Maintenance Manual ZAL40S Int Use

ZA40S
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Installation
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Engine type ZAL40S
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Engine number
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This manual is intended for the personal use of engine operators and
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should always be at their disposal. The content of this manual shall neither
be copied nor communicated to a third person.
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¤ Copyright 2004 by Wärtsilä Corporation

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All rights reserved. No part of this publication may be reproduced or copied in any form or
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by any means (electronic, mechanical, graphic, photocopying, recording, taping or other

information retrieval systems) without the prior written permission of the copyright owner.
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THIS PUBLICATION IS DESIGNED TO PROVIDE AN ACCURATE AND AUTHORITATIVE INFORMATION

WITH REGARD TO THE SUBJECT-MATTER COVERED AS WAS AVAILABLE AT THE TIME OF
PRINTING. HOWEVER, THE PUBLICATION DEALS WITH COMPLICATED TECHNICAL MATTERS
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SUITED ONLY FOR SPECIALISTS IN THE AREA, AND THE DESIGN OF THE SUBJECT-PRODUCT IS
SUBJECT TO REGULAR IMPROVEMENTS, MODIFICATIONS AND CHANGES. CONSEQUENTLY, THE
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PUBLISHER AND COPYRIGHT OWNER OF THIS PUBLICATION CAN NOT ACCEPT ANY
RESPONSIBILITY OR LIABILITY FOR ANY EVENTUAL ERRORS OR OMISSIONS IN THIS PUBLICATION
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 CONSEQUENTIAL DAMAGES OR OTHER LOSS, OR ANY OTHER DAMAGE OR
INJURY, SUFFERED BY ANY PARTY MAKING USE OF THIS PUBLICATION OR THE INFORMATION
CONTAINED HEREIN.
Contact Informations WÄRTSILÄ
Service Department
Wärtsilä Italia S.p.A., Business Unit Service
Bagnoli della Rosandra, 334
34018 San Dorligo della Valle
Trieste --- ITALY
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24h Phone
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Nights and weekends, please call mobile phone for service engineer or spare parts
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+39 335 784 1217
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DIRECT DIAL NUMBERS
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SALES SUPPORT TECHNICAL SERVICE

Fax: +39 040 319 5216 Fax: +39 040 319 5767
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North, Central and East Europe Wärtsilä 64 engines

Phone: +39 040 319 5071 Phone: +39 040 319 5080
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Americas Wärtsilä 38B engines

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Phone: +39 040 319 5072 Phone: +39 040 319 5081
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Middle East and South Asia Wärtsilä 26 engines

Phone: +39 040 319 5073 Phone: +39 040 319 5082
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Southern Europe and Africa Sulzer Z engines

Phone: +39 040 319 5074 Phone: +39 040 319 5083
Italy GMT engines

Phone: +39 040 319 5075 Phone: +39 040 319 5084
The list of Wärtsilä Network companies is available at www.wartsila.com web site.
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WÄRTSILÄ Contact information
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This page is intentionally left blank.
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ZA40S Maintenance 0002–1/A1
Table of Contents
Table of Contents
Group 0
For Particular Attention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0000-1/A1
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001-1/A1
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002-1/A1
General Guidelines for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003-1/A1
Safety Precautions During Maintenance Work
General Guidelines for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003-2/A1
Criteria for the Replacement of Bearing Shells
Numbering of Bearings and Cylinders, as well as Definition of Engine Sides . . . . . . . . . . . . . . . . . . . . . . . 0022-1/A1
Inspection / Service Intervals and Service Life of Engine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0030-0/A1
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Maintenance Schedule (for Engines Operating on Heavy Fuel Oil) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0030-1/A1
Inspection and Overhaul Intervals (Guidelines)
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Engine Cross Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0030-1/A1
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Masses (Weights) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0051-1/A1
Individual Components per Piece in kg
Dimensions and Material Specifications of OĆRings and Round Rubber Rings . . . . . . . . . . . . . . . . . . . . . 0328-1/A1
Dimensions and Material Specifications of Piston and Rod Seal Rings
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and Applicable OĆRings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0328-2/A1
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Clearance and Wear Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0352-1/A1
Crankshaft Main Bearing and Crankshaft Thrust Bearing
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Cylinder Liner, Valve Rocker Arms
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Inlet and Exhaust Valve Guide, Crankpin Bearing
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Rotating Piston
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Piston Rings and Oil Scraper Rings
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Camshaft Bearing, Camshaft Thrust Bearing, Camshaft Drive,
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Tooth Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NonĆReversible Engine

Camshaft Bearing, Camshaft Drive, Tooth Backlash . . . . . . . . . . . Reversible Engine
Starting Air Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with Control Disc
Starting Air Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NonĆReversible Engine
Reversing Servomotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reversible Engine
Valve Drive
Governor Drive
Mechanical Overspeed Trip and Safety CutĆOut Device
Wärtsilä Switzerland Ltd 1 3.00

0002–1/A1 Maintenance
ZA40S
Table of Contents

Fuel Injection Pump
Lubricating Oil and Fuel Oil Booster Pump . . . . . . . . . . . . . . . . . . with EngineĆDriven Pumps
Cylinder Cooling Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with EngineĆDriven Pumps
Raw Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with EngineĆDriven Pumps
Fuel Nozzle Cooling Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . with EngineĆDriven Pumps
Tightening Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0355-1/A1
Tightening Values of Important Screwed Connections
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Taking Lubricating Oil Samples for Laboratory Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0356-1/A1
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Group 1
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Engine Housing (Frame) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001-1/A1
Replacement of Cylinder Head Studs
Crankshaft Main Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1201-1/A1
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Loosening and PreĆTensioning of the Transverse Tie Rods and Main Bearing Studs
Crankshaft Main Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1201-2/A1
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Replacement of Crankshaft Main Bearing Shells (Standard Shell Bearing)
Crankshaft Thrust Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1202-1/A1
Replacement of Bearing Shells and Thrust Ring Halves
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Group 2
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Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2105-1/A1

Measuring Wear and ReĆmachining of Cylinder Liner Bore
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Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2105-2/A1

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Removing and Fitting a Cylinder Liner

Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2701-1/A1
Removing and Fitting a Cylinder Head
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Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2701-2/A1

Replacing Valve Seats
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Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2701-3/A1

Grinding the Valve Seats of Inlet and Exhaust Valves
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2701-4/A1
Replacing the Insert Bush for the Fuel Injection Valve and Lapping the Seating Surfaces
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2701-5/A1
Replacing the Valve Guides for the Inlet and Exhaust Valves
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2701-6/A1
Pressure Test of Water Spaces
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2701-7/A1
Reconditioning a Relief Valve
Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2705-1/A1
Replacing the Rocker Arms of Inlet and Exhaust Valves
High Pressure Fuel Pipe and Fuel Delivery Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2716-1/A1
Removal, Reconditioning and Fitting
3.00 2 Wärtsilä Switzerland Ltd

Table of Contents
Inlet and Exhaust Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2720-1/A1

Replacing Valve Springs as well as Removing and Fitting of Valves
Inlet and Exhaust Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2720-2/A1
Regrinding the Seats
Fuel Injection Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2722-1/A1
Removing, Dismantling and Assembling
Checking the Condition of Spraying and the Spraying Pressure
Cleaning and Reconditioning
Starting Valve in the Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2728-1/A1
Removing from the Cylinder Head, Dismantling, LappingĆin, Assembling and Fitting
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Group 3
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3101-1/A1
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Measuring Crank Deflections
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3101-2/A1
Loosening and Tightening the Coupling Bolts
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Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3101-3/A1
Fitting the Counterweights
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Torsional Vibration Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3130-1/A1
Taking a Silicon Fluid Sample
Turning Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3212-1/A1
Maintenance
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Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3302-1/A1

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Inspection and Replacement of Crankpin Bearing Shells

Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3302-2/A1
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Loosening and PreĆTensioning the Studs of the Lower Connecting Rod Head
Rotating Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3401-1/A1
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Removal and Fitting a Piston

Rotating Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3401-2/A1
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Dismantling and Assembling

Piston Rings and Oil Scraper Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3402-1/A1
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Removing and Fitting
Group 4
Camshaft Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4101-1/A1
Checking Gear Tooth Backlash, Bearing Clearances and Adjusting Camshaft Driving Wheels
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4201-1/A1
Checking the Cams, Removing and Fitting the Camshaft
Cams on Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4211-1/A1
Replacing Original Cams by TwoĆPart Cams . . . . . . . . . . . . . . . . . . NonĆReversible Engine
Starting Air Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4301-1/A1
Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NonĆReversible Engine
Starting Air Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4301-1/A2
Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with Control Disc
ShutĆOff Valve for Starting Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4304-1/A1

0002–1/A1 Maintenance
ZA40S
Table of Contents
Inlet and Exhaust Valve Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4401-1/A1

Adjusting the Valve Clearance
Inlet and Exhaust Valve Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4401-2/A1
Reversing Servomotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4500-1/A1
Dismantling, Checking and Assembling . . . . . . . . . . . . . . . . . . . . . Reversible Engine
Regulating Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4501-1/A1
Removal and Fitting of the Spring Linkage Rod Springs
CutĆOut Servomotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4612-1/A1
Group 5
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Speed Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5101-1/A1
Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WOODWARD EGBĆ58P
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Speed Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5101-1/A2
Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WOODWARD PGA58
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Speed Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5101-1/A3
Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WOODWARD PGGĆEG58
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Governor Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5105-1/A1
Mechanical Overspeed Trip and Safety CutĆOut Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5303-1/A1
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Removing and Fitting the Spring
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5501-1/A1
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Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5501-2/A1

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Adjusting and Checking
Group 6
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Charge Air Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6601-1/A1

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Removal, Cleaning and Mounting

Flap for Charge Air Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6730-1/A1
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WasteĆGate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6735-1/A1
Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Variant 'A'
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WasteĆGate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6735-1/A2
Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Variant 'B'
Group 7
Lubricating Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7101-1/A1
Dismantling and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with EngineĆDriven Pumps
Fuel Booster Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7102-1/A1
Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with EngineĆDriven Pumps
Cylinder Cooling and Raw Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7103-1/A1
Fuel Valve Cooling Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7105-1/A1
SCAMATIC Fine Filter for Cylinder Lubricating Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7203-1/A1
Function Check and Maintenance
Cylinder Lubricating Oil Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7220-1/A1
Flushing out the Housing

Table of Contents
*URXS
([KDXVW :DVWH*DWH $
6WDUWLQJ $LU 3LSHV $
Overhauling the Flame Traps and Relief Valves
*URXS
7RROV $
Explanation
+\GUDXOLF 3UH7HQVLRQLQJ -DFNV $
Storage, Care, Spares Stock and Sealing Rings
7RROV $
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Tools List
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General Guidelines for Maintenance
Safety Precautions During Maintenance Work
The maintenance work which is required to be carried out on the engine at regular intervals is described in the MainteĆ
nance Schedule group 0030-1 of this manual and is to be understood as a general guide. The maintenance intervals are
dependent on the mode of operation, on the power as well as on the quality of the fuel used.
Experience will show whether the intervals may be extended or need to be shortened. The below mentioned recommenĆ
dations regarding safety measures and maintenance work must be obeyed, they are not final.
4. General safety precautions

- It is the operator's duty to assure that all personnel is familiar with all safety, health as well as environment protection
rules released for operating and maintaining a diesel engine plant. In particular greatest attention has to be given to
the functionality, handling and dangers of cranes and lifting devices.
- The safety officer has to assure that all precautions have been taken in order to avoid dangerous situations.
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- The operator has to nominate a person responsible for assigning work tasks to every person who is participating on
maintenance work.
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- Assure that fluids or gases draining or escaping during maintenance work cannot cause accidents, fires or explosions.
Keep the engine and the surroundings clean. Cleanliness increases the quality of the work and helps to prevent acciĆ
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dents. Before beginning with maintenance work the corresponding systems which are influenced by the maintenance
work must be relieved of pressure and/or drained if necessary. Keep a record of these activities such that it is visible to
everybody.
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- Certain media, i.e. fuels etc., are highly inflammable, therefore all precautionary measures have to be taken that they
do not get in contact with fires, glowing or hot parts. Smoking in the engine room is strictly forbidden.
Special attention has to be paid to the rules of fire fighting. Make absolutely sure that in case of fire alarm no fire
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extinguishing gases can be released into the engine room while people are in it.
Emergency escapes are to be marked and personnel is to be instructed of what to do in case of fire.
- Oils and other media can cause slippery surfaces. In order to avoid injury all surfaces which can be stepped on must be
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kept clean and dry.

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5. Precautionary measures before beginning of maintenance work

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Before starting any maintenance work on the engine (particularly on the running gear), take the following precautionary
measures:
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- Installations with automatic controls: Set automatic control switch to OFF position.
- Close stop valves of starting air receivers and vent the pipework to the engine.
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- To prevent unintentional starting, as well as in reversible engines unintentional shifting of the camshaft, please refer
additionally to the instructions of the respective engine control.
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- Open all indicator valves on the cylinder heads and leave them in this position until all maintenance work is comĆ
pleted.
- Engage turning gear (gear pinion must be meshed) and lock the lever.
- If the engine had to be stopped due to overheating in the running gear or bearings, do not open the crankcase doors
immediately; wait at least 20 minutes.
6. Special safety measures

- Prior to turning the crankshaft with the turning gear, make sure that no person is inside the engine and no loose parts,
tools or devices can get jammed.
- At all times when somebody is inside the engine casing another person must stand by in order that he can give the
necessary aid if something unexpected happens to the person inside the engine. The person who is inside the engine
casing must be equipped with all safety gears which are required to prevent suffocation within the limited space and
atmospheric conditions.

