Wärtsilä 20DF Engine O&MM 04.

Maintenance schedule

04. Maintenance schedule

Maintain the engine regularly according to the maintenance schedule. Regular maintenance
helps to avoid engine malfunction and increases the engine's lifespan.
The actual operating conditions and the quality of the fuel used have a large impact on the
recommended maintenance intervals. Because of the difficulty in anticipating the engine
operating conditions encountered in the field, the maintenance intervals stated in the schedule
are for guidance only.

NOTE
Do not exceed the maintenance intervals during the warranty period.

If there is any sign indicating the need for a maintenance operation in advance of the scheduled
time, prudent industry practice dictates that the maintenance operation must be performed.
Likewise, if an inspection or observation reveals wear of any part or use beyond the prescribed
tolerances, replace the part immediately.
In some cases, the fuel quality used affects the length of the maintenance intervals.
The maintenance schedule distinguishes the following fuel types:

HFO 1 Heavy fuel oil of normal quality

HFO 2 Heavy fuel oil of a quality below normal standard quality

DO Diesel oil or light fuel oil (LFO)

NG Natural gas

For more information on the fuel types, see the fuel specifications and limit values.
For maintenance instructions, see the references given in the schedule. Also see the
turbocharger instructions and other equipment manufacturer's instructions.

04.1 Basic maintenance principles

● Observe utmost cleanliness and order during all maintenance work.
● Before dismantling, check that all concerned systems are drained and the pressure released.
● After dismantling, immediately cover the lubricating oil, fuel oil and air holes with tape,
plugs, clean cloth or similar means.
● When exchanging a worn-out or damaged part provided with an identification mark stating
cylinder or bearing number, mark the new part with the same number on the same spot.
Enter every exchange in the engine log along with the clearly stated reason for the exchange.
● Always renew all gaskets, sealing rings and O-rings at maintenance work.

NOTE
The O-rings in the cooling water system must not be lubricated with oil based
lubricants. Use soap or similar.

● After reassembling, check that all screws and nuts are tightened and locked (as required).

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● If any welding is performed on the engine, disconnect the electronic equipment according
to the welding instructions. Keep the return connection near the welding point.
● Consider that well cleaned oil spaces (oil sump and camshaft spaces) spare the oil pump
and oil filter.
● When supervising engine operation or doing maintenance, record all relevant data in the
measurement records. This helps you evaluate the engine condition and follow up changes
over time. You can find the measurement records in Chapter 09 Installation-specific data.

04.2 Before starting maintenance

WARNING
To prevent personal injury or engine damage, take all the necessary safety
precautions before starting any maintenance work on a stopped engine.

● Check that the engine mode selector switch is in the blocked position.
● Disconnect the engine’s automatic start.
● Disconnect all the concerned circulation pumps, for example, for prelubricating oil,
lubricating oil, cooling water and fuel.
● Close the starting air shut-off valve located before the main starting valve.
● Drain the starting air system.
● Set the turning device in engaged position and secure the generator breaker or disengage
the gearbox to avoid accidental crankshaft rotation.
● Disconnect the power supply before removing any electrical components.

04.3 Maintenance intervals

04.3.1 Once for a new engine or after an overhaul
Part or system Maintenance task Chapter
Connecting rod Check the tightness of the connecting rod nuts.
On a new engine:
Check the tightness of the connecting rod nuts within the first 50 oper-
11
ating hours.
After the first test run after an overhaul:
Check the tightness of the connecting rod nuts which have been opened.
Cooling water Check the water quality.
02
Check the content of additives. See bulletin 4619Q002.
Injection pipes Check the tightness of the injection pipe connections.
On a new engine:
Check the tightness of the injection pipe connections within the first 50
operating hours. 16
After the first test run after an overhaul:
Check the tightness of the injection pipe connections which have been
opened. The engine should be in normal operating temperature.

