1 Manual

38
Manual
23328
ENGINE TYPE Wärtsilä 38
AUTHORIZATION Management WNL
DOCUMENT Manual
Author SERVICE
Date of issue November 2001
Status Approved
Distribution --
Number 23328
E Copyright 2001 by Wärtsilä Nederland B.V.

All rights reserved. No part of this booklet may be reproduced or copied in any form or
by any means (electronic, mechanical, graphic, photocopying, recording, taping or other
information retrieval systems) without the prior written permission of the copyright
owner.
THIS PUBLICATION IS DESIGNED TO PROVIDE AS ACCURATE AND AUTHORITATIVE INFORMATION

IN REGARD TO THE SUBJECT--- MATTER COVERED AS WAS AVAILABLE AT THE TIME OF WRITING.
HOWEVER, THE PUBLICATION DEALS WITH COMPLICATED TECHNICAL MATTERS SUITED ONLY FOR
SPECIALISTS IN THE AREA, AND THE DESIGN OF THE SUBJECT--- PRODUCTS IS SUBJECT TO REG-
ULAR IMPROVEMENTS, MODIFICATIONS AND CHANGES. CONSEQUENTLY, 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. THE PUBLISHER AND COPYRIGHT HOLDER SHALL
UNDER NO CIRCUMSTANCES BE HELD LIABLE FOR ANY FINANCIAL OR OTHER LOSS, OR ANY OTHER
DAMAGE OR INJURY, SUFFERED BY ANY PARTY MAKING USE OF THIS PUBLICATION OR THE IN-
FORMATION CONTAINED HEREIN.
23328
Manual
TABLE OF CONTENTS Wärtsilä 38
0.0. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0 - 1

0.0.1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0 -- 2
0.0.2. Documentation overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0 -- 3
0.0.3. Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0 -- 4
1.0. Main Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 -- 1

1.0.1. Basic information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 -- 2
1.0.2. Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 -- 3
1.0.3. Derating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 -- 4
1.0.4. Operating Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 -- 5
1.1. Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 - 1

1.1.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 -- 2
1.1.1.1. HFO engines running on distillate fuels . . . . . . . . . . . . . . . . . . 1.1 -- 2
1.1.2. Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 -- 3
1.1.2.1. Residual fuel oil (HFO) quality . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 -- 3
1.1.2.2. Distillate fuel oil (LFO) quality . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 -- 5
1.1.2.3. Other fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 -- 6
1.1.2.4. Fuel before engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 -- 6
1.1.2.5. Fuel conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 -- 7
1.1.2.6. Avoiding difficulties during operation on HFO . . . . . . . . . . . . . 1.1 -- 11
1.1.2.7. Comments on fuel characteristics . . . . . . . . . . . . . . . . . . . . . . . 1.1 -- 12
1.1.3. Internal fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 -- 15
1.1.4. Draining of fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 -- 16
1.2. Lubricating Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 1

1.2.1. Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 2
1.2.1.1. Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 3
1.2.1.2. Influences on the lubricating oil condition . . . . . . . . . . . . . . . . . 1.2 – 5
1.2.1.3. Testing of main lubricating oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 5
1.2.1.4. Condemning limits main lubricating oil . . . . . . . . . . . . . . . . . . . 1.2 – 7
1.2.1.5. Comments on lubricating oil characteristics . . . . . . . . . . . . . . . 1.2 – 8
1.2.1.6. Recommendations for refreshing lubricating oil . . . . . . . . . . . . 1.2 – 10
1.2.2. Internal lubricating oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 11
1.2.2.1. Components of internal system . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 12
1.2.2.2. Overview lubricating oil system . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 13
1.2.2.3. Engine lubricating oil circuits (main flow) . . . . . . . . . . . . . . . . . 1.2 – 14
1.2.2.4. Oil flow gearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 19
1.2.2.5. Engine top side lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 21
1.2.3. Components of lubricating oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 23
1.2.3.1. Duplex filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 23
1.2.3.2. Sample valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 23
1.2.3.3. Commissioning filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 23
1.2.3.4. Lubricating oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 24
1.2.3.5. Centrifugal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 30
1.2.3.6. Crankcase breathing system . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 33
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Wärtsilä 38 TABLE OF CONTENTS
1.3. Starting Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 - 1

1.3.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 -- 2
1.3.2. Internal starting air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 -- 2
1.3.3. Components of starting air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 -- 4
1.3.3.1. Starting air distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 -- 4
1.3.3.2. Starting air valve cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 -- 7
1.3.3.3. Starting air pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 -- 8
1.3.3.4. Pneumatic control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 -- 9
1.4. Cooling Water System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 - 1

1.4.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 -- 2
1.4.2. Cooling water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 -- 2
1.4.2.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 -- 2
1.4.2.2. Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 -- 3
1.4.2.3. Qualities of cooling water additives . . . . . . . . . . . . . . . . . . . . . . 1.4 -- 4
1.4.2.4. Cooling water control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 -- 5
1.4.3. Internal cooling water system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 -- 6
1.4.3.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 -- 6
1.4.3.2. Description HT cooling water system . . . . . . . . . . . . . . . . . . . . 1.4 -- 7
1.4.3.3. Description LT cooling water system . . . . . . . . . . . . . . . . . . . . . 1.4 -- 7
1.4.3.4. Cooling water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 -- 8
1.4.3.5. Flexible pipe connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 -- 13
1.4.4. Maintenance cooling water system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 -- 14
1.4.4.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 -- 14
1.4.4.2. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 -- 14
1.4.4.3. Cooling water venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 -- 15
1.5. Charge Air and Exhaust Gas System . . . . . . . . . . . . . . . . . . . . . . . 1.5 - 1

1.5.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 2
1.5.2. Quality of suction air filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 2
1.5.3. Internal system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 3
1.5.4. Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 4
1.5.4.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 4
1.5.4.2. Charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 5
1.5.4.3. Condensate draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 7
1.5.4.4. Charge air ducting between charge air receiver
and cilinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 14
1.5.5. Exhaust gas system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 15
1.5.5.1. Exhaust gas manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 15
1.5.5.2. Compensators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 16
1.5.5.3. Insulation box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 17
1.5.5.4. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 18
1.5.5.5. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 18
1.5.6. Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 19
1.5.6.1. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 19
1.5.6.2. Turbocharger cleaning devices . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 19
1.5.6.3. Compressor side cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 20
1.5.6.4. Turbine side cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 21
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1.6. Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 – 1

1.6.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 – 2
1.6.2. Speed control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 – 3
1.6.2.1. Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 – 3
1.6.2.2. Booster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 – 4
1.6.3. Fuel control mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 – 5
1.6.3.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 – 5
1.6.3.2. Load indication HP fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 – 6
1.6.3.3. Checking linkage between actuator
and common fuel control shaft . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 – 7
1.6.3.4. Checking linkage between fuel rack
1.6.3.5. Mechanical limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 – 9
1.6.3.6. Stop mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 – 10
1.6.3.7. Checking actuator stop position . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 – 11
1.6.3.8. Removing the actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 – 11
1.6.3.9. Mounting of the actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 – 12
1.6.4. Governing system maintenance and trouble shooting . . . . . . . . . . . . . . . 1.6 – 12
1.6.5. Engine instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 – 14
1.6.5.1. Switches, transmitters and temperature elements . . . . . . . . . 1.6 – 14
1.6.5.2. Speed sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 – 16
1.6.6. Local Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 – 18
2.3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 - 1

2.3.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 -- 2
2.3.2. Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 -- 3
2.3.2.1. Preheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 -- 3
2.3.2.2. Preparations before the start . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 -- 3
2.3.2.3. Local start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 -- 4
2.3.2.4. Remote or automatic start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 -- 5
2.3.2.5. Start after a normal stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 -- 5
2.3.2.6. Start after overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 -- 6
2.3.2.7. Emergency start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 -- 8
2.3.3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 -- 9
2.3.3.1. Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 -- 11
2.3.3.2. Loading performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 -- 12
2.3.3.3. Operating range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 -- 14
2.3.3.4. Maintenance points during operation . . . . . . . . . . . . . . . . . . . . . 2.3 -- 15
2.3.3.5. Measurement of cylinder pressure . . . . . . . . . . . . . . . . . . . . . . . 2.3 -- 17
2.3.3.6. Running--in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 -- 18
2.3.3.7. Operating problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 -- 19
2.3.3.8. Emergency operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 -- 25
2.3.4. Engine stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 -- 26
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2.4. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 - 1

2.4.1. Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 2
2.4.1.1. Safety aspects and rules for inspection and maintenance . . . 2.4 -- 2
2.4.1.2. Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 4
2.4.2. Maintenance Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 15
2.4.2.1. Miscellaneous tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 20
2.4.2.2. Charge air and exhaust gas system . . . . . . . . . . . . . . . . . . . . . 2.4 -- 28
2.4.2.3. Engine block, main bearing, cylinder liner . . . . . . . . . . . . . . . . 2.4 -- 29
2.4.2.4. Crankshaft, connecting rod, piston . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 37
2.4.2.5. Cylinder head with valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 44
2.4.2.6. Camshaft and valve drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 52
2.4.2.7. Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 59
2.4.3. Background information of hydraulic tools and torque spanners . . . . . . 2.4 -- 65
2.4.3.1. Pneumatic driven hydraulic pump unit . . . . . . . . . . . . . . . . . . . 2.4 -- 66
2.4.3.2. Hydraulic tool set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 70
2.4.3.3. Hydraulic extractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 72
2.4.3.4. Hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 73
2.4.3.5. Quick–release coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 74
2.4.3.6. Hydraulic hand pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 75
2.4.3.7. Safety instructions for hydraulic tools . . . . . . . . . . . . . . . . . . . . 2.4 -- 76
2.4.3.8. Loosening of hydraulically tightened connection . . . . . . . . . . . 2.4 -- 77
2.4.3.9. Tightening of hydraulically tightened connection . . . . . . . . . . . 2.4 -- 79
2.4.3.10. Torque spanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 80
2.4.4. Tightening torque and jack pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 83
2.4.4.1. Lubricating oil system components . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 83
2.4.4.2. Cooling water system components . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 84
2.4.4.3. Control system components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 85
2.4.4.4. Engine block with bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 86
2.4.4.7. Camshaft and drive mechanism . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 92
2.4.4.8. Injection system components . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 96
2.4.4.9. General table of tightening torques
for not specified bolt connections . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 99
2.4.5. Adjustments and Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 101
2.4.5.1. Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 101
2.4.5.2. Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 102
2.4.6. Dimensions and masses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 115
xx-- 4
Manual
2.5. Engine Block with Bearings and Cylinder Liner . . . . . . . . . . . . . 2.5 - 1

2.5.1. Engine block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 2
2.5.2. Main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 3
2.5.2.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 3
2.5.2.2. Removal of a main bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 4
2.5.2.3. Inspection of main bearings and journals . . . . . . . . . . . . . . . . . 2.5 -- 11
2.5.2.4. Main bearing assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 11
2.5.3. Crankshaft axial locating bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 18
2.5.3.1. Removal of the ’0’--bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 19
2.5.3.2. Inspection of axial thrust rings and thrust collars
on the crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 20
2.5.3.3. ’0’--bearing assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 20
2.5.4. Camshaft bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 21
2.5.4.1. Inspection of the camshaft bearing bush . . . . . . . . . . . . . . . . . 2.5 -- 21
2.5.4.2. Removal of the camshaft bearing bush . . . . . . . . . . . . . . . . . . . 2.5 -- 22
2.5.4.3. Mounting the camshaft bearing bush . . . . . . . . . . . . . . . . . . . . 2.5 -- 23
2.5.5. Cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 24
2.5.5.1. Inspection of the cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 24
2.5.5.2. Removal of the cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 25
2.5.5.3. Mounting the cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 27
2.5.6. Replacing cylinder head stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 29
2.5.7. Crankcase explosion relief valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 30
2.6. Crankshaft, Connecting Rod, Piston . . . . . . . . . . . . . . . . . . . . . . . 2.6 - 1

2.6.1. Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 2
2.6.1.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 2
2.6.1.2. Crankshaft deflections check . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 2
2.6.1.3. Measurement axial clearance crankshaft thrust bearing . . . . 2.6 -- 3
2.6.2. Connecting rod and piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 4
2.6.2.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 4
2.6.2.2. Removing and dismantling of piston and connecting rod . . . . 2.6 -- 5
2.6.2.3. Inspection and maintenance of piston rings
and gudgeon pin bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 12
2.6.2.4. Assembling and mounting of piston and connecting rod . . . . 2.6 -- 13
2.6.3. Big end bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 18
2.6.3.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 18
2.6.3.2. Removing big end bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 18
2.6.3.3. Removing the big end bearing shells
without removing piston / connecting rod . . . . . . . . . . . . . . . . . 2.6 -- 22
2.6.3.4. Assembling the big end bearing . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 24
2.6.4. Vibration damper crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 26
2.6.4.1. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 26
2.6.4.2. Liquid sampling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 27
2.6.5. Cranking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 29
2.6.5.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 29
2.6.5.2. Maintenance turning device . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 30
xx-- 5
Manual
2.7. Cylinder Head with Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 1

2.7.1. Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 2
2.7.1.1. Maintenance of cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 3
2.7.1.2. Removing the cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 4
2.7.1.3. Mounting of the cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 9
2.7.2. Adjusting the valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 12
2.7.3. Exhaust and inlet valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 14
2.7.3.1. Removing the valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 15
2.7.3.2. Check and reconditioning of valve disc and valve seat . . . . . 2.7 -- 17
2.7.3.3. Valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 18
2.7.3.4. Valve guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 21
2.7.3.5. Assembling of valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 22
2.7.4. Valve rotators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 23
2.7.4.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 23
2.7.4.2. Maintenance of inlet valve rotator . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 24
2.7.4.3. Maintenance of exhaust valve rotator . . . . . . . . . . . . . . . . . . . . 2.7 -- 24
2.7.5. Indicator cock and safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 25
2.7.6. Starting air valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 26
2.7.7. Fuel injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 26
2.8. Camshaft and Valve Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 - 1

2.8.1. Camshaft driving gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 -- 2
2.8.1.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 -- 2
2.8.1.2. Inspection gear wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 -- 4
2.8.1.3. Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 -- 5
2.8.1.4. Camshaft gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 -- 10
2.8.1.5. Intermediate gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 -- 15
2.8.1.6. Crankshaft gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 -- 18
2.8.2. Valve drive mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 -- 19
2.8.2.1. Dismantling valve drive mechanism . . . . . . . . . . . . . . . . . . . . . 2.8 -- 20
2.8.2.2. Assembling valve drive mechanism . . . . . . . . . . . . . . . . . . . . . . 2.8 -- 23
2.8.3. Actuator drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 -- 24
xx-- 6
Manual
2.9. Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 - 1

2.9.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 2
2.9.2. HP fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 2
2.9.2.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 2
2.9.2.2. HP fuel pump maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 3
2.9.2.3. Removing HP fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 3
2.9.2.4. HP fuel pump dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 5
2.9.2.5. Assembling of the HP fuel pump . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 7
2.9.2.6. HP fuel pump mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 9
2.9.2.7. HP fuel pump adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 10
2.9.3. Fuel pump bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 13
2.9.3.1. Removing fuel pump bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 13
2.9.3.2. Inspection of fuel pump drive tappet . . . . . . . . . . . . . . . . . . . . . 2.9 -- 17
2.9.3.3. Mounting fuel pump bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 18
2.9.4. Fuel injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 19
2.9.4.1. Removing the fuel injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 21
2.9.4.2. Fuel injector maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 22
2.9.4.3. Fuel injector overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 23
2.9.4.4. Testing of fuel injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 26
2.9.4.5. Mounting the fuel injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 28
2.9.5. HP fuel line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 29
2.9.5.1. Assembling HP fuel line to connecting piece . . . . . . . . . . . . . . 2.9 -- 29
xx-- 7
Manual
xx-- 8
Manual
LIST OF FIGURES Wärtsilä 38
Fig. 0.0 -- 1 Engine definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0 -- 4

Fig. 0.0 -- 2 Example of reading the flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0 -- 6
Fig. 0.0 -- 3 Designation of main bearings / camshaft bearings . . . . . . . . . . . . . . . . . 0.0 -- 7
Fig. 1.1 – 1 Viscosity conversion diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 -- 7
Fig. 1.1 – 2 Viscosity temperature diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 -- 8
Fig. 1.1 – 3 Nomogram for deriving CCAI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 -- 13
Fig. 1.1 – 4 Low pressure fuel pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 -- 15
Fig. 1.2 -- 1 Overview lube oil system (example) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 13
Fig. 1.2 -- 2 Cross section lubricating oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 14
Fig. 1.2 -- 3 Commissioning filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 15
Fig. 1.2 -- 4 Oil flow main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 16
Fig. 1.2 -- 5 Oil flow cross--over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 17
Fig. 1.2 -- 6 Oil flow connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 17
Fig. 1.2 -- 7 Oil flow piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 18
Fig. 1.2 -- 8 Oil flow axial/end bearing and gear drive . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 19
Fig. 1.2 -- 9 Detail oil flow gearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 20
Fig. 1.2 -- 10 Oil flow to engine top side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 21
Fig. 1.2 -- 11 Oil flow engine top side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 22
Fig. 1.2 -- 12 Gearwheel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 25
Fig. 1.2 -- 13 Mounting of clamping rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 26
Fig. 1.2 -- 14 Pressure control lube oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 28
Fig. 1.2 -- 15 Centrifugal filter on engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 30
Fig. 1.2 -- 16 Centrifugal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 31
Fig. 1.2 -- 17 Crankcase breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 34
Fig. 1.3 -- 1 Internal starting air system (example) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 -- 3
Fig. 1.3 -- 2 Starting air distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 -- 4
Fig. 1.3 -- 3 Pilot air lines, (example) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 -- 6
Fig. 1.3 -- 4 Starting air valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 -- 7
Fig. 1.3 -- 5 Starting air pipe arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 -- 8
Fig. 1.4 -- 1 Cooling water pump assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 -- 8
Fig. 1.4 -- 2 Cooling water pump assembled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 -- 9
Fig. 1.4 -- 3 Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 -- 10
Fig. 1.5 -- 1 Charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 5
Fig. 1.5 -- 2 Condensate drain point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 8
Fig. 1.5 -- 3 Levelling charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 9
Fig. 1.5 -- 4 Removal / mounting of the charge air cooler stack . . . . . . . . . . . . . . . . 1.5 -- 10
Fig. 1.5 -- 5 Charge air ducting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 14
Fig. 1.5 -- 6 Exhaust gas manifold configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 15
Fig. 1.5 -- 7 Gas flow through compensators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 16
Fig. 1.5 -- 8 Insulation box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 17
Fig. 1.5 -- 9 Compressor cleaning devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 20
Fig. 1.5 -- 10 cleaning device turbine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 22
Fig. 1.6 -- 1 Fuel control mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 – 5
Fig. 1.6 -- 2 Load indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 – 6
Fig. 1.6 -- 3 Linkage actuator / common control shaft . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 – 7
Fig. 1.6 -- 4 Indication on control shaft and HP fuel pump . . . . . . . . . . . . . . . . . . . . . 1.6 – 8
Fig. 1.6 -- 5 Mechanical limiters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 – 9
Fig. 1.6 -- 6 Stop device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 – 10
Fig. 1.6 -- 7 Stop mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 – 11
Fig. 1.6 -- 8 Speed sensor at the turning gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 – 16
Fig. 1.6 -- 9 Speed sensors at camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 – 17
Fig. 2.3 -- 1 Local control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 -- 4
xx-- 9
Manual
Wärtsilä 38 LIST OF FIGURES
Fig. 2.3 -- 2 Gradual load increase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 -- 12

Fig. 2.3 -- 3 Maximum sudden power increase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 -- 13
Fig. 2.3 -- 4 Operating range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 -- 14
Fig. 2.3 -- 5 Running--in diagram (n = constant 600 rpm) . . . . . . . . . . . . . . . . . . . . . . 2.3 -- 18
Fig. 2.3 -- 6 Local control unit, emergency stop button . . . . . . . . . . . . . . . . . . . . . . . . 2.3 -- 26
Fig. 2.3 -- 7 Manual stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 -- 27
Fig. 2.4 -- 1 Diagram pneumatically driven hydraulic pump unit . . . . . . . . . . . . . . . . 2.4 -- 67
Fig. 2.4 -- 2 Pneumatic driven hydraulic pump and jacks . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 69
Fig. 2.4 -- 3 Cross section single hydraulic jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 71
Fig. 2.4 -- 4 Cross section twin hydraulic jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 71
Fig. 2.4 -- 5 Hydraulic jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 72
Fig. 2.4 -- 6 H.P. quick--release coupling (example) . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 74
Fig. 2.4 -- 7 Dust caps H.P. quick--release coupling (example) . . . . . . . . . . . . . . . . . 2.4 -- 74
Fig. 2.4 -- 8 Hydraulic hand pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 75
Fig. 2.4 -- 9 Lubricating oil pump assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 83
Fig. 2.4 -- 10 Cooling water pump assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 84
Fig. 2.4 -- 11 Linkage, fuel rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 85
Fig. 2.4 -- 12 Main bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 86
Fig. 2.4 -- 13 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 87
Fig. 2.4 -- 14 Big end bearing and counter weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 88
Fig. 2.4 -- 15 Exhaust connection cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 89
Fig. 2.4 -- 16 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 90
Fig. 2.4 -- 17 Starting valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 90
Fig. 2.4 -- 18 Rocker arm mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 91
Fig. 2.4 -- 19 Tappet assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 92
Fig. 2.4 -- 20 Intermediate gear shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 93
Fig. 2.4 -- 21 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 94
Fig. 2.4 -- 22 Actuator drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 95
Fig. 2.4 -- 23 High pressure fuel injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 96
Fig. 2.4 -- 24 Injector, HP fuel pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 97
Fig. 2.4 -- 25 HP fuel pump drive and tappet housing . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 98
Fig. 2.4 -- 26 Gear wheel train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 103
Fig. 2.4 -- 27 Measuring the cylinder liner bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 104
Fig. 2.4 -- 29 Valve stem and valve disc burning in wear . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 109
Fig. 2.4 -- 30 Inlet valve and valve seat in cylinder head . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 109
Fig. 2.4 -- 31 Exhaust valve and valve seat in cylinder head . . . . . . . . . . . . . . . . . . . . 2.4 -- 109
Fig. 2.4 -- 32 Driving gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 110
Fig. 2.4 -- 33 Governor drive gear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 111
Fig. 2.4 -- 34 Valve drive mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 112
Fig. 2.4 -- 35 Fuel pump bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 113
Fig. 2.4 -- 36 Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 114
Fig. 2.4 -- 37 HP fuel pump adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 114
Fig. 2.4 -- 38 Engine components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 115
Fig. 2.4 -- 39 Turbochargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 116
Fig. 2.4 -- 40 Charge air cooler inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 116
Fig. 2.5 -- 1 Engine block (view free--end side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 2
Fig. 2.5 -- 2 Position bearing temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 4
Fig. 2.5 -- 3 Positioning jack on side stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 5
Fig. 2.5 -- 4 Positioning the main bearing jacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 7
Fig. 2.5 -- 5 Lowering the main bearing cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 8
Fig. 2.5 -- 6 Bearing shell driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 10
xx-- 10
Manual
LIST OF FIGURES Wärtsilä 38
Fig. 2.5 -- 7 Inserting main bearing shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 11

Fig. 2.5 -- 8 Pushing the upper main bearing shell into position . . . . . . . . . . . . . . . . 2.5 -- 12
Fig. 2.5 -- 9 Crankshaft axial locating bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 18
Fig. 2.5 -- 10 Camshaft and axial bearing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 21
Fig. 2.5 -- 11 Connect the hoses to the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 22
Fig. 2.5 -- 12 ’0’--bearing bush in engine block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 23
Fig. 2.5 -- 13 Liner in engine block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 24
Fig. 2.5 -- 14 Liner lifting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 25
Fig. 2.5 -- 15 Lifting the cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 26
Fig. 2.5 -- 16 Centre of gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 26
Fig. 2.5 -- 18 Marks on cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 28
Fig. 2.5 -- 19 Replacing cylinder head stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 29
Fig. 2.5 -- 20 Crankcase safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 31
Fig. 2.6 -- 1 Taking crankshaft deflection readings . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 2
Fig. 2.6 -- 2 Connecting rod and piston assembling . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 4
Fig. 2.6 -- 3 Removing anti--bore polishing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 5
Fig. 2.6 -- 4 Hydraulic tool connecting rod studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 6
Fig. 2.6 -- 5 Connection of the hydraulic tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 6
Fig. 2.6 -- 6 Hoisting tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 7
Fig. 2.6 -- 7 Fitting the protecting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 8
Fig. 2.6 -- 8 Hoisting the piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 9
Fig. 2.6 -- 9 Piston with fixating tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 9
Fig. 2.6 -- 10 Piston with connecting rod in vertical position . . . . . . . . . . . . . . . . . . . . . 2.6 -- 10
Fig. 2.6 -- 11 Removing the retainer spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 10
Fig. 2.6 -- 12 Removing gudgeon pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 11
Fig. 2.6 -- 13 Removing connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 11
Fig. 2.6 -- 14 Marks on piston and connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 13
Fig. 2.6 -- 15 Securing the piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 14
Fig. 2.6 -- 16 Moving the connecting rod into the piston . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 14
Fig. 2.6 -- 17 Piston on connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 15
Fig. 2.6 -- 18 Lowering the piston and connecting rod into the cylinder liner . . . . . . . 2.6 -- 16
Fig. 2.6 -- 19 Hydraulic tool big end bearing studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 19
Fig. 2.6 -- 20 Connection HP hoses big end bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 19
Fig. 2.6 -- 21 Frame and support big end bearing caps . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 20
Fig. 2.6 -- 22 Carriers big end bearing caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 21
Fig. 2.6 -- 23 Mount piston support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 22
Fig. 2.6 -- 24 Fit hydraulic tightening tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 23
Fig. 2.6 -- 25 Positioning device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 23
Fig. 2.6 -- 26 Liquid sampling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 27
Fig. 2.6 -- 27 Electrically driven turning device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 29
Fig. 2.7 – 1 Cross section cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 2
Fig. 2.7 – 2 Tilting frame cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 3
Fig. 2.7 – 3 Cooling water discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 4
Fig. 2.7 – 4 Cylinder head assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 5
Fig. 2.7 – 5 Sensor junction box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 5
Fig. 2.7 – 6 Loosening the cylinder head nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 6
Fig. 2.7 – 7 Lifting the cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 7
Fig. 2.7 – 8 Cylinder head on liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 8
Fig. 2.7 – 9 Protecting ring for cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 8
Fig. 2.7 – 10 Valve clearance adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 13
Fig. 2.7 – 11 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 14
xx-- 11
Manual
Wärtsilä 38 LIST OF FIGURES
Fig. 2.7 – 12 Dismantling of valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 15

Fig. 2.7 – 13 Valve definition, inlet (I) exhaust (X) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 16
Fig. 2.7 – 14 Blueing test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 17
Fig. 2.7 – 15 Removing valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 18
Fig. 2.7 – 16 Mounting valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 20
Fig. 2.7 – 17 Extracting valve stem guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 21
Fig. 2.7 – 18 Detail valve guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 22
Fig. 2.7 – 19 Valve rotators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 23
Fig. 2.7 – 20 Indicator cock / safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 25
Fig. 2.8 -- 1 Gearwheel drive camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 -- 2
Fig. 2.8 -- 2 Camshaft section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 -- 3
Fig. 2.8 -- 3 Starting air distributor with drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 -- 4
Fig. 2.8 -- 4 Securing fuel cam roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 -- 5
Fig. 2.8 -- 5 Tappet securing plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 -- 6
Fig. 2.8 -- 6 Position of pillar bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 -- 7
Fig. 2.8 -- 7 Removal of camshaft section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 -- 7
Fig. 2.8 -- 8 Removal of camshaft journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 -- 8
Fig. 2.8 -- 9 Axial bearing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 -- 10
Fig. 2.8 -- 10 Removal of camshaft end journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 -- 11
Fig. 2.8 -- 11 Position of jack bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 -- 12
Fig. 2.8 -- 12 Position of pillar bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 -- 12
Fig. 2.8 -- 13 Removal of the camshaft gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 -- 13
Fig. 2.8 -- 14 Tool for intermediate gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 -- 15
Fig. 2.8 -- 15 Intermediate gear wheel section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 -- 16
Fig. 2.8 -- 16 Removal of intermediate gear wheel shaft . . . . . . . . . . . . . . . . . . . . . . . 2.8 -- 16
Fig. 2.8 -- 17 Mount shaft intermediate gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 -- 17
Fig. 2.8 -- 18 Crankshaft gear wheel assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 -- 18
Fig. 2.8 -- 19 Valve drive mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 -- 19
Fig. 2.8 -- 20 Rocker arm bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 -- 20
Fig. 2.8 -- 21 Rocker arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 -- 21
Fig. 2.8 -- 22 Push rod assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 -- 21
Fig. 2.8 -- 23 Tappet guide block assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 -- 22
Fig. 2.8 -- 24 Actuator drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 -- 24
Fig. 2.9 -- 1 HP fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 3
Fig. 2.9 -- 2 Lifting the HP fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 4
Fig. 2.9 -- 3 Detail of the HP fuel pump bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 4
Fig. 2.9 -- 4 HP Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 5
Fig. 2.9 -- 5 Assembling tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 6
Fig. 2.9 -- 6 Checking measurement ”X” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 10
Fig. 2.9 -- 7 HP fuel pump adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 11
Fig. 2.9 -- 8 Fuel pump bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 13
Fig. 2.9 -- 9 Low pressure fuel pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 14
Fig. 2.9 -- 10 Extrusion profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 15
Fig. 2.9 -- 11 Locking tool for tappet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 16
Fig. 2.9 -- 12 Fuel pump bracket securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 16
Fig. 2.9 -- 13 Removal roller and shaft from tappet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 17
Fig. 2.9 -- 14 Fuel injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 19
Fig. 2.9 -- 15 Cylinder head with injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 20
Fig. 2.9 -- 16 Preparation injector removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 21
Fig. 2.9 -- 17 Fuel injector assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 22
Fig. 2.9 -- 18 Fuel injector cross section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 23
Fig. 2.9 -- 19 Protecting the nozzle tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 24
Fig. 2.9 -- 20 Testing fuel injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 26
Fig. 2.9 -- 21 HP fuel pipe assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 30
xx-- 12
Manual
General Wärtsilä 38
0.0. General
Table of contents
0.0. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0 - 1

0.0.1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0 -- 2
0.0.2. Documentation overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0 -- 3
0.0.3. Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0 -- 4
23328 0.0 -- 1
Manual
Wärtsilä 38
General
0.0.1. Introduction
The purpose of this manual is to give the user a guide for operation and
maintenance of the engine. This manual has been prepared using the
manufacturer’s best knowledge and experience. The manual is part of
the documentation supplied with the engine.
It is imaginable that, before starting or during performing particular
jobs, you have questions to which the manual gives no answer. In this
case do not take any unnecessary risks and contact the Service
department of Wärtsilä Nederland B.V. or your local Wärtsilä Service
station.
Wärtsilä Nederland B.V. reserves the right to minor alterations and

improvements due to engine development without the obligation to
enter the corresponding changes in this manual.
The operation and/or maintenance work described in this manual must
only be carried out by trained technicians specialised in diesel engines.
Make sure, everyone who works with the engine has this manual
available and understands the contents.
Ensure, all equipment and tools for maintenance are in good order.
Use only genuine parts to ensure the best efficiency, reliability and life
time of the engine and its components.
Modifications as to the settings may only be made after written approval
from Wärtsilä Nederland B.V. Altering settings may effect the warranty.
During the warranty period of the engine the owner is obliged to follow
strictly the instructions for operation and maintenance outlined in this
manual.
The customer will be solely responsible in the following cases, among
other things:
--- For failure caused by neglecting to consult the engine
documentation, resulting in malfunction of the engine, short life
time of components, personal injury or damage to property or
environment.
--- For wrong treatment or mal operation, also when the circumstances
are not described in the engine documentation.
--- For any consequence resulting from incorrect translation or
interpretation of the original engine documentation supplied with
the engine.
0.0 -- 2 23328
Manual
0.0.2. Documentation overview
The engine documentation delivered with your engine consists of four

volumes:
1: Manual
--- General Description of the engine
--- Main Data
--- Description of the various gas ---,fluid --- and control systems
--- Operation directives
--- Maintenance schedule, ---tools and ---instructions
--- Description of main engine parts
2: Catalogue
--- Test Report
--- Pipe Arrangement/Internal Diagrams
--- Electrical Documentation
--- Spare Parts Catalogue (of the engine)
3: Sub---suppliers Manual
--- Documentation as received from the Sub---suppliers if not
incorporated in another way in the engine documentation.
4: After Sales Information

--- Division with separate tabs for filling standard forms and all
commercial and technical, product related after sales documents
which are mailed customer specific.
23328 0.0 -- 3
Manual
Wärtsilä 38
General
0.0.3. Terminology
The following definitions are used in the engine documentation:

Operating side
Longitudinal side of the engine where the operating controls are
located.
Non--operating side
Longitudinal side opposite of the operating side.
Driving end
End of the engine where the flywheel is located.
Free end
The end opposite the driving end.
Designation of cylinders
Designation of cylinders begins at the driving end.
Clockwise rotating
The rotation as viewed from the position of the observer.
Counter-- clockwise rotating
The rotation as viewed from the position of the observer.
A--bank and B--bank
See figure in relation to observer.
Inlet and exhaust valves
See figure in relation to observer.
RELATED TO ISO 1204
Fig. 0.0 - 1 Engine definitions
0.0 -- 4 23328
Manual
Top dead centre (TDC)

The top turning point of the piston in the cylinder. TDC for every
cylinder is marked on the gradation of the flywheel.
In a complete diesel process on a four cycle engine the piston reaches
TDC twice:
TDC at scavenging
The first time when the exhaust stroke of the previous working cycle
ends and the suction stroke of the following one begins. Exhaust valves
as well as inlet valves are then partly open and scavenging takes place.
If the crankshaft is turned back and forth in this TDC area, both
exhaust and inlet valves tend to open, a fact that indicates the piston is
near top position which is called TDC at scavenging.
TDC at firing
The second time is at the end of the compression stroke and before the
working stroke starts. Slightly before this TDC the fuel injection takes
place and this TDC can therefore be defined as TDC at firing. In this
case, all valves are closed and do not move if the crankshaft is turned.
The roller of the fuel pump tappet is on the lifting side of the fuel cam.
Bottom dead centre (BDC)

The bottom turning point of the piston in the cylinder.
23328 0.0 -- 5
Manual
Wärtsilä 38
General
Marks on the flywheel

The circumference of the flywheel is divided into sections of 5_, starting
at TDC of cylinder 1. TDC for every following cylinder is individually
indicated. Where two TDC’s are indicated at the same mark, one
cylinder is in TDC at firing and the other in TDC at scavenging. See also
the firing order in chapter 1.0.
The indicator (1) is provided with a scale per degree, starting at 5_
before TDC till 5_ after TDC.
Fig. 0.0 -- 2 Example of reading the flywheel
0.0 -- 6 23328
Manual
Designation of bearings
Main bearings
The crankshaft locating bearing is No. 0, the first standard main
bearing is No. 1, the second No. 2 etc. The crankshaft locating bearing
outer ring close to the flywheel is marked with 00 and the inner ring
with 0.
Camshaft bearing
Camshaft bearings are designated in the same sequence as the main
bearings.
Intermediate gear wheel bearings

Bearings located at flywheel side are designated 00 and the inner
bearings 0.
7 6 5 4 3 2 1 0
Fig. 0.0 -- 3 Designation of main bearings / camshaft bearings
--o--o--o--o--o--
23328 0.0 -- 7
Manual
Wärtsilä 38
General
0.0 -- 8 23328
Manual
Main Data Wärtsilä 38
1.0. Main Data

Table of contents
1.0. Main Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 -- 1

1.0.1. Basic information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 -- 2
1.0.2. Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 -- 3
1.0.3. Derating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 -- 4
1.0.4. Operating Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 -- 5
23328 1.0 -- 1
Manual
Wärtsilä 38
Main Data
1.0.1. Basic information
Project name Bodewes 504

Engine designation number 23328
Engine type 6L38

Cylinder bore 380 mm
Stroke 475 mm
Number of cylinders 6
Direction of rotation Clockwise
Firing order 1---4---2---6---3---5
The Wärtsilä 38 diesel engine is a 4–stroke, medium speed,

turbocharged and intercooled engine with direct fuel injection.
1.0 -- 2 23328
Manual
1.0.2. Output
Engine output according to engine rating plate

Output 100% kW 3960
Engine speed rpm 600
Suction air temperature oC 45
Charge air coolant temperature oC 38
Engine output according to ISO substitute reference conditions

Output 100% kW 3960
Engine speed rpm 600
ISO 3046--1:1995(E) Substitute reference conditions
Ambient air pressure mbar 1000
Site altitude above sea level m 0
Suction air temperature oC 45
Charge air coolant temperature oC 38
Total exhaust gas back pressure mbar 30
Note! The full output of the engine is available at the ISO substitute
reference conditions. No compensation (uprating) is allowed for
operating conditions better than the ISO substitute reference
conditions. For derating data see section 1.0.3.
Fuel limiter is set at 100 % and no overload is allowed.
23328 1.0 -- 3
Manual
Wärtsilä 38
Main Data
1.0.3. Derating conditions
1 Derating of the engine output:

For the ISO substitute reference conditions see section 1.0.2.
Derating is according to ISO 3046---1:1995(E) applying: ηm = 0.90
– 0.35% per oC that suction the air temperature is above the ISO
substitute reference condition.
– 0.40% per oC that the suction air temperature is below 15 oC.
– 0.30% per oC that the charge air coolant temperature is above the
ISO substitute reference condition.
– 1.33% per kPa (10 mbar) that the total exhaust gas back pressure is
above the ISO substitute reference condition.
– 0.4% per ‰ relative pressure loss in the charge air cooler 1).
– 0.5% per 10% glycol unless the charge air coolant temperature is
reduced by 1oC for every 10% glycol in the cooling water.
Note! Data mentioned in Operating Data (section 1.0.4.) must stay at the
nominal values
2 Reduce engine load if operating temperatures of lubricating oil or

cooling water exceed the nominal values or exhaust gas tend to exceed
the maximum values, see section 1.0.4.
High operating temperatures can be caused by:

– contamination of coolers
– reduction of charge air pressure by:
– contamination of turbocharger compressor and/or turbine
– contamination of air in take filter
– contamination of air side cooler.
--- too much wear of the turbine.
– deviation of setting of (individual) high pressure fuel pumps
– worn fuel injectors
– worn high pressure fuel pumps
– high fuel CCAI value (> 870)
– high ambient temperature.
Note! Never change fuel rack settings to equalize the exhaust gas
temperature.
1) pressure loss air cooler in mbar

Relative pressure loss = ‰
absolute charge air pressure bar
1.0 -- 4 23328
Manual
1.0.4. Operating Data
Operating Data Conditions

Max. Nom. Min.
Fuel condition before injection pumps:
-- Pressure bar -- 7--8 --
-- Viscosity (HFO) cSt -- 16--24 --
-- Viscosity (LFO) cSt -- -- 2
-- Temperature (HFO) oC 130 -- --
-- Temperature (LFO) oC 50 -- --
Lube oil condition:
-- Temperature before engine oC -- 63 --
-- Pressure before engine bar -- 4.5 --
HT cooling water condition:
-- Temperature before engine oC -- 73 --
-- Temperature after engine oC -- 93 --
-- Pressure before engine bar 4.6 3.8* --
LT cooling water condition:
-- Temperature before engine oC 38 -- --
-- Temperature after engine oC -- -- 44
-- Pressure before engine bar 4.6 3.4* --
HT and LT cooling water static pressure:
-- at inlet cooling water pump bar 0.8 -- 0.5
Charge air temperature in air receiver oC -- 50 --
Starting air pressure (min. pres. at 20 oC) bar 33 30 12
Firing pressure bar 180 -- --
* ---static pressure to be added.
--o--o--o--o--o--
23328 1.0 -- 5
Manual
Wärtsilä 38
Main Data
1.0 -- 6 23328
Manual
Fuel System Wärtsilä 38
1.1. Fuel System
Table of contents
1.1. Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 - 1

1.1.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 -- 2
1.1.1.1. HFO engines running on distillate fuels . . . . . . . . . . . . . . . . . . 1.1 -- 2
1.1.2. Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 -- 3
1.1.2.1. Residual fuel oil (HFO) quality . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 -- 3
1.1.2.2. Distillate fuel oil (LFO) quality . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 -- 5
1.1.2.3. Other fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 -- 6
1.1.2.4. Fuel before engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 - 6
1.1.2.5. Fuel conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 - 7
1.1.2.6. Avoiding difficulties during operation on HFO . . . . . . . . . . . . . 1.1 -- 11
1.1.2.7. Comments on fuel characteristics . . . . . . . . . . . . . . . . . . . . . . . 1.1 -- 12
1.1.3. Internal fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 -- 15
1.1.4. Draining of fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 -- 16
23328 1.1 -- 1
Manual
Wärtsilä 38
Fuel System
1.1.1. General
Selection of the most economical fuel for diesel engines depends on

several variables such as engine requirements, operating conditions,
fuel quality, availability, and costs. Engines vary widely in the grade of
fuel required for satisfactory operations. In general high speed engines
require a more refined fuel than low speed types.
High cetane number light distillate fuels are more expensive than low
cetane heavier---type fuels. For any class of fuel, careful control of
uniformity generally carries a price premium because of the operating
limitations imposed on the refiner.
Engine operation on any fuel resulting in excessive maintenance is
obviously uneconomical regardless of fuel cost. The engine
manufacturer’s recommendation is the logical starting point for
selecting the fuel of an engine. These recommendations may
subsequently be tempered to obtain additional economies in view of
experience and the local fuel situation. Such steps, however, should be
taken carefully.
1.1.1.1. HFO engines running on distillate

fuels
The engine is designed for continuous operation on heavy fuel. For limited
periods it is possible to operate the engine on distillate fuel without
modification. For periods longer than 250 hours the cylinder head
(exhaust valves) has to be modified. Engines intended for continuous or
prolonged operation on distillate fuels corresponding to ISO 8217: 1996,
F---DMA, DMB and DMC are adapted to such fuels.
Engines can be started and stopped on heavy fuel oil provided that the
engine and fuel system are preheated to operating temperature.
It is only recommended to change over from HFO to distillate fuel
operation when it is necessary to fill or flush the fuel oil system.
1.1 -- 2 23328
Manual
1.1.2. Fuel
1.1.2.1. Residual fuel oil (HFO) quality
The residual fuel oil quality as bunkered must be within the following
specification:
Property Unit Typical Limit Test meth. ref.
Viscosity at: 100C cSt max. 55 55 ISO 3104
Viscosity at: 50C cSt max. 730 730 ISO 3104
Viscosity at: 100F Redwood
No. 1 sec max. 7200 7200 ISO 3104
Density at: 15C kg/m3 max. 9911) 9911) ISO 3675 or
kg/m3 max. 1010 1010 ISO 12185
CCAI max. 850 8702) Shell formula
Water % volume max. 1.0 1.0 ISO 3733
Sulphur % mass max. 20 5.0 ISO 8754
Ash % mass max. 0.05 0.20 ISO 6245
Vanadium mg/kg max. 100 6003) ISO 14597
Sodium mg/kg max. 50 1003) ISO 10478
Aluminium + Silicon mg/kg max. 30 80 ISO 10478
Conradson Carbon % mass max. 15 22 ISO 10730
residue
Asphaltenes % mass max. 8 14 ASTM D 3279
Flash point (PMCC) C max. 60 60 ISO 2719
Pour point C max. 30 30 ISO 3016
Total sediment, potential % mass max. 0.10 0.10 ISO 10307--2
1) Maximum of 1010 kg/m3 at 15C, provided the fuel treatment system
can remove water and solids.
2) Straight run residues show CCAI values in the 770 to 840 range and are
very good ignitors.
Cracked residues delivered as bunkers may vary from 840 to --- in
exceptional cases --- above 900 CCAI. Most bunkers remain in the max. 850
to 870 range at the moment.
3) Sodium contributes to hot corrosion on exhaust valves when combined
with high sulphur and vanadium contents. Sodium also strongly
contributes to fouling of the exhaust gas turbine blading at high loads.
23328 1.1 -- 3
Manual
Wärtsilä 38
Fuel System
The aggressiveness of the fuel depends on its proportions of sodium and

vanadium, but also on the total amount of ash. Other ash constituents
however, also on the the sodium and vanadium content of the fuel. Also
a fuel with lower sodium and vanadium contents than specified above.
can cause hot corrosion on engine components.
Foreign substances or chemical waste, hazardous to, the safety of the
installation or detrimental to the performance of engines, should not be
contained in the fuel.
The limits above also correspond to the demands of:
--- BS MA 100: 1996, RMH55 and RMK 55
--- CIMAC 1990, Class H55 and K55
--- ISO 8217: 1996(E), ISO ---F---RMH 55 and RMK 55
1.1 -- 4 23328
Manual
1.1.2.2. Distillate fuel oil (LFO) quality
The distillate fuel oil quality as bunkered must be in the following

specification based on ISO 8217: 1996(E) ISO---F---DMA, DMB and DMC:
Property Unit DMA DMB DMC1) Test meth. ref.

Viscosity at 40C cSt min. 1.5 2) 2.0 2.0 ISO 3104
cSt max. 6.0 11.0 14.0
Density at 15C kg/m3 max. 890.0 900.0 920.0 ISO 3675 or
12185
Water % vol- max. -- 0.3 0.3 ISO 3733
ume
Sulphur % mass max. 1.5 2.0 2.0 ISO 8574
Ash % mass max. 0.01 0.01 0.05 ISO 6245
Vanadium mg/kg max. -- -- 100 ISO 14597
Aluminium + Silicon mg/kg max. -- -- 25 ISO 10478
Conradson carbon % mass max. 0.3 0.3 2.5 ISO 10370
residue
Flash point (PMCC) C min. 60 60 60 ISO 2719
Pour point ISO 3016
-- Summer C max. 0 6 6
-- Winter C max. -- 6 0 0
Sediment % mass max. -- 0.07 -- ISO 3735
Total sediment % mass max. -- -- 0.1 ISO 3735
potential
Cetane number [--] min. 40 35 -- ISO 5165
1)The use of ISO ---F---DMC category fuel is allowed provided that the
fuel treatment system is equipped with a fuel centrifuge.
2) The temperature of the fuel shall be adjusted such that the minimum
viscosity before the engine is well above 2 cSt.
Foreign substances or chemical waste, hazardous to the installation or
detrimental to the performance of the engines, should not be contained
in the fuel.
Some distillate fuel oils may contain wax particles which solidify at
temperatures below 50 oC and may clog the fuel filter. It is advised to
install a heater in the supply line to the fuel filter. In case of a clogged
filter the heater can be switched on to overcome the problem.
23328 1.1 -- 5
Manual
Wärtsilä 38
Fuel System
1.1.2.3. Other fuels
For fuel oils out of the specifications as stated in this paragraph, please
contact Wärtsilä Nederland B.V.
1.1.2.4. Fuel before engine
All fuel oil supplied to the engine must be properly conditioned and fulfil
the following requirements:
Property Unit Value
Fuel condition before injection pumps:

For pressure, temperature (LFO / HFO) and viscosity
(LFO / HFO) see section 1.0.4.
The HFO must be purified in an efficient centrifuge
system. Furthermore, the fuel should pass through an
automatic filter before entering the engine.
Automatic backflush filter; fineness 90%abs. [←m] 10/25
Water / volume % max. 0.3
Sodium mg/kg max. 30
Aluminium + Silicon mg/kg max. 15
Quantity of clean leak HFO (at 100% load) %* ca. 0.4
Fuel flow / fuel consumption ratio (at 100% load) min. 4 : 1
*)% of Specific Fuel Oil Consumption
1.1 -- 6 23328
Manual
1.1.2.5. Fuel conditioning
World wide different viscosity units are used. Fig. 1.1 – 1 shows a
diagram to convert the viscosity from one unit to another.
The unit [mm2/s] is equal to [cSt].
[mm2/s]
Fig. 1.1 – 1 Viscosity conversion diagram
Conversion from various viscosity units to [mm2/s] can be made in the

diagram, fig. 1.1 – 1 . The diagram should be used only for conversion of
viscosities at the same temperature. The same temperature should then
be used when entering the viscosity / temperature point into the diagram
of fig. 1.1 – 2 .
23328 1.1 -- 7
Manual
Wärtsilä 38
Fuel System
Fuel oil viscosity and temperature

Pumping, centrifuging and proper atomisation in the combustion space
of the engine requires each its specific fuel viscosity. Controlled heating
to obtain the corresponding temperatures is required. These
temperatures can be determined from the diagram in fig. 1.1 – 2 . The
diagram shows:
--- The viscosity---temperature lines for a number of viscosity grades
(lines running from top---left to bottom---right). For residual fuels
(ISO RM..) the viscosity grade is normally specified at 50_C or at
100_C. For distillate fuels (ISO DM..) this temperature is 40_C.
The (straight) line for 380 mm2/s at 50_C fuel for instance is the one
running through (top to bottom) points H through E.
Lines for fuels with other viscosities at 50_C run parallel left (lighter
fuels) and right (heavier fuels) to the 380 mm2/s at 50_C line.
mm2/s
5000
Residual fuels
2000
RM--55 (700 mm2/s at 50 oC)
1000
H Approximately pumping limit
600
400 G
300
Distillate fuels
A
200 RM--35 (380 mm2/s at 50 oC)
Centrifuging
Minimum storage temperature
100 temperature
80
Maximum viscosity
60 C before HP fuel pumps
50
40
K
Viscosity range
30 F before HP fuel pumps
25
B
20
D
16
14
12
E
10
9 DMC (14 mm2/s at 40 oC) Maximum
8 temperature
DMB (11 mm2/s at 40 oC) before
7
HP fuel pumps
6 DMA (6 mm2/s at 40 oC)
RM--25 (180 mm2/s at 50 oC)
5
RM--15 (80 mm2/s at 50 oC)
4
RM--10 (40 mm2/s at 50 oC)
--10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 _C
Fig. 1.1 – 2 Viscosity temperature diagram
1.1 -- 8 23328
Manual
--- The (horizontal) line at 1000 mm2/s above which pumping is

difficult.
--- The line with sharp bends through point G, which shows the
minimum storage temperature for all viscosity classes. For higher
viscosity class fuels a higher storage viscosity is accepted to limit the
heating demand.
--- The line with sharp bends through point F, shows the required
centrifuging temperature. For viscosity classes higher than 40
mm2/s at 50_C a higher centrifuging viscosity than 14 mm2/s is
accepted to save heating power. Finally the line turns vertical at 97_C
because boiling of the sealing and operating water in the centrifuge
must be avoided. With further increase of viscosity the throughput
through the centrifuge must be reduced for maintaining the
required degree of purification.
--- The maximum temperature before the HP fuel pumps is 130 _C for
fuels of the highest viscosity.
Example:
RM35 a fuel with a viscosity of 380 mm 2/s at 50_C (point A) or 35 mm 2/s
at 100_C (point B):
--- Is pumpable above 37_C (point H).