0003–1/A1 Maintenance ZA40S
- For maintenance work on the engine use the tools and devices intended for the particular job, which, as a rule, are
supplied with the engine (please refer to the tools list group 9400-3).
- Tools and devices should be made ready prior to use, make sure they are in perfect condition.
- Check hydraulic tools periodically for tightness and perfect functioning.
- The allowed load capacity of the engine room crane, the lifting tools, ropes and chains must be sufficient for the parts
to be lifted (see group 0051-1) pay attention to the weight distribution and attachment of the lifting tackle in order
that the part which must be lifted cannot tip over or crash down.
- Sharp edges, mating faces etc. as well as ropes are to be protected by wooden pieces, leather or special edge guards
which are placed between the part and the rope or chain.
- For your own safety keep away from under hanging loads never undersling hanging parts with your fingers or hands
and never embrace lifting ropes with your hands.
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- Removed parts must be secured in the engine room.
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Note For further notes regarding safety precautions and warnings (general remarks) see also operating
instructions group 0200-1.
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7. Recommendations for performing work
- Carry out all work carefully, observing utmost cleanliness. se
- Protect running faces and sealing faces of removed parts by suitable means to prevent damages.
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- Close all openings which form when certain parts are removed e.g. pipes, oil holes any opening etc. to prevent dirt
from entering the engine. (This includes also the pipes which are removed).
- Check all repaired, overhauled or replaced parts for perfect functioning before starting the engine.
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- Check all pipes, which have been removed, for tightness after they are refitted.
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- Clearances of moving parts must be checked periodically. Should the maximum permissible values (see Clearance
and Wear Table group 0352-1) have been reached or have even been exceeded, these parts must be replaced.
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- Arrange to replace all parts taken from spares stock. When ordering new parts refer to Code Book, mention code
numbers and description.
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- When tightening studs, nuts or screws, take the utmost care not to damage their thread. They must be screwed in by
hand until metal to metal contact is achieved. Always use the prescribed lubricants on the threads (see group
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0355-1).
- Adhere to tightening values wherever they are indicated. Use the specified lubricant on the threads (please refer to
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the Tightening Instructions 0355-1).

- Fit locking devices correctly and carefully. Use locking plates and locking wires only once.
- Use OĆrings only once. The new OĆrings should comply with the requirements of group 0328-1.
- Where the reference 'D' (sealing compound) indicates that a sealing compound should be used in place of a gasket,
(for example on end casings, claddings, casings) use a product which does not harden and has good resistance to waĆ
ter, oil and fuel. Examples are indicated below.

- Before you apply the sealing compound, clean the sealing faces with a suitable solvent to remove grease and oil (for
example Trichlorethylene).
The engine manufacturer uses the following sealing compounds:
Hylomar SQ 32 M (blue) Golden Hermetite
Manufacturer: Manufacturer:
Hermetite Products Ltd.
Marston Lubricant LTD. Tavistock Road
Rock Ferry Oil Works West Drayton, Middlesex
Birkenhead, England England
- Where the reference indicates 'fit with LOCTITE' without specifying any type, use one of the mentioned LOCTITE
threadĆlocking products.
LOCTITEĆNo. 59 (violet) or LOCTITEĆNo. 222 (violet)
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- For threads of screws and studs which are getting very hot, (for example exhaust pipe or turbocharger fastenings)
apply a high temperature resistant lubricant before assembly, to prevent a heat seizure.
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Where the remark 'use high temperature resistant lubricant' appears, the manufacturers use one of the following
products:
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Thread Gard Ultra Therm
Manufacturer: Manufacturer:
Walter Zepf
Crane Packing Ltd.
Slough, Bucks
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an der Linde 12
England D-78462 Konstanz a/B.
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Wärtsilä Switzerland Ltd 3 z 2.97

General Guidelines for Maintenance
Criteria for the Replacement of Bearing Shells
For the crankshaft main bearings as well as for the connecting rod bottom end bearings, bearing shells of the following
production types are used:
- Aluminium bearings with running layer No. 212.*)
- "Rillenlager" grooved bearings with running layer No. 336
For easy identification of the bearing shell type, their front faces are correspondingly marked (see Fig. 'A'). The last three
digits of the marking indicate the running layer of the bearing shell.
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A
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Depending on operating conditions, the running layer of a bearing is subjected to more or less wear.
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Bearings are therefore considered as wear parts, and depending on operating conditions must be replaced sooner or
later. In order to ensure a trouble free operation and a long life of the bearings, the following points must be observed:
- Optimum lubrication of the bearings, prior to starting and while operating the engine.
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- Optimum treatment of the lubricating oil by centrifuging.

- Perfectly working oil filters.
- Through cleaning of the crankcase after overhaul work, and adequately long flushing through of the oil piping system.
- Plugging the oil drillings in the crankshaft during overhaul work on the connecting rod bottom end bearing.
Remark *) Crankshaft main bearings as well as connecting rod bottom end bearings with a running layer
No. 212 should be used for engines with a nominal output of more than 660 kW per cylinder.
Wärtsilä Switzerland Ltd 1 1995

Criteria for the replacement of bearing shells
The following indications should facilitate a decision whether a bearing shell has to be replaced or can be fitted again for
further use. It is of paramount importance that in case of a reĆfitting of used shells, they are installed in the same place i.e.
in the same bearing saddle or connecting rod as well as shaft journal, whereby the bearing shell should clamp lightly in
the saddle bore when assembling.
Before assembling a bearing shell its expanded dimension L1 and L2 (Fig. 'B') are to be measured. If a smaller dimension
is established than the values mentioned in Fig. 'B', the bearing shell is to be exchanged.
a) Aluminium bearing No. 212

A bearing shell with the above running layer No. may be reĆfitted provided:
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1. The wear lies within the tolerance (see Fig. 'B').
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2. The running surface and contact surface are good.
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3. Only individual scratches or isolated beddedĆin dirt traces are observed in the running surface.
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A bearing shell with the above running layer No. must be replaced if:
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1. The wear in the bearing centre lies outside the tolerance (see Fig. 'B').
2. The running surface is rough or damaged.
3. The running surface contains several grooves and several dirt indentations.
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B
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Main bearing shells Bottom end bearing shells

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L1
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15mm
95.7184
L2
Wear limit: d0 – d1 = max. 0.07 mm d2 – d3 = max. 0.10 mm

Expanded dimension: L1 = min. 370 mm L2 = min. 365 mm
Additional criteria: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shell has to clamp
in bottom end bore.
8.96 / L-Mot. 2 Wärtsilä Switzerland Ltd

b) "Rillenlager" grooved bearing No. 336

The bearing surfaces of a new grooved bearing shell correspond with the values given in Fig. 'C'. However, these values
are only meant as a general guide. The groove shape and dimensions may differ from one supplier to another.
C
20 – 33% Aluminium web 33%
80 – 67% Overlay 67%
Nickel barrier layer
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95.7185
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The following criteria are applicable for the replacement of grooved shells
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- A bearing shell must be replaced when, on the max. loaded area of the running surface, the AlĆweb has increased by
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75% (see Fig. 'D'). This does not apply to running surface sections which show some wear caused during runningĆin by
small directional faults.
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D
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Aluminium
175%
Overlay
100%
95.7186

- Should the overlay be worn from its grooves on more than 30% of the complete running surface, then a new bearing
shell must be fitted (Fig. 'E').
Aluminium
Missing overlay
or
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95.7187
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- Should, in a surface without overlay, 10% of the AlĆwebs be worn such that their width has increased by more than
75%, then a new bearing shell must be fitted.
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- Should the AlĆwebs on either or both sides of the bearing be fully worn on a width of over 8 mm, then the bearing shell
must be replaced.
- Should the overlay be worn out of its grooves on either or both sides by more than 15% of the full running width, then
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the bearing shell must be replaced.

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Remark If cavitation traces are noticed ink the bearing shells of the connecting rod bottom end bearing as
depicted in Fig. 'F' then such bearing shells may again be fitted for reĆuse; provided however that the
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bearing shells show none of the above mentioned wear limits.

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Upper shell Lower shell

F
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95.7188
1995 4 z Wärtsilä Switzerland Ltd

Numbering of Bearings and Cylinders, as well as Definition of Engine Sides
Turbocharger Crankshaft Main Bearing Bearing Number

FUEL PUMP SIDE
1 2 3 4 5 6 7
DRIVING END
FREE END
1 2 3 4 5 6
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EXHAUST SIDE
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Thrust Bearing Camshaft Driving Wheel Cylinder Number Turbocharger
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Exhaust valve
FUEL PUMP SIDE
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FUEL PUMP SIDE
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DRIVING END
FREE END
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Exhaust valve Inlet valve

EXHAUST SIDE EXHAUST SIDE
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DIRECTION OF ROTATION VIEWED FROM DRIVING END
Camshaft
Crankshaft
95.7364
CLOCKWISE ROTATION ANTI-CLOCKWISE ROTATION
Wärtsilä Switzerland Ltd 1 z L-Mot. / 1995

Inspection / Service Intervals and Service Life of Engine Components
Expected inspection and service lifetimes
As already mentioned in group 0003-1, the recommended intervals in the maintenance schedule, group 0030-1 serve
only as general g u i d a n c e.
The actually applicable intervals or lifetimes depend on the following points:
- Quality of fuel and lubricating oils (group 0356-1 of the Operating Instructions)
- Environmental and operating conditions
- Fuel and lubricating oil care
- Maintenance work
- Use of genuine spare parts
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- Engine load factor
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The actual service intervals are to be determined according to the actual operating conditions.
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Expected service life of engine components operating on heavy fuel oil
Operating hours
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Fuel nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8'000
Inlet valve and valve seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24'000 - 36'000
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Exhaust valve and valve seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24'000 - 36'000 *)
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48'000 - 60'000
a
Piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12'000

Oil scraper rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12'000
rn
Piston ring groove (reĆchroming) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36'000 - 48'000

e
Rotating mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48'000 - 60'000

Top end (spherical) bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48'000 - 60'000
nt
Bottom end bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24'000 - 36'000

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Main bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24'000 - 36'000

Fuel pump plunger and guide bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24'000 - 36'000
Fo
Cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48'000 - 60'000
Remark *) Depending on actual fuel and lube oil operating conditions.
Wärtsilä Switzerland Ltd 1 z 1995

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1995 / V-Mot. 8 ` Wärtsilä Italia S.p.A.

Masses (Weights)
Individual Components per Piece in kg
Design Description kg
Group
1001 Engine housing . . . . . . . . . . . . . . . . . 6 Cylinder with bearing covers and studs . . . . . . . . . . . . . . . . 20'970
1001 Main bearing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
1008 Oil sump . . . . . . . . . . . . . . . . . . . . . . . 6 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1'180
1202 Crankshaft thrust bearing . . . . . . . . . . . . . . . . . . . . one half, without shell and oil catcher . . . . . . . . . . . . 90
1607 Casing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . to the camshaft space . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1609 Cladding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . on free end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611
y
Cladding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . on free end (with engineĆdriven pumps) . . . . . . . . 1'030
1611 Front plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . on driving end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 738
nl
Front plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . on driving end, turbocharger at the free end . . . . . . 827
2105 Cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493
O
2701 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . incl. valves (complete) . . . . . . . . . . . . . . . . . . . . . . . . 900
2703 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . without valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 830
2722 Fuel injection valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
se
2728 Starting valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2760 Rocker gear housing . . . . . . . . . . . . . . . . . . . . . . . . incl. rocker arms, without cover . . . . . . . . . . . . . . . . 125
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3101 Crankshaft . . . . . . . . . . . . . . . . . . . . . 6 Cylinder incl. counterweights approx. . . . . . . . . . . . . . . . . . . 8'300
3101 Crankshaft . . . . . . . . . . . . . . . . . . . . . 8 Cylinder incl. counterweights approx. . . . . . . . . . . . . . . . . . 10'660
3101 Crankshaft . . . . . . . . . . . . . . . . . . . . . 9 Cylinder incl. counterweights approx. . . . . . . . . . . . . . . . . . 11'840
3101 Counterweight to crankshaft . . . . . . . . . . . . . . . . . depending on execution approx. . . . . . . . . . . . . . . . . 203
a
3130 Vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . depending on execution up to . . . . . . . . . . . . . . . . . 2'000

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3206 Turning gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393

3301 Connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
3302 Bottom end bearing . . . . . . . . . . . . . . . . . . . . . . . . complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
e
3401 Rotating piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . complete (without connecting rod) . . . . . . . . . . . . . 310

nt
4101 Camshaft drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . intermediate gear wheels . . . . . . . . . . . . . . . . . . . . . 385

4201 Camshaft . . . . . . . . . . . . . . . . . . . . . . 6 Cylinder complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1'350
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4211 Fuel cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Fo
4301 Starting air distributor . . . . . . . 6 + 8 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

4301 Starting air distributor . . . . . . . . . . . 9 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4301 Starting air distributor . . . . . . . . . . . . . . . . . . . . . . (for reversible engines) . . . . . . . . . . . . . . . . . . . . . . . . 51
4304 Starting air shutĆoff valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Starting air shutĆoff valve . . . . . 6 + 8 Cylinder with slow turning device . . . . . . . . . . . . . . . . . . . . . . . 65
Starting air shutĆoff valve . . . . . . . . . 9 Cylinder with slow turning device . . . . . . . . . . . . . . . . . . . . . . . 62
4401 Valve actuating gear . . . . . . . . . . . . . . . . . . . . . . . . without push rod and casing . . . . . . . . . . . . . . . . . . . . 37
4501 Reversing servomotor . . . . . . . . . . . . . . . . . . . . . . . (for reversible engines) . . . . . . . . . . . . . . . . . . . . . . . 380
4503 Reversing valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . (for reversible engines) . . . . . . . . . . . . . . . . . . . . . . . . 50
4807 Operating unit for local control stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
5103 Speed governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

5105 Governor drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5303 Overspeed safeguard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
5501 Fuel injection pump . . . . . . . . . . . . . . . . . . . . . . . . complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Wärtsilä Switzerland Ltd 1 L-Mot. / 1995

6502 Exhaust gas turbocharger . . . . . . . . . 6 Cylinder VTR 354 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1'900

6502 Exhaust gas turbocharger . . . . . 8 + 9 Cylinder VTR 454 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3'250
6601 Charge air cooler . . . . . . . . . . . . . . . . 6 Cylinder with casing and water separator . . . . . . . . . . . . . . . 1'534
6601 Charge air cooler . . . . . . . . . . . . . 8+9 Cylinder with casing and water separator . . . . . . . . . . . . . . . 1'850
6601 Air inlet casing . . . . . . . . . . . . . . . . . . 6 Cylinder with diffusor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
6601 Air inlet casing . . . . . . . . . . . . . . 8 + 9 Cylinder with diffusor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
6701 Air branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . connection engine housing / cylinder head . . . . . . . . 40
7201 Cylinder lubricator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8101 Exhaust pipe section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

8145 Casing for exhaust pipes . . . . . . . . . . . . . . 6 Cyl. complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452
y
7103 Lubricating oil pump . . . . . . . . . . . . . . . . . . . . . . . (with engineĆdriven pumps) . . . . . . . . . . . . . . . . . . . 330
nl
7403 Fuel booster pump . . . . . . . . . . . . . . . . . . . . . . . . . (with engineĆdriven pumps) . . . . . . . . . . . . . . . . . . . . 95
7505 Cooling water pump . . . . . . . . . . . . . . . . . . . . . . . . (with engineĆdriven pumps) . . . . . . . . . . . . . . . . . . . 142
O
(high temperature circuit)
7506 Cooling water pump . . . . . . . . . . . . . . . . . . . . . . . . (with engineĆdriven pumps) . . . . . . . . . . . . . . . . . . . 184
(low temperature circuit)
7507 se
Nozzle cooling water pump . . . . . . . . . . . . . . . . . . (with engineĆdriven pumps) . . . . . . . . . . . . . . . . . . . . 55
Complete engine . . . . . . . . . . . . . . . . 6 Cylinder without water, oil, gangway, . . . . . . . . . . . . . . . . . 59'000