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Part or system Maintenance task Chapter
Main bearings Check the tightness of the main bearing nuts.
On a new engine:
Check the tightness of the main bearing nuts within the first 50 operating
hours.
After the first test run after an overhaul: 10
Check the tightness of the main bearing nuts which have been opened.
Note!
Pump to the stated pressure. Tighten the nuts, if possible.
Do not loosen the nuts!
Starting air system Clean the filter before the engine after the first 50 operating hours
21
on a new engine.
Valve mechanism Check the valve clearances.
On a new engine:
Check the valve clearances within the first 50 operating hours. 14
After the first test run after an overhaul:
Check the valve clearances.

04.3.2 Once a day

Part or system Maintenance task Chapter
Automatic prelubrication Check the function of the automatic prelubrication's operation.
Check that the pump is rotating and that the pressure is over the start
block limit.
Cooling water Check that there are no water leaks from the engine.

Gas system Check the gas system for leakage using a hand held or stationary
17
gas detector.
Lubricating oil Check that there are no lubricating oil leaks from the engine.

Starting air system Drain the starting air vessels and treatment unit(s).
21
Drain more often, if necessary.

04.3.3 Every second day

Perform these maintenance tasks irrespective of the engine being in operation or not.

Part or system Maintenance task Chapter

Crankshaft In a stopped engine, turn the crankshaft into a new position with the
03
prelubricating pump running.

04.3.4 Once a week

Perform these maintenance tasks irrespective of the engine being in operation or not.

Part or system Maintenance task Chapter

Air intake filter, external (if Check the intake air filter pressure drop.
equipped) For more info, see bulletin WV92Q214.

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Part or system Maintenance task Chapter
Charge air shut-off valve (if Check the function of the charge air shut-off valve.
equipped)
Gas system Inspect the gas system for leakage using a hand held gas detector.

Start process Test start (if the engine is on stand-by). 03

04.3.5 Interval: 50 operating hours

Part or system Maintenance task Chapter
Charge air system Check draining of the charge air system.
Check that the drain pipes are open. 03, 15
Check for leaks from the charge air cooler.
Cooling water system Check the water level in the cooling system.
Check the water level in the expansion tank(s) and the static pressure 19
in the engine cooling circuits.
Fuel filters Check the pressure drop.
17
Change the filter cartridges if a high pressure drop is indicated.
Governor, actuator Check the oil level and check for leaks in the governor/actuator, See
if equipped. manufacturer's
instructions.
Injection and fuel system Check the leak fuel quantity.
Check the amount of leak fuel from the fuel injection pumps and injection 03, 17
nozzles.
Lubricating oil Check the lubricating oil level using an oil dipstick.
02, 18
Refill with more oil, if needed.
Lubricating oil filters Check the pressure drop.
Clean and change the filter candles if a high pressure drop is indicated. 18
Check that the filter shaft rotates when there is oil pressure.
Operation data Record all temperature and pressure readings and the respective
engine load using the operating data record form WV98V091.
03
Record firing pressures and fuel rack position of each cylinder every
1000 hrs.
Turbocharger Clean the compressor by injecting water.
15
Visually check for leaks or defects.

04.3.6 Interval: 72 operating hours

Part or system Maintenance task Chapter
Turbocharger Clean the turbine by injecting water, if the engine has been operating
15
on HFO2.

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04.3.7 Interval: 168 operating hours

Part or system Maintenance task Chapter
Turbocharger Clean the turbine by injecting water, if the engine has been operating
15
on HFO1.

04.3.8 Interval: 250 operating hours

Part or system Maintenance task Chapter

Control mechanism Check for free movement.

22
Clean and lubricate the control mechanism.

04.3.9 Interval: 500 operating hours

Part or system Maintenance task Chapter

Centrifugal filter Clean the centrifugal filter.

