DATA &

SPECIFICATIONS

Services, Wärtsilä Finland Oy

Engine section Engine type Ref. Date Issue Document No. Page
04 Maintenance Schedule Auxpac 20 WFI–S 26-Oct-2008 01 2004N011 1(2)+12

Maintenance schedule for WÄRTSILÄ® Auxpac 20 engines

General This document contains the latest version of the maintenance schedule for the
WÄRTSILÄ® Auxpac 20 engines.

The new maintenance intervals are dependent on fuel type and load and are
to be seen as guidelines only.

A prerequisite for the implementation of the new maintenance intervals is that

all previous maintenance has been done in accordance with the Maintenance
Manual originally supplied with the engine, and that all upgrades
recommended in previous service bulletins have been made.

Recommendation Replace the maintenance schedule in chapter 04 of your Maintenance Manual.

Distribution Wärtsilä Service Network and owners / operators of concerned engines.

Letter validity Until further notice.

Enclosure Chapter 04 Maintenance Schedule, version 2008-38, 12 pages.

Wärtsilä Finland Oy P.O. Box 252 (Tarhaajantie 2) Telecop. +358 10 709 1847 Tel. +358 10 709 0000 Business ID 0773744-3
Services, Vaasa FIN-65101 Vaasa, Finland Telecop. +358 10 709 1380 Registered Office: Vaasa
Wärtsilä Finland Oy P.O. Box 50 (Stålarminkatu 45) Telecop. +358 10 709 3279 Tel. +358 10 709 0000
Services, Turku FIN-20811 Turku, Finland Telecop. +358 10 709 3410
© 2008 Wärtsilä Finland Oy – All rights reserved
No part of this publication 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 holder. Wärtsilä Finland Oy makes no
representation, warranty (express or implied) in this publication and assumes no responsibility for the correctness, errors or omissions for
information contained herein. Information in this publication is subject to change without notice.
Unless otherwise expressly set forth, no recommendation contained in this document is to be construed as provided due to a defect in
the engine, but merely as an improvement of the engine and/or the maintenance procedures relating thereto. Any actions by the
owner/operator as a result of the recommendations are not covered under any warranty provided by Wärtsilä and such actions will
thus be at the owners/operators own cost and expense.
NO LIABILITY WHETHER DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL, IS ASSUMED WITH RESPECT TO THE
INFORMATION CONTAINED HEREIN. THIS PUBLICATION IS CONFIDENTIAL AND INTENDED FOR INFORMATION PURPOSES
ONLY.
 Maintenance Schedule

04. Maintenance Schedule V1

The actual operating conditions, and above all the quality of the fuel
used, will largely determine the maintenance necessary for the gen‐
erating set. Because of the difficulty in anticipating the various oper‐
ating conditions that may be encountered in the field, the periods sta‐
ted in the schedule should be used for guidance purposes only, but
must not be exceeded during the warranty period.
Where any indications are encountered that the performance of a
maintenance procedure is required in advance of the recommended
time period, prudent industry practice dictates that the suggested
maintenance procedure be performed. Additionally, where inspection
or observation reveals that a part shows wear or use beyond the pre‐
scribed tolerances, that part should be renewed immediately. See al‐
so the instruction books of the turbocharger and the actuator, sepa‐
rate instructions for additional equipment and chapter 03.
1 Before any steps are taken, carefully read the corresponding item in
this Manual.
2 Note the Risk Reduction in chapter 00A.
3 Note the Environmental Hazards in chapter 02A.
4 At all maintenance work, observe the utmost cleanliness and order.
5 Before dismantling, check that all systems concerned are drained or
the pressure is released. After dismantling, immediately cover holes
for lubricating oil, fuel oil and air with tape, plugs, clean cloth or similar.
6 When exchanging a worn-out or damaged part provided with an iden‐
tification mark stating cylinder or bearing number, mark the new part
with the same number on the same spot. Every exchange should be
entered in the engine log and the reason should be clearly stated.
7 Always renew all gaskets, sealing rings and O-rings at maintenance
work.
8 After reassembling, check that all screws and nuts are tightened and
locked, if necessary.

Warning!
When overhauling the engine, make absolutely sure that the auto‐
matic start and the priming pump are disconnected. Make also sure
that the starting air shut-off valve located before main starting valve
is closed. Otherwise it might cause engine damage and/or personal
injury.