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flywheel, engineĆdriven pumps, reversing
device, EC40Ćparts

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1995 / L-Mot. 2 Wärtsilä Switzerland Ltd

ZA40S Maintenance 0328--1/A1
Dimensions and Material Specifications of O-Rings and Round Rubber Rings
Material
Inner Diameter
Code Book
Thickness
NBR = Nitrile
Group in
in mm
in mm
Component where the O-ring FPM = Viton
or the rubber ring is installed MVQ = Silicone
Round rubber joints
1008---1 Oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 cylinder 7 *11’400 NBR 50 Sh
Oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 cylinder 7 *14’200 NBR 50 Sh
Oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 cylinder 7 *15’600 NBR 50 Sh
y
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Rubber rings and O-rings
1001---1 Horizontal tie rod for main bearing . . . . . . . . . . . . . . . . . . . . . . 5.33 78.74 NBR 70 Sh
O
Horizontal tie rod for main bearing . . . . . . . . . . . . . . . . . . . . . . 5.33 66.04 NBR 70 Sh
se
2103---1 Cylinder liner (below) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder liner (above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.99
6.99
443.36
532.26
FPM 75 Sh
FPM 75 Sh
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2701---1 Nut for cylinder head stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.33 78.74 NBR 70 Sh
Oil passage (engine housing / cylinder head) . . . . . . . . . . . . . . . 3.53 32.92 NBR 70 Sh
a
Oil passage (cylinder head / rocker arm housing) . . . . . . . . . . . 3.53 18.64 NBR 70 Sh
rn
Bush for fuel injection valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.33 81.92 FPM 70 Sh

Valve guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.53 28.17 FPM 70 Sh
e
2716---1 High pressure fuel pipe and fuel delivery valve . . . . . . . . . . . . . 3.53 63.09 FPM 70 Sh
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2722---1 Fuel injection valve / nozzle holder . . . . . . . . . . . . . . . . . . . . . . . 5.33 81.92 FPM 75 Sh

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Fuel injection valve / nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.33 66.04 FPM 75 Sh

Fo
2728---1 Starting valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.33 100.97 FPM 70 Sh

Starting valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.53 18.64 NBR 70 Sh
2754---1 Valve seat for exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.53 120.24 FPM 70 Sh

Valve seat for exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.53 120.24 FPM 70 Sh
2760---1 Plug for auxiliary rocker arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.33 40.64 NBR 70 Sh

Plug for main rocker arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.33 78.74 NBR 70 Sh
3101---1 Intermediate piece for shaft extension . . . . . . . . . . . . . . . . . . . . 5.33 40.64 NBR 70 Sh

Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.53 20.22 FPM 70 Sh
Screwed connection flywheel / vibration damper (GEISLINGER) 6.99 608.08 MVQ 50 Sh
Screwed connection flywheel / vibration damper (GEISLINGER) 6.99 380.37 MVQ 50 Sh
Wärtsilä Italia S.p.A. 1 L-Mot. / 12.04

Material
Inner Diameter
Code Book
Thickness
NBR = Nitrile
Group in
in mm
in mm
Component where the OĆring FPM = Viton
3401-1 Piston crown . . . . . . . . . (P = 660 kW/cylinder) . . . . . . . . . . . . 6.99 342.27 FPM 70 Sh
Piston crown . . . . . . . . . (P = 720 kW/cylinder) . . . . . . . . . . . . 6.99 342.27 FPM 70 Sh
Upper piston half . . . . . (P = 720 kW/cylinder) . . . . . . . . . . . . 6.99 227.97 FPM 70 Sh
4101-1 Journal pin for camshaft drive . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.99 148.59 NBR 70 Sh
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4301-1 Slide valve / flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.33 40.64 NBR 70 Sh
Starting air distributor / guide flange . . . . . . . . . . . . . . . . . . . . . . 5.33 88.27 NBR 70 Sh
nl
Starting air distributor / housing . . . . . . . . . . . . . . . . . . . . . . . . . . 6.99 177.17 NBR 70 Sh
O
4304-1 Throttle nonĆreturn valve for shutĆoff valve . . . . . . . . . . . . . . . . 3.53 28.17 FPM 75 Sh
PreĆcontrol valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 10 Rubber No. 750
se
Throttle nonĆreturn valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.53 28.17 FPM 70 Sh
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4401-1 Housing for valve drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.99 148.59 NBR 70 Sh
Casing for push rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.33 100.97 NBR 70 Sh
a
4503-1 Reversing valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.33 40.64 NBR 70 Sh

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4509-1 Fuel locking slide valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.53 32.92 NBR 70 Sh

Fuel locking slide valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.53 18.64 NBR 70 Sh
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nt
4604-1 3/2 Ć way valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.53 28.17 FPM 75 Sh

Control valve to shutĆdown servomotor . . . . . . . . . . . . . . . . . . . . 5.33 53.34 NBR 70 Sh
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Control valve to shutĆdown servomotor . . . . . . . . . . . . . . . . . . . . 5.33 40.64 NBR 70 Sh

Control valve to shutĆdown servomotor . . . . . . . . . . . . . . . . . . . . 2 10 Rubber No. 750
Fo
4608-1 Pressure sensor for control / needle valve in connecting block 1.78 3.68 NBR 70 Sh
Pressure sensor for control / sealing flange for connecting block 1.78 6.07 NBR 70 Sh
4612-1 ShutĆdown servomotor / cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.53 34.52 NBR 70 Sh

ShutĆdown servomotor / cylinder . . . . . . . . . . . . . . . . . . . . . . . . . 5.33 53.34 NBR 70 Sh
ShutĆdown servomotor / flange . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.33 40.64 NBR 70 Sh
ShutĆdown servomotor / cylinder . . . . . . . . . . . . . . . . . . . . . . . . . 3.53 24.99 NBR 70 Sh
ShutĆdown servomotor / guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.33 66.04 NBR 70 Sh
ShutĆdown servomotor / housing . . . . . . . . . . . . . . . . . . . . . . . . . 5.33 46.99 NBR 70 Sh
ShutĆdown servomotor / flange . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.99 126.37 NBR 70 Sh

Material
Inner Diameter
Code Book
Thickness
NBR = Nitrile
Group in
in mm
in mm
4807-1 Local control stand / valve connection . . . . . . . . . . . . . . . . . . . . . 2.62 4.42 NBR 70 Sh
Local control stand / valve connection . . . . . . . . . . . . . . . . . . . . . 2 10 Rubber No. 750
4807-2 Local control stand / valve connection . . . . . . . . . . . . . . . . . . . . . 2 10 Rubber No. 750
5303-1 Intermediate wheel shaft to overspeed safety cut out . . . . . . . . 3.53 37.69 NBR 70 Sh
y
5501-1 Fuel injection pump / housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 158.12 MVQ 50 Sh
Fuel injection pump / cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.33 91.44 FPM 75 Sh
nl
Fuel injection pump / cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.33 66.04 FPM 75 Sh
O
6730-1 Flap for bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 10 Rubber No. 750
se
7005-1 Pump attachment / lubricating oil pump . . . . . . . . . . . . . . . . . . . 6.99
Pump attachment / fuel transfer pump . . . . . . . . . . . . . . . . . . . . 6.99
393.07
291.47
NBR 70 Sh
NBR 70 Sh
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Pump attachment / nozzle cooling water pump . . . . . . . . . . . . . 6.99 215.27 NBR 70 Sh
Pump attachment / cylinder cooling water pump . . . . . . . . . . . . 6.99 291.47 NBR 70 Sh
a
7201-1 Drive of cylinder lubricating pump / flow control valve . . . . . . . 3.53 18.64 NBR 70 Sh
rn
Flow valve / base plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.53 18.64 NBR 70 Sh
7403-1 Fuel transfer pump / cover . . . . . . . . . . . . diesel oil . . . . . . . . 6.99 148.59 NBR 70 Sh
e
Fuel transfer pump / sealing disc . . . . . . . diesel oil . . . . . . . . 5.33 43.82 NBR 70 Sh
nt
Fuel transfer pump / driving shaft . . . . . . diesel oil . . . . . . . . 3.53 37.69 NBR 70 Sh
Fuel transfer pump / cover . . . . . . . . . . . . heavy fuel oil . . . . . 6.99 148.59 FPM 70 Sh
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Fuel transfer pump / sealing disc . . . . . . . heavy fuel oil . . . . . 5.33 43.82 FPM 70 Sh
Fuel transfer pump / driving shaft . . . . . . heavy fuel oil . . . . . 3.53 37.69 FPM 70 Sh
Fo
7505-1 Cylinder cooling water pump / cover . . . . . . . . . . . . . . . . . . . . . . 6.99 227.97 NBR 70 Sh

Cylinder cooling water pump / bearing housing . . . . . . . . . . . . . 6.99 177.17 NBR 70 Sh
(high temperature circuit)
7506-1 Raw water pump / cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.99 291.47 NBR 70 Sh

Raw water pump / bearing housing . . . . . . . . . . . . . . . . . . . . . . . 6.99 177.17 NBR 70 Sh
(low temperature circuit)
7507-1 Nozzle cooling water pump / cover . . . . . . . . . . . . . . . . . . . . . . . . 6.99 177.17 NBR 70 Sh

Nozzle cooling water pump / bearing housing . . . . . . . . . . . . . . . 5.33 91.44 NBR 70 Sh

Material
Inner Diameter
Code Book
Thickness
NBR = Nitrile
Group in
in mm
in mm
8301-1 Cyl. cooling water piping / connecting piece on cyl. head . . . . . 5.33 40.64 FPM 70 Sh
Washing plant for charge air cooler, intermediate flange . . . . . 5.33 40.64 NBR 70 Sh
Oil main piping / connecting flange on engine housing . . . . . . . 6.99 164.47 NBR 70 Sh
8701-1 Fuel oil pressure retaining valve . . . . . . . . . . . . . . . . . . . . . . . . . . 3.53 28.17 FPM 70 Sh

Connecting piping to shutĆoff cock of fuel piping . . . . . . . . . . . . 3.53 34.52 FPM 70 Sh
y
Control piping / connecting block . . . . . . . . . . . . . . . . . . . . . . . . . 1.78 3.68 NBR 70 Sh
nl
9322-1 Pressure sensor for alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.78 6.07 NBR 70 Sh
O
9323-1 Pressure sensor for remote indication . . . . . . . . . . . . . . . . . . . . . 1.78 6.07 NBR 70 Sh
Tubular joints
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1603-1 Cover to crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 *1850 MVQ 50 Sh
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Cover to camshaft space . . . . . . . . . . . . . . . . . . . . 6ā-ā9 cylinder 15 *3300 MVQ 50 Sh
Cover to camshaft space . . . . . . . . . . . . . . . . . . . 9 cylinder only 15 *1850 MVQ 50 Sh
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2762-1 Cover on rocker arm housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 *2220 MVQ 50 Sh

rn
Rocker arm housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 *2220 MVQ 50 Sh

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6701-1 Air connection to cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . 15 *575 MVQ 50 Sh

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OĆrings on tools
9408.36 Hydraulic jack 150 mm stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.62 9.19 NBR 70 Sh

9427.06 Pressure test cylinder cover, sealing ring . . . . . . . . . . . . . . . . . . . 6.99 532.26 MVQ 50 Sh
9427.31 Fitting or mounting device, valve seat . . . . . . . . . . . . . . . . . . . . . 5.33 66.04 NBR 70 Sh
*) Length of joint
1995 / L-Mot. 4 z Wärtsilä Switzerland Ltd

Dimensions and Material Specifications of Piston and Rod Seal Rings and Applicable OĆRings
Seal Ring Support Ring
PTF/MoS2 /Glass
70±10 Shore A
70±5 Shore A
Abbreviation
Nitrile NBR
PTF/Bronze
Code Book
Viton FPM
Component where the Piston Seal Ring (PSR) or
Group in
the Rod Seal Ring (RSR) is installed. Nominal

Dimensions
2728-1 Starting valve / piston . . . . . . . . . . . . . . . . . . . . . . . . . . . PSR 85x81x3.8 x x
Starting valve / housing . . . . . . . . . . . . . . . . . . . . . . . . . RSR 50x54x3.8 x x
4301-1 Starting air distributor / piston . . . . . . . . . . . . . . . . . . . PSR 100x95x3.8 x x

Starting air distributor / cylinder . . . . . . . . . . . . . . . . . . RSR 75x79x3.8 x x
y
Starting air distributor / thrust washer . . . . . . . . . . . . . RSR 25x27x1.8 x x
nl
4304-1 ShutĆoff valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PSR 120x115x3.8 x x
ShutĆoff valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PSR 30x27x2.8 x x
O
ShutĆoff valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PSR 20x18x1.8 x x
4503-1 Piston of reversing valve . . . . . . . . . . . . . . . . . . . . . . . . se PSR 50x46x3.8 x x
4604-1 Control valve of cutĆout servomotor / piston . . . . . . . . PSR 50x46x3.8 x x

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4612-1 CutĆout servomotor / piston . . . . . . . . . . . . . . . . . . . . . PSR 50x46x3.8 x
CutĆout servomotor / piston . . . . . . . . . . . . . . . . . . . . . PSR 140x135x3.8 x x
a
5303-1 Overspeed safeguard / piston . . . . . . . . . . . . . . . . . . . . PSR 45x42x2.8 x x

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Overspeed safeguard / cylinder . . . . . . . . . . . . . . . . . . . RSR 25x27x1.8 x x
5501-1 Fuel injection pump, rack . . . . . . . . . . . . . . . . . . . . . . . RSR 24x26x1.8 x x

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6730-1 Flap for bypass / rack . . . . . . . . . . . . . . . . . . . . . . . . . . . PSR 50x46x3.8 x x

Flap for bypass / rack . . . . . . . . . . . . . . . . . . . . . . . . . . . PSR 0x27x2.8 x x
rI
Flap for bypass / support . . . . . . . . . . . . . . . . . . . . . . . . PSR 30x27x2.8 x x
6735-1 WasteĆgate / piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PSR 140x135x3.8 x x