--- Minimum storage temperature is 41_C (point G). It is advised to keep
the fuel about 10_C above this temperature.
--- Centrifuging temperature is 97_C (point F).
--- Heating temperature before entering the engine for proper
atomisation in the engine, is maximum 127_C, minimum injection
temperature 112_C.
Example:
To obtain temperatures for intermediate viscosities, draw a line from the
known viscosity / temperature point in parallel to the nearest viscosity /
temperature line in diagram.
--- Known viscosity of 60 mm 2/s at 50_C (point K), the following can be
read along the dotted line: 11 mm 2/s at 100_C.
--- Minimum storage temperature is 28_C.
--- Centrifuging temperature is 85_C.
--- Heating temperature before entering the engine for proper
atomisation in the engine, is maximum 87_C, minimum injection
temperature 74_C.
23328 1.1 -- 9
Manual
Wärtsilä 38
Fuel System
Purification
Heavy fuel (residuals, and mixtures of residuals, distillate and DMC)
must be purified in an efficient working centrifuge before entering the
day tank. The fuel should be heated before centrifuging.
Recommended temperatures, depending on the fuel viscosity, are stated
in the diagram, see fig. 1.1 – 2 .
Sufficient heating capacity is needed to make centrifuging at
recommended levels possible. The temperature must be controlled on
2_C before centrifuge when centrifuging high viscosity fuels with
densities approaching or exceeding 0.991 g/ml at 15_C.
Be sure the correct gravity disc is used. Never exceed the flow rates
recommended for the centrifuge for the grade of fuel in use. The lower
the flow rate the better the purification efficiency.
Recommended centrifuge flow rate

Viscosity at 100_C mm2/s -- 10 15 25 35 45 55
Viscosity at 50_C mm2/s 12 40 80 180 380 500 730
Centrifuge flow
% of rated capacity 100 60 40 30 25 20 15
Sufficient separating capacity is required. The best and most

disturbance---free results are obtained with purifier and clarifier in
series. Alternatively the main and stand ---by separators may run in
parallel, but this makes heavier demands on correct gravity disc choice
and constant flow and temperature control to achieve optimum results.
Flow rate through the centrifuges should not exceed the maximum fuel
consumption of the engine by more than 10 %.
In case pure distillate fuel is used, centrifuging is still recommended as
fuel may be contaminated during transport and in storage tanks. The
full rated capacity of the centrifuge may be used provided the viscosity
is less than 12 mm2/s at centrifuging temperature.
1.1 -- 10 23328
Manual
1.1.2.6. Avoiding difficulties during operation

on HFO
The engine is designed for burning HFO. In order to avoid difficulties

mind the following points:
1 At all loads the charge air temperature should be kept at design

temperature by controlling the LT cooling water temperature.
2 Fuel injection temperature with regard to HFO. For requirements
see ”Fuel viscosity / temperature in the engine”. Poor fuel quality will
adversely influence wear, engine component life time and maintenance
intervals.
3 Clean the turbocharger turbine side frequently straight from the
beginning. Fuels with high vanadium and sodium contents in
unfavourable ratio’s may lead to rapid contamination of the turbine and
higher gas temperatures. In such cases more frequently cleaning is
necessary.
4 Limit low load operation as much as operating conditions permit if
fuel is known or suspected to have higher sulphur content above 2 %,
carbon content ” carbon residue” above 15 % and/or asphaltene content
above 8 %.
5 Avoid unstable and incompatible fuels (precipitation of heavy
components in the fuel) by avoiding blending of fuels unless the fuels
are known to be compatible. Store fuels from different deliveries in
separate tanks.
If stability and compatibility problems occur never add distillate fuel as
this will probably increase precipitation. A fuel additive with highly
powerful dispersing characteristics can be of help until a new fuel
delivery takes place.
6 Some of the difficulties may occur on heavy fuels blended from
cracked residuals, see section 1.1.2.7.
23328 1.1 -- 11
Manual
Wärtsilä 38
Fuel System
1.1.2.7. Comments on fuel characteristics
1 Viscosity is not a yardstick of the fuel quality, but determines the

complexity of the fuel heating and handling system, which should be
considered when estimating installation economy. The standard engine
fuel system is designed for fuels up to the viscosity class 55.
2 When the density exceeds 0.991 g/ml at 15_C water, and to some
extent solid matter, can no longer be removed with certainty by a
centrifuge. Centrifuging systems claiming to clean fuel oils with
densities up to 1.010 g/ml at 15_C are on the market. If such systems of
the so called controlled discharge design are installed, fuels with
densities up to 1.010 g/ml at 15_C may be used.
Note! High density fuels with low viscosity may have low ignition
quality.
3 Higher sulphur content increases the risk for corrosion and wear,
particularly at low loads, and may contribute to high---temperature
deposit formation. The lubricating oil specification must be matched to
such qualities.
4 High ash content causes abrasive wear, and may cause high
temperature corrosion and contributes to formation of deposits. The
most harmful ash constituents are the vanadium---sodium
combinations.
5 High vanadium content causes high temperature corrosion on hot
parts like exhaust valves, particularly in combination with high sodium
content. The corrosion accelerates with increased temperatures
(increased engine output).
6 Sodium (Na)contributes to hot corrosion on hot parts like exhaust
valves in combination with high vanadium (V) content. Sodium also
contributes strongly to fouling of the turbine blading of the
turbocharger at high exhaust gas temperature. The permissable
content of Na of the cleaned fuel should be below 30 ppm.
7 High ”carbon residue” may cause deposit formation in combustion
chamber and exhaust system, particularly at low engine output.
8 High content of asphaltenes may contribute to deposit formation in
the combustion chamber and exhaust systems (at low loads).
Asphaltenes may under certain circumstances precipitate from the fuel
and will block filters and/or cause deposits in the fuel system.
Precipitating asphaltenes may also cause excessive centrifuge sludge.
9 Heavy fuels may contain up to 1 % water at delivery. Water can
originate from the installation bunker tanks. To avoid difficulties in the
engine fuel injection system water must be removed.
1.1 -- 12 23328
Manual
10 Reduced ignition and combustion quality can be caused by using

HFO from modern refinery processes compared with ”traditional”
heavy fuels. HFO from modern refinery processes may approach at least
some of the limits of fuel characteristics.
Ignition quality is not defined nor limited in marine residual fuel
standards. The same applies to ISO ---F---DMC marine distillate fuel.
The ignition quality of these fuels cannot for a variety of reasons be
determined by methods used for pure distillates, i.e. Diesel Index,
Cetane Index and Cetane Number.
Low ignition quality may cause trouble during starting and at low load
operation, especially at too low charge air temperature. This may result
in long ignition delay and as a consequence, in high firing pressure rise
ratio. The combustion will be more noisy in this case, known as ”Diesel
knock”, i.e. hard, high pitch combustion noise. Diesel knock increases
mechanical load on components surrounding the combustion space,
increases thermal load, increases lube oil consumption and increases
lube oil contamination. Basically a low viscosity, in combination with a
high density, will result in a low ignition quality and is expressed in a
CCAI value.
mm2/s at 50 oC kg/m3 at 15 oC
Fig. 1.1 – 3 Nomogram for deriving CCAI
23328 1.1 -- 13
Manual
Wärtsilä 38
Fuel System
What do the CCAI values mean?

Straight run residues show CCAI values (Calculated Carbon Aromaticy
Index) in the 770 to 840 range and are very good igniters. Cracked
residues delivered as bunkers may range from 840 to, in exceptional
cases, above 900.
Normal diesel engines should accept CCAI values up to 850 with no
difficulties. CCAI values between 850 and 870 may cause difficulties
under unfavourable conditions such as low charge air temperatures,
insufficient preheating of the engine at the start, malfunctioning of fuel
injection system (in particular, badly maintained nozzles).
CCAI values above 870 are not advised.
Note! Although low ignition quality produces long ignition delay,

advancing the ignition timing makes things only worse; fuel is
injected at a lower compression temperature and this will
produce even longer ignition delay.
11 Aluminum + Silicon. Fuels may contain highly abrasive particles

composed of aluminium and silicon oxides known as ”catalytic fines”
from certain refining processes. If not removed by efficient fuel
treatment, wear of high pressure fuel pumps, nozzles and cylinder
liners can be expected in a few hours.
1.1 -- 14 23328
Manual
1.1.3. Internal fuel system
General
The fuel system on the engine consists of a Low Pressure a High
Pressure system and a leak---off fuel system. The systems are basically
situated inside the Hot Box.
--- The Low Pressure systems consists of supply (1) and return lines (2).
--- The High Pressure injection system consists of the High Pressure
(HP) fuel pumps, fuel injectors and High Pressure fuel lines.
These components are described in chapter 2.9., ”Injection system”.
--- The clean leak---off fuel from injectors, HP fuel pumps and possible
leak from damaged or broken HP fuel lines is drained to the
atmospheric pressure. The clean leak fuel can be pumped to the day
tank without treatment. Other possible leak fuel the ”dirty” fuel is
drained separately and has to be led to the sludge tank.
For the diagram see section ”Diagrams” of the Catalogue which is
delivered with the engine documentation.
1 2
Fig. 1.1 – 4 Low pressure fuel pipes
Note! For maintenance background information , safety aspects, tools,

intervals, tolerances, inspection, tightening torque and procedures
see chapter 2.4
23328 1.1 -- 15
Manual
Wärtsilä 38
Fuel System
1.1.4. Draining of fuel system
As the fuel quantity in the supply and discharge line is relatively large,
it is preferred to purge the fuel lines into a waste tank before
commencing any maintenance to this system and components.
Engines, operating on HFO, should be drained when engine and fuel are
still hot. Prior to overhaul of the engine the fuel system is recommended
to be flushed with Light Fuel Oil.
1 Close the supply and return to the engine fuel system.

2 Drain the fuel system at the lowest point in the external system.
3 Drain the fuel supply and return lines of the HP fuel pumps
--o--o--o--o--o--
1.1 -- 16 23328
Manual
Lubricating Oil System Wärtsilä 38
1.2. Lubricating Oil System
Table of contents
1.2. Lubricating Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 1

1.2.1. Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 2
1.2.1.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 2
1.2.1.2. Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 3
1.2.1.3. Influences on the lubricating oil condition . . . . . . . . . . . . . . . . . 1.2 – 5
1.2.1.4. Testing of main lubricating oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 5
1.2.1.5. Condemning limits main lubricating oil . . . . . . . . . . . . . . . . . . . 1.2 – 7
1.2.1.6. Comments on lubricating oil characteristics . . . . . . . . . . . . . . . 1.2 – 8
1.2.1.7. Recommendations for refreshing lubricating oil . . . . . . . . . . . . 1.2 – 10
1.2.2. Internal lubricating oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 11
1.2.2.1. Components of internal system . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 12
1.2.2.2. Overview lubricating oil system . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 13
1.2.2.3. Engine lubricating oil circuits (main flow) . . . . . . . . . . . . . . . . . 1.2 – 14
1.2.2.4. Oil flow gearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 19
1.2.2.5. Engine top side lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 21
1.2.3. Components of lubricating oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 23
1.2.3.1. Duplex filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 23
1.2.3.2. Sample valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 23
1.2.3.3. Commissioning filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 23
1.2.3.4. Lubricating oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 24
1.2.3.5. Centrifugal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 30
1.2.3.6. Crankcase breathing system . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 33
23328 1.2 – 1
Manual
Wärtsilä 38
Lubricating Oil System
1.2.1. Lubricants
Lubricating oil should feature a number of physical and chemical

qualities required for reliable diesel engine operation. Apart from
lubricating bearings, cylinder liners, gears, valve mechanism etc.,
cooling is an important function. The main engine lubricating oil must
also be able to neutralize combustion products on engine parts and to
keep these products well dispersed.
Under normal operation the engine lubricating oil is exposed to high
pressures and temperatures. The oil is often finely divided as a spray or
mist, intimately mixed with air and subjected to catalytic effects of
various contaminators. Contact with air results in oxidation and the
production of gums, resins and acids.
Other major contaminators are products of combustion, such as soot,
ash and (partially) unburnt fuel mixed with the lubricating oil on the
cylinder wall. High sulphur content of the fuel may also accelerate the
rate of oil deterioration.
Some of the contaminators can be removed by purification or filtering.
Other contaminators eventually will accumulate to the point where the
oil must be discarded. To determine the condition of the oil regular
sampling and testing is necessary. The samples should therefore be sent
to a qualified laboratory for a detailed analysis regarding the oil
condition.
The oil manufacturer remains responsible for the quality of the oil
under operating conditions. It is the responsibility of the operator
together with the advise of the oil supplier and no–go criteria given by
Wärtsilä Nederland B.V., to determine whether or not the oil should be
refreshed.
1.2 – 2 23328
Manual
1.2.1.1. Requirements
1.2.1.1.1. Main lubricating oil

Main lubricating oil for the engine must be of an approved brand
according to the following specifications:
Viscosity class : SAE 40
Viscosity index (VI) : Min.95
Alkalinity (BN) : The required lubricating oil alkalinity is
tied to the fuel specified for the engine, which is shown in the table
below.
Category Fuel standard Lube oil BN [mg KOH/g]

ISO 8217: 1996(E) Required Recommended
A DMX, DMA 10 -- 30 10 -- 22
B DMB 15 --30 15 -- 22
C DMC, RMA10 -- RMK55 30 --55 40
Remarks
Category A and B: If the recommended lube oil BN is not available an
approved lube oil with a BN of 24---30 can also be used.
Category C: If the recommended lube oil BN causes short oil change
intervals (fuel with high sulphur content), it is recommended to use
lubricating oil with BN 50 --- 55. If experience shows that the lube oil BN
equilibrium remains at an acceptable level (fuel with very low sulphur
content) lube oil with a BN 30 can also be used.
Additives
The oil should contain additives that ensures good oxidation stability,
corrosion protection, load carrying capacity, neutralisation of acid
combustion and oxidation residues and should prevent deposit
formation on internal engine parts (piston cooling gallery, piston ring
zone and bearing surfaces in particular).
Foaming characteristics
Fresh lubricating oil should meet the following limits for foaming
tendency and stability, according to the ASTM D 892---92 test method:
Sequence I, II and III : 100/0 ml
Base oils
Only the use of virgin base oils is allowed, i.e. recycled or re---refined
base oils are not allowed.
Approved lubricating oils
For a list with approved lubricating oils, please contact Wärtsilä.
Lubricating oils that are not approved have to be tested according to the
engine manufacturer’s procedures.
23328 1.2 – 3
Manual
Wärtsilä 38
Engine lubricating oil system requirements

Lubricating oil, supplied to the engine, must be conditioned:
– centrifugal separated on water and dirt
– filtered
– controlled to the correct temperature.
Water content max. % vol 0.3
Fineness automatic back--flushingfilter:
fine filter 30 ←m Absolute mesh size
safety filter 100 ←m Absolute mesh size
The suction height of the main lubricating
oil pump (including pressure losses in the
pipes and suction filter): max. m 4
Before any operation the lubricating oil
should be at least at preheated condition: min. C 40
1.2.1.1.2. Other lubricants
Lubricating oil for turbocharger

See the sub---supplier manual for the turbocharger.
Lubricating oil for turning gear

For lubrication of the turning gear the use of an EP---gear oil is
recommended, viscosity 400---500 cST/40C = ISO VG 460.
The lubricating oil is added before the start---up procedure.
Actuator
See the sub–supplier manual for the actuator. Usually, the same oil can
be used in the actuator as is used in the engine system.
Oil for hydraulic tools

These tools require an oxidation resistant oil with a viscosity of about
45 mm2/s at 40 _C. The following oil specifications meets the
requirements:
– ISO hydraulic oil type HM
– DIN 51525 hydraulic oil type HL–P
– DIN 51585 corrosion test with steel, corrosion degree 0
– DIN 51759 corrosion test with copper, corrosion degree 1
– ASTM D 665 corrosion test approved.
1.2 – 4 23328
Manual
1.2.1.2. Influences on the lubricating oil

condition
When the engine is in operation under ”extreme” conditions the

operator should check the oil condition more frequently.
The following engine conditions are ”extreme” :
– During the running–in period of an engine when a relative large
quantity of metal wear products are formed entering the lubricating
oil.
– After replacement of liners and piston rings. The engine running–in
process will introduce larger quantities of blow–by gas existing in
combustion products (sulphur dioxide, water and CO2) and liner and
piston ring wear products.
– Strong fluctuations in engine load create more blow–by.
– A bad fuel combustion process caused by bad condition of injectors
and/or fuel pumps and insufficient scavenging air pressure.
– A fuel oil quality with a CCAI > 850.
– Frequent engine overhaul introduces a relative high percentage of
dirt into the crankcase.
– Postponed engine maintenance introduces the possibility of water
and fuel oil entering the lubricating oil. Piston and liner wear
increase the quantity of blow–by gas.
– Frequently cold starting.
– High sulphur content in fuel (> 3% ) causing fast BN depletion.
1.2.1.3. Testing of main lubricating oil
It is the duty of the operator to monitor the behaviour of the lubricating

oil carefully and regularly in order to ensure the oil remains in a good
condition. This is particularly necessary when a new engine is put into
operation or when a change is made in brand of oil in an engine already
in operation or when oil is taken from a batch with different
composition. However it is not advised to mix different types of
lubricating oil and in such a case always consult the lubricating oil
supplier. During testing the quality of lubricating oil the instructions of
the oil supplier have to be observed. It is advised with a new engine or
after a major overhaul to take samples of the lubricating oil at intervals
of 250 operating hours and send it to a qualified laboratory.
On the basis of the results it is possible to determine suitable intervals.
23328 1.2 – 5
Manual
Wärtsilä 38
Recommendations for sampling

– Samples should be drawn from the sampling valve which is
specifically fitted for this purpose.
– Ensure the total quantity of oil in circulation is approximately the
same prior to drawing each sample.
– Draw samples only when the engine is running and the oil is at
normal operating temperature.
– Before filling the sampling container open the sampling cock and
drain some oil to make sure that it is flushed and hot oil is flowing
slowly from the outlet point.
– Draw oil samples directly into clean, dry containers of one litre
capacity.
– Draw a sample during a period of about ten minutes.
– Shake the sample thoroughly before pouring into the sample bottle
provided for this purpose; the bottle should not be filled over 90% of
its content.
Information required for oil analysis

1 Name of vessel or plant
2 Owners
3 Date of sampling
4 Date and place sample handed in
5 Oil brand, product name, nominal viscosity
6 Hours lubricating oil in service
7 Running hours of the engine.
8 Engine model, manufacturer and serial number
9 Position in lubrication oil system from which drawn
10 Type of fuel oil used including sulphur content
11 Date previous sample from same source drawn
12 Quantity of lubricating oil in system and top up
13 Any special reasons for analysis being required if non–routine
samples
Unacceptable sampling
An unsatisfactory sample will be the result if oil is drawn from areas of
stagnation or where little flow is occurring. These places are:
– Sumps
– Auxiliary / smaller pipelines
– Purifier suction lines or discharge lines
– Drain plugs of filters, coolers etc.
Samples drawn from those points will not be representative for the bulk
of oil in active circulation.
1.2 – 6 23328
Manual
1.2.1.4. Condemning limits main lubricating oil
Condemning limits for used main lubrication oil system

When estimating the condition of used lubricating oil the following
properties along with the corresponding limit values most be noted. If
the limits are exceeded measures must be taken.
Compare the condition also with guidance values for fresh lubricating
oil of the brand used.
On basis of test results it can be determined whether lubricating oil is

suitable for further use.
Condemning limits for used lubricating oil

Property Unit Limit Test method
Viscosity cSt at 40 ° C max. 25% decrease ASTM D 445
max. 45% increase
Viscosity cSt at 100 ° C max. 20% decrease ASTM D 445
max. 25% decrease
Water vol--% max. 0.30 ASTM D 96 or
ASTM D 1744
Base Number mg KOH/g min. 20 for HFO ASTM D 2896
operation
max. 50% depletion
for LFO operation
Insolubles w--% in n--Pentane max. 2.0 ASTM D 893b
Flash Point, PMCC °C min. 170 ASTM D 93
Flash Point, COC °C min. 190 ASTM D 92
23328 1.2 – 7
Manual
Wärtsilä 38
1.2.1.5. Comments on lubricating oil

characteristics
1 Centrifuging of the system oil is required in order to separate water

and insolubles from the oil. Do not supply water during purifying. The
oil should be preheated till 80–90C. Many oil manufacturers
recommend a separation temperature of 85–95C for an effective
separation. Please check with the supplier of your lubricating oil for the
optimal temperature. Select the highest recommended temperature.
For efficient centrifuging, use not more than 20% of the rated flow
capacity of the separator. For optimum conditions, the centrifuge should
be capable of passing the entire oil quantity in circulation 4–5 times
every 24 hour at 20% of rated flow. The gravity disc should be selected
according to the oil density at separation temperature.
Note! Defects on “self–cleaning“ separators can, under certain

circumstances, quickly increase the water content of the oil
2 Flash point
At 150_C a serious risk of a crankcase explosion exists.
3 Water content
Lubricating oil with a high water content must be purified or discarded.
4 Choose BN according to our recommendations.
A too low BN value increases the risk of corrosion and contamination
of the engine components.
5 Insolubles
The quantity of insolubles allowed depends on various factors. The oil
supplier’ s recommendations should be closely followed.
1.5% Insolubles in n–Pentane call for action, however, it can be said that
changes in the analyses usually give a better basis for estimation than
the absolute values.
Rapid and big changes of insolubles may indicate abnormal operation
of the engine or system.
6 Sudden increase of wear metals indicates that there is abnormal
wear. Immediate actions should be taken to find the cause. If necessary
contact the oil supplier and/or the engine manufacturer
1.2 – 8 23328
Manual
7 Measure and record the quantity added for compensation of the oil
consumption. Attention to lubricating oil consumption may give
valuable information about the engine condition. A continuous increase
may indicate wear of piston rings, pistons and cylinder liners. A sudden
increase demands inspection of pistons if no other reason is found.
8 Intervals between changes are influenced by system content (oil
volume), operating conditions, fuel oil quality, centrifuging efficiency and
total oil consumption. Efficient centrifuging in combination with large
systems (dry sump operation) generally allow longer intervals between
changes.
9 Daily top up of the circulating tank/wet sump will extend the life
time of the lubricating oil.
23328 1.2 – 9
Manual
Wärtsilä 38
1.2.1.6. Recommendations for refreshing

lubricating oil
Note! Utmost cleanliness should be observed during lubricating oil

treatment. Dirt, metal particles, rags etc. may cause serious bearing
damage. After disconnecting pipes or components from the system
cover all openings with gaskets and or tape. Avoid dirt and water
entering the lubricating oil during transport and storage.
1 Drain the oil system when the oil is hot. Be sure oil filters, coolers and
external pipes are also emptied.
2 Clean oil spaces including filters and camshaft compartment.
3 Check if filter elements from external system are clean and
undamaged.
4 Supply the required quantity of oil into the system.
5 The oil interval can efficiently be predicted by plotting the analyses
taken at regular intervals.
Copies of the lubrication oil analysis should be kept on archive for at
least 12,000 running hours of the engine.
1.2 – 10 23328
Manual
1.2.2. Internal lubricating oil system
The lubricating oil system of the engine is integrated in the engine

construction. The main oil supply line in the sump feeds the main
bearings, connecting rods and pistons. From this supply line a separate
line feeds the camshaft(s) and the cylinder heads. The piston skirt is
lubricated by means of nozzles in the skirt. Most of the small feeding
lines are integrated in the engine parts.
During the first 100 running hours the engine is protected against dirt
by means of commissioning filters.
Components built–on the engine are:
--- Lubricating oil pump with pressure control, safety and non return
valve.
--- Centrifugal filter(s)
--- Sampling valve
--- Crankcase air breather
--- Commisioning filters


see chapter 2.4
23328 1.2 – 11
Manual
Wärtsilä 38
1.2.2.1. Components of internal system
Lube oil pump engine driven

The engine is provided with build ---on engine driven lube oil pumps. The
capacity of the pumps is sufficient to maintain the nominal lube oil
pressure at engine operating conditions. During start---up of the engine
the engine driven lube oil pumps must be supported by an electric
driven stand ---by pump till lubricating oil pressure is safe.
Control and safety valve

A pressure control valve, build---on the pump housing, avoids fluctuations in
oil pressure due to variations in pump speed and or variations in lube oil
viscosity. The reference for this control valve is the pressure at the inlet of
the engine lube oil manifold. A safety valve is integrated in the body of the
control valve. The safety valve is factory adjusted at 10 bar.
Non return valve

The discharge of the engine driven lube oil pump is provided with a non
return valve to avoid a reverse flow in case only an external driven lube
oil pump is installed.
Duplex filter
A duplex filter is mounted in the main supply to the engine lube oil
manifold. The filter is a full flow filter and can be opened for cleaning
during engine operation.
The duplex filter is a safeguard and not intended as the prime cleaner.
Sample valve
The lube oil supply line on the engine is provided with a branch with
valve for taking lube oil samples.
Centrifugal filter
A centrifugal filter is standard mounted on the engine to be taken in
operation on the moment the engine lube oil system is pressurised. The
filter starts working after the supply valve is opened. The discharge of
the filter drains into the crankcase of the engine. After closing of the
supply valve the filter stops working and can be opened for cleaning.
Filtering properties up till 1 micron.
Dry sump
The lube oil supplied to the engine is collected in the sump after service
in the engine. From here the lube oil is continuously drained to an
external installed sump tank. From the external sump the lube oil pump
takes the oil for conditioning and supply to the engine.
Drain connections are available in the dry sump at front and rear side
of the engine, 2 at each side.
1.2 – 12 23328
Manual
1.2.2.2. Overview lubricating oil system
SECTION 1.2.2.5.
SECTION 1.2.2.4.
SECTION 1.2.2.3.
Fig. 1.2 - 1 Overview lube oil system (example)
23328 1.2 – 13
Manual
Wärtsilä 38
1.2.2.3. Engine lubricating oil circuits

(main flow)
From the engine manifold inlet, at the free end of the engine, the oil
distribution through the engine is as follows:
piston
gudgeon pin bearing
connecting rod
connecting rod bearing
crankshaft
main bearings
hydraulic jacks
distributing pipe at the bottom

of the oil sump
Fig. 1.2 - 2 Cross section lubricating oil circuit
The rectangular manifold is provided with branches. One for each main
bearing and a separate branch connected to a second header positioned
on top of the cylinder block at the camshaft side.
1.2 – 14 23328
Manual
1.2.2.3.1. Lube oil commissioning filter
The lube oil supply to each main bearing (see fig. 1.2 --- 3 ) and to the top
side of the engine (see fig. 1.2 --- 10 ) passes a commissioning lube oil
filter that, after the first 100 running hours of the engine, has to be
removed. After removal of the commissioning filter out of the supply
line to the main bearing, the jack below can be extended and connected
to the main bearing cap.
Should a filter become clogged within the first 100 running hours the
lube oil supply will be continued passing a spring loaded by-pass valve
in the filter.
Fig. 1.2 -- 3 Commissioning filter
23328 1.2 – 15
Manual
Wärtsilä 38
1.2.2.3.2. Oil flow main bearing
From the middle at the under side of the main bearing cap the oil find
a horizontal drilling to both the bearing cap stud holes. These vertical
holes are oversized in diameter and leaves sufficient space for the oil to
flow upwards to the joint faces with the saddle in the cylinder block. In
the joint faces are recesses and from here the oil find its way to the
groove in the main bearing saddle on top of the upper main bearing. The
upper main bearing is over part of the circumference provided of large
size holes from where the oil flows into one end of the diametrical hole
in the crankshaft journal.
Fig. 1.2 - 4 Oil flow main bearings
1.2 – 16 23328
Manual
1.2.2.3.3. Oil flow crankshaft / connecting rod
Via a ”cross ---over” the oil enters a diametrical drilled hole through the
crankpin.
Fig. 1.2 - 5 Oil flow cross--over
From here the oil flows through the crankpin hole further into large
bores in the bottom bearing shell in a circumferential groove in the
bottom bearing cap and then vertical up into drillings in the upper
bearing cap. From here the oil flows into the connecting rod sole
through 2 holes in the filling plate.
Fig. 1.2 - 6 Oil flow connecting rod
23328 1.2 – 17
Manual
Wärtsilä 38
1.2.2.3.4. Oil flow piston
In the sole, two slanting drilled holes conduct the lube oil in one long
centrically drilled hole up to the connecting rod small end bearing head.
Through 2 of the 3 holes in the gudgeon the oil enters a distribution
space inside the gudgeon. At both ends of this space in the gudgeon 3
holes are equally divided over the circumference through which the oil
will be discharged into 4 vertical passages in the piston skirt. At top of
these passages the lube oil flow is restricted by orifices.
Fig. 1.2 - 7 Oil flow piston
Halfway each of these 4 passages a horizontal hole is drilled to the outer

circumference of the piston skirt. This lube oil flow is also restricted by
an orifice. These 4 spray holes take care of the lubrication of liner, piston
skirt and piston rings during engine operation. The surplus is scraped
off of the liner by the scraper ring and drained via an extra groove just
below the scraper ring through 4 holes to the inside of the piston skirt
down to the crankcase.
After passing the restrictions in the top of the skirt the lube oil enters
the outer space of the piston crown.
1.2 – 18 23328
Manual
The outer space is separated from the centre space by a wall with a
number of horizontal holes at certain height. Due to these overflow
holes the outer crown space is always partly filled with oil.
During the up and down stroke of the piston the lube will be shaken and
by this increased oil speed the oil will intensively cool the piston crown.
The heated oil will be displaced by new cold lube oil and flows to the
centre section of the piston crown. Here a second shaker action takes
place cooling the centre part of the crown.
1.2.2.4. Oil flow gearing
Part of the lube oil flow to the axial/end bearing is branched for
lubrication of the intermediate gearing. See also fig. 1.2 --- 1 .
to governor drive mechanism
from manifold
Fig. 1.2 - 8 Oil flow axial/end bearing and gear drive
23328 1.2 – 19
Manual
Wärtsilä 38
From this branch lube oil is supplied to:

--- the camshaft axial bearing,
--- the intermediate gear wheel trunnion and tooths
--- the governor drive mechanism.
Fig. 1.2 -- 9 Detail oil flow gearing
1.2 – 20 23328
Manual
1.2.2.5. Engine top side lubrication
From the main lube oil manifold a branch is connected to manifold (4)
connected to the top outside of the cylinder block. See fig. 1.2 --- 10 .
Fig. 1.2 - 10 Oil flow to engine top side
23328 1.2 – 21
Manual
Wärtsilä 38
From manifold (4) lube oil is supplied to:

--- the camshaft bearings
--- the HP fuel pump drive unit and mechanism
--- the tappet drive unit
--- the rocker arm, valve spindle mechanism and push rods
--- the fuel injector for nozzle tip cooling.
Fig. 1.2 - 11 Oil flow engine top side
1.2 – 22 23328
Manual
1.2.3. Components of lubricating oil system
1.2.3.1. Duplex filter
A duplex filter is mounted in the main supply to the engine lube oil
manifold. The filter is a full flow filter and can be opened for cleaning
during engine operation. The filter is provided of a large number of
cartridges with a fineness of 10 micron nominal.
The duplex filter is a safeguard and not intended as the prime cleaner.
For maintenance see sub---suppliers manuals.
1.2.3.2. Sample valve
Use sample valve (2) see fig. 1.2 --- 10 . to take lubricating oil samples.
Take the lubricating oil samples according the instuctions in section
1.2.1.3.
1.2.3.3. Commissioning filter
The connecting pipe between the manifold at the free end of the engine is
the clean oil supply to the engine top side lubrication system. During
installation and commissioning a filter (1) is placed. The filter must be
removed after the first 100 running hours and replaced by a dummy, see
fig. 1.2 --- 10 .
Note! The commisioning filter for engine top side and main bearings are
identical. After a main overhaul it is advised to mount clean filters
for the first 100 running hours.
23328 1.2 – 23
Manual
Wärtsilä 38
1.2.3.4. Lubricating oil pump
1.2.3.4.1. General
The lubricating oil pump is of a positive displacement type with 2 spindles.

One spindle, driven by the engine, is driving the second spindle. During
engine running engine oil is taken from the engine sump and displaced
under pressure into the engine lubricating oil system.
The required oil pressure is controlled by a pressure control valve
mounted to the side of the pump body.
The lubricating oil pump and pressure control valve are exchangeable.
In general, an in ---line engine is equipped with one pump unit and a
V---engine with two pump units.
Each engine configuration requires different lubricating oil capacities
and consequently different pump capacities. Differences in pump
capacities are realised by difference in spindle length; the connections
of pump house to the engine is similar for all pumps.
1.2 – 24 23328
Manual
1.2.3.4.2. Pump construction
Pump body (2) contains 2 spindles with helical grooves. The engine
driven spindle (4) drives the second spindle (5), see fig. 1.2 --- 12 .
18 11 5 4 2 18
Fig. 1.2 - 12 Gearwheel pump
Each spindle is at the end supported in a sleeve bearing mounted in the

pump body and pump cover and are lubricated by system oil. This oil is
after lubricating the bearings pressureless drained to the suction side
of the pump or engine crankcase.
Wrong assembling of the pump cover is avoided by dowels (11).
Sealing of pump cover to pump casing is made by an O ---ring (18).
The pump side, for mounting to the engine, is calibrated machined and
makes adjustment of backlash superfluous.
The pump requires little maintenance and this maintenance consist
mainly in inspection to wear of bearing sleeves and spindles. For
clearances see chapter 2.4.
23328 1.2 – 25
Manual
Wärtsilä 38
1.2.3.4.3. Gearwheel connection to pump shaft
The recess in the gear wheel contains 3 sets of clamping rings. Each set
consist of an inner and outer clamping ring, see fig. 1.2 --- 13 .
Fig. 1.2 -- 13 Mounting of clamping rings
Clamping rings are matched and have to be kept as a pair. Axial forcing
the clamping rings in the recess by a gland creates a high friction
between shaft and gear wheel.
1 Place the clamping rings in the recess of the gear wheel according
drawing. Do not use a lubricant for mounting.
2 Place gear wheel and clamping rings over the shaft till the shaft rim.
3 Place the gland on the shaft and turn in the 4 gland bolts. Tighten
the 4 gland bolts crosswise and evenly by a torque spanner, see chapter
2.4.4.
4 After mounting, check the gear wheel oscilation by means of a dial
gauge.
The pump body is mounted to the engine by means of 4 bolts and sealed
by an O ---ring. Although the backlash can not be adjusted it is advisable
to check for clearance between the gearwheels.
Check the connecting pipes are stress free mounted to avoid stresses in
the pump casing. All connecting bolts have to be tightened by torque
spanner, see chapter 2.4.4.
1.2 – 26 23328
Manual
1.2.3.4.4. Operation
Avoid a suction pressure of more than 0.4 bar as this influences the
possibility of cavitation of pump spindles.
During a first running of the pump or after a prolonged stand still, fill
the pump casing with lubricating oil through filling hole. This avoids
dry running of the pump and creates faster vacuum in the suction pipe.
1.2.3.4.5. Pressure control valve
The pressure control valve housing is mounted against the pump body
and connects the pressure side of pump and engine oil system with the
suction side of the pump.
The pressure control valve acts as a regulating valve to maintain the
system pressure at a preset value within certain limits and to function
as a safety valve in case the pump pressure rises too high.
Working as control valve

At start of the pump, pressure at ’A’ (pump discharge and engine inlet)
is zero, see fig. 1.2 --- 14 .
Piston with valve (2) is forced in closed position by spring (8). Port at
’B’ will be closed. Lube oil is forced into the main system and the system
pressure increases. Pressurized oil passes nozzle (5). Chamber ’C’ fills
slowly with oil creating a back pressure and with the force of spring (8)
piston with valve (2) will close.
Pilot piston (18) is at one side spring loaded and holds pilot piston in
’bottom’ position. Oil in chamber ’C’ can not be drained to the drain hole
at ’F’ and pressure at ’C’ is increasing.
Via the pressure control line, connected to the engine inlet system,
pressure at ’D’ increases and the oil pressure moves piston (18) against
the spring force releasing the oil pressure in chamber ’C’ and opening
piston with valve (2). Pressure at ’A’ and ’D’ will lower.
Note! The system pressure is factory adjusted with spindle (6) and should
not be changed without investigation of the possible pressure drop.
23328 1.2 – 27
Manual
Wärtsilä 38
6 C 8 2 B
F 5
X
18
D
A
View X View A
Fig. 1.2 - 14 Pressure control lube oil pump
Working as safety valve

Suppose the normal system pressure via connection at ’D’ is not
functional on piston with valve (2) and consequently the pump pressure
rises too much. In this situation maximum pressure at ’A’ is predicted
by spring force (8) and can not be adjusted during operation. The safe
working pressure of spring force (8) is factory adjusted. Chamber at ’F’
is in open connection with the pump suction.
Parallel operation
In the parallel operation of two lubricating oil pumps each pump is
provided with a control valve. Chambers ’C’ of the control valves are
inter connected by a balancing line. The pilot piston is then controlling
two control valves.
1.2 – 28 23328
Manual
Maintenance
The pressure control valves require little maintenance. When the
system pressure is not stable the control valve internals should be
inspected for sticking of piston (2) and valve and the orifice hole (5).
Make sure the pressure control line connected at ’D’ is free of air.
Operation
During commissioning and after overhaul of the pump turn spindle (6)
anticlockwise to release piston (18) from spring force. During pump
start up slowly turn in the spindle till required system pressure is
obtained. Secure spindle (6) with counter nut.
Fig. 1.2 -- 15 Pump arrangement L-- engine
23328 1.2 – 29
Manual
Wärtsilä 38
1.2.3.5. Centrifugal filter
Standard a centrifugal filter is mounted on the engine as a complement

to the main filter and to be taken in operation on the moment the engine
lubricating oil system is pressurized and on temperature. The
centrifugal filter starts working after opening the supply valve (1), see
fig. 1.2 --- 16 . The discharge of the filter drains into the crankcase. After
closing the supply valve the filter stops working and can be opened for
cleaning.
The centrifugal filter should be cleaned more frequent when at the
moment of cleaning the maximum sludge content of the bowl is reached.
Fig. 1.2 - 16 Centrifugal filter on engine
1.2 – 30 23328
Manual
1.2.3.5.1. Working centrifugal filter
The filter comprises a housing (12) containing a hardened steel spindle

(2) on which a dynamically balanced rotor unit (3) rotates. Oil flows
through the housing up the central spindle into the rotor. The rotor
comprises a cleaning chamber and a driving chamber. Oil flows from the
central tube (13) into the upper part of the rotor where it is subjected
to a high centrifugal force. The dirt is deposited on the walls of the rotor
in the form of heavy sludge. The oil then passes from the cleaning
compartment into the driving compartment formed by the stand tube
(11) and the lower part of the rotor (4), which carries two driving
nozzles. The passage of the clean oil through the nozzles provides a
driving torque to the rotor. The oil returns through the nozzles into the
filter housing back to the engine oil sump.
10 9 14 1 2 8
13
11
4
7 15
12
Fig. 1.2 -- 17 Centrifugal filter
23328 1.2 – 31
Manual
Wärtsilä 38
1.2.3.5.2. Cleaning
It is very important to clean the centrifugal filter regularly as it may

collects considerable quantities of dirt.
Note! Clean more frequently if the centrifugal filter has collected the
maximum quantity of dirt (the dirt deposit layer is 25mm thick)
within the recommended cleaning intervals.
Cleaning centrifugal filter

1 Close valve (15) in the supply line, see fig. 1.2 --- 17 .
2 Open and slacken the cover clamp (7). Remove the cover nut (1) and
lift off the filter body cover (8).
3 Lift off the rotor assembly from the spindle (2) and drain oil from
the nozzles (on the bottom of the rotor assembly) before removing the
rotor from the filter body. Hold the rotor body and remove the rotor
cover jack nut (9), then separate the rotor cover (3) from the rotor (4).
4 Remove sludge from the inside of the rotor cover and body by means
of a wooden spatula or suitably shaped piece of wood and wipe clean.
Remove the stand tube and clean. Ensure all rotator components are
thoroughly cleaned and free from dirt deposits.
5 Clean out the nozzles with a brass wire and compressed air.
Examine the top and bottom bearings in the tube assembly to ensure
they are free from damage or excessive wear. Examine the O ---ring (5)
for damage. Renew if necessary.
6 Reassemble the rotor in opposite order. Ensure the alignment pins
(6) in the joint face body aligns with the holes in the cover and the stand
tube fits correctly in the rotor base.
7 Examine the spindle journals to ensure they are free from damage
or excessive wear. Examine the O ---ring (14) for damage. Renew if
necessary.
8 Replace rotor over the spindle ensuring the rotor rotates freely and
replace body cover. Tighten the cover nut by hand and refit safety cover.
Tighten the centrifugal filter cover clamp (7).
1.2 – 32 23328
Manual
1.2.3.6. Crankcase breathing system
The function of the crankcase breather is to vent gases entering the

crankcase after leaking the piston rings and thus avoiding an
overpressure in the crankcase.
Check the working of the vent line periodically during engine operation.
The free end of the vent system should be covered by an anti flame
gauze. Clean this anti flame gauze periodically to avoid crankcase
overpressure.
Part of the combustion gases consists of water vapour that, in contact
with the relative colder vent pipe, will condensate. This condensate
flows down and should be drained periodically.
The separately drained condensate during ”normal” engine operation
at certain load is a fixed amount and should daily be estimated on
quantity. An increased quantity of condensate might indicate:
--- more gas blow---by by possible broken piston rings
--- free water in the crankcase caused by
--- leaking lubricating oil cooler
--- leaking liner
Smoke from vents or breathers is an indication that a hot spot is
vaporizing lubricating oil and is often observed as a precursor to an
crankcase explosion.
23328 1.2 – 33
Manual
Wärtsilä 38
Crankcase breather
The crankcase breather consists of a housing. containing a horizontally
positioned tiny plate valve. The breather housing is at one side in open
contact with the crankcase. Any crankcase overpressure can be released
via the plate valve and the vent pipe into the atmosphere, see fig.
1.2 --- 18 .
Fig. 1.2 -- 18 Crankcase breather
The breather needs little attention. If, during normal engine operation,
no water is drained the drain line is possible chocked.
--o--o--o--o--o--
1.2 – 34 23328
Manual
Starting Air System Wärtsilä 38
1.3. Starting Air System
Table of contents
1.3. Starting Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 - 1

1.3.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 -- 2
1.3.2. Internal starting air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 -- 2
1.3.3. Components of starting air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 -- 4
1.3.3.1. Starting air distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 -- 4
1.3.3.2. Starting air valve cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 -- 7
1.3.3.3. Starting air pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 -- 8
1.3.3.4. Pneumatic control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 -- 9
23328 1.3 -- 1
Manual
Wärtsilä 38
Starting Air System
1.3.1. General
The starting of an engine requires a large in ---rush of high pressure air

for a relatively brief period. To meet this demand it is necessary to
provide a system for compressing air and storing that air in vessels until
needed.
The starting air system should consist of an air compressor driven by
an electric motor, air vessel(s), pressure gauge, relief valve, piping to the
engine and control valve located near the engine.
The minimum compressor capacity normally should be sufficient to
replenish the starting air supply for the largest unit in one hour, after
such supply has been reduced to the minimum pressure necessary to
start the engine.
The total air vessels volume will depend on the air storage pressure, the
number of starts required before recharging the vessels, the number of
engines in the installation and the starting air requirements for the
largest engine. At least two vessels should be available in each
installation to insure that starting air pressure is always available even
though one vessel may be out of service for any reason.
The compressed air system should on several places in the system be
provided of accessible water drains or bottom blow---off valves.
1.3.2. Internal starting air system
The engine is started with compressed air of max 30 bar. Minimum

pressure required is 15 bar. The supply line for starting air is provided
with a non return valve (13). (See fig. 1.3 --- 1 ).
The supply line for control air is provided with a ball valve (15).
The solenoid valve (20) is operated electrically (remote control) or
manually (on the engine) and send after activation a pilot air signal to
the main starting air valve (01). Interruption of the control air closes the
main starting air valve.
After the main starting air valve is activated the air flows through the
flame arresters (02) to the starting air valves (03) in the cylinder heads.
Part of the air flows via the starting air distributor (04) to each of the
main starting air valves in the cylinder heads. The starting air
distributor controls opening and closing of the main starting air valves.
On the moment the main starting air valve (01) is operated also the
actuator booster (05) is energised. The main starting air line is provided
with a safety valve (18). Interlock valve (09) is a safety device to avoid
an engine start with engaged turning gear.
1.3 -- 2 23328
Manual
System components
01 Main starting valve
02 Flame arrester
03 Starting air--valve in cylinder head
04 Starting air distributor
05 Booster for speed governor
06 Air filter
07 Air bottle
08 Pneumatic stop cylinder at each
HP fuel pump
09 Blocking valve, when turning gear
engaged
10 Valve for automatic draining
13 Non--return valve
15 Ball valve
17 Stopping valve fuel injection pumps
18 Safety valve Pipe connections
20 Starting valve 301 Starting air inlet
21 Emergency stop/overspeed valve 302 Control air inlet
Fig. 1.3 -- 1 Internal starting air system (example)
23328 1.3 -- 3
Manual
Wärtsilä 38
Starting Air System
1.3.3. Components of starting air system
1.3.3.1. Starting air distributor

General
The starting air distributor is of the piston type with precision machined
inter changeable liners. The pilot pistons (27) are controlled by a cam
(28) connected to the camshaft end. When the main starting valve
opens, the pilot pistons are pressed onto the cam whereby the pilot
piston for the engine cylinder, which is in starting position, admits
control air to the main piston of the starting valve see Fig. 1.3 --- 4 . The
starting air valve opens and admits compressed air into the engine
cylinder forcing that piston down. Shortly before the exhaust valves are
opened the pilot valve interrupt the control air to the starting air valve
and starting air to that cylinder is interrupted. This procedure will be
repeated as long as the main starting valve is activated or until the
engine speed is so high that the engine fires. After the main starting air
valve is closed the main starting air system is depressurised and the
springs (32) will lifts the pilot plungers off the cam. This means the pilot
plungers touches the cam only during the starting process. The pilot air
lines are connected to the starting air distributor according fig. 1.3 --- 3 .
supply air
33
28
30
26 32
27
31 to starting air
valve
Fig. 1.3 -- 2 Starting air distributor
1.3 -- 4 23328
Manual
Maintenance
Normally, the starting air distributor does not require much
maintenance. For maintenance remove the complete distributor from
the engine as follows:
1 Disconnect all pilot pipes from the distributor, see fig. 1.3 --- 3 .
Remove the connecting bolts and take the distributor off the cylinder
block. The (negative) cam remains in place.
2 Remove the plugs (31). The pilot plungers (27) will come out by the
spring force (32).
3 Take care not to damage the plungers and liners.
4 In case of a sticking plunger use a pipe with M8 thread inside to
draw the plunger out of the liner, if necessary.
5 It is recommended not to interchange the positions the plungers in the
distributors, although they are precision machined and inter changeable.
Utilize cylinder number markings at the control air connections.
6 Clean the parts and check for wear.
7 If a pilot liner is worn out, press it out. It may be necessary to heat the
distributor up till about 200C as Loctite is used for locking and sealing.
8 Clean the bore carefully to insert the new liner easily by hand.
Otherwise there is a risk of deformation of the liner and sticking of the
plunger as result.
9 Apply Loctite 242 on the outside surfaces during mounting of the
liner. Check the openings in the liner correspond to those in the housing.
10 Check that no Loctite has been left on the inside of the liner.
11 Apply Molykote Paste G to the plunger sliding surfaces before
reassembling. Wipe off the surplus. Check that plungers after mounting
do not stick.
12 Applysilicon sealantto bothsides oftheintermediateplate(33).Do
not use too much as the surplus sealant will be forced into the system
during tightening.
13 After mounting the distributor to the engine, however before
connecting the control air pipes and the end cover (30), check all
plungers are satisfactorily working, e.g. by connecting compressed air
(working air of 6 bar) to the distributor air inlet and by turning the
crankshaft. It then is possible to observe the plungers will follow the
cam profile.
Warning! During testing of the starting air distributor always keep the
starting air supply to the engine closed and vented to avoid the
engine from starting.
23328 1.3 -- 5
Manual
Wärtsilä 38
Starting Air System
Fig. 1.3 -- 3 Pilot air lines, (example)
1.3 -- 6 23328
Manual
1.3.3.2. Starting air valve cylinder head
General
The starting air valve is operated by control air pressure coming from
the starting air distributor. The valve consists of a valve spindle (1) with
a spring loaded piston (2) mounted in a separate housing.
7
2
1
9
3
4 5
Fig. 1.3 - 4 Starting air valve
Maintenance
Check and clean the valve during the normal maintenance intervals of
the cylinder head.
1 Remove the holding plate and pull out the valve together with
control piston.
2 Take off the self locking nut (9) and take off the piston (2).
3 Clean all components.
4 Check the seat condition of valve and valve housing. If necessary,
lap the seats by hand. Keep the piston on the valve spindle mounted for
support during grinding.
5 Check the vent holes (4) in the valve housing are open.
6 Lubricate piston and liner with lubricating oil.
7 After reassembling the valve, check the valve spindle with piston
moves smoothly and closes completely.
8 Check the O --- ring (5) of the valve housing is intact. Lubricate
with oil.
9 Renew the copper ring (3) between starting air valve housing and
cylinder head.
10 Tighten the bolts (7) to the torque setting as mentioned in section 2.4.4.
23328 1.3 -- 7
Manual
Wärtsilä 38
Starting Air System
1.3.3.3. Starting air pipes
Starting air distribution pipes supply the cylinder units of starting air
of max. 30 bar. After the main starting valve is remotely opened starting
air is flowing to each of the starting air valves, mounted in the cylinder
heads. On command of the starting air distributor the starting air valve
in the cylinder head opens and starting air flows into the cylinder.
From the main distribution pipe air has to pass a flame extinguisher (11).
The extinguisher is extended by a connecting pipe (12) into the cylinder
head. See fig. 1.3 --- 5 .
Upon removal of the cylinder head this connecting pipe is left in place.
If necessary this connecting pipe can be removed. Normally, the
connecting pipes (12), (13) and (14) are left in place.
For removing the air distribution pipe sections slide at both sides the
circlips (16) a little. Slide the distribution pipe sections (14) into the
union (17) and turn the union out of the T---junction.
O ---rings that have been taken out of position should be replaced.
Always use silicon grease before mounting O ---rings.
14 16 17 12
11 16 13
15
Fig. 1.3 - 5 Starting air pipe arrangement
1.3 -- 8 23328
Manual
1.3.3.4. Pneumatic control system
General
The following devices are part of the start and stop process see fig. 1.3 --- 1 :
--- Start interlock (09), a safety device to avoid the start of the engine
with engaged turning gear.
--- Cylinders (08), connected to the fuel rack of each HP fuel pump. In
case of an emergency engine stop, solenoid valve (21) in combination
with solenoid valve (17) will pressurize all cylinders (08) retracting
the fuel pump racks to zero.
--- Push button on solenoid valve (21), gives the possibility to stop the
engine locally.
--- Air container (07), taking care of sufficient pressure in the system in
case of lack of air supply. A pressure transmitter connected to this air
vessel will warn in case of too low air pressure.
--- Drain valves (10) and (24), taking care of draining receiver (07)
respectively filter (06) (with automatic draining (o6 only) each time
the engine is started.
--- Solenoid valve (20) for activating the main starting valve.
--- Main starting valve (01).
Maintenance
The system is built up of high class components and it requires no other
maintenance than a function check and cleaning of the air filter (06).
Check during a start the automatic working of the water drain valve.
Filter
The bottom section of the air filter is connected by an internal spindle
to the top section. To open the filter, release the air pressure and turn
out the central spindle to take the bottom section of. Clean the insert
and inside of the filter each 8000 h.
Solenoid valve
In case of a malfunction in the electric working of the valve, test the
valve by pushing the button on the solenoid. Should there be a
mechanical malfunction, a special tool is required to open the valve.
Change the valve if not working after cleaning.
Water drain valve

Clean the valve if there is any disturbance.
--o--o--o--o--o--
23328 1.3 -- 9
Manual
Wärtsilä 38
Starting Air System
1.3 -- 10 23328
Manual
Cooling Water System Wärtsilä 38
1.4. Cooling Water System
Table of contents
1.4. Cooling Water System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 - 1

1.4.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 -- 2
1.4.2. Cooling water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 -- 2
1.4.2.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 -- 2
1.4.2.2. Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 -- 3
1.4.2.3. Qualities of cooling water additives . . . . . . . . . . . . . . . . . . . . . . 1.4 -- 4
1.4.2.4. Cooling water control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 -- 5
1.4.3. Internal cooling water system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 -- 6
1.4.3.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 -- 6
1.4.3.2. Description HT cooling water system . . . . . . . . . . . . . . . . . . . . 1.4 -- 7
1.4.3.3. Description LT cooling water system . . . . . . . . . . . . . . . . . . . . . 1.4 -- 7
1.4.3.4. Cooling water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 -- 8
1.4.3.5. Flexible pipe connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 -- 13
1.4.4. Maintenance cooling water system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 -- 14
1.4.4.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 -- 14
1.4.4.2. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 -- 14
1.4.4.3. Cooling water venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 -- 15
23328 1.4 -- 1
Manual
Wärtsilä 38
Cooling Water System
1.4.1. General
To prevent formation of scale and to maintain the highly efficient and

uniform heat transfer rate through the engine liners and cylinder
heads, only soft, treated water (cooling water), should be used.
Furthermore, water should be free of corrosive properties. A competent
water chemist specialised in closed cooling water circuits or
manufacturer of water treatment chemicals should be consulted for
recommendations.
1.4.2. Cooling water
1.4.2.1. General
Cooling water = Make---up water + additives.

Make–up water has to meet certain requirements. Water that normally
fulfils these requirements, in order of preference :
--- Demineralized water.
--- Reverse osmosis water.
--- Distillate, (provided the quality is good, little corrosion products,
salts etc.).
--- Softened and decarbonated water.
--- Softened water.
Cooling water must be treated with an additive in order to prevent

corrosion, scale or other deposits in closed circulating water systems.
Example of water that normally NOT fulfils these requirements:

--- Rainwater has a high oxygen and carbon dioxide content; great risk
of corrosion.
--- Drinking water in many places is practically too hard and may
contain considerable quantities of chlorides.
--- Sea water will cause severe corrosion and deposit formation, even if
supplied to the system in small amounts.
Note! The better the water quality the less additive has to be supplied.
Make–up water must be checked before adding the additive. For
requirements see below.
1.4 -- 2 23328
Manual
1.4.2.2. Requirements
Make–up water must be checked before adding the additive.

For make---up water quality see table.
Make-- up water quality

Free of any foreign particles, air, gases and within the following
specification:
Property Unit
Chloride (Cl) [mg/l] max. 80
Sulphate content (S) [mg/l] max. 150
pH [--] min. 6.5
Hardness [ dH] max. 10
Engine cooling water system

Cooling -- cooling water loss through evaporation should be
water supply compensated by make--up water.
-- cooling water loss through leakages or otherwise
should be compensated by adding fully treated
water.
Cooling Cooling water to be drained may be re--used provided
water re--use that it is collected in a clean tank.
Property Unit
Temperatures and pressure See operating data
Preheating:
-- Temperature of HT cooling
water system before starting. [C] min. 60
Note! Re--use of cooling water provided that the quality is beyond any
doubt is highly recommended instead of new. Used cooling water
contains very little oxygen, is environmentally more friendly and
needs less correction.
Not re--usable cooling water should be drained and disposed of in
an ecologically safe way.
23328 1.4 -- 3
Manual
Wärtsilä 38
1.4.2.3. Qualities of cooling water additives
General
Use of approved cooling water additives during the warranty period is
mandatory and is also strongly recommended after the warranty period.
Start always with the maximum concentration of additives due to the
fact that the concentration of active corrosion inhibitors drops in time.
Approved cooling water additives

For approved cooling water additives and systems please contact
Wärtsilä Nederland B.V.
Recommended
Coolant based on
Nitrite --- borate --- Not to be used with soldered surfaces,
aluminium and zinc.
--- Toxic.
Limited suitable (see restrictions when mentioned):
Coolant based on
Nitrite (sole) --- In combination with borate (pH control)
nitrite performs better.
--- Not to be used with soldered surfaces,
aluminium and zinc.
--- Toxic.
Silicate --- Harmless to handle.
--- Can protect steel as well as copper and
aluminium.
--- Not so efficient.
Molybdate --- Harmless to handle.
--- Can form undesirable deposits.
Organic --- May contain phosphonates, polymers
(like polycarboxylic acid) and azoles (for
instance tolytriazole).
Not advised
Chromate, Phosphate, Borate (sole) and Zinc.
The use of glycol is not recommended. If however glycol is used an
additional de---rating has to be applied. See section de---rating, 1.0.3.
1.4 -- 4 23328
Manual
1.4.2.4. Cooling water control
Check the cooling water quality according the maintenance schedule.

