose, in accordance with chapter 07
XX means operation to do only one time on new component or after overhaul
Servicing checks and maintenance operations
M1 M2 M3 M4 M5 M6
M
W
D o 1500 3000 6000 12000 24000 48000
e
To do every : a n
e
y t hours hours hours hours hours hours
k
h
Replace lube oil filter cartridges on
X X X X X X
engine
Replace lub oil filter cartridges on
X°° X°° X°° X°° X°° X°°
turbo (12V Ph1 )
Clean centrifugal filter X X X X X X
Overhaul centrifugal filter X X X X
Clean oil cooler X X X
Overhaul lub oil module X
Overhaul lub oil pump X
Replace lube oil pump X
Change thermostatic valves X X
Replace prelub pump coupling spi-
X X X
der
Check mechanical state of lube oil
X°°°
hoses (replace if damaged)
Replace lube oil hoses X X X
19. COOLING WATER SYSTEM
Check water level X
Check water treatment (1) X X X X X
Change thermostatic valves X X
Clean venting pipes X X X X X
Clean water coolers X X X X
Overhaul of water pump & sea wa-
X X
ter pump
Replace water pump X
Check mechanical state of water
X°°°
hoses (replace if damaged)
Replace water hoses X X X
20. EXHAUST SYSTEM
Replace exhaust bellows X
21. STARTING AIR SYSTEM
Check oil level of lubricating de-
X
vice of the air starter (only 18V)
Check air starting system X X X X X X
Check the starting gear status X X X
Lubricate the turning gear X X X X X X
Check mechanical state of flexible
X°°°
hoses (replace if damaged)
Replace flexible hoses X X X

Page 6 0936
 W200 Maintenance Schedule 04.

X° Engine with Paulstra couplings - X°° If engine equiped with

X°°° Check the date on the hose, in accordance with chapter 07
XX means operation to do only one time on new component or after overhaul
Servicing checks and maintenance operations
M1 M2 M3 M4 M5 M6
M
W
D o 1500 3000 6000 12000 24000 48000
e
To do every : a n
e
y t hours hours hours hours hours hours
k
h
22. CONTROL MECHANISM GOVERNOR
Check governor’s oil level X
Replace governor’s oil X X X X X
Check governor’s gear status X X X
Governor overhaul X X
Check tightening and status of gov-
X X X X X
ernor linkage
Replace joint balls on governor
X X X
linkage
23. INSTRUMENTATION & AUTOMATION
Simulate safety devices action X X X X
Check pressure safety devices
X X X
(replace if damaged)
Replace temperature safety de-
X X X
vices
Check and tighten electrical con-
X
nections on engine
Check and tighten electrical con-
X X X X
nections on all electrical cabinets
Check setting value of the safety
X X X
sensors
Check the MPD (Metal Particle De-
tector) and the electrical connec- X
tion
Replace MPD X X X
Replace all sensors devices X
Replace wiring, all electrical boxes,
X
control pannel
Check batteries voltage X
GENERAL
Check correct tightening of main
X X X X X X
sub assemblies

(1) Replace water treatment every 2 years

0936 Page 7
 04. Maintenance Schedule W200

04.3. Power plant & Marine applications (1200 rpm)

04.3.1. Engine running more than 1500 hours/year
X° Engine with Paulstra couplings - X°° If engine equiped with
X°°° Check the date on the hose, in accordance with chapter 07
XX means operation to do only one time on new component or after overhaul
Servicing checks and maintenance operations
M1 M2 M3 M4 M5 M6
M
W
D o 1500 3000 6000 12000 24000 48000
e
To do every : a n
e
y t hours hours hours hours hours hours
k
h
01. GENERAL DESCRIPTION
Clean engine X
Look for leaks or other defects X
Record all engine parameters X
10. ENGINE BLOCK, CYLINDER LINERS
Check cylinder liners
X
(Boroscop inspection)
Replace main bearings X X
Replace liners X X
Replace Piston-rings X X
Replace antipolishing ring X X
Replace cover gaskets X X
11. CRANKSHAFT, CONNECTING ROD, PISTON, DAMPER
Check the crankshaft alignment XX X X X
Check elastic mounting (under en-
X X X
gine) status and compression
Replace elastic mounting X°° X°°
Replace engine coupling X° X° X
Replace connecting rod
X X
(bearings, studs & nuts)
Check engine pistons X X
Take Damper silicone samples
X X X X
(12V-16V )
Replace Damper (only 12V-16V) X X
12. CYLINDER HEAD & VALVES
Check rocker arm
X X
And replace if needed
Check and adjust valve clearances XX X X X X
Overhaul of cylinder heads X X
13. CAMSHAFT DRIVE
Check camshafts X X X
Replace camshaft bushing X
Check camshaft gears X X
Check roller tappet X X
Replace roller tappet X