Fo
Piston Seal Ring (PSR) Rod Seal Ring (RSR)

(nominal dimensions da x di x b) (nominal dimensions di x da x b)
Cylinder Bush
Support ring
Seal ring
Seal ring b
Support ring
b
Piston Rod
di da di da

Seal ring Support Ring

in Group 9400-2
PTF/MoS2 /Glass
70±10 Shore A
70±5 Shore A
Abbreviation
Nitrile NBR
PTF/Bronze
Viton FPM
Tool where the Piston Seal Ring (PSR)
Tool No.
or the Rod Seal Ring (RSR) are used. Nominal

Dimensions
9410.01 PreĆtensioning jack to crankshaft main bearing / pisĆ PSR 220x214x5.8 x x

ton RSR 120x125x3.8 x x
PreĆtensioning jack to crankshaft main bearing / cylĆ
y
inder
nl
9427.01 PreĆtensioning jack to cylinder head / piston PSR 140x135x3.8 x x
PreĆtensioning jack to cylinder head / cylinder RSR 90x94x3.8 x x
O
9433.01 PreĆtensioning jack to connecting rod / piston PSR 110x105x3.8 x x
PreĆtensioning jack to connecting rod / cylinder se
RSR 60x64x3.8 x x
9433.07 PreĆtensioning jack to crank web counterweights / PSR 120x115x3.8 x x

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piston RSR 60x64x3.8 x x
PreĆtensioning jack to crank web counterweights /
cylinder
a
e rn
nt
rI
Fo

Clearance and Wear Table
The normal clearances given in the following clearance and wear tables correspond to those resulting from manufactuĆ
ring tolerances or clearances as adjusted on the new engine.
The laid down maximum clearances resp. max/min. dimensions are such values as may be reached after a lengthy operaĆ
ting period, which however may not be allowed to be exceeded or fall below. On components where the clearance is
adjustable by modifying the thickness of shims, discs, spacers etc. the value given as 'Normal Clearance' should always be
arrived at, or striven to attain. Where this is not possible, worn parts must be replaced by standard new ones or recondiĆ
tioned by suitable material buildup.
If during an overhaul clearances are measured which almost have reached the permissible limit it must be left to indiviĆ
dual judgement to decide whether a component part should be replaced or remain fitted till the next overhaul. This deĆ
pends for example from the duration of the next operation period till the next overhaul and what wear has to be expected
based on experience made.
y
nl
O
se
a lU
e rn
nt
rI
Fo


Crankshaft Main Bearing
y
nl
1
O
se 95.7160
a lU
Crankshaft Thrust Bearing

e rn
4
nt
5
rI
Fo
95.7161
1995 2 Wärtsilä Switzerland Ltd


Direction of Nominal Maximum clearance

Key No.
Group
Part description measuring dimension (due to wear)

mm mm
Ovality . . . . . max. 0.05
Outer 0
1201 1 Journal 350 Parallelism . . max. 0.025
Diameter - 0.06
Diameter . . . max. -0.10
Bearing shells (studs tightened acĆ Inner
350 + 0.35
cording to instructions) Diameter + 0.27
y
Ovality . . . . . max. 0.05
nl
1201 2 Journal O.D. 350 0 Parallelism . . max. 0.025
- 0.06
O
Bearing shells (studs tightened acĆ
I.D. 350 + 0.29
cording to instructions) + 0.21
Bearing clearance
se
vertical 0.21 0.35 For reuse of bearing shells,
please note group 0003-2
lU

Ovality . . . . . max. 0.05
a
1202 3 Shaft end piece O.D. 350 0 Parallelism . . max. 0.025

- 0.06
rn

Thrust bearing shells (bearing
For reuse of bearing shells,
screws tightened according to I.D. 350 + 0.36
e
+ 0.29 please note group 0003-2

instructions)
nt
Bearing clearance vertical 0.29 0.42

rI
1202 4 Crankshaft axial clearance axial (total) 0.20 0.44 0.80

Fo
(both thrust rings installed)
1202 5 Shaft end piece O.D. 350
Oil catcher I.D. 350
Clearance all around 1.0


Cylinder Liner
125mm
1
y
nl
O
se
lU
95.7162
a
rn
Valve Rocker Arms

e
nt
rI
Fo
2 4
3 5
95.7163



Key No.
Group

mm mm
Cylinder Liner
2105 1 Cylinder liner I.D. 400 + 0.057
0
Measuring point A Diameter . . . max. 401.5
Measuring point B, C, D I.D. 400 Diameter . . . max. 400.4
Measuring point A Ovality . . . . . max. 0.5
y
(see also group 2105-1
nl
O
Valve Rocker Arm
2705 2 Main rocker pin O.D. se 90
Bearing bush (fitted) I.D. 90 + 0.090

lU
+ 0.036
Clearance radial 0.036 0.112 0.15
a
2705 3 Main rocker arm axial clearance axial (total) 0.5 1.0
e rn
nt
2705 4 Auxiliary rocker pin O.D. 50

rI

+ 0.025
Fo
2705 5 Auxiliary rocker arm axial (total) 0.5 1.0

axial clearance


Valve with Rotocap Valve with Turnomat
172
y
nl
50
25
O
1 1
se
Crankpin Bearing
lU
1
1
a
rn 35
45
e
nt
rI
2
Fo
95.7165



Key No.
Group

mm mm
Inlet and Exhaust Valves
2701 1 Valve spindle O.D. 28 min. Ø 27.85
(measuring point see Fig.)
Valve guide bush I.D. 28
Clearance 0.06-0.11 0.30
(measuring point see Fig.)
y
nl
O
Crankpin Bearing
3302 2 Crankpin 0 Ovality . . . . . max. 0.08
O.D.se 350
- 0.06 Parallelism . . max.
0.03
lU
Bearing shells For reuse of bearing shells,
(bearing studs tightened accordĆ I.D. 350 + 0.29 see group 0003-2
+ 0.22
ing to instructions)
a
Bearing clearance vertical 0.22 - 0.35

rn
3302 3 Crankpin 0 Ovality . . . . . max. 0.08

O.D. 350
- 0.06 Parallelism . . max. 0.03
e

nt
Bearing shells For reuse of bearing shells,

(bearing studs tightened accordĆ I.D. 350 + 0.35 see group 0003-2
+ 0.28
rI
Fo


Rotating Piston
The specified clearances are identical

for both piston designs.
y
nl
see
see page 10
page 10 and 11
O
and 11 1
Piston with
se Piston with
2
inner lubrication external lubrication
lU
1
3
a
rn
4
e
nt
rI
Fo
see
page 10
and 11
96.7225 95.7166


Rotating Piston

Key No.
Group

mm mm
Rotating Piston
3401 1 Piston crown (measuring point at O.D. 398.85
lower edge of piston crown)
Cylinder liner I.D. 400 + 0.057

0
y
Clearance radial (total) 1.150 1.307
nl
3401 2 Piston skirt O.D. 399.75
O
Cylinder liner I.D. 400 + 0.057
se 0
Clearance radial (total) 0.250 0.357

lU
3401 3 Ratchet pawl O.D. 30

a
rn
Guide bush I.D. 30

e
Clearance radial (total) 0.020 0.062 0.15

nt
3401 4 Clearance between ratchet ring axial 0.15 0.50 0.60

and upper bearing cup
rI
(waisted bolts connecting piston

crown to skirt, tightened accordĆ
ing to instruction)
Fo
3401 5 Clearance between lower bearing radial 0.07 0.23 0.35

cup and spherical head of connectĆ
ing rod
(waisted bolts connecting piston
crown to skirt, tightened accordĆ
ing to instruction)


Arrangement of the piston rings and

oil scraper rings see group 3402–1
2 1 1
y
nl
O
2
se
lU
3
5 4 4
a
e rn
5
nt
rI
8 7 9 7
Fo
96.7249
9 10



Key No.
Group

mm mm
Piston Ring
+ 0.20
3402 1 Piston ring groove (groove height) axial 10 + 0.17
0
Piston ring (ring height) axial 10 - 0.025 max. groove height 10.45
Clearance axial 0.17-0.225 0.50

3402 2 Piston ring groove depth 13.5 All piston rings to be reĆ
y
placed at every piston overĆ
haul.
nl
Piston ring width 13
3402 3 Piston ring gap measured in a 1.4 ± 0.2
O
ring of
400 + 0.05 D.
0
3402 4 Piston ring groove (groove height) axial
se 8 + 0.20
- 0.17
max. groove height 8.45
Piston ring (ring height) axial 8 0

lU
- 0.025
Clearance axial 0.17-0.225

3402 5 Piston ring groove depth 13.5
a
+0 2
Piston ring (ring width) width 13 - 0.2
0.3
rn
3402 6 Piston ring gap measured in a 2.2 ± 0.2

ring of
e
400 + 0.05 D.
0
nt
Oil Scraper Ring

Oil scraper ring groove
9 + 0.040
rI
3402 7 axial
(groove height) + 0.020
Oil scraper ring (ring height) axial 9 - 0.013

Fo
- 0.053
Clearance axial 0.033-0.093
3402 8 Oil scraper ring groove depth 13 + 0.45

+ 0.30
3402 9 Scraping edge height 0.8 ± 0.07 1.0
3402 10 Oil scraper ring gap measured in a 1 ± 0.2 4.0
ring of
400 + 0.05 D.
0


Camshaft Bearing, Camshaft Thrust Bearing, Camshaft Drive, Tooth Backlash NonĆReversible Engine
y
6
nl
2
O
1
1 se 95.7190
a lU
4 5
e rn
nt
3
rI
Fo
6 1
95.7168
95.7169


Camshaft Bearing, Camshaft Thrust Bearing, Camshaft Drive, Tooth Backlash NonĆReversible Engine

Key No.
Group

mm mm
Camshaft Bearing
4101 1 Camshaft O.D. 140
Bearing shells
(bearing screws tightened accordĆ I.D. 140 + 0.195
+ 0.13
y
Camshaft Thrust Bearing
nl
4101 2 Camshaft / stop ring axial (total) 0.2 0.3 0.4
O
Camshaft Drive
4101 3 Bearing journals O.D. se 180
0
lU
4101 4 Intermediate gear wheel axial (total) 0.4 0.8 0.9

a
rn
4101 5 Intermediate gear wheel / camĆ tooth backlash 0.16 ± 0.32 0.5
shaft gear wheel
e
4101 6 Driving gear wheel on crankshaft tooth backlash 0.22 ± 0.39 0.45
nt
(split gear),
intermediate gear wheel
rI
Fo


Camshaft Bearing, Camshaft Drive, Tooth Backlash Reversible Engine
y
6
nl
O
95.7190
1 se
1
a lU
rn
5
4
e
nt
3
rI
Fo
95.7170
95.7169


Camshaft Bearing, Camshaft Drive, Tooth Backlash Reversible Engine

Key No.
Group

mm mm
Camshaft Bearing
Bearing shells
(bearing screws tightened accordĆ I.D. 140 + 0.195
+ 0.13
y
Camshaft Axial Clearance (Please refer to page 20 and 21:
nl
Reversing Servomotor)
O
se
lU
Camshaft Drive
4101 3 Bearing journal O.D. 180
Bearing bush (fitted) 180 + 0.04
a
I.D.
0
rn

e
4101 4 Intermediate gear wheel axial (total) 0.4 0.8 0.9

(axial clearance)
nt
4101 5 Intermediate gear wheel / camĆ tooth backlash 0.16 0.32 0.5
rI
shaft gear wheel

Fo
4101 6 Driving gear wheel on crankshaft tooth backlash 0.22 0.39 0.45
(split gear)


Starting Air Distributor with Control Disc
3 2
y
nl
O
4
se
a lU
e rn
nt
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96.8567
Fo
+0
10 + 0.03
+0
10 + 0.03


Starting Air Distributor with Control Disc
Nominal Maximum clearance

Key No.
Group
Part description Direction of dimension (due to wear)

measuring mm mm
Starting Air Distributor
4301 1 Slot in intermediate shaft radial 10 + 0.05
and shaft + 0.02
Cross intermediate piece radial 10 0 0.10

- 0.03
y
Clearance radial 0.02-0.08
nl
4301 2 Shaft O.D. 24 - 0.065
- 0.098
O
DU bush I.D. 24 + 0.071 0.20
se - 0.010
Clearance radial 0.055-0.169

lU
4301 3 Intermediate shaft / cross axial 0.80-3.0

intermediate piece
a
rn
4301 4 Ball / disc axial 0.70-1.70

e
nt
rI
Fo


Starting Air Distributor NonĆReversible Engine
y
nl
O
se
a lU
rn
1
e
nt
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Fo
95.7172


Starting Air Distributor NonĆReversible Engine

Key No.
Group

mm mm
Staring Air Distributor
4301 1 Pilot control valve O.D. 30
Casing I.D. 30
Clearance radial 0.020 0.062
y
nl
4301 2 Roller pin O.D. 10
O
Roller bush I.D. 10
Clearance
se
radial 0.01 0.084
lU
4301 3 Roller axial (total) 0.3 0.7
a
e rn
nt
rI
Fo


Reversing Servomotor Reversible Engine
y
nl
O
se
lU
1
a
rn
e
nt
rI
Fo
95.7173


Reversing Servomotor Reversible Engine

Key No.
Group

mm mm
Reversing Servomotor
Bearing bush I.D. 140 + 0.195
+ 0.13
y
4500 2 Piston / locating rings axial (total) 0.324 1.024
(central stud preĆtightened acĆ
nl
cording to instruction)
O
se
a lU
e rn
nt
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Fo