Clean more often, if necessary. After cleaning, open the valve present
18
before the filter.
Check the condition of bearings and shaft journals.
Cooling water Check the water quality.
19
Check the content of additives. See bulletin 4619Q002.
Lubricating oil Take an oil sample for analysis:
- in a new installation
- after changing to a new lubricating oil brand
- every 500-1000 operating hours intervals, or every six months at the
latest (to ensure safe operation)
18
Change the lubricating oil if the oil analysis results are not within the
limits set by the engine manufacturer. When changing the oil, clean all
oil spaces with a high-quality fibre-free and lint-free cloth.
Regardless of the analysis results, change the oil at every piston over-
haul, or every fourth year, whichever comes first.
Turbocharger(s) Wash the filter mat on the turbocharger silencer.
Clean according to manufacturer's instructions (or more often, if neces-
sary). 15
Clean the turbine by injecting water if the engine has been running on
MDO/LFO or gas.

04.3.10 Interval: 1000 operating hours

Part or system Maintenance task Chapter

Flexible Coupling Check the couplings condition in new installations or when the
coupling has been replaced, if equipped.
A more thorough inspection is to be carried out every 4000 hrs or annu-
ally, whichever comes first.

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Part or system Maintenance task Chapter

Fuel filter Replace the fuel oil filter cartridges, if equipped.

Clean the wire gauze and the filter housing. Replace the filter cartridges.
17
The cartridges must be replaced earlier if the pressure difference in-
dicator shows high pressure drop.
Starting air system Clean the filter before the engine. 21
Valves Check the valve clearances.
Check that the inlet and exhaust valves move freely in their guides.
06, 12
This should preferably be done when the engine has been out of oper-
ation for a couple of hours.

04.3.11 Interval: 2000 operating hours

Part or system Maintenance task Chapter

Charge air cooler(s) Check the differential pressure.

Check the pressure difference over the charge air cooler air side at 15
high load. Clean the cooler if necessary.
Control and monitoring system Check the function of the safety system and automatic stop
devices. 23
Replace faulty sensors.
Electro-pneumatic stop device Check function and tripping speed. 22
Fuel injectors Inspect the fuel injectors.
Test the opening pressure. 16
Replace the sealing rings.
Gas system Perform a leak test with 3 bar compressed air or 3 bar nitrogen
pressure. 17
See separate instructions for the gas valve unit.
Governor Change oil in the governor, if equipped.
22
Change lubricating oil.
Lubricating oil cooler Check that the lubricating oil cooler temperature before the engine
is within normal operating values, see chapter 01. 18
Check for leakage. Clean if necessary.

04.3.12 Interval: 4000 operating hours

Part or system Maintenance task Chapter

Automatic lubricating oil filter Inspect the lubricating oil filter candles.
Clean the filter candles and safety filter mesh, if necessary. Do not
18
clean mechanically.
Replace worn parts.
Camshaft and valve mechanism Visually inspect the camshaft's contact faces and tappet rollers.
Check the valve yoke and the adjusting screw nut.
14
Check that the rollers rotate.
Rotate the crankshaft with the turning device.

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Wärtsilä 20DF Engine O&MM 04. Maintenance schedule

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Part or system Maintenance task Chapter

Control and monitoring system Check the connectors and connector holders.
Check the mounting and connector holders. Verify the presence of
contact lubricant and add, if necessary. Check the tightness of the 23
connections. Check the condition of cables, wires and cable glands.
Rectify, improve or replace the equipment, if necessary.
Control mechanism Check the control mechanism.
Check for wear in all connecting links between the governor or actuator 22
and all injection pumps.
Crankshaft Check the alignment on a warm engine. Use form No. WV98V036. 11
Cylinder liners Inspect the cylinder liner jacket water spaces once in a new install-
ation, and at the first 4000 hours after a major overhaul.
Pull out one cylinder liner. If the deposits are thicker than 1 mm, clean 02, 10
all cylinder liners and the engine block water space. Improve the cooling
water treatment. Replace the distance shim under the liner, if installed.
Flexible coupling Check the coupling's condition, if equipped.
Use measurement record form no. WV98V041 to check the alignment
every 4000 hrs or annually, whichever comes first.
See the manufacturer's instructions.
Injector valves Replace the nozzles by new ones. 16
Resilient mounts Inspect the buffer clearance at least once a year.
Reset the buffer clearance, if necessary.
Turbocharger Inspect the compressor and clean it mechanically, if necessary.
15
Inspect the nozzle ring and clean it, if necessary.