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 Maintenance Schedule

04.1. How to select application and fuel quality V2

There are two different types of applications defined:

● Average load is above 75 % of nominal engine output.
● Average load is below 75 % of nominal engine output.
Three types of fuel are defined:
● HFO 1 Heavy fuel oil of normal quality.
● HFO 2 Heavy fuel oil of below normal standard quality.
● DO Diesel oil or light fuel oil (LFO).

Fuel characteristics, maximum limits

HFO 1 HFO 2
Sulphur % mass 1.5 1.5 - 4.5
Ash % mass 0.05 0.05 - 0.15
Vanadium mg/kg 100 100 - 600
Sodium mg/kg 50 50
Sodium, before en‐ mg/kg 30 30
gine
Aluminium + silicon mg/kg 30 30 - 80
Aluminium + silicon, mg/kg 15 15
bef. eng.
Conradson Carbon % mass 15 15 - 22
residue
Asphaltenes % mass 8 8 - 14
CCAI 850 850 - 870

Note!
If any of specified fuel properties exceed HFO 1 maximum value the
fuel should be classified as HFO 2.

04.2. Every second day V2

Every second day, irrespective of the engine being in operation or not

Automatic prelubrica‐ Check operation. 03.2.1
tion
18.7
Crankshaft Marine engine: In a stopped engine, turn the crankshaft into a new
position.

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 Maintenance Schedule

04.3. Once a week V2

Once a week irrespective of the engine being in operation or not

Start Process Test start (if the engine is on standby). 03.2

04.4. Interval: 50 operating hours V1

Interval: 50 operating hours

Air cooler Check draining of air cooler. 15.2.1 03.4.1
Check that the draining pipe is open, check if any leakage.
Cooling system Check water level in cooling system. 19
Check the water level in the expansion tank(s) and/or the static
pressure in the engine cooling circuits.
Connecting rod Check tightening of the connecting rod screws. 11.4.3
Check the tightening of the connecting rod screws after the first 50 07
operating hours on a new engine and after overhaul, those screws
that have been opened.
Lubricating oil filters Check pressure drop indicators. 18
Change filter cartridges if high pressure drop is indicated. 03.4.1
Gauges and indicators Take readings. 03.4.1
Read and record (use form No. WV98V089) all temperature and
pressure gauges, and at the same time the load of the engine.
Injection and fuel sys‐ Check leak fuel quantity. 03.4.1
tem
Check the amount of leak fuel from the injection pumps and injection 17
nozzles.
Injection pipes Check tightening of injection pipe connections. 16.3.1
Check the tightening of injection pipe connections on a hot engine 07.1
after the first 50 operating hours on a new engine and, after overhaul,
those connections that have been opened.
Lubricating oil sump Check oil level in sump. 18.1
Change filter cartridges if high pressure drop is indicated. 01.1
Main bearings Check tightening of main bearing screws. 10
Check the tightening of main bearing screws after the first 50 oper‐ 07.1
ating hours on a new engine and after overhaul, those screws that
have been opened.
Valve mechanism Check valve clearances. 12.2.5
06.1
Check the valve clearances after 50 hours’ running in new and over‐
hauled engines. Check tightening of rocker arm screws and valve/
yoke adjusting screw nuts.

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 Maintenance Schedule

Interval: 50 operating hours

Multiduct Check tightening of the multiduct screws. 07.1
Check the tightening of the multiduct screws after the first 50 oper‐
ating hours on a new engine and, after overhaul, those screws that
have been opened. The engine should be in normal operating tem‐
perature.
Turbocharger Water cleaning of compressor. Clean the compressor by injecting 15.1.5
water.
Check the turbine side V-clamp ring tightening Check the turbine
side V-clamp ring tightening on TPS charger, if specified, after the
first 50 operating hours on a new engine and, after overhaul. See
turbocharger makers manual.
Check fastening bolts at feet, tighten housing bolts and piping joints.
Once after commissioning or overhaul; then every 4000 hrs. See
turbocharger makers manual.

04.5. Interval: 100 Operating Hours V2

Interval: 100 operating hours

Turbocharger Water cleaning of turbine 15.1.3
Clean the turbine by injecting water; adjusted acc. to operation.

