Service Bulletin

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Wrtsil NSD Switzerland Ltd PO Box 414 Tel. +41 52 262 49 22Wrtsil NSD Schweiz AG CH-8401 Winterthur Fax +41 52 212 49 17Wrtsil NSD Suisse SA Switzerland Tlx 896 659 NSDL CH

1. Introduction 1

2. Pre-Adjusting of Fuel Pumps 13. Fuel Pump Adjustment 14. Deviations in Exhaust 2

Temperatures After Cylinder

5. Conclusion 3

6. Service Bulletins Published for 4ZA 40S Engines

Contents: Page

ZAS3725.02.2000Technical Information to all Owners / Operators

of Sulzer ZA 40S Engines

Checking and Adjusting ofFuel Injection Pumps

1 / 4 Service Bulletin ZAS-37

1. INTRODUCTION

With the different types of plungers also the adjustment values for the specific fuel pumps aredifferent. This Service Bulletin has been issued to support our clients in this matter and also togive an overview of the different plunger types such as CIT (constant injection timing), VIT(variable injection timing), Variable Damping Plungers and also how the adjustment must becarried out.

This Service Bulletin should be kept in a separate file in the control room. The respective pages ortables of the Service Bulletin with modifications to the Operating Manual, Maintenance Manualor Code Book should be copied and filed in the respective Manual or Book.

2. PREADJUSTING OF FUEL PUMPS

Each time a fuel pump has been dismantled for overhaul and new parts have been fitted, thepump must be preadjusted first. This can be done either outside of the engine, or with the pumpfitted on the engine. For easier handling we suggest to do the preadjustment of the fuel pumpoutside the engine. For the adjustment outside of the engine a special tool (9444.01) which isalso used for dismantling the pump into its parts, as well as for the assembly has to be used. Veryimportant to get a correctly adjusted pump is also to have absolutely no air leakage between thepump cover and the measuring device (945504).

3. FUEL PUMP ADJUSTMENT

All fuel pumps of an engine are adjusted such that the specified delivery stroke is achieved at aload indicator position of 8.65 and at the same time the distance between the pump housing andthe clamping ring amounts to 10 0.03 mm. This fundamental adjustment with the specifieddelivery stroke of the fuel pump must not under any circumstances be changed at a later date, asit is a prerequisite for a balanced fuel delivery for all cylinders and, therefore, for a wellregulated engine.

All important values such as Load indicator position, Plunger identification No., Correctionvalue, Plunger diameter, and Specified delivery stroke for the different plunger and enginetypes are listed in table 1 and 2. Actual detailed Adjusting Instructions are in possession of theService Personnel of our Network Companies and we recommend to call in one of our ServiceEngineers for carrying out the fuel pump checking and adjusting.

LI Pos. Fuel PumpPlunger

Engine Type Output[kW/Cyl]

Speed[rpm]

Plungerdiam.[mm]

Specified deliverystroke[mm]

8.65 019

1)

ZA 40Sgeneral

up to 750 500 / 510 / 514 35 15.88

8.65 617 ZA 40Smarine

up to 720 500 / 510 / 514 35 14.73

8.65 958 ZA 40Sgeneral

up to 600 500 / 510 / 514 35 11.77

1) Variable Damping plunger

Table 1: CIT plunger, including Variable Damping plunger

2 / 4 Service Bulletin ZAS-37

LI Pos. Fuel PumpPlunger

Engine Type Output[kW/Cyl]

Speed[rpm]

Plunger diam.

[mm]

Specified deliverystroke[mm]

Correctionvalue

8.65 542 ZA 40Spower plants

up to 720 500 / 510 / 514 35 14.73 2.07

8.65 466 ZA 40Smarine

up to 600 500 / 510 / 514 35 12.32 1.78

8.65 465 ZA 40Spower plants

up to 600 500 / 510 / 514 35 12.32 1.98

Table 2: VIT - plunger

4. DEVIATIONS IN EXHAUST TEMPERATURES AFTER CYLINDERS

Even a correctly adjusted engine with balanced fuel delivery and maximum cylinder pressureswithin tolerances can, depending on the number of cylinders, exhibit individual temperaturesafter cylinder which vary greatly from one another, as can be noted from the Acceptance TestResults.