Most suppliers of cooling water additives can provide a test kit for measuring the
active corrosion inhibitors.
Note! With most additives correct dosing is very important. Under dosing of
additives causes spot corrosion while overdoses may cause
deposits.
Request the supplier of the treatment product for instructions, procedures, dosage
and concentration based on the applicable make --up water.
1 Follow thoroughly the instructions of the supplier.
2 Record results of tests in the engine log book.
23328 1.4 -- 5
Manual
Wärtsilä 38
1.4.3. Internal cooling water system
1.4.3.1. General
Engine cooling is arranged by two separate cooling water circuits.

The High Temperature circuit and the Low Temperature circuit.
--- The HT cooling water circuit cools the cylinders the turbocharger
and the HT section (first stage) of the charge air cooler.
--- The LT cooling water circuit cools the LT section (second stage) of
the charge air cooler.
Most components are connected to the engine without external piping.

Built---on are:
--- HT and LT cooling pumps with non return valves.
--- Charge air cooler HT and LT section.
--- Turbocharger.
--- Common cooling water venting point.

Note! For maintenance background information, safety aspects, tools,

see chapter 2.4 .
1.4 -- 6 23328
Manual
1.4.3.2. Description HT cooling water system
At the suction side of the HT cooling water pump water returning from
the engine and water from the external cooler is mixed by an external
thermostatic valve. Via the pump the cooling water at the correct
temperature is forced to the engine manifold which is cast in the engine
block.
Flow from cylinder liner to cylinder head

From the manifold the water is distributed to all cylinder liner sections and
from each liner upwards through the cooling water channels in the liner
collars. From the liner collars into the cylinder heads.
Cylinder head
In the cylinder head the water is forced by an intermediate deck to flow along
the flame plate, around the valves to the exhaust valve seats and up along
the fuel injector sleeve. From the cylinder head the water is discharged via
a connection piece into the discharge manifold.
Turbocharger
Parallel to the flow to the cylinders, part of the water flows through the
turbocharger.
HT cooling water charge air cooler

The return water from the cylinder heads and turbocharger is supplied
to the HT section (first stage) of the charge air cooler.See also charge air
and exhaust gas system, chapter 1.5.
In the first stage of this cooler, most of the heat from the charge air is
extracted.
From the charge air cooler the water is conducted to the engine cooling
water outlet.
1.4.3.3. Description LT cooling water system
At the suction side of the LT cooling water pump water returning from
the engine and water from the external cooler is mixed by an external
thermostatic valve. Via the pump the cooling water at the correct
temperature is forced to the engine manifold which is cast in the engine
block.
23328 1.4 -- 7
Manual
Wärtsilä 38
1.4.3.4. Cooling water pump
Engine driven cooling water pumps (1) for the HT and LT circuit are
identical in components, however, will slightly differ after assembling.
The maintenance is for both types of pumps similar and exist in
replacing the roller and ball bearing and replacing the seals in case of
excessive gland leaking.
The bearings are lubricated by engine oil and need no further attention.
1 2 30
Fig. 1.4 - 1 Cooling water pump assembly
1.4 -- 8 23328
Manual
1.4.3.4.1. Disassembling
1 Observe and write down the mentioned torque settings.

2 Disconnect the suction and discharge line and remove the bolts (2).
Remove the complete pump together with gear wheel (3).
3 To remove the gear wheel (3) from the pump shaft, remove the 2 tap
bolts (4), the gland (5) and the 4 tapered rings (6). See fig. 1.4 --- 1 .
9 10 29 8 7 19 18 20
11
12
16
15
21
13
14
22
25
17 24 23
Fig. 1.4 - 2 Cooling water pump assembled
4 Loose the nuts (7) and remove the spring washers (8). See fig.
1.4 --- 2 .
Suction cover
5 Loose the nuts (9) and remove the spring washers (10) and the
suction cover (11).
6 Remove the wear ring (12) out of the suction cover (11) if the ring
has to be replaced.
23328 1.4 -- 9
Manual
Wärtsilä 38
Impeller
7 Remove the locking screw (13) and impeller nut (14).
8 Extract the impeller (15) from the pump shaft (16). Therefore screw
3 bolts in the threaded holes in the impeller (15) to create force. If
necessary heat the impeller (15) on the hub.
Mechanical seal
9 Remove the rotating parts of the mechanical seal (17).
Pump cover
10 Loose the nuts (18) and remove the spring washers (19). See fig.
1.4 --- 2 .
11 Remove the oil catcher (20) and throttle ring (21) out of the pump
cover (22).
Bearing bracket
12 Remove circlip (23) and extract the outer race of the roller bearing
(24).
13 Remove pump shaft (16) with ball bearing (27) and inner race of the
roller bearing (24) out of the bearing bracket (25).
Pump shaft
14 Bend back the lip of the locking ring (26), loose and remove the
locking nut (27). See fig. 1.4 --- 3 .
15 Heat the inner ring of the roller bearing (24) and turn off the ring
from the pump shaft (16).
16 Heat and remove the ball bearing (28) from the pump shaft (16).
24 16
27 26 28
Fig. 1.4 -- 3 Drive shaft
1.4 -- 10 23328
Manual
1.4.3.4.2. Assembling
General
1 Always use new gaskets and clean all parts before assembling the
pump.
2 Replace all wearing parts when the pump is serviced (bearings, oil
catcher, mechanical seal, throttle bush, wear ring impeller).
3 Grind impeller (15) to pump shaft (16) with grinding compound.
See fig. 1.4 --- 2 .
Pump shaft
4 Heat ball bearing (28) till 80° C and fit bearing on pump shaft (16).
See fig. 1.4 --- 2 and 1.4 --- 3 .
5 Fit locking ring (26) and turn on locking nut (27) on pump shaft
(22). Secure locking nut (27) by bending over a lip of locking ring (26).
6 Heat the inner race of roller bearing (24) to 80° C and shrink the
race on pump shaft (16).
Bearing bracket
7 Mount the outer race of roller bearing (24) and circlip (23) in
bearing bracket (25). See fig. 1.4 --- 2 .
8 Mount the assembled pump shaft (16) in the bearing bracket (25).
Pump cover
9 Fit throttle ring (21) in pump cover (22) and lock with Chetraloc 75
(green). See Fig. 1.4 --- 2 .
10 Fit oil catcher (20) in pump cover (22).
11 Place gasket in the bearing bracket and mount pump cover (22).
12 Mount spring washers (19) and screw nuts (18) to fasten the pump
cover (11) (14 Nm).
Note! After the pump is assembled, and mounted to the engine, the oil
catcher in the bearing bracket has to face to top. Only in this
position splashing oil is collected and drained to both bearings for
lubrication.
Mechanical seal
13 Press the static ring of the mechanical seal (17) in the pump cover
(22). Use a plastic pressure piece. See fig. 1.4 --- 2 .
14 Put some soap suds on the bellows of the mechanical seal (17) and
mount the rotating parts on shaft (16) until the seal (17) faces touch
each other.
23328 1.4 -- 11
Manual
Wärtsilä 38
Impeller
15 Mount the impeller (15) on the pump shaft (16) without using
Loctite. See Fig. See fig. 1.4 --- 2 .
16 Screw the impeller nut (14) (62 Nm) on pump shaft (16) and lock
the impeller nut with locking screw (13) (1.7 Nm).
Suction cover
17 Fit wear ring (12) in suction cover (11) and lock with Chetraloc 75
(green). See fig. 1.4 --- 2 .
18 Place gasket in pump housing (29) and mount the suction cover (11)
with the baffle in the direction to the discharge. Mount spring washers
(10) and fasten nuts (9) (21 Nm). See Fig. 1.4 --- 2 .
Pump
19 Place gasket in pump housing (29) and mount bearing bracket unit
with the oil catcher facing top. See Fig. 1.4 --- 2 .
20 Mount spring washers (8) and fasten nuts (7) (21 Nm).
21 Place gear wheel (3) on the pump shaft and slide the tapered rings
(6) in position. Place gland (5) and fit tap bolts (4).
22 The bolts should gradually be cross tightened. For torque setting
see section 2.4.4.. Check pump shaft and impeller for free turning.
Note! New pump units are provided with a dust cover over the drive shaft
to protect the roller bearing during transport and storage against
dust penetration. This dust cover has to be removed before the
pump is taken into service.
Pump mounting instructions

Mounting of the pump on the engine is possible in one position only.
This position is determined by a dowel pin in the engine frame.
Before mounting, the pump flange with the engine frame should be
absolute clean. After cleaning apply some sealing compound at (30). See
fig. 1.4 --- 1 .
The tolerated machining of engine parts makes it redundant to readjust
the backlash between the two gear wheels. The presence of any backlash
can be determined via the small covered opening below the pump.
Fit the suction and discharge lines. The pipe connections with the pump
casing shall be stress free mounted. Tighten the flange bolts gradually
and cross wise.
1.4 -- 12 23328
Manual
1.4.3.5. Flexible pipe connections
Some cooling water pipe connections are made flexible by the

application of a ”mono ---grip---coupling”. To apply the ”mono ---grip---
coupling” the pipe ends should be well in line and lateral within 1% of
the pipe diameter.
Fitting instructions
1 Remove sharp edges and burrs.
2 Clean pipe where coupling mounts. Eliminate such as scratches,
cracks, remove coatings, non ---adherent rust and paint.
3 Mark half width of coupling symmetrically on both pipe ends.
4 Slide coupling over pipe end (do not rotate coupling if teeth are
engaged).
5 Push pipes together and make sure they are in line.
6 Position coupling such that marks are visible on both sides.
7 Tighten bolt with a torque wrench.
Note! Torque indicated on coupling is valid for radially rigid pipes.

Couplings can be used several times! No dirt under sealing lips!
Disassembling coupling
Loosen screw. Casing must eventually be spread and grip ring with
screw driver released from anchoring on pipe. Do not rotate coupling as
long as teeth are engaged. Grease bolt before new assembly.
23328 1.4 -- 13
Manual
Wärtsilä 38
1.4.4. Maintenance cooling water system
1.4.4.1. General
Normally, no reason for maintenance of the cooling water systems exists

unless the temperatures tend to rise without clear reason. A deviation in
cooling water temperature can be caused by malfunctioning of one of the
cooling water thermostats. Normally, all inspections and cleaning of cooling
water system components should be carried out at planned intervals.
If the risk of freezing occurs, drain all cooling water. Collect drained
water for reuse.
1 If an emulsion oil has been used the entire system must be cleaned
from oil deposits.
2 Changing brand and type of additives requires cleaning by flushing
of the entire system.
3 Compensate leakage or spillage with treated water.
1.4.4.2. Cleaning
In completely closed systems fouling will be minimal if cooling water is

treated according instructions in section 1.4.2.
Depending on the cooling water quality and the efficiency of the
treatment, cooling water spaces may or may not foul over the length of
time. Deposits on cylinder liners, cylinder heads and cooler stacks
should be removed to avoid disturbance in heat transfer to the cooling
water with thermal overload as consequence.
The necessity of cleaning should be investigated, especially during the
first year of operation. This may be executed during a cylinder liner
inspection on fouling and deposits on liner and block.
1.4 -- 14 23328
Manual
1.4.4.3. Cooling water venting
To keep the quantity of air in the cooling water low, the water surface
in the make---up tank and expansion tank must be free of turbulence.
Permanent venting pipes are to end below the water level. Check
periodically the tank level.
Air also enters the cooling water through a defective shaft seal of a
cooling water pump when the suction pressure is below zero.
Exhaust gas (CO2) can enter the water system through a damaged
cylinder head seal. The cooling water will then deteriorate quickly.
For the venting point connections of the HT and LT cooling water
system see the pipe connection diagram.
For the pipe connection diagram see section ”Diagrams” of the
Catalogue which is delivered with the engine documentation.
--o--o--o--o--o--
23328 1.4 -- 15
Manual
Wärtsilä 38
1.4 -- 16 23328
Manual
Charge Air and Exhaust Gas System Wärtsilä 38
1.5. Charge Air and Exhaust Gas System
Table of contents
1.5. Charge Air and Exhaust Gas System . . . . . . . . . . . . . . . . . . . . . . . 1.5 - 1

1.5.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 2
1.5.2. Quality of suction air filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 2
1.5.3. Internal system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 3
1.5.4. Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 4
1.5.4.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 4
1.5.4.2. Charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 5
1.5.4.3. Condensate draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 7
1.5.4.4. Charge air ducting between charge air receiver
and cilinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 14
1.5.5. Exhaust gas system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 15
1.5.5.1. Exhaust gas manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 15
1.5.5.2. Compensators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 16
1.5.5.3. Insulation box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 17
1.5.5.4. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 18
1.5.5.5. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 18
1.5.6. Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 19
1.5.6.1. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 19
1.5.6.2. Turbocharger cleaning devices . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 19
1.5.6.3. Compressor side cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 20
1.5.6.4. Turbine side cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 21
23328 1.5 -- 1
Manual
Wärtsilä 38
Charge Air and Exhaust Gas System
1.5.1. General
The term ”charge air” or ”supercharging” refers to the practice of filling
the cylinder, with air at a pressure substantially higher than
atmospheric pressure to support the combustion of the fuel, plus a
sufficient excess to control internal combustion and exhaust gas
temperatures.
Supercharging is realised by a turbo charging system consisting of
centrifugal compressor(s) each driven by an exhaust gas turbine.
Turbochargers utilise energy in the exhaust gasses and improve the
engine efficiency. The speed of turbochargers has no fixed ratio to the
engine speed but will vary with the load.
1.5.2. Quality of suction air filtration
The highest allowable concentration of dust and harmful components

at the turbocharger inlet, after filtration, is given in the table below.
Property Unit
Dust concentration (particles > 5 ←m) 3.0 [mg/m3n]
Chlorides (Cl) 1.5 [mg/m3n]
Hydrogen Sulphide (H2S) 375 [←g/m3n]
Sulphur dioxide (SO2) 1.25 [mg/m3n]
Ammonia (NH3) 94 [←g/m3n]
Note! m3n is given at 0° C and 1013 mbar.
Measurements are to be performed during a 24---hour period and the
highest 1---hour average is to be compared with the above mentioned
boundary values.
Weather conditions such as wind speed, wind direction, ambient
temperature and air humidity may vary considerable during one year.
Therefore a one---day measurement may not reflect the most critical
situation.
A detailed investigation concerning filtration has to be done in
installations where the air includes components that are known to be
caustic, corrosive or toxic.
1.5 -- 2 23328
Manual
1.5.3. Internal system
Components of the internal system built---on the engine are:

--- Air intake filter with silencer on the turbocharger.
--- Two stage charge air cooler with HT and LT section
--- Compressor cleaning device
--- Turbine cleaning device

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1.5.4. Charge air system

1.5.4.1. General
If the engine takes combustion air from the engine room, all combustion
air should than first be supplied into the engine room. The design of
engine room ventilation, special in the vicinity of the charge air intake
filters, can highly influence the good performance of the engine
combustion process. Full air supply to the air intake filter under arctic
conditions may create too low combustion gas temperature, and
ambient air further heated in the engine room under tropical conditions
will raise the exhaust gas temperatures in the engine far too much. For
good engine operation the following should be taken into consideration:
--- Engine room ventilation should be such that water, foam, sand, dust
exhaust smoke etc. can’t enter the engine room.
--- Avoid heating of fresh combustion air by striking hot engine room
machinery.
--- In case the engine room temperature raises over 45C the engine
room ventilation ducting should be directed even nearer to the
turbocharger inlet filter to avoid further heating of the fresh air. If
such situation cannot be arranged, derating of the engine load
should be considered to avoid thermal overloading the engine.
--- Avoid discharge of generator cooling air to the turbocharger intake.
--- For restrictions on suction air temperatures, see chapter 2.3.
It is recommended to have separate ventilators for combustion air and

ventilating system provided. Air supply fans must be dimensioned to
obtain a slight over pressure in the engine room, but must not exceed
1 mbar.
Note! For maintenance background information, safety aspects,

intervals, tolerances, inspections, tools and torque spanner
instructions, see chapter 2.4.
1.5 -- 4 23328
Manual
1.5.4.2. Charge air cooler

To maintain the required charged air temperature at higher engine load
the charge air has to be cooled.
The temperature at the compressor discharge side at full load is
approximately 200C. To cool the charged air after the compressor the
air passes a two stage air cooler (1) in which the compressed air is cooled
by water. See fig. 1.5 --- 1
The first stage is cooled by HT water and cools the charge air till
approximately 90–100C. The second stage is cooled with water from the
LT water system and cools the charge air till the required temperature
of approximately 50C.
Fig. 1.5 -- 1 Charge air cooler
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Wärtsilä 38
1.5.4.2.1. Cooler stack
The cooler stack (1) together with the cooling water header (2) and
cooling water return header (3) is one unit. See fig. 1.5 --- 2 .
The unit is located in the housing inside the turbocharger bracket.
The cooling water header (2) contains the HT and LT supply and return
connections with the drain plugs (4) and the venting plugs (5) for both
systems.
HT water enters the cooler at (6) and is discharged at (7).
LT water enters the cooler at (8) and is discharged at (9).
5 8 6 5 air flow direction
4 9 7 4 2 1 3
Fig. 1.5 -- 2 Cooler stack
1.5 -- 6 23328
Manual
1.5.4.2.2. Operation
To prevent the cooling water from freezing when the engine is not in
operation the temperature in the engine room should be kept at a
minimum temperature of + 5 C. When the temperature is below 5 C
precautions have to be taken by means of anti freeze additives. In this
case it must be realized that this affects the heat balance.
A rising air temperature accompanied by a fall in air pressure indicates
the fin plates around the tubes are becoming contaminated. A rising air
temperature with water pressure difference over the cooler indicates
contamination inside the tubes by scale or dirt. In either case cleaning
of the cooler stack is required.
1.5.4.3. Condensate draining
Check daily, during operation of the engine, if the condesate drain pipes
located on the housing of the charge air cooler and charge air receiver
are open. Under normal operating conditions only compressed air
should escape from these holes and possible some condensate.
If excessive water escapes from the condensate drain pipes this can be
caused by:
--- Condensate due to high air humidity.
Condensate can be formed at the outside of the tubes of the LT part of
the air cooler and is carried together with the air into the combustion
chambers of the cylinders.
The quantity of condensate depends on the suction air temperature,
humidity, charge air pressure and charge air temperature. There will
always be some condensate on the pipes of the LT section of the charge
air cooler. By increasing the temperature of the the LT cooling water
before the charge air cooler the quantity of condensate is reduced.
Do not reduce the cooling water flow.
Excessive water (condensate) in the combustion chambers can cause
corrosion on liners, piston rings and pistons and cold corrosion on fuel
injector nozzles.
--- Charge air cooler stack has one or more leaking tubes.
This should be confirmed by a lowering of the level of the HT and / or
LT expansion tank. Check the kind of water (treated water or not)
Continuously water leaking when the engine is out of operation may
indicate a leaking cooler stack.
Inspection of the cooler stack on short notice is required.
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Note! Condensate drain points have the function to inform the operator on
the presence of water in the charge air receiver.
Condensate drain points are not designed to drain large quantities
of water and should always be open.
Fig. 1.5 -- 3 Condensate drain point
1.5 -- 8 23328
Manual
1.5.4.3.1. Maintenance
Clean the cooler at intervals according to chapter 2.4. or, if at full load,
the charge air temperature cannot be maintained.
Removal of the cooler stack

1 Drain the HT and LT cooling water from the engine and collect
water for re---use.
2 Remove instruments to avoid damage to them.
3 Remove the vent line or remove plug in order to drain all the water.
4 After all water is drained, disconnect and remove cooling water
pipes from water header.
5 Remove bolts (8) at front side of the cooler stack and remove from
support plate (9) self locking nuts (10) and plate. The cooler stack is
supported at bottom side by 2 bars (7). See fig. 1.5 --- 4 .
10
situation
before mounting
cooler stack
7 7
6 2 3
9 situation
4 after mounting
cooler stack
8
5
10
13
Fig. 1.5 -- 4 Levelling charge air cooler
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Manual
Wärtsilä 38
6 Use jack bolts 9622DT192 to push the cooler stack from the housing.
The cooler stack cooler may now be pulled approximately 10 cm. out of the
housing.
7 Fit the support (11) of tool 9622DT937 against the housing and
connect both supports to each other with rods (14), see fig. 1.5 --- 5
8 Fit both carriers (12) to the cooler stack and fit for guidance of the
carriers both strips (15) to support (11), see fig. 1.5 --- 5 .
9 Slide the cooler stack completely out of the housing.
Note! If the cooler stack does easily slide out of the housing check first
if nuts (10) are completely removed. Next measure the length of
the adjusting bolts (13) and loosen these bolts a few turns.
10 After the cooler stack is free from the housing fit eye bolts in top
of the cooler stack and apply a sling to lift the stack.
9622DT191
9622DT192
15
12
14
9622DT937 14
11 12
Fig. 1.5 - 5 Removal / mounting of the charge air cooler stack
1.5 -- 10 23328
Manual
Mounting the cooler stack

1 Examine the cooler for damage and in particularly the joint faces
and sealing strips (4), (5) and (6), see fig. 1.5 --- 4 .
2 Fit guide pins 9622DT191 to the cooler stack housing,
see fig.1.5 --- 5
3 Apply some grease on top of sealing strips (5), see fig. 1.5 --- 4
4 Slide the stack completely into the housing and bring adjusting
bolts (13) to the original length.
5 Check if the distance between the between the cooler stack flange
and the housing is at all four sides the same.
In case of a new stack it might be necessary to adjust the bottom bars
(7) to support the cooler stack over the full lenght.
After levelling secure the adjustment bolts (13) with the counter nuts,
see fig. 1.5 --- 4 .
6 Slide the cooler stack a few centimetre backwards and apply sealing
compound where the stack fits against the charge air housing.
7 Slide the cooler stack completely in the housing and fit the self
locking nuts (10) together with plate to fasten support plate (9), see fig
1.5 --- 4 .
8 Remove the guide pins 9622DT191 and fasten the cooler stack.
9 Connect the cooling water pipes vent lines and plugs.
10 Fill the HT and LT cooling water sections, vent the cooler and
examine for water leakages.
23328 1.5 -- 11
Manual
Wärtsilä 38
1.5.4.3.2. Cleaning
General
Cleaning of the water and air side of the charge air cooler is required to
restore thermal cooler performance. Cleaning can be done either
mechanical, hydraulic or chemical. Several international companies
supply equipment and chemicals for cleaning of heat exchangers.
Cleaning intervals vary with the mode of operation, cooling water and
intake air quality, etc.
During cleaning the cooler should internally be inspected on scaling and
corrosion.
Scale increases the risk of pitting corrosion and scale coming loose
blocks the tubes leading to erosion.
Always check for erosion after cleaning.
Cleaning water side

Remove the water covers from the stack and inspect the tubes
internally. When deposits are soft, which will occur in most of the
installations, use special nylon brushes connected to a rod. The type of
brush must be selected in accordance with the finned tube. Replace
gaskets or O–rings.
Cleaning air side

Remove the cooler stack. To clean the fins of the tubes, immerse the
stack in a chemical bath containing a degreasing solvent. Raising and
lowering the stack in the solution or bringing the solution into
movement by means of a steam jet or air, will accelerate the cleaning
process. Direct after the cleaning is completed the cooler is to be flushed
by applying a powerful water jet
Note! When using chemicals take the necessary precaution and follow the
instructions provided by the manufacturer of the chemicals.
Hydraulic cleaning
Hydraulic cleaning has to be carried out with the cooler stack removed
using a high pressure spray gun with a special nozzle to remove dirt
deposits inside the tubes. For the outside of the tubes a nozzle with a
diameter of 3 mm is recommend. Attack and the cooling tubes with the
water yet vertical this means parallel to the fins. A suitable distance to
avoid damage is 2 meter.
Note! When using a high pressure water cleaning device take care not to
damage the fins. Damaged fins will result in an decreased capacity
of the cooler stack.
1.5 -- 12 23328
Manual
1.5.4.3.3. Repairs
Leaking tubes
Tube leaks can be caused by corrosion, erosion or improper operation
of the cooler. A leaking tube cannot be removed, they are roller expanded
into tube plates.
Leaking tubes may be sealed by turned hardwood plugs or rubber plugs
on both sides. Up till 10 tubes per system may be sealed. Fit a new cooler
stack or send the cooler stack for repair if more than 10 tubes are
leaking.
Hydro test cooler with the specified test pressure which is stated on the
name plate fitted on the cooler side wall or casing.
Leaking seal
All seals are either O–rings, soft metal rings, gaskets or liquid gasket.
If necessary disassemble the cooler as far as needed. Remove dirt and
corrosion residues and restore the surfaces in good shape again. Mount
new seals.
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Manual
Wärtsilä 38
1.5.4.4. Charge air ducting between charge air

receiver and cilinder head
After passing the charge air cooler the air goes to the charge air receiver
and from there it is distributed to the cylinder units.
The connection between the receiver and the cylinder heads are bends,
fixed mounted to the cylinder heads and flexible mounted in the charge
air receiver, see fig. 1.5 --- 6 .
In case the cylinder heads have to be lifted only the 4 tapbolts at the
cylinder head side have to be removed.
The tapered position of the flanges makes lifting and lowering of the
cylinder heads easy.
The flange connections against the cylinder head as well as the
connection with the charge air receiver has an O ---ring.
Before each cylinder head mounting, check the presence of O ---rings (1),
(2) and (3). The rings should be renewed when they have flat sides.
During lowering of the cylinder head onto the cylinder liner the bend
has to be kept a little lifted to let the cylinder head pass.
Air flow
Fig. 1.5 - 6 Charge air ducting
1.5 -- 14 23328
Manual
1.5.5. Exhaust gas system
1.5.5.1. Exhaust gas manifold

The exhaust gas manifold is assembled of manifold sections (1)
interconnected by compensators (2). Branches of the manifold sections
are rigid mounted via V---clamps (3) to the cylinder heads, see fig.
1.5 --- 7 .
The manifold is connected to the turbocharger.
The exhaust gas manifold requires under normal operation conditions
no maintenance. A periodical inspection to connections and to the
condition of the compensators is sufficient.
The manifold can be inspected after removal of one or more panels from
the insulation box.
When one or more cylinder heads have to be removed the manifold
sections (1) must be properly supported to avoid excessive distortion of
the compensators.
During lowering of a cylinder head for mounting on the engine, the
manifold section (1) must first be lifted a little to make a proper fit
against the exhaust flange connection of the head possible.
1 2
Fig. 1.5 -- 7 Exhaust gas manifold configuration
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Manual
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1.5.5.2. Compensators
Compensators in the exhaust gas manifold enable thermal expansion of
the manifold. Make sure that, whenever the compensators have to be
replaced, the arrow on the compensators corresponds to the gas flow
direction, see fig. 1.5 --- 8 . There is no gasket between the compensators
and exhaust manifold, it is a face to face connection.
Gas flow direction
Fig. 1.5 -- 8 Gas flow through compensators
Note! When re--installing a compensator, check if flanges of the exhaust

manifolds are in line and parallel. Maximum deviation 1mm.
1.5 -- 16 23328
Manual
1.5.5.3. Insulation box
The insulation box (1), enclosing the exhaust gas manifold, is flexible
mounted to a structure (2) by means of shock absorbers (3). This
structure is rigid mounted to the engine block.
The shock absorbers should be inspected regular on condition. Replace
broken shock absorbers.
3 1
2 3
Fig. 1.5 - 9 Insulation box
Warning! The insulation box is not designed to carry weight.
The heat insulating material, as part of the panels, is at the inside

cladded with stainless steel sheeting. This sheeting should not be
painted as part of the heat insulation exist in the reflection of heat
radiation.
23328 1.5 -- 17
Manual
Wärtsilä 38
1.5.5.4. Maintenance
Well designed and installed exhaust gas systems require little

maintenance and can be limited to long term visual periodical
inspections consisting of:
--- Inspection of all the connections in the exhaust gas manifold.
--- Inspection of all rigid and flexible mountings between exhaust gas
system and the engine room structure. Special attention should be
paid to the support of the ducting after the turbocharger.
--- Inspection of the exhaust ducting insulation and cladding between
turbocharger and uptake.
--- Check the exhaust system after the turbocharger is proper supported
by the engine room structure.
(Load on the turbocharger is not allowed).
1.5.5.5. Operation
1 Check the working of water separating pockets and drainage

system of the external exhaust system.
2 The exhaust gas back pressure should not exceed the maximum
mentioned, see section 1.0.2.
3 Check the good working of the sliding supports of the ducting after
the turbocharger.
4 Check during operation of the engine the entire exhaust gas system
on gas leakage’s.
5 Check after every start and daily the working of lubricating pumps
of the turbocharger at compressor and turbine side.
1.5 -- 18 23328
Manual
1.5.6. Turbocharger
The turbocharger consist of a single stage radial flow turbine and a

centrifugal air compressor connected by a single rotor shaft supported
by rolling contact bearings.
Each bearing point has its own self supporting lubricating oil system.
Sight glasses are provided to observe the oil levels.
The gas inlet and outlet housing of the turbocharger is cooled by HT
cooling water.
The turbocharger is equipped with a cleaning device for the compressor
side and the turbine side.
The rotor shaft speed is measured by a speed sensor installed at the
compressor side.
Maintain the turbocharger according instructions of the turbocharger

manufacturer. It is recommended to make use of the service network of
Use high temperature resistant grease on exhaust bolt connections.
1.5.6.2. Turbocharger cleaning devices
The diesel engine efficiency is highly related to the efficiency of the

turbocharger. The turbocharger efficiency is directly influenced by the
degree of fouling of the compressor wheel, diffuser ring, nozzle ring and
turbine wheel. Regularly cleaning is essential during engine operation.
The cleaning is not effective when the water cleaning is not carried out
on regularly schedule. See maintenance schedule section 2.4.1.
The following factors may influence the degree of fouling e.g.:
--- Environment.
--- Fuel quality.
--- Load pattern.
--- Bad combustion.
23328 1.5 -- 19
Manual
Wärtsilä 38
1.5.6.3. Compressor side cleaning
The compressor should be cleaned by water injection during the engine

operation. The cleaning process will have good results as long as the
deposit formation has not gone too far.
In this method of cleaning the water is not acting as a solvent but
instead removes the deposits mechanically by the impact of the water
droplets. Use clean water without additives.
Daily cleaning of the compressor prevents or delays excessive build ---up
of dirt.In case a very thick hardened crust of dirt is formed the
compressor has to be dismantled for cleaning.
The turbocharger is provided with a water container (1). During
cleaning the container is pressurised by the charge air via (2) by which
water is via pipe (3) forced to the compressor inlet.
3
5
4
6
2
1
Fig. 1.5 - 10 Compressor cleaning devices
1.5 -- 20 23328
Manual
cleaning procedure
Water injection is to be executed when the engine is running at normal
operating conditions at high load and the compressor running at high
speed. Record the charge air pressure, exhaust gas temperatures and
the turbocharger speed to ascertain the efficiency of cleaning.
1 Loosen grip screw (4) and remove container (1), see fig. 1.5 --- 10 .
2 Fill container with clean water till approximate 1 cm below the edge.
3 Replace container and retighten grip screw (4).
4 By opening both valves (5) and (6) charged air enters the container
via pipe (2). The water content is via pipe (3) forced to the compressor
wheel inlet.
5 The complete water volume should be injected in 4 --- 10 sec. After
the water is injected close valves (5) and (6). The success of cleaning can
be evaluated by comparing engine exhaust gas temperatures before and
after cleaning. If unsuccessfully, the cleaning process should be repeated
earliest after an interval of 10 minutes.
6 On completion of the cleaning process the engine should at least run
another 5 minutes at high load.
1.5.6.4. Turbine side cleaning
Depending on the fuel quality and installation the interval for turbine
cleaning procedure is between 24...150 hours and has to be carried out
at reduced engine load.
Note! Regular cleaning of the turbine during operation prevents or retards
excessive formation of deposits.
Use only clean, fresh water with no additives or solvents. The fresh
water supply is connected to nozzles mounted to the exhaust manifold
before the turbocharger inlet. Fresh water is injected through these
nozzles.
23328 1.5 -- 21
Manual
Wärtsilä 38
9 8
10
Fig. 1.5 -- 11 cleaning device turbine
cleaning procedure
During the cleaning process the exhaust gas temperature has to be
lowered to retard the evaporation of the injected water. It is the impact
of the water drops that skips dirt from the turbine material.
A small amount of the injected water has to be drained together with dirt
particles. As long as dirty water is flushed from the turbine components
the cleaning should be continued to be judged to the colour of the drain
water.
Additives or solvents should not be added to the cleaning water. The use
of salt water is prohibited.
1.5 -- 22 23328
Manual
Before commencing the turbine cleaning procedure, take engine

readings at an engine load that can be run every time comparisons have
to be made with previous readings.
1 Previous to turbine cleaning, reduce engine load till gas
temperature before the turbine max. 430 C.
2 Operate the engine for about 10 minutes to stabilise before
commencing water injection.
3 Connect the water hose to the water injection equipment and
commence the cleaning process after the exhaust gas temperatures
does not further lower.
4 Open the valve (7) of the drain line of the turbocharger casing and
check that the line is open.
5 Open the needle valves (8) in the supply line slowly in approx. 30
sec. till the water flow of 30 l/min is obtained. During cleaning the water
pressure at nozzle (9) has to be kept constant at 4 bar. Inject the water
as long as dirty water appears from the turbine housing drain
connection. The drain water quantity will be approx. 0.1 --- 0.2 l/min.
The cleaning process will take 5 till max. 10 minutes.
After the drain water remains clean, close needle valve (8) and the water
supply valve.
6 After completing the cleaning process of the turbine, operate the
engine for another 5 minutes at the same load to evaporate remaining
water.
7 After cleaning, check all valves are closed. Disconnect water supply
hose to avoid uncontrolled water access to the exhaust system.
8 Run engine at ”reference load” and take engine readings after
engine is stabilised. Compare readings with readings taken before
cleaning.
Note! During the cleaning process the turbine speed drops by about 10%
and will accordingly increase the exhaust gas temperature before
the turbine.
Do not exceed the maximum permissible exhaust gas temperature.
Note! The cleaning of the turbine should not be performed shortly before
stopping of the engine to avoid corrosion of the turbine components.
--o--o--o--o--o--
23328 1.5 -- 23
Manual
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1.5 -- 24 23328
Manual
Control System Wärtsilä 38
1.6. Control System
Table of contents
1.6. Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 – 1

1.6.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 – 2
1.6.2. Speed control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 – 3
1.6.2.1. Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 – 3
1.6.2.2. Booster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 – 4
1.6.3. Fuel control mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 – 5
1.6.3.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 – 5
1.6.3.2. Load indication HP fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 – 6
1.6.3.5. Mechanical limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 – 9
1.6.3.6. Stop mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 – 10
1.6.3.7. Checking actuator stop position . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 – 11
1.6.3.8. Removing the actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 – 11
1.6.3.9. Mounting of the actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 – 12
1.6.4. Governing system maintenance and trouble shooting . . . . . . . . . . . . . . . 1.6 – 12
1.6.5. Engine instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 – 14
1.6.5.1. Switches, transmitters and temperature elements . . . . . . . . . 1.6 – 14
1.6.5.2. Speed sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 – 16
1.6.6. Local Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 – 18
23328 1.6 – 1
Manual
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Control System
1.6.1. General
The engine is delivered with a Local Control System the LCS.

The LCS comprises:
--- Measuring of the engine and turbocharger speed
--- Controlling the engine speed / load.
--- Engine safety system
--- starting of the engine
--- stopping of the engine
--- start blocking
--- automatic shut down of the engine
--- load reduction request
--- The signal processing of all monitoring and alarm sensors
--- The read out of important engine parameters
--- The data communication with external systems (e.g. alarm and
monitoring systems).
For functional description of the LCS, see sub---suppliers manual.
Control of the rotating speed of an engine is accomplished by varying

the rate of fuel admission in the engine cylinders. The duty to which the
engine is applied usually determines the degree of accuracy required in
engine speed control.
An actuator/governor is used to control the engine speed and thus
enables the engine to respond to changing load requirements.

intervals, tolerances, inspection, tightening torque and instructions
see chapter 2.4
1.6 – 2 23328
Manual
1.6.2. Speed control system
1.6.2.1. Actuator
Many governing problems are the result of improper selection or

improper treatment of oil used in the actuator. The actuator should be
serviced on a routine schedule. Develop the schedule with consideration
to the operating temperature and the conditions in which the governing
system operates.
When changing oil types be sure to flush the hydraulic system before
oil change. Do not mix different types of oil. Most actuators with sumps
do not have filters, therefore, add only clean oil. If water enters the
change oil immediately. Clean oil is of most importance in hydraulic
governing system.
Consult the sub---suppliers manual for oil quality and viscosity selection
as well for acceptable operating temperatures.
Maintain the oil level in the actuator between the limits on the sight
glass and do not overfill. During a refill of the keep the oil level low and
add more oil during the running of the engine if needed. Oil in bad
condition causes approximately 50% of all governing troubles.
When during engine operation one of the following circumstances are
observed the engine should be stopped, the oil changed and the reason
for the oil deterioration be examined:
--- The oil looks different from new.
--- The oil feels dirty.
--- The oil fumes bad.
--- There is water, or dirt in the oil.
--- The viscosity of the oil has changed; increased or decreased.
--- Actuator parts are damaged or bad.
--- The actuator has run at a higher temperature than recommended for
the oil being used.
--- Governing operating temperatures have changed.
--- The oil in operation has a wrong viscosity range.
For specific actuator information consult the sub–suppliers manual.
23328 1.6 – 3
Manual
Wärtsilä 38
Control System
1.6.2.2. Booster
The booster activated by air the moment the engine is started, boosts
the oil pressure in the actuator accumulator. This makes fast response
of the actuator power piston and fuel rack possible at initial start of the
engine.
The booster supplies pressurized oil to mechanical–hydraulic actuators
and electro–hydraulic actuators instantaneous the starting air fills the
starting air header on the engine. This instant oil pressure eliminates
the time required for gear pump in the actuator to build up enough oil
pressure to move the linkage. This produces a faster start, conserving
starting air.
The booster is positioned lower than the actuator to prevent trapped air
in booster and oil lines.
When the booster is inactive, a piston is held at one end of a cylinder by
a spring. The cylinder is full of oil supplied from a line from the
actuator’s sump.
Compressed air at one side of the piston pressurises the oil at the other
side and oil is forced through ports and piping into the oil system of the
actuator.
Check valves control the oil to flow in only one way.
This avoids the returning of booster oil during the starting process.
1.6 – 4 23328
Manual
1.6.3. Fuel control mechanism
1.6.3.1. General
The movement of the power output shaft of the actuator is transferred

to the common fuel control shaft (1) through a link. The common fuel
control shaft is supported to the engine block by bearings (2) and (3),
see fig. 1.6 --- 1 .
Rotation of the common fuel control shaft is transferred through lever
(4) to the HP fuel pump racks.
Torsion springs enable the common fuel control shaft to be moved to
zero position in case one of the fuel racks will jam.
Warning! Special attention should be paid to easy movement of the fuel

linkage mechanism as a defect may result in a disastrous over
speeding of the engine, unstable engine operation or an engine
unable to take load.
3 1 2
Fig. 1.6 -- 1 Fuel control mechanism
23328 1.6 – 5
Manual
Wärtsilä 38
Control System
1.6.3.2. Load indication HP fuel pump
The common fuel control shaft rotation is monitored by a transmitter

(5) to indicate the engine load in the control room.
Check if measurement ”X” is 3 mm when the common fuel control shaft
(1) indicates ’4 mm’ on the load indicator (10).
5 1
11 10
Fig. 1.6 -- 2 Load indication
1.6 – 6 23328
Manual

and common fuel control shaft
1 Place the HP fuel pump racks on position (50mm) by moving lever

(6) of the common fuel control shaft (4), see fig. 1.6 --- 3 .
If necessary adjust the HP fuel pump racks to the average position. See
section 1.6.3.4.
2 Check if the angles between the levers (1) and (6) with rod (5) are
about 90 ° .
3 Check if the power output shaft (3) indicates ’ 7 ’ on the load
indicator (7) (scale 0–10).
4 If necessary adjust the length of rod (5) and secure all lockings on
levers etc.
5 Place the HP fuel pump racks on position 0 mm by moving lever (6).
indicator scale (7).
7 Place the HP fuel pump racks on position 60 mm by moving lever (6).
8 Check if the power output shaft (3) indicates between ’ 8 and 8.5 ’
on the load indicator scale (7).
1
5
3
2 6
Fig. 1.6 -- 3 Linkage actuator / common control shaft
23328 1.6 – 7
Manual
Wärtsilä 38
Control System

and common fuel control shaft
1 Spring loaded levers (8) are set with set screws (9) (preset distance
of 5 mm), see fig. 1.6 --- 4 .
8
5 mm
Fig. 1.6 - 4 Indication on control shaft and HP fuel pump
2 Record all HP fuel pump rack positions and calculate the average
position. With set screws (9) all HP fuel pump rack readings should be
adjusted at the average value calculated.
3 Check and if necessary adjust the linkage between the actuator and
the common fuel control shaft. See section 1.6.3.3.
4 Secure all lockings on levers etc.
5 Place the HP fuel pump racks on position (35mm) by moving lever
(6) of the common fuel control shaft (4), see fig. 1.6 --- 3 .
6 Check and if necessary adjust the dial disc indicator (10) at the end
of the common fuel rack control shaft. See fig. 1.6 --- 2 .
To adjust release the hexagon socket screw (11) and slide the disc into
position 35 mm. Fixate the disc in this position by tightning the hexagon
socket screw.
1.6 – 8 23328
Manual
1.6.3.5. Mechanical limiter
Mechanical limiters limit the rotation of the common fuel control shaft
at minimum position (1) and at maximum position (2) and thus the
stroke of the fuel racks. The limiters are adjusted and locked to avoid
the engine running in overload.
1
2
Fig. 1.6 - 5 Mechanical limiters
23328 1.6 – 9
Manual
Wärtsilä 38
Control System
1.6.3.6. Stop mechanism
1.6.3.6.1. Manual stop
Move stop lever (6) from normal operating position ’A’ into stop position
’B’. Check if pin (8) locks the stop lever see fig. 1.6 --- 7 . If necessary
adjust the linkage (5) and secure all lockings.
1.6.3.6.2. Local stop
Push stop button (2) on the stop solenoid mounted on the start/stop
unit, see fig. 2.3 --- 6 . The stop signal activates solenoid (21) and stop
valve (17), see fig. 1.6 --- 6 , and air is admitted to the stop cylinders (8)
mounted to the fuel racks of the HP fuel pumps. The air pressure in the
stop cylinders will be released after solenoid (21) is deactivated.
1.6.3.6.3. Remote stop

Push stop button in the control room. The stop signal deactivates the
actuator controller, activates solenoid (21) (see local stop) and the stop
solenoid in the actuator.
1.6.3.6.4. Stop device
Check of stop cylinder adjustment (limit position).

1 Place stop lever (6) in operating position ’A’ see fig. 1.6 --- 7 .
2 Place actuator in maximum position (fuel pump racks in full
position).
3 Push button (2) on the stop solenoid mounted on the start/stop
unit, see fig. 2.3 --- 6 , to move all stop cylinder pistons to zero position.
4 Check all fuel racks are moved into ”zero” fuel position.
Fig. 1.6 -- 6 Stop device
1.6 – 10 23328
Manual
1.6.3.7. Checking actuator stop position
1 Place lever (6) in stop position ’B’ see fig. 1.6 --- 7 .
indicator (7) (scale 0–10), see fig. 1.6 --- 3 .
3 Check all HP fuel pump racks are now in the ’no fuel position’.
Position zero mm.
4 Release stop lever by pulling locking pin (8).
’A’
6
’B’
5
Fig. 1.6 - 7 Stop mechanism
1.6.3.8. Removing the actuator
1 Make a clear match mark on lever (1) and power shaft (3) for
refitting the power shaft lever (1), see fig. 1.6 --- 3 .
2 Remove lever (1) and disconnect the electrical connections of the
actuator.
3 Drain actuator oil by opening the drain plug
4 Remove pipe connections to booster.
5 Remove bolts (2) and lift actuator from engine.
Note! The actuator should not rest on its drive shaft.
23328 1.6 – 11
Manual
Wärtsilä 38
Control System
1.6.3.9. Mounting of the actuator
1 Clean the joint faces of the actuator drive and engine block.
Check the condition of the serrated power shaft (3) of the actuator. See
fig. 1.6 --- 3
2 During assembling use Loctite 5910 or similar as gasket.
3 Be careful not to damage the serrated drive sleeve when lifting the
actuator into position.
4 Fasten bolts (2), booster pipe connections and electrical
connections. See fig. 1.6 --- 3
5 Mount power shaft lever (1) according to the match mark on the
power shaft (3).
6 Check the position of the actuator in relation with the HP fuel
pump rack position, see section 1.6.3.3.
1.6.4. Governing system maintenance and

trouble shooting
Maintenance of the actuator is limited and should mainly exist of:
--- periodically renewal and level control of the lubrication oil

--- observation to proper working of the actuator
--- observation to proper connections of the linkage mechanism
Trouble shooting
Fluctuations in engine speed or load are usual ascribed to an improper
working of the actuator however before exchanging or doing any
inspection of the actuator check the following:
1 Check engine load is not beyond maximum load.
2 Check if the fuel supply to the fuel pumps is at operating pressure
and no vapour locks exist.
3 Check cylinder firing pressures and proper working of injectors.
4 Check adjustment of external setting devices of the actuator.
5 Check adjustment and linkage between actuator and fuel pumps.
1.6 – 12 23328
Manual
6 Check actuator drive for any misalignment or excessive backlash.

7 Check level and quality of actuator lube oil. Replace lube oil and
flush lube oil system if in doubt.
8 Check actuator oil pressure at test port of the actuator.
Booster maintenance
1 Check if the sump of the actuator is filled with oil till the correct
level.
2 Check the starting air supply is connected to the appropriate
booster air inlet. Use the inlet with the built–in orifice if a slower fuel
rack move is required.
3 When all air and oil connections are secured, purge air from booster
and oil lines by cycling air to the booster from a independent air supply
without cranking the engine. Add oil to the actuator as needed. Failure
to purge air completely may result in a sluggish governing system
response.
Stop device maintenance

1 Check control air pressure.
2 Check for air leaks.
3 Check stop cylinder parts for wear (piston, cylinder and sealing
rings) and replace if necessary.
Fuel control mechanism maintenance

1 The fuel control mechanism should be operated with minimal
friction.
Bearings in linkages and on the common fuel control shaft require no
lubrication and should not be in contact with degreasing agents.
Pivoting points should be lubricated periodically with engine oil.
2 Clearances of all connections should be minimal. Total backlash
should not exceed 0.5 mm at the HP fuel pump rack position.
3 Check regularly the adjustment of the mechanism, the stop lever
position, the actuator stop position and the mechanical limiter.
4 Keep all parts of the fuel control system clean and well preserved
against rust.
5 For disassembling the common control shaft the following is
important:
--- the shaft bearing supports are bolted to the engine block and secured
by cylindrical pins.
--- most levers connected to the regulating shaft are secured by tapper
pins.
23328 1.6 – 13
Manual
Wärtsilä 38
Control System
1.6.5. Engine instrumentation
The engine is equipped with instruments for alarm, control and moni-
toring. All signals from the engine are collected in a main terminal box.
The following basic documents are enclosed in the Parts Catalogue,

chapter 3 --- Electrical documentation:
--- Instrument list Sensor signals are categorised and all
sensor functions are displayed.
--- Setpoint list Description of setpoints for alarm, safety
and control functions.
--- Input / Output list (I/O list) List of sensor signals with
corresponding pin numbers and
connector identification labels.
--- Wiring diagram Connection diagram of engine
instrumentation signals, like
thermocouples, switches, actuator and
speed monitoring signals.
Warning! Do not modify any parameter setting of the listed documents without
written permission of the engine manufacturer.
1.6.5.1. Switches, transmitters and

temperature elements
Switches
All switches are drawn in ”non operated” position (see wiring diagram).
Which means that the actual switches (as mounted) are drawn as being
disengaged. This is very important for the fail safe aspects of the alarm
and safety system when changing switches or wiring.
For the main safety functions a connecting loop is prescribed for the
main terminal box In the wiring diagram.
Note! Some switches are normally opened e.g. will be engaged in normal
engine operating conditions. For example oil mist detection switch
failure will be engaged in case the system is OK power-- and air
supply connected (see wiring diagram for details).
1.6 – 14 23328
Manual
Transmitters
All pressure transmitters are of the 4---20 mA type. This means that wire
break detection is possible. All pressure transmitters are located on a
central panel next to the main terminal box.
Temperature elements
PT---100 elements are standard equipped with 3 core wires and routed to
a terminal strip or directly to the output connectors in the main terminal
box.
The wiring from the thermocouple connection to the terminal box of the
engine is made by a compensation cable. For cold junction compensa-
tion additional PT---100 elements are installed.
Warning! Check / calibrate the switches, transmitters and temperature

elements according the maintenance schedule, section 2.4.1.
23328 1.6 – 15
Manual
Wärtsilä 38
Control System
1.6.5.2. Speed sensors
General about speed sensors connections.

The engine is equipped with speed sensors at three locations.
It is advised to make use of pre---fixed connection cables and in case
connections has to be soldered take care it is done in a correct way and
that there is no short circuit.
After assembling of the speed sensors use tie wraps on the cables, to
avoid vibrations.
Turning gear wheel

Two magnetic pick---ups (2) to detect the engine speed at the turning
gear wheel (1) at the driving---end. The speed controller converts the
pulses from the magnetic pick---up to engine rpm.
Fig. 1.6 -- 8 Speed sensor at the turning gear wheel
1.6 – 16 23328
Manual
Camshaft gearwheel
Two inductive proximity switches (3) to detect engine speed at the
camshaft gearwheel cover (4). The speed monitoring system converts
the pulses from the proximity switches to engine rpm.
4 3 5
Fig. 1.6 - 9 Speed sensors at camshaft
Turbocharger
One magnetic pick---up for each turbine to detect the turbine speed. See
sub---suppliers manual for details. The speed monitoring system
converts the pulses from the magnetic pick---up’s to turbine rpm.
Engine speed sensor adjustment check
Warning! Check the speed sensor adjustment only with a stopped engine.
Improper sensor adjustments can result in failure of overspeed

detection and loss of speed/control functions. Therefore it is necessary
23328 1.6 – 17
Manual
Wärtsilä 38
Control System
to check the sensor adjustment prior to a first start of the engine. The
following checks should be carried out, see fig. 1.6 --- 8 and 1.6 --- 9 :
1 Remove the connector of the sensor.
2 Check the distance “X“ between the sensor tip and tooth of gear
wheel. X must be 1.5 mm 0.5 mm.
3 Adjust the gap if necessary and secure the locking nut (use Loctite
to avoid loosening).
4 Check if tooth of gear wheel will not touch the sensor tip while
turning.
5 Install the connector of the sensor.
1.6.6. Local Control System
The Local Control System (LCS) is an independent autonomous

computer system for handling of all control, safety and monitoring
functions related to the diesel engine, along with the installation
components which can affect engine operational conditions directly.
Its functions are not affected whenever some other external computer
system would suffer from complete breakdown. Even a temporary loss
of main power supply will not affect these functions.
All engine parameters measured and calculated by the LCS are
available for post---processing in other, external computer systems.
Serial communication link facilities are provided for the connection of
LCS with these computer systems. External computer systems can be
used for tasks of a more supervisory nature like, for instance, more
advanced user interfaces with dynamic engine data presentations on a
colour graphic screen, (extra) alarm systems, integrated propulsion
control systems, power management system, extensive condition
monitoring, scheduling of tasks, etc.
The name Local Control System symbolises the fact that the System is
to be regarded as an integral part of the diesel engine while, at the same
time, offering a great amount of additional functions.
Note! Detailed information of the Local Control System can be found in

separate documentation.
--o--o--o--o--o--
1.6 – 18 23328
Manual
Operation Wärtsilä 38
2.3. Operation
Table of contents
2.3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 - 1

2.3.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 -- 2
2.3.2. Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 -- 3
2.3.2.1. Preheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 -- 3
2.3.2.2. Preparations before the start . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 -- 3
2.3.2.3. Local start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 -- 4
2.3.2.4. Remote or automatic start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 -- 5
2.3.2.5. Start after a normal stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 -- 5
2.3.2.6. Start after overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 -- 6
2.3.2.7. Emergency start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 -- 8
2.3.3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 -- 9
2.3.3.1. Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 -- 11
2.3.3.2. Loading performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 -- 12
2.3.3.3. Operating range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 -- 14
2.3.3.4. Maintenance points during operation . . . . . . . . . . . . . . . . . . . . . 2.3 -- 15
2.3.3.5. Measurement of cylinder pressure . . . . . . . . . . . . . . . . . . . . . . . 2.3 -- 17
2.3.3.6. Running--in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 -- 18
2.3.3.7. Operating problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 -- 19
2.3.3.8. Emergency operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 -- 25
2.3.4. Engine stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 -- 26
23328 2.3 -- 1
Manual
Wärtsilä 38
Operation
2.3.1. General
Before an operator takes an engine a first time in operation he should

be acquainted with the location and function of the components of the
installation.
It is desirable, in case of new installations or those which have been out
of service for some time, before starting, that the operator tests all fuel,
lubricating oil, water and air lines, to see they are tight and functional.
Air should be purged from liquid systems through vents at the highest
point while filling or circulating the liquid.
The engine should be cranked a few revolutions to ensure there are no
restrictions. After all necessary preparations have been made prior to
starting, the engine should run at idle speed recommended in the main
data, see chapter 1.0. The engine speed should be increased gradually
while observing pressures and temperatures to make sure all parts are
working properly.
Wärtsilä Nederland B.V. issues instructions for each engine and such
instructions are the result of wide experience. To secure the utmost in
reliability and efficiency these instructions should be read, understood,
and followed.
All well---managed installations maintain engine room logs. The logs
should have provision for recording the starting and stopping time of
each engine, the loads, pressures and temperatures. These logs are
usually based on a 24---hours operating period and provide space for
each of the shift engineers. Well maintained logs will provide an
invaluable record of the performance of the engines and all
maintenance made or needed.
Note! For running HFO engines on distillate fuels see section 1.1.1.1.
2.3 -- 2 23328
Manual
2.3.2. Start
2.3.2.1. Preheating
In a stand ---by preheated mode the engine is ready to accept load

instantly.
Stand ---by preheated mode of the engine means:
--- Fuel must be of the correct viscosity in the internal engine system.
--- HT cooling water preheated as near as possible to the operating
temperature ore preheating water preheated to a temperature of
minimum 60 C by means of an external preheating system.
Preheating water flow shall be minimum 4% of nominal water flow.
--- Lubricating oil temperature minimum 40 C.
2.3.2.2. Preparations before the start
Before a trial run and after maintenance/repairs or a prolonged stop, the

engine and system should be thoroughly inspected and prepared for
operation.
Before an engine is started, pay attention to:
--- Levels in tanks.
--- Systems vented.
--- Check correct valve positions in supply and discharge on the engine.
--- Observe the system diagrams.
--- Required coolers are in service.
--- Leaking pipes.
--- Safety systems tested and operational.
--- Check crankcase for possible water leakages from liner walls.
--- Cooling water has preheated the engine.
--- Fuel is circulating at the required pressure and viscosity.
--- The prelubricating to the engine is correct.
--- Filters on differential pressures.
--- Starting air vessels are on pressure and drained from water and oil.
--- Gauges for normal readings.
--- All covers are closed and locked.
--- Prohibiting tags removed.
--- Start blocking is released.
--- Engine and engine shafting clear for rotating.
--- Engine room is free of obstructions.
--- Bar engine two revolutions with indicator cocks open.
Note! Keep engine clear during start--up and operation.