04.6. Interval: 250 Operating Hours V2

Interval: 250 operating hours

Centrifugal filter Clean centrifugal filter 18.6
Clean more often if necessary. Remember to open the valve before
the filter after cleaning. Check the condition of bearings and shaft
journals.
Control mechanism Maintenance of control mechanism 22.1
Check for free movement, clean and lubricate.
Lubricating oil Take oil sample 02.2.3
In a new installation or after change to use of a new lubricating oil
brand, take samples for analyzing.

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 Maintenance Schedule

04.7. Interval: 500 operating hours V2

Interval: 500 operating hours

Circulating water Check water quality 02.3
Check content of additives.
Cylinder pressure Check cylinder pressure 03.4.3
Record firing pressures of all cylinders.
Lubricating oil Take oil sample 18.1
Take oil sample for analysis. Use of lubricating oil can be prolonged 02.2.1
as long as the analysis results are within the specified limits set by
the engine manufacturer. For a new installation, see the interval:
1000 hours.
Turbochargers Wash filter mat on silencer 15.1.2
After being washed five times or fulfilling 3000 operating hours, re‐
place by new one. See turbocharger makers manual.
Generator Inspect generator
Take a general check/clean on a generator. Future intervals 4000
running hours or more often depending to the rate fouling which oc‐
curs locally. See manufacturers instructions. On a generator with
sleeve bearings, check oil level (must be visible in the viewing
glass). For information on oil changes or regreasing interval, etc.,
see lubrication instruction plate on the generator.

04.8. Interval: 1000 operating hours V2

Interval: 1000 operating hours

Automation Functional check of automation 23.1.4
Check function of the alarm and automatic stop devices. 01.2
Lubricating Oil Change lubricating oil 18.1
Change oil in a new installation (wet sump installations). Take sam‐ 02.2.1
ples for analyzing. Use of lubricating oil can be prolonged, in steps
of 500 operating hours, as long as the analysis results are within the
specified limits set by the oil supplier or the engine manufacturer.
Change oil in an installation (wet sump installations) that is not pu‐
rifying regularly the lubricating oil, independently of oil analysis re‐
sult. Clean all oil spaces with a high quality fibre-free / lint free cloth
when changing lubricating oil.
Valves Check of valve condition 12.2.5
Check valve clearances. Check cylinder tightness (valves, piston 06.1
rings) with a pneumatic test. Check that the inlet and exhaust valves
12A
move freely in their guides. This should preferably be done when
the engine has been out of operation for a couple of hours.

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 Maintenance Schedule

04.9. Interval: 2000 Operating Hours V2

Interval: 2000 operating hours

Charge air cooler Check water side of charge air cooler 15.2
The first time check and possible cleaning of the waterside. If in good
condition and deposits unsignificant: future intervals 4000 running
hours.
Measuring instruments Checking of gauges 23
Check pressure and temperature gauges. Replace faulty ones.
Injection valves Inspect injection valves 16.4.2
Test the opening pressure. Dismantle and clean nozzles. Check the
effective needle lift. Check the springs. Replace the O-rings.
Overspeed trip device Check function of overspeed trip 22.4
Check function and tripping speed

04.10. Interval: 4000 operating hours V1

Interval: 4000 operating hours

Air cooler Clean the charge air cooler. 15.2.1
Clean the air and water side of the charge air cooler and pressure
test it. Look carefully for corrosion.
Automation Check connectors and cables. 23
Check mounting and connection. Make a visual check of all cables
and replace these cables that are damaged.
Camshaft and valve Visually inspect contact faces of camshaft. 14
mechanism
Check the contact faces of the cams and tappet rollers. Check valve
yoke and adjusting screw nut and that the rollers rotate. Rotate the
engine with the turning gear.
Control mechanism Check control mechanism. 22.1
Check for wear in all connecting links between the governor and all
injection pumps.
Flexible coupling If specified check alignment, use form WV98V041. Check condition
of coupling.
See manufacturers instructions.
Crankshaft Check crankshaft alignment. 11.1.2
Check alignment, use form No. WV98V036. Alignment check has
to be performed on a warm engine.
Resilient mounts Inspect buffer clearance, reset if necessary. Inspection to be made
at least once a year.

