Wärtsilä Services Switzerland Ltd PO Box 414 Tel (24h): +41 52 262 80 10 CH-8401 Winterthur
Engineering Services, 2-stroke engines Switzerland [email protected]
Inspection and overhaul intervals
Table 1 Component Inspection or Overhaul interval1) [RH: Running Hours] Estimated lifetime 1), 2) [RH: Running Hours] Comments Maintenance methodsSystem Oil 3,000 Lube. Oil sample laboratory analysis.
Main lubricating oil filters
(plant side)
3,000
Check filter elements - in particular for white metal particles (clean or replace filter if required).
Follow manufacturer’s instructions. Bedplate foundation
bolts 12,000 Engine lifetime
Check pre-tension according to the Maintenance Manual.
Crankcase 1,500 – 3,000
Visual examination, search for white metal particles from bearings and for abnormalities in general.
Main bearing
6,000 Bearing clearance measurements. 6,000 Bearing edge check by wire 3).
At indications of excessive wear or damage 90,000 Replacement if required
Bearing shell open-up inspection is only necessary if bearing clearance, crankshaft deflection, wire check, oil analysis or crankcase inspection indicates excessive wear or damage.
Thrust bearing
6,000 Bearing clearance measurements.
Replacement if required 6,000 Check bottom drain for free passage.
At indications of excessive wear or
damage
Engine Life Time
Replacement if required
Thrust Bearing pads open-up
inspection is only necessary if bearing clearance, oil analysis or crankcase inspection indicates excessive wear or damage.
Tie rods
Check pre-tension: First time after one year
Successive inspections: Random check at major overhauls or
all every 30,000
Engine lifetime Check pre-tension according to the Maintenance Manual.
Cylinder liner 4) At each piston
removal Up to 90,000
Inspect liner & establish wear in bore at every piston removal.
Hours] Hours] Lubricating quill (Pulse lubrication) Check non-return valves: At each piston removal
Check function and tightness. Check function of non-return valves.
Replacement if required Lubricating quill (CLU-3) Check non-return valves: At each liner removal
Check function and tightness.
Check function of non-return valves. Replacement if required Accumulator
diaphragm: 6,000
Check diaphragm for oil leakages and replace if required.
Piston rod gland At each piston removal
36,000 (refers to rings)
Clean rings & establish wear at every piston removal.
Replace rings if required.
Overhaul on board
Cylinder cover at every piston
removal Engine lifetime
Check for cracks and dirty or damaged seat sealing faces of injection valves. Remanufacture if required.
Remanufacturing
Standard injector and FAST injector
Before starting engine after a longer engine stop
Check externally for tightness
1,000 RH after replacement of injector parts
Re-confirmation of opening pressure.
Standard injector
6,000
Function check (opening pressure). Visual inspection of all parts. Replace parts if required.
Replace the nozzle tip.
Up to 24,000 5) Replace or recondition the nozzle
body. Condition on board is influenced by fuel quality and treatment. FAST Injector 6,000
Function check (opening pressure). Visual inspection of all parts.
Replace the parts if required 18,000 Replace the nozzle tip & nozzle body.
Starting valve
weekly
Check pipe upstream of the valve during operation, if pipes are too hot, disassemble starting valve.
monthly Make sure that the nut on the solenoid is tight, if necessary tighten the nut.
6,000 Solenoid valve; random functional check.
12,000
Remove and disassemble one starting valve, from the condition, calculate the time of overhaul for remaining valves.
18,000 Solenoid valve. Overhaul on board engine lifetime Starting valve.
Hours] Hours]
Exhaust valve spindle
Inspection at 18,000RH, 36,000RH and
72,000RH
108,000 6)
Check condition and wear of valve spindle (if necessary regrind seat by machining). Valve plates with corrosion layer deeper than the limit given in the Maintenance Manual or seating surface ground back more than 3 mm can be remanufactured. Nimonic 80A spindles can be remanufactured up to 2 times.
Remanufacturing
Exhaust valve seat
Inspection at 18,000RH, 36,000RH and
72,000RH
72,000
Check condition and wear of valve seat (if necessary regrind seat by machining). Valves with seat surface ground back more than 3 mm or with burn scars on the inside of the seat that exceed the limit given in the Maintenance Manual must be remanufactured.