The reason for such deviations is the effect of gas pressure waves within the single pipe exhaustsystem (SPES) and also on the position at which temperature measurement takes place. Thetemperature sensor is only acted upon for a short time by the exhaust gas as the exhaust valvesopens, whereas it is influenced for a much longer period of time after the scavenging phase. Thesensors of different cylinders are, therefore, acted upon in different ways due to thecomplicated interaction of the gas flows from each cylinder during scavenging.

The exhaust gas temperature after cylinder cannot be taken as a binding indication of theoutput being produced by a particular cylinder.

Under no circumstances can it be used to adjust individual cylinders to give a constanttemperature after cylinder by differing the fuel delivery quantity or delivery begin.

This applies not only to initial running on the test bed but also later in service. The negativeeffect which incorrect increased adjustment of an individual fuel pump can have on the exhaustvalve and seat, and thus on the lifetime of the valve, is shown in the enclosure ZAS-37/2.Conversely manual reduction of the fuel pump setting of an individual cylinder due to asupposedly too high exhaust temperature will create such a negative effect on all the remainingcylinders that their output will be increased accordingly.

The large increase in temperature at the centre of the exhaust valve plate and at the valve seatdue to the increase in load indicator position of a cylinder is not allowed as it questions thereliability of the exhaust valve in heavy fuel oil service.

The readings of exhaust gas temperature after cylinder are useful as a longterm indication of amalfunction or changed conditions, if the deviation of each individual cylinder from the averagevalue is monitored over a period of time. This is the only purpose of this temperaturemeasurement arrangement.

3 / 4 Service Bulletin ZAS-37

5. CONCLUSION

After the engine has been regulated according to the instructions previously mentioned,balancing of the maximum cylinder pressures within the nominal value 2 bar is only allowed asfollows:

ADJUSTMENT OF: ALLOWED:

Fuel pump cam YesValve drive cam NoFuel pump NoClamping ring NoRegulating linkage NoCompression shims No

As previously explained, a correctly adjusted engine can exhibit deviations in the individualexhaust temperatures after cylinder. Despite the measured temperature of some cylindersbeing higher than others, the turbocharging system (charge air pressure, valve timing etc.) islaid out such that the excess air required for complete fuel combustion at an acceptablecombustion chamber temperature level is sufficient for all cylinders.

The practice of balancing exhaust temperatures after cylinder by adjustment of any of the abovecomponents is strictly forbidden.

This would cause an imbalance in the output of each cylinder and, in addition to the negativeeffects on thermal loading, could also have serious consequences regarding the torsionalvibration behaviour of the crankshaft.

5.1. Control Sheet for Fuel Pumps, Inlet and Exhaust ValvesEnclosure ZAS-37/1 Setting Table 1

After adjusting the fuel pumps on the engine it is always useful to write the adjusting valuesdown in the Valve Setting Table sheet for later reference.

Enclosures: ZAS37/1 Setting Table 1ZAS37/2 8 ZAL40S Test with higher load indicator position

on one cylinder (cyl.1)

Wrtsil Switzerland Ltd has issued this Service Bulletin with their best knowledge and ability.However, Wrtsil Switzerland Ltd can not take any liability for any or all information containedin this or any other Service Bulletin.Changes of any nature to the form and or to the content of this or any other Service Bulletin aspublished by Wrtsil Switzerland Ltd, are not permitted.

4 / 4 Service Bulletin ZAS-37

6. SERVICE BULLETINS PUBLISHED FOR ZA 40S ENGINES

We have so far published the following Service Bulletins which are valid for ZA 40S type engines:

ZAS-1.2 dated 02.02.96 Cylinder Liner Overhaul

ZAS-2.1 dated 29.08.97 Overhaul of Cylinder Head

ZAS-3 dated 10.06.93 Oil Scraper Rings

ZAS-4.4 dated 26.02.99 Piston Rings

ZAS-5 dated 03.12.93 Instruction for Testing of Fuel Injection Nozzles

ZAS-6.1 dated 23.02.96 Piston Rotating Mechanism

ZAS-7 dated 05.04.94 Adjustments and Maintenance Requirements on Oil Mist Detector