04.3.13 Interval: 8000 operating hours

Part or system Maintenance task Chapter

Automatic lubricating oil filter Drain the filter housing.

Clean the protective filter.
18
Replace the filter candles after two years in service at the latest or if
the differential pressure alarm occurs.
Air starter Carry out the air starter maintenance along with the general engine
maintenance or after three years at the latest.
21
Replace the bearings, the solenoid valve and worn parts.
See the manufacturer's instructions.
Air wastegate and air by-pass valve Check the function of the air wastegate.
Replace the positioner pilot valve. 15
Replace the air wastegate silencer(s), if equipped.

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Part or system Maintenance task Chapter

Control and monitoring system General control and monitoring system inspection.
Check for insulation wear, loose terminals and loose wires.
Check for cable insulation wear, damages, loose cable glands, connect-
ors, holders and loose grounding shields.
Check for loose grounding straps and corrosion.
Check the sensors, actuators, solenoids etc. for leakages and physical
damages. Also check the signal and measurement, where applicable. 23
Check the condition of vibration dampers and replace them, if neces-
sary.
Verify correct readings on engine displays and meters.
Check the electronic modules visually for damages. Rectify, improve
or replace the equipment, if necessary.
Check the sealing condition on cabinets and boxes.
Flexible hoses Visually inspect the flexible hoses.
Replace, if necessary.
Fuel system Check the adjustment of the fuel system.
Check for leakages. 17
Replace worn parts, if necessary.
Gas valve unit For overhaul of gas pressure regulating and safety shut-off valves,
17
see the manufacturer's instructions.
Governor driving gear Inspect the governor driving gear, if equipped.
22
Replace parts, if necessary.
Pilot fuel injector Replace the pilot fuel injector. 17
Pilot fuel pump Replace the pilot fuel feed pump.
17
Adjust the gear wheel backlash when fitting the new pump.

04.3.14 Interval: 10,000 operating hours

Part or system Maintenance task Chapter

Cylinder heads Inspect the cylinder heads.

Inspect the condition of at least one cylinder by checking the condition
of the flame plate, valves and valve sealing surfaces. If necessary,
overhaul all cylinder heads:
- Dismantle and clean the underside, inlet and exhaust valves and ports.
- Grind the valves and exhaust/inlet seat rings (lapping by hand is often
enough).
- Inspect the valve rotators. 12
- Pull out the exhaust gas seat rings and inspect the cooling spaces.
Clean them, if necessary. Replace the sealing ring(s), if necessary.
- Replace the valve guide stem seal rings.
- Use the cylinder head overhaul report measurement record form
number 2012V015.
Note!
Overhaul the cylinder heads at every piston overhaul at the latest.
Gas admission valves Replace the main gas admission valves.
17
Clean the main gas admission valve filter insert. Replace, if necessary.

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Wärtsilä 20DF Engine O&MM 04. Maintenance schedule

04.3.15 Interval: 12,000 operating hours

Part or system Maintenance task Chapter

Control and monitoring system Recalibrate the I/P converter and replace the filter.
This should be done every 12,000 operating hours or every second 15
year at the latest.
Exhaust manifold Check the expansion bellows, nuts and pipe supports of the flange
connections. 20
Replace parts, if necessary.
Turbocharger Inspect the bearings of radial type turbocharger.
Open the turbocharger and clean all the parts.
15
Replace the bearings, if necessary.
See manufacturer's instructions.

04.3.16 Interval: 16,000 operating hours

Part or system Maintenance task Chapter

Camshaft driving gear Inspect the camshaft driving gear.