Page 8 0936
 W200 Maintenance Schedule 04.

X° Engine with Paulstra couplings - X°° If engine equiped with

X°°° Check the date on the hose, in accordance with chapter 07
XX means operation to do only one time on new component or after overhaul
Servicing checks and maintenance operations
M1 M2 M3 M4 M5 M6
M
W
D o 1500 3000 6000 12000 24000 48000
e
To do every : a n
e
y t hours hours hours hours hours hours
k
h
15. TURBOCHARGING & INTERCOOLING
Check turbochargers clearances XX X X X X X
Clean compressor X X X X X
Replace turbochargers
X X X
bearings & clean T/C
Clean filtering cover around T/C si-
lencer X
(replace if necessary)
Replace filtering cover around T/C
X°° X°° X°° X°° X°° X°°
silencer
Clean T/C silencer
X°° X°° X°° X°° X°° X°°
(replace if necessary)
Replace T/C silencer (if equipped) X°° X°°
Tighten the V clamps on T/C X°° X°° X°° X°° X°° X°°
Replace the V clamps on T/C X°° X°° X°° X°°
Overhaul charge air cooler X X X X
Replace the charge air cooler X X
16. INJECTION SYSTEM
Drain the fuel oil prefilter X
Clean the fuel oil prefilter X X X
Replace fuel prefilter element X X X X
Replace fuel oil cartridges X X X X X X
Lubricate fuel rack & fuel rack
X X X X X X
linkage
Check injectors X
Replace injectors X X X X
Replace fuel feed pump coupling
X X X X
spider
Clean fuel cooler X X X X
Overhaul fuel feed pump X X
Replace injection pump head valve X X
Overhaul injection pump X X
Check mechanical state of flexible
hoses on fuel circuit (replace if X°°°
damaged)
Replace fuel hoses X X X
18. LUBRICATING OIL SYSTEM
Check Lube-oil level
X
(adjust level if necessary)
Take oil samples for analysis X X X X X X
Change lube oil X X X X X X

0936 Page 9
 04. Maintenance Schedule W200

X° Engine with Paulstra couplings - X°° If engine equiped with

X°°° Check the date on the hose, in accordance with chapter 07
XX means operation to do only one time on new component or after overhaul
Servicing checks and maintenance operations
M1 M2 M3 M4 M5 M6
M
W
D o 1500 3000 6000 12000 24000 48000
e
To do every : a n
e
y t hours hours hours hours hours hours
k
h
Replace lube oil filter cartridges on
X X X X X X
engine
Replace lub oil filter cartridges on
X°° X°° X°° X°° X°° X°°
turbo (12V Ph1 )
Clean centrifugal filter X X X X X X
Overhaul centrifugal filter X X X X
Clean oil cooler X X X
Overhaul lub oil module X
Overhaul lub oil pump X
Replace lube oil pump X
Change thermostatic valves X X
Replace prelub pump coupling spi-
X X X
der
Check mechanical state of lube oil
X°°°
hoses (replace if damaged)
Replace lube oil hoses X X X
19. COOLING WATER SYSTEM
Check water level X
Check water treatment (1) X X X X X
Change thermostatic valves X X
Clean venting pipes X X X X X
Clean water coolers X X X X
Overhaul of water pump & sea wa-
X X
ter pump
Replace water pump X
Check mechanical state of water
X°°°
hoses (replace if damaged)
Replace water hoses X X X
20. EXHAUST SYSTEM
Replace exhaust bellows X
21. STARTING AIR SYSTEM
Check oil level of lubricating de-
X
vice of the air starter (only 18V)
Check air starting system X X X X X X
Check the starting gear status X X X
Lubricate the turning gear X X X X X X
Check mechanical state of flexible
X°°°
hoses (replace if damaged)
Replace flexible hoses X X X

Page 10 0936
 W200 Maintenance Schedule 04.