Check if there is air supply to the stop device and leave valve (4)
always open during engine operation. See fig. 2.3 - 1 .
23328 2.3 -- 3
Manual
Wärtsilä 38
Operation
2.3.2.3. Local start
1 Depending on the system, start the prelubricating oil system to

obtain the start blocking release. If an external full flow lubricating oil
pump is installed adjust the pressure at nominal. See section 1.0.4.
Warning! In case a stand-- by pump is used for prelubrication prevent

continuous operating to avoid excessive fouling of the
turbocharger. See also sub-- suppliers manual of the turbocharger.
2 Adjust actuator at idle speed, see sub---suppliers manual.

Be sure the propeller blades are placed in 0---pitch position.
3 Follow the instructions in section 2.3.2.2.
4 Check if the automatic alarm and stop devices are in service.
5 Switch the engine to local control.
Fig. 2.3 -- 1 Local control unit

6 Push the start button (1) at the local control unit, see fig.2.3 --- 1 and
observe the crankshaft starts to rotate. The actuator displaces the racks
of the HP fuel pumps. At a minimum of approx. 50 rpm, combustion takes
place accelerating the engine speed. At the moment combustion takes place,
stop the starting air supply.
2.3 -- 4 23328
Manual
7 During the start procedure a fuel limiter, integrated in the speed

control unit, limits the fuel rack movement to avoid excessive fuel
injection and unnecessary smoke. The limiter is automatically released
after the engine reaches idle speed.
8 Direct after engine start check:
--- pressures of the engine systems
--- engine systems are free of leakages
--- no engine alarms appear
--- engine and system for anomalies
--- engine gauges for deviations
--- actuator stability and uniformity of crankshaft rotation.
--- levels in tanks and sumps remain normal
--- combustion in all cylinders to be indicated by a rise in exhaust gas
temperature
2.3.2.4. Remote or automatic start
A remote or automatic start of an engine requires the same preparations

as for a normal (local) start with the exception the engine was not in
maintenance for any reason.
To start the engine remotely the engine should first have been started
locally under full supervision of the operator. After performing the start,
a successfully run, and the engine left in a stand by position, it is
permitted to switch the engine controls from local to remote.
After switching to remote or automatic engine control, every person in
the engine room has to be aware of an engine start without notice.
2.3.2.5. Start after a normal stop
If, after a normal engine stop, the engine has to run again within a few
hours the following should be observed:
--- The engine is left in the stand ---by preheated mode.
See section 2.3.2.1.
--- Pressures, flows and fuel viscosity remain at values as required for
a local start.
--- Fuel and lubricating oil separators are kept in operation.
--- No maintenance is carried out.
--- All covers are closed and locked.
--- The turning gear is not engaged.
--- If the engine stop takes 8 hours ore more, the engine should be
cranked 2 revolutions with open indicator cocks before starting to be
sure there is no liquid on top of the pistons.
23328 2.3 -- 5
Manual
Wärtsilä 38
Operation
2.3.2.6. Start after overhaul

In general, overhaul means the engine is out of service for some purpose.
The more extensive the overhaul, the more carefully the operator has
to be during the start---up procedure.
General
1 After any kind of maintenance the operator should be fully
informed regarding the results of the maintenance to be able to operate
the engine accordingly.
2 Full attention should be paid to the cleaning of pipe systems
between filters and engine.
3 Depending on the kind of maintenance, safety devices should be
tested on setting and function.
4 Activate stop solenoid with governor power shaft at maximum and
stop lever in operating position and check all HP fuel pump racks move
to zero at once.
5 Prelubricate the engine. Check where possible, if all points which
have to be lubricated receive oil.
Test run
After maintenance and/or repair work on engine parts run the engine
at idling speed.
Note! If anything is suspected during the test run procedure, stop the
engine immediately.
1 Start the engine according to the local start procedures as

mentioned in section 2.3.2..
2 Immediately after starting up special---check for:
--- Leakage of air, water, fuel or lubricating oil. Especially, observe
fuel lines, HP fuel pumps and injectors.
--- Excessive quantities of the leak oil pipes.
--- Pressures.
--- Temperatures.
--- Strange sounds.
--- Fluid levels.
3 After 5 minutes test run stop the engine.
2.3 -- 6 23328
Manual
Warning! Removing of the crank case covers immediately after engine stop
is only allowed after maximal 5 minutest test running.
4 Open crank case covers.

5 Check main and connecting rod bearing temperatures, in particular
bearings that have been in maintenance.
Check if the connecting rod big end moves easily in axial direction.
6 Inspect during cranking liners and pistons for normal pattern from
the crankcase side.
7 Check bottom part of cylinder liners for water leakage.
Operating check
If the 5 minutes test run is ok, close and lock all covers.
Start the engine and pay attention to the following points:
1 Check readings and alarms of safety and alarm system.
2 Check pressure and temperature gauges.
3 Check automatic alarm and stop devices.
4 Check pressure drop over fuel filter and lubricating oil filter.
5 Check oil level in the oil sump/oil tank. Make some simple quality
checks of the oil.
6 Check venting of engine cooling water systems.
7 Check quantity of fuel leak.
8 Check condensate drain points in charge air receiver on presence of
water.
9 Check cooling water quality.
10 Check exhaust gas temperatures.
11 Listen for strange sounds.
12 Check crankcase pressure.
13 Check maximum cylinder pressures, see section 2.3.3.5.
23328 2.3 -- 7
Manual
Wärtsilä 38
Operation
2.3.2.7. Emergency start
In case of an emergency the engine can be started by means of the

emergency start push button (1) at the local control unit. See fig. 2.3 --- 1 .
The engine will start by–passing all the safety devices.
Keep the emergency start button activated until the engine fires.
Take notice that the appropriate switches of the speed control unit and
the stop lever are in the ”RUN” position. See fig. 2.3 --- 7 .
Warning! Be aware that all safety devices are overruled if the engine is started
by using the emergency start push button.
2.3 -- 8 23328
Manual
2.3.3. Operation
Normal operation and supervision includes all activities to assure a

smooth and trouble free operation of the complete installation against
the lowest costs as well as to guarantee the safety of operators working
at that plant.
Golden rule
Satisfactorily operation of a diesel engine depends mainly on the
quality of the systems supporting the engine.
To guarantee a trouble free and smooth plant operation one should take
the following remarks into account:
14 There is no automatic supervision or control arrangement that

replaces an experienced engineer observations.
It is not only a matter of FEEL, LOOK and LISTEN, but also a correct
interpretation of signals from monitoring devices.
Do not jumper safety devices in case of malfunction but make the safety
equipment reliable. In case the malfunction can not locally be solved
contact Wärtsilä Nederland B.V., service department.
15 Keep the engine installation in operation in a way it is designed.
16 The operator has to know what normally can be expected of a plant
in operation and ought to have admission to all relevant technical data
being part of the installation such as:
--- testbed --- and commissioning protocols
--- manual, parts catalogue and sub---suppliers manuals
--- engine log book for each engine etc.
17 The operator must be convinced that the instrument readings are
correct.
The indicated process values must be according to operating data.
18 The operator should, by consequent keeping the engine and/or
installation logs, be in time aware of all changes in engine and
installation processes and be able to take necessary corrective actions.
23328 2.3 -- 9
Manual
Wärtsilä 38
Operation
19 Operators involved should have more than marginal

knowledge of on ---going processes in engine and installation.
--- The basic acknowledge to be gained by intensive basic studies, by
long term practical experiences on comparable installations and
studies of relevant manuals available.
20 Safety of operators should, during their stay at the installation, be
guarantied in an optimum way.
--- Only under safe working conditions of operators a safe running
situation of the installation can be realised. Unsafe locations in
general will be avoided.
--- Safety of operators includes also the use of adequate clothes and
shoes complemented with helmed, glasses, gloves and ear protectors.
--- Furthermore, safety of operators depends largely on observing of the
rules.
21 Sufficient means and ”tools” have to be available for optimum
working conditions of the operator and for uninterrupted operation of
engine and installation.
22 Run engine and installation in a safe way.
This can be realised when one keeps the following in mind:
--- The installation is assembled and in operation according to
manufactures prescriptions.
--- Specified genuine parts have been used.
--- The operator is well informed about the systems and their safeties.
--- Reliable working of all safety systems are approved periodically.
23 Loading :
The way of increasing the output of the engine depends largely on the
engine preheating time and load level. See also section 2.3.3.2.
24 Do not exceed the restrictions for low load and ildling.
See section 2.3.3.1.2.
Note! Unnecessary idling should be avoided as much as possible.
25 Check condensate drain points in charge air cooler and charge air
ducting are open and free of condensate.
26 Never try to adjust exhaust gas temperatures all to the same level
by readjusting rack positions of HP fuel pumps.
Note! The maximum deviation between fuel rack positions is ¦ 0.5 mm.
2.3 -- 10 23328
Manual
2.3.3.1. Restrictions
2.3.3.1.1. Restrictions for operation at excessive

suction air temperature
To load an engine in case of excessive ambient conditions consider that

derating of the engine may be required, see section 1.0.3.
For suction air temperature < ---5 oC heating of the suction air and / or
special requirements may be required.
2.3.3.1.2. Restrictions for low load and idling
During idling and low load operation, and depending on the fuel quality
and combustion, more soot and sludge will be formed than during
higher loads. These combustion products will contaminate the internals
of the engine. As a result lubricating oil filters and separator will be
higher loaded during such periods. As well as sticking of piston rings
and valve stems may occur after a stop. Furthermore, combustion prod-
ucts, not sufficiently neutralised by the lubricating oil, may cause cor-
rosion. By reloading of the engine the concentration of all kind of com-
bustion products reduces. This is specially important if the engine is to
be stopped.
Restrictions for idling:
(declutched main engine, unloaded generator):
--- Maximum 15 minutes and recommended minimum 10 minutes if
the engine is to be stopped after idling.
--- Maximum 6 hours if the engine is to be loaded after idling.
Note! Unnecessary idling should be avoided as much as possible.
Restrictions for low load operation:

(operation 5...20% load):
--- Maximum 100 hours continuous operation.
--- At intervals of 100 operating hours and also before stopping the
engine must be loaded to minimum 70% load during 1 hour.
2.3.3.1.3. Restrictions for a planned stop

For a planned stop decrease the engine load with 20% every minute.
23328 2.3 -- 11
Manual
Wärtsilä 38
Operation
2.3.3.2. Loading performance
The load steps must be controlled to deliver sufficient air for a complete
combustion in the cylinders. Turbocharged engines should be loaded
successively due to the air deficit, which is apparent, until the
turbocharger has reached the required speed. The engine loading
should preferably be controlled by a load/speed increase program
included in the control system.
Note! Maximum loading speed should only be used when absolutely

necessary.
2.3.3.2.1. Gradual load increase
The limiting curves for loading of the engine at certain engine

conditions in [%] as a function of the time [s] are shown in fig. 2.3 --- 2 .
Load the engine as gradually as possible.
Note! Fast loading creates larger thermal load strain and reduces life time
of the engine components considerably.
Load increase [%]

100
Preheating
temperature
75
Operating
50 temperature
25
Emergency at
preheated
condition
0
0 30 60 90 120 150 180 210 240 270 300 330
Time [s]
Fig. 2.3 - 2 Gradual load increase
2.3 -- 12 23328
Manual
2.3.3.2.2. Sudden load increase
A limiting curve for load increase as a function of engine load in % are

shown in fig. 2.3 --- 3 . The maximum sudden power increase fulfils
requirements of ISO 8528---5.
Load increase [%]

40
30
20
Maximum sudden
power increase
10
0
0 20 40 60 80 100
Engine load [%]
Fig. 2.3 - 3 Maximum sudden power increase
23328 2.3 -- 13
Manual
Wärtsilä 38
Operation
2.3.3.3. Operating range
Controllable pitch propeller

As the propeller can be adapted to the actual conditions the propulsive
power can be controlled rather accurately. Depending upon the
operating conditions the engine may be selected such that the nominal
power including any power take---off, is in the range of 90 to 100% of
maximum continuous rating of the engine.
For operating range see fig. 2.3 --- 4
Load control of the controllable pitch propeller is recommended for all
installations. It is mandatory in installations where several engines are
connected to the same propeller.
Overload protection is provided by the electronic governing system.
700 MECHANICAL
Output [kW/cyl]
FUEL STOP MCR
600
RANGE FOR TEMPORARY
OPERATION ONLY
500
400
RANGE FOR
CONTINUOUS OPERATION
300
200 MIN.
LOAD LIMIT CURVE
SPEED
100
0
300 400 500 600
Speed [rpm]
Fig. 2.3 - 4 Operating range
2.3 -- 14 23328
Manual
2.3.3.4. Maintenance points during operation
The following points give some additional information about

maintenance points mentioned in the maintenance schedule.
Note! For the complete maintenance schedule see section 2.4.1.2.
1 Observe all temperature and pressure readings.

To keep a close check on engine in operation it is advised to keep a log
book. For an engine log sheet example see section 2.3.3.4.1. .
2 Temperature and pressure readings
Check daily the good working of temperature and pressure sensors.
Defective instruments should be replaced as soon as possible.
3 Check engine circulating water venting system is working.
4 Fluid levels
Checks should include the following:
--- lubricating oil level
--- level of fresh cooling water system(s)
--- level of daily service fuel tank.
5 Leaks
During operation check following for leaks:
--- fuel system
--- lubricating oil system
--- cooling water system
--- charge air system (condensate drain holes must be open) and exhaust gas
system
--- start, stop and pneumatic control system.
6 Draining
The daily fuel service tank must regularly be drained at the lowest points for
water and sludge. If water or sludge of any importance appears, check origin.
Air vessels and water separators in air lines should be regularly drained.
7 Keep the HP fuel pump racks clean (free from sticky components),
check rack linkage connections on movability and excessive clearances.
8 Circulate the lubricating oil on a stopped engine once a week. This
reduces the risk of CORROSION of engine parts.
9 Check cylinder firing pressures. At the same time record engine
load, fuel rack position, turbine speed, charge air pressure and inlet air
temperature. All offer information about the engine performance.
10 Record lube oil analysis and lube oil service time.
11 Record the cleaning intervals of engine mounted centrifugal
lubricating oil filters.
12 Record the cleaning intervals of lubricating oil filter candles.
23328 2.3 -- 15
Manual
Wärtsilä 38
Operation
2.3.3.4.1. Engine log sheet (example)
To keep a close check on engine in operation it is advised to keep a log

book for temperatures, pressures and other observations. This provides
a good overview of the normal values. Deviations can be detected early.
YEAR .. WEEK .. day ... ... ... ... ... ... ...
Time ... ... ... ... ... ... ...
Engine speed rpm ... ... ... ... ... ... ...
Turbocharger speed rpm ... ... ... ... ... ... ...
Fuel rack position mm ... ... ... ... ... ... ...
Load kW ... ... ... ... ... ... ...
Load indication governor ... ... ... ... ... ... ...
HT cooling bar ... ... ... ... ... ... ...
LT cooling bar ... ... ... ... ... ... ...
Lubricating oil bar ... ... ... ... ... ... ...
Fuel bar ... ... ... ... ... ... ...
Charge air receiver bar ... ... ... ... ... ... ...
Exhaust gases after turboch. m.bar ... ... ... ... ... ... ...
Barometer m.bar ... ... ... ... ... ... ...
Crankcase pressure m.bar ... ... ... ... ... ... ...
Ambient air oC ... ... ... ... ... ... ...
Air after turbocharger oC ... ... ... ... ... ... ...
Air in receiver oC ... ... ... ... ... ... ...
Water before air coolers oC ... ... ... ... ... ... ...
Water before oil coolers oC ... ... ... ... ... ... ...
Lubricating oil before coolers oC ... ... ... ... ... ... ...
Lubricating oil after coolers oC ... ... ... ... ... ... ...
Lubricating oil before engine oC ... ... ... ... ... ... ...
HT water before the engine oC ... ... ... ... ... ... ...
HT water after the engine oC ... ... ... ... ... ... ...
HT water after the HT cooler oC ... ... ... ... ... ... ...
Fuel before the engine oC ... ... ... ... ... ... ...
Fuel after the engine oC ... ... ... ... ... ... ...
Exhaust gases cyl.1, A1 / B1 oC ./. ./. ./. ./. ./. ./. ./.
” cyl.2, A2 / B2 oC ./. ./. ./. ./. ./. ./. ./.
” cyl.3, A3 / B3 oC ./. ./. ./. ./. ./. ./. ./.
” cyl.4, A4 / B4 oC ./. ./. ./. ./. ./. ./. ./.
” cyl.5, A5 / B5 oC ./. ./. ./. ./. ./. ./. ./.
” cyl.6, A6 / B6 oC ./. ./. ./. ./. ./. ./. ./.
” cyl.7, A7 / B7 oC ./. ./. ./. ./. ./. ./. ./.
” cyl.8, A8 / B8 oC ./. ./. ./. ./. ./. ./. ./.
” cyl.9, A9 / B9 oC ./. ./. ./. ./. ./. ./. ./.
Exhaust gases before turboch. oC ... ... ... ... ... ... ...
Exhaust gases after turboch. oC ... ... ... ... ... ... ...
2.3 -- 16 23328
Manual
2.3.3.5. Measurement of cylinder pressure
General
The maximum cylinder pressure is measured with a peak pressure
meter connected to the indicator cock on top of the cylinder head.
The obtained pressure can only be used for comparison with pressures
of other cylinders of the engine.
Depending on type of fuel, engine load and rpm, the pressure measured
at the indicator cock differs from the maximum pressure in the cylinder
and can be 5---15 bar higher.
Note! Cylinder pressure measurement at the indicator cock is useful for

individually comparison, however, the value measured is not
representative for the real pressure in the combustion space.
More sophisticated instruments can present the cylinder pressure /

crank angle diagram showing the start of combustion and angle of
maximum pressure. However, the mean indicated pressure and heat
release, as calculated with these data, does in no way represent the
engine performance as measured at the indicator cock.
The obtained data should not be used for this purpose as:
--- The cylinder pressure indicator is placed at the end of a small bore
on top of the cylinder head. In this bore the pressure is developing
steeper giving pressure fluctuations and higher maximum values
than in the cylinder space.
--- Due to length of the indicator channel the pressure pulse is delayed
giving a wrong time monitoring.
Note! It is not permitted to switch off fuel injection of a cylinder to

measure compression pressure.
Checking cylinder firing pressure

Check cylinder firing pressures. At the same time record engine load,
fuel rack position, turbine speed, charge air pressure and inlet air
temperature. All offer information about the engine performance.
Note! Recording cylinder combustion pressures without
simultaneously recording engine load is practically worthless.
23328 2.3 -- 17
Manual
Wärtsilä 38
Operation
2.3.3.6. Running--in
The running---in procedure is mainly intended for piston rings and

liners.
For a good running---in it is important to change the load. Ring grooves
in the piston have different tilting angles at each load and consequently
piston rings have different contact lines to the cylinder liner walls.
Running---in may be performed either on distillate or heavy fuel, using
the lubricating oil specified for the fuel. (Keep BN value in mind).
1 Carry out the start after overhaul procedure (except the operating
check), see section 2.3.2.6..
2 Start the running---in procedure.
a = gradual load increase 30 minutes.
b = constant load period 30 minutes.
c = recovery period 5 minutes.
1..7= load steps to be followed after changing piston rings, pistons or
cylinder liners.
1A ..3A = load steps to be followed after piston overhaul.
Engine load %
100 7
6
a b c
80 3A 5
4
2A 3
60
40 1A 2
20 1
0
0 1 2 3 4 5 6 7 8Operating hours
Fig. 2.3 -- 5 Running-- in diagram (n = constant 600 rpm)
3 Record data on engine log sheet at the end of each load step. Use the
test report as reference.
Never try to adjust the cylinder exhaust gas temperatures by
readjusting fuel rack position.
4 After completion the engine is ready for operation.
2.3 -- 18 23328
Manual
2.3.3.7. Operating problems
For preventive action, see chapter 2.4. Some possible operating

problems require prompt action. Operators should acquire knowledge
of this chapter for immediate action.
2.3.3.7.1. Trouble and possible reason
Action
1. Crankshaft does not rotate in
a start attempt on air
a) Turning gear is engaged.
b) Starting air pressure too low.
c) Starting air valve kept closed by safety system. Locate the p
problem.
d) Engine in overspeed stop position.
e) Main starting air valve jams.
f) Incorrect adjustment of the pilot starting air system.
2. Crankshaft rotates however
the engine does not fire
a) Too low speed. See 1b.
b) Stop solenoid in actuator is activated. Locate the problem.
c) Load limiter is set incorrect.
d) Fuel limiter is set incorrect.
e) Fuel pump rack blocked.
f) In case of starting on HFO, too low
engine and/or fuel temperature.
g) Too low compression pressure.
h) Combustion air temperature too low.
j) Vapour in high pressure fuel lines. P too low and/or T too high.
k) Vapour in fuel booster line.
23328 2.3 -- 19
Manual
Wärtsilä 38
Operation
Action
3. Engine fires irregularly
a) See points 2e, 2f, 2g, 2h 2j, 4d.
b) Fuel pump rack is set incorrectly or jams.
jams Readjust fuel rack.
rack
c) HP pump operates improper.
d)) Bad workingg fuel injector.
j Nozzle holes clogged.
gg
e) Piston rings do not seal properly.
f) Fuel booster pressure too lowlow. Check compression pressure.
pressure
g) Valves in supply/return manifold to HP
fuel pump closed.
4. Engine speed not stable
a) Actuator incorrectly adjusted.
b) See point 3b.
3b
b) Control mechanism jams.
c) Too much clearances in control mechanism.
d)) Water in ffuel.
e) Automatic load control mechanism faulty.
faulty
f) Actuator drive worn.
5. Knock or detonation
a) Big end bearing clearance excessive.
b) Valve
V l springs
i or cam follower
f ll spring
i broken.
b k
c) Excessive valve clearance.
clearance Find cause of excessive wear.
wear
Readjust valve clearance.
d) Valve(s) jams.
e) HP fuel pump bolts not fixed.
f) One or more cylinders too much fuel.
fuel See 3b,
3b 3c.
3c
h) Piston seizure.
j) Ignition delay. Locate the problem.
2.3 -- 20 23328
Manual
Action
6. Exhaust gases dark coloured
a) Engine overloaded. Check HP fuel pump rack
positions, exhaust gas tem-
peratures and charged air
pressure/temperature.
b) Delayed injection, wrong cam setting, Check timing.
opening suction hole wrong adjusted.
c) See points 3b, 3c.
d) Insufficient charge air pressure due to:
-- clogged air filter of turbocharger
-- dirty compressor section
-- clogged nozzle ring
-- turbine speed too low
-- too much clearance between rotor
and shroud ring.
e) Deteriorated injectors.
f) Too fast engine loading e.g. during start up.
7. Exhaust gases blue or grey coloured
a) Excessive lubricating oil consumption Endoscopic inspection of the
due to gas blow--by of piston rings, or cylinder liner.
broken sticking piston rings or too
much wear of rings / liners.
liners
b) Grey--whitish gases due to water
leakage in the combustion chamber.
Note:
Blue-- whitish smoke appears when running at low
load or at low ambient temperature shortly after
starting.
8. Exhaust gas temperatures of one or more cylin-
ders too high
a) Engine overloaded. See engine log sheet, test bed
protocol.
b) See points 3c and 4g.
c) Charge air temperature too high. Inspection air cooling system.
d) Exhaust valve leaking. Inspection/overhaul exhaust
valve.
e) Turbocharger contaminated.
f) Malfunctioning of exhaust gas
temperature measuring equipment.
g) See point 3d.
23328 2.3 -- 21
Manual
Wärtsilä 38
Operation
Action
9. Exhaust gas temperature of one cylinder below
normal
a) Malfunctioning of exhaust gas
temperature measuring equipment.
b) Leaking of fuel injector or HP fuel pipe.
c) Malfunctioning of HP fuel pump plunger. Inspection/overhaul HP fuel
pump.
d) See points 3b, 3d.
10. Exhaust gas temperatures very unequal
a) Too low fuel booster feed pressure. Insufficient filling of HP fuel
pumps (see points 2j, 2k),
which may cause great load
differences between cylinders
although HP fuel pump rack
positions are equal.
Dangerous ! Causes high
thermal overload in individual
cylinders.
b) See points 2g, 3b and 6b when idling.
11. Lubricating oil pressure too low
a) Malfunctioning of pressure gauge / transmitter.
b) Lubricating oil level in oil tank too low.
low
c)) Filter contaminated. Renew filter elements.
d) Lubricating oil temperature too high. See 13.
e) Lubricating oil seriously diluted with fuel or water.
water
f) Malfunctioning of lubricating oil pressure control valve. Inspection/overhaul pressure
g) Lubricating oil suction pipe leakage. control valve.
h) Suction
S ti strainer
t i dirty
di t or blocked.
bl k d
j) Malfunctioning of lubricating oil pump.
k) Lubricating oil pipes inside engine damaged.
12. Lubricating oil pressure too high
a) See point 11f.
2.3 -- 22 23328
Manual
Action
13. Lubricating oil temperature:
too high
a) Wrong temperature indication. Check temperature reading.
b) Disturbance of cooling water system.
c) Too high LT water temperature.
d) Oil cooler contaminated.
e) Malfunction of thermostatic valve.
f) Insufficient heat transferred to coolant to
maintain temperature.
too low
g) See points 13a and 13e.
14. Cooling water:
temperature too high
a) Malfunctioning of pump.
b) Water cooler contaminated.
c) Malfunction of thermostatic valve.
d) Incorrect valve position in the system.
difference between inlet and
outlet temperature too high
e) See point 14a.
f) Water cooler clogged or contaminated.
g) Insufficient flow of cooling water through engine, air in
system, valves leaking.
15. Water in lubricating oil
a) Leaking oil cooler.
b) Leakage along cylinder liner O--rings.
c) Wrongly adjusted water seal of the oil separator. See separator instruction
book!
d) Defective cylinder liner or cylinder head.
16. Charge air receiver temperature too high
a) Insufficient performance of the charge air cooler(s). Vent the water side of the
charge air cooler and/or clean
b) HT and/or LT cooling water temperature too high.
23328 2.3 -- 23
Manual
Wärtsilä 38
Operation
Action
17. Water in charge air receiver
a) Charge air coolers leakage. Inspect cooler
b) Condensate (charge air temperature too low) Increase charge air
temperature
18. Engine looses speed at constant or increased
load
a) Engine overloaded. A further increase of fuel supply is
prevented by the mechanical load limiter.
b) See points 2c, 2e, 4e and 4f.
19. Engine stops
a) Shortage of fuel. See point 4d.
b) Overspeed trip device is activated.
c) Automatic stopping device is activated.
d) Malfunctioning of actuator. See actuator manual
e) Malfunctioning of actuator drive.
20. Engine does not stop although stop lever is set
in stop position or remote stop signal is given
a) HP fuel pump control rack wrongly set (3b, 3c). Activate overspeed trip device
manually. If the engine does
not stop immediately, close the
fuel supply to the engine.
Before starting the engine, the
fault must be located and
corrected.
Great risk of overspeed.
b) Malfunction remote engine stop. Use stop lever on the engine.
c) The engine is driven by generator,
propeller or other source.
21. Engine continuous running with activated over-
speed trip device
a) HP fuel pump control rack wrongly set (3b, 3c). Load the engine, if possible.
Close fuel supply to engine.
Make proper adjustment fuel
racks.
2.3 -- 24 23328
Manual
2.3.3.8. Emergency operation
2.3.3.8.1. Operation with defective air cooler(s)
Defective cooling tubes of an air cooler permit cooling water entering

the cylinders. Water in the charge air receiver can be indicated by the
telltale hole. If water or water mist escapes the telltale hole, check
whether it is cooling water or condensate. If it is condensate, increase
the charge air temperature a few degrees (see section 1.0.4.). If it is
cooling water, stop the engine as soon as possible and plug off the
leaking tube. If cooler leakage cannot be remedied by tube plugging
exchange cooler for a spare. Leaking cooling water is indicated by the
water level in expansion tank.
2.3.3.8.2. Operation with defective turbocharger
A defective turbocharger should be treated in accordance with

instructions given in the turbocharger instruction book.
Permissible engine output with blocked turbocharger is approx. 20%
load. Engine output must, however, be limited not to exceed the normal
full load exhaust temperatures. Maximum permissible exhaust gas
temperature after the cylinder at continuous operation with blocked
turbocharger is 500 C.
2.3.3.8.3. Operation with one cylinder misfiring
A torsional vibration analysis is made for each installation and all

possible modes of operation. This is done for as well normal conditions
as for so called misfire conditions.
With misfire conditions we mean: no combustion in one cylinder, only
compression and expansion. This can occur due to for instance a defect
HP fuel pump. In case there is also no compression and expansion,
Wärtsilä Nederland B.V. has to be consulted.
Eventual restrictions, from point of view of torsional vibration
behaviour, mentioned in a torsional vibration analysis report, have to
be obeyed! Otherwise, especially in emergency operation ---one cylinder
unit out of operation --- critical components as torsional vibration
damper, crankshaft, torsional elastic coupling, gearwheel, propeller
shaft etcetera, are subjected to not allowable torsional vibration loads.
Note! Engine operation, with one cylinder misfiring, is only allowed in

case restrictions, mentioned in a report concerning torsional
vibration behaviour of this particular installation, are observed!
23328 2.3 -- 25
Manual
Wärtsilä 38
Operation
2.3.4. Engine stop
The engine can always be stopped: remotely, locally or manually.

The local(/remote) stop involves the following devices:
--- Stop cylinders on fuel pumps.
--- Stop signal to actuator controller.
--- Stop solenoid in actuator (if applicable).
Note! Idle engine 5 – 10 minutes before a normal stop.
Local (emergency) stop

Push the (emergency) stop button (2) until the engine is completely
stopped. The engine stops hard wired via the relay module.
1
2
Fig. 2.3 -- 6 Local control unit, emergency stop button
Remote stop:
Push stop button in the control room, the engine stops electronically.
If applicable, the engine can be stopped by the emergency stop button.
2.3 -- 26 23328
Manual
Manual stop
Move stop lever (6) from operating position ’A’ into stop position ’B’.
Check if pin (8) locks the stop lever.
’A’
’B’ 8
Fig. 2.3 - 7 Manual stop
Actions after final stop of the engine

For safety reasons the following actions have to be done after final stop
of the engine:
1 Open the indicator cocks.
2 Close the shut off valve in the starting air system.
--o--o--o--o--o--
23328 2.3 -- 27
Manual
Wärtsilä 38
Operation
2.3 -- 28 23328
Manual
Maintenance Wärtsilä 38
2.4. Maintenance
Table of contents
2.4. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 - 1

2.4.1. Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 2
2.4.1.1. Safety aspects and rules for inspection and maintenance . . . 2.4 -- 2
2.4.1.2. Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 4
2.4.2. Maintenance Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 15
2.4.2.1. Miscellaneous tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 20
2.4.2.2. Charge air and exhaust gas system . . . . . . . . . . . . . . . . . . . . . 2.4 -- 28
2.4.2.3. Engine block, main bearing, cylinder liner . . . . . . . . . . . . . . . . 2.4 -- 29
2.4.2.6. Camshaft and valve drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 52
2.4.2.7. Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 59
2.4.3. Background information of hydraulic tools and torque spanners . . . . . . 2.4 -- 65
2.4.3.1. Pneumatic driven hydraulic pump unit . . . . . . . . . . . . . . . . . . . 2.4 -- 66
2.4.3.2. Hydraulic tool set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 70
2.4.3.3. Hydraulic extractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 72
2.4.3.4. Hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 73
2.4.3.5. Quick–release coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 74
2.4.3.6. Hydraulic hand pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 75
2.4.3.7. Safety instructions for hydraulic tools . . . . . . . . . . . . . . . . . . . . 2.4 -- 76
2.4.3.8. Loosening of hydraulically tightened connection . . . . . . . . . . . 2.4 -- 77
2.4.3.9. Tightening of hydraulically tightened connection . . . . . . . . . . . 2.4 -- 79
2.4.3.10. Torque spanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 80
2.4.4. Tightening torque and jack pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 83
2.4.4.1. Lubricating oil system components . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 83
2.4.4.2. Cooling water system components . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 84
2.4.4.3. Control system components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 85
2.4.4.4. Engine block with bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 86
2.4.4.7. Camshaft and drive mechanism . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 92
2.4.4.8. Injection system components . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 96
for not specified bolt connections . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 99
2.4.5. Adjustments and Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 101
2.4.5.1. Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 101
2.4.5.2. Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 102
2.4.6. Dimensions and masses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 -- 115
23328 2.4 -- 1
Manual
Wärtsilä 38
Maintenance
2.4.1. Maintenance Schedule
This section describes when and which inspection and maintenance

actions have to be carried out. In case you need more information, please
contact the Service department of Wärtsilä Nederland B.V.
The maintenance necessary for the engine depends primarily on the
operating conditions. The periods stated in this schedule are guidance
values only and must not be exceeded during the guarantee period. See
also the sub---suppliers manuals for additional information.
2.4.1.1. Safety aspects and rules for inspection

and maintenance
General
1 When the engine is in overhaul, make sure the remote or automatic
start device and external pumps are out of operation and provided with
prohibiting tags. Switch of the electric power to the engine.
2 Provide engine parts of marks for remounting in the same position.
Marks on engine parts should be copied on new parts to be installed at
the same location. Every exchange should be recorded in the engine
logbook mentioning the reason.
3 Use the MANUAL during maintenance work together with the
PARTS CATALOGUE.
4 During all maintenance work, observe the utmost cleanliness and order.
5 Be aware of the risk of crankcase or camshaft case explosion!
Before performing any maintenance or inspection jobs on the engine,
always allow the engine to cool down sufficiently. A 10 minute cooling
period will do after a normal stop.
6 Observe the fire precautions when maintenance jobs or cleaning on
the engine will be done.
7 Always replace locking washers, copper rings, split pins, locking
wires, self locking nuts and ”O” rings during assembling. In case copper
rings have to be used a second time, please take care of proper annealing.
8 In general never leave ”O”---rings mounted on spares. Store
”O”---rings in a dry, cool and dark place.
9 Never carry out electric welding to the engine nor use the engine as
conductor for welding.
In addition the following precaution must be taken before welding in
the vinicity of a LCS control system; Deactivate the system by
disconnecting all external connectors and all the connectors of the unit.
If necessary protect harness, cables, sensors and other equipment from
sparkles with a proper metal sheet.
2.4 -- 2 23328
Manual
Removal
1 Before using the hydraulic tools read section 2.4.3. carefully.
2 Before dismantling, check all pipe systems concerned are drained
and pressure released. After dismantling, cover immediately all holes
for lubricating oil, fuel oil and air with tape, plugs, clean cloth or similar.
Engage the turning gear. Open the indicator cocks.
3 If heavy parts are removed from the engine, e.g. a piston and
connecting rod, the crankshaft may start turning due unbalance. For
safety reasons always keep the turning gear engaged throughout the jobs.
4 In many cases it is advisable to record clearances before disassembling.
Mounting
1 Make sure all parts are carefully clean (free of carbon deposit)
before mounting. Do not use cotton waste for inside cleaning of engine
but use lint free cleaning rags.
2 Before using the hydraulic tools read section 2.4.3. carefully.
3 For advised glues, lubricants, sealants, see the parts catalogue.
Never use other lubricants for bolt connections of engine components
than those advised. Tightening torques will strongly differ if lubricants
of different brand or type are used.
4 Before fitting spare parts, available as complete sub---assemblies,
all ”O” rings integrated must be inspected on ageing and damage, and
replaced if necessary.
5 In general, all piping should be carefully cleaned before installing.
Fuel, lubricating oil and air lines should be acid cleaned and
neutralized. Also after heating of pipe sections iron oxidation has to be
removed by pickling (acid cleaning).
6 Fit all piping stress free.
Last check
1 It is important no tools, parts or other foreign matters have been
left in or on the engine and all parts have been thoroughly cleaned
before closing the engine.
2 Due to the compression ability of some gasket material the
prestress of some flange connections should be checked after 24 hours
of operation.
3 Record engine parts renewed.
4 Record engine running hours.
23328 2.4 -- 3
Manual
Wärtsilä 38
Maintenance
2.4.1.2. Maintenance schedule
The total running hours between overhauls as well as the effective life
time of components depend generally on the following aspects:
--- The operation and maintenance of the engine should be in
accordance with instructions as specified in the engine
documentation.
--- The intervals stated in the maintenance schedule are guidance
values only, but must not be exceeded during the guarantee period.
--- Everyone concerned with the maintenance of the engine should be
trained and qualified for the job and should have the engine
documentation available.
--- To ensure the efficiency, reliability and lifetime of the engine and its
components, only genuine spare parts should be used.
--- The load of the engine should be between 60% and 100% of the
output, indicated on the engine type plate, making 3,000 to 6,000
running hours annually.
--- The build on sub---suppliers components should be maintained
according the sub---suppliers manufacturers instructions.
--- Quality and treatment of lubricating oil, fuel, cooling water and air
should be on accordance with the rules.
Deviation from the above factors may result in adapting the running
hours between overhauls and/or effective life time of the components.
2.4.1.2.1. Procedure for inspection and maintenance
Inspection
--- If, for example, two valve rotators have to be replaced inspect also
two rotators of an other cylinder unit. If the result of this second
inspection is also negative replace all valve rotators.
--- The results of the first 4,000 hours inspection are mend to establish
the further service intervals.
2.4 -- 4 23328
Manual
General maintenance points

Every
S
W P
D E E 1 2 3
A E C 1 2 4 2 4 6
I K I 5 0 0 0 0 0 0
L L A 0 0 0 0 0 0 0
Description Y Y L 0 0 0 0 0 0 0
Check the engine on leakages, bolt D D D D D D D D D

connections, cables and wiring.
Check the telltale hole of the charge air receiver D D D D D D D D D
on possible water.
Record performance data in the engine log D D D D D D D D D
sheet.
Check fluid levels of: D D D D D D D D D
-- Turbocharger oil
-- Engine lube oil
-- Cooling water systems
-- actuator.
Record combustion pressures. D D D D D D D
Engine arrangement
Check foundation bolts and chocks / girders. D
For stationary, the first year every 2 months.
Check foundation bolts and chocks / girders. D D D D
Inspect elastic engine mounting elements (if D D D D
applicable).
Check
Ch k reference
f points
i off epoxy resin
i chocks
h k (if D D D D
applicable).
Inspect elastic elements of flexible coupling D D D D
according manufacturers instruction.
Measure axial displacement and crankshaft D D D D
deflections of crankshaft.
Check alignment between engine and engine D D D D
driven machinery.
23328 2.4 -- 5
Manual
Wärtsilä 38
Maintenance
Fuel System (Chapter 1.1.)

Every
S
W P
D E E 1 2 3
A E C 1 2 4 2 4 6
I K I 5 0 0 0 0 0 0
L L A 0 0 0 0 0 0 0
Check the leak fuel quantity of the fuel system. D D D D D D D D D

Drain impurities and condensate of fuel day D D D D D D D D D
tank.
Renew O--rings of fuel supply and return lines. D D D
Inspect one fuel pump bracket. D
Inspect all fuel pump brackets. D D D
Lubricating oil system (Chapter 1.2.)
Remove commissioning lube oil filters after the D
first 100 running hours.
Clean centrifugal filter. D D D D D D D D
Inspect / overhaul the thermostatic valve. D D D
Sample / analyze lubricating oil; D D D D D D
record analyze results, lubricating oil service
time consumption and charge changes.
Maintain the lube oil filter elements according to D D D D D D
manufacturers instructions.
Inspect / overhaul lubricating oil pump(s). D D D
2.4 -- 6 23328
Manual
Starting air system (Chapter 1.3.)

Every
S
W P
D E E 1 2 3
A E C 1 2 4 2 4 6
I K I 5 0 0 0 0 0 0
L L A 0 0 0 0 0 0 0
Drain starting air vessels and air treatment D D D D D D D D D

unit(s). Check the entire system on leakages,
oxidation and water.
Inspect / overhaul the starting air valves. D D D
Inspect / overhaul the main starting air valve. D
Inspect the starting air distributor and drive. D D
Cooling water system (Chapter 1.4.)
Check cooling water quality. D D D D D
Clean the cooling water system and check on D D D
corrosion.
Check working of cooling water venting system. D D D D D D D D
Inspect / overhaul the thermostatic valve. D D D
Inspect / overhaul HT and LT cooling water D D D
pumps and renew seals and bearings.
Driving gear pump
Inspect driving gear of the built--on pumps. D D D D
23328 2.4 -- 7
Manual
Wärtsilä 38
Maintenance
Charge air and exhaust gas system (Chapter 1.5.)

Every
S
W P
D E E 1 2 3
A E C 1 2 4 2 4 6
I K I 5 0 0 0 0 0 0
L L A 0 0 0 0 0 0 0
Clean turbine every 24 ... 150 operating hours. D

Clean turbine by water injection.
Clean compressor by water injection. D D D D D
Inspect / clean the entire turbocharger after the D
first 4,000 running hours.
Refresh lubricating oil in turbocharger. D D D D D D
Inspect and clean the compressor and turbine D
mechanically depending on turbocharger
performance.
Overhaul turbocharger(s) and renew bearings D
after 8,000 running hours.
Renew compressor wheel after 50,000 running D
hours.
Inspect / clean air filter. D D D D D
Renew filter material if applicable. D D D
Make endoscopic inspection of the air side of D D D D
Check / clean the water and air side of the D D
charge air cooler.
cooler
Overhaul the charge air cooler. D D
Inspect / repair the exhaust gas lines, D D D
compensators, insulation etc.
2.4 -- 8 23328
Manual
Control system (Chapter 1.6.)

Every
S
W P
D E E 1 2 3
A E C 1 2 4 2 4 6
I K I 5 0 0 0 0 0 0
L L A 0 0 0 0 0 0 0
Check and lubricate the control mechanism. D D D D D D D

Inspect / overhaul the control mechanism. D
Refresh oil in actuator. D
Inspect / overhaul the actuator. D D D
Inspect the actuator drive. D
Overhaul the actuator drive. D D D
Check functioning of load limiter / fuel rack D D D D D D D D D
position.
Check the alarm and safety system in operation D D D D D D D D D
and after every start.
Check and calibrate the alarm and safety D D D D D D D
system.
Check the measuring devices on proper D D D D D D D D D
working.
Calibrate the measuring devices. D D D D
Check functioning of the oil mist detector. D D D D D D D D D
23328 2.4 -- 9
Manual
Wärtsilä 38
Maintenance
Operation (Chapter 2.3.)

Every
S
W P
D E E 1 2 3
A E C 1 2 4 2 4 6
I K I 5 0 0 0 0 0 0
L L A 0 0 0 0 0 0 0
Test start process in stand--by position. D D D D

Carry out a start after overhaul. D D D D
Carry out a running--in program and record D D D
readings.
Check operation of turning and start interlock D D D D
device.
Refresh lube oil of turning device. D
Engine block with bearings and cylinder liner (Chapter 2.5.)
Make endoscopic inspection of cylinder liners. D
Inspect one cylinder liner after the first 4,000 D
running hours.
Make endoscopic
p inspection
p of cylinder
y liners. D
Overhaul of cylinder liners including honing and D D D
renew anti--polishing ring.
Inspect the crankcase visually. D D D D
Inspect the cooling water spaces. D D
Inspect one main bearing and one main journal. D D
Renew main bearings and inspect the main D
journals.
Sample fluid of vibration damper(s). D D D
Inspect one camshaft bearing and journal. D D D
Renew camshaft bearings after 48
48,000
000 running D
hours.
2.4 -- 10 23328
Manual
Crankshaft, connecting rod, piston (Chapter 2.6.)

Every
S
W P
D E E 1 2 3
A E C 1 2 4 2 4 6
I K I 5 0 0 0 0 0 0
L L A 0 0 0 0 0 0 0
Inspect one gudgeon pin and bearing after the D

first 4000 running hours.
Inspect
p one g
gudgeon
g p
pin and bearing.
g D D D
Renew gudgeon
g g pins
p and bearings
g after 48,000
, D
running hours.
Inspect one connecting rod after the first 4,000 D
running hours.
Inspect one connecting rod. D D
Inspect / overhaul connecting rods. D
Inspect one crankpin journal and crankpin D D
bearing.
Inspect crankpin journals. D
Renew crankpin bearings. D
Inspect one piston with piston rings, without D
dismantling of piston rings after the first 4,000
running hours.
Inspect / overhaul pistons and renew piston D D D
rings.
23328 2.4 -- 11
Manual
Wärtsilä 38
Maintenance
Cylinder head with valves (Chapter 2.7.)

Every
S
W P
D E E 1 2 3
A E C 1 2 4 2 4 6
I K I 5 0 0 0 0 0 0
L L A 0 0 0 0 0 0 0
Check valve clearances after the first 100 D

operating hours in new and overhauled engines.
Inspect
p one cylinder
y head after the first 4,000
, D
running hours.
Overhaul cylinder heads. D D D
Inspect safety valves. D D D
Check valve clearances. D D D D D D
Check function of valve rotators. D D
Make endoscopic inspection of valves and valve D
seats
seats.
Inspect / overhaul valves. D D D
Renew exhaust valves. D
Renew inlet valves. D
Camshaft and valve drive mechanism (Chapter 2.8.)
Inspect one fuel pump bracket and roller. D
Inspect / overhaul all fuel pump brackets and
rollers. D D D
Inspect one inlet and exhaust tappet guide D
block and tappet.
Inspect / overhaul all inlet and exhaust tappet D D D
guide blocks and tappets.
Check pushrod pivots. D D D
Check bearing clearances of rocker arms. D D
Inspect / overhaul rocker arms and bracket. D
Inspect camshaft sections. D D D D
Inspect camshaft driving gear. D D D D
2.4 -- 12 23328
Manual
Injection system (Chapter 2.9.)