Check the clearances and backlash. 13
Replace worn parts, if necessary.
Gas system Replace the sealings in pipe connections.
Inspect the sealing faces for wear and corrosion. 17
Perform the leak test.
Governor (mechanical), if equipped Governor general overhaul should be performed at an authorized
workshop latest after 5 years in use.
22
Check the function and adjustments of the governor.
Replace worn parts.
Governor drive Check the governor drive bearing, if equipped.
22
Check the governor driving shaft bearing clearance in situ.
Intermediate gears and bearings Inspect the gear teeth and measure backlash and axial clearance.
13
Replace the bearings at least every 48,000 operating hours.
Prelubricating oil pump Inspect the prelubricating oil pump.
Replace parts, if necessary.
18
Replace the roller bearings for the prelubricating oil electrical motor
latest after three years of use.

04.3.17 Interval: 10,000 - 20,000 operating hours

This overhaul interval depends on the fuel characteristics according to the table below.

Fuel Overhaul interval (hours)

HFO 2 10,000

HFO 1 14,000

DO/NG 20,000

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04. Maintenance schedule Wärtsilä 20DF Engine O&MM

Part or system Maintenance task Chapter

Camshaft Inspect the camshaft bearings.

14
Replace the bearings, if necessary.
Connecting rod Replace the big end bearings.
Inspect the mating face and surface of serrations.
Measure the big end bore using measurement record form number
2011V001.
06, 11
Inspect the small end bearings.
Measure the small end bore using measurement record form number
2011V007.
Replace the small end bearings, if necessary.
Crankshaft Check the thrust bearing clearance.
10
Check the axial clearance.
Cylinder heads Overhaul cylinder heads.
- Dismantle and clean the underside, inlet and exhaust valves and ports.
- Grind the valves and exhaust/inlet seat rings (lapping by hand is often
enough).
- Inspect the valve rotators.
- Pull out the exhaust gas seat rings and inspect cooling spaces. Clean 12
them, if necessary. Replace the sealing ring(s), if necessary.
- Replace the valve guide stem seal rings.
- Use the cylinder head overhaul report measurement record form
number 2012V015.
Note! Overhaul the cylinder heads at every piston overhaul at the latest.
Cylinder liners Inspect the cylinder liners.
Measure the bore using measurement record form number 2010V002
and replace the liner if wear limits have exceeded.
Hone the liners.
Renew the antipolishing ring.
10, 19
Inspect all cylinder liners water side and replace O-rings.
Pull all cylinder liners.
If the deposits are thicker than 1 mm, clean all liners and the engine
block water space.
Replace the O-rings at the bottom part by new ones at every overhaul.
Electrial motor for prelubricating oil Replace the roller bearings after three (3) years in use, at the latest.
18
pump
Fuel feed pump Inspect the fuel feed pump (if equipped).
17
Replace the gaskets.
Fuel injection pumps Clean and inspect the fuel injection pumps.
Replace worn parts.
16
Replace all the seal rings and the constant pressure valve.
Check the erosion plugs and replace, if necessary.
HT water pump Dismantle and inspect the HT water pump.
Replace worn parts. 19
Check the backlash.
HT water pump driving gear Inspect the HT water pump driving gear.
Replace worn parts, if necessary. 19
Check the backlash.
HT water termostatic valve Clean and inspect the HT water thermostatic valve.
Clean and check the thermostatic element cone casing, and replace
19
the sealings.
Check the functioning of the thermostatic valve.
LT water pump Dismantle and inspect the LT water pump.
Replace worn parts. 19
Check the backlash.