X° Engine with Paulstra couplings - X°° If engine equiped with

X°°° Check the date on the hose, in accordance with chapter 07
XX means operation to do only one time on new component or after overhaul
Servicing checks and maintenance operations
M1 M2 M3 M4 M5 M6
M
W
D o 1500 3000 6000 12000 24000 48000
e
To do every : a n
e
y t hours hours hours hours hours hours
k
h
22. CONTROL MECHANISM GOVERNOR
Check governor’s oil level X
Replace governor’s oil X X X X X
Check governor’s gear status X X X
Governor overhaul X X
Check tightening and status of gov-
X X X X X
ernor linkage
Replace joint balls on governor
X X X
linkage
23. INSTRUMENTATION & AUTOMATION
Simulate safety devices action X X X X
Check pressure safety devices
X X X
(replace if damaged)
Replace temperature safety de-
X X X
vices
Check and tighten electrical con-
X
nections on engine
Check and tighten electrical con-
X X X X
nections on all electrical cabinets
Check setting value of the sensors X X X
Check the MPD (Metal Particle De-
tector) and the electrical connec- X
tion
Replace MPD X X X
Replace all sensors devices X
Replace wiring, all electrical boxes,
X
control pannel
Check batteries voltage X
GENERAL
Check correct tightening of main
X X X X X X
sub assemblies

(1) Replace water treatment every 2 years

0936 Page 11
 04. Maintenance Schedule W200

04.4. Power plant & Marine applications (standby mode)

04.4.1. Engine running less than 1500 hours/year
X° Engine with Paulstra couplings - X°° If engine equiped with
X°°° Check the date on the hose, in accordance with chapter 07
XX means operation to do only one time on new component or after overhaul
Servicing checks and maintenance operations
M1 M2 M3 M4 M5 M6
M
W
D o
e 1 2 3 6 12 18
To do every : a n
e year years years years years years
y t
k
h
01. GENERAL DESCRIPTION
Clean engine X
Look for leaks or other defects X
Record all engine parameters X
10. ENGINE BLOCK, CYLINDER LINERS
Check cylinder liners
X
(Boroscop inspection)
Replace main bearings X X
Replace liners X X
Replace Piston-rings X X X
Replace antipolishing ring X X X
Replace cover gaskets X X X
11. CRANKSHAFT, CONNECTING ROD, PISTON, DAMPER
Check the crankshaft alignment XX X X X
Check elastic mounting (under en-
X X X
gine) status and compression
Replace elastic mounting X°° X°°
Replace engine coupling X° X° X
Replace connecting rod
X X X
(bearings, studs & nuts)
Check engine pistons X X
Take Damper silicone samples
X X X X
(12V-16V )
Replace Damper (only 12V-16V) X X
12. CYLINDER HEAD & VALVES
Check rocker arm
X X X
And replace if needed
Check and adjust valve clearances XX X X X X
Overhaul of cylinder heads X X X
13. CAMSHAFT DRIVE
Check camshafts X X X
Replace camshaft bushing X
Check camshaft gears X X
Check roller tappet X X
Replace roller tappet X

Page 12 0936
 W200 Maintenance Schedule 04.

X° Engine with Paulstra couplings - X°° If engine equiped with

X°°° Check the date on the hose, in accordance with chapter 07
XX means operation to do only one time on new component or after overhaul
Servicing checks and maintenance operations
M1 M2 M3 M4 M5 M6
M
W
D o
e 1 2 3 6 12 18
To do every : a n
e year years years years years years
y t
k
h

