T-Z40e

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Wrtsil Italy, Service

Subject Engine type Ref. Date Document No. DLC Issue Page

High pressure fuel pipe ZA40S WIT-S 18.02.2003 T-ZA40S.0014.GB 162 03 1/5

Wrtsil Italia SpA Bagnoli della Rosandra, 334 Telephone : +39 040 319 5000Service 34018 San Dorligo Della Valle (TS) ITALY Fax : +39 040 319 5647

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ZAS-14.3High-pressure Fuel Pipe

1 Introduction

This Technical Bulletin supersedes previous Service Bulletin ZAS-14.2 and its purpose is to declaresuperseded previous high-pressure pipe Type 808.

It still informs you about different types of high-pressure fuel pipe together with tightening instructions andguidelines to be observed when changing the type of high-pressure fuel pipe on a cylinder unit.

2 Superseded Fuel Pipe Types

2.1 Original Type 714

The following Type 714 high-pressure pipe was originally introduced on the first ZA40S engines in 1986.Its main features were: flat seal between pressure pipe, fuel stud and fuel pump cover as well as a

corrugated protection tube with metal gauze jacketed around the high pressure pipe.

It has been superseded because of possible friction between corrugated protection tube and pipe. Type714 is not interchangeable with Type 723.

2.2 Intermediate Type 808

The first type of high-pressure fuel pipe introduced with conical seal was Type 808 in 1995. It alsopresents a solid protection tube surrounding the pipe.

Type 808 type has already a double shielded high-pressure fuel pipe and it has been declaredsuperseded because of a tendency for cavitation at upper end. Type 808 is interchangeable withType 723 under the specific conditions of paragraph 4.2of the present document.

2.3 Alternative Type 111

The retrofit package Type 111 was also introduced in 1995 in order to profit from the benefits of the newType 808 design, without changing the fuel pump cover.

It has been declared superseded because of the tendency for cavitation at the upper end might beincreased. Type 111 is not interchangeable with Type 723.

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3 Present Fuel Pipe Type 723

Type 723 high-pressure fuel pipe is the present standard, introduced since February 1998.

Compared to Type 808, the Type 723 has:

(a) a shorter pipe, and

(b) an inner diameter of the pipe enlarged(from 6 mm) to 7 mm in order tominimise any tendency for cavitation atthe upper end.

4 Up-grading recommendations

4.1 Summary of present status

Type Status Remarks

714 Superseded Original type, no longer available

808 Superseded Intermediate type, no longer available111 Superseded Alternative retrofit set for Type 714, no longer available

723 Present standard -

4.2 Conditional maintenance for existing superseded types

If the installed fuel pipe is a superseded type and doesn't show any leaking or cavitation problems,it can be kept on the engine only ifapplying the following conditional maintenance follow-up.

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4.2.1 Parameters to follow

In order to identify if a problem exist on the installed superseded fuel pipe, the fuel pressure shouldbe followed-up and within the limits, as per Technical Bulletin T-ZAS-22:

Fuel oil service pressure at engine inlet ....................................................................................................8-10 bar

p across the engine fuel injection pump at engine stand-still - 550 kW.................................... 0.8 bar- 600 kW .................................... 0,9 bar- 660 kW .................................... 1,1 bar- 720 kW .................................... 1,3 bar

In case of deviation from the above information, the hereunder conditional recommendations ofyour installed fuel pipe should be performed.

4.2.2 Condition checking

for Type 714Control of the flat sealing surfaces: check if leaking.Control of inner pipe: check if crack are present on the internal pipe surface resulting from afriction between corrugated protection tube and fuel pipe.

for Type 808Control of inner pipe: check if traces of cavitation are present inside the pipe at the upper end.

for Type 111Control of inner pipe: check if traces of cavitation are present inside the pipe at the upper end.

4.2.3 Corrective action

If one of the above mentioned problem is found, the installed high-pressure fuel pipe should be up-graded for a 723-Type.

5 Tightening instructions

Please find in the following table an overview of the tightening torques suitable for the different types.

Type Fuel stud (1) Delivery valve bolts (2) High pressure pipe cap nut (3)

714 290 Nm 28 Nm 170 Nm

111 290 Nm 28 Nm 250 Nm

808 300 Nm 28 Nm 250 Nm

723 300 Nm 28 Nm New 130-150 Nm (*)

(*) Notice: The threads of the 723 cap nut should be lubricated with Molykote 1000 or Copper Slip.All other threads in this table remain oil lubricated.

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Important All joint faces should be dry and clean.

6 Conversion from Types 714, 111, and 808 to present Type 723

6.1 Fuel Pipe up-grading

6.1.1 Solution for 714-Type and 111-Type

The 714-Type and 111-Type can be upgraded as per following indications:

Replacement of fuel injection pipe, fuel stud with delivery valve and accessories ...........KS27245

Replacement of fuel pump cover .....................................................................................................KS55008 Replacement of fuel pump cover o-ring .........................................................................................KS55036

Replacement of back-up ring .............................................................................................................KS55038

6.1.2 Solution for the 808-Type

The 808-Type can be upgraded as per following indications:

Replacement of fuel pressure pipe ................................................................................................... KS27248 Replacement of existing compression spring ...............................................................................KS27270 Replacement of fuel pump cover .....................................................................................................KS55270

Replacement of fuel pump cover o-ring .........................................................................................KS55036

Replacement of back-up ring .............................................................................................................KS55038

The pump cover can also be up-graded by machining as per Technical Bulletin T-ZAS-32.

Index to Figure

(1) Fuel stud(2) Delivery valve bolts

(Allen screw M8x20)(3) High pressure pipe cap nut

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6.2 Tool up-grading

If the fuel pump is equipped with the conical seal pump cover, the adjusting device 9455.02 canonly be used if the following tool parts are added:

Additional flange and gasket ............................................................................................................... 9455.09 Measuring pin (174 mm instead of 143 mm) ...........................................................................9455.05.004

6.3 Spare part kits

Up-grading set of parts are presented in the Spare Part Notice P-ZAS-01, paragraphs 3.1 and 3.2.

7 Distribution

Wrtsil Italy Service Wrtsil Service Network Owners of engines concerned

8 Liability

NO LIABILITY WHETHER DIRECT, INDIRECT, SPECIAL INCIDENTAL OR CONSEQUENTIAL, ISASSUMED WITH RESPECT TO THE INFORMATION CONTAINED HEREIN. THIS PUBLICATION IS

CONFIDENTIAL AND INTENDED FOR INFORMATION PURPOSES ONLY.

9 Validity

This general instruction is valid until further notice.

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