Remanufacturing
Exhaust valve drive Inspection at 18,000RH, 36,000RH and
72,000RH
Check condition of piston seal ring, air spring, rod seal ring and guide bush. Replace parts as needed.
Check condition of exhaust valve hydraulic drive parts.
Overhaul on board
Exhaust valve
damper 6) 18,000
For old designed dampers, replace with new designed damper at 20,000RH (Refer to RT-120)
For new designed dampers, random check every 18,000RH.
Replacement if required
Crankshaft 6,000 Engine lifetime
Measure crank deflection, always after the ship grounded and after each docking
Connecting rod
Top end bearing and Bottom end bearing
6,000 Bearing clearance measurements 6,000 Wire check on all bearing edges 3)
70,000 8) Random open-up inspection.
90,000
Replacement if required
Bearing shell open-up inspection is only necessary if bearing clearance, wire check, oil analysis or crankcase inspection indicates excessive wear or damage.
Piston head Condition based 18,000 – 36,000
Ring grooves: 18,000 - 36,000
Crown surface: 72,000
Inspect condition of chromium plating and measure ring groove clearance. Check condition of piston top surface and clean oil cooling bores if needed. Recondition/rechrome if required.
Overhaul on board. Remanufacturing
Piston rings
1,500 – 2,000 Measure thickness of chrome-ceramic layer.
Replacement Condition based
18,000 – 36,000
Replace piston rings based on remaining coating thickness. Starting air shut-off
valve 30,000 – 36,000 Engine lifetime
Clean and check seat, springs and
Hours] Hours]
Servo oil pumps (Dynex)
Initial: 24,000
– Pumps with serial number < 147899: remanufacture initially at 24,000 hours. Thereafter the higher interval of 42,000 hours applies. – Pumps with serial number ≥ 147899: only exchange of pump cover on board at 24,000 hours.
Remanufacture initially at 42,000 hours. Thereafter the interval of 42,000 hours applies.
Remanufacturing
Successive: 42,000
Pumps with serial number ≥ 160686: remanufacture only at 42,000 hours. Servo oil pump
(Bosch) 60,000 Remanufacturing
Supply unit pinion
bearing bushes 42,000 90,000 Visual inspection.
Replacement if required
Supply unit camshaft
bearings 6,000 90,000
Inspect condition & check bearing clearances. Check for white metal pieces coming out of the bearings or in the casing.
Replacement if required
Supply unit fuel drain
pipes 6,000 Engine lifetime
Inspect fuel drain system to find clogged drain pipes.
Refer to technical bulletin RT-102.
Cleaning on board.
Fuel pump
weekly Check the oil leakage on FOP top
cover caused NRV O-ring brittle. Replace
3,000 FOP Roller running surface check. Cam surface can be checked together.
6,000
Random flow check of lubricating oil at every 6,000 RH according to RT-180.
18,000 Remanufacturing at every 18,000 RH. Remanufacturing Heinzmann electrical
actuator StG-16 & StG-30 for FOP
6,000 – 12,000
Check condition of the carbon brushes and replace if required Only RT-flex82C/T & W-X82 engine.
Overhaul on board
Injection control unit (ICU) 9)
24,000
Only ICUs on 84 and 96 bore engines built before 2010, which have not been remanufactured.
Remanufacturing
36,000
Applies to ICUs on engines built from 2010 onwards and to the already remanufactured ICUs on engines built before 2010.
Remanufacturing
Filter: 18,000
Clean and check filter condition.
Replace only if required. Replacement
Rail valve: Monitored
Check “on-time” of rail valves through flexView and replace if “on-time” > 2.6 ms.
Replacement
Control oil pump
(Bucher) 60,000 Replace with a new pump. Replacement Control oil pump
electric motor bearings 60,000
Replace ball bearings and
overhaul motor. Replacement
Servo oil rail hoses 30,000 Check condition and replace if
Hours] Hours]
Exhaust valve control unit
Piston and slide rod:
36,000
Engine lifetime Random check of piston and slide rod at
overhaul. Replace only if required. Replacement
Filter: 18,000
Clean and check filter condition.