Every
S
W P
D E E 1 2 3
A E C 1 2 4 2 4 6
I K I 5 0 0 0 0 0 0
L L A 0 0 0 0 0 0 0
Check the spill fuel quantity. D D D D D D D D D

Inspect / test fuel injectors. D D D D D
Renew fuel injector nozzles. D D D D
Renew inner parts of injector holder. D D D
Renew nozzle holder complete after 48,000 D
running hours.
Inspect one HP fuel pump, after the first 4,000 D
running hours.
Renew fuel pump elements and anti--cavitation D
plugs.
Inspect / overhaul HP fuel pumps. D D D
Renew O--rings in supply and discharge lines of D D D
HP fuel pumps.
Check the HP fuel pump adjustment. D D D
Inspect one HP fuel line. D D D
Renew all HP fuel lines. D
23328 2.4 -- 13
Manual
Wärtsilä 38
Maintenance
2.4 -- 14 23328
Manual
2.4.2. Maintenance Tools
Maintenance of a diesel engine requires a number of special tools

developed in the course of engine design. Some of these tools are
supplied with the engine and others are available through our service
stations or for direct purchase by the customer.
Tool requirements for a particular installation may vary greatly
depending on the use and service area. Special tools are therefore
selected to meet basic requirements.
This section shows a selection of tools for the engine.
These tools are not all described in the related sections.
The tools are grouped in order to facilitate selection for specific service
operations.
Miscellaneous tools, as mentioned in section 2.4.2.1., are used in various
chapters.
Tools for instance needed for cylinder head are grouped in section
2.4.2.5. The chapter mentioned between brackets refers to the chapter
where these tools are used.
Depending on the scope of supply the following tool sets are available:
1. Tool set for restricted area ”Economic Set”

2. Tool set for unrestricted area ”Standard Set”
3. Extended tool set for restricted area ”Workshop Set”
4. Supplement extended tool set ”Extended Workshop Set”
5. Special tools ”Special Tool Set”
23328 2.4 -- 15
Manual
Wärtsilä 38
Maintenance
1. ”Economic Set” Article number 9622DT991
Article number Description Number
9612DT259 Socket for nozzle tip 1

9622DT902 Cleaning tool injector sleeve 1
9622DT925 Clamp nozzle holder 1
9612SW510 T---wrench indicator cock 1
9612DT212 Pneumatic driven hydraulic pump 1
9622DT918 Lifting/extracting device nozzle holder 1
9622DT917 Compress tool valve springs 1
9612DT246 Crow foot wrench 41 mm 1
9612DT947 Lifting tool fuel pump 1
9612DT100 Tool pin 3
9622DT133 Hydraulic hand pump + hose 1
9622DT911 Tool set cylinder head 1
(9622DT910) Hydraulic jack set (included in 9622DT911) 4
9612DT909 Lifting tool cylinder head 1
9622DT916 Testing device injector 1
9622DT250 Socket 36 mm 1
9612DT570 Torque spanner 260---800 Nm 1
9622DT164 Protecting ring cylinder head 1
9612DT961 Hydraulic hose set 1
9622DT162 Valve clearance feeler gauge 1
9612DT965 Lever fuel cam roll 1
9612DT216 Adaptor 3/4”---1” 1
9622DT214 Torque wrench 22---140 Nm 1
9612DT922 Lifting tool rocker arm bracket 1
9622DT147 Hydraulic jack 12 ton 1
9622DT146 Hydraulic hose set + distribution block 1
9612DT236 Socket driver 1
9622DT171 Tappet securing plate 1
9622DT179 Grease pump 1
9612DT760 Locking pin fuel pump tappet 1
2.4 -- 16 23328
Manual
2. ”Standard Set” Articlenumber 9622DT992

consists of:
”Economic Set” 9622DT991 extended with the following tools
Articlenumber Description Number
9622DT149 Tool set for main bearing studs 2

9622DT150 Spare seal set 1
9622DT148 Hydraulic jack 20 ton 1
9622DT224 Spare seal set 1
9612DT250 Piston ring pliers 1
9622DT152 Main bearing shell driver 1
9622DT919 Dis/assembling tool anti bore polishing ring 1
9612DT926 Positioning tool for cylinder liner 1
9622DT923 Lifting tool piston 1
9622DT922 Protecting plate connecting rod foot 1
9622DT924 Guide ring piston rings 1
9622DT168 Piston support in liner 2
9622DT170 Big end bearing lock 1
9612DT907 Hydraulic twin jack for connecting rod 2
9622DT915 Extracting tool cylinder liner 1
9622DT901 Trolley for main bearing 1
9622DT163 Tap M16 for piston crown 1
9612ZT334 Air tool 3/8” 1
9622DT913 Tool set for side studs 2
9622DT914 Lifting tool for cylinder liner 1
9622DT178 Circlip pliers for piston 1
9622DT928 Fixating tool connecting rod 1
9612DT901 Hand pump set for main bearing cap 1
9622DT921 Frame+support connecting rod caps 1
23328 2.4 -- 17
Manual
Wärtsilä 38
Maintenance
3. ”Workshop Set” Article number 9622DT994

consists of:
”Standard Set” 9622DT992
(without 9622DT921 Dis/assembling tool connecting rod cap)
extended with the following tools
9612DT234 Jack bolt camshaft thrust journal 1

9612DT257 Pin camshaft bearing bush 1
9622DT929 Measuring strip cylinder liner 1
9622DT912 Tool set for counter weight studs 1
9612DT911 Suction cup for valves 1
9622DT930 Extractor valve guide 1
9612DT801 Pillar bolt camshaft sections/gearwheel assembly 1
9612DT963 Fixating tool camshaft 1
9622DT931 Hydraulic nipple for gearwheel 1
9612DT969 Remover connecting rod studs M36x3 1
9612DT976 Remover cylinder head studs M64x4 1
9612DT977 Remover main bearing cap studs M72x4 1
9612DT916 Tilting frame cylinder head 1
9622DT907 Tool for mounting valve seats 1
9622DT908 Extractor camshaft bearing bush 1
9612DT401 Micrometer gauge cylinder liner 1
9612DT807 Valve seat cutter tool set 1
9622DT934 Extractor exhaust valve seat 1
9612DT479 Lapping ring contact face cyl.liner---cyl. block 1
9612DT484 Lapping ring contact face cyl.head ---cyl. liner 1
9612DT936 Tool for intermediate gearwheel shaft 1
9612DT948 Disassembling tool fuel pump 1
9612DT504 Compress tool fuel pump bracket spring 1
9622DT938 Extractor injector sleeve 1
9612DT968 Hydraulic nipple camshaft end journal 1
2.4 -- 18 23328
Manual
4. ”Extended Workshop Set” Article number 9622DT995

(Supplement on ”Workshop Set” Article number 9622DT994)
9622DT927 Dis ---assembly tool camshaft section 1

9612DT988 Dis/assembly tool camshaft journal 1
9612DT985 Dis/assembly tool camshaft gearwheel 1
9612DT986 Dis/assembly tool intermediate gearwheel 1
9622DT921 Frame+support connecting rod caps 1
9622DT905 Dummy counter weight 1
9622DT937 Dis/assembly tool for charge air cooler 1
5. ”Special Tool Set” Article number 9622DT997
9622DT906 Honing machine 1

9622DT935 Valve seat reconditioning tool 1
9701DT507 Peak pressure gauge 1
7508 039 Crankshaft deflection gauge 1
9622DT936 Mobile tool kit 1
6749 900 Pneumatic calibration tool fuel pump timing 1
9612DT215 Depth gauge 1
9622DT939 Water pressure testing tool cylinder head 1
23328 2.4 -- 19
Manual
Wärtsilä 38
Maintenance
2.4.2.1. Miscellaneous tools
Description Code Weight Dimensions

number kg
Pneumatic driven 9612DT212
hydraulic pump

number kg
Hydraulic hand pump + 9622DT133
hose
2.4 -- 20 23328
Manual

number kg
Hydraulic hose set 9612DT961

number kg
Hydraulic hose set + 9622DT146
distribution block
23328 2.4 -- 21
Manual
Wärtsilä 38
Maintenance

number kg
Tool pin 9612DT100

number kg
Air tool 3/8” 9612ZT334
2.4 -- 22 23328
Manual

number kg
Crow foot wrench 41 mm 9612DT246

number kg
Socket 36 mm 9622DT250
23328 2.4 -- 23
Manual
Wärtsilä 38
Maintenance

number kg
Torque spanner 9612DT570
(260--800 Nm)
consisting of:
1. torque spanner
2. extension
3. adaptor
4. ratchet

number kg
(50--340 Nm)
2.4 -- 24 23328
Manual

number kg
Torque wrench 9622DT214
(22--140 Nm)

number kg
(8--40 Nm)
23328 2.4 -- 25
Manual
Wärtsilä 38
Maintenance

number kg
Adaptor 3/4”--1” 9612DT216

number kg
Hydraulic jack set 9622DT910
consisting of:
1. hydraulic jack 9622DT232
2. nut 9622DT233
is used in the following
combinations:
-- Tool set for side studs 9622DT913
-- Tool set for
main bearing studs 9622DT149
-- Tool set for
counter weight studs 9622DT912
2.4 -- 26 23328
Manual

number kg
Socket driver 9612DT236

number kg
Grease pump 9622DT179
23328 2.4 -- 27
Manual
Wärtsilä 38
Maintenance
2.4.2.2. Charge air and exhaust gas system

(Chapter 1.5.)
Tools for turbocharger, see toolbox sub---supplier.

number kg
Dis/assembly tool for 9622DT937
charge air cooler.
2.4 -- 28 23328
Manual
2.4.2.3. Engine block, main bearing,

cylinder liner
(Chapter 2.5.)

number kg
Tool set for side studs 9622DT913
consisting of:
1 tie rod 9622DT126
2 distance piece 9622DT125
in combination with:
-- hydraulic jack set 9622DT910

number kg
Trolley for main bearing 9622DT901
23328 2.4 -- 29
Manual
Wärtsilä 38
Maintenance

number kg
Tool set for 9622DT149
main bearing studs
consisting of:
1 tie rod 9622DT237

number kg
Hand pump set for main 9612DT901
bearing cap
consisting of:
1 LP Hydraulic pump 9612DT150
2 Nipple (2x) 9612DT310
3 LP Hose (2x) 9612DT151
2.4 -- 30 23328
Manual

number kg
Main bearing shell driver 9622DT152

number kg
Extractor camshaft 9622DT908
bearing bush
--hydraulic jack 20 ton 9622DT148
23328 2.4 -- 31
Manual
Wärtsilä 38
Maintenance

number kg
Hydraulic jack 20 ton 9622DT148

combinations:
-- extractor camshaft 9622DT908
bearing sleeve bush
-- extractor exhaust valve 9622DT934
seat
-- extractor injector 9622DT938
sleeve
-- extracting tool cylinder 9622DT915
liner
-- Extractor valve guide 9622DT930

number kg
Pin camshaft bearing 9612DT257
bush
2.4 -- 32 23328
Manual

number kg
Dis/assembling tool anti 9622DT919
bore polishing ring

number kg
Lifting tool for cylinder 9622DT914
liner
--.Extracting tool 9622DT915
cylinder liner
23328 2.4 -- 33
Manual
Wärtsilä 38
Maintenance

number kg
Extracting tool cylinder 9622DT915
liner
-- lifting tool cylinder liner 9622DT914
-- hydraulic jack 20 ton 9622DT148

number kg
Positioning tool for cyl- 9612DT926
inder liner
2.4 -- 34 23328
Manual

number kg
Measuring strip cylinder 9622DT929
liner

number kg
Remover main bearing 9612DT977
cap studs M72x4
23328 2.4 -- 35
Manual
Wärtsilä 38
Maintenance

number kg
Lapping ring contact face 9612DT479
cylinder liner--cylinder
block
2.4 -- 36 23328
Manual
2.4.2.4. Crankshaft, connecting rod, piston

(Chapter 2.6.)

number kg
Hydraulic twin jack for 9612DT907
connecting rod
consisting of:
1 nut 9622DT231
2 hydraulic jack 9622DT234
3 tie rod 9622DT230
4 tool pin 9612ZT125

number kg
Lifting tool piston 9622DT923
23328 2.4 -- 37
Manual
Wärtsilä 38
Maintenance

number kg
Tap M16 for piston crown 9622DT163

number kg
Protecting plate 9622DT922
connecting rod foot
consisting of:
1 pen 9622DT165
2 protecting plate 9622DT166
2.4 -- 38 23328
Manual

number kg
Big end bearing lock 9622DT170

number kg
Circlip pliers for piston 9622DT178
23328 2.4 -- 39
Manual
Wärtsilä 38
Maintenance

number kg
Piston ring pliers 9612DT250

number kg
Guide ring piston rings 9622DT924
2.4 -- 40 23328
Manual

number kg
Frame+support con- 9622DT921
necting rod caps
consisting of:
1 support 9622DT161
2 frame 9622DT160
3 support 9622DT161
4 carrier 9622DT158
5 carrier 9622DT157

number kg
Tool set for 9622DT912
counter weight studs
consisting of:
1 tie rod 9622DT124
23328 2.4 -- 41
Manual
Wärtsilä 38
Maintenance

number kg
Remover connecting rod 9612DT969
studs M36x3

number kg
Piston support in liner 9622DT168
including:
1 bolt M16x30
2.4 -- 42 23328
Manual

number kg
Fixating tool connecting 9622DT928
rod

number kg
Dummy counter weight 9622DT905
23328 2.4 -- 43
Manual
Wärtsilä 38
Maintenance
2.4.2.5. Cylinder head with valves

(Chapter 2.7.)

number kg
Valve clearance feeler 9622DT162
gauge

number kg
T--wrench indicator cock 9612SW510
2.4 -- 44 23328
Manual

number kg
Tool set 9622DT911
cylinder head
consisting of:
1 shackle 9622DT122
2 tie rod 9622DT121
3 hydraulic jack set 9622DT910
6 frame 9622DT119

number kg
Lifting tool cylinder head 9612DT909
23328 2.4 -- 45
Manual
Wärtsilä 38
Maintenance

number kg
Protecting ring cylinder 9622DT164
head

number kg
Lifting tool rocker arm 9612DT922
bracket
2.4 -- 46 23328
Manual

number kg
Compress tool valve 9622DT917
springs
note:
only use the adaptor
rings (1) in case of four
identical valve rotaters

number kg
Extractor exhaust valve 9622DT934
seat
23328 2.4 -- 47
Manual
Wärtsilä 38
Maintenance

number kg
Hydraulic jack 12 ton 9622DT147
combinations:
-- compress tool valve 9622DT917
springs
-- lifting/extracting 9622DT918
device nozzle holder
-- extractor exhaust 9622DT934
valve seat

number kg
Suction cup for valves 9612DT911
2.4 -- 48 23328
Manual

number kg
Extractor valve guide 9622DT930
consisting of:
1. nut 9622DT113
2. tie rod 9622DT181
3. tube 9622DT180

number kg
Remover cylinder head 9612DT976
studs M64x4
consisting of:
1. stud remover 9612DT390
2. bolt 9612DT389
23328 2.4 -- 49
Manual
Wärtsilä 38
Maintenance

number kg
Lapping ring contact face 9612DT484
cylinder head--cylinder
liner

number kg
Tilting frame cylinder 9612DT916
head
2.4 -- 50 23328
Manual

number kg
Tool for mounting 9622DT907
valve seats
including adaptor for:

1 inlet valve seat 9622DT111
2 exhaust valve seat 9622DT112
23328 2.4 -- 51
Manual
Wärtsilä 38
Maintenance
2.4.2.6. Camshaft and valve drive

(Chapter 2.8.)

number kg
Dis--/assembly tool 9622DT927
camshaft section

number kg
Jack bolt camshaft thrust 9612DT234
journal
2.4 -- 52 23328
Manual

number kg
Hydraulic nipple for 9622DT931
gearwheel

number kg
Hydraulic nipple for 9612DT968
camshaft end journal
23328 2.4 -- 53
Manual
Wärtsilä 38
Maintenance

number kg
Fixating tool camshaft 9612DT963

number kg
Tool for intermediate 9612DT936
gearwheel shaft
2.4 -- 54 23328
Manual

number kg
Dis/assembly tool cam- 9612DT988
shaft journal

number kg
Dis/assembly tool cam- 9612DT985
shaft gearwheel
23328 2.4 -- 55
Manual
Wärtsilä 38
Maintenance

number kg
Dis/assembly tool inter- 9612DT986
mediate gearwheel

number kg
Tappet securing plate 9622DT171
2.4 -- 56 23328
Manual

number kg
Pillar bolt camshaft 9612DT801
sections/gearwheel
assembly
combination item 1 and 2

for camshaft sections:
1. press piece 9612DT802
2. threaded rod 9612DT803
combination item 3 and 4

for camshaft gearwheel:
3. press piece 9612DT804
4. threaded rod 9612DT805

number kg
Lever fuel cam roll 9612DT965
23328 2.4 -- 57
Manual
Wärtsilä 38
Maintenance

number kg
Locking pin fuel pump 9612DT760
tappet
2.4 -- 58 23328
Manual
2.4.2.7. Injection system

(Chapter 2.9.)

number kg
Testing device injector 9622DT916

number kg
Extractor injector sleeve 9622DT938
consisting of:
1. Threaded bar 9622DT212
2. nut 9622DT207
3. disc 9622DT209
4. disc 9622DT210
5. plug 9622DT211
23328 2.4 -- 59
Manual
Wärtsilä 38
Maintenance

number kg
Lifting / extracting device 9622DT918
nozzle holder

number kg
Socket for nozzle tip 9612DT259
2.4 -- 60 23328
Manual

number kg
Lifting tool fuel pump 9612DT947

number kg
Clamp nozzle holder 9622DT925
23328 2.4 -- 61
Manual
Wärtsilä 38
Maintenance

number kg
Disassembling tool fuel 9612DT948
pump

number kg
Cleaning tool injector 9622DT902
sleeve
2.4 -- 62 23328
Manual

number kg
Compress tool fuel pump 9612DT504
bracket spring
23328 2.4 -- 63
Manual
Wärtsilä 38
Maintenance
2.4 -- 64 23328
Manual
2.4.3. Background information of hydraulic

tools and torque spanners
A number of important engine components are fitted by means of

hydraulic tools. With the use of hydraulic tools is it possible to stress a
bold or stud of a connection till very high tension. This tightening
process can be done within very small tension limits and a great force
and accuracy.
It is necessary to understand the working principle of the hydraulic
tools. For this reason an explanation of the principle is given.
For safety reasons it is important the tools are used in the correct way.
The tightening procedures have to be carried out strictly in accordance
with the instructions in this manual.
For the following subjects general background information is described:
”Rolled thread”
The thread of the studs of important connections is manufactured by a
”cold rolled” process to make the stud thread strong and good resistant
against fatigue. Due to this process the circumference of the thread
becomes smooth and hard. This process make studs also sensitive to
breakage in case of damage. Therefore, studs must always carefully be
handled. Replace a stud when damaged.
The ”easy going” nut

The stud becomes a little bit longer over its entire length during
elongation. This includes that also the pitch of the thread is a little
extended. However, the pitch of the nut mounted is not extended. To
make it possible to turn the nut on the elongated stud ”quite some
clearance” must exist between the thread of the nut and the thread of
the stud. This clearance can be felt when turning on the nut. For this
reason it must be possible, without any restriction, to turn on a nut by
hand.
In case of ”heavy points” remove the nut and find and solve the problem
before starting the tightening procedure.
Studs
All hydraulically stretched studs are made of high tensile strength steel.
To obtain the correct force in the studs, the studs have to be stretched
to approximately 90% of the yield point of the material.
This means, a force 10% more than the tightening force does overstretch
the stud. This may never happen because over--- stretched studs
becomes sensitive to fatigue and may break after some time.
23328 2.4 -- 65
Manual
Wärtsilä 38
Maintenance
Therefore, overstretched studs should be replaced. This is particular

important for connecting rod studs and counter weight studs.
Use genuine parts

There is a real danger in employing studs not delivered by Wärtsilä
Nederland B.V. in particular studs hydraulically stretched.
If these studs are not made from the same high tensile strength material and
not provided with ”cold rolled thread”, problems may occur. Studs, made of
material not sufficient strong, will continue to elongate even if the correct
oil pressure is applied. The nuts can be turned further until breaking.
Use of locking fluids

Clean parts carefully with a degreasing agent and dry parts before
applying locking fluid.
Note! See for specification relevant drawing / parts list (Parts Cata-
logue).
The hydraulic tool set consist of :

--- Hydraulic pump pneumatically driven or a manually operated
pump.
--- A number of hydraulic jacks, distance pieces, tie rods, knurled nuts,
high pressure hoses with quick release coupling and tool pins to
tighten or to loosen the nuts of the relevant components.
2.4.3.1. Pneumatic driven hydraulic pump unit

Figure 2.4 --- 1 shows the main components and the working principle
--- connection (7) for service air supply (min. 5.5 and max.7 bar).
--- filter / water separator (12).
--- lubricator (13).
--- reducing valve (6) to adjust the service air between 0 and 6 bar.
--- manometer (5) direct mounted after the service air reducing valve.
--- air valve (4) to control the pump.
--- air---operated piston (3) (large surface) connected to a piston in the
lower section (small surface) for pressurizing the hydraulic oil.
--- container (1) for hydraulic oil with level indicator.
--- double pointer manometer (8) indicating the hydraulic jack pressure.
--- quick---release couplings with non return valve (10).
--- valve (9) in the HP oil return line.
--- reset valve (16).
2.4 -- 66 23328
Manual
The manometer (5) is connected to the air pressure line after the
reducing valve (6). The manometer scale converts the air pressure in a
comparable oil pressure and makes it possible to set the required oil
pressure before pressurizing the hydraulic jacks.
To prevent over stretching of the studs manometer (5) has to be adjusted
to a pressure which indicates 10% less as the required oil pressure.
The manometer (8) indicates the pressure in the HP hydraulic system.
This calibrated manometer contains two independently working
measuring mechanisms, each provided with a scale and pointer.
Recalibrating of this manometer is necessary when the indication of
both pointers differs more then 10 %.
1 2 14 3 4 5 6 12 13 7
16
8 10 11
a) Pump components
b) Pressurising
c) Releasing the pressure
Fig. 2.4 -- 1 Diagram pneumatically driven hydraulic pump unit
23328 2.4 -- 67
Manual
Wärtsilä 38
Maintenance
Operating
The maximum working pressure of the hydraulic pump is 2500 bar.
Always keep the pump unit horizontal and maintain sufficient
hydraulic oil in the container to avoid air in the system. The container
can be filled through the filling plug (2). For specification of the
hydraulic oil, see chapter 1.2..
For lubrication of the pump adjust the lubricator (12) to 1 drop of oil for
every 20 pump strokes.
1 Check if oil supply valve (14) is open. See fig. 2.4---2
2 Close valves (4) and (9),
3 Connect at (10) the HP hose(s) (11) to the hydraulic jacks (15).
4 Connect the service air at (7).
5 After adjusting the ”air pressure” with reducing valve (6) at a value
of 10% lower than the required oil pressure, start the pump by opening
air valve (4).
The hydraulic system will be pressurized, visible on manometer (8).
The pump will stop at a value of approx. 10% below the required oil
pressure.
6 Slowly turn the spindle of the reducing valve (6) clockwise, by which
the hydraulic oil pressure will increase.
7 Continue to increase the pressure slowly until the reading on the
manometer of the hydraulic system (8) shows the required oil pressure.
8 After the correct oil pressure has been reached, push down the locking
ring over the reducing valve spindle to fix the setting of the reducing valve.
Every time the pump is operated, the pressure will rise automatically and
accurately till the fixed pump setting. When the hydraulic stretching
procedure is completed close valve (4) and always open slowly valve (9).
Quick opening of valve (9) may damage the hydraulic pressure manometer.
9 At the end of the complete procedure turn the spindle of reducing
valve (6) counter clockwise to discharge the air pressure.
Note! If there is sufficient air pressure and the pump will not start after
opening valve (4) push the button on the reset valve (16).
2.4 -- 68 23328
Manual
Remark
When the required pressure is reached and the pump is still continues
slowly working, the hydraulic system is leaking, e.g. a leaking coupling
or a leaking hydraulic jack.
When the hydraulic system contains air, disconnect the hose at (10).
Press the small valve in the coupling by means of a pin and run the pump
slowly. Let oil escape as long as it contains air.
Warning! Always check the correct connecting of hose couplings to pump

unit and jacks special when more jacks are connected at the time.
An incorrect connection may cause that the jack in question is not
pressurized although the manometer indicates the correct pressure.
Fig. 2.4 - 2 Pneumatic driven hydraulic pump and jacks
23328 2.4 -- 69
Manual
Wärtsilä 38
Maintenance
2.4.3.2. Hydraulic tool set
For the hydrauliccaly tightened components two different types of

hydraulic jacks are used. A single jack see fig. 2.4---3 and a twin jack see
fig 2.4---4. The single jack is used for the cylinder head and the main
bearing. The twin jack is used for the connecting rod. The hydraulic jack
consists basically of a housing, (1) a piston, (2)and a knurled nut (3). The
piston is accommodated in a recess in the housing and sealed with
sealing sets (4) and (5). An other part of the tool set is the tie rod (6) and
the distance piece (7)
The oil from the hydraulic pump enters under pressure via connection
(8) between piston and housing resulting in a stretching force in tie rod
(6) and stud (9). The stud shall as a consequence of the applied force be
lengthened and nut (10) becomes free from the contact face. Every time
when the same force (oil pressure) is applied, the same lengthening of
the stud will be realised. To exert the required force in the stud, only a
limited lengthening of the stud is required. The stroke of the jack which
can differ with the type of jack is sufficient for the stud required
elongation.
Note! It is very important that the jack piston is always in bottom position
before pressurizing
The piston is in bottom position for the single jack when no clearence
excists between housing and piston at (11).
The pistons for the twin jack ares in bottom position when top faces of
the pistons are level with the top face of the housing.
After the nut (10) is fastened or loosened with tool pin (12) and the oil
pressure is released, the stretching process can be repeated.
Every time the oil pressure is released the jack’s piston has to be forced
in bottom position by turning the knurled nut with the tool pin.
Because of the friction which exists in the returning of the hydraulic oil
to the container of the hydraulic pump the knurled nut has be tightened
firmly.
If the jack’s piston is not forced in bottom position, for instance by too
quickly disconnecting the hoses from the jack the piston finally has no
working stroke left. A dangerous situation arises the thread of the nuts
and studs is not fully used and will damage the stud and sealings.
2.4 -- 70 23328
Manual
3
12
1
4
8
5
2
11
6
10
Fig. 2.4 - 3 Cross section single hydraulic jack
3 12
6
2
4
1 5
10
Fig. 2.4 -- 4 Cross section twin hydraulic jack
23328 2.4 -- 71
Manual
Wärtsilä 38
Maintenance
2.4.3.3. Hydraulic extractor
For some power demanding operations a hydraulic extractor jack is

applied. The jack is utilized in connection with the manual operated
pump, see fig. 2.4 --- 5 .
Stroke : 50 mm 75 mm
9622DT147 9622DT148
9622DT133
Fig. 2.4 - 5 Hydraulic jack
2.4 -- 72 23328
Manual
2.4.3.4. Hydraulic hoses
The hydraulic hoses are devided in:

High Pressure hydraulic hoses used in combination with H.P. pump
9612DT212 with a the maximum workig pressure of 2500 bar.
Hydraulic hoses used in combination with hand pump 9622DT133 and
jacks 9622DT147 and 9622DT148 with a the maximum working
pressure of 700 bar.
Hydraulic hoses used in combination with hand pump 9622DT150 for
lifting and lowering the main bearing cap, with a the maximum working
pressure of 150 bar
Note! Never change the combination of pump and hoses
Work safely!
1 Check the hose and quick---release couplings for damage before use.
2 Ensure the quick---release couplings are thoroughly clean before use.
Dirt can cause damage to the quick---release couplings so leaks may develop.
3 After use, seal the quick---release couplings with dust caps.
Never work with damaged hoses! The hoses will remain in good
condition if you:
4 never try to remove the clamp fitting from the hose
5 never bend the hose into a radius smaller than 160 mm
6 never twist the hose
7 never damage the hose by, for example, placing heavy objects on it
8 never apply a tensile load to the hose, for example, by pulling
9 never use any oil other than is specified
10 never use the hose for other purposes.
Note! Damaged hoses or quick-- release couplings should be discarded.

DO NOT CARRY OUT REPAIRS!
23328 2.4 -- 73
Manual
Wärtsilä 38
Maintenance
2.4.3.5. Quick–release coupling
A complete quick---release couplings consists of:

1. male connector
2. female connector
3. spring controlled valves
2 1
3 3
Fig. 2.4 -- 6 H.P. quick-- release coupling (example)
The quick---release couplings are used to facilitate easy connecting and

disconnecting of various parts of the hydraulic tool and are self---closing.
This means that it is impossible for air to enter the hose or the jacks, and
oil losses are minimal.
In order to guarantee the valves function efficiently, the couplings should
be thoroughly clean before use. For this reason the quick---release
couplings should always be sealed with dust caps (4) and (5).
5 4
Fig. 2.4 -- 7 Dust caps H.P. quick-- release coupling (example)
The couplings have a conical thread (NPT) which is self-sealing when the
coupling is mounted to the hose fitting or a jack. Do not use sealing tape.
Pieces of tape in the hydraulic system will impair efficient operation.
2.4 -- 74 23328
Manual
2.4.3.6. Hydraulic hand pump
The hydraulic pump consists of the following main components.

1. oil container
2. pump element
3. hose connection
4. release valve
5. filling plug with dip stick
6. pump handle
7. hydraulic hose with comes with the pump (not on drawing)
4 5
3 2 1
Fig. 2.4 -- 8 Hydraulic hand pump
Operating
1 Before using check if there is sufficient hydraulic oil in the
container (1) in order to avoid air in the system. (Always use oxidation
resistant oil see chapter 1.2.1.1.)
2 Connect the pump to the jacks, by hose connection (3).
3 Close the release valve (4) of the pump.
Note! Never apply pressure to a jack which is not in use for, extracting
otherwise the plunger will exceed its maximum stroke.
4 Always reduce the pressure slowly to zero in order to avoid forming
of foam of the oil.
De--aerating of the hand pump
5 Connect the pump with the jack and place the jack up side down on
a lower position then the pump and close the release valve.
Pump the plunger of the jack completely out till the end of the stroke.
Remove the filling plug, open the release valve and push the piston back.
The air in the system will escape through the hose and the pump. Repeat
this procedure if necessary.
23328 2.4 -- 75
Manual
Wärtsilä 38
Maintenance
2.4.3.7. Safety instructions for hydraulic tools
The following general instructions and guides will be helpful to

determine if your system components are properly connected.
1 Be sure all hydraulic hoses and fittings are connected to the correct
inlet and outlet ports of the pump, cylinders, valves and other system
components. An incorrectly made connection may cause a not
connected jack in question and not pressurized although the
manometer indicates the correct pressure.
2 Be sure all threaded connections are fully tightened and free of
leakage. Seal threaded connections with a high---grade thread sealer.
Do not over---tighten any connection.
3 Excessive tightening will cause strain on threads and castings
which could cause fitting failure at pressures below rated capacity.
4 Fully tighten hydraulic connectors (avoid excessive force). Loose
connectors will act as a partial or complete line restriction causing little
or no oil flow and resulting in equipment damage or failure.
5 If the maximum stroke is exceeded the sealing sets of the piston will be
damaged. Pressurized oil will escape and the pressure drops to zero. If this
has happens the jack has to be disassembled, the sealings inspected and
if damaged, replaced by new.
6 Do not drop heavy objects on hydraulic hoses. A sharp impact may
cause bends or breaks to internal hose wire strands. Applying pressure
to the damaged hose will cause internal flexing which will eventually
break the hose strands causing the hose to rupture.
7 Do not use the hydraulic hose to carry a hydraulic component (i.e.
pumps, cylinders and valves).
8 Avoid sharp bends and kinks when routing hydraulic hoses. If
pressure is applied to a bend or kinked hose, the oil flow will be
restricted causing severe back---pressure. Also the sharp bend and kinks
will internally damage the hose leading to premature failure.
9 Avoid situations where loads are not directly centered on the
cylinder plunger. Off---center loads produce considerable strain on
cylinder plungers and may slip or fail causing potentially dangerous
results. Avoid point loading. Distribute the load evenly across the entire
saddle surface.
2.4 -- 76 23328
Manual
10 Always provide clearance for hoses and connectors to avoid moving

objects, abrasion or sharp objects.
11 Use hydraulic gauges which indicate safe operating loads in the
hydraulic system. Do not exceed the safe limit of the lowest rated
component used within your system.
12 Keep hydraulic equipment away from flames and heat. Excessive
heat (above 70C) will soften packings and seals, resulting in fluid leaks.
13 Never attempt to lift a load which exceeds the capacity of a cylinder
or jack. Overloading causes equipment failure and possible personal
injury.
14 Do not overextend the hydraulic jack. The cylinder will take the
load on the plunger stop ring. However, using the full stroke does not
supply power and only adds unnecessary strain to the cylinder.
15 Keep oil lines clean. When connector halves are disconnected,
always put on dust caps. Use every precaution to guard unit against
entrance of dirt because dirt and foreign matters may cause pump,
cylinder and valve failures.
2.4.3.8. Loosening of hydraulically

tightened connection
Note! Loosening pressure = tightening pressure.
To loosen a connection the same oil pressure, or somewhat lower than the
final pressure with which the connection has been tightened, is required.
Prevent overstretching
To prevent overstretching, the hydraulic pressure applied to the studs should
never exceed the tightening pressure plus 5%. Furthermore, operate the
pneumatic driven hydraulic pump according the instructions.
There is no reason to apply a higher pressure than the tightening
pressure. When studs have been tightened to the setting value, the
prestress in the studs may decrease slightly during running of the
engine as a result of the forces incurred in the engine components.
Therefore, the oil pressure in the hydraulic jacks, required for
disassembly will be the same or somewhat lower than the tightening
pressure.
23328 2.4 -- 77
Manual
Wärtsilä 38
Maintenance
If one or more nuts can’t be loosened at setting value check with a feeler
gauge of 0.05 mm if the nut is free from the contact surface. If the nut
is free and it is still not possible to turn the nut, the nut is sticking due
to dirt, corrosion or damage. In such case try to turn the nut using a
copper pin and a hammer.
If still not successful don’t increase the oil pressure because it serves no
purpose. Applying a too high oil pressure introduces the risk of
damaging the thread in the engine component in which the stud is
mounted.
If the nut is not free

1 Check if the oil supply and pressure to all the jacks is correct.
2 Check the quick---release couplings and the non return valves.
3 Check if the nut is free from the tools.
4 Increase the oil pressure by maximum 5%.
If the nuts can still not be loosened the connection has previously been
tightened with a too high oil pressure, possible resulting in
overstretched studs. In this case increase the oil pressure till final
setting value + 10%. More than 10% is not allowed as other construction
parts can be damaged.
If, at 10% overpressure, the nuts can be loosened always replace the
studs as they may be overstretched.
If the nuts even at an increased oil pressure are still tight, remove the
tools, cut the nuts off and remove the studs. Fit new studs and nuts.
Make sure no iron parts enters the engine.
Note! If e.g one cylinder head nut has to be cut leave the other three nuts
tightened to prevent damage to cylinder head and liner.
If, due to any cause, doubt exist regarding the stress in hydraulically
tensioned studs the loosening value must be found.
5 Increase the oil pressure in the hydraulic jacks in steps e.g. of 50 bar.
6 Check after each step whether the nuts can be turned.
7 If this value is more than 10% below the stated value investigate
the reason.
2.4 -- 78 23328
Manual
2.4.3.9. Tightening of hydraulically

tightened connection
In order to describe the tightening and checking procedure the

following is defined:
Checking the procedure by counting the number of holes

In the circumference of the nut from the stud to be elongated are a
number of holes. The nut can be shifted by using a tool pin which fits
in these holes. Checking of the stetching procedure has to be done by
counting the numbers of holes the nut is shifted. The correct numbers
of holes is mentioned in chapter 2.4.4 in the figures of the related
connections
First step, positioning of engine components ( pre--stress )

Turn manually the nuts on the studs and check the nuts moves easily
without feeling any restriction. Tighten the nuts with the tool pin mount the
hydraulic tools and pressurize the hydraulic jacks to the setting value for the
pre---stress.
This pressure is applied to position the engine components to be assembled.
Turn the nuts on with the tool pin. Release slowly the oil pressure in the
hydraulic jacks to prevent damage to the calibrated oil pressure gauge. Now
we have obtained a basis for the tightening procedure.
Second step, setting of materials

Pressurize the jacks till setting value of the final stress. Turn the nuts
with the tool pin and count the number of holes in the circumference of
the nuts the nuts can be shifted.
When all nuts can be shifted the same number of holes and correspond
with the values mentioned in the chapter 2.4.4. the elongation of all
studs is the same and that is how it should be.
In case one or more nuts can’t be turned the same number of holes
compared to the others, remove and inspect the tools on good
functioning and check the engine components for the correct position.
After releasing the jack pressure the force will set the engine
components and nuts and the remaining stress in the studs becomes
somewhat lower.
Third step, obtaining the correct final stress

To correct for ”setting of materials” the jacks have to be pressurized
again to the pressure of the value setting of the final stress.
Now the engine components are set it is possible to turn all nuts a little
further. After the jack pressure is released the correct final stress in the
studs will exist.
23328 2.4 -- 79
Manual
Wärtsilä 38
Maintenance
Fourth step, checking the correct final stress

To make absolutely sure the connection is correct we have to make a
”checking step”. Pressurize the jacks again till setting value of the final
stressand try, with the tool pin, to turn the nuts any further. This may
not be possible.
If that is the case the studs have the required final stress and the
components are correctly connected.
Warning! In case it is possible to tighten the nuts more than the prescribed
number of holes or there is still clearance between nut and contact
surface, the connection is NOT safe. In such a case all components
have to be disconnected and examined:
- on deviation in material
-- wrong assembling
-- wrong assembling procedure.
2.4.3.10. Torque spanner
Modern technology requires more and more accuracy of threaded

connections. To make this possible a torque spanner is nescessary.
To apply a torque spanner the following must be known to avoid
mistakes resulting in unsafe connections.
--- A torque spanner is a precision instrument that should be handled
with utmost care. Every time after the torque spanner is used the
tension of the spanner should be released before storing in its box.
--- The spanner should be kept clean, not dropped and free from water
or dirty oil.
--- The spanner is calibrated between 20% and 100% of its scale and has
a tolerance within 4% of its reading. Take care the spanner is
periodically recalibrated.
--- Calibrate the torque spanner always in the horizontal or vertical
plane to compensate for the spanner weight.
--- Never use the spanner over the 100% scale. Distortion may exist and
readings may become inaccurate.
--- Always apply force on the torque spanner in a clockwise rotation and
on the centre of the handle. Only apply force in the direction shown
2.4 -- 80 23328
Manual
on the spanner. When the desired torque is reached the spanner

clicks and gives a few degrees of free movement . The spanner
automatically resets for the next torque application if no force is
excerted on the handle.
--- Never use a torque spanner to loosen connections.
--- A high degree of torque accuracy can be obtained in the application
of the correct lubricant on the thread of the connection. Where the
contrary is not mentioned only use engine lubricating oil.
--- Keep the torque spanner in line during tightening.
The tightening torques are torque spanner readings and should be
realised by an even tightening of bolt and nut. (if applicable,
crosswise).
--- Always apply force on a torque spanner in a slow on–going move not
passing the required setting. Using the spanner in a fast move will
easily do pass the required setting.
--- The rachet requires periodic cleaning and lubrication to ensure
proper operation. Lubricate with a light oil. DO NOT USE GREASE.
23328 2.4 -- 81
Manual
Wärtsilä 38
Maintenance
2.4 -- 82 23328
Manual
2.4.4. Tightening torque and jack pressure
2.4.4.1. Lubricating oil system components

(Chapter 1.2.)
Pos. Connection for: Torque

Nm
1. Gear wheel on shaft 79
2. Control valve to pump 410
2
1
Fig. 2.4 - 9 Lubricating oil pump assembly
23328 2.4 -- 83
Manual
Wärtsilä 38
Maintenance
2.4.4.2. Cooling water system components

(Chapter 1.4.)

Nm
Fig. 2.4 - 10 Cooling water pump assembly
2.4 -- 84 23328
Manual
2.4.4.3. Control system components

(Chapter 1.6.)

Nm
1. Bolt connection fuel rack 50
Fig. 2.4 - 11 Linkage, fuel rack
23328 2.4 -- 85
Manual
Wärtsilä 38
Maintenance
2.4.4.4. Engine block with bearings

(Chapter 2.5.)
Pos. Connection for: Torque / Nut shifting

Jack
pressure
1. Main bearing stud 400 Nm
2. Main bearing stud hydraulic jack nr. 9622DT232
first step ( pre--stress ) 560 bar
second step ( final stress ) 2170 bar 4.0 -- 4.5 holes
third step ( final stress ) 2170 bar Equal (few degrees)
fourth step ( final stress ) 2170 bar None
3. Side stud 0 Nm
(20_ back)
4. Side stud hydraulic jack nr. 9622DT232
first step ( pre--stress ) 180 bar
second step ( final stress ) 680 bar 2.5 -- 3.0 holes
third step ( final stress ) 680 bar Equal (few degrees)
fourth step ( final stress ) 680 bar None
Note! The sequence of stretching side studs and main bearing studs is
important and is described in section 2.5.2.4.
1 2
Fig. 2.4 - 12 Main bearing
2.4 -- 86 23328
Manual
2.4.4.5. Crankshaft, connecting rod, piston

(Chapter 2.6.)

Nm
1. Vibration damper and pump drive 3850
2. Split gear wheel on crankshaft 540
3. Split gear wheel 540
4. Turning wheel space bolt nut 4300
5. Turning wheel fitting bolt nut 4300
6. Flywheel on turning wheel (if applicable) 570
2 3 4
Fig. 2.4 -- 13 Crankshaft
23328 2.4 -- 87
Manual
Wärtsilä 38
Maintenance

Jack
pressure
1. Big end stud 200 Nm
2. Big end stud hydraulic jack nr. 9612DT907
first step (pre--stress) 700 bar
second step (final stress) 2050 bar 2.5 -- 3.0 holes
third step (final stress) 2050 bar Equal (few degrees)
fourth step (final stress) 2050 bar No shifting
3. Connecting rod stud 200 Nm
4. Connecting rod stud hydraulic jack nr. 9612DT907
5. Counter weight stud 300 Nm
6. Counter weight stud hydraulic jack nr. 9622DT232
3 4
5
1 2 6
Fig. 2.4 -- 14 Big end bearing and counter weight
2.4 -- 88 23328
Manual
2.4.4.6. Cylinder head with valves

(Chapter 2.7.)

Nm
1. Exhaust V--clamp 85
2. Exhaust gas pipe 85
B
A
A B 2
Fig. 2.4 - 15 Exhaust connection cylinder head
23328 2.4 -- 89
Manual
Wärtsilä 38
Maintenance

Jack
pressure
1. Cylinder head stud 600 Nm
2. Cylinder head stud hydraulic jack nr. 9622DT232
1
2
Fig. 2.4 -- 16 Cylinder head
Pos. Connection for: Torque Nm

1. Starting valve 79
2. Starting valve spindle 28
1 2
Fig. 2.4 -- 17 Starting valve
2.4 -- 90 23328
Manual

Nm
1. Rocker arm bracket 330
2. Locking nut valve clearance 500
3. Bridge piece guide 79
4. Cylinder safety valve 150
5. Flange for exhaust gas pipe (bolt M12) 117
6. Locking nut bridge piece guide 220
1 2 3 6
4 5
Fig. 2.4 - 18 Rocker arm mechanism
23328 2.4 -- 91
Manual
Wärtsilä 38
Maintenance
2.4.4.7. Camshaft and drive mechanism

(Chapter 2.8.)

Nm
12/ Tappet assembly 195
13
13 12
Fig. 2.4 - 19 Tappet assembly
2.4 -- 92 23328
Manual

Nm
1. Intermediate gear shaft 195
Fig. 2.4 -- 20 Intermediate gear shaft
23328 2.4 -- 93
Manual
Wärtsilä 38
Maintenance

Nm
1. Camshaft flange 550
2. Camshaft end journal 200
3. Camshaft end journal cover 200
1 2 3
Fig. 2.4 -- 21 Camshaft
2.4 -- 94 23328
Manual

Nm
1. Actuator drive housing 195
2. Drive shaft nut 100
3. Locking bolt 10
Warning! If helical gear wheels are damaged, both gear wheels

have to be renewed as a set.
Special tools are necessary to adjust the gearwheels.
2 4
Fig. 2.4 - 22 Actuator drive
23328 2.4 -- 95
Manual
Wärtsilä 38
Maintenance
2.4.4.8. Injection system components

(Chapter 2.9.)

Nm
1. Injector gland 125
Fig. 2.4 - 23 High pressure fuel injector
2.4 -- 96 23328
Manual

Nm
1. Sleeve nut injector 450
2. Connecting piece 150
3. Sealing flange bolts (M10) 12
4. HP fuel pipe to cylinder head 180
5. HP fuel pipe to HP fuel pump 210
6. Locking flange bolts (M16) 195
2 4 5 3 6
1)
1
1) USE MOLYCOTE G
Fig. 2.4 - 24 Injector, HP fuel pipe
23328 2.4 -- 97
Manual
Wärtsilä 38
Maintenance

Nm
1. Tappet housing 195
2. Spindle locking bolt 40
3. Spindle bolt 40
4. HP fuel pump 390
5. HP fuel pump cover 80
6. HP fuel pump cover 200
5 6
2
3
Fig. 2.4 -- 25 HP fuel pump drive and tappet housing
2.4 -- 98 23328
Manual

for not specified bolt connections
When the tightening torque is not specified, use the values from the
table below.
Unless stated otherwise all threads and contact surfaces of the nuts and
bolts should be sparingly lubricated with engine oil before tightening.
For general information, see also:

--- DIN 13
--- ”VDI Richtliniën 2230”
--- DIN --- 912 --- 931 --- 933 --- 6912 --- 7984.
Norm bolt connections

Thread Bolt class Torque
Dim. Pitch Nm
8.8 2,8
M4 0,7 10.9 4,1
12.9 4,8
8.8 5,5
M5 0,8 10.9 8,1
12.9 9,5
8.8 9,5
M6 1,0 10.9 14,0
12.9 16,5
8.8 23,0
M8 1,25 10.9 34,0
12.9 40,0
8.8 46,0
M10 1,5 10.9 68,0
12.9 79,0
8.8 79,0
M12 1,75 10.9 117,0
12.9 135,0
23328 2.4 -- 99
Manual
Wärtsilä 38
Maintenance
Norm bolt connections

Thread Bolt class Torque
Dim. Pitch Nm
8.8 125,0
M14 2,0 10.9 185,0
12.9 215,0
8.8 195,0
M16 2,0 10.9 280,0
12.9 330,0
8.8 280,0
M18 2,5 10.9 390,0
12.9 460,0
8.8 390,0
M20 2,5 10.9 560,0
12.9 650,0
8.8 530,0
M22 2,5 10.9 750,0
12.9 880,0
8.8 670,0
M24 3,0 10.9 960,0
12.9 1120,0
8.8 1350,0
M30 3,5 10.9 1900,0
12.9 2250,0
2.4 -- 100 23328

Manual
2.4.5. Adjustments and Tolerances
2.4.5.1. Adjustments
Timing, clearances and settings
Valve clearances engine:

-- Inlet valve 1.0 mm
-- Exhaust valve 1.0 mm
Fuel delivery commencement See test records

Opening pressure fuel injector needle 450 bar
Nominal speed Speed reduction Overspeed stop

600 rpm 660 + 10 rpm 690 + 10 rpm
23328 2.4 - 101

Manual
Wärtsilä 38
Maintenance
2.4.5.2. Tolerances
Part, measuring point
Sleeve bearings
The following engine bearings have a steel back and a running layer
of Aluminium alloy:
-- crankshaft
-- connecting rod big end
-- camshaft
A bearing is suitable for use as long as:

-- the shell thickness is expected to stay within the given tolerances, until the
next inspection, (see this chapter).
-- the inside diameter is within the given tolerances, until the next inspection,
(see this chapter).
-- the bearing shell is free of any damage.
-- the bearing shell is free of any corrosion.
-- the wear pattern is equal.
-- the running layer is not overloaded. An overloaded bearing shell can be
recognized by locally melted, cracked or smeared lining.
New bearings are treated with a corrosion protection oil that has to be removed
before mounting.
Where bearings show heavy wear grooves in the running layer, the quality of the
lubricating oil cleaning process should be investigated.
Note! For determination of wear, engine components and measuring

equipment should for some hours first be acclimated at room
temperature ( 20 _C).
2.4 -- 102 23328

Manual
Part, measuring point Design measurements [mm] No - Go

Max. Min. Clearance [mm]
Lubricating oil pump (chapter 1.2.)
Backlash driving gear wheel (1)
lubricating oil pump gear wheel (2) 0.39--0.54
Cooling water pump (chapter 1.4.)
H.T. cooling water pump gear wheel (3) 0.63--0.78
L.T. cooling water pump gear wheel (4) 0.63--0.78
Fig. 2.4 - 26 Gear wheel train
23328 2.4 - 103

Manual
Wärtsilä 38
Maintenance

Cylinder liner (chapter 2.5.)

Cylinder liner diameter:
(fig.2.4 -- 27 )Level: I, II, III, IV, V 380.057 380.000
I > 380.900
II > 380.600
III, IV, V > 380.300
Cylinder liner ovality at TDC 0.02 ------ > 0.06
Cylinder liner height ”A” 349.10 349.00 >348.75
Cylinder liner height ”B” 79.60 79.40 > 79.15
Anti polishing ring height ”C” 81.10 80.90
Anti polishing ring wall thickness ”D” 10.740 10.693 > 10.65
0
B
92 I
147 II
A C
202 III
9612DT401
568 IV
9622DT929
872 V
Fig. 2.4 - 27 Measuring the cylinder liner bore
2.4 -- 104 23328

Manual

Main bearing (chapter 2.5.)

Crankshaft journal diameter 380.000 379.964
Crankshaft journal straightness 0.015 ------
Crankshaft journal parallelism 0.025 ------
Main bearing housing.bore 400.036 400.000
Main bearing shell thickness 9.835 9.810
Assembled main bearing bore 380.447 380.361
Main bearing clearance (also ’0’--bea- 0.361--0.483
ring)
Crankshaft thrust bearing ring thick- 15.000 14.950
ness
Crankshaft thrust bearing axial clear- 0.25 -- 0.50
ance
Camshaft bearing (chapter 2.5.)
Camshaft journal diameter 250.000 249.971
Camshaft bearing housing bore 265.033 265.000
Camshaft bearing bush thickness 7.395 7.375
Assembled bearing bore 250.309 250.237
Camshaft bearing clearance (also 0.237--0.338
’0’--bearing)
Camshaft thrust bearing ring thick- 12.000 11.950
ness
Camshaft thrust bearing axial clear- 0.35 -- 0.55
ance
23328 2.4 - 105

Manual
Wärtsilä 38
Maintenance
Part, measuring point Max.

mm
Crankshaft deflection criteria (chapter 2.6.)
Measuring the deflections of the crankshaft the commissioning report is
considered as a reference.
The centre point on the counter weight for the dial gauge is situated
15 mm from the mounting face counter weight / crankweb.
The crankshaft deflection criteria:
-- free and driving end not coupled to the installation -- all cylinders 0.05
-- driving end coupled to the installation -- first cylinder 0.10
-- free and driving end coupled to the installation -- first and last cylinder 0.10
The crankshaft deviation between adjacent cranks: (0.7 x criteria)
compare crankshaft deflections at the same points A--A; B--B etc.
-- free and driving end not coupled to the installation -- all cylinders 0.035
-- driving end coupled to the installation -- first cylinder 0.07
-- free and driving end coupled to the installation -- first and last cylinder 0.07
The crankshaft deviation on the same crank between A and E is : 0.01

Checking the measurement results:
Average between A and E = 0.5(A+E) = F
-- free and driving end not coupled to the installation, for all cylinders:
Deviation between F and B; B and C; C and D; D and F 0.025
-- driving end coupled to the installation, for first cylinder:
-- free and driving end coupled to the installation, for first and last cylinder
operating side non--operating side
Note:
-- Not coupled to the installation means:
free end and driving end of the crankshaft have to be free from extra
loads due to for instance the weight of elastic couplings etc.
-- Mentioned values are with engine and foundation at ambient temperature.
-- If the values are > max.:
-- check measurement tools and measurement procedure,
see section 2.6.1.
-- check foundation and alignment of the engine and driven shaft.
Re--align if necessary.
2.4 -- 106 23328

Manual

Big end bearing (chapter 2.6.)

Crank pin diameter 360.000 359.964
Crank pin straightness 0.015 ------
Crank pin parallelism 0.15/ ------
1000
Connecting rod big end bore * 378.036 378.000
Big end bore circularity * 0.02 ------ > 0.05
Big end bearing shell thickness 8.890 8.865
Assembled bearing bore * 360.373 360.288
Difference between bore ”A” and ”B” * > 0.02
Big end bearing clearance 0.288--0.409
Note! * Big end bores only to be measured with assemled connecting rod.
A B
23328 2.4 - 107

Manual
Wärtsilä 38
Maintenance

Piston / Gudgeon (chapter 2.6.)

Gudgeon pin diameter 175.000 174.988 < 174.970
Connecting rod small end bore 195.029 195.000
Small end bearing bush thickness 9.940 9.925
Assembled small end bearing bore 175.179 175.120
Gudgeon pin bearing clearance 0.120--0.191
Gudgeon pin bore in piston 175.068 175.050 >175.070
Clearance gudgeon pin -- piston 0.05--0.08
Axial clearance small end bearing -- 0.4 -- 0.7
-- piston
Piston ring gap:
-- Compression ring 1 0.8--1.2
-- Compression ring 2 and 3 2.0--2.4
-- Oil scraper ring 4 1.2--1.65
Piston ring height:
-- Compression ring 1 7.937 7.925
-- Compression ring 2 and 3 7.987 7.975
-- Oil scraper ring 4 9.987 9.975
Piston ring groove height:
-- Groove 1, 2 and 3 8.17 8.15 > 8.40
-- Groove 4 10.08 10.06 > 10.20
Piston ring axial clearance:
-- Compression ring 1 0.213--0.245
-- Compression ring 2 and 3 0.163--0.195
-- Oil scraper ring 4 0.073--0.105
Piston diameter at bottom in cross 379.780 379.750
direction of engine
Corresponding clearance piston -- liner 0.220--0.307
2.4 -- 108 23328

Manual

Valves (chapter 2.7.)

Exhaust valve guide inner diameter 30.161 30.134 > 30.300
Inlet valve guide inner diameter 30.181 30.154 > 30.300
Valve stem diameter level: I, II, III 30.000 29.979 < 29.900
Exhaust valve stem clearance 0.134--0.182 > 0.350
Inlet valve stem clearance 0.154--0.202 > 0.350
Valve disc hight at ”A” 13.00 12.90 < 12.00
Valve disc burning in wear at ”B” > 1.0
Oscillation of valve stem and disc at ”C” 0.03 > 0.06
Free length of valve springs 207.00 203.00
C
B
C C
I II III
A
0 66 110 325
Fig. 2.4 -- 29 Valve stem and valve disc burning in wear
+5’ +4’
29_50’ --5’ 30_ +0’
0 0
Ø102.0 -- 0.5 min. Ø128 -- 0.2 nom. / Ø130 max.
0 + 0.03
Ø105.5 nom. Recess Ø140 0
-- 0.5
Fig. 2.4 - 30 Inlet valve and valve seat in cylinder head
+ 0.03
Recess Ø125 0
+5’
29_50’ --5’
+4’
30_ +0’
0
Ø102.0 min. 0
-- 0.5 Ø128 nom. / Ø130 max.
-- 0.2
0 + 0.03
Ø105.5 -- 0.5 nom. Recess Ø144 0
Fig. 2.4 -- 31 Exhaust valve and valve seat in cylinder head
23328 2.4 - 109

Manual
Wärtsilä 38
Maintenance

Gearwheel train (chapter 2.8.)

Backlash crankshaft gear wheel (1) --
large intermediate gear wheel (2) 0.24--0.51
Backlash small intermediate gear
wheel (3) -- camshaft gear wheel (4) 0.12--0.33
Backlash camshaft gear wheel (4) --
governor drive unit gear wheel (5) 0.47--0.59
Axial clearance intermediate < 0.50
gearwheel 0.50--0.99 > 1.10 *
Note! * Clearance measured with engine at ambient temperature.
Fig. 2.4 -- 32 Driving gear
2.4 -- 110 23328

Manual
Part, measuring point Design measurements [mm] No -- Go

Actuator drive (chapter 2.8.)

Backlash helical gear wheels * 0.12--0.18
Adjustment dimension ”x” 28.52 28.48
* Shaft clearance in direction ”d” is zero.
Warning! If helical gear wheels are damaged, both gear wheels

have to be renewed as a set.
Special tools are necessary to adjust the gearwheels to
dimension ”x”.
d
x
Fig. 2.4 - 33 Governor drive gear wheels
23328 2.4 -- 111

Manual
Wärtsilä 38
Maintenance

Valve mechanism (chapter 2.8.)

Tappet guide bore (1) 92.035 92.000 > 92.10
Tappet diameter (2) 91.928 91.893 < 91.85
Clearance tappet / tappet guide 0.072--0.142 > 0.20
Pin diameter (3) 40.000 39.984
Pin bore in the tappet (4) 40.020 40.005
Clearance pin / bore in the tappet 0.005--0.036
Roller bore (5) 50.041 50.025
Bearing bush outer diameter (6) 49.947 49.930 < 49.90
Clearance bearing bush /.roller 0.078--0.111 > 0.15
Bearing bush bore (6) 40.050 40.030 > 40.08
Clearance bearing bush bore /.pin 0.030--0.066 > 0.10
Rocker arm bearing bore (9) 85.102 85.05 > 85.17
Rocker arm shaft diameter (10) 84.988 84.966
Clearance shaft / rocker arm bearing 0.062--0.136
Bridge piece pin diameter (11) 34.050 34.034
Pin bore in bridge piece (12) 34.119 34.080 > 34.20
Clearance pin / bore bridge piece 0.03--0.085
1,2 9,10
12
11
4,5
3 6
Fig. 2.4 - 34 Valve drive mechanism
2.4 -- 112 23328

Manual

Fuel pump bracket (chapter 2.9.)