Valve Drive
y
nl
O
se 1
a lU
rn
e
nt
rI
2
Fo
2
3
95.7174
4 5


Valve Drive

Key No.
Group

mm mm
Valve drive
4401 1 Valve clearance (cold engine) Inlet valve 0.6 + 0.1

0
Exhaust valve 1.2 + 0.1

0
y
4401 2 Guide piston O.D. 120
nl
Housing I.D. 120
O
Bearing bush
Clearance
I.D.se
radial
42
0.025 0.080 0.10
lU
4401 4 Bearing bush / guide piston axial (total) 0.2 0.4

a
4401 5 Locating discs / guide piston axial (total) 0.26 0.54

e rn
nt
rI
Fo


Governor Drive
y
nl
O
se
lU
1 6
a
2
rn
4
e
nt
rI
Fo
3 5
95.7175


Governor Drive

Key No.
Group

mm mm
Governor Drive
5105 1 Vertical shaft O.D. 44

+ 0.045
y
5105 2 Bevel gear / bearing bush axial (total) 0.25 0.45
nl
5105 3 Bevel gear shaft O.D. 44
O
+ 0.045
5105 4 Driving spur gear wheel

se
axial (total) 0.25 0.45
lU
5105 5 Camshaft gear / driving spur gear tooth backlash 0.16 0.32 0.4
wheel
a
rn
5105 6 Bevel gears tooth backlash 0.1 0.2 0.3

e
nt
rI
Fo


y
1
nl
O
se
a lU
rn
5
e
6
nt
3
rI
Fo
95.7176



Key No.
Group

mm mm
Mechanical Overspeed Safety
CutĆOut Device
5303 1 Pin shaft O.D. 44

+ 0.045
y
5303 2 Shaft / bearing bush axial (total) 0.3 0.65 0.8
nl
5303 3 Shaft of intermediate gear O.D. 44
O
+ 0.045
Clearance se
radial 0.054 0.095 0.15
5303 4 Shaft intermediate gear / interĆ axial (total) 0.2 0.55

lU
mediate gear
5303 5 Camshaft gear / intermediate gear tooth backlash 0.16 0.32 0.4
a
rn
5303 6 Intermediate shaft / driving gear tooth backlash 0.16 0.32 0.4
e
nt
rI
Fo


Fuel Injection Pump
y
nl
O
se
a lU
rn
3
e
nt
7a
rI
7
Fo
6
5
2
4
95.7177


Fuel Injection Pump

Key No.
Group

mm mm
Fuel Injection Pump
5501 1 Pump plunger O.D. 35
Plunger guide I.D. 35
5501 2 Control rack O.D. 30
Housing (bore) I.D. 30
y
nl
5501 3 Guide piston O.D. 130
Pump housing I.D. 130
O
5501 4 Bearing bush O.D. 60
Roller
Clearance
I.D.
se
radial
60
0.03 0.09 0.1
lU
Bearing bush I.D. 50
a

rn
Guide piston (bore) I.D. 50

e
5501 7 Axial clearance, bearing bush axial 0.2 0.4 0.5

nt
5501 7a Total clearance between guide pisĆ axial 0.26 0.54 0.7
ton and roller with locating discs
rI
Fo


Lubricating Oil and Fuel Oil Booster Pump with EngineĆDriven Pumps
Lubricating Oil Pump
y
nl
O
se
3 3a 2
lU
95.7178
a
rn
Fuel Oil Booster Pump

4
e
nt
rI
Fo
95.7179
4 4


Lubricating Oil and Fuel Oil Booster Pump with EngineĆDriven Pumps

Key No.
Group

mm mm
7101 1 Shaft O.D. 75

+ 0.020
y
7101 2 Total clearance between pump axial 0.20 0.296 0.4
transport wheels and pump housing
nl
7101 3 Tooth backlash between pump drivĆ tooth backlash 0.16 0.32 0.4
O
ing gear wheel and driving gear
wheel on crankshaft
7101 3a Tooth backlash between pump tooth backlash

transport wheels
se 0.34 0.49 0.55
lU
Fuel Booster Pump

a
7102 4 Cog wheel shaft O.D. 40

rn

0
e
nt
7102 5 Total clearance between cog wheels axial 0.10 0.15 0.20
and pump housing
rI
Fo

wheel on crankshaft
7102 7 Tooth backlash between cog wheels tooth backlash 0.10 0.20 0.25
Wärtsilä Switzerland Ltd 31 L-Mot. / 4.97


Cylinder Cooling Water Pump with EngineĆDriven Pumps
y
nl
O
2 se
5
alU
e rn
nt
rI
Fo
1 95.7180


Cylinder Cooling Water Pump with EngineĆDriven Pumps

Key No.
Group

mm mm
Cylinder Cooling Water Pump
7103 1 Shaft sleeve O.D. 70

+ 0.095
Clearance (shaft nut tightened) radial 0.075 0.124 0.15
y
7103 2 Axial clearance between bearing axial 0.34 0.48 0.6
bush and pump drive gear wheel
nl
(shaft nut tightened)
O
7103 3 Tooth backlash between pump tooth backlash 0.16 0.32 0.4
drive gear wheel and driving gear
wheel on crankshaft
7103 4 Impeller O.D.

se 188
lU
Pump housing I.D. 188.3 + 0.1
0
a
rn
7103 5 Impeller O.D. 180
Inlet cover I.D. 180.3 + 0.1

0
e

nt
rI
Fo


Raw Water Pump with EngineĆDriven Pumps
y
nl
O
2
se
lU
4
a
e rn
nt
rI
5
Fo
95.7181
1 3


Raw Water Pump with EngineĆDriven Pumps

Key No.
Group

mm mm
Raw Water Pump

+ 0.095
y
7104 2 Axial clearance between bearing axial 0.34 0.48 0.6
bush and pump driving gear wheel
nl
(shaft nut tightened)
O
Pump housing I.D. 210.3 + 0.1

0
Clearance
se
radial 0.350 0.496
lU
Suction cover I.D. 195.3 + 0.1

0
a

rn
e
wheel on crankshaft
nt
rI
Fo


Fuel Nozzle Cooling Water Pump with EngineĆDriven Pumps
y
nl
O
se
a lU
ern
nt

rI

Fo
95.7182
3 2 1


Fuel Nozzle Cooling Water Pump with EngineĆDriven Pumps

Key No.
Group

mm mm
y
Fuel Nozzle Cooling Water Pump
nl
O
+ 0.05
7105 2 Axial clearance between driving

gear wheel and bearing bush
axial
se 0.30 0.44 0.6
lU
7105 3 Tooth backlash between pump tooth backlash 0.16 0.32 0.4
driving gear wheel and driving
a
gear wheel on crankshaft

e rn
nt
rI
Fo
Wärtsilä Switzerland Ltd 37z 1995

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K OIL PRESSURE 600 + 20 0 bar 180-190 Nm 250 Nm O 300 Nm Joint faces to be dry
O 540 Nm With engine-driven pumps:
Control dimension L = 1.4 + 0.1 mm For checking: Flange must be touching
--
See procedure for control dimension cylinder cover Tightening instructions given on
O 22 Nm
the separate pump assemblies
O 70 Nm
Elongation of bolt *
590 Nm L = 0.39 + 0.02 mm. Oil pressure
0355--1/A1
--
3.00 / V--Mot.
100 bar - equivalent to 2300 Nm
0 Nm
O 140+ 10
O 250 Nm
O 28 Nm
M16 O 220 + 20
0 Nm
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M12 O 90 + 10
0 Nm
O 290 Nm Alternative design

130-150 Nm Joint faces to be dry
K OIL PRESSURE 600 + 20 0 bar
O 600 Nm Control dimension
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L = 1.0 +-- 0.1 mm
See procedure for control dimension
O 350 Nm
780 Nm Read off power
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multiplier 220 Nm
Control: Gap clearance = 0
Pre tightened with 150 +

e 1230 Nm Read off power
multiplier 350 Nm
-- 10 Nm 150 Nm
Completly tightened with a torque O
angle of 60 ... 65
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4
a O Pretightening with 120+ 20
0 Nm
Followed by final tightening with an
`
angle of 90 -- mark on collar
Maintenance
O 50 ... 100 Nm
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K OIL PRESSURE 600 + 20
0 bar Control dimension L = 0.5 + -- 0.1 mm
Control dimension L = 0.9 + -- 0.1 mm
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Pretensioning to 200 bar
K OIL PRESSURE 600 + 20 0 bar See procedure for control dimension
Pretensioning to 200 bar
O 50 ... 100 Nm
O
O 350 Nm
740 Nm
2060 Nm
Read off power multiplier 590 Nm Oil pressure 100 bar (2300 Nm)
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PROCEDURE FOR OBTAINING THE ’CONTROL DIMENSION’ OF HYDRAULICALLY
100 bar for hydr. cylinder with a piston TENSIONED STUDS
* area of 6.41 cm2 HYDR. JACK
For hydr. cylinder with a different piston area 1. Pretensioning pressure on hydr. jack 100 bar (Note! stud of lower connecting
the oil pressure should be determined acc. to rod bearing and main bearing pretensioned to 600 bar to be released
641 to 200 bar). Nut to be tightened firmly. Pressure to be released to 40 bar. X
95.7549 the formula P (bar) =
new piston area in cm2
1 X
2. Protrusion ’X’ to be determined.
On first assembly of engine, all bolt connections which are coated 3. Tensioning of studs to 600 bar, nut to be tightened firmly.
MOLYKOTE PASTE G-n O OIL LUBRICATION K NO ADDITIONAL LUBRICATION with MOLYKOTE paste G-n have to be tightened to instructed torque Pressure to be released to 40 bar. PISTON
ZA40S
On threads and contact On threads and contact (Anti-corrosion oil can remain values, subsequently to be loosened again. Afterwards the contact
4. Protrusion ’X1’ to be determined. CYLINDER
Wärtsilä Italia S.p.A.

surfaces of bolts and surfaces of bolts and in thread) surfaces have to be recoated with MOLYKOTE G-n and to be tigh-
nuts. nuts. tened to instructed torque values again. 5. Control dimension L = X1-- X
Taking Lubricating Oil Samples for Laboratory Analysis
In the course of time, even the best quality lubricating oil tends to change it properties due to ageing, oxidation and conĆ
tamination. Therefore in intervals of approx. 3000 operating hours a sample should be taken from the engine lubricating
oil and sent to a laboratory for analysis. The sample must be taken from the oil in circulation and at normal service temĆ
perature from a cock specially fitted for this purpose, and which is situated at the inlet of the main lubricating oil pipe into
the engine.
Before taking the sample, drain about 2 litres into a container to remove any possible dirt accumulation in the drain cock.
Now remove the sample oil (about 1 litre) from the engine into an absolutely clean container (glass is best).
Mark the container with the oil sample with the following data:
- Name of Vessel or Plant
- Engine type
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- Engine No. or cylinder No.
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- Date of sampling
- Operating hours of lubricating oil and of engine
- Oil brand
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Monitoring the lubricating oil
The condition of the lubricating oil charge or its alteration during operation can be assessed on the basis of some analysis
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data. With regular checks a deterioration can be detected at an early stage and remedial measures taken.
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The test should at least cover the following characteristics:

- Viscosity
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- Flash point
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- BN
- Insolubles
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- Water content and nature of water

Possibly also contamination by fuel and metal content might be included.
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The significance of such analysis results can best be assessed if they are considered as a whole and in relation to the past
analytical history of the oil.
In the course of time, even the best quality lubricating oil changes its properties in such a way that a change of the oil
charge must be considered. However, it is not possible to give a fixed time interval for this purpose since this is influenced
by the operating conditions and the efficiency of the oil treatment.
A rather sudden change of one or the other of these parameters can indicate abnormal operating conditions or failures
in the system. In such a case it would be of little help just to change the oil without investigating the cause.
The values for used lubricating oil indicated in the relevant group 0110-1 of the Operating Manual are given for general
guidance. Normally, the oil is still fit for further use if the parameters are within the limits indicated.

ZA40S Betrieb Group1
Group 1
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Wärtsilä Switzerland Ltd 1

Engine Housing (Frame)

Replacement of Cylinder Head Studs
Tools: Key to Illustrations:

Spanner 1 Upper edge of engine DF Sealing surface
Cleaning materials housing RR Annular space
2 Cylinder head stud
3 Sealing compound
The cylinder head studs 2, studs for short, must be protected against corrosion at the lower end. The annular space 'RR'
and the stud shank must be fully sealed off with a suitable sealing compound, without cavities, up to about the level of the
upper edge of the engine housing 1 (see illustration).
Remark - No filling material may be added to the sealing compound.

- Only use a compound which will allow the studs to be unscrewed again without difficulty.
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Working procedure during fitting and sealing
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- Other than the corrosion protection oil already supplied, no lubricant or 2
locking agent may be applied to the threads of the stud 2.
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1
- Thoroughly clean and deĆgrease the sealing surfaces 'DF' before fitting 3
(e.g. with white spirit).
turer's instructions.
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- Prime the sealing surfaces 'DF' with primer according to the manufacĆ
DF
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- Screw in the studs and tighten with a torque of 50-200 Nm. Utilize alĆ
ways stud driver or two locked nuts. Tools like pipe wrench etc. which
would damage the stud shank must never be used. RR
- As a sealant we recommend the following two component silicon comĆ
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pounds.
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- Fill the annular space 'RR' completely. In order to allow the sealing
compound to be poured above the level of the top of the engine housing
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1, a ring of cardboard, putty or similar having an internal diameter of

about 60 mm has to be laid around the stud shank until the sealing comĆ
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pound has fully set. This is particularly important for ZAVĆS engines.
95.7191
- The ring has to be removed after hardening.
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Recommended sealing compounds and primers

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Type description No. of Hardener Primer Supplier

of sealant components
RTVĆME 622A 2 ME 622B G 790 Wacker Chemie (Switzerland) Ltd.
Lautengartenstr. 23
PO Box 4002 Basel
CH-4052 Basel BS
Polastosil M56 2 OLĆ1 PĆ3 Polish product
Silcoset 105 2 A or D no type description or OP Wachendorf Ltd.
Auf dem Wolf 17
PO Box 4002 Basel
CH-4052 Basel BS
Similar products from other suppliers may be used.