Replace only if required. Replacement
Rail valve: Monitored
Check “on-time” of rail valves through flexView and replace if “on-time” > 2.6 ms. Replacement Cylinder lubricating pump (Pulse lubrication) Accumulator: every 3 months
Check gas (nitrogen) pre-charge
pressure. Refill if required. Overhaul on board Lubricating pump: 30,000 Remanufacturing Cylinder lubricating pump (CLU-3) According to instruction of pump manufacturer According to instruction of pump manufacturer Overhaul on board Intermediate fuel accumulator (IFA)
Random check for
leakages Remanufacture IFA if required. Remanufacturing
Fuel pressure control valve (PCV)
Overhaul only necessary when
PCV is failing
Engine lifetime Perform a function check once a year.
Remanufacture part if required. Remanufacturing
Crank Angle Sensor (belt driven at free end)
Check pre-tension, cracks and wear of
toothed belt visually:
3,000
24,000 Replace belt after 24,000 hours and
measure run-out of the drive shaft. Replacement
Overhaul drive: 48,000
Replace ball bearings and sealing rings at overhaul. Replacement of relevant parts Crank angle sensor: 48,000
Replace sensor at 48,000 hours. Replacement
CAS with LEMAG increment wheel (engines with Retrofit Pulse Lubrication)
Check and clean sensor lenses
quarterly
Replace only if required
— Check and clean
wheels quarterly Engine lifetime
Remove dirt, oil or other contamination from the slits of the increment wheels.
WECS-9520 Components
quarterly Do a visual check of the cables. Replace the damaged cables and wires
60,000 Replace FCM-20, ALM-20, ACM-20
modules if failing Replacement
60,000 Replace Exh. Valve stroke sensor and
TDC sensor if failing. Replacement
WECS-9500
are based on past experience and valid for engines fully according to currently
applicable Wärtsilä Switzerland Ltd specifications. They are given for information
purposes only and do not constitute any guarantee or warranty whatsoever, as the
actual service life can vary considerably due to numerous conditions and influences
such as but not limited to:
− Environmental and operating conditions;
− Heavy fuel and lubricating oil qualities;
− Engine load factor;
− Fuel, lubricating oil and cooling water treatment;
− Overhaul according to engine manuals;
− Only genuine spare parts used;
− Careful and continuous engine monitoring.
2. “Estimated lifetime” refers to the life expectancy in hours under normal operating
conditions before the component is removed for replacement or remanufacturing.
3. Use welding rod with the end flattened and bent at 90°.
4. The anti-polishing ring is recommended to be replaced at the liner replacement.
5. Lifetime can be achieved with remanufacturing provided that the clearance between
nozzle needle and nozzle body is within specified limits.
6. Spindle lifetimes can be reached with remanufacturing. Remanufacturing of spindles
must only be done at Wärtsilä workshops.
7. The current exhaust valve dampers have a tendency to suffer from cavitation and the
damper can break up over a long period of time. Consequently broken parts can enter
the valve drive and cause subsequent damage. Wartsila recommends replacing all
dampers with the new design during the next overhaul, or anyway after 20,000
operating hours. Refer to RT-120.
8. It is recommended to open for inspection one connecting rod top end bearing and one
bottom end bearing at 70,000 running hours. In case either the connecting rod top or
bottom end bearing is found damaged, it is recommended to inspect other bearings
of same type at the next opportunity.
9. For ICUs on 82 cm bore engines built before June 2011 refer to Technical
Bulletin RT-122.
NOTE:
Appendix 3 with Table 1 “Inspection and overhaul intervals” is part of the Data &
Specifications bulletin RT-123.
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For questions about the content of this Data & Specifications bulletin, or if you need
Wärtsilä assistance, services, spare parts and/or tools, please contact your nearest
Wärtsilä representative.
Contact details for emergency issues
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representative or your key account manager.
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Unless otherwise expressly set forth, no recommendation contained in this document or any of its appendices is to be construed as provided due to a defect of the product, but merely as an improvement of the product and/or the maintenance procedures relating thereto. Any actions by the owner/operator as a result of the recommendations are not covered under any warranty provided by Wärtsilä and such actions will thus be at the owners/operators own cost and expense.
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