Tappet diameter (2) 114.928 114.893 < 114.80
Tappet guide bore (1) 115.035 115.000 >.115.10
Clearance tappet / tappet guide 0.072 -- 0.142 > 0.20
Pin diameter (3) 50.000 49.989
Pin bore in tappet 50.020 50.005
Clearance pin / pin bore in tappet 0.005 -- 0.031
Roller bore (4) 50.105 50.080
Clearance pin / roller bore 0.080 -- 0.116 > 0.15
Fig. 2.4 - 35 Fuel pump bracket
23328 2.4 - 113

Manual
Wärtsilä 38
Maintenance

Injection system (chapter 2.9.)

Nozzle needle lift ’A’ 0.90 0.75
Distance ’X’ fuel pump 100 0.05
’A’
Fig. 2.4 -- 36 Nozzle
’X’
Fig. 2.4 - 37 HP fuel pump adjustment
2.4 -- 114 23328

Manual
2.4.6. Dimensions and masses

Item Description [kgf] Item Description [kgf]
1. Main bearing shell 7 8. Crank pin bearing shell 11
2. Cylinder liner 612 9. Piston + pin 195
3. Cylinder head 690 10. Connecting rod 304
4. Inlet and exhaust valve 6+6 11. Crankshaft gearwheel 219
5. Valve spring 3 12. Camkshaft gearwheel 147
6. Fuel injector 1 13. Intermediate gearwheels 202
7. Piston pin bearing bush 6 14. Fuel pump 60
1. 2. 3. 4. 5.
6. 7. 8. 9. 10.
11. 12. 13. 14.
Fig. 2.4 - 38 Engine components
23328 2.4 - 115

Manual
Wärtsilä 38
Maintenance
Turbocharger A [mm] B [mm] Weight [kgf]

VTR 354 1650 1105 1800
VTR 454 2075 1387 3400
VTR 454 2075 1387 3400
Fig. 2.4 -- 39 Turbochargers
Charge air cooler insert C [mm] D [mm] E [mm] Weight [kgf]

6L38 969 610 810 496
8L38 1065 636 810 720
9L38 1065 636 810 720
Fig. 2.4 - 40 Charge air cooler inserts
--o--o--o--o--o--
2.4 -- 116 23328

Manual
Engine Block with Bearings and Cylinder Liner Wärtsilä 38
2.5. Engine Block with Bearings and

Cylinder Liner
Table of contents
2.5 Engine Block with Bearings and Cylinder Liner . . . . . . . . . . . . . 2.5 - 1

2.5.1. Engine block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 2
2.5.2. Main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 3
2.5.2.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 3
2.5.2.2. Removal of a main bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 4
2.5.2.3. Inspection of main bearings and journals . . . . . . . . . . . . . . . . . 2.5 -- 11
2.5.2.4. Main bearing assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 11
2.5.3. Crankshaft axial locating bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 18
2.5.3.1. Removal of the ’0’--bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 19
2.5.3.2. Inspection of axial thrust rings and
thrust collars on the crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 20
2.5.3.3. ’0’--bearing assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 20
2.5.4. Camshaft bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 21
2.5.4.1. Inspection of the camshaft bearing bush . . . . . . . . . . . . . . . . . 2.5 -- 21
2.5.4.2. Removal of the camshaft bearing bush . . . . . . . . . . . . . . . . . . . 2.5 -- 22
2.5.4.3. Mounting the camshaft bearing bush . . . . . . . . . . . . . . . . . . . . 2.5 -- 23
2.5.5. Cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 24
2.5.5.1. Inspection of the cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 24
2.5.5.2. Removal of the cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 25
2.5.5.3. Mounting the cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 27
2.5.6. Replacing cylinder head stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 29
2.5.7. Crankcase explosion relief valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 30
23328
2.5 -- 1
Manual
Wärtsilä 38
Engine Block with Bearings and Cylinder Liner
2.5.1. Engine block

The engine block is a one piece stiff nodular cast iron component able
to absorb internal forces. The engine block carries the underslung
crankshaft. The nodular cast iron main bearing caps (1) are tightened
by hydraulically tensioned studs, two vertically (main bearing cap)
studs (2) and two horizontally (side) studs (3). Together they provide a
very rigid crankshaft bearing construction.
The sump, mounted under the engine block and sealed by a rubber
stringgasket,isprovidedwithanintegratedmainlubricatingoilsupply
manifold. Camshaft bearing pockets (4) and charge air receiver (5) are
incorporated in the engine block. A number of crankcase covers are
equipped with explosion relief valves.
5 4
2
1
3
non--operating operating
side side
Fig. 2.5 - 1 Engine block (view free-- end side)
2.5 -- 2 23328
Manual
2.5.2. Main bearings
2.5.2.1. General
In order to mount the bearing caps always in the same position, it is

necessary to pre---tighten the side stud at the non operating side first,
before tightening the main bearing cap studs.
Note! It is essential to follow the sequence described in this chapter of the

manual to avoid bearing and crankshaft damages.
Main bearing shells are axially guided by lugs to obtain a correct

position during assembly. The crankshaft axial locating bearing,
number ’0’, differs from the other bearings and is provided with thrust
rings to limit the axial displacement of the crankshaft.
Bearing shells are of a bi---metal type. All main bearing caps are
provided with a temperature sensor. If abnormal temperatures appear
the suspected bearing and crankshaft deflections and the alignment
have to be checked.
For maintenance intervals, tolerances, inspections and background
information of hydraulic tightening procedures, see chapter 2.4.
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2.5 -- 3
Manual
Wärtsilä 38
2.5.2.2. Removal of a main bearing
Warning! Never remove two main bearings mounted side by side at the same time.
Removal side stud nuts

1 Remove the crankcase covers on both sides of the main bearing to
be inspected.
2 Remove the protecting caps from the side studs concerned.
3 Disconnect the temperature sensor from main bearing cap. Remove
bolts holding the temperature sensor cable.
Take care not to damage the cable and sensor, see fig. 2.5 --- 2 .
C
C--C
Fig. 2.5 - 2 Position bearing temperature sensor
2.5 -- 4 23328
Manual
4 Turn from tool set 9622DT913 tie rods 9622DT126 completely on

the side studs. Place distance sleeves 9622DT125 and jacks 9622DT232
over the tie rods.
5 Turn knurled nuts 9622DT233 on the tie rods and tighten with tool
pin 9612DT100, see fig. 2.5 --- 3 .
9622DT233
9622DT126
9622DT125
9612DT212
9612DT961
9622DT232
Fig. 2.5 - 3 Positioning jack on side stud
6 Connect HP hoses 9612DT961 between jacks 9622DT232 and

hydraulic pump 9612DT212 and open release valve at the pump.
7 Turn knurled nuts further on tie rods until jack pistons are forced
in bottom position. After jack pistons are in bottom position turn
knurled nuts 6 holes counter clockwise.
Note! See fig. 2.4 -- 16 for jack pressures and nut shifting.
8 Pressurise jacks till final stress value, see section 2.4.4.4. Check at
which pressure the nut comes loose.
9 Loosen side stud nuts with tool pin 9612DT100 about 5 to 6 holes.
10 Open release valve and slowly lower pressure till zero.
11 Check if the knurled nuts and the nuts of the side studs are loose
and remove the tool set
Note! Do not yet remove side studs.
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2.5 -- 5
Manual
Wärtsilä 38
Removal of main bearing cap nuts

12 Place trolley 9622DT901 on the sliding bars in the crankcase, see
fig. 2.5 --- 4 .
13 Place in the recesses in the top plate of the trolley the hydraulic
jacks 9622DT232 from tool set 9622DT910
14 Place one by one from tool set 9622DT149 the distance pieces
9622DT236 on the jacks and the tie rods 9622DT237 into the distance
pieces. The lifting tool can be raised and lowered with spindle (1) to
facilitate the insert of the tools.
15 Raise the lifting tool by means of the spindle (1) till the tie rods are
just a few mm free from the main bearing cap stud.
16 Level with adjusting bolts (2) the trolley in such away that the
distance (X) is equal on both sides of the distance pieces
17 Turn the tie rods completely on the studs.
18 Raise the lifting tool further till the distance pieces are just touching
the bearing cap. Check if the tie rods are completely on the studs.
19 Turn the knurled nuts 9622DT233 on the tie rods and tighten with
tool pin 9612DT100.
20 Lower the lifting tool
21 Connect the hoses 9612DT961 to the hydraulic pump 9612DT212,
open the release valve on the pump and tighten the knurled nuts firmly
to force the jack pistons in bottom position.
22 After the jack pistons are in bottom position turn both knurled nuts
one full turn counter clockwise.
23 Close the release valve on the pump and pressurise the jack till final
stress value. See section 2.4.4.4.
24 The main bearing cap nuts should now be free from the bearing
caps. Loosen the nuts one full turn (8 holes).
25 Slowly lower the hydraulic pressure till zero and check if the
knurled nuts and the main bearing cap nuts are loose.
26 Remove the main bearing jacks using the trolley.
2.5 -- 6 23328
Manual
9622DT236
A
9622DT232
1
9622DT233
2 9622DT237
A 9622DT901
X X
9622DT236
9622DT232
9622DT233
2
9622DT237
9622DT901
A--A
Fig. 2.5 - 4 Positioning the main bearing jacks
23328
2.5 -- 7
Manual
Wärtsilä 38
Removal of main bearing cap

The hydraulic jack (3) for lowering and lifting the main bearing cap is
fitted on the main lube oil supply manifold (4). This jack is called the
main bearing cap centre jack and operates on normal engine lube oil.
27 Where on the main bearing cap centre jack is mentioned ”UP” and
”DOWN” remove the plugs and fit in a nipple (5), part of pump set
9612DT901.
28 Connect the hoses from the hydraulic pump set 9612DT901 and the
nipples (5) with the delivery hose to the ”UP” connection and the drain
line hose to the ”DOWN” connection.
UP DOWN
5
9612DT901
3
Fig. 2.5 -- 5 Lowering the main bearing cap
29 Bring the ”Up---side” of the main bearing cap center jack under a
pressure of approx. 20 bar, the pressure required to lift the cap. Lift the
main bearing cap a few mm against the abutting face. Both main
bearing cap nuts will come free.
30 Remove the side studs.
31 Maintain the pressure on the ”Up---side” of the main bearing cap
center jack and remove the main bearing cap nuts.
32 Close the valve in the return line of pump set 9612DT901.
33 Change both hoses of position so that the discharge side of the pump
is connected to the ”Down ---side” and the return hose to the ”Up---side”
of the jack. Due to a relief valve in the nipples and hoses, which closes
automatically the lines, the build up pressure will remain in the jack.
2.5 -- 8 23328
Manual
34 Open the valve at the pump in the return line. When no friction
exists between bearing cap and engine block the cap slowly moves down
over the stroke of the top section of the centre jack. The lowering speed
may be controlled by throttling of the valve in the return line.
35 When friction exists the cap may be lowered by pressurizing the
main bearing cap centre jack. The valve in the return line should be fully
opened then. In this case the bottom section of the centre jack is
working. The stroke of the centre jack is sufficient to bring the cap out
of the friction influence of the engine block. The lowering of the
remaining distance is effected by gravity.
Note! The maximum pressure of the hydraulic pump set 9612DT901 is

internally limited at 150 bar.
36 In case too high friction exists between bearing cap and engine
block and the maximum pump pressure is not sufficient, the side studs
of the adjacent bearing caps have to be loosened.
23328
2.5 -- 9
Manual
Wärtsilä 38
Removal of the bearing shells

37 With the main bearing cap in lowest position the lower bearing shell
can be taken out of the main bearing cap manually
38 In some cases the upper bearing shell can be pushed out manually.
If the bearing shell cannot be pushed out manually, then make use of the
bearing shell driver 9622DT152, see fig. 2.5 --- 6 .
9622DT152
Fig. 2.5 -- 6 Bearing shell driver
39 Bar the crankshaft to make the lube oil hole in the crankshaft
journal fully visible.
40 Insert bearing shell driver into the lube oil hole.
41 Carefully bar crankshaft till driver starts pushing against the
bearing shell and turn slowly further.
42 After most of the bearing shell is pushed out of the housing the
remaining part can be slide out manually.
2.5 -- 10 23328
Manual
2.5.2.3. Inspection of main bearings and

journals
Main Bearings
1 Clean bearing shells and check for wear, scoring and other damages.
Journals
2 Main bearing journals should be inspected for surface finish.
Damaged journals, i.e. rough surface, scratches, marks, indents etc.
should be polished.
Note! No scraping of bearing shells, caps and housings is permitted.
2.5.2.4. Main bearing assembling
Bearing shell mounting

1 Clean both main bearing shells, cap and journal very carefully.
Degrease new bearings before mounting.
2 Oil upper bearing shell only at running side. Avoid any oil at the
back side of the shell and bearing cap.
3 Place end of bearing shell in slot of housing with lug guiding in oil
groove and push shell manually as far as possible. Usually it is possible
to mount bearing shell manually in position. Support shell sufficiently
by hand, see fig. 2.5 --- 7 .
Note! Take care part no. on main bearing shell is facing the driving end of
the engine and the location lug is in the correct position.
Fig. 2.5 - 7 Inserting main bearing shell
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2.5 -- 11
Manual
Wärtsilä 38
4 If the bearing shell cannot completely be inserted manually, insert

driver 9622DT152 into the lube oil hole. See fig. 2.5 --- 8 .
5 Bar crankshaft carefully until bearing shell is pushed into position.
Take care not to damage the bearing shell lug during turning in.
6 Remove driver.
9622DT152
Fig. 2.5 - 8 Pushing the upper main bearing shell into position
7 Oil the lower bearing shell only at the running side. Avoid any oil
at the back side of the bearing shell.
8 Place lower bearing shell in main bearing cap with part no. facing
to the driving end of the engine. Make sure the bearing shell positioning
lug fits in the recess of the bearing cap, and contact faces are free from
damages and indents.
Lifting the bearing cap

9 Lubricate the bearing cap guiding sides.
10 Connect the two hoses between hydraulic pump 9612DT901 and
the nipples (3) with the delivery hose to the ”UP” connection and the
drain line hose to the ”DOWN” connection.
11 Pressurize the main bearing cap centre jack and lift the bearing cap.
Turn on the bearing cap nuts when this is possible.
12 Continue lifting until the cap fits against the contact faces of the
engine block. Do not increase the pressure of the main bearing cap
centre jack more than strictly necessary to keep the cap lifted. Fit the
main bearing cap nuts and tighten the nuts firmly with tool pin
9612DT100. Check with feeler gauge of 0.05 mm the fitting between cap
and nuts.
13 Disconnect the hoses from the centre jack and replace the nipples
at the ”Up---side” and the ”Down---side” in the centre jack with plugs.
Note! The pressure of the hydraulic pump set 9612DT901 is internally
restricted at 150 bar.
2.5 -- 12 23328
Manual
Mounting side studs

14 Fit both bearing cap side studs after cleaning and oiling and provide
new O ---rings with silicon grease.
15 After the studs are completely turned in, turn the studs about 20 
counter clockwise. The side studs should not touch the main bearing cap
studs
16 Tighten the nuts at both side studs by hand, with tool pin
9612DT100
Side stud non operating side

17 1st step
--- Turn tie rod 9622DT126 of tool set 9622DT913 completely on side
stud at non operating side only, see fig. 2.5 --- 3 .
--- Place distance sleeves 9622DT125 and jack 9622DT232 over the tie
rod and tighten knurled nut 9622DT233 with the tool pin
9612DT100
--- Connect hose 9612DT961 between jack and pump 9612DT212, open
release valve at pump and tighten knurled nut further to force the
jack piston in bottom position.
Note! See section 2.4.4.4. for jack pressures and nut shifting.
--- Pressurize jack till pre---stress value of the first step and tighten side
stud nut firmly with tool pin.
--- Check with feeler gauge of 0.05 mm for any clearance between nut
and contact face. Clearance should not exist.
--- Slowly lower pressure till zero. Tighten the knurled nut to force the
jack piston to bottom position.
--- Do not remove the hydraulic tools from the side stud.
Main bearing cap studs

18 Fit the main bearing cap tool set 9622DT149 and jacks 9622DT232
with knurled nuts 9622DT233 as mentioned in section 2.5.2.2. and take
care the jack pistons are in bottom position before pressurizing.
19 1st step
--- Close the release valve at the hydraulic pump and pressurize the
jacks till the pre---stress value of the first step.
--- Tighten the bearing cap nuts with the tool pin.
--- Open release valve at the pump and slowly lower the jack pressure
till zero.
Tighten the knurled nuts firmly to force the jack pistons in bottom
position.
23328
2.5 -- 13
Manual
Wärtsilä 38
20 2nd step
--- Check if the jack pistons are completely in bottom position.
--- Close the release valve at the hydraulic pump and pressurize the
jacks till final stress value of the second step.
--- While firmly tightening the nuts, count and note the number of holes
the nuts can be shifted. The nut shifting should be equal for all the
nuts.
--- Check if the number of holes which the nuts are shifted are within
the values mentioned in section 2.4.4.4.
till zero. Tighten the knurled nuts firmly to force the jack pistons in
bottom position.
21 3rd step
--- Close release valve and pressurize the jacks till final stress value of
the third step and tighten the nuts with the tool pin further. This
should be possible over a few degrees only.
till zero.
22 4th step
--- Close release valve and pressurize the jacks till final stress value of
the fourth step and try to tighten the nuts with the tool pin further.
This should not be possible.
till zero.
--- Disconnect the hoses and use the trolley to remove the tool set.
2.5 -- 14 23328
Manual
Side stud non operating side continued

23 2nd step
--- Close the release valve at the pump and pressurize the jack till
pre---stress value of the first step. Loosen the side stud nut.
till zero.
--- Check for clearance between hydraulic tools and engine block, so the
side stud finds its own stress ---free position. Tighten the side stud
nut again with the tool pin.
--- Close the release valve at the pump and pressurize the jack again till
pre---stress value of the first step. Firmly tighten the side stud nut.
till zero. Tighten the knurled nut to force the jack piston in bottom
position.
--- Close the release valve at the hydraulic pump and pressurize the jack
till final stress value of the second step.
--- While firmly tightening the nut, count and note the number of holes
the nut can be shifted.
--- Check if the number of holes which the nut has shifted is within the
value mentioned in section 2.4.4.4.
till zero. Tighten the knurled nut to force the jack piston in bottom
position.
24 3rd step
--- Close release valve and pressurize the jack till final stress value of the
third step and tighten the nut with the tool pin further. This should
be possible over a few degrees only.
--- Open release valve at the pump and slowly lower the jack pressures
till zero.
25 4th step
fourth step and try to tighten the nut with the tool pin further. This
should not be possible.
till zero.
--- Disconnect the hose and remove the tool set.
23328
2.5 -- 15
Manual
Wärtsilä 38
Side stud operating side

26 1st step
--- Turn tie rod 9622DT126 of tool set 9622DT913 completely on side
stud at operating side. See fig. 2.5 --- 3 .
--- Place distance sleeves 9622DT125 and jack 9622DT232 over the tie
rod and tighten knurled nut 9622DT233 with the tool pin
9612DT100
--- Connect hose 9612DT961 between jack and pump 9612DT212, open
release valve at pump and tighten knurled nut further to force jack
piston into bottom position.
Note! See section 2.4.4.4. for jack pressures and nut shifting.
--- Pressurize jack till pre---stress value of the first step and tighten side
stud nut firmly with tool pin.
--- Check with feeler gauge of 0.05 mm for any clearance between nut
and contact face. Clearance should not exist.
--- Slowly lower pressure till zero. Tighten the knurled nut to force the
jack piston to bottom position.
27 2nd step
--- Check if the jack piston is completely in bottom position.
--- Close the release valve at the hydraulic pump and pressurize the jack
till final stress value of the second step.
--- While firmly tightening the nut, count and note the number of holes
the nut can be shifted.
--- Check if the number of holes which the nut is shifted is within the
values mentioned in section 2.4.4.4.
till zero. Tighten the knurled nut firmly to force the jack piston in
bottom position.
28 3rd step
third step and tighten the nut with the tool pin further. This should
--- Open release valve at the pump and slowly lower the jack pressures
till zero.
2.5 -- 16 23328
Manual
29 4th step
fourth step and try to tighten the nut with the tool pin further. This
till zero.
--- Disconnect the hose and remove the hydraulic tools from the side stud.
30 Re---install the bearing temperature sensor and check the proper

indication.
31 Fit the protecting caps on the side studs concerned.
32 Inspect the crankcase for cleanness e.g. forgotten rags or tools.
33 Run the pre---lubricating oil pump and check the bearing
lubrication.
34 Close the crankcase.
23328
2.5 -- 17
Manual
Wärtsilä 38
2.5.3. Crankshaft axial locating bearing
The axial crankshaft locating bearing is located at the driving end of the
engine. This bearing further referred as the ’0’ ---bearing (zero ---
bearing). The construction is similar to other main bearings however
the ’0’ ---bearing cap and bearing shells are different in dimensions. The
axial forces of the engine are taken by two sets of thrust rings (1), which
are accommodated in recesses on both sides of the the bearing housing
of the engine block and bearing cap. The axial movement of the
crankshaft is limited by these thrust rings. The lower thrust rings are
hold in position against rotation by a locating pin (2) in the ’0’ ---bearing
cap (3). The ’0’ ---bearing cap is axially guided during lifting by four
guiding strips (4), mounted on the ’0’ ---bearing cap. See fig. 2.5 --- 9 .
Main bearing ’0’--bearing

no. 1
Driving end
1 1
2 2
4
3
Fig. 2.5 - 9 Crankshaft axial locating bearing
2.5 -- 18 23328
Manual
2.5.3.1. Removal of the ’0’--bearing
Warning! Never remove the main bearing next to the ’0’-- bearing at the same
time and never move the crankshaft in axial direction by exerting a
force on the counter weights.
Before removal of the ’0’ ---bearing, first measure the axial clearance of
the crankshaft. To be able to measure this clearance it is necessary to
move the crankshaft to and fro in axial direction.
The removal procedure for the crankshaft axial locating bearing is the
same as for the other main bearings.
Measuring the axial clearance.

1 Pre---lubricate the engine for a few minutes.
2 Move the crankshaft to and fro in axial direction e.g. with a jacking
bolt between flywheel and engine block or foundation.
3 Move the crankshaft as far as possible to the driving end side.
4 Place a dial gauge between engine block and flywheel and adjust it
to zero.
5 Move the crankshaft as far as possible to the free end side.
6 Note the value found, and verify the clearance with the
commissioning report, see also chapter 2.4.5.2. for the nominal
clearance.
Removal of ’0’--bearing.
7 Remove the ’0’ ---bearing cap and bearing shells according to the
procedure mentioned in section 2.5.2.2. Inspect bearing and journal
according to section 2.5.2.3.
8 With the ’0’ ---bearing cap in lowest position both axial lower thrust
rings (1) can be removed. The lower thrust rings are secured by locating
pins (2) in the main bearing cap. See fig. 2.5 --- 9 .
9 The upper thrust rings, can be slide downwards, these rings are not
secured.
23328
2.5 -- 19
Manual
Wärtsilä 38
2.5.3.2. Inspection of axial thrust rings and

thrust collars on the crankshaft.
1 Clean the thrust rings and check for wear, scoring and other damages.
2 Clean running surfaces of the crankshaft and inspect for surface
finish, scoring and wear. See chapter 2.4.5.2. for tolerances and wear.
2.5.3.3. ’0’--bearing assembling
1 Mount upper and lower bearing shells. See chapter 2.5.2.4.

2 Slide the clean upper thrust rings in the recesses.
3 Fit the lower thrust rings in the recesses of the bearing cap. Take
care the locating pins fit properly.
Note! Check if strips (4) on the bearing cap are still tightened and if locking
plates are in good condition, see fig. 2.5 - 9 .
4 Lift the ’0’ ---bearing cap into position and tighten bearing cap studs
and side studs by hand using the tool pin.
5 Position the axial lower and upper thrust rings in line by moving the
crankshaft to and fro in axial direction e.g. with a jacking bolt between
flywheel and engine block or foundation.
6 Place a dial gauge between engine block and flywheel and make
sure that there is axial clearance.
7 Move the crankshaft as far as possible to the driving end side and
keep it in position and adjust the dial gauge on zero.
8 Tighten the side studs and bearing cap studs according to the
sequence mentioned in section 2.5.2.4.
9 Move the crankshaft to and fro in axial direction.
10 Check the axial clearance, note the value found and verify the
clearance with the commissioning report, see also section 2.4.5.2. for the
nominal clearance.
11 Re---install the bearing temperature sensor and check the proper
indication.
12 Fit the protecting caps on the side studs concerned.
13 Inspect the crankcase for cleanness e.g. forgotten rags or tools.
14 Run the pre---lubricating oil pump and check the bearing lubrication.
15 Close the crankcase.
2.5 -- 20 23328
Manual
2.5.4. Camshaft bearings
The camshaft bearing bushes (1) are shrunk in housings machined in

the engine block. The bearing bushes can be inspected and measured
after removing the camshaft section (2) and journal (3).
In this section only the removal and mounting procedure of the
camshaft bearing bushes located in the engine block are described. The
camshaft bearing bush (0) at the driving end is the ’0’ ---bearing bush,
the next is bearing bush number 1 etc.
For camshaft and camshaft drive see section 2.8.1.
3 1 2 4 0
Fig. 2.5 -- 10 Camshaft and axial bearing assembly
2.5.4.1. Inspection of the camshaft bearing bush
1 Remove the camshaft section and journal of the bearing bush to be

inspected. In case of ’0’ ---bearing the camshaft gearwheel (4) with shaft
has to be removed, see section 2.5.4.2.
2 Clean the camshaft bearing bush and check for wear, scoring or
damages. See chapter 2.4.5.2. for measurements and tolerances.
Camshaft bearing bushes are made of bi---metal.
Note! If the inspected bearing bush is worn the others will most probably
be in the same condition and have to be inspected as well.
3 The camshaft bearing journals should be inspected for surface

finish. Damaged journals, i.e. rough surface, scratches, or other
damages. See section 2.4.5.2. for measurements and tolerances.
23328
2.5 -- 21
Manual
Wärtsilä 38
2.5.4.2. Removal of the camshaft bearing bush
If the camshaft bearing bush has to be renewed it is necessary to remove

the camshaft sections on both sides of the bearing concerned.
1 Mount the extracting tools according to fig 2.5 --- 11 .
2 Connect hydraulic jack 9622DT148 with hose to pump 9622DT133.
3 Tighten nut (1) and pressurize the jack to extract the bearing bush
out of the housing.
9622DT148
9622DT908
9622DT133
Fig. 2.5 -- 11 Connect the hoses to the pump
4 Stop extracting when the jack piston protrudes 48 mm (which is

nearly the max. stroke of the jack). At this point open the release valve
at the pump and push down the jack piston by shortening the effective
tie rod length.
5 Pressurize the jack again and force the bearing bush in this second
stroke completely out of the housing. Take care for the weight of the tool
and bearing bush.
6 Remove the tool set and bearing bush.
2.5 -- 22 23328
Manual
2.5.4.3. Mounting the camshaft bearing bush
1 Clean the camshaft bearing bush housing in the engine block and
check the bore carefully for any damage.
2 Cool the new bearing bush in liquid nitrogen till a temperature of
approx. ---180C. This temperature is achieved on the moment the liquid
nitrogen stops bubbling.
Note! Wear special low temperature resistance gloves and safety glasses!
3 Insert the bearing bush by hand in the camshaft bearing bush
housing.
4 The lube oil supply hole in the bearing bush has to come in line with
the lube oil supply hole in the engine block. Use tool pin 9612DT257 to
position the bearing bush.
Note! The lube oil supply hole of the ’0’--bearing should have the same
position as the other bearing bushes, but tool pin 9612DT257 can
not be used. There is no supply hole in the engine block, but a
groove. Keep the outside of the bearing bush in line with the outside
of the engine block, see fig 2.5 -- 12 .
5 Mount the camshaft journal and camshaft sections, tappets, push

rods, and fuel pumps. See the chapters concerned.
6 Remove tool set and adjust valve clearances.
7 Check the camshaft spaces for cleanness and lubrication and close
the camshaft covers.
Fig. 2.5 -- 12 ’0’-- bearing bush in engine block
23328
2.5 -- 23
Manual
Wärtsilä 38
2.5.5. Cylinder liner
The cylinder liner (1) is centrifugally cast of a special cast iron alloy. The
collar is equipped with bores (2) for cooling of the upper part. The inner
part of the collar is provided with an anti polishing ring (3). The liner
is secured during maintenance by clamps (4).The cooling water space
(5) is sealed by sealing compound between engine block and liner at (6),
and by O ---rings at (7). The bottom part of the liner is supported by a rim
(8). Space (9) is not specially cooled, but is in open connection to the
crankcase via two flat sides (10) at the lower part of the liner. The liner
temperature is monitored by sensors fitted in drillings (11).
2 1
11
6
5
7
9
10
8
Fig. 2.5 -- 13 Liner in engine block
2.5.5.1. Inspection of the cylinder liner
The inside of the cylinder liner can be inspected by endoscope, or after

removal of the cylinder head. For complete maintenance the cylinder
liner has to be removed.
For maintenance schedule see chapter 2.4.1.
Clean the cylinder liner cooling water spaces and inspect the contact
faces in the engine block during cylinder liner overhaul.
2.5 -- 24 23328
Manual
2.5.5.2. Removal of the cylinder liner
1 Drain the engine cooling water and remove the cylinder head and
piston with connecting rod. See chapter 2.6. and 2.7.
2 Remove the cylinder liner clamps (2).
3 Remove the cylinder liner temperature sensors.
4 Fit the cylinder liner lifting device 9622DT914 in position and
tighten the nuts (1) lightly. Check that the lower part (3) of the lifting
device fits properly in the bore and against the bottom part of the liner.
9622DT914 4 1
Fig. 2.5 -- 14 Liner lifting device
5 Remove eye bolt (4) and place from extracting tool 9622DT915
frame 9622DT131, tie rod 9622DT132 and hydraulic jack 9622DT148.
Secure the jack with nut 9622DT113 and connect with pump
9622DT133. See fig 2.5---15
6 Pressurize the jack and pull the cylinder liner free from the joint
faces. The maximum stroke of the jack is 48mm. If necessary shorten
the effective tie rod length.
When the liner starts to move freely, remove the extracting tool and fit
eye bolt in the correct position
7 Use a crane to lift the liner further carefully out of the cylinder
block.
23328
2.5 -- 25
Manual
Wärtsilä 38
9622DT148 9622DT113
9622DT131
9622DT132
9622DT914
9622DT133
Fig. 2.5 - 15 Lifting the cylinder liner
8 Remove the tools.
Note! Mind the centre of gravity when lifting the cylinder liner. Free
standing liners must be properly supported.
CENTRE OF GRAVITY
Fig. 2.5 -- 16 Centre of gravity
2.5 -- 26 23328
Manual
2.5.5.3. Mounting the cylinder liner
Measuring of the cylinder liner can be done in the engine as well as

detached.
1 Measure the cylinder liner inner diameter with tool 9612DT401 and
record readings. Use the liner measuring strip 9622DT929 for the
required reference heights. See also section 2.4.5. fig. 2.4 --- 27 .
9622DT929
2 9612DT401
1 3
4 4
2 In case of indents or other damages of the sealing faces of the engine

block and\or liner, they have to be reconditioned by grinding.
3 Clean the grooves for the O ---rings (1) and replace both O ---rings,
apply a thin layer of silicon grease on the rings and Molycote TP 42 at
rim (3). See fig. 2.5 --- 17 .
For code number of Molycote see parts catalogue.
4 Apply liquid sealant (Permatex super 300) all around surface (2).
For sealing compound see parts catalogue).
5 Apply surface (4) with a large amount of Molycote TP 42.
6 Clean and inspect the sealing face locations of the liner and
O ---rings in the engine block.
23328
2.5 -- 27
Manual
Wärtsilä 38
7 Place positioning tool 9612DT926 with positioning pins in the

cooling bores marked with ’X’. Marks ’X’ on the tool must correspond
with the marks ’X’ on the liner rim. See fig. 2.5 --- 18 .
5
9612DT926 9612DT926
Fig. 2.5 -- 18 Marks on cylinder liner
8 Let the tool bar slide between cylinder head stud (5), at inlet side,
and (6) during lowering of the liner. See fig. 2.5 --- 18 .
9 Lower the liner carefully into the bore of the engine block.
10 Apply a little force to press the liner O ---rings in the engine block
bore till the collar rests on the engine block.
11 Mount clamps (2) see fig 2.5 --- 14 and tighten the cylinder liner
clamp bolts to the stated torque according the table of section 2.4.4.9.
12 Re---install the temperature sensors connection.
13 Mount the piston with connecting rod. Mount the cylinder head and
refill the engine with cooling water. See chapters 2.6. and 2.7.
14 Check the O ---ring seals on water leakage.
2.5 -- 28 23328
Manual
2.5.6. Replacing cylinder head stud

1 Fit tool 9612DT976 onto the stud and tighten the bolt on top of it.
Loosen the stud by using a spanner on the bolt (the bolt is provided with
left---handed thread).
9612DT976
”Y”
Fig. 2.5 -- 19 Replacing cylinder head stud
2 Clean thread and recess in top of the engine block and check for
corrosion.
3 Clean both thread ends of the stud and check the thread ends are
free of damage by using a cylinder head nut and by turning the stud in
and out the threaded hole in the engine block.
4 Apply the thread of the lower part of the stud with Castrol Tarp and
turn the stud into the threaded hole in the engine block.
5 Tighten the stud with a torque spanner and socket of 55 mm, see
section 2.4.4.6.
6 Fill the space between the stud and the block with Castrol storage
oil till measurement ”Y” ( approx. 40---60 mm ). For code numbers of
Castrol see parts catalogue.
7 Place O ---ring (1) around the stud 4 --- 5 mm below the cylinder block
surface , see fig. 2.5 --- 19 .
23328
2.5 -- 29
Manual
Wärtsilä 38
2.5.7. Crankcase explosion relief valves
Crankcase explosions result from ignition of a combustible mixture of

lubricating oil or gas and air. Combustion pressure, which develops
following ignition within the confined space, frequently exceeds the
strength of the crankcase housing or covers, causing destructive failure.
The ignition source may be gas blow–by or an overheated engine part.
Any part moving relative to another potentially can become excessively
hot through friction to initiate combustion if not lubricated or cooled
properly. All bearings, bushing, thrust surfaces, pistons, etc. as well as
the surfaces these parts touch, are included. Broken piston or rings that
allow fire in the combustion chamber to blow through to the crankcase
is also a source of crankcase ignition.
Operators must recognize that all engine/compressors have the
potential to develop hot spots capable of igniting crankcase vapours and
producing a crankcase explosion. The potential can be reduced or safely
contained by attention to good maintenance practices.
Engine stop / cool down period

If a crankcase explosion occurs, allow the equipment to cool down at
least 15 minutes before attempting to open any crankcase cover doors.
The heat inside the crankcase will promote an inrush of fresh air when
cover doors are removed and hot spots remaining from the explosion
may cause a violent secondary explosion.
If smoke is observed coming from crankcase vents ore breathers, safely
shut down the equipment and vacate the area.
Smoke from vents or breathers (especially white smoke) is an indication
that a hot spot is vaporizing lubricating oil and is often observed as a
precursor to a crankcase explosion.
A sudden increase in crankcase pressure is an indication of gas blow–by
probably caused by broken piston rings indicates an increased risk of a
crankcase explosion.
Working
A corrugated plate valve (1), see fig. 2.5 --- 20 , is by a conical shaped
spring (2) forced on an O–ring seat (3) closing the crankcase to the
outside. In case of an excessive overpressure (explosion) the plate valve
is forced into open position allowing gasses to escape through a number
of baffle plates (4). The baffle plates extinguish the flames. The conical
shape spring closes the plate valve and avoids the entering of fresh air.
2.5 -- 30 23328
Manual
Maintenance
1 Periodically open the plate valve manually over the full stroke and
check plate valve returns to its seat without hamper, see section 2.4.1.
2 Check conical spring on spring force. Renew oxidised springs.
3 Periodically renew all O–rings, see chapter 2.4.1..
4 Check by feeler gauge if plate valve is resting on the O–ring and not
on the steel O–ring housing.
5 After O–ring renewal move plate valve manually over the full
stroke, see point 1.
Closed
position
3
1
2
Open
position
Fig. 2.5 -- 20 Crankcase safety valve
--o--o--o--o--o--
23328
2.5 -- 31
Manual
Wärtsilä 38
2.5 -- 32 23328
Manual
Crankshaft, Connecting Rod, Piston Wärtsilä 38
2.6. Crankshaft, Connecting Rod, Piston
Table of contents
2.6. Crankshaft, Connecting Rod, Piston . . . . . . . . . . . . . . . . . . . . . . . 2.6 - 1

2.6.1. Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 2
2.6.1.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 2
2.6.1.2. Crankshaft deflections check . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 2
2.6.1.3. Measurement axial clearance crankshaft thrust bearing . . . . 2.6 -- 3
2.6.2. Connecting rod and piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 4
2.6.2.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 4
2.6.2.2. Removing and dismantling of piston and connecting rod . . . . 2.6 -- 5
2.6.2.3. Inspection and maintenance of piston rings
and gudgeon pin bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 12
2.6.2.4. Assembling and mounting of piston and connecting rod . . . . 2.6 -- 13
2.6.3. Big end bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 18
2.6.3.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 18
2.6.3.2. Removing big end bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 18
without removing piston / connecting rod . . . . . . . . . . . . . . . . . 2.6 -- 22
2.6.3.4. Assembling the big end bearing . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 24
2.6.4. Vibration damper crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 26
2.6.4.1. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 26
2.6.4.2. Liquid sampling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 27
2.6.5. Cranking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 29
2.6.5.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 29
2.6.5.2. Maintenance turning device . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 -- 30
23328 2.6 -- 1
Manual
Wärtsilä 38
Crankshaft, Connecting Rod, Piston
2.6.1. Crankshaft
2.6.1.1. General
The crankshaft design features a very short cylinder distance with a

maximum bearing width resulting in a short engine. The crankshaft is
forged from one piece of high tensile steel.
Counterweights are mounted hydraulically onto the crankshaft webs. The
high degree of balancing results in an even and thick oil film for all bearings.
Main bearings and big end bearings are of the bi---metal type with a steel
back and a soft running layer with excellent corrosion resistance. The gear
wheel on the crankshaft is mounted by a flange connection.
The crankshaft is provided with a torsional vibration damper at the free
end of the engine.
2.6.1.2. Crankshaft deflections check
Take crankshaft deflection readings only when engine and foundation

are at ambient temperature.
1 Lubricate the bearings for a few minutes by running the pre

lubricating pump.
2 Remove crankcase covers at both sides.
3 Start at cylinder 1 and turn crankshaft clockwise till crankpin is
 15 _ after Bottom Dead Centre ( BDC ).
This crankshaft position is starting point ’A’ for the dial gauge reading,
see fig. 2.6 --- 1 .
operating side non--operating side
Fig. 2.6 - 1 Taking crankshaft deflection readings
2.6 -- 2 23328
Manual
4 Place a dial gauge in between the counter weights in the centre

points at position ’A’ and adjust dial gauge at zero. Rotate dial gauge a
few times between centre points and check reading is still at zero.
5 Turn crankshaft till dial gauge is in positon ’B’ and record dial
gauge reading in protocol.
6 Turn crankshaft till dial gauge is in position ’C’ and record dial
7 Turn crankshaft till dial gauge is in position ’D’ and record dial
8 Turn crankshaft till dial gauge is in position ’E’ and record dial
9 Repeat procedure for remaining cranks.
10 Compare crankweb deflection readings with readings of
installation protocol or engine test bed report. In case deviations are out
of tolerance investigate reason. If no improvements can be obtained,
consult the nearest Wärtsilä Network Company.
11 Replace crankcase covers.
2.6.1.3. Measurement axial clearance

crankshaft thrust bearing
1 Pre---lubricate the engine for a few minutes.

2 Move the crankshaft to and fro in axial direction e.g. with a jacking
bolt between flywheel and engine block or foundation.
3 Move the crankshaft as far as possible to the driving end side.
4 Place a dial gauge between engine block and flywheel and adjust it
to zero.
5 Move the crankshaft as far as possible to the free end side.
6 Note the value found, and verify the clearance with the
commissioning report, see also chapter 2.4.5.2. for the nominal
clearance.
23328 2.6 -- 3
Manual
Wärtsilä 38
2.6.2. Connecting rod and piston
2.6.2.1. General
The connecting rod of the ”Marine type” consists of a connecting rod (1)
with a removable big end.
The big end consists of a big end upper part (2) and a big end lower part (3).
Between the big end upper part and connecting rod foot an intermediate
plate (4) is mounted.
The piston is of the composite type with a nodular cast iron skirt (6) and
steel crown (5).
All connecting rod studs are hydraulically tightened, for background
information see section 2.4.3.
Note! Always handle pistons and connecting rods with care.
4
2
Fig. 2.6 -- 2 Connecting rod and piston assembling
2.6 -- 4 23328
Manual
2.6.2.2. Removing and dismantling of piston

and connecting rod
Removing of the piston

1 Turn the crankshaft 20 _ out of TDC.
2 Remove cylinder head, see chapter 2.7., and scrape off the carbon
deposits around the upper part of the cylinder liner. It is advisable to
cover the piston top with cloth or paper, pressed tightly against the
cylinder wall to collect the deposits removed. The liner must be free of
carbon to protect the piston rings when removing the piston out of the
liner.
3 Fit the free ends of tool 9622DT919 in the grooves of the
anti---bore---polishing ring (8).
--- Tighten bolt (6) and slowly turn the piston through TDC forcing the
anti---bore polishing ring out of the liner top.
--- Remove the ring from the liner.
6 9 8
9622DT919
Fig. 2.6 -- 3 Removing anti-- bore polishing ring
4 Remove cloth or paper protection with the collected carbon from the
piston crown.
5 Clean the threaded holes in the piston crown with tap 9622DT163
and fasten hoisting tool 9622DT923 with the bolts to the piston crown
see fig. 2.6 --- 6 .
23328 2.6 -- 5
Manual
Wärtsilä 38
6 Turn the piston in bottom position. Remove at both sides of the

engine the crankcase doors.
7 Place from the hydraulic tool set 9612DT907 the tie rods
9622DT230 on each of the 4 studs of the connecting rod --- big end
bearing connection. See fig. 2.6 --- 4 .
8 Place at each side of the connecting rod the jacks 9622DT234 over
the tie rods and turn on the knurled nuts 9622DT231. See fig. 2.6 --- 4 .
9622DT230
9622DT231
9612ZT125
9622DT234
Fig. 2.6 - 4 Hydraulic tool connecting rod studs
9 Connect the HP hoses 9612DT961 between pump 9612DT212 and

jacks 9622DT234, open the release valve at the pump and tighten the
4 knurled nuts by means of tool pin 9612ZT125 until the jack pistons
are fully forced in bottom position.
9612DT961
9612DT212
Fig. 2.6 - 5 Connection of the hydraulic tools
2.6 -- 6 23328
Manual
10 Loosen the knurled nuts 1 full turn.

11 Close the release valve and pressurise the jacks till final stress
value, see section 2.4.4.5. fig. 2.6 --- 17 .
12 Loosen the connecting rod nuts 3/4 turn (6 holes).
13 Release the jack pressure slowly till zero and check if the knurled
nuts and the connecting rod nuts are loose. Disconnect the hoses and
remove the tool set.
14 Remove the four nuts from the connecting rod studs.
15 Connect the crane with lifting tool 9622DT923 on the piston.
9622DT923
Fig. 2.6 -- 6 Hoisting tool
23328 2.6 -- 7
Manual
Wärtsilä 38
16 Hoist the piston ---connecting rod assembly a few cm free from the
studs and fit the protecting device 9622DT922 against the connecting
rod sole. See fig. 2.6 --- 7
Note! During hoisting of the piston and connecting rod assembly hold
connecting rod free and take good care not to damage anything.
Check also that the piston comes easily out of the liner without
excessive force and the connecting rod foot slides easily into the
bottom side of the liner.
9622DT922
Fig. 2.6 - 7 Fitting the protecting device
17 Mark the intermediate plate for remounting at the corresponding

connecting rod and remove the plate.
18 Seal the lubricating oil holes in the big end upper part.
19 Remove lifting tool.
2.6 -- 8 23328
Manual
96922DT923
96922DT922
Fig. 2.6 -- 8 Hoisting the piston
For temporarily storing and handling of the piston and connecting rod
use fixating tool 9622DT928.
9622DT928
Fig. 2.6 -- 9 Piston with fixating tool
23328 2.6 -- 9
Manual
Wärtsilä 38
Dismantling of piston
1 Place the piston/connecting rod assembly top side down on a flat ply
wood surface holding the connecting rod with sling and crane vertical.
Fig. 2.6 - 10 Piston with connecting rod in vertical position
2 Remove the retainer spring (9) out of the gudgeon pin hole by using
pliers 9622DT178.
9622DT178
Fig. 2.6 - 11 Removing the retainer spring
Note! Never compress the retainer spring more than necessary to remove
from the groove.
2.6 -- 10 23328
Manual
3 Control the strain in the sling such that the gudgeon pin becomes
floating in piston and connecting rod bore.
Fig. 2.6 -- 12 Removing gudgeon pin
4 Slide the gudgeon pin carefully out of the piston. See fig. 2.6 --- 12 .
Note! Be careful!! The gudgeon pin is heavy and should be supported

during sliding out.
Fig. 2.6 -- 13 Removing connecting rod
23328 2.6 -- 11
Manual
Wärtsilä 38
2.6.2.3. Inspection and maintenance of piston

rings and gudgeon pin bearing
1 Clean all parts carefully. Remove the piston rings with pliers
9612DT250.
Remove carbon deposits from the piston and piston ring grooves.
Special care should be taken not to damage the piston material.
Never use emery cloth on the piston skirt and crown.
For cleaning from carbon deposits it is advised to immerse the material

in kerosene or fuel oil. Use a carbon solvent --- e.g. ARDROX No. 668 or
similar--- for cleaning of the piston crown. Do not clean the piston skirt
with chemical cleaning agents as such agents may damage the
phosphate / graphite overlay.
Check of the piston rings

When a piston inspection is carried out according the maintenance
program the piston rings may be worn and due to replacement.
2 Measure the height of the piston ring grooves and height clearance
of the rings in their respective grooves. See clearances and wear limits
in section 2.4.5.2. Rings, once taken from the piston, should not be
mounted again.
Piston rings should not definitely be replaced during a piston inspection

as long as the rings are not damaged and not taken from the piston. The
liner surface should be in a good condition.
Check of the gudgeon pin

3 Check the gudgeon pin bearing clearances by measuring the
gudgeon pin diameters and bearing bores separately.
Measure the gudgeon pin bearing diameter at four different places and
in four directions.
4 Check the plugs at both ends of the gudgeon pin are properly
secured.
5 Check the oil bores in the gudgeon pin are in good condition.
2.6 -- 12 23328
Manual
2.6.2.4. Assembling and mounting of piston

and connecting rod
Note! During assembling of piston and connecting rod be sure that

identification marks of components are according to fig. 2.6 -- 14 .
Note! The number of the cylinder concerned is indented in the upper part
of the piston and in the connecting rod. See fig. 2.6 -- 14 . When the
piston has to be changed for a new one the same marks have to be
indented at the same position as in the previous one.
marks of the
classification society
factory marks
All marks on
the same side
(towards the
driving end in
in--line engines)
view A
Cylinder numbers
on the same side
Fig. 2.6 -- 14 Marks on piston and connecting rod
23328 2.6 -- 13
Manual
Wärtsilä 38
Assembling of piston and connecting rod

1 Place the piston top side down on a flat piece of ply wood.
Fig. 2.6 - 15 Securing the piston
2 Lift the connecting rod by a sling and crane top side down and lower
the connecting rod slowly into the piston.
Fig. 2.6 -- 16 Moving the connecting rod into the piston

3 Line up the gudgeon pin holes of connecting rod and piston.
4 Insert the gudgeon pin into the piston gudgeon pin bore and by
carefully lining the bore in the connecting rod push the gudgeon pin
completely in the bore.
5 Refit the retainer spring (9) with pliers 9622DT178.
6 Mount the piston lifting tool 9622DT923 and turn the piston /
connecting rod assembly over.
2.6 -- 14 23328
Manual
Mounting of piston / connecting rod assembly

7 Turn the crankshaft to BDC.
Note! During turning of the crankshaft make sure that the big end bearing
cap assembly is in its normal running position (standing vertical).
8 Mount the piston rings by using the pliers 9612DT250. When new
rings are mounted, check the height clearance with a feeler gauge with
the rings fitted into their grooves.
Fig. 2.6 -- 17 Piston on connecting rod
9 Shift the piston rings with slots equally divided over the
circumference 180 _ opposite to each other. Ample lubricate the piston
rings with engine oil.
Note that the mark ”TOP” near the spring slot is pointing upwards.
10 Clean the cylinder liner bore carefully and lubricate the surface
with engine oil.
11 Place guide ring 9622DT924 on top of the liner.
12 Clean and check the contact surface of the connecting rod foot.
Be sure the oil drillings are open and clean. Make sure the markings on
the connecting rod foot are on the same side as at the big end bearing
caps. See Fig. 2.6 --- 14 .
13 Check and clean the big end bearing upper cap contact surface. Be
sure the surface is dry and clean.
14 Check condition of both locating pins and holes.
23328 2.6 -- 15
Manual
Wärtsilä 38
15 Check if the position of the locating pins correspond with the

counter bore holes in the connecting rod foot.
16 Place the intermediate plate (5) in position. See fig. 2.6 --- 18 .
17 Mount protecting plate 9622DT922 against the connecting rod foot
to protect the liner surface.
18 Lubricate the piston skirt with engine oil.
19 Lower the piston carefully into the cylinder liner.
Note! Take good care not to damage anything when the connecting rod
foot comes free the liner
20 Remove the protecting plate after the connecting rod foot has
passed the liner.
21 Make a final check to the contact surfaces of the connecting rod foot
(clean and free from oil), before the foot slides over the studs.
9622DT923
9622DT924
9622DT922
10
5
Fig. 2.6 - 18 Lowering the piston and connecting rod into the
cylinder liner
2.6 -- 16 23328
Manual
22 Lower the piston completely and take care the foot of the connecting
rod slides over the studs (10) without hampering.
See fig. 2.6 --- 18 .
23 Remove the lifting tool and the guide ring.
24 Fit the connecting rod nuts and tighten the 4 nuts with the tool pin.
25 Fit from the hydraulic tool 9612DT907 the tie rods 9622DT230 on
the connecting rod studs.
Place both jacks 9622DT234 over the tie rods and fit the knurled nuts
9622DT231.
26 Connect the HP hoses 9612DT961 to the hydraulic pump
9612DT212 according to fig. 2.6 --- 5 and open the release valve on the
pump.
27 Tighten the knurled nuts completely on by means of the tool pin
9612ZT125 to force the jack pistons to bottom position.
See section 2.4.4.5. fig 2.6 - 17 for jack pressure and nut shifting.
28 1st step
--- Close the release valve and pressurise the jacks till the value of the
first step ( pre---stress ).
--- Use the tool pin to tighten the bearing cap nuts by hand.
--- Open the release valve slowly to lower the pressure till zero.
--- Tighten the knurled nuts completely by means of the tool pin to force
the jack pistons to bottom position.
29 2nd step
--- Increase the hydraulic pressure till the value of the second step ( final
stress ).
--- While firmly tightening the nuts with the tool pin count and note the
number of holes the nuts can be shifted. The nut shifting should be
equal.
--- Check if the numbers of holes the nuts are shifted is within the values
mentioned in section 2.4.4.5.
--- Tighten the knurled nuts completely on by means of the tool pin to
force the jack pistons to bottom position.
23328 2.6 -- 17
Manual
Wärtsilä 38
30 3rd step
--- Increase the pressure till the value of ,the first step ( final stress ).
Tighten on the nuts with tool pin. Further shifting of the nuts should
--- Release the hydraulic jack pressure slowly.
31 4th step
--- Increase the pressure till the value of the fourth step ( final stress).
Try to tighten on the nuts any further. Further shifting of the nuts
--- Release the hydraulic jack pressure slowly till zero, disconnect the
hoses and remove the jacks and tie rods.
32 Fit the anti bore polishing ring with the aid of tool 9622DT919,
see fig. 2.6 --- 3 .
33 Fit cylinder head see chapter 2.7.
2.6.3. Big end bearing
2.6.3.1. General
The big end bearing is of the bi---metal type with a steel back and a soft
running layer with excellent corrosion resistance.
The big end bearing caps contain an upper and lower bearing shell.
Upper and lower bearing shell are not identical!
2.6.3.2. Removing big end bearing
1 Remove the cylinder head and piston.