Sealing compound requirements
Required properties:
- nonĆacidic, e.g. acetic acid;
- resistant to oil, diesel oil, heavy fuel oil, water at a continuous temperature of about 100 _C;
- short hardening time (approx. 24 hours);
- flows easily so that the annular space will be completely filled without cavities;
- binds well to primed metal surfaces;
- simple preparation and mixing;
- minimum to not shrinkage;
- the external surface may not harden with porosity;
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- the sealing compound must remain sufficiently elastic so that the stud bolts may be unscrewed at any time.
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Loosening and PreĆTensioning of the Transverse Tie Rods and Main Bearing Studs

1 Hydraulic hand pump 9408.02 1 Bearing cover 12 Round nut to item 3
with accessories 2 Engine housing 13 Cylinder for hydr. jack
2 HP hoses 9408.09 *3 Transverse tie rod 14 Shaft seal ring
1 Feeler gauge 9408.15 *4 Main bearing stud 15 Piston seal ring
1 Depth gauge 9408.16 5 Round nut to item 4 16 Piston for hydr. jack
2 Hydr. jacks 9410.01 6 Cylinder for hydr. jack 17 OĆring
1 Round bar 9410.01a 7 Piston for hydr. jack 18 Protection cap
1 Lifting device for hydr. 9412.10 8 Shaft seal ring
preĆtensioning jacks 9 Piston seal ring * Tightening according to
2 Hydr. jacks 9427.01 10 OĆring instructions
1 Round bar 9427.01a 11 Disc
1 Special spanner 9431.03
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To loosen and preĆtension transverse tie rods and main bearing studs for the removal and fitting of the main bearings
proceed as follows:
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Removal Fitting
1. Loosen both transverse tie rods
simultaneously
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1. Press bearing cover upwards (group 1201-2)
and hand fit round nuts
2. Loosen both main bearing stud nuts 2. ScrewĆin transverse tie rods
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simultaneously
3. Unscrew transverse tie rods 3. PreĆtension both main bearing stud nuts
simultaneously
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4. Lower bearing cover (group 1201-2) 4. PreĆtension both transverse tie rods
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simultaneously
Remarks
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- If all the crankshaft main bearings must be removed, loosen first all the transverse tie rods. If only one of the main
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bearings must be removed, loosen the transverse tie rods of the specific bearing and also the transverse tie rods in the
immediate vicinity, otherwise it is difficult to lower and later lift back the bearing cover.
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- When screwingĆon the piston 16 or 7 of the cylinder 13 or 6 respectively of the preĆtension jack (Fig. 'A1' and 'A2'), the
oil is being pushed back to the hydraulic hand pump. To permit the oil to flow back open the relief valve of the hydrauĆ
lic hand pump 9408.02 and connect the preĆtensioning jacks with the hydraulic hand pump by HP hoses.
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If you want to screw the piston on without draining the oil to the hydraulic hand pump open the nonĆreturn valve on
the hose socket of the preĆtensioning jack by pressing it inwards. The oil will then flow out.
- Before actuating the hydraulic hand pump make sure that the hose couplings are all completely tightened otherwise
the nonĆreturn valve may not open, preventing oil from reaching the preĆtensioning jacks, thus not achieving correct
preĆtensioning.
L o o s e n i n g the transverse tie rods
Working procedure: (Fig. 'A' and 'A1')

- Remove protection cap from transverse tie rod.
- Clean connecting surface of the disc 11 and screw one preĆtensioning jack 9427.01 on each opposing transverse tie rod
3, till the cylinders 13 land on the discs 11.
- Using special spanner 9431.03 screw the pistons 16 into the cylinders until they land.
- Screw both preĆtensioning jacks back again until a gap of 2 mm appears between the cylinder 13 and the discs 11.

- Build up a pressure of 600 to 620 bar with the hydraulic hand pump 9408.02 and maintain this pressure constant until
the two round nuts 12 have been loosened (with the round bar 9427.01a) by 4-5 hole spacings on the nuts circumferĆ
ence.
- Relieve the pressure by opening the relief valve on the hydraulic hand pump, until the pressure gauge shows 'zero'.
- Remove preĆtensioning jacks and also the round nuts.
L o o s e n i n g the crankshaft main bearing studs
Please refer to notes on the obverse page!
Working procedure: (Fig. 'A' and 'A2')

- Use lifting device 9412.10 (Fig. 'B') to screw one preĆtensioning jack each onto the two main bearing studs 4 until the
jack cylinders 6 are resting against the bearing cover 1.
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- ScrewĆin the pistons 7 with the round bar 9410.01a until they land.
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- Screw back both preĆtensioning jacks until a gap of 2 mm appears between the cylinder 6 and the bearing cover 1.
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- BuildĆup a pressure of 600 to 620 bar with the hydraulic hand pump 9408.02 and keep pressure constant until you have
unscrewed both round nuts 5 by 4-5 hole spacings (on nut circumference) by using the round bar 9410.01a.
- Relieve the pressure by opening the relief valve on the hydraulic hand pump, until the pressure gauge shows 'zero'.
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- Remove the preĆtensioning jacks with the aid of the lifting device 9412.10 and screw the two round nuts 5 by about 130
to 140 mm downwards! (For the further procedure to lower the bearing cover please refer to group 1201-2).
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Attention
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It is important to unscrew the round nuts as described for both the transverse tie rods and the bearing cover studs. If the
round nuts are unscrewed too much, the jacks cannot be removed as they jam against the round nuts.
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If the round nuts are unscrewed too little, they cannot be loosened after releasing, as the transverse tie rod studs or main
bearing studs are still under preĆtension.
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P r e Ć t e n s i o n i n g main bearing studs

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Conditions at start of preĆtensioning:

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- The bearing covers are fitted according to the instructions in group 1201-2 and are held by two round nuts 5.
- The transverse tie rods of the respective bearing as well as of the neighbouring bearings are not yet preĆtensioned.
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- The threads of the main bearing studs must not be lubricated with MOLYKOTE paste.
Working procedure of preĆtensioning:

- After the bearing cover is pressed upwards till fully seated against the engine housing (see group 1201-2) and held in
place by both round nuts 5, screw the two preĆtensioning jacks 9410.01 onto the two main bearing studs with the aid of
the lifting device 9412.10 (Fig. 'B') till their cylinders 6 are resting against the bearing cover 1.
- Connect the preĆtensioning jacks to the hydraulic hand pump 9408.02 with the HP hoses 9408.09, open relief valve
and screw the pistons 7, using round bar 9410.01a, into the cylinders 6 until they land.
- Close the relief valve of the hydraulic hand pump and preĆtension the main bearing studs initially at a pressure of 600
bar. Hold this pressure constant. Subsequently the pressure has to be reduced to 200 bar and kept at this level, till the
round nut 5 has been tightened firmly till full seating (check seating with the feeler gauge). With the above mentioned
procedure a full seating of all bearing components is ensured.

- Release pressure to 40 bar and measure the protrusion 'X' on the jacks 5
and note carefully (please refer to adjacent figure).
- Raise the pressure to 600 bar and hold constant until the round nuts have 6
been tightened with the round bar for full seating (check seating with the
feeler gauge).
4* 7
- Release the pressure to 40 bar and measure the protrusion 'X1' and note
it carefully.
- The difference between protrusions 'X1' and 'X' should be 1.2 ± 0.1 mm.
These measures serve as a safety check of the hydraulic preĆtensioning X
method.
- When the measured elongation is approximately correct, remove the X1
preĆtensioning jacks with the lifting device 9412.10.
- For extra safety establish the vertical bearing clearance. 95.7063
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P r e Ć t e n s i o n i n g the transverse tie rods
Conditions at start of preĆtensioning:
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3* 18 12 11
- Main bearing studs must be tightened according to instructions.
- The thread of the transverse tie rods must not be lubricated with MOLYĆ
KOTE paste. se
- OĆring 17 and disc 11 are fitted and the round nuts 12 are screwed onto
17
the two opposing transverse tie rods requiring preĆtensioning (please reĆ
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fer to adjacent figure).
- The contact face of the disc 11 is clean.
Remark The adjacent figure shows a transverse tie rod with

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mounted protection cap 18.

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Working procedure of preĆtensioning:

- Screw one preĆtensioning jack 9427.01 onto each of the two transverse
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tie rods until their cylinders 13 are fully seated on the discs 11. 95.7192
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- Open relief valve of the hydraulic hand pump and screw the piston 16 of
the preĆtensioning jack, with the aid of special spanner 9431.03, into the
cylinders 13 until they are fully seated.
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- Close the relief valve of the hydraulic hand pump and preĆtension the
transverse tie rods initially with 100 bar. Hold this pressure until you
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have tightened the round nuts 12 with the round bar until they are fully
seated (check seating with the feeler gauge). X1
- Release pressure to 40 bar and measure the protrusion 'X' on both preĆ
tensioning jacks and note it carefully (please refer to adjacent figure). 12 13 16
- Raise the pressure to 600 bar and hold it constant until the round nuts 12 X
are tightened till fully seated (check seating with feeler gauge).
- Release the pressure to 40 bar and measure the protrusion 'X1' and note
it carefully.
- The difference between protrusions 'X1' and 'X' should be
on ZALĆS engines 0.7 ± 0.1 mm
on ZAVĆS engines 0.9 ± 0.1 mm
when the preĆtension of the transverse tie rods is correct. These meaĆ
sures serve as a safety check of the hydraulic preĆtensioning method.
- If the established value is practically correct, remove the preĆtensioning 95.7063
3*
jacks.
- Grease the thread lightly to prevent corrosion and fit protection cap 18.

B 9412.10 A1 9427.01
9410.01 3 16
10
11
12 13 13 16
16
15
14
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95.7193
95.7194
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A
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9408.09
9427.01
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9408.09
9431.03
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9410.01 9410.01a
95.7195
9408.02 8
A2 1
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5
6 9410.01
6 7
95.7196
9 7


Replacement of Crankshaft Main Bearing Shells (Standard Shell Bearing)

1 Hydraulic hand pump 9408.02 1 Main bearing cover 19 Counterweight
with accessories 2 Engine housing 20 Upper shell
2 HP hoses 9408.09 3 Transverse tie rod 21 Lower shell
2 Hydraulic jacks 9408.36 4 Main bearing studs 22 Crankshaft
1 Hydraulic jacks 9408.38 5 Round nut 23 Oil sump
2 Supports 9410.02
1 Segment ZAVĆS 9412.01
1 Segment ZALĆS 9412.08
Condition at the start of work
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- Transverse tie rods and main bearing studs of the bearing to be removed as well as the transverse tie rods of the two
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adjacent main bearings have been slackened (refer to group 1201-1).
- The transverse tie rods oft he bearing to be removed have been unscrewed and removed.
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Working procedure
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- Screw the two round nuts 5 downwards, until a space of about 130 mm has been provided between the lower edge of
the bearing cover and the connecting face of the nut (see Fig. 'A').
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- Fasten the two supports 9410.02 to the bearing cover 1 with two screws.
- Place two hydraulic jacks 9408.36 between the supports and the counterweight 19, and connect them to the hand
pump 9408.02 by HP hoses.
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- Actuate the pump to push the bearing cover from its guided position. After pressing it for about 110 mm the bearing
cover will slide down onto the round nuts 5 by its own weight.
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- Remove the two hydraulic jacks and the two supports 9410.02 from the engine. The supports must on no account be
left fitted to the bearing cover as the counterweights 19 would knock against them causing damage, when turning the
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engine (Fig. 'B' and 'C').

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- Place a hydraulic jack 9408.38 under the bearing cover and connect it to the hand pump. The bearing cover and the
bottom of the oil sump have been provided with drilled recesses into which the hydraulic jacks fit.
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- Actuate the pump to lift the bearing cover sufficiently off the round nuts to permit unscrewing them for the main
bearing studs.
- Open the venting valve 'EV' of the hand pump allowing the bearing cover to descend as much as the jack permits.
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Removing the bearing shells (Fig. 'C')
- In this position, the lower bearing shell 21, descending with the bearing cover, can be checked and if necessary be
removed.
- The upper bearing shell 20 can be pushed out using the segment 9412.01 or 9412.08. Clean the segment well, press it
against the journal and at the same time upwards against the bearing shell.
Attention Safeguard the upper shell by hand, to prevent it from falling out when pressing it out with the segĆ
ment.
Judging the bearing shells for possibility of reĆuse
the possibility of reĆusing a bearing shell depends in principle on the condition of its running surface. Please refer in this
matter to the recommendations in group 0003-2.

Crankshaft main bearing shells for undersize journals
If the surface of the journal becomes rough and requires regrinding, thicker bearing shells with undersize bores are reĆ
quired. The table below indicates the diameters to which the journals must be ground to fit stocked undersize bearing
shells: (All dimensions are in mm).
Undersize Shaft diameter Shell thickness Vertical bearing Bearing Design

bore diameter
refer to Clearance Key No.
(vertical)
diameter
(Shell fitted)
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0,4 349.6 0 10.12 0 349.6 + 0.29 200
-0.06 - 0.02 + 0.21
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0,8 349.2 0 10.32 0 349.2 + 0.29 201
- 0.06 - 0.02 se + 0.21
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1.2 348.8 0 10.52 0 348.8 + 0.29 202
ZALĆS
-0.06 - 0.02 + 0.21
Z
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2.0 348 0 10.92 0 0.21-0.35 348 + 0.29 203

- 0.06 - 0.02 + 0.21
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3.0 347 0 11.42 0 347 + 0.29 204

- 0.06 - 0.02 + 0.21
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0 0 + 0.29
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4.0 346 11.92 346 205

- 0.06 - 0.02 + 0.21
5.0 345 0 12.42 0 345 + 0.29 206

- 0.06 - 0.02 + 0.21
0.4 369.6 0 10.12 0 369.6 + 0.31 200

-0.06 - 0.02 + 0.21
1.2 368.8 0 10.52 0 368.8 + 0.31 202
-0.06 - 0.02 + 0.21
ZAVĆS
0.21-0.37
3.0 367 0 11.42 0 367 + 0.31 204
-0.06 - 0.02 + 0.21
365 0 12.42 0 365 + 0.31
5.0 -0.06 - 0.02 + 0.21 205

Fitting the bearing shells (Fig. 'C')
Remark Never reduce the clearance by filling the mating faces of the bearing shells. The ends of the bearing
shells protrude somewhat over the faces of the bearing cover or the bearing saddle. This is meant to
be and is absolutely necessary!
- Push the upper bearing shell, with well lubricated running surface but dry back, by hand between journal and bearing
saddle bore, until its mating surfaces are equally spaced on both sides. If the shell cannot be easily pushed in, assist the
fitting by pressing the crankshaft slightly in the required direction using a hydraulic jack.
- Place the lower bearing shell with dry back and well lubricated running surface into the bearing cover.
- Using the hydraulic jack 9408.38, press the bearing cover 1 upwards to the stop in the engine housing.
- Fit the two round nuts 5 onto the main bearing studs 4 till they are landed on the bearing cover. Remove the hydraulic
jack.
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- Fit the two transverse tie rods 3 into the bearing cover 1.
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- Proceed with preĆtensioning the main bearing studs and the transverse tie rods in accordance with the instructions in
group 1201-1.
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1995
A
1201–2/A1
19 19
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EV 9408.02 19
I 9408.09
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9408.09
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9408.36 9408.36
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2
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9410.02
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4
a 9410.02 3
3
Maintenance
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95.7197
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4 5 1 22 1 22
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23
ZA40S
Wärtsilä Switzerland Ltd

ca. 130mm
20
21
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5 1
23
9408.38
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9408.02 EV
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C 20
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9412.01
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9412.08
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21
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23 1
9408.38
95.7198
9408.02 EV