15. TURBOCHARGING & INTERCOOLING

Check turbochargers clearances XX X X X X X
Clean compressor X X X X X
Replace turbochargers
X X X
bearings & clean T/C
Clean filtering cover around T/C si-
lencer X
(replace if necessary)
Replace filtering cover around T/C
X°° X°° X°° X°° X°° X°°
silencer
Clean T/C silencer
X°° X°° X°° X°° X°° X°°
(replace if necessary)
Replace T/C silencer X°° X°°
Tighten the V clamps on T/C X°° X°° X°° X°° X°° X°°
Replace the V clamps on T/C X°° X°° X°° X°°
Overhaul charge air cooler X X X X
Replace the charge air cooler X X
16. INJECTION SYSTEM
Drain the fuel oil prefilter X
Clean the fuel oil prefilter X X X
Replace fuel prefilter element X X X X
Replace fuel oil cartridges X X X X X X
Lubricate fuel rack & fuel rack
X X X X X X
linkage
Check injectors X
Replace injectors X X X X
Replace fuel feed pump coupling
X X X X
spider
Clean fuel cooler X X X
Overhaul fuel feed pump X X
Replace injection pump head valve X
Overhaul injection pump X X X
Check mechanical state of flexible
hoses on fuel circuit (replace if X°°°
damaged)
Replace fuel hoses X X X
18. LUBRICATING OIL SYSTEM
Check Lube-oil level
X
(adjust level if necessary)
Take oil samples for analysis X X X X X X
Change lube oil X X X X X X

0936 Page 13
 04. Maintenance Schedule W200

X° Engine with Paulstra couplings - X°° If engine equiped with

X°°° Check the date on the hose, in accordance with chapter 07
XX means operation to do only one time on new component or after overhaul
Servicing checks and maintenance operations
M1 M2 M3 M4 M5 M6
M
W
D o
e 1 2 3 6 12 18
To do every : a n
e year years years years years years
y t
k
h
Replace lube oil filter cartridges on
X X X X X X
engine
Replace lub oil filter cartridges on
X°° X°° X°° X°° X°° X°°
turbo (12V Ph1 )
Clean centrifugal filter X X X X X X
Overhaul centrifugal filter X X X X
Clean oil cooler X X X
Overhaul lub oil module X
Overhaul lub oil pump X
Replace lube oil pump X
Change thermostatic valves X X
Replace prelub pump coupling spi-
X X X
der
Check mechanical state of lube oil
X°°°
hoses (replace if damaged)
Replace lube oil hoses X X X
19. COOLING WATER SYSTEM
Check water level X
Check water treatment (1) X X X X X
Change thermostatic valves X X
Clean venting pipes X X X X X
Clean water coolers X X X X
Overhaul of water pump & sea wa-
X X
ter pump
Replace water pump X
Check mechanical state of water
X°°°
hoses (replace if damaged)
Replace water hoses X X X
20. EXHAUST SYSTEM
Replace exhaust bellows X
21. STARTING AIR SYSTEM
Check oil level of lubricating de-
X
vice of the air starter (only 18V)
Check air starting system X X X X X X
Check the starting gear status X X X
Lubricate the turning gear X X X X X X
Check mechanical state of flexible
X°°°
hoses (replace if damaged)
Replace flexible hoses X X X

Page 14 0936
 W200 Maintenance Schedule 04.

X° Engine with Paulstra couplings - X°° If engine equiped with

X°°° Check the date on the hose, in accordance with chapter 07
XX means operation to do only one time on new component or after overhaul
Servicing checks and maintenance operations
M1 M2 M3 M4 M5 M6
M
W
D o
e 1 2 3 6 12 18
To do every : a n
e year years years years years years
y t
k
h

22. CONTROL MECHANISM GOVERNOR

Check governor’s oil level X
Replace governor’s oil X X X X X
Check governor’s gear status X X X
Governor overhaul X X
Check tightening and status of gov-
X X X X X
ernor linkage
Replace joint balls on governor
X X X
linkage
23. INSTRUMENTATION & AUTOMATION
Simulate safety devices action X X X X
Check pressure safety devices
X X X
(replace if damaged)
Replace temperature safety de-
X X X
vices
Check and tighten electrical con-
X
nections on engine
Check and tighten electrical con-
X X X X
nections on all electrical cabinets
Check setting value of the sensors X X X
Check the MPD (Metal Particle De-
tector) and the electrical connec- X
tion
Replace MPD X X X
Replace all sensors devices X
Replace wiring, all electrical boxes,
X
control pannel
Check batteries voltage X
GENERAL
Check correct tightening of main
X X X X X X
sub assemblies

(1) Replace water treatment every 2 years

0936 Page 15
 04. Maintenance Schedule W200

Page 16 0936