2 Turn the big end into B.D.C. and turn the big end bearing top side
down.
3 Place from hydraulic tool set 9612DT907 the tie rods 9622DT230 on
each of the 4 studs of the big end . See fig. 2.6 --- 19 .
4 Place at each side of the big end the jacks 9622DT234 over the tie
rods and turn on the knurled nuts 9622DT231 and tighten with tool pin
9612ZT125.
2.6 -- 18 23328
Manual
9622DT230
9622DT231
9612ZT125
9622DT234
Fig. 2.6 -- 19 Hydraulic tool big end bearing studs
5 Connect the jacks 9622DT234 with HP hoses 9612DT961 and to the

hydraulic pump 9612DT212 open the release valve at the pump and
tighten the knurled nuts with tool pin 9612ZT125 to force the jack
pistons to bottom position. See fig. 2.6 --- 20 .
6 Loosen the knurled nuts one full turn.
9612DT961
9612DT212
Fig. 2.6 -- 20 Connection HP hoses big end bearing
23328 2.6 -- 19
Manual
Wärtsilä 38
7 Pressurise the jacks till final value and use tool pin to loosen the big
end bearing cap nuts 1 turn (8 holes).
8 Open the release valve and slowly lower the hydraulic jack pressure
to zero and check if the knurled nuts and the big end bearing cap nuts
are loose. Disconnect the hoses and remove the tool set.
9 Turn the big end bearing assembly till the bottom end studs are
pointing to the engine operating side.
10 Place from tool 9622DT921 the supports 9622DT161 over the
crankcase door studs at each side of the crankcase opening and secure
the supports with nuts.
Place frame 9622DT160 in between the supports see fig 2.6 --- 21 .
Turn the crankshaft slowly in clockwise direction till about 60 _ after
T.D.C. and leave the big end bearing assembly a few mm free from the
frame.
9622DT161 9622DT161
9622DT160 9622DT158 9622DT157
Fig. 2.6 -- 21 Frame and support big end bearing caps
2.6 -- 20 23328
Manual
11 Remove at operating side first the 2 lower nuts.

12 Place carrier 9622DT157 on support and slide carrier under the
lower big end bearing cap. See fig. 2.6 --- 22 .
13 Place carrier 9622DT158 under the upper bearing cap and secure
the carrier with two bearing cap nuts. Let both bearing caps rests on the
carriers.
14 Remove the upper nuts separate the bearing caps by sliding them
outwards till the end of the support.
9622DT158 9622DT157
Fig. 2.6 - 22 Carriers big end bearing caps
15 Take the bearing shells out of the caps. The big end bearing journal,
shells and caps can be inspected.
16 Remove the big end bearing caps by using a sling.
17 Cover the big end bores.
23328 2.6 -- 21
Manual
Wärtsilä 38

without removing piston /
connecting rod
For inspection of only the connecting rod bearings it is not always

necessary to remove the cylinder head and piston. For this purpose
supports are available to keep the piston in lifted position in the liner,
disconnected from the connecting rod.
1 Remove the connecting rod bolts. See dismantling process 2.6.2.2.

2 Turn the piston in top and fit the two supports 9622DT168 against
the bottom rim of the liner.
3 Slowly turn the crankshaft and let the disconnected piston /
connecting rod assembly rest on the mounted supports.
9622DT168
Fig. 2.6 -- 23 Mount piston support
4 Continue turning and take care the connecting rod foot comes free
from the big end.
Note! Take care the connecting rod is not damaging anything when it
comes free from the big end.
2.6 -- 22 23328
Manual
5 Slowly turn the crankshaft and big end in to bottom position.

6 Place the hydraulic tools according to fig.2.6 --- 24 , loosen the big
end bearing cap nuts, separate the big end and remove the bearing
shells. See section 2.6.3.2.
9622DT230
9622DT231
9612ZT125
9622DT234
Fig. 2.6 - 24 Fit hydraulic tightening tool
In case more pistons have to be lifted from the engine by which the
crankshaft has to be turned, use tool 9622DT170 to fix the individual
connecting rod bearings to the crankweb. This is to avoid free rotating
of the connecting rod bearings.
9622DT170
Fig. 2.6 -- 25 Positioning device
23328 2.6 -- 23
Manual
Wärtsilä 38
2.6.3.4. Assembling the big end bearing
1 Remove the protection from the big end oil bores. Clean and
lubricate the big end properly with clean engine oil.
2 Place the big end bearing lower cap on carrier 9622DT157 into the
support see 9622DT155 fig. 2.6 --- 21
3 Fit the big end bearing upper cap to carrier 9622DT158 with two
bearing cap nuts, and place into the support 9622DT156 see fig.
2.6 --- 21
Note! Always assemble bearing caps with part numbers facing the engine
operating side.
4 Clean both bearing shell at both sides and lubricate only the
running side of the shells with engine oil. Check the bore and joint faces
of the cap for damage.
5 Place the upper bearing shell into the bearing cap upper half.
Warning! Check carefully that the positioning lug of the shell fits properly in
the recess of the bearing cap.
6 Slide the big end bearing cap---shell assembly carefully to the big
end journal. Note that the crankshaft is turned to the right position,
approx. 60 _ after T.D.C. Observe the correct position of the shell in the
cap again.
7 Place the lower bearing shell into the bearing cap lower half.
8 Slide the big end bearing lower half together with carrier over the
studs towards the big end journal. The locating pin in the lower bearing
cap fits in the counter hole of the upper half. Check proper positioning
of bearing caps and bearing shells.
9 Turn on the 2 nuts on the upper studs tighten with the tool pin and
remove carrier.
10 Turn on the 2 nuts on the lower studs tighten with the tool pin and
remove. Remove carrier frame and both supports.
11 Bar the big end to B.D.C. Turn the big end bearing cap assembly
with the 4 bottom end studs pointing vertical upwards.
12 Place from hydraulic tool 9612DT907 the tie rods on the 4 studs see
fig 2.6 --- 19 .
13 Place the jacks over the tie rods and tighten the knurled nuts
completely on.
2.6 -- 24 23328
Manual
14 Connect the HP hoses between the jacks and HP pump and open the
release valve at the pump.
15 Tighten the knurled nuts further on by means of the tool pin to
force the jack pistons into bottom position.
16 1st step
--- Close the release valve and pressurize the jacks till the value of the
first step ( pre---stress ).
--- Use tool pin to tighten the bearing cap nuts completely on.
--- Tighten the knurled nuts further on by means of the tool pin to force
the jack pistons into bottom position.
17 2nd step
--- Increase the hydraulic pressure till the value of the second step ( final
stress ).
--- While firmly tightening the nuts with tool pin count the number of
holes the nuts can be turned further. The nut shifting should be
equal.
--- Check if the total numbers of holes the nuts are shifted are within
the values mentioned in fig 2.4 --- 13 .
--- Release the hydraulic pressure slowly.
--- Tighten the knurled nuts further on by means of the tool pin to force
the jack pistons into bottom position.
18 3rd step
--- Increase the hydraulic pressure till the value of the third step ( final
stress ) and tighten the nuts firmly with the tool pin. This should be
possible over a few degrees only.
--- Release the hydraulic pressure slowly till zero.
19 4th step
--- Increase the hydraulic pressure again till the value of the fourth step
( final stress ) and try to turn on the nuts any further. This should
not be possible.
--- Release the hydraulic pressure slowly. Disconnect the hoses and
remove the tool set.
23328 2.6 -- 25
Manual
Wärtsilä 38
2.6.4. Vibration damper crankshaft
The vibration damper serves to reduce the torsional vibration in the

crankshaft. The damper consists of a housing and a free rotating inertia
ring supported by an axial and radial bearing. It forms a totally enclosed
unit. The free space between inertia ring and damper housing is filled
with a high viscosity fluid. The combustion pressure, exerted on the
pistons, causes a torsional vibration in the crankshaft. The energy
caused by the vibration, is converted into heat and cooled by engine
lubricating oil at the outside of the vibration damper.
The viscous damper fluid is subject to ageing during engine operation.

In sending fluid samples on a regular base to Wärtsilä Nederland B.V.
the change of the viscosity can be determined. In the analysis the quality
of the fluid is mentioned and a forecast is given of the number of running
hours still to go.
The damper cover has two sampling plugs located 180_ opposed. If one
of the sampling plugs is accessible, a fluid sample can be taken with the
damper in situ. For liquid sampling, a kit can be ordered from Wärtsilä
Nederland B.V. department under part no. 66325 904A.
Note! Dampers with a viscosity out of range may cause crankshaft

breakdown.
2.6 -- 26 23328
Manual
2.6.4.2. Liquid sampling
It is advisable to take a sample when the engine is still warm.

Proceed as follows:
1 Bar the crankshaft until a sampling plug is easy accessible.

2 Remove the lubricating oil pump if neither of the sampling plugs in
the damper is accessible for sampling.
3 Remove locking of sampling plug, using a punch and unscrew plug
with spanner 9612ZT497. Do not yet remove plug!
4 Unscrew one cap nut from (plastic) liquid container, the thread of
which corresponds to that of the sampling plug in the damper. The sides
of the liquid container have various threads for other damper types.
5 Remove sampling plug and screw liquid container instead.
Fig. 2.6 -- 26 Liquid sampling
6 Remove the outer cap nut from the liquid container. Make sure that
no machine oil or dirt can enter while filling the liquid container!
7 The filling period of the container may take from a few seconds up
to more than an hour depending on liquid condition.
23328 2.6 -- 27
Manual
Wärtsilä 38
If no liquid appears:
--- Remove second sampling plug.
--- Supply nitrogen of 3.5 bar maximum pressure through the open
second sampling plug hole. If no nitrogen is available air may be used
provided this air is properly filtered and dry.
If a liquid sample can not be obtained in this way it can be assumed that
the damper liquid has thickened to much.
In this case the damper has to be replaced.
8 Once the liquid has reached the open end of the liquid container:
--- Cut off the nitrogen if applicable.
--- Screw the outer cap nut onto the liquid container.
9 Unscrew the container from the damper and fit the second cap onto
the container.
10 Fit the damper sampling plug(s) with new joint ring(s) supplied
with the mounting kit. Replace any damaged sampling plug if necessary.
11 Tighten the sampling plugs at a torque of 35 Nm.
12 Lock the sampling plugs.
13 After sampling, provide the sample with a label (included in the
sampling kit) showing the following data :
--- serial number of the vibration damper (if possible)
--- engine type
--- engine number
--- number of operating hours
--- date of sampling
Forward the sample to : Wärtsilä Nederland B.V.
Service Department
P.O. Box 10608
8000 GB Zwolle
Once we have examined the sample the result will be reported to you in
writing. This report will also include our recommendation.
14 Max. 10 liquid samples of 1 cm3 each are allowed to be taken.
2.6 -- 28 23328
Manual
2.6.5. Cranking
2.6.5.1. General
Cranking is performed by means of an electrically driven device built on

the engine.
The turning device consists of an electric motor which drives the
turning gear through a gear drive and a worm gear. A remote control
box, including a cable, makes turning from any position near the engine
possible. The turning speed is about 3 rpm.
Engaging and disengaging of the turning gear is made possible by lever
(1). The lever is secured by a locking pin (6). See fig. 2.6 --- 27 .
Interlock (7) prevents the engine from starting in case the turning gear
is engaged.
For fine adjustment of the crankshaft position is hand wheel (2).
Fig. 2.6 - 27 Electrically driven turning device
23328 2.6 -- 29
Manual
Wärtsilä 38
2.6.5.2. Maintenance turning device
The turning device needs no other maintenance than a change of

lubricating oil once during the first year of operation. After that the oil
should be changed according the intervals mentioned in section 2.4.1.
Check also vent hole (3) is open.
1 Drain old oil, preferably warm, through drain hole (4).
2 Rinse the gear box with clean gas oil.
3 Fill the gear box with oil through the filling hole (5) until the oil
level reaches the level screw. Utmost cleanliness must be observed.
4 Close the filling hole and run the turning gear a few revolutions.
5 Check the oil level and fill if necessary.
--o--o--o--o--o--
2.6 -- 30 23328
Manual
Cylinder Head with Valves Wärtsilä 38
2.7. Cylinder Head with Valves
Table of contents
2.7. Cylinder Head with Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 1

2.7.1. Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 2
2.7.1.1. Maintenance of cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 3
2.7.1.2. Removing the cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 4
2.7.1.3. Mounting of the cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 9
2.7.2. Adjusting the valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 12
2.7.3. Exhaust and inlet valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 14
2.7.3.1. Removing the valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 15
2.7.3.2. Check and reconditioning of valve disc and valve seat . . . . . 2.7 -- 17
2.7.3.3. Valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 18
2.7.3.4. Valve guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 21
2.7.3.5. Assembling of valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 22
2.7.4. Valve rotators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 23
2.7.4.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 23
2.7.4.2. Maintenance of inlet valve rotator . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 24
2.7.4.3. Maintenance of exhaust valve rotator . . . . . . . . . . . . . . . . . . . . 2.7 -- 24
2.7.5. Indicator cock and safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 25
2.7.7. Starting air valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 26
2.7.8. Fuel injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 26
23328 2.7 -- 1
Manual
Wärtsilä 38
Cylinder Head with Valves
2.7.1. Cylinder head
The cylinder head is provided with two inlet--- (1) and two exhaust
valves (2) with valve rotators (10), a bridge piece (11), a fuel injector (3),
a safety valve, an indicator cock, a starting air valve at the B ---bank side
and a dummy at the A---bank side. The starting air valve is described in
chapter 1.3.
The cylinder head and exhaust valve seats are cooled by HT cooling
water. The HT cooling water is supplied from the engine block, via
drillings in top of the cylinder liner to the cylinder head through several
holes at (5). HT cooling water is discharged through an outlet channel
(6) at the top side of the cylinder head via a flexible pipe connection to
the HT cooling water outlet manifold.
The valve lifting gear (7) is mounted to the cylinder head by six bolts and
described in chapter 2.8. A single pipe connects the cylinder head with
the engine lubricating oil system and takes care for lubricating of the
valve lifting gear, bridge piece, valves and valve stems.
The top part of the cylinder head is sealed by a cover, split in a lower (8)
and a upper part (9).
9 11
7 10
3
6 8
2
5 3 4
Fig. 2.7 – 1 Cross section cylinder head
2.7 -- 2 23328
Manual
2.7.1.1. Maintenance of cylinder head
Cylinder head maintenance consists mainly in measurement checks,

cleaning, grinding of sealing surfaces and maintenance of cylinder head
components.
Scale formation in cooling water spaces will disturb the cooling effect.
Cleaning can be realised by chemical solvents. Contact a specialised
company for chemical cleaning.
When scale formation exists observe the cooling water treatment.
A comfortable manner for maintenance of cylinder heads is with the aid
of a tilting frame 9612DT916. After placing the cylinder head onto the
tilting frame fixate the cylinder head by 4 nuts (12) with threaded rods.
The cylinder head can be turned over and fixed in position by means of
locking pin (13) in one of the holes (14).
12 13 14
9612DT916
Fig. 2.7 – 2 Tilting frame cylinder head
Note! For maintenance background information, safety aspects,

intervals, tolerances, inspections, and hydraulic tightening
procedures, see chapter 2.4.
23328 2.7 -- 3
Manual
Wärtsilä 38
Inspection cylinder head

After dismantling inspect the cylinder head carefully for possible
damage.
Clean gas sealing surfaces between cylinder head and cylinder liner.
Check with cylinder head polishing ring 9612DT484 the condition of the
sealing surface. If reconditioning is necessary this has to be done with
special grinding tools.
2.7.1.2. Removing the cylinder head
1 Before commencing maintenance, drain cooling water and collect

water for re---use.
2 Remove the protecting plate. Loosen flexible pipe connection (15)
and disconnect the discharge cooling water pipe bolts (16).
See fig. 2.7 – 3 .
16
15
Fig. 2.7 – 3 Cooling water discharge
3 Remove from the cylinder head cover the upper part (9). See fig.
2.7 – 1 .
4 Turn piston in T.D.C. combustion. Check correct position by freely
rotating of both push rods.
5 Loosen and remove the valve lifting gear (7).
6 Remove the cylinder head cover lower part (8).
2.7 -- 4 23328
Manual
7 Remove the ”Hot box” panels (24). See fig. 2.7 – 4 .

8 Remove from the exhaust connection, the protecting plate the
upper half clamping ring (22).
Remove the bolts (17) from the inlet air bend.
21
24 22
23 17
20 19 18
Fig. 2.7 – 4 Cylinder head assembly
9 Disconnect the fuel spill line (18), the fuel drain line (19), the pilot
starting air line (20), the HP fuel line (21), the cylinder head lubrication
supply pipe and cover all holes against dirt penetration.
10 Remove cover (25) and loosen the connection of the temperature
monitoring sensors for exhaust valves. See fig. 2.7 – 5 .
25
Fig. 2.7 – 5 Sensor junction box
11 Remove the protecting caps from the cylinder head stud. Make sure
the thread of the cylinder head studs are clean and free of damages.
23328 2.7 -- 5
Manual
Wärtsilä 38
12 Fit the hydraulic tool set 9622DT911 in position according to fig.

2.7 – 6 and connect the HP hoses 9612DT961 and HP hose set
9622DT146 to hydraulic pump 9612DT212.
9622DT122
9622DT121 9612DT100
9622DT233
9622DT932
9622DT119
9622DT120
9622DT146
9612DT961 9612DT212
Fig. 2.7 – 6 Loosening the cylinder head nuts
2.7 -- 6 23328
Manual
13 Open the release valve on the hydraulic pump and tighten the
knurled nuts completely to force the jacks pistons into bottom position.
After the four jacks are in bottom position turn the knurled nut one full
turn counter clockwise (6 holes).
14 Pressurise the hydraulic jacks to setting value and loosen the
cylinder head nuts 3/4 of a turn with tool pin 9612DT100.
15 Open the release valve and slowly lower the pressure till zero and
remove the hoses. Check if the knurled nuts and the cylinder head nuts
are loose and remove the the tool set.
16 Remove the cylinder head nuts.
17 Use lifting tool 9612DT909 to remove the cylinder head. During
lifting of the head push the push rod protecting pipes (23) down to the
cylinder block. See fig. 2.7 – 4 .
Use eye bolt for lifting the head. Lift the cylinder head a bit to drain the
remaining water outside the cylinder liner. Slide the push rod protecting
pipes out of the cylinder head. Check the starting air pipe is free as well.
Hold both the push rod protecting pipes till the cylinder head is
completely removed to avoid possible damage.
9612DT909
Fig. 2.7 – 7 Lifting the cylinder head
23328 2.7 -- 7
Manual
Wärtsilä 38
18 Remove the ”O” ring (26) and fit the protecting ring 9622DT164.
This ring protects the gas sealing and injector tip when the cylinder
head is directly placed onto the floor. Lower the cylinder head vertically.
26
27
Fig. 2.7 – 8 Cylinder head on liner

19 Remove the gas sealing ring (27), see fig. 2.7 – 8 . Remove both push
rods and the push rod protecting pipes.
20 Cover the cylinder opening and holes to the camshaft space with a
piece of plywood or similar.
9622DT164
Fig. 2.7 – 9 Protecting ring for cylinder head
21 Remove valve lifting gear, see section 2.8.2.1.
2.7 -- 8 23328
Manual
2.7.1.3. Mounting of the cylinder head
1 Clean the sealing surfaces and use a new cylinder head O ---ring (26).
Lubricate the O ---ring with silicon grease. Renew the sealing rings of the
charge air channel, starting air line and push rod protecting pipes.
2 Lubricate the O ---rings with silicon grease. Place the push rod
protecting pipes in position and place the push rods.
3 Turn the piston in TDC combustion and be sure the cam followers
for in and exhaust rest on the cam’s base circle.
4 Mount lifting tool 9612DT909 to the cylinder head. See fig. 2.7 – 7 .
5 Hoist the cylinder head. Place a new gas sealing ring (27) on top of
the liner and remove the protecting ring. When lowering the head onto
the liner take care the starting air connecting pipe and push rod
protecting pipes slides into the O ---rings without friction. Make sure the
cylinder head exhaust flange fits into the lower half clamping piece.
6 Tighten the cylinder head nuts by means of tool pin 9612DT100.
7 Place the hydraulic tool set 9622DT911 in position according to
fig. 2.7 – 6 . Connect the HP hoses according to the scheme. Open the
release valve on the hydraulic pump and tighten the knurled nuts
completely to force the jack pistons into bottom position.
Note! See fig. 2.4 - 16 for jack pressure and nut shifting.
8 1st step
--- Close the release valve on the pump and pressurize the jacks till the
value of the first step ( pre---stress ).
--- Tighten the nuts by means of tool pin until firm contact between the
nuts and cylinder head is obtained.
--- Open the release valve on the pump and slowly lower the jack
pressure till zero.
--- Turn the knurled nuts down by means of the tool pin to lower the
jack piston into bottom position.
23328 2.7 -- 9
Manual
Wärtsilä 38
9 2nd step
--- Close the release valve and increase the hydraulic pressure till the
value of the second step ( final stress ).
Firmly tighten the nuts by means of tool pin. Count the number of
holes the nuts can be turned further. The nut shifting should be
equal.
--- Check if the numbers of holes which the nuts are shifted are within
the values mentioned in fig 2.4 --- 16 .
--- Open slowly the release valve and lower the hydraulic jack pressure
till zero.
--- Turn the knurled nuts further down to lower the jack piston into
bottom position.
10 3rd step
--- Close the release valve and increase the jack pressure till the value
of the third step ( final stress ).
--- Tighten the nuts by tool pin any further. This should be possible over
a few degrees only.
--- Slowly open the release valve and lower the hydraulic jack pressure
till zero.
11 4th step
--- Close the release valve and increase the jack pressure till the value
of the fourth step ( final stress )
--- Try to tighten on the nuts by tool pin any further. This should not
be possible.
--- Slowly open the release valve and lower the hydraulic jack pressure
till zero.
12 Disconnect the HP hoses and remove the jacks.

13 Fit the protecting caps over the cylinder head studs.
14 Fit the valve lifting gear on the cylinder head. Observe the
mounting torques mentioned in the settings. See also section 2.8.2.2.
15 Connect the exhaust gas temperature sensors to the cylinder head.
Mount cover (25). See fig. 2.7 – 5 .
16 Mount the HP fuel line, (21), see fig. 2.7 – 4 . Mount the fuel spill
line (18), fuel drain line (19), the cylinder head lubrication supply pipe
and pilot starting air line (20).
2.7 -- 10 23328
Manual
17 Mount the upper half clamping ring (22). To install the clamping
ring grease the contact surfaces of clamp halves with ducting flanges
and grease the 4 clamp bolts.
Tighten the 4 bolts crosswise till the correct torque. See section 2.4.4.6.
18 Mount the inlet air bend with bolts (17).
19 Fit the flexible pipe connection (15). Apply if necessary new sealing
rings.
20 Mount the protecting plates.
21 Adjust the valve clearance. See section 2.7.2.
22 Check the valve lifting gear lubrication.
23 Mount the cylinder head cover lower part (8), upper part (9) and the
”Hot box” panels.
24 Fill the engine cooling water system.
25 Before starting turn the crankshaft two revolutions with the
indicator cocks open.
23328 2.7 -- 11
Manual
Wärtsilä 38
2.7.2. Adjusting the valve clearance
Note! Adjust valve clearance only after a cooling down period

of 30 minutes.
Note! Adjust inlet and exhaust valves as sets.
1 Remove cylinder head upper part cover.

2 Turn piston in TDC combustion and check valve spring load is
taken off the pushrods.
3 Loosen locking nut (1) and valve adjuster (2) a few turns out.
4 If present, remove oil film between pivots by tapping a few times
with a plastic hammer on the ends of the valve levers.
5 Lift bridge piece (3) a little and place a feeler gauge of 0.05 mm at
(4) between pivot and valve stem.
6 Lower bridge piece and check if feeler is not movable.
7 Lift bridge piece, remove feeler gauge and repeat the same
procedure at (5) between adjustable pivot (6) and the valve stem.
8 If the clearance is more than 0.05 mm the bridge piece has to be
levelled, otherwise continue with point 16.
Levelling the bridge piece

9 Loosen locking nut (7) of adjustable pivot (6) in bridge piece (3).
10 Turn adjustable pivot (6) a few turns out, so far that it is free from
the valve stem.
11 Place dial gauge on the bridge piece and adjust to zero see fig.
2.7 – 10 .
12 Turn adjustable pivot in till the pointer of the dial gauge just starts
to move.
13 Tighten locking nut (7) by hand without turning the adjustable
pivot.
14 Check the clearance according to the procedure of point 5 till 8
Note! Avoid torque forces on the bridge piece conductor during

tightening.
15 Tighten locking nut (7) further, to the correct torque, without

turning the adjustable pivot. For torque setting see section 2.4.4.6.
2.7 -- 12 23328
Manual
Adjusting the valve clearance

16 Place feeler gauge 9612DT249 at (8) between bridge piece (3) and
thrust cup (9). For valve clearance see section 2.4.5.1.
17 Turn down valve adjuster (2) with feeler gauge inserted until feeler
is just tight and stiff movable.
9 1 2 6 7 3
4 5
8
Fig. 2.7 – 10 Valve clearance adjustment
18 Tighten locking nut (1), to the correct torque, without turning the
valve adjuster. For torque settings, see section 2.4.4.6.
19 Remove feeler gauge and repeat the complete procedure for other
pair of valves.
20 Fit cylinder head upper part cover.
23328 2.7 -- 13
Manual
Wärtsilä 38
2.7.3. Exhaust and inlet valves
The valve stem is guided in the valve guide (4) and is lubricated and
sealed with the aid of O ---ring (5)
The valve guides and seats are frozen in the cylinder head.
A valve rotator rotates the valve which will ensure smooth and even
wear.
The valve rotator is fixed to the valve by means of collets (7).
Note! Exhaust (1) and inlet valves (2) differ in material and must not be
mixed. Inlet valves can be recognised to the concentric recess (3)
in the valve disc and at the notation at the valve stem top.
5
4
Fig. 2.7 – 11 Valves
2.7 -- 14 23328
Manual
2.7.3.1. Removing the valves
After the cylinder head has been taken off the engine and the injector
removed see section 2.9.4.1. the valves can be removed.
1 Place tool assembly 9622DT917 in position and mount with 2 M16
nuts to the cylinder head. See fig. 2.7 – 12 .
Mount the hydraulic jack 9622DT147 with stud and eye nut to the tool
assembly. Leave about 40 mm distance between jack and eye nut to allow
the springs to expand after removal of the collets.
9622DT147
9622DT917
9622DT133
Fig. 2.7 – 12 Dismantling of valves
2 Use hydraulic pump/hose set 9622DT133 to press the spring

assembly down far enough to remove the valve collets (7). See fig.
2.7 – 11 .
3 Knock at the centre of the valve discs with a plastic hammer to
loosen the valve cotters for removal.
23328 2.7 -- 15
Manual
Wärtsilä 38
4 Open the release valve on the pump slightly to discharge the valve
springs slowly. Take care the springs are fully discharged before
removing the eye nut.
5 All 4 spring discs and springs may now be removed.
Take care to keep the collets, springs and rotators pair by pair.
Take care not to damage the spring coating.
air in exh. out
I2 X2
I1 X1
bottom view
Fig. 2.7 – 13 Valve definition, inlet (I) exhaust (X)
2.7 -- 16 23328
Manual
2.7.3.2. Check and reconditioning of valve disc

and valve seat
1 Checking;
If pitting exists over nearly the entire sealing face or if imperfect sealing
is observed, valve discs and valve seats should be machined.
2 Machining:
Inlet and exhaust valve seat rings can be machined with grinding or
cutter tools to a maximum diameter. For tolerances and angles see
figures 2.4 --- 30 and 2.4 --- 31 .
Replace rings after exceeding the maximum diameter.
Note! Grinding with grinding paste is not permitted in order to maintain
the difference in angle between valve seat and valve disc.
Tools and instructions for reconditioning of valve discs and seats are
available through Wärtsilä Nederland Service Department or through
your local Wärtsilä service agent.
3 Blueing test:
Apply marginal Prussian Blue on the contact surface of the valve disc.
Place the valve in the cylinder head and make a contact print by
slamming the valve onto the valve seat. Do not rotate the valve.
The obtained contact area should be between 20% and 40%, for inlet
valve as well as exhaust valve seats, see fig. 2.7 – 14 .
*)
*)
*) *)
*) 20 -- 40 %
Fig. 2.7 – 14 Blueing test
23328 2.7 -- 17
Manual
Wärtsilä 38
2.7.3.3. Valve seats
Valve seats are mounted into the cylinder head by means of a shrinking
process and fits in the cylinder head with high force.
Removing of the exhaust valve seat

1 Turn the cylinder head up side down. Clean inner side of the valve
seat and place from tool set 9622DT934, disc set (1) and tie rod (2) in the
valve seat. Be sure that the rim on the outside of the four tightening
pieces fit in the recess between the valve seat and the cylinder head.
Secure the discs by tightening nut (3) with a torque of 100 Nm. See fig.
2.7 – 15 .
9622DT148
9622DT934
4
2
3
5
1
9622DT133
Fig. 2.7 – 15 Removing valve seats
2 Place bridge piece (4), hydraulic jack 9622DT148 and connect to

pump 9622DT133.
3 Apply pressure till ± 500 bar if necessary release pressure and
increase slowly the pressure again till max 550 bar. If needed repeat this
procedure a few times to loosen the seat. Pull the valve seat (5) out of
the cylinder head.
4 Loosen nut (3) and remove the seat from the tool.
2.7 -- 18 23328
Manual
5 Clean and degrease valve seat recesses in cylinder head and check
diameter in two directions at two heights. Compare diameters with
nominal dimensions mentioned in section 2.4.5. fig. 2.4 --- 31 .
Removal of the inlet valve seat

1 Turn the cylinder head up side down and place e.g. an old valve with
reduced diameter in normal way into the cylinder head or use a plate
which fits in the valve seat.
2 Weld valve and seat or plate together by 4 short electric welding
runs with a standard electrode (3.2 mm).
3 Turn the cylinder head on a side and drive the valve seat out of the
recess by a few hammer strokes on top of the valve stem or on the plate.
4 Clean and degrease valve recesses in cylinder head and check
diameter in two directions. Compare the diameter with the nominal
dimension mentioned in section 2.4.5. fig. 2.4 --- 30 .
Mounting
Note! Wear low temperature resistance gloves and safety glasses during
handling of deep frozen engine parts and take notice of the safety
measures of the suppliers from the liquid nitrogen. Before mounting
a new valve seat, check condition of valve guide see section 2.7.3.4.
1 Degrease valve seats.

2 Procedure for:
--- Exhaust valve seat:
--- Heat cylinder head slowly and equally, till 90_C.
--- Cool exhaust valve seat e.g. in a deep freeze unit till –50_C.
--- Lubricate O–ring (12) with silicon grease and place it into the
groove of the valve seat, see fig. 2.7 – 16 .
--- Apply a sealing compound at the biggest outer diameter of the
valve seat. Type of sealing compound is mentioned in the parts
catalogue.
--- Continue direct with mounting the seat in the cylinder head.
--- Inlet valve seat:
--- Heat cylinder head slowly and equally, till 90_C.
--- Cool inlet valve seat in liquid nitrogen till –180_C.
--- Continue direct with mounting the seat in the cylinder head.
3 Place the cooled inlet valve seat (8) or exhaust valve seat (9) onto
tool 9622DT907 and immediately into the cylinder head recess. Fixate
the tool with plate (13) and nut (14) and keep tool tight for at least 5
minutes to keep the seat in correct position during warming up.
Note! Inlet and exhaust valve seats require different counter plates,
exhaust (10) and inlet (11), see fig. 2.7 – 16 .
23328 2.7 -- 19
Manual
Wärtsilä 38
4 After mounting of the exhaust valve seat and cooling down of the
cylinder head it is strongly advised to make a water pressure test (5 bar).
9622DT907 11 8
10 9 12 13 14
Fig. 2.7 – 16 Mounting valve seats
Machining of the valve seat

5 Although the angle of the valve seat ring is accurate machined, due
to the shrinking process of the valve seat in the cylinder head, the seat
will slightly deform in profile resulting in small deviations of the
required valve seat angle with the valve.
Every time a new valve seat is mounted the valve seat has to be
machined and the blueing test has to be carried out, see section 2.7.3.2.
2.7 -- 20 23328
Manual
2.7.3.4. Valve guide
1 Clean and inspect the valve guide.

Measure the inner diameter of the valve guide, see section 2.4.5.2.
Renew if necessary.
Extracting valve guide

2 Remove the valve spring washer (5) and the circlip (6) from the
valve guide (7), see fig. 2.7 – 18 .
3 Place cylinder head on a side and fit extractor 9622DT930 in
conjunction with jack 9622DT148.
9622DT148
9622DT930
Fig. 2.7 – 17 Extracting valve stem guide
4 Apply pressure on jack 9622ZT148 and continue till the guide is

extracted from the cylinder head.
5 Clean and degrease valve guide recess in cylinder head.
Mounting valve guide

Mounting procedure for inlet and exhaust valve guide is similar.
6 Heat cylinder head slowly and equally till 90_C.
7 Fit circlip (6) in the groove of the valve guide (7).
8 Cool valve guide in liquid nitrogen till bubbling stops ( ---180_C).
Note! Wear low temperature resistance gloves and safety glasses during
handling of deep frozen engine parts and take notice of the safety
measures of the suppliers from the liquid nitrogen.
9 Oil valve guide recess in cylinder head scarcely.

10 Place valve guide into the cylinder head. Check that the valve guide
is completely inserted.
Note! If the valve guide is renewed the contact faces of the valve disc and
seat have to be checked by the blueing test, see section 2.7.3.2.
11 Place the valve spring washer around, the valve guide.
23328 2.7 -- 21
Manual
Wärtsilä 38
2.7.3.5. Assembling of valves
1 Check valve springs on cracks and wear marks. Replace springs in

case of wear marks or other damage.
2 Clean valve guides thoroughly and fit new O–rings (8).
Fig. 2.7 – 18 Detail valve guide
3 Lubricate valve stems with clean engine oil.

4 Fit valves and check the free movement. Before the valve touches
the valve seat seat be sure the seat surfaces are absolute clean. Replace
valves in their original locations.
5 Carry out the blueing test, see section 2.7.3.2.
6 Install springs and rotators make sure the contact surfaces of
springs and spring discs are undamaged and clean.
7 Place assembling tool 9622DT917 in combination with jack
9622DT147 in position, see fig. 2.7 – 12 .
8 Compress valve springs and fit valve collets.
9 Unload springs slowly. Check if valve collets do fit properly during
unloading of the springs and clearances between the two valve collets
halves is equal.
2.7 -- 22 23328
Manual
2.7.4. Valve rotators
2.7.4.1. General
Exhaust and inlet valves may be provided with valve rotators devices.
These devices slightly rotate the valves at every valve stroke. The valve
rotation results in an even wear pattern with better metallic contact
between valve and valve seat. The better cooling of the valve improves
which in turn considerably extends the maintenance interval period of
the valve.
The inlet valves are each provided with a valve rotator rotating the
valves a little during the opening stroke of the valve.
The exhaust valves are also each provided with a rotator rotating the
valves during the closing stroke. Both designs are of different
constructions.
For lubrication only engine lube oil should be used. Do not apply grease
on the steel balls during maintenance of the valve rotator bearings as
this may result in a less effective working of the rotator.
Valve rotators should periodically be checked on working i.e. the valve
should rotate slowly. At each valve maintenance the valve rotator should
be checked on wear. During maintenance work the rotator components
should be kept as a set and not be mixed with parts of other sets.
Exhaust valve rotator Inlet valve rotator

3 6 1 7 5 3 1 7 5 4
2 6
10
9
11
12
13
Fig. 2.7 – 19 Valve rotators
23328 2.7 -- 23
Manual
Wärtsilä 38
2.7.4.2. Maintenance of inlet valve rotator
1 After removal of the valve cotters (7) the inlet valve rotator
assembly may be removed, see fig.2.7 – 19 .
2 Turn the assembly top side down on a workbench.
3 Remove spring wire (6).
4 Remove cover plate (2).
5 Remove spring disc (3).
6 Remove steel balls (4) and springs (5).
7 Clean base plate (1) and other components.
8 Check the components on wear and damage. Renew the entire unit
in case a single component is worn.
9 After mounting on the engine check the valve rotator revolves.
2.7.4.3. Maintenance of exhaust valve rotator
1 Remove the valve spindle cotters (7) and take off the rotator top
drive section consisting of spring disc (2), axial bearing (3) and valve
spindle disc (1), see fig.2.7 – 19 .
2 Take off the valve spindle.
3 Remove the bottom drive base section (13) from the valve guide.
4 The top drive unit may be taken in parts by removing circlip (6).
5 The bottom drive unit may be taken in parts by removing circlip (12).
Be careful when the bottom drive section is taken into pieces as small
springs, pawls and cylindrical pins, being part of the freewheel, may fall
out of the assembly.
6 Clean all parts from sludge and possible carbon.
7 Check oil grooves are open and free of sludge.
8 Inspect the top drive section and special the helical groove in
cylindrical part of the valve disc on wear, corrosion and fretting.
9 Check the condition of the steel balls (10) in the bottom drive
section that slides in the helical grooves of the top drive section.
10 Check the axial bearing (5) in the top drive section for wear.
11 Check the freewheel parts on wear and scoring.
12 Any damaged or worn part of the valve rotator should be replaced.
13 In case a single component of the top or bottom drive section is worn
the entire top or bottom unit should be replaced.
14 Assemble the parts with clean engine oil. Do not use grease.
2.7 -- 24 23328
Manual
15 Before mounting on the cylinder head check the working of the

freewheel drive, the free sliding of top section in the bottom section and
the frictionless rotation of the axial bearing.
16 After mounting on the engine check the valve rotator revolves.
17 Valve rotators to be stored should externally be greased and
wrapped in plastic against corrosion and dirt.
2.7.5. Indicator cock and safety valve

Indicator cock
Each cylinder head is provide with an indicator cock (1). The inside
construction is such that pressure in the cylinder closes the valve.
Consequently the force needed to close the valve is relatively low.
1 Previous to an engine start close the indicator cocks with just
enough force to close the sealing surfaces. The cylinder pressure will
further close the valve.
2 After an engine stop open the indicator cocks only half a turn. In
this process the tightening effect due to the temperature decrease will
not occur.
3 Avoid inadvertent tightening during measuring cylinder pressures.
4 Add high temperature resistant lubricant (up to 1000C) to spindle
threads when it gives friction.
5 Always use tool 9612SW510 to open and close the indicator cocks
(1), see fig. 2.7 – 20 .
Fig. 2.7 – 20 Indicator cock / safety valve
23328 2.7 -- 25
Manual
Wärtsilä 38
Safety valve
Each cylinder head is provided with a spring loaded safety valve (2) , see
fig. 2.7 – 20 . This valve emits an alarming sound at excessive cylinder
pressures. The blow--off pressure is stamped on the valve. Replace at
once safety valves leaking during operation. Mount valve with a high
temperature resistance lubricant.
2.7.6. Starting air valve
The starting valve is explained in chapter 1.3.

Before mounting starting air valves, the outer cylindrical surfaces
should be well lubricated with engine oil.
2.7.7. Fuel injector

The fuel injector is explained in chapter 2.9.
--o--o--o--o--o--
2.7 -- 26 23328
Manual
Camshaft and Valve Drive Wärtsilä 38
2.8. Camshaft and Valve Drive
Table of contents
2.8. Camshaft and Valve Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 - 1

2.8.1. Camshaft driving gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 -- 2
2.8.1.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 -- 2
2.8.1.2. Inspection gear wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 -- 4
2.8.1.3. Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 -- 5
2.8.1.4. Camshaft gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 -- 10
2.8.1.5. Intermediate gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 -- 15
2.8.1.6. Crankshaft gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 -- 18
2.8.2. Valve drive mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 -- 19
2.8.2.1. Dismantling valve drive mechanism . . . . . . . . . . . . . . . . . . . . . 2.8 -- 20
2.8.2.2. Assembling valve drive mechanism . . . . . . . . . . . . . . . . . . . . . . 2.8 -- 23
2.8.3. Actuator drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 -- 24
23328 2.8 -- 1
Manual
Wärtsilä 38
Camshaft and Valve Drive
2.8.1. Camshaft driving gear
2.8.1.1. General
The camshaft is driven by the crankshaft through gear wheels. The gearing
consists of a split gear wheel (1) on the crankshaft, an intermediate gear
wheel (2) and a camshaft gear wheel (3), see fig. 2.8 --- 1 . The camshaft
rotates in the same direction as the crankshaft at half the speed.
Fig. 2.8 - 1 Gearwheel drive camshaft

The camshaft is assembled of camshaft sections (4) and camshaft
journals (5) which are connected by bolts (6), see fig. 2.8 --- 2 . The
camshaft sections are per camshaft identical.
Each cylinder has its own camshaft section in which is integrated the
fuel, exhaust and inlet cam. The camshaft journals are not identical in
2.8 -- 2 23328
Manual
relation to the position of the locating pins (7) on both sides of the
camshaft journal. The position of the locating pins determine the firing
order.
It is therefore that the camshaft journals have to be remounted to their
original position or replaced by a similar camshaft journal.
5 7 6 4 6 5
Fuel Exhaust Inlet 7
Fig. 2.8 - 2 Camshaft section
At the driving end the camshaft is provided with an axial thrust

bearing, the ’zero’ --- bearing. This bearing consists of two identical
bearing rings (0), see fig 2.8 --- 1 .
23328 2.8 -- 3
Manual
Wärtsilä 38
For the correct position and part number of the camshaft journals
consult the parts catalogue.
For lubrication of camshaft and camshaft drive see chapter 1.2.
At the free end the camshaft is provided with an extension shaft (8) with
a cam to operate the starting air distributor (9).
The starting moment can be adjusted by slackening bolts (10) and
releasing clamping rings (11).
9
12
10
11
Fig. 2.8 -- 3 Starting air distributor with drive
2.8.1.2. Inspection gear wheel drive
Inspect the gear wheels, camshaft sections and camshaft journals

according the maintenance schedule for clearance and possible wear, see
chapter 2.4. Early detection and replacement of damaged parts will
prevent serious damage.
2.8 -- 4 23328
Manual
2.8.1.3. Camshaft
2.8.1.3.1. Removal of camshaft section and journal
To remove the camshaft section and journal it is necessary to shift the

camshaft sections and journals to the driving, or to the free end side. To
prevent damages of the fuel, inlet and exhaust rollers, cams and valves, the
rollers have to be lifted from the camshaft sections which have to be shifted.
Removal of camshaft section

1 Remove covers from cylinder head and camshaft cover.
2 Turn the fuel cam, adjacent to the camshaft journal to be inspected,
into top position.
3 Lift with lever 9612DT965 the fuel cam roller (1) a little and turn the
locking pin 9612DT760 completely in. The fuel cam roller will be secured
in top position and will be free from the fuel cam. See fig. 2.8 --- 4 .
4 Repeat this procedure for all cylinder units of the camshaft sections
which are not connected to the driving side of the camshaft, after
removal of the camshaft section.
9612DT760 1
9612DT965
Fig. 2.8 - 4 Securing fuel cam roller
23328 2.8 -- 5
Manual
Wärtsilä 38
5 Remove the rocker arm bracket from the cylinder head, see fig.
2.8 --- 20 of section 2.8.2.1. Take care the rollers for inlet and exhaust
are resting on the base circle of the cams.
9622DT171 2 2
Fig. 2.8 -- 5 Tappet securing plate
6 Take the push rods out of the protecting pipes.

7 Turn the crankshaft in TDC for scavenging. Fit securing plate
9622DT171 on top of the tappets (2). The tappet rollers will be kept free
from the cams. See fig. 2.8 --- 5 .
8 Repeat this procedure (points 5, 6 and 7 ) for all cylinder units of the
camshaft sections which are not connected to the driving side of the
camshaft, after removal of the camshaft section.
9 Remove the starting air distributor plate (12) See fig. 2.8 --- 3 .
10 Remove on both sides of the camshaft section concerned, all the
bolts except two bolts (3) and (4) at each side of the upper part of the
camshaft section and two bolts (5) and (6) at the lower part. Turn these
four bolts 10 mm loose, see fig. 2.8 --- 6 .
11 Place tool 9612DT801 between bolts (5) and (6).
12 Extend tool 9612DT801 by turning part (7) so far that the locating
pins (8) are free and the camshaft section is loose from both journals.
Push remaining camshaft sections and journals to the free --- end side.
See fig. 2.8 --- 6 .
2.8 -- 6 23328
Manual
Fuel 3 Exhaust Inlet 4

8
Free
end
5 7 9612DT801 6
Fig. 2.8 -- 6 Position of pillar bolt
13 Mount tool 9622DT927 to the engine block for support of the

camshaft section. See fig. 2.8 --- 7 .
14 Remove tool 9612DT801 and bolts (3), (4), (5) and (6), see fig. 2.8 --- 6 .
15 The camshaft section is now fully resting on tool 9622DT927 and can
be moved to the outside. Use sling and crane to lift camshaft section.
9622DT927
Fig. 2.8 - 7 Removal of camshaft section
23328 2.8 -- 7
Manual
Wärtsilä 38
Removal of camshaft journal

Before removal of the camshaft journal first remove the camshaft
sections at both sides of the journal according to the previous
description.
16 Mount tool 9612DT988 according to fig. 2.8 --- 8 against the

cylinder block with 2 bolts.
17 Fit with two M20 bolts tool 9612DT988 to the journal and move
lever with journal outwards.
9
9612DT988
Fig. 2.8 - 8 Removal of camshaft journal
18 Fit clamp (9) for removal of the camshaft journal.

19 Mark the position of the journal in relation to the camshaft bearing
bush number.
2.8 -- 8 23328
Manual
2.8.1.3.2. Replacing the camshaft section and journal
Warning! Not all camshaft journals are identical! Before mounting check the
parts catalogue for the correct location of the camshaft journal in
the engine block.
1 Inspect the camshaft bearing bush for measurements and

damage. Inspection and mounting of the bearing bush is mentioned
in section 2.5.4. Check that the lube oil supply bore is clean.
2 Clean the journals and the threaded holes in the journals. Check for
wear and damages.
3 Lubricate the journals and bearing bushes and use tool 9612DT988
to place the journal in the camshaft bearing bush. See fig 2.8 --- 8 .
4 Use tool 9612DT927 to install the camshaft section and start with
the section nearest to the driving end to prevent turning during
tightening, see fig. 2.8 --- 7 .
5 Take care that the locating pin holes in the journal and the locating
pins of the camshaft section are in line before inserting the connecting
bolts. Check that the locating pin (8) is pushed completely in the
locating pin hole. See fig. 2.8 --- 2 .
6 Insert all the socket head bolts in the journal and tighten first 4
bolts crosswise handtight (± 40 Nm). Start with the bolts nearest to the
driving end of the engine, so that the camshaft is blocked during
tightening. Tighten first the bolt next to the locating pin. Tighten the
second bolt 180 opposite the first bolt and the third bolt 90 opposite
the second bolt and the fourth bolt 180 opposite the third bolt.
Before final torque check with a feeler gauge of 0.05 mm that all parts
fit properly. Tighten all the bolts to the correct torque setting, see
section 2.4.4.
23328 2.8 -- 9
Manual
Wärtsilä 38
2.8.1.4. Camshaft gear wheel
Warning! Turning of the crankshaft with disconnected camshaft results in

damaging of inlet and exhaust valves, push rods, etc.
Removal of camshaft gear wheel

1 Remove the actuator and actuator drive unit.
2 Bar the crankshaft in TDC of cylinder number 1 and place proper
markings on camshaft gear wheel and intermediate gearwheels.
3 Remove from all the cylinder units the rocker arm brackets, push
rods and lift the tappets from inlet and exhaust according to points 5,
6 and 7 of the procedure of section 2.8.1.3.1.
4 Lift fuel cam rollers according to points 2 and 3 of the procedure of
section 2.8.1.3.1.
5 Remove speed pick---up sensors (if applicable) out of camshaft gear
wheel cover and remove cover.
6 Remove cover (1) and outer thrust ring (2). See fig. 2.8 --- 9 .
7 Loosen connecting bolts (5) from end journal to the camshaft gear
wheel.
8 Remove bolts (6) except two bolts, one next to the locating pin and
one 180 opposite, just loosen these bolts.
8
Driving
end
1
3
5
11
2
13
10 6 9
Fig. 2.8 - 9 Axial bearing camshaft
2.8 -- 10 23328
Manual
9 Insert hydraulic tool adapter 9612DT968 in the centre hole of the

camshaft end journal. Connect the adapter with hose 9612DT961 to
hydraulic pump 9612DT212. See fig. 2.8 --- 10 .
10 Increase slowly the hydraulic pressure until the end journal (11) is
forced from the camshaft gear wheel shaft (9). In case the hydraulic
pressure is not sufficient to separate the parts completely use jack bolt
9612DT234 for the last few mm. See fig. 2.8 --- 11 .
12
9612DT968
11
9612DT961
9612DT212
Fig. 2.8 - 10 Removal of camshaft end journal
23328 2.8 -- 11
Manual
Wärtsilä 38
11 Slide the end journal partly out of the bearing bush and use a sling
to remove the end journal completely out of the bearing bush.
9612DT234
11
Fig. 2.8 -- 11 Position of jack bolt

12 Remove inner thrust ring (12), see fig 2.8 --- 10 .
13 Loosen the bolt next to the locating pin and the one 180 opposite
10 mm. See fig. 2.8 --- 9 .
9612DT801 7
Fig. 2.8 -- 12 Position of pillar bolt
14 Place tool 9612DT801 between camshaft gearwheel and the bolt

next to the locating pin. See fig. 2.8 --- 9 .
2.8 -- 12 23328
Manual
15 Fit tool 9612DT985 to the engine block for support of the camshaft
camshaft gear wheel . See fig. 2.8 --- 13 .
14
9612DT985
Fig. 2.8 -- 13 Removal of the camshaft gear wheel
16 Extend tool 9612DT801 by turning part (7) so far that the locating
pin (8) is just free and the camshaft gear wheel shaft is loose from the
journal. See fig. 2.8 --- 12 .
17 Remove if applicable cover (12) from the starting air distributor. See
fig. 2.8 --- 3 .
18 Shift the complete camshaft 10 mm to the free end side.
19 Move camshaft gearwheel with shaft out of the engine and use
clamp (14) for lifting.
23328 2.8 -- 13
Manual
Wärtsilä 38
Mounting of camshaft gear wheel

20 Use tool 9612DT985 to move the camshaft gear wheel into the correct
position. Mind the marks as placed before removal.
21 Place inner thrust ring (12), mind the position of the locating pins.
22 Fit the end journal (11) with tap bolts (5) to the camshaft gear wheel
(if bolts (5) are too short use threaded rods and nuts). Pull them together
and tighten bolts to the correct torque. Check with feeler gauge of 0.05
mm that all parts fit properly. See fig. 2.8 --- 9 and section 2.4.4.
23 Insert all the socket head bolts (6) in the journal (10) and tighten
4 bolts cross wise hand tight ( 40 Nm).
Tighten first the bolt next to locating pin. Tighten the second bolt 180
opposite the first bolt and the third bolt 90 opposite the second bolt and
the fourth bolt 180 opposite the third bolt. Before final torque check
with a feeler gauge of 0.05 mm that all parts fits properly. Tighten all the
bolts to the correct torque setting. See section 2.4.4.
24 Place the outer thrust ring, mind the position of the locating pins (3),
see fig. 2.8 --- 9 .
25 Fit cover (1) with new O---rings for cover and lube oil drain pipe (13),
see fig 2.8 --- 9 .
26 Check the axial bearing clearance of the camshaft and backlash of
the gear wheels. See section 2.4.5.2.
27 Check the fuel pump timing of one cylinder and compare with testbed
protocol. If not correct check the mounting procedure and marks. In case
of a new gearwheel contact the local Wärtsilä service station.
28 Mount the actuator drive and check the backlash between camshaft
gear wheel and actuator drive gear wheel, see section 2.4.5.2.. Mount the
actuator.
29 Mount camshaft gear wheel cover and speed pick---up sensors (if
applicable).
2.8 -- 14 23328
Manual
2.8.1.5. Intermediate gear wheel
Removal of intermediate gear wheel

If the intermediate gear wheel has to be removed for maintenance, the
camshaft gear wheel with shaft has to be removed first, see previous
section.
Note! Place proper markings on camshaft gear wheel, intermediate gear

wheel and crankshaft gear wheel for reassembling into the correct
position.
1 Fit tool 9612DT986 to the engine block.