Replacement of Bearing Shells and Thrust Ring Halves

1 Hydr. hand pump 9408.02 1 Bearing housing lower part 15 Screws
1 Branch piece 9408.03 2 Upper thrust ring half 16 Oil containing piece
1 Pressure gauge 9408.04 2a Lower thrust ring half 17 Fitted bolts Fig. 'A'
2 HP hoses 9408.09 3 Bearing shell 18 Through bolts and 'D'
1 Torque wrench 9408.17 4 Thrust bearing shaft end 23 Dial gauge
1 Force amplifier 9408.19 5 Positioning pins 24 Flywheel Fig. 'B'
1 Segment 9412.08 6 Oil catcher upper part 25 Hydr. jack 9421.06 and 'C'
1 Mandrel 9412.09 6a Oil catcher lower part * 26 Stud
1 Hydraulic jack 9421.06 7 Bearing housing upper part 27 Nut
2 Hydraulic jacks 9433.01 8 End cover 28 Piston
1 Round bar 9433.01a 9 Main bearing cover 29 Cylinder
1 Eye bolt M16 10 Camshaft drive gear wheel
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1 Dial gauge with mounting pedestal * 11 Screws
* 12 Thrust bearing screw D Apply sealing compound
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13 Positioning pin (long) S Clearance
14 Positioning pin (short) GL Threaded hole
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I-I II - II
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2 6 11* 15 7 GL 8 2 3 10 16
11* I
12*
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12*
18
D
a
17
III
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III
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13
D 14
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5 I
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2a 6a D 1 2a 3 4 9
III - III
Remark Depending on the execution, 11*

hydraulically tensioned studs D 5
26 are used instead of thrust
bearing screws 12.
Pay attention to the section II
'Loosening and tensioning of 5
studs 26'! 95.7199
II

Check the condition of the bearing shells and thrust ring halves in accordance with the instructions in the Maintenance
Schedule or according to the prescribed intervals of the classification society. Within a period of 5 years all the bearings
must have been inspected at least once.
Whether a bearing shell may be reĆinstalled, depends mainly on the condition of its running surface. Please refer to
group 0003-2 for respective information.
Thrust ring halves
For these parts the same recommendations apply as for the bearing shells, i.e. only such thrust ring halves may be reĆ
used, which are in good condition. It is also of the greatest importance that the ring halves are refitted in the same locaĆ
tion from where they were removed.
When removing the thrust ring halves, the shaft shoulders must also be inspected; they must be smooth and clean.
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Oversize thrust ring halves
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If the shoulder of the thrust bearing shaft, which was subjected to the load during operation, has become rough and has
therefore to be reĆmachined, then oversize thrust ring halves have to be fitted.
When reĆmachining the shoulder as little material as possible should be removed, but the distance between shaft shoulĆ
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ders must, after machining, correspond to one of the ('steps') dimensions 'L' in the table below.
Oversize thrust ring halves have to be selected in accordance with the dimension 'L' and they have, without fail, to be
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fitted on that side where the shoulder had been reĆmachined! Shaft shoulder and locating ring half must be marked acĆ
cordingly.
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Oversize Length 'L' Axial clearance

Index
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mm mm mm
200 0.8 150.8 + 0.04 0.20 - 0.44
0
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201 2.0 152 + 0.04 0.20 - 0.44

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0
202 4.0 154 + 0.04 0.20 - 0.44
0
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Re-machined
shaft shoulder
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Thrust Bearing Shaft
95.7200
Standard ring half

Oversize ring half
on re-machined side Thickness: 15 –– 0.10
0.15

Removing the bearing shells and the thrust ring halves
Working sequence: (follow Fig. 'A' on preceding page)

- Loosen the screws 15 of the oil catcher upper part 6 and remove. Separate oil catcher upper part 6 from the bearing
housing upper part 7; use jack screws if necessary.
- Remove all the screws 11 of the bearing housing upper part 7 and loosen the two thrust bearing screws 12 in two or
three equal steps and remove.
- Fit an eye bolt (M16) into the treaded hole 'GL' in the bearing housing upper part 7 and lift the housing upper part off
(about 80 kg).
- Remove both upper thrust ring halves 2 as well as the upper bearing shell.
- Adjust a (micrometer) dial gauge 23 on the top of the thrust bearing shaft (Fig. 'B'). Place a hydraulic jack 25 under the
flywheel and with it lift the shaft by about 0.15 mm (Fig. 'C'). Take care that the shaft remains radially in the centre!
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- Use segment 9412.08 - pressing it against the shaft - to push the lower bearing shell out (Fig. 'B') and remove it.
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- Use mandrel 9412.09 to press both thrust bearing ring halves 2a out till you can lift them out.
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Attention Before you attempt to pull the lower bearing shell or the lower thrust ring halves 2a out, check and
ensure that the shaft does not push axially against one of the thrust rings. If necessary shift the crankĆ
shaft axially in the appropriate direction. The shaft must also be equally spaced in the centre radially,
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as otherwise the bearing shell is jammed and can only be removed with difficulty.
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I-I II
B C
23
24
a
9412.08
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9412.09
3
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9412.08
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25
II 2a
9412.09 9408.09
9408.02
I
9412.08 95.7201
3 2a

Fitting the bearing shells and the thrust ring halves (Fig. 'A', 'B' and 'C')
- Clean thrust bearing shaft 4 and the bore of bearing housing lower part 1 carefully, lubricate the shaft journal lightly.
- Check whether the bearing shells and the thrust ring halves are undamaged.
- Check whether the crankshaft is in such a position that sufficient space is available axially to fit the thrust ring halves.
If necessary shift the crankshaft slightly axially.
- Using hydraulic jack 25 under the flywheel lift it and the shaft until the (micrometer) dial gauge 23 mounted above the
shaft journal shows 0.15 mm (Fig. 'B'). Take great care that the journal is radially in the centre.
- Push the lower bearing shell as well as the two lower thrust ring halves by hand as far as possible between shaft journal
and housing bore. Ensure that the bearing surface of the thrust ring halves lie against the corresponding shaft shoulĆ
der.
- Press segment 9412.08 against the shaft journal and slip in the lower bearing shell until the dividing faces protrude by
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the same amount on both sides.
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- Slide both thrust bearing ring halves in with the aid of mandrel 9412.09 until the dividing faces protrude by the same
amount on both sides.
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- Release the pressure in jack 25 under the flywheel and remove the tools.
- Apply oil lavishly on the shaft journal; use new engine oil.
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- Apply sealing compound to the engine side of the bearing housing upper part. (Also a very thin coat of sealing comĆ
pound on the horizontal separating faces).
- Place the upper bearing shell 3 and the upper thrust ring halves 2 into the bearing housing upper part and secure them
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with the locating pins 5.
Fitting condition: Bearing shell on its rear side dry, on the running surface coated with oil, bore of the thrust bearing
housing upper part dry.
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Important! Before fitting them apply MOLYKOTE paste GĆn to the threads and landing faces of the screws 11
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and 12, as the tightening torque values are only valid if this lubricant is used.
- Fit bearing housing upper part 7 and fasten to the engine end plate with the screws 11 uniformly, at first only lightly
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with about 100 Nm.

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- Fit and tighten uniformly the two screws 12 in several equal steps with a torque wrench to 780 Nm. If you use the force
multiplier contained in the engine tools, the tightening value is 220 Nm.
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- Check that no clearance exists between the bearing housing upper and lower part.
- Tighten the screws 12 with a torque wrench to the final value of 1230 Nm or when using the force multiplier to 350 Nm.
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- Finally tighten the screws 11 also in several equal steps to the final value of 740 Nm.
- Measure the axial clearance of the crankshaft with the thrust ring halves fitted, by pressing the crankshaft with a hyĆ
draulic jack alternately into both end positions. The axial movement is measured with a dial gauge (please refer to
Clearance and Wear Table 0352-1).
- Finally lock the screws 11 in pairs with locking wire (Fig. 'A').

Fitting the oil catcher (Fig. 'D')
- Clean and degrease carefully front and horizontal separating faces of oil catcher upper and lower part (6 and 6a) and
apply sealing compound to these surfaces.
- Fit oil catcher lower part 6a first, locate with taper pins 14 and tighten with the screws.
- Place oil catcher upper part 6 into position, fit locating bolts 17 and through bolt 18.
- Apply LOCTITE to the treads of screws 15 and bolts 18 (refer to group 0003-1).
- Alternately tighten the nuts of bolts 17 and 18, then of screws 15, again nuts of bolts 17 and 18 in very small steps.
- The clearance 'S' between shaft and oil catcher should be about 1 mm all round.
D
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15
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D
18
6
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17
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17
II
II
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14 14
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S
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6a
I
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II - II
95.7202
17

Loosening and tensioning of studs 26 (Fig. 'E')
Loosening
- Clean the contact faces of the hydraulic jacks.
- Screw the hydraulic jacks 9433.01 onto the studs 26 till their cylinders 29 rest on the bearing housing upper part 7.
- Connect the hydraulic jacks by HP hoses 9408.09 with the hydr. hand pump 9408.02.
- Open relief valve on hydr. hand pump, and screw the pistons 28 of the hydraulic jacks in, till they land on the cylinders
of the hydraulic jacks (see Fig. 'E').
- Now turn the hydraulic jacks back a little until a gap of about 2ā-ā3 mm appears between the preĆtensioning jack and
the bearing housing upper part.
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- Build up a pressure of 600 bar (or a little more) with the hydr. hand pump and unscrew the two nuts of the studs by
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about 4ā-ā5 hole intervals.
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- Release the pressure to 'zero' and remove the hydraulic jacks.
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Tensioning
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- Clean the contact faces of the nuts 27, screw them on and tighten them with the round bar 9433.01a until landed.
- Screw hydraulic jacks 9433.01 onto the studs 26 till their cylinders 29 are landed.
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- Connect the jacks with the hydr. hand pump 9408.02 by the HP hoses 9408.09.
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- Open relief valve on hydr. hand pump, and screw the pistons 28 of the hydraulic jacks in, till they land on the cylinders
29 of the hydraulic jacks (see Fig. 'E').
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- Build up a pressure of 100 bar with the hydr. hand pump and keep this pressure constant.
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- Tighten the round nuts 27 with the round bar until they are firmly seated (check seating with feeler gauge).
- Release the pressure to 40 bar.
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- Measure protrusion 'X' of piston 28 and make a note of it (see Fig. 'E').
- Raise tensioning pressure to 600 bar. Keep this pressure constant and tighten the nuts 27 with the round bar until they
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are firmly seated (check seating).

- Release pressure to 40 bar and measure protrusion 'X1' of piston on both hydraulic jacks and make a note of it. When
the waisted studs are correctly preĆtensioned the elongation amounts to: X1 - X = 1.0 ± 0.1 mm.
- If the measured elongation deviates considerably from the above figure, repeat the whole tensioning procedure.
- Release the pressure to 'zero' and remove the hydraulic jacks.

E
X1
29
28
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26*
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27
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se 9433.01
26*
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27
a
7
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9408.09
9408.04
9408.02
00.7286
9408.03

Group 2
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Cylinder Liner
Measuring Wear and ReĆmachining of Cylinder Liner Bore

1 Measuring rail 9421.02 1 Cylinder liner
1 Measuring tool 9421.03 2 Top piston ring
1 Setting gauge 9421.03a
1 Wear ridge milling tool 9421.09
1 Carbon removing machine 9421.10
(for carbon removal in upper
part of cylinder liner)
1 Honing machine 9421.11
The wear of the cylinder liners should be checked during every overhaul or whenever a piston is removed. Always meaĆ
sure cylinder liners in situ and when engine is cooled down.
To permit comparisons with previous measures it is inevitable that measuring is always done in the same place and that
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the measured values are noted in a log.
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To this end always use the measuring rail 9421.02 (Fig. 'A') which is available in the engine tools. It is so designed that it
can simply be hooked over the top face of the liner. Measure at the four points A, B, C and D in the engine axis and at
right angles to it.
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Avoid measuring errors by preventing the measuring tool 9421.03 being exposed to large temperature variations. The
setting gauge 9421.03a must be used for calibrating the measuring tool.
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Generally the most important wear occurs at point 'A'. For maximum permissible inside diameter please refer to ClearĆ
ance Table group 0352-1.
1 9421.03 9421.02 9421.02

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A
125
a
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A 175
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B
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175
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C
360
00.7287

After a long operating time a soĆcalled wear ridge appears in the top part of the running surface. During overhaul this
wear ridge must be ground off carefully with the wear ridge milling tool 9421.09 without damaging the running surface in
any way. It is possible that the wear ridge must be removed to permit withdrawal of the piston. If this is the case, lower the
piston by barring the engine and cover the piston and the liner surface above it carefully to prevent any foreign particles
from penetrating between piston and cylinder liner.
For removal of the wear ridge on the cylinder liner milling tool 9421.09 must always be used. The removal of wear ridges
should be carried out after the first piston removal and after the first replacement of piston rings, whereby the machiĆ
ning has to be done as shown in Fig. 'B'.
A repetition of the machining of the wear ridge may be necessary after a longer operating period or after replacing a
piston.
After completing the reĆmachining, the cylinder liner bore must be cleaned very carefully in order to avoid scratch marks
on the piston.
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On cylinder liners which are provided with a fine thread in the uppermost portion, the hard combustion residue must be
removed prior to pulling the piston. For removal of the combustion residue the carbon removing machine 9421/10 must
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be used (Fig. 'C'). For this work the space above the piston has to be well covered, so that no combustion residue can
enter between piston and cylinder liner bore.
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In order to avoid damaging the fine thread it is necessary to carefully centre it in the cylinder liner 1, before starting maĆ
chine 9421/10.
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When removing combustion residue, be sure to pay attention not to damage the fine thread. Combustion residue within
the thread itself has not to be removed.
Avoid removing combustion residue by using wire brushes, scrapers, pointed utensils etc.
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After having removed the combustion residue, the inner diameter of the cylinder liner in the region of the fine thread
must measure Ø 400 +0
-0.1
mm.
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After having removed the combustion residue, the cylinder liner bore must be thoroughly cleaned.
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Should a piston have been removed and equipped with new piston rings and oil scraper rings, then the cylinder liner bore
must be honed with the honing machine 9421.11. Possible hard wear areas must be levelled by honing. During this work,
it isabsolutely necessary to prevent machining residues from entering the crankcase. To prevent this, the best means is to
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place a suitablle dirty oil catcher bowl into the crankcase of the respective cylinder.
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After honing, the cylinder liner bore has to be washed with clean Diesel fuel or kerosine using a clean paint brush.
Attention Reworking of the cylinder liner's running surface may only be carried out by honing. Under no cirĆ
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cumstances may the bore of cylinder liner be simply cylindrically rebored by turning out, as otherĆ
wise the guidance of the piston is impeded.
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Note For the utilization of the honing machine mentioned above, the working instruction of the respective
manufacturer must be followed.