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 Maintenance Schedule

Interval: 4000 operating hours

Cylinder liners Inspect jacket water spaces. 02.3
Pull one cylinder liner. If the deposits are thicker than 1 mm, clean 10
all liners and engine block water space. Improve the cooling water
treatment.
Replace the distance shim under liner if installed.
Exhaust manifold Check the expansion bellows, nuts and pipe support of the flange 20.1
connections.
Tighten loose nuts. Replace supports and bellows if necessary.
Lubricating oil cooler Clean the lubricating oil cooler. 18.4
If the lubricating oil temperature before the engine is within normal
operating values ( section 01.1), the interval can be prolonged. Un‐
necessary opening of the cooler should be avoided. Clean the lu‐
bricating oil cooler before the alarm limit is reached. Examine care‐
fully for corrosion.
Lubricating oil automat‐ Inspect lubricating oil filter candles. 18
ic filter
Replace worn parts and clean the candles and safety filter mesh, if
necessary.
Mechanical cleaning not allowed.
Nozzles Check the nozzle condition in a test pump. 16.4.2
Recommendation: Replace the nozzles by new ones
Turbocharger Inspect and clean. 15.1.2
Clean the compressor and turbine mechanically if necessary.
Inspect nozzle ring 15.1.2

04.11. Interval: 8000 operating hours V1

Interval: 8000 operating hours

Flexible hoses Visually inspect the flexible hoses.
Renew if necessary.
Balancing shaft Inspect balancing shaft bearing. 11B
4L20 Take one bush out for inspection. If in bad condition, check the other 11E
bushes. Replace if necessary.
Camshaft driving gear Inspect camshaft driving gear. 13
Check clearances and backlash. Replace parts if necessary.
HT-water pump Inspect HT-water pump. 19.8
Dismantle and check. Replace shaft seals and worn parts. Check
backlash.

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 Maintenance Schedule

HT-water pump Inspect HT-water pump. 19.8

Dismantle and check. Replace shaft seals and worn parts. Check
backlash.
HT-water pump driving Inspect HT-water pump driving gear. 19.8
gear
Replace parts if necessary. Check backlash.
HT-water thermostatic Clean and inspect HT-water thermostatic valve. 19.9
valve
Clean and check the thermostatic element, valve cone-casing and
sealings.
LT-water thermostatic Clean and inspect LT-water thermostatic valve. 19.9
valve
Clean and check the thermostatic element cone-casing and replace
sealings.. Check the function of the valve.
LT-water pump Inspect LT-water pump. 19.8
Dismantle and check. Replace shaft seals and worn parts. Check
backlash.
LT-water pump driving Inspect LT-water pump driving gear. 19.8
gear
Replace parts if necessary. Check backlash.
Lubricating oil pump Inspect the lubricating oil pump. 18.2
Dismantle and check. Replace worn parts. Check backlash.
Oil pump driving gear Inspect oil pump driving gear. 18.2
Replace parts if necessary. Check backlash.
Oil thermostatic valve Clean and inspect oil thermostatic valve. 18.5
Clean and check the thermostatic element, valve cone-casing and
sealings.
Prelubricating oil pump Inspect the pre lubricating oil pump. 18.7
Replace shaft seals and worn parts.
Electrical motor Electrical motor for pre lubricating oil pump.
Replace roller bearings on electrical motor or latest after three (3)
years in use.
Lubricating oil automat‐ Replace lubricating oil filter candles. 18
ic filter
Drain the filter housing. Clean the wire gauze. Replace the filter
candles.
Conduct visual inspection of all filter candles once a year. Replace
the filter candles after latest 2 years in service or if Δp alarm occurs.
Fuel system Check and adjust fuel system. 17
Check the adjustment of fuel system. Check for possible leakage.
Replace parts if necessary.
Starting/smoke fuel Check function of starting/smoke fuel limiter. 22
limiter
23
Air starter General overhaul of air starter motor. 21.1
Air starter maintenance in connection to general engine mainte‐
nance or latest after 3 years. Replace bearings, solenoid valve and
worn parts.