2 Lower the trolley (21) over the intermediate gear wheel and fixate
with bolts (22). See fig. 2.8 --- 15 .
23
21
22
9612DT986
23
20
Fig. 2.8 - 14 Tool for intermediate gear wheel
23328 2.8 -- 15
Manual
Wärtsilä 38
3 Remove bolts (3), (4) and make use of tooll 9612DT936 to pull cover
(5) together with shaft (6) free from the engine block. See fig. 2.8 --- 15 .
3
5
4
7
8
9
6
2
1
Fig. 2.8 -- 15 Intermediate gear wheel section
4 Remove cover (5) and mount tool 9612DT936 and pull shaft (6) with
the use of three jack bolts (10). Remove the shaft out of the intermediate
gear wheel, see fig. 2.8 --- 16 .
5 Use winch (23) to pull the intermediate gear wheels out of the
engine. If necessary lift the intermediate gear wheel with spindle (20)
free from the crankshaft gear wheel teeth. See fig. 2.8 --- 14
6
10
9612DT936
Fig. 2.8 - 16 Removal of intermediate gear wheel shaft
2.8 -- 16 23328
Manual
Note! Do not separate the intermediate gear wheels unless absolutely

necessary. If the gear wheels have to be separated place proper
markings for reassembling into the correct position, in relation to
the oil supply.
Mounting of intermediate gear wheel

6 Use tool 9612DT986 to move the intermediate gear wheel into the
correct position. See fig. 2.8 --- 14 .
7 Insert shaft (6), mind the position of the threaded holes in the shaft.
See fig. 2.8 --- 15 .
8 Mount tool 9612DT936 together with distance pieces (13) on shaft (6)
with tool bolts (10).
9 Mount the plate with tool bolts (11) on the engine block and push
shaft (6) into position with nuts (12). See fig. 2.8 --- 16 .
6
13
10
11
12
9612DT936
Fig. 2.8 -- 17 Mount shaft intermediate gear
10 Remove the tools 9612DT986 from the engine block see,

fig. 2.8 --- 14 .
11 Remove tools 9612DT936 from the intermediate shaft.
12 Apply new O ---rings (7) and (8) with silicon grease to shaft (6).
13 Apply new O ---ring (9) with silicon grease to cover (5) and tighten
cover and shaft with bolts (3) and (4), to the correct torque.
See chapter 2.4.4.
14 Check the axial clearance by moving the gear wheels and measure
the movement with a dial indicator. See section 2.4.5.2.
23328 2.8 -- 17
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Wärtsilä 38
2.8.1.6. Crankshaft gear wheel
The crankshaft gear wheel (split gear wheel) consists of two parts
connected together with bolts (1) and to the crankshaft flange with
bolts (2). The split gear wheel can be changed part by part.
1 2
driving end
Fig. 2.8 -- 18 Crankshaft gear wheel assembly
2.8 -- 18 23328
Manual
2.8.2. Valve drive mechanism
The valve drive mechanism consists of a tappet guide block (1) with
tappets (2) for inlet and exhaust, connected to the engine block.
See fig. 2.8 --- 19 .
The tappets are of the plunger type and follow the cam profiles on the
camshaft and transfer the vertical movement by push rods (3) to the
rocker arms (4) which are fitted on a shaft in the rocker arm bracket (5),
see fig. 2.8 --- 19 .
The rocker arms operate via bridge pieces (6) the inlet and exhaust
valves. For lubrication of the valve drive mechanism, see chapter 1.2.
6
5
2
3
Fig. 2.8 - 19 Valve drive mechanism
23328 2.8 -- 19
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Wärtsilä 38
2.8.2.1. Dismantling valve drive mechanism
Note! Before dismantling, mark the parts properly.
Rocker arm bracket

1 Remove the cylinder head cover upper and lower part (7), hot box
shields and the camshaft cover from the cylinder concerned.
2 Turn crankshaft in TDC at firing for cylinder concerned. Inlet
and exhaust rollers are now on base circle of the cams (push rods can
rotate freely).
3 Remove the bolts (8) and lift the rocker arm bracket (5) from the
cylinder head using tool 9612DT922.
4 Remove the bridge pieces (6).
8 6 7
9612DT922
Fig. 2.8 -- 20 Rocker arm bracket
2.8 -- 20 23328
Manual
Removal of rocker arms only

5 Remove bolts (8) and washer (9) and slack the remaining bolts (10).
6 Slide the rocker arms shaft (11) out of the bracket (5) and remove
the rocker arms (4) one by one.
11 5 8--9 10 4 10 4 10 8--9
10
Fig. 2.8 - 21 Rocker arms
7 Remove first the push rods (3) and secondly the protecting pipes (12).
13
12
Fig. 2.8 - 22 Push rod assembly
23328 2.8 -- 21
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Wärtsilä 38
Tappet guide block assembly

8 Remove socket head bolts (14) and (15).
9 Fit tappet lifting tool 9612DT962. See fig. 2.8 --- 5 .
10 Remove the tappet guide block assembly from the engine block, for
inspection of the components.
Tappet roller and shaft

11 Take care that all parts are properly marked.
12 Slide the tappets (2) out of the guide block (1), push the spring
loaded locking pin (16) fully into the roller shaft (17), pull the roller
shaft out of the tappet (direction R). Remove rollers (18) and bearing
bushes (19).
15
1
2 20 15
2
15 15 19
17
R
R 18
14
20
16 21
15
Fig. 2.8 - 23 Tappet guide block assembly
2.8 -- 22 23328
Manual
2.8.2.2. Assembling valve drive mechanism
Clean and inspect all parts for measurements and wear, see section 2.4.5.2.
1 Lubricate parts of tappet assembly with clean engine oil and

assemble.
2 Slide roller shaft (17) into tappet (2) and roller (18) with bearing
bush (19), observing spring loaded locking pin (16) clips into
corresponding hole of the tappet, see fig. 2.8 --- 23 .
3 Check if lube oil channel in engine block is clean and place new
O ---ring (20), before mounting in recess of engine block.
4 Fit tappet lifting tool 9612DT962, see fig. 2.8 --- 5 .
5 Place tappet guide assembly on the locating pins (21) in the engine
block and fit bolts (14) and (15). See fig. 2.8 --- 23 .
6 Remove tappet lifting tool 9612DT962.
7 Renew O ---ring (13), see fig. 2.8 --- 22 .
8 Slide pushrod protecting pipes from top side down.
9 Insert both push rods.
10 Clean top side cylinder head and bottom side rocker arm bracket.
Check if locating pins and counter bores are undamaged.
11 Place both bridge pieces.
Note! Take care rollers are resting on base circle of the cams before
mounting rocker arm bracket.
12 Lift rocker arm bracket in position, mind if locating pins are fitting
properly in counter bores, fit bolts (8) with washers (9) and tighten all
bolts of the rocker arm bracket to the correct torque, see section 2.4.4.
13 Check free movement of rocker arms.
14 Check and adjust valve clearances according chapter 2.7. and
check lubrication. Mount cylinder head covers, hot box shields and
camshaft cover.
23328 2.8 -- 23
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2.8.3. Actuator drive
The actuator is driven by a separate drive unit, which in turn, is driven

by the camshaft through helical gear wheels. The actuator is mounted
on the drive unit and connected into the drive shaft (1).
5
6
4
3
1
Fig. 2.8 - 24 Actuator drive
Pressurized oil is supplied through drillings in the intermediate plate (2)

and through the drive unit (3) to the bearings, the helical gear wheels and
to a nozzle (4) for lubricating the gear wheel drive.
2.8 -- 24 23328
Manual
Maintenance
Actuator drive maintenance exists mainly of inspection of:
1 Radial and axial clearances of bearings.
2 Backlash and condition of gear wheels.
3 Oil supply to bearings and gear wheels.
4 Condition of serrations of actuator drive shaft (5) and coupling
sleeve (6).
Warning! If helical gear wheels are damaged, both gear wheels have to be
renewed as a set.
Special tools are necessary to adjust the gearwheels.
--o--o--o--o--o--
23328 2.8 -- 25
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2.8 -- 26 23328
Manual
Injection System Wärtsilä 38
2.9. Injection System

Table of contents
2.9. Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 - 1

2.9.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 2
2.9.2. HP fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 2
2.9.2.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 2
2.9.2.2. HP fuel pump maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 3
2.9.2.3. Removing HP fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 3
2.9.2.4. HP fuel pump dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 5
2.9.2.5. Assembling of the HP fuel pump . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 7
2.9.2.6. HP fuel pump mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 9
2.9.2.7. HP fuel pump adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 10
2.9.3. Fuel pump bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 13
2.9.3.3. Removing fuel pump bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 13
2.9.3.4. Inspection of fuel pump drive tappet . . . . . . . . . . . . . . . . . . . . . 2.9 -- 17
2.9.3.5. Mounting fuel pump bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 18
2.9.4. Fuel injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 19
2.9.4.1. Removing the fuel injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 21
2.9.4.2. Fuel injector maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 22
2.9.4.3. Fuel injector overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 23
2.9.4.4. Testing of fuel injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 26
2.9.4.5. Mounting the fuel injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 28
2.9.5. HP fuel line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 -- 29
2.9.5.1. Assembling HP fuel line to connecting piece . . . . . . . . . . . . . . 2.9 -- 29
23328 2.9 -- 1
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Injection System
2.9.1. General
Basically the entire engine mounted fuel system is situated inside the
insulated Hot Box. Circulating fuel, together with heat radiation from
the engine, keeps the whole space hot so that heat tracing on the engine
fuel lines is not required. Every cylinder is provided with a HP fuel
pump and a fuel injector. The fuel injector is cooled by lubricating oil and
is situated in the middle of the cylinder head. The spill fuel from the
injectors is drained into a fuel leak monitoring device. In case a HP fuel
supply line breaks the leaking fuel is collected in a shielded pipe
mounted around the HP fuel line. This leaking fuel is also drained to the
monitoring device. The fuel leak monitoring device will alarm in case of
excessive quantities.
2.9.2. HP fuel pump
2.9.2.1. General
The HP fuel pumps are one cylinder pumps of a monoblock design

where cylinder and cylinder cover are integrated. Each pump is
equipped with a main delivery valve, a constant pressure valve and a
pneumatic operated stop cylinder.
Main delivery valve

The main delivery valve closes at the moment the fuel delivery stops.
Constant pressure valve

This valve maintains a residual pressure in the HP pipe after the fuel
injection is completed.
Stop cylinder
This pneumatic operated cylinder, mounted at the end of the HP fuel
pump rack, forces the fuel rack to zero position after a shut---down
command.
2.9 -- 2 23328
Manual
3
4
6 5
2
7
Fig. 2.9 -- 1 HP fuel pump
2.9.2.2. HP fuel pump maintenance
Inspect the HP fuel pump according to the maintenance intervals. See

section 2.4.1. On completion of camshaft or gear train maintenance it
always is important to check the HP fuel pump adjustments.
2.9.2.3. Removing HP fuel pump
Only in case of extensive maintenance it is advised to change over to and

flush the fuel system on distillate fuel. If only the HP fuel pump has to
be changed leave the system on HFO. Remove the HP fuel pump with
the fuel cam in base circle.
1 Close the fuel supply to the engine and stop the lube oil pump.
2 If possible use air to blow the LP fuel system empty.
3 Remove the HP fuel discharge pipe (1) and the fuel drain line (2)
and drains (3) and (4). See fig. 2.9 --- 1 .
4 Disconnect the air line to the stop cylinder (5).
23328 2.9 -- 3
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Injection System
5 Disconnect the fuel rack (6) from the common fuel control shaft.
6 Take off the nuts (7) at the base plate.
7 Lift the HP fuel pump from the engine using tool 9612DT947.
9612DT947
Fig. 2.9 -- 2 Lifting the HP fuel pump
Note! Cover immediately all openings with tape or plugs to avoid dirt
admission.
Fig. 2.9 -- 3 Detail of the HP fuel pump bracket
Note! Be careful not to damage the O-- ring grooves (8) in the HP fuel pump
bracket after the HP fuel pump is removed.
2.9 -- 4 23328
Manual
2.9.2.4. HP fuel pump dismantling
21 20
22
23
30
24
31
25
28 26
27
32
18
29
6 40
19
17
14
16 13
15 33
11
12
10
9
34
Fig. 2.9 -- 4 HP Fuel pump
23328 2.9 -- 5
Manual
Wärtsilä 38
Injection System
1 Before dismantling, clean carefully the outside of the pump.

2 Place the pump upside down in a stand.
3 Remove bolts (9), plate (10) and guide block (11). See fig. 2.9 --- 4 .
4 Mount tool 9612DT948 to the pump base and push the push rod a
few mm inwards to remove circlip (13) with plier 9622DT178.
9612DT948
13
Fig. 2.9 - 5 Assembling tool
Warning! The plunger is spring loaded.
5 Release the spring tension by loosening the spindle of tool

9612DT948 and remove the tool.
Note! Plungers, elements and discharge valves are matched and must be
kept together during overhaul.
6 Remove push rod (12), spring disc (14), spring (15) and plunger (16).
7 Remove spring disc (17) and remove control sleeve (18) with fuel
rack (6) in mid position. Mind that pin (19) is located between the two
marks in the fuel rack.
2.9 -- 6 23328
Manual
8 Turn the pump over into the normal vertical position.

9 Remove tap bolts (20) and next bolts (21).
10 Remove cover (22) with discharge valve (23) and spring and
constant pressure valve (24) with spring.
11 Turn pump horizontally and remove the liner (25) out of the pump
house by applying slight force at the bottom of the liner. The element
might stick a little due to the glueing effect of sealing ring (26) and
O ---ring (27).
12 Remove circlip (28) and plug (29) and pull out the fuel rack (6).
13 Keep the pump components together. The parts must be protected
against rust and especially the running surface of the element plunger
should not unnecessarily be handled with bare fingers.
14 Flush the plunger and liner in clean fuel for inspection and keep the
plunger and liner as a set.
2.9.2.5. Assembling of the HP fuel pump
For item numbers see fig. 2.9 -- 4 .
1 Wash the components in absolutely clean diesel oil and lubricate the
internal parts with clean engine oil. During handling of the injection
equipment components, keep your hands absolutely clean and greased
with oil.
2 Reinstall the main delivery valve (23) and constant pressure
valve (24) with their springs into the cover (22).
Note! Be careful with the valves in the pump cover. Some grease may be
used to keep the valves in position during assembly.
3 Bolt the liner element (25) with bolts (20) handtight to the cover (22).
Note that the cover fits properly over the locating pin (30).
4 Fit a new O ---ring (31) in top of the pump house (40).
5 Fit new sealing ring (26) with silicon grease into the fuel pump
house (40), make sure the ring is fully in the recess and mind the
position of the sealing ring. See fig. 2.9 --- 4
6 Fit new O ---ring (27) with silicon grease around the liner element
(25).
7 Lift the assembly (25) and (22) into position in the pump housing
with the recess in the cover over the locating pin at top of the pump.
8 Tighten the assembly with bolts (21) handtight on the housing.
9 Tighten first bolts (20) crosswise in three steps to the correct torque
setting and then bolts (21) in the same way. See section 2.4.4.8..
23328 2.9 -- 7
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Injection System
10 Lubricate and mount the fuel rack (6) and fit guide plug (29)
together with a new O ---ring (32) and circlip (28).
11 Turn the pump upside down and after lubrication, fit the control
sleeve (18). The control sleeve is at the serration provided of a pin. This
pin has to fit between the marks of the fuel rack.
12 Reinstall the upper spring disc (17) and spring (15).
13 Insert the plunger (16) with lower spring disc (14) and push rod (12).
14 Use tool 9612DT948 to compress the spring (15) and insert circlip (13)
in position.
Note! The protruding vanes at both sides of the plunger lower side have
to slide in the grooves of the control sleeve. To make this mounting
easy going move at the same time the fuel rack to and fro.
15 Release slowly the spring compression on the tool and check that
the fuel rack slides easily.
16 Lubricate the push rod and guide block.
17 Check that the lubricating oil holes and grooves in the guide block (11)
are open and clean.
18 Check also that the guide block slides without any clearance or
friction over the push rod.
19 Slide the guide block (11), also provided of a new O ---ring (33), over
the push rod. Be sure that the ceramic shaft seal (34) is in a good
condition. If necessary replace the seal.
Note! If this seal is leaking during engine operation, fuel can enter the
lubricating oil system.
20 Mount the guide block (11) and locking plate (10) and fasten the
bolts (9).
21 Unless the pump is immediately mounted on the engine it must be
well oiled and protected by a plastic cover or similar. All openings in the
pump house should be solid covered by plastic caps or tape.
2.9 -- 8 23328
Manual
2.9.2.6. HP fuel pump mounting
Be sure that the HP fuel pump to be mounted is ready for use. This
means that the pump internals are correct and clean assembled and the
fuel rack index is calibrated.
1 Check if fuel cam is in base circle.
2 Clean the HP fuel pump of preservation oil and check the free
movement of the control rack.
3 Clean carefully the HP fuel pump bracket surface.
4 Place new O ---rings with silicon grease in the sealing grooves (8) in
the bracket top surface of the fuel supply and return. See fig. 2.9 --- 3 .
5 Remove all protection and check if pump bracket is clean.
6 Hoist the pump to its position by using tool 9612DT947. Be careful
not to damage the O ---rings during lowering the pump.
7 Place the HP fuel pump on the fuel pump bracket and tighten the
nuts (7) handtight, see fig 2.9 --- 1 . Mind the position of the locating pins.
8 Tighten the nuts (7) to the correct torque setting. See section 2.4.4.8..
9 Connect the fuel rack (6) to the common fuel control shaft.
10 Rotate the common fuel control shaft and check that all pumps
follow the shaft movement. Check that the fuel rack positions of all
pumps are adjusted within ±0.5 mm tolerance.
11 See section 2.9.5. for connection of the HP fuel pipe (1) and the fuel
drain line (2). See chapter 1.6. for maintenance of the stop cylinder.
23328 2.9 -- 9
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Injection System
2.9.2.7. HP fuel pump adjustment
The injection timing is determined by the moment the top of the plunger
is in line with the top of the suction holes of the plunjer housing
The timing may deviate due to manufacturing tolerances in pumps,
cams and drive. To obtain the best possible performance of the engine
it is important that the injection timing is in accordance with the test
bed protocol. See test records.
Note! Checking of the injection timing is always necessary after major

components have been replaced, e.g. HP fuel pump, pump element,
pump drive, camshaft section or some maintenance has been done
on gears, especially to the intermediate gear.
Checking the fuel pump drive

1 Remove the pump. See section 2.9.2.3.
2 Be sure the pump bracket is properly mounted.
3 Remove the camshaft cover and check the fuel cam roller rests on
the base circle of the cam.
4 Measure distance ”X” between top of push rod (1) and upper surface
of pump bracket (2). See fig. 2.9 --- 6 and 2.4 --- 37 .
5 If distance ”X” is out of range, see adjustment of fuel pump drive
and section 2.9.3.2.
9612DT215
”X”=100±0.05 mm
2
Fig. 2.9 - 6 Checking measurement ”X”
2.9 -- 10 23328
Manual
Adjustment of the fuel pump drive

1 For adjustment of the push rod for the fuel pump drive ;
--- Release locking bolt (35).
--- Release and remove bolts (36) and distance sleeves (37) out of fuel
pump bracket.
--- Turn locking nut (38) completely in and then two turns counter
clockwise.
--- Insert both bolts (36) with distance sleeves (37) in fuel pump bracket.
Do not tighten the bolts.
--- Turn push rod (39) to adjust distance ”X” within the required
tolerance, see fig. 2.4 --- 37 .
--- Tighten bolts (36) evenly in steps of 20 Nm. For the correct torque
setting see fig. 2.4 --- 25 .
--- Tighten locking bolt (35) to the correct torque, see fig. 2.4 --- 25 .
--- Release bolts (36) and tighten again evenly in steps of 20 Nm till the
correct torque setting.
--- Check locking bolt (35) on torque setting.
--- Check if distance ”X” is still within the tolerance
”X”
39
36
35
37
38
Fig. 2.9 - 7 HP fuel pump adjustment
23328 2.9 -- 11
Manual
Wärtsilä 38
Injection System
Checking the fuel pump timing

Checking the fuel pump timing is necessary after any major gearwheel
or camshaft maintenance jobs.
2 Starting point is that measurement ”X” is within tolerance with the
fuel cam in base circle.
3 Turn the crankshaft in direction of rotation till the mark on the
flywheel which indicates the injection moment mentioned in the test
bed protocol.
4 Measure again distance ”X” the measured value should be
”X” + 8 mm with a tolerance of ±0.1 mm. See fig. 2.9 --- 6 .(This is the
point where the effective pressure stroke of the fuel pump starts).
For maintenance of the fuel pump drive unit see section 2.9.3.
2.9 -- 12 23328
Manual
2.9.3. Fuel pump bracket
The fuel pump brackets (1), with integrated supply (2) and return (3)
channels are each interconnected by pipe lines (7). See fig. 2.9 --- 8 and
2.9 --- 9 .
In top of the fuel pump bracket two small drillings (4), each surrounded
by an O ---ring (5), are connected to the internal fuel supply and return
of the HP fuel pumps. These drillings are fixed restrictions to damp the
chock pulses generated after the pump plunger releases the compressed
fuel oil.
The fuel pump bracket is also a guidance for the fuel pump tappet (6).
5
5 4
4 2
3 1
Fig. 2.9 - 8 Fuel pump bracket
2.9.3.1. Removing fuel pump bracket
For removal of the fuel pump bracket it is necessary, to remove on both

sides of the bracket, the supply and return lines.
1 Drain the engine fuel system, see section 1.1.4.

2 Remove the HP fuel pipe and HP fuel pump, see chapter 2.9. Take
care to lift the HP fuel pump in centre line direction from bracket to
avoid jamming.
23328 2.9 -- 13
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Injection System
3 Remove from the supply and return lines of the bracket bolts (1)
and bolts (3).
Remove from the adjacent fuel pump brackets also the bolts (1) and (3).
Slide flanges (2) of the pipe lines concerned backwards and take pipe
lines (7) away. See fig. 2.9 --- 9 .
12 13 12 11 10
10
1 2 3
Fig. 2.9 - 9 Low pressure fuel pipes
2.9 -- 14 23328
Manual
4 Remove the two socket head bolts (5), which connect the extrusion
profile to the fuel pump bracket see fig. 2.9 --- 10 .
Fig. 2.9 -- 10 Extrusion profile
23328 2.9 -- 15
Manual
Wärtsilä 38
Injection System
5 Bar the crankshaft till fuel pump roller is on base circle of the cam
and fit locking tool 9612DT504. See fig. 2.9 --- 11 .
6 Tighten the nuts (6) till fuel pump roller is free from the fuel cam.
9612DT504
Fig. 2.9 - 11 Locking tool for tappet
7 Remove nuts (8) from studs (9).
9
8 8 -- 9
8 -- 9
Fig. 2.9 -- 12 Fuel pump bracket securing
8 Lift fuel pump bracket out of the engine block, using the eye bolts
of tool 9612DT504.
2.9 -- 16 23328
Manual
2.9.3.2. Inspection of fuel pump drive tappet
For inspection on wear of the tappet components remove the fuel pump
bracket from the engine block and take it apart.
1 Remove fuel pump bracket from engine according section 2.9.3.1..

2 Remove the tools 9612DT504 from the fuel pump bracket.
See fig. 2.9 --- 11 .
Fig. 2.9 -- 13 Removal roller and shaft from tappet
3 Slide tappet (5) out of the bracket (7), together with spring (6).
4 Press locking pin (1) to slide roller shaft out of the tappet.
5 Clean and inspect all parts for wear. See section 2.4.5.2.
6 For assembling of fuel pump bracket, assemble in reversed order.
Note! For adjustment of the length of the push rod (2), see section 2.9.2.7.
23328 2.9 -- 17
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Injection System
2.9.3.3. Mounting fuel pump bracket
1 Clean components and check with service air, if the lube oil
channels are open.
2 Clean the contact faces for the bracket in the engine block and check
if lube oil supply to the bracket is clean and open.
3 Fit locking tool 9612DT504 according fig. 2.9 --- 11 .
4 Pull the tappet inside the bracket, by tightening nuts (6) till
measurement ”Y” is achieved (35mm). See fig. 2.9 --- 11 .
5 Renew and apply O ---rings (3) and (4) with silicon grease, see fig.
2.9 --- 13 .
6 Bar the crankshaft till the fuel cam is in base circle.
7 Lift fuel pump bracket, using the eye bolts of tool 9612DT504 into
the engine block. Tighten nuts (8) from studs (9). See fig. 2.9 --- 12 .
8 Check with feeler of 0.05 mm that no clearance exists between
bracket sole and engine top side.
9 Loosen nuts (6) , and remove tool 9612DT504. See fig. 2.9 --- 11 .
10 Fit the extrusion profile with the two socket head bolts (5) to the
bracket. See fig. 2.9 --- 10 .
11 Renew from the supply and return lines the O ---rings (10) support
ring (11), back---up rings (12), and O ---ring (13). See fig. 2.9 --- 9 .
12 Fit the supply and return lines, between the fuel pump brackets.
13 Mount the HP fuel pump and HP fuel pipe, see chapter 2.9.
14 Close the drain valves.
15 Open fuel supply, circulate fuel over the engine and check for fuel
leaks.
2.9 -- 18 23328
Manual
2.9.4. Fuel injector
The fuel injector (1) is connected with the HP fuel pump by the HP fuel
line (2) and a connecting piece (3), which is mounted in the nozzle
holder. See fig. 2.9 --- 14 .
1
2
Fig. 2.9 -- 14 Fuel injector
23328 2.9 -- 19
Manual
Wärtsilä 38
Injection System
H.P. fuel enters the injector sideways at (5) through a connecting piece
mounted in the nozzle holder.
Spill fuel from the nozzle needle can escape half---way the holder (8),
along the connecting piece, in a hole in the cylinder head. Against the
cylinder head is at the outside the fuel spill line connected. O ---rings
avoid leaking of the fuel to lower and higher sections of the injector.
5. H.P. fuel
6. Lubricating oil in
7. Lubricating oil out
8. Spill fuel
9. Combustion gases
7
8 9
6
9
5
8
Fig. 2.9 -- 15 Cylinder head with injector
2.9 -- 20 23328
Manual
The injector nozzle is cooled with lubricating oil supplied to the lubrication
system of the cylinder head. The oil enters the injector at (6) and after
cooling of the injector nozzle the oil is released at (7) at the top of the
injector. From there the oil runs down to the crankcase. To avoid the lube
oil leaking down an O---ring is fitted around the injector. See fig. 2.9 --- 15 .
Leaking gases, passing the joint between the injector bottom and the
injector sleeve insert, will escape through hole (9). The combustion
gases will be discharged together with the spill fuel.
2.9.4.1. Removing the fuel injector
1 Remove the cylinder head upper cover and the Hot---Box cover.
2 Remove the HP fuel line (2) and leak---off fuel line (4) between
pump and cylinder head.
3 Turn out the HP fuel connecting piece (3) and disconnect the lube
oil supply line (10), see fig. 2.9 --- 16 . Avoid any lube oil entering the
combustion space after the injector is removed.
10
Fig. 2.9 - 16 Preparation injector removal
23328 2.9 -- 21
Manual
Wärtsilä 38
Injection System
4 Disconnect the nuts (11) and take off the distance sleeves (12) and
the gland (13). See fig. 2.9 --- 17 .
11
12
13
3
15
14
Fig. 2.9 -- 17 Fuel injector assembly
5 Extract the injector with tool 9622DT918.

6 Protect all holes in the injector and the injector hole in the
cylinder head.
7 Protect the fuel discharge of the HP pump and the lube oil supply
against dirt.
2.9.4.2. Fuel injector maintenance
1 Inspect the nozzle immediately after removal out of the engine.

Carbon deposits (trumpets) may indicate that the nozzle is in poor
condition, or that the spring is broken.
2 Test the injector on fuel spray pattern and opening pressure with
test equipment 9622DT916 before dismantling.
3 Clean injector holder, except the nozzle, externally with a brass wire
brush and diesel fuel.
Fuel injector maintenance is to be done according to the maintenance
schedule or when the engine performance gives an indication of poor
injection (e.g. large deviation from normal exhaust gas temperature).
2.9 -- 22 23328
Manual
2.9.4.3. Fuel injector overhaul
1 Release the nozzle spring tension by loosening the counter nut (16)
and adjusting screw (17), see fig. 2.9 --- 18 .
17
16
20
21
19
22
18
Fig. 2.9 - 18 Fuel injector cross section
23328 2.9 -- 23
Manual
Wärtsilä 38
Injection System
2 Remove the nozzle (18) from the holder by turning off the sleeve
nut (19) with socket 9612DT259 and torque spanner. Be careful not to
drop the nozzle. If there is coke between the nozzle and the nut it may
be difficult to remove the nozzle. In such a case, place the nozzle with
the nut on a soft support and knock the nozzle out by using a piece of
pipe. Never knock directly on the nozzle tip. See fig. 2.9 --- 19 .
Fig. 2.9 -- 19 Protecting the nozzle tip
3 Check the nozzle needle movement which may vary as follows:

--- needle moves free over the full length
--- needle moves freely within normal the lifting range
--- needle is sticking.
Do not use any force to free the needle because this often results in
complete jamming. Unless it can be easily removed, immerse the nozzle
in lubricating oil and heat the oil up till 150...200 _C. Normally, the
needle can be removed out off the hot nozzle.
4 Cleaning of the components.
If possible, use a chemical carbon dissolving solution. If such is not
available, immerse the components in clean fuel oil, white spirit or
similar to soak carbon, then clean the parts carefully. Do not use steel
wire brushes or hard abrasive tools.
Clean the nozzle orifices with needles provided for this purpose. After
cleaning, flush the parts clean to remove carbon residues and dirt
particles. Before inserting the needle in the nozzle body, immerse the
components in clean fuel oil or special oil for injection systems.
Seat surfaces, sliding surfaces (needle and housing) and sealing faces
against the nozzle holder should be carefully checked.
Note! The nozzle may also be sent to the engine manufacturer for possible
reconditioning. Note that the nozzle can be reconditioned only once
due to surface hardening on the nozzle body.
2.9 -- 24 23328
Manual
5 Dismantle the nozzle holder by removing the counter nut (16) and
adjusting spindle (17). Remove the guiding screw of the spindle and
turn the injector body upside down to remove the spring (20) and the
push rod (21).
6 Clean and check the parts carefully. Do not mix---up nozzle parts.
7 Check the HP sealing faces of the nozzle holder, i.e. the contact face
to nozzle and the bottom of the fuel inlet hole.
8 Check the bottom surface of the holder for indentation of the
nozzle needle.
9 Check max. needle lift ”A” of nozzle. If the lift is out of limit value
given in fig. 2.4 --- 36 and the nozzle is already reconditioned once, the
nozzle should be replaced for a new one.
10 Place the nozzle carefully onto the injector body. Turn on the sleeve
nut (19) and check the position of locating pins (22). See fig. 2.9 --- 18 .
Note! Use Molycote G between the contact surfaces of the cap nut and
nozzle and in the thread.
11 Use socket 9612DT259 and torque spanner to tighten the sleeve nut
to the correct torque setting. See section 2.4.4.8.
12 If the tests according to section 2.9.4.4. give satisfactory results
then the injector may be mounted in the engine. Otherwise, replace the
nozzle for a new one.
23328 2.9 -- 25
Manual
Wärtsilä 38
Injection System
2.9.4.4. Testing of fuel injectors
Check of the opening pressure
Warning! Be utmost careful when testing a fuel injector. The fuel is sprayed
in a fine mist when testing a nozzle. Fuel spread into a fine mist is
powerful and may penetrate directly into the underlying skin layers
and blood. Such an accident calls for direct specialist treatment.
Should this aid not be available, rinse the affected part of the body
with lukewarm water for a long time. However, it remains necessary
to see a specialist.
Fig. 2.9 -- 20 Testing fuel injectors
1 Fill pump reservoir (of test equipment 9622DT916) with absolute

clean fuel or calibration fluid although a filter is mounted in the reservoir.
2 Connect injector to test equipment.
2.9 -- 26 23328
Manual
3 Before final tightening connecting line between pump and injector

fill connecting line with fuel and vent air by a few pump strokes.
4 Tighten connection.
5 Open the manometer valve.
6 Increase the pump pressure slowly and watch the manometer
pressure when the nozzle opens.
7 Adjust the opening pressure of the nozzle with the spindle (17) in
top of the injector, see fig. 2.9 --- 18 .
Check spray pattern

1 Close the manometer valve to protect the manometer.
2 Hold a dry sheet of paper below the nozzle and give the pump a
quick blow.
3 Check the uniformity of the spray pattern.
4 If the spray pattern is not symmetrical it means that some impurities
are obstructing the nozzle spray holes. Repeat the test after cleaning.
Check of the needle seat tightness

1 Increase the pressure to a value appr. 20 bar below the injector
opening pressure.
2 Keep the pressure for about 10 seconds constant.
3 Check that no fuel drops occur on the nozzle tip. A slight wetting
is acceptable.
4 If drops are formed the nozzle has to be reconditioned or replaced
with a new one.
Note! Some spill fuel may appear from the nozzle holder due to the back
flow.
Check of the needle spindle tightness

1 Raise the injector pressure until appr. 20 bar below the opening
pressure.
2 Measure the time for a pressure fall of 200 bar.
A short time in pressure fall indicates excessive wear of the needle
spindle and/or housing. The nozzle has to be replaced for a new one.
More than 25 seconds indicates a fouled spindle. Both the needle and
body have to be cleaned.
Check the tightness of sealing surfaces

If leakages occurs on the high pressure sealing surfaces, the damaged
part should be replaced with a new one or reconditioned one.
23328 2.9 -- 27
Manual
Wärtsilä 38
Injection System
2.9.4.5. Mounting the fuel injector
Before mounting an injector, test the injector on the required opening

pressure, spray pattern and internal leak of the nozzle needle.
1 Check that the bottom of the stainless sleeve (14) in the cylinder
head is clean. If necessary, clean or lap the bottom sealing surface with
tool 9622DT902. For lapping, fine lapping compound should be used.
The injector seals directly to the bottom of the stainless sleeve without
a sealing washer. See fig. 2.9 --- 17 .
2 Fit new O --- rings (15) around the injector body. Lubricate the
injector body.
3 Fit the injector body into the cylinder head injector hole.
4 Place the gland over the injector and the distance sleeves over the
studs. Fit the nuts (11) hand tight and loosen them a half turn.
5 Fit the fuel connecting piece (3) in the injector and tighten to the
correct torque setting, see section 2.4.4.8.
6 Place locking plate (23) with new O --- ring (24) and bolts (25), see
fig. 2.9 --- 21 . Don’t tighten the bolts.
7 Continue mounting according to section 2.9.5.
2.9 -- 28 23328
Manual
2.9.5. HP fuel line
The connecting piece seals on plain metallic surfaces and these surfaces
are to be checked on condition before mounting. Always tighten the
connecting piece with the correct torque before the HP fuel line is
mounted and also when only the HP fuel line has been removed.
2.9.5.1. Assembling HP fuel line to connecting

piece
1 Check if connecting piece (3) is tight, see fig. 2.9 --- 14 .

2 Place the HP fuel line (2) in the correct position and make sure that
the conical connections are straight mounted to the conical seats.
3 Slide gland (27) backwards onto the sleeve nut (30)
4 Turn on both sleeve nuts of the HP fuel line hand tight.
5 Mount the injector holder definitely by tightening the nuts (11)
equally in steps of 10 Nm till the correct torque setting. See fig. 2.4 --- 23 .
6 Tighten the sleeve nut at pump side with crowfoot wrench
9612DT247 and torque spanner to the correct torque setting, see
section 2.4.4.8.
7 Tighten the bolts M16 (25) in locking plate (23), see fig. 2.9 --- 21 ,
to the correct torque setting, see section 2.4.4.8.
8 Tighten the sleeve nut (30) at cylinder head side with crowfoot
wrench 9612DT246 and torque spanner to the correct torque setting,
see section 2.4.4.8.
23328 2.9 -- 29
Manual
Wärtsilä 38
Injection System
9 Slide the gland (27) back and tighten the bolts M10 (29) to the
correct torque setting. See section 2.4.4.8.
23 24 26 28 3
25 27 30
25
29
Fig. 2.9 -- 21 HP fuel pipe assembling
10 Fit the drain line to the HP fuel line.

11 Open the fuel supply and discharge lines to the engine and circulate
the fuel for some time to vent the system. Turn the crankshaft
simultaneously.
--o--o--o--o--o--
2.9 -- 30 23328
Manual
INDEX Wärtsilä 38
A Big end bearing shells, 2.6 -- 22

BN, 1.2 – 8
Actuator Booster, 1.6 – 4
checking linkage, 1.6 – 7 Booster maintenance, governing system, 1.6 – 13
drive, 2.8 -- 24
mounting, 1.6 – 12 Bottom dead centre, 0.0 -- 5
removing, 1.6 – 11
stop position check, 1.6 – 11 C
Adjusting, valve clearance, 2.7 -- 12 Camshaft, camshaft section, replacing, 2.8 -- 9
Adjustments Camshaft bearings, 2.5 -- 21
fuel delivery commencement, 2.4 -- 101
Camshaft driving gear, 2.8 -- 2
nominal speed, 2.4 -- 101
overspeed stop, 2.4 -- 101 Camshaft gear wheel
valve clearance, 2.4 -- 101 mounting, 2.8 -- 14
removal, 2.8 -- 10
After Sales Information, 0.0 -- 3 Camshaft journal
Anti--bore polishing ring, removing, 2.6 -- 5 removal, 2.8 -- 8
replacing, 2.8 -- 9
Axial clearance
camshaft thrust bearing, 2.4 -- 105 Camshaft section, removal, 2.8 -- 5
crankshaft thrust bearing, 2.4 -- 105, 2.5 -- 19, Catalogue, 0.0 -- 3
2.6 -- 3 CCAI, 1.1 -- 14
Axial thrust rings, inspection, 2.5 -- 20 Centrifugal cleaner, cleaning, 1.2 – 32
Charge air
cooler, 1.5 -- 5
B cooler stack, 1.5 -- 6
internal system, 1.5 -- 3
system, 1.5 -- 4
Background information
easy going nut, 2.4 -- 65 Charge air cooler
genuine parts, 2.4 -- 66 cleaning cooler stack, 1.5 -- 12
locking fluids, 2.4 -- 66 condensate drain, 1.5 -- 7
rolled thread, 2.4 -- 65 maintenance, 1.5 -- 9
studs, 2.4 -- 65 mounting cooler stack, 1.5 -- 11
removal of cooler stack, 1.5 -- 9
Bank, A--bank and B--bank, 0.0 -- 4 repairs, 1.5 -- 13
BDC, 0.0 -- 5 Charge air ducting, 1.5 -- 14
Bearing Charge air system, operation, 1.5 -- 7
’0’--bearing Clockwise rotating, 0.0 -- 4
assembling, 2.5 -- 20 Commissioning filter, 1.2 – 23
removal, 2.5 -- 19
Condemming limits, lubricating oil main, 1.2 – 7
’0’--bearing camshaft, 2.5 -- 23
camshaft bearing bush Condesate drain, charge air cooler, 1.5 -- 7
inspection, 2.5 -- 21 Connecting rod and piston, general, 2.6 -- 4
mounting, 2.5 -- 23 Controllable pitch propeller, 2.3 -- 14
removal, 2.5 -- 22
Cooling water, 1.4 -- 2
crankshaft axial locating bearing, 2.5 -- 18
additives, qualities, 1.4 -- 4
main bearings control, 1.4 -- 5
assembling, 2.5 -- 11 requirements, 1.4 -- 3
inspection, 2.5 -- 11
removal, 2.5 -- 4 Cooling water flow
charge air cooler HT, 1.4 -- 7
Bearing, big end bearing cylinder head, 1.4 -- 7
assembling, 2.6 -- 24 HT cooling water, 1.4 -- 7
removing, 2.6 -- 18 liner to cylinder head, 1.4 -- 7
removing without removing piston, 2.6 -- 22 LT cooling water, 1.4 -- 7
ii-- 1
Manual
Wärtsilä 38 INDEX
Cooling water pump, 1.4 -- 8 Engine instrumentation, 1.6 – 14

assembling, 1.4 -- 11 Engine log sheet example, 2.3 -- 16
disassembling, 1.4 -- 9
mounting instructions, 1.4 -- 12 Exhaust gas ducting, 1.5 -- 15
Cooling water system Exhaust gas system, 1.5 -- 15
cleaning, 1.4 -- 14 compensators, 1.5 -- 16
internal, general, 1.4 -- 6 insulation box, 1.5 -- 17
maintenance, 1.4 -- 14 maintenance, 1.5 -- 18
venting, 1.4 -- 15 operation, 1.5 -- 18
Counter--clockwise rotating, 0.0 -- 4 Exhaust valve seat, removing, 2.7 -- 18
Crankcase breathing system, 1.2 – 33 Exhaust valves, 2.7 -- 14
Crankcase explosion relief valves, 2.5 -- 30
Cranking, turning device, 2.6 -- 29 F
maintenance, 2.6 -- 30
Flexible pipe connections, cooling water system,
Crankshaft, deflections, 2.6 -- 2
1.4 -- 13
Crankshaft gear wheel, 2.8 -- 18
Flywheel, marks, 0.0 -- 6
Cylinder head
Free end, 0.0 -- 4
mounting, 2.7 -- 9 Fuel
removing, 2.7 -- 4 conditioning, 1.1 -- 10
purification, 1.1 -- 10
Cylinder head stud, replacing, 2.5 -- 29 requirements, before engine, 1.1 -- 5, 1.1 -- 6
Cylinder liner Fuel control mechanism, 1.6 – 5
centre of gravity, 2.5 -- 26
inspection, 2.5 -- 24 Fuel injector, 2.9 -- 19
mounting, 2.5 -- 27 maintenance, 2.9 -- 22
removal, 2.5 -- 25 mounting, 2.9 -- 28
overhaul, 2.9 -- 23
Cylinder pressure, maximum, 2.3 -- 17 removing, 2.9 -- 21
testing, 2.9 -- 26
D Fuel oil, specifications LFO, 1.1 -- 5

Fuel pump bracket
Derating conditions, 1.0 -- 4 general, 2.9 -- 13
Designation mounting, 2.9 -- 18
of bearings, 0.0 -- 7 removing, 2.9 -- 13
of cylinders, 0.0 -- 4 Fuel rack, checking linkage, 1.6 – 8
Dimensions and masses, engine components, Fuel system, draining, 1.1 -- 16
2.4 -- 115
DMA, DMB, DMC, 1.1 -- 5
Documentation overview, 0.0 -- 3
G
Driving end, 0.0 -- 4 Gear wheel drive, inspection, 2.8 -- 4
Governing system, trouble shooting, 1.6 – 12
Gudgeon pin bearing, Inspection and maintenance,
E 2.6 -- 12
Emergency operation
defective air cooler(s), 2.3 -- 25
defective turbocharger, 2.3 -- 25 H
one cylinder unit out of operation, 2.3 -- 25
Hand--operated hydraulic pump, operating,
Engine block, 2.5 -- 2 2.4 -- 75
Engine definitions, 0.0 -- 4 HFO, 1.1 -- 3
ii-- 2
Manual
INDEX Wärtsilä 38
HFO engines running on distillate fuels, 1.1 -- 2 Load, increase, 2.3 -- 13

HP fuel line, 2.9 -- 29 Load decrease, before stop, 2.3 -- 11
HP fuel line , assembling, to connecting piece, Load indication HP fuel pump, 1.6 – 6
2.9 -- 29 Local Control System, 1.6 – 18
HP fuel pump Local start, 2.3 -- 4
adjustment, 2.9 -- 10
assembling, 2.9 -- 7 Locking fluids, 2.4 -- 66
dismantling, 2.9 -- 5 Loosening, hydraulically tightened connection,
general, 2.9 -- 2 2.4 -- 77
Low load and idling, restrictions, 2.3 -- 11
mounting, 2.9 -- 9
removing, 2.9 -- 3 Lubricants additional equipment
actuator, 1.2 – 4
HP fuel pump, load indication, 1.6 – 6
hydraulic tools, 1.2 – 4
HP hose, 2.4 -- 73 turbocharger, 1.2 – 4
quick--release coupling, 2.4 -- 74 turning gear, 1.2 – 4
Hydraulic extractor, 2.4 -- 72 Lubricating oil
Hydraulic jack, 2.4 -- 70 comments on characteristics, 1.2 – 8
flash point, 1.2 – 8
Hydraulic pump influences on condition, 1.2 – 5
hand--operated, 2.4 -- 75 insolubles, 1.2 – 8
pneumatic driven, 2.4 -- 66 refreshing, 1.2 – 10
Hydraulic tools, safety instructions, 2.4 -- 76 requirements, 1.2 – 3
engine, 1.2 – 4
Hydraulically tightened connection
sampling, 1.2 – 6
loosening, 2.4 -- 77
sampling valve, 1.2 – 23
tightening, 2.4 -- 79
testing, 1.2 – 5
Lubricating oil flow
I commissioning filter, 1.2 – 15
connecting rod, 1.2 – 17
Indicator cock and safety valve, 2.7 -- 25 engine, 1.2 – 14, 1.2 – 21
gearing, 1.2 – 19
Inlet valve seat, removing, 2.7 -- 19 main bearing, 1.2 – 16
Inlet valves, 2.7 -- 14 piston, 1.2 – 18
Inlet--Exhaust valve seat Lubricating oil main, condemming limits, 1.2 – 7
machining, 2.7 -- 20 Lubricating oil pump
mounting, 2.7 -- 19 gearwheel connection, 1.2 – 26
Input / Output list, 1.6 – 14 general, 1.2 – 24
operation, 1.2 – 27
Instrument list, 1.6 – 14
pressure control valve, 1.2 – 27
Intermediate gear wheel pump construction, 1.2 – 25
mounting, 2.8 -- 17
removal, 2.8 -- 15
M
L Maintenance
crankshaft explosion relief valves, 2.5 -- 31
LFO, 1.1 -- 5 stop device, 1.6 – 13
ii-- 3
Manual
Wärtsilä 38 INDEX
Maintenance schedule Piston and connecting rod

camshaft and valve drive mechanism, 2.4 -- 12 assembling, 2.6 -- 14
charge air and exhaust gas system, 2.4 -- 8 mounting, 2.6 -- 15
control system, 2.4 -- 9 Piston rings, inspection and maintenance, 2.6 -- 12
cooling water system, 2.4 -- 7 Pneumatic control system, 1.3 -- 9
crankshaft, connecting rod, piston, 2.4 -- 11 maintenance, 1.3 -- 9
cylinder liner, 2.4 -- 10
Pneumatic hydraulic pump, operating, 2.4 -- 68
cylinderhead with valves, 2.4 -- 12
engine block with bearings, 2.4 -- 10 Preheating, 2.3 -- 3
fuel system, 2.4 -- 6 Procedure for inspection and maintenance, 2.4 -- 4
general points, 2.4 -- 5
injection system, 2.4 -- 13
lubricating oil system, 2.4 -- 6 R
operation, 2.4 -- 10 Residual fuel oil (HFO), quality, 1.1 -- 3
starting air system, 2.4 -- 7 Restrictions
Maintenance tools, 2.4 -- 15 low load and idling, 2.3 -- 11
camshaft and valve drive mechanism, 2.4 -- 52 operation at excessive suction air temperature,
charge air and exhaust gas system, 2.4 -- 28 2.3 -- 11
crankshaft, connecting rod, piston, 2.4 -- 37 Rocker arm bracket, removal, 2.8 -- 20
cylinder head with valves, 2.4 -- 44 Rules for inspection and maintenance, 2.4 -- 2
engine block, main bearing, cylinder liner, Rules for maintenance and inspection
2.4 -- 29 general, 2.4 -- 2
injection system, 2.4 -- 59 last check, 2.4 -- 3
miscellaneous, 2.4 -- 20 mounting, 2.4 -- 3
Manual, 0.0 -- 3 removal, 2.4 -- 3
Running--in, 2.3 -- 18
Marks on the flywheel, 0.0 -- 6
Mechanical limiter, 1.6 – 9
S
Safety, aspects, 2.4 -- 2
N Safety instructions, hydraulic tools, 2.4 -- 76
Safety valve / indicator cock, 2.7 -- 25
Non--operating side, 0.0 -- 4 Setpoint list, 1.6 – 14
Speed control system, 1.6 – 3
Speed sensor, 1.6 – 16
O Start
after a normal stop, 2.3 -- 5
Operating after overhaul, 2.3 -- 6
hand--operated hydraulic pump, 2.4 -- 75 emergency, 2.3 -- 8
pneumatic hydraulic pump, 2.4 -- 68 local, 2.3 -- 4
problems, 2.3 -- 19 putting the engine into operation, 2.3 -- 3
remote or automatic, 2.3 -- 5
Operating data, 1.0 -- 5
Starting air distributor, 1.3 -- 4
Operating range, 2.3 -- 14 maintenance, 1.3 -- 5
Operating side, 0.0 -- 4 Starting air pipes, 1.3 -- 8
Output, engine, 1.0 -- 3 Starting air valve, maintenance, 1.3 -- 7
Stop
device, 1.6 – 10
emergency, 2.3 -- 26
P final stop, actions, 2.3 -- 27
local, 1.6 – 10
Piston manual, 2.3 -- 27
dismantling, 2.6 -- 10 mechanism, 1.6 – 10
removing, 2.6 -- 5 remote, 2.3 -- 26
ii-- 4
Manual
INDEX Wärtsilä 38
Sub--suppliers Manual, 0.0 -- 3 Torque spanner, 2.4 -- 80

Suction air filtration, quality, 1.5 -- 2 Transmitters, 1.6 – 15
Switches, 1.6 – 14 Trouble and possible reason, 2.3 -- 19
Turbocharger, 1.5 -- 19
cleaning devices, 1.5 -- 19
T compressor side cleaning, 1.5 -- 20
Lubricating oil, 1.2 – 4
Tappet guide block, 2.8 -- 22 maintenance, 1.5 -- 19
TDC, 0.0 -- 5 turbine side cleaning, 1.5 -- 21
at firing, 0.0 -- 5 Turning device, maintenance, 2.6 -- 30
at scavenging, 0.0 -- 5
Temperature elements, 1.6 – 15
Terminology, 0.0 -- 4 V
Testing Valve clearance, adjusting, 2.7 -- 12
fuel injector, 2.9 -- 26
lubricating oil, 1.2 – 5 Valve drive mechanism, 2.8 -- 19
assembling, 2.8 -- 23
Tightening, hydraulically tightened connection, 2.4 dismantling, 2.8 -- 20
-- 79
Valve guide
Tightening torque extracting, 2.7 -- 21
camshaft and valve drive mechanism, 2.4 -- 92 mounting, 2.7 -- 21
control system components, 2.4 -- 85
cooling water system components, 2.4 -- 84 Valve rotator
crankshaft, connecting rod, piston, 2.4 -- 87 exhaust, maintenance, 2.7 -- 24
cylinder head with valves, 2.4 -- 89 inlet, maintenance, 2.7 -- 24
engine block with bearings, 2.4 -- 86 Valve rotators, 2.7 -- 23
injection system components, 2.4 -- 96
Valve seat
lubricating oil system components, 2.4 -- 83
blueing test, 2.7 -- 17
Tolerances checks and reconditioning, 2.7 -- 17
actuator drive, 2.4 -- 111 machine grinding, 2.7 -- 17
big end bearing, 2.4 -- 107
Valves
camshaft bearing, 2.4 -- 105
assembling, 2.7 -- 22
Cooling water pump, 2.4 -- 103
checks and reconditioning, 2.7 -- 17
Crankshaft deflection, 2.4 -- 106
removing, 2.7 -- 15
cylinder liner, 2.4 -- 104
fuel pump bracket, 2.4 -- 113 Vibration damper crankshaft
gearwheel train, 2.4 -- 110 liquid sampling, 2.6 -- 27
injection system, 2.4 -- 114 maintenance, 2.6 -- 26
lubricating oil pump, 2.4 -- 103 Viscosity, conversion diagram, 1.1 -- 7
main bearing, 2.4 -- 105
piston / gudgeon pin bearing, 2.4 -- 108
valve drive mechanism, 2.4 -- 112
valves, 2.4 -- 109 W
Top dead centre, 0.0 -- 5 Wiring diagram, 1.6 – 14
ii-- 5
Manual
Wärtsilä 38 INDEX
ii-- 6
Hanzelaan 95
8017 JE Zwolle, The Netherlands
P.O. Box 10608, 8000 GB Zwolle
Tel +31 38 425 32 53
Telefax +31 38 422 35 64

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38

AUTHORIZATION Management WNL

E Copyright 2001 by Wärtsilä Nederland B.V.

THIS PUBLICATION IS DESIGNED TO PROVIDE AS ACCURATE AND AUTHORITATIVE INFORMATION

0.0. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0 - 1

1.0. Main Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 -- 1

1.1. Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 - 1

1.2. Lubricating Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 – 1

1.3. Starting Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 - 1

1.4. Cooling Water System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 - 1

1.5. Charge Air and Exhaust Gas System . . . . . . . . . . . . . . . . . . . . . . . 1.5 - 1

1.6. Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 – 1

2.3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 - 1

2.4. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 - 1

2.5. Engine Block with Bearings and Cylinder Liner . . . . . . . . . . . . . 2.5 - 1

2.6. Crankshaft, Connecting Rod, Piston . . . . . . . . . . . . . . . . . . . . . . . 2.6 - 1

2.7. Cylinder Head with Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 1

2.8. Camshaft and Valve Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 - 1

2.9. Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 - 1

Fig. 0.0 -- 1 Engine definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0 -- 4

Fig. 2.3 -- 2 Gradual load increase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 -- 12

Fig. 2.5 -- 7 Inserting main bearing shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 -- 11

Fig. 2.7 – 12 Dismantling of valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 15

0.0. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0 - 1

Wärtsilä Nederland B.V. reserves the right to minor alterations and

0.0.2. Documentation overview

The engine documentation delivered with your engine consists of four

4: After Sales Information

The following definitions are used in the engine documentation:

RELATED TO ISO 1204

Fig. 0.0 - 1 Engine definitions

Top dead centre (TDC)

Bottom dead centre (BDC)

Marks on the flywheel

Fig. 0.0 -- 2 Example of reading the flywheel

Intermediate gear wheel bearings

Fig. 0.0 -- 3 Designation of main bearings / camshaft bearings

1.0. Main Data

1.0. Main Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 -- 1

1.0.1. Basic information

Project name Bodewes 504

Engine type 6L38

The Wärtsilä 38 diesel engine is a 4–stroke, medium speed,

Engine output according to engine rating plate

Engine output according to ISO substitute reference conditions

Fuel limiter is set at 100 % and no overload is allowed.

1.0.3. Derating conditions

1 Derating of the engine output:

2 Reduce engine load if operating temperatures of lubricating oil or

High operating temperatures can be caused by:

1) pressure loss air cooler in mbar

1.0.4. Operating Data

Operating Data Conditions

* ---static pressure to be added.

1.1. Fuel System

1.1. Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 - 1

Selection of the most economical fuel for diesel engines depends on

1.1.1.1. HFO engines running on distillate

1.1.2.1. Residual fuel oil (HFO) quality