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Part or system Maintenance task Chapter

LT water pump driving gear Inspect the LT water pump driving gear.
Replace worn parts, if necessary. 19
Check the backlash.
LT water thermostatic valve Clean and inspect the LT water thermostatic valve.
Clean and check the thermostatic element cone-casing and replace
19
sealings.
Check the function of the valve.
Lubricating oil cooler Clean the lubricating oil cooler before the alarm limit is reached.
If the lubricating oil temperature before the engine is within normal op-
18
erating values, the maintenance interval can be prolonged.
Carefully check for corrosion.
Lubricating oil pump Dismantle and inspect the lubricating oil pump.
Replace worn parts. 18
Check the backlash.
Lubricating oil pump driving gear Inspect the lubricating oil pump driving gear.
Replace parts, if necessary. 18
Check the backlash.
Lubricating oil thermostatic valve Clean and inspect the lubricating oil thermostatic valve.
Clean and check the thermostatic element, valve cone casing and 18
sealings.
Main bearings Inspect the bearing shells of one main bearing.
10
Replace all bearing shells, if necessary.
Pistons Inspect the piston.
Dismantle one composite piston for inspection of mating surfaces
between piston skirt and piston crown. 11
Inspect and clean the oil spaces.
Repeat the procedure with other pistons, if necessary.
Piston, piston rings Inspect pistons and piston rings.
Pull, inspect and clean.
Check the height of the ring grooves using measurement form number
2011V003. 11
Check the retaining rings of the gudgeon pins.
Replace complete set of piston rings.
Note the running-in programme.
Prelubricating oil pump Inspect the prelubricating oil pump.
18
Replace shaft seals and worn parts.
Valve mechanism Inspect the rocker arms, screws, yokes, adjusting screw nuts,
valve tappets and tappet roller bearing bushes.
06, 14
Inspect the VIC unit (if installed) and replace the sealings.
Replace parts, if necessary.

04.3.18 Interval: 24,000 operating hours

Part or system Maintenance task Chapter

Actuator Check the actuator and flexible couplings.

Check clearances of bearings. 22
Replace parts if necessary.
Connecting rod Replace the connecting rod screws with new ones every 24,000
11
operating hours, at the latest.

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Part or system Maintenance task Chapter

Control and monitoring system Replace the drive electronics such as cylinder control module,
coil drivers, fuel injection controls and power distribution modules.
At the latest, the electronics must be replaced every tenth year.
Replace the vibration dampers (rubber elements).
Replace the rubber elements for components such as the connection
boxes, control modules, connection rails and the main cabinet.
Replace the vibration damper every 24,000 operating hours or every
fourth year whichever comes first.
Replace the I/P converter. 23
Check and clean the Seitz solenoid valves with a neutral cleaning 15
agent.
Replace wear parts. Use only original repair kit components. Add lub-
ricant to the seals and gliding surfaces.
Seitz solenoid valves are typically start solenoid CV321, stop solenoid
CV153, and slow turning CV331. Others can be identified from installa-
tion-specific attachments.
This should be done every 24,000 operating hours or every fifth year
depending on whichever comes first.
Control mechanism Replace the support bearing bushes and V-rings on the fuel control
22
shaft.
Crankshaft Inspect the crankshaft bearing surfaces.
06
Measure the crankpin diameter and ovality.
Electro-pneumatic stop device Overhaul the electro-pneumatic stop device cylinder on the fuel
injection pump. 22
Check the condition of the piston, and replace the slide ring.
Engine fastening bolts Check the tightness of the engine fastening bolts.
07
Replace, if necessary.
Turbocharger Replace the turbocharger bearings.
15
See the manufacturer's instructions.
Vibration damper (viscous type) Take an oil sample from the vibration damper for analysis.
11
See manufacturer's instructions.

04.3.19 Interval: 32,000 operating hours

Part or system Maintenance task Chapter

Vibration damper (mechanical) See manufacturer's instructions. See

manufacturer's
instructions.

04.3.20 Interval: 48,000 operating hours

Part or system Maintenance task Chapter

Control and monitoring system Replace measuring electronics and display units.
23
At the latest, the electronics must be replaced every tenth year.
Turbocharger Replace the complete turbocharger or turbocharger cartridge.
15
See the manufacturer's instructions.

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