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 Maintenance Schedule

04.12. Interval: (8000 - 20000) operating hours V1

Fuel Overhaul Interval

Average load > 75 % Average load < 75 %
HF02 8000 10000
HFO 1 12000 14000
DO 16000 20000

Interval: (8000 - 20000) See table above

Connecting rod Inspect big end bearings. 11.4.4
Replace big end bearings. Inspect mating face and surface of ser‐ 11.4.5
rations. Measure the big end bore, use form 2011V001.
Inspect small end bearings 06.2
Replace if necessary, use form 2011V007.
Crankshaft Check thrust bearing clearance. 10
Check axial clearance
Cylinder heads Overhaul of cylinder head. 12
Dismantle and clean the underside, inlet and exhaust valves and
ports. Pull out the exhaust gas seat rings, inspect cooling spaces
and clean, replace the O-ring(s). If necessary, grind the valves and
EX / IN seat rings (often lapping by hand is enough). Inspect the
valve rotators.
Replace the O-rings in the valve guides. Use the Cylinder Head
Overhaul Report measurement record 2015V015.
Cylinder liners Inspect the cylinder liners. 10
Measure the bore using form No. 2010V002, replace liner if wear
limits are exceeded. Hone the liners. Renew the antipolishing ring.
Inspect all cylinder liners water side and replace O-rings. 19.7
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 in
10
the bottom part by new ones at every overhaul.
Injection pumps Overhaul of injection pumps. 16.2
Clean and inspect injection pumps, replace worn parts. Replace all
seal rings and constant pressure valve. Check the erosion plugs,
replace if necessary.
Pistons Inspect the piston. 11.4.5
Dismantle one composite piston for inspection of mating surfaces
between piston skirt and piston crown. Inspect and clean oil spaces.
Repeat the procedure with other pistons if necessary.
Piston, piston rings Inspect pistons and piston rings. 11.4.4
Pull, inspect and clean. Check the height of the ring grooves. Check
the retainer rings of the gudgeon pins. Replace complete set of pis‐
ton rings. Note the running-in program.

Wärtsilä Auxpac 2008-38 04 - 9

 Maintenance Schedule

Interval: (8000 - 20000) See table above

Main bearings Inspect the bearing shells of one main bearing. 10
Replace all bearing shells, if necessary.
Turbocharger Inspect the bearings of radial type charger. 15.1.2
Replace bearings if necessary.
See manufacturers instructions.
Valve mechanism Check valve mechanism bearings. 14.1.2
Check tappets and rocker arms. Replace valve tappet roller bearing 06.2
bush, if specified.

04.13. Interval: 16000 operating hours V2

Interval: 16000 operating hours

Vibration damper Dismantle and check. 11.1
See manufacturers instructions.
Viscous vibration Take oil sample from vibration damper. 11.1
damper
Take oil sample for analyzing.
Camshaft Inspect camshaft bearings.
Replace if necessary. 14.1.2
06.2
Intermediate gears and Inspect gear teeth and measure backlash and axial clearance. 13
bearings.
Replace bearings at least every 32 000 hrs 06.2

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 Maintenance Schedule

04.14. Interval: 24000 operating hours V1

Interval: 24000 operating hours

Connecting rod Replace connecting rod screws. 11.4.6
Replace connecting rod screws at the latest every 24000 operating
hrs. with new ones.
Crankshaft Inspect crankshaft. 06.2
Inspect the crankshaft bearing surfaces. Measure the crankpin di‐
ameter and ovality.
Engine fastening bolts Check tightening of engine fastening bolts 07.3
Replace if necessary.
Overspeed trip device General overhaul of overspeed trip device 22.4
Elektro-pneumatic Check function and tripping speed. 22.4.2
Turbocharger Replace turbocharger bearings. 15.1.2
See manufacturers instructions.

04.15. Interval: 24000 operating hours/after 5

years V2

Interval: 24000 operating hours / after 5 years

Valve mechanism Rocker arm screws, yoke and adjusting screw nuts 14.1
Replace rocker arm screws, yoke and adjusting screw nuts.
Injection valve yoke Injection valve yoke tension screws 12.2.5
Replace screws
Exhaust gas piping Exhaust gas piping support, plates, nuts and screws 20.1
Replace supports, nuts and screws.
Control mechanism Replace support bearing bushes and V-rings on fuel control shaft. 22.1

04.16. Interval: 48000 operating hours V2

Interval: 48000 operating hours

Turbocharger Replace rotor 15.1.2
See manufacturers instructions.

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 Maintenance Schedule

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