ZAS-8.1 dated 16.05.97 Turnomat for Exhaust Valves and Rotocap for Inlet Valves

ZAS-9 dated 01.06.94 Exhaust Pipe Expansion Bellows

ZAS-10 dated 01.08.94 High Temperature Cooling Water System

ZAS-11.1 dated 31.03.98 Cylinder Liner with a Thread

ZAS-12 dated 01.03.95 New Spindle Design for Pressure Control Valve KS 87085

ZAS-13.1 dated 18.12.98 Inlet Valves

ZAS-14.1 dated 27.02.98 High Pressure Fuel Pipe

ZAS-15.1 dated 30.01.98 Fuel Injection Nozzle Specification

ZAS-16 dated 10.08.95 Flow Control Valve KS 72126 for Cylinder Lubrication

ZAS-17.3 dated 18.05.99 VTR ..4 Turbochargers After Sales Service Information issued by ABB

ZAS-18.1 dated 27.02.98 Tightening Instructions

ZAS-19 dated 17.11.95 New Piston Ring Fitting Tool

ZAS-20 dated 17.11.95 New Spring Cage KS 28042 for Rocker Gear

ZAS-21 dated 22.03.96 Differences in the Drive for the Cylinder Lubrication between Engines with 660 kW/Cyl. and 720 kW/Cyl.

ZAS-22 dated 08.11.96 Adjustments of Fuel Oil Systems

ZAS-23 dated 19.11.96 Modification to the Oil Mist Detector

ZAS-24 dated 28.01.97 Alphabetical Index of Topics of Service Bulletins

ZAS-25 dated 16.05,97 Tightening Instructions for the Connecting Rod Big End Bearing

ZAS-26 dated 30.05.97 ABB Type VTR..4 Turbochargers Cleaning of Turbine and Blower Side

ZAS-27 dated 29.08.97 Lubricating Oil Treatment and Requirements

ZAS-28 dated 29.08.97 Assessment of Main and Connecting Rod Bearings

ZAS-29 dated 29.08.97 Undersized Bearings and Reconditioning of Crankshafts

ZAS-30 dated 31.10.87 ABB Type VTR..4 Turbochargers Cooling Water Arrangement

ZAS-31 dated 31.10.97 Flushing Instructions

ZAS-32.1 dated 13.12.99 Fuel Injection Pump

ZAS-33 dated 31.03.98 Shim between Connecting Rod and Big End Bearing

ZAS-34 dated 26.08.98 Hand Rails for Enginemounted Platforms

ZAS-35 dated 09.06.99 Variable Damping Plunger

ZAS-36 dated 11.10.99 Exhaust Pipe at Support for ByPass Arrangement

ZAS-37 dated 25.02.00 Checking and Adjusting of Fuel Injection Pumps

Should you not be in possession of the above mentioned documentation suitable for your plant, kindly contactyour local Wrtsil NSD representative for your copy.

Service Bulletin Enclosure ZAS-37/1

Fuel Pumps: Adjusted with Load Indicator at Position 8.65

Service Bulletin Enclosure ZAS-37/2

8 ZAL40S Test with higher load indicator position on one cylinder (Cyl. 1)

100 % Load 5760 kW (720 kW / Cyl.)Speed 514 rev / min

TEac(C)

430

0.2 0.4 0.6 0.8 1.00

420

410

400

390

380

370 1.5 3 4.5 6 7.5 x (mm)

+60

+40

+20

01.5 3 4.5 6 7.5

0.2 0.4 0.6 0.8 1.00

x (mm)

LI - Difference of load indicator position between Cyl. 1 and the other cylinders

+60

+40

+20

0

TEac - Exhaust temperature after cylinderTVC - Mean temp. at exh. valve centre Cyl. 1TVS - Mean temp. at exh. valve seat Cyl. 1

TVC

TVS

TEac Mean Cyl. 2 - 8

TVC(C)

TVS(C)

x (mm)

LI

LI

Wrtsil

Title PageIntroductionPre-adjusting of Fuel PumpsFuel Pump AdjustmentDeviations in Exhaust Temperatures After CylindersConclusionControl Sheet for Fuel Pumps, Inlet and Exhaust Valves

Service Bulletins Published for ZA 40S EnginesService Bulletin Enclosure ZAS-37/1Service Bulletin Enclosure ZAS 37/2