B
Ø 402,5mm
after machining
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prior to machining
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TDC
1.5mm
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2
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2
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ern
C
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1 9421.10
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Ø 400 -0,1
0
1
95.7085

Cylinder Liner
Removing and Fitting a Cylinder Liner

1 Hydr. hand pump 9408.02 1 Cylinder liner 9 Screws
1 Branch piece 9408.03 2 OĆrings 10 Connecting rod head
1 Pressure gauge 9408.04 *3 Screw M20 11 Screws
2 HP hoses 9408.09 4 Centring piece 12 Screws
1 Torque wrench 9408.17 5 Screws 13 Counterweight
1 Device for lapping 9421.01 6 Engine housing
1 Pressure yoke 9421.04 7, 7a OĆrings * Tightening according
1 Suspension device 9421.08 8 Cylinder lubrication pipe to instructions
1 Fixing plate 9433.08
1 Shackle
1 Rope (capacity 1000 kg)
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Remark regarding runningĆin of new cylinder liners
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When one or more cylinder liners are replaced, these have first to be runĆin, whereby the instructions of the Operating
Manual in group 0300-1 'RunningĆin the Engine after an Overhaul' have to be followed.
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Preparatory work for the removal of a cylinder liner
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- Drain all the cooling water from the engine. Remove the cylinder head and withdraw the piston of the cylinder liner
concerned (see group 2701-1 and 3401-1).
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- Bar the crankshaft until the crank of the liner concerned stands in T.D.C.
- Cover the space below the cylinder liner concerned with clean cardboard or similar to ensure that no foreign particles
can enter the crankcase.
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Removal
- On engines equipped with pistons without inner lubrication, loosen pipe connections 8 and remove the banjo bolts
(Fig. 'A').
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- Loosen screw 3 of the centring piece 4 and remove it (Fig. 'A').

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- Turn the connecting rod head 10 to the position shown in Fig. 'B'.
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- Connect the jacking yoke 9421.04 by two HP hoses 9408.09 to the hydraulic hand pump 9408.02 and fasten it with the
screws 11 to the connecting rod head 10 as shown in Fig. 'B'.
- Turn the connecting rod head with fastened jacking yoke into the position as shown in Fig. 'C'.
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- At the same time fasten the fixing plate 9433.08 by screws 12, as shown in Fig. 'A1', to connecting rod head 10. The
fixing plate must come to lie on counterweight 13. The fixing of the connecting rod head is necessary for safety reasons
in order to prevent an inadvertent turning of the connecting rod head with the pressure yoke fitted.
- Actuate the hand pump 9408.02 carefully paying attention that the yoke correctly mates the bottom of the cylinder
liner.
- Check again whether the screw 3 has actually been removed (Fig. 'A').
- Continue pumping and jack the cylinder liner out of its guide.
(Attention! The stroke of the jack in the yoke is only 54 mm)
- Mount the suspension device 9421.08 on the cylinder liner top and fasten it with the screws 9 (Fig. 'C' and 'E'). Watch
that the screws 9 mate with the holes in the cylinder liner collar.
- Fasten one shackle with the rope at 'AH' on the suspension device and pull the cylinder liner (about 450 kg) out (Fig.
'C').
- Remove the jacking yoke, the hydr. hand pump as well as the fixing plate 9433.08 from the engine.

- Place the removed cylinder liner on an even surface and remove the suspension device.
- Clean the landing surface on the engine housing and check whether it is damaged.
- Clean the guiding bores in the engine housing and if necessary smooth out with emery cloth.
Fitting
- Check whether the landing surface for the cylinder liner and the guiding bores in the engine housing are clean and
smooth.
- Smear the landing surface on cylinder liner/engine housing with sealing compound Hylomar SQ32/M or Golden HerĆ
metite.
- Equip the cylinder liner with new heat resisting OĆrings (please refer to Operating Instructions group 0328-1) and
smear these as well as the guiding surfaces 'F' in the engine housing with fresh engine lubricating oil.
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- Mount the suspension device 9421.08, fasten it with the screws 9 in the liner collar and lift the cylinder liner with the
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crane on shackle and rope at the suspension point 'AH' (weight about 450 kg).
- With the cylinder liner suspended, blow compressed air through the lubricating oil bores at the bottom (only for enĆ
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gine equipped with pistons without inner lubrication).
- Lower the cylinder liner slowly and carefully into the engine housing.
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- Before the cylinder liner mates the guide bores, turn it so that the centring piece 4 when further lowered will fit into
the bore provided on the camshaft side. With smooth and well lubricated guide bores 'F' and OĆrings, the cylinder
liner the cylinder liner will slide down under its own weight into the engine housing. If necessary tap the liner collar
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lightly with a lead hammer.
- Finally locate the liner with the screw 3 dipped in oil and attach cylinder lubricating pipes to the bottom end of the
liner (only for engine equipped with pistons without inner lubrication). Tighten the screw 3 with 150 Nm.
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- If necessary lap the sealing surface on the liner collar with lapping ring 9421.01 and lapping paste.
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- Actuate the hand crank of the cylinder lubricator and check that the oil issues from both lubricating holes in the releĆ
vant cylinder liner (only for engine equipped with pistons without inner lubrication).
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A I-I II
1 2
3*
4 6
II 5
7a
I I
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5 3* 4 1 7
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A1
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1
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1
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9421.04
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10 10
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9433.08
13
95.7075
13 12

E D C
9421.08
AH 9421.08 9421.08
2105–2/A1
1995 / L-Mot.
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9
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4
9 1
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9421.04
4 z
Maintenance
9421.04 B 10
9421.04
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F
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9408.09 O 10
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95.7203
11 9408.02 9408.03 9408.04

ZA40S

Cylinder Head
Removing and Fitting a Cylinder Head

1 Hand pump with accessories 9408.01 1 Nut 21 Soft iron gasket
1 Depth gauge 9408.16 2 Rocker arm cowling 22 Insert bush
1 Torque wrench 9408.17 3 Thread protecting cap 23 OĆrings
8 Hydraulic jacks 9427.01 *4 Cylinder head studs 24 Oil connecting piece
1 Round bar 9427.01a 5 OĆring 25 Screw
7 HPĆhoses 9427.02 6 Nut for item 4 26 Flange
1 Lifting device 9427.03 7 OĆrings 27 Screw
2 Special nuts 9427.04 8 Valve guides 28 Engine casing
2 Jacking screws 9427.09 9 Valve seat 29 Screw
1 Mandrel 9427.10 10 OĆrings 30 Centring pin
1 Cleaning tool 9427.11 11 Push rod cladding 31 Piston of hydr. jack
1 Lifting device 9427.34 12 OĆrings 32 Cylinder of hydr. jack
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1 Socket spanner 9427.57 13 Connecting piece 33 Hose coupling
Assorted spanners 14 Screws
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15 Tubular rubber ring
16 Push rod
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17 Cylinder head * Tightening according
18 HPĆfuel pipe to instructions
20 Cylinder liner
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A major overhaul includes a thorough check of the cylinder heads. This also covers an inspection of the cooling water
spaces. When treated cooling water is used these spaces generally remain clear. Untreated cooling water, however,
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usually causes scale formation which impairs the cooling effect. For the removal of this scale we recommend consulting a
specialist firm for chemical descaling.
The surfaces in contact with the combustion must be inspected for cracks. If cracks are suspected, and also after replacĆ
ing valve seats and insert bushes, the water spaces have to be subjected to a water pressure test (7 bar), (please refer to
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group 2701-6).
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Valve seats with water side leakage must be replaced. Damaged seat surfaces have to be reconditioned (please refer to
instruction in groups 2701-2 and 2701-3 respectively).
The OĆrings 7 of the valve guide bushes 8 must be replaced at each overhaul. The same applies to damaged or badly worn
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valve guide bushes 8 (please refer to group 2701-5).

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Leaking insert bushes 22, also badly damaged ones, must be replaced (please refer to group 2701-4).
Uneven or slightly damaged insert bushes 22 can be reconditioned with the aid of tool 9427.10 and the prescribed grinĆ
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ding/lapping paste (please refer to group 2701-4).

If the seating surface for the soft iron gasket between cylinder head and cylinder liner is damaged it can be reconditioned
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with the help of lapping device tool No. 9421.01 and grinding/lapping paste. The same tool can be used for seating surfaĆ
ces of cylinder head and cylinder liner.
R e m o v i n g a cylinder head
Preparations:
- Drain the cylinder cooling water from the engine and shut the shutĆoff cocks for the fuel valve cooling water.
- Bar the crankshaft to bring the piston of the respective cylinder to T.D.C. on the firing stroke. This means the inlet and
exhaust valves are closed.
- Loosen the nuts 1 of the rocker arm cowling 2 in even steps and lift the cowling 2 with the help of lifting device 9427.34
(please refer to Fig. 'J').
- Remove both push rods 16 and the screws 14 holding the connecting piece 13.

- Unscrew and remove HPĆfuel pipe 18 and plug the openings on the fuel valve as well as in the HPĆfuel pipe, using clean
cloth. Separate all other pipe connections (exhaust, air, etc.) from the cylinder head.
- Remove the thread protecting caps 3 and clean the thread of the cylinder head studs 4 and the area around the stud
nuts on the top of the cylinder head.
L o o s e n i n g the cylinder head stud nuts (Fig. 'C')
Remarks When screwing the pistons 31 of the jacks 9427.01 onto the stud thread (Fig. 'D') the oil is pressed
out of the cylinder and can return to the pump when the HPĆhoses are correctly connected to the
jack, whereby the nonĆreturn valve on the jack is opened. If this valve is pressed in by hand on the
unconnected jack the oil can flow out.
Do not start pumping before all the hose couplings are correctly and firmly joined otherwise oil may
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not enter the jacks as the nonĆreturn valve does not open.
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Working procedure:
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- Fit a jack 9427.01 on each of the 8 cylinder head studs, until the cylinders 32 touch the cylinder head of the engine at
'S'. Continue screwing the pistons 31 in until they are at 'B' flush with the jack cylinders 32. Then unscrew the complete
jacks until at 'S' a gap of about 2 mm exists (observe the notes above).
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- Connect all the short HPĆhoses 9427.02 according to Fig. 'C' and connect the two long HPĆhoses to the hand pump.
- Actuate the pump and preĆtension the eight cylinder head stud with 600-620 bar and hold this pressure constant.
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- Unscrew all the nuts 6 by 4 5 hole spaces.
- When all the nuts are in this position release the pressure to 'Zero', by opening the relief valve on the pump.
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- Disconnect the hose couplings between the eight jacks and remove jacks and hoses. If they are not immediately reĆ
used, close the connecting openings with closing caps.
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- Remove all the nuts 6.

- Apply the jack screws 9427.09 and jack the cylinder head off the cylinder liner (Fig. 'G').
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- The cylinder head freed, fit the lifting device 9427.03 on the studs of the rocker arms cowling 2 and lift the cylinder
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head off by crane (please refer to Fig. 'K' for ZALĆS and Fig. 'K1' for ZAVĆS engines).
- Cover the open combustion space with a wooden or cardboard lid to prevent foreign bodies falling in. The same
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should be done with the openings of the push rod claddings.

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F i t t i n g a cylinder head
Preparations: (Fig. 'A' and 'B')

- Clean the seating face on cylinder liner and cylinder head thoroughly. Any unevenness is to be ground off with grindĆ
ing device 9421.01 and grinding paste.
- Place a new cylinder head soft iron gasket on the cylinder liner. (It should be a principle practice not to reĆuse any
gaskets, joints or OĆrings etc.) Check whether the gasket lies flat.

- Place new OĆrings 10 into the grooves at the collar of the cylinder liner. Smear these before with engine lub. oil. AlĆ
ways use only original OĆrings corresponding to our specification, see group 0328-1.
- Ascertain that all the cylinder head studs 4 are screwed in until fully seated.
- Smear the guide area on the cylinder liner collar and the inner side on the bottom of the cylinder head lightly with
engine lub. oil.
- In order to have the oil connecting piece 24 (see Fig. 'E') correctly centred when cylinder head 17 is placed in position,
loosen first screws 25 and 27 before positioning the cylinder head.
- Check the drilling in the cylinder head 17 for centring pin 30 and the drilling in flange 26 for the oil connecting piece 24
for cleanliness. Smear the drilling in the flange and the OĆrings on the oil connecting piece lightly with engine lub. oil.
- Check combustion space for cleanliness and remove any foreign particles.
Working sequence:
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- Fit the lifting device 9427.03 on the cylinder head and attach it to the crane. Position of rope loop as per Fig. 'K' for
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ZALĆ engines' and 'K1' for ZAVĆS engines.
- Lower the cylinder head slowly over the cylinder head studs until the centring pin 30 and the oil connecting piece 24
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have mated. If the cylinder head does not slip down under its own weight to rest on the cylinder head gasket on the
cylinder liner apply the two special nuts 9427.04 on two opposite studs. Tighten these nuts alternately with the socket
spanner 9427.57 and a ratchet or a spanner until the cylinder head is seated (please refer to Fig. 'H').
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- After fitting the cylinder head tighten screws 25 and 27 of the oil connecting piece 24 again (Fig. 'E').
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P r e Ć t e n s i o n i n g the cylinder head studs
- Clean the seating surface of all the nuts 6. Lubricate the thread of the studs and the seating surfaces with oil, do not use
MOLYKOTE paste.
a
- Screw down, by hand, all the nuts 6 until they seat and only then tighten them with round bar 9427.01a.
rn
It is important that all the nuts run freely on their threads and that they can be screwed down by hand until seated.
- Fit all the hydr. jacks 9427.01 on the cylinder head studs, screw them down until their cylinders 32 are seated on the
cylinder head.
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- The pistons 31 of the hydraulic jacks must be screwed into the cylinders 32 until they are flush with their upper edges at
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'B'! As a result of nonĆobservance the required stroke cannot be obtained by the jack. Use the special spanner 9431.03
to screw down the pistons 31 (Fig. 'D'). Please refer to the note on the previous page.
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- Connect the hand pump 9408.01 by the HPĆhoses with the hydr. jacks
9427.01.
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- Shut the relief valve, actuate the pump and raise the pressure to 100
X1
bar. Hold this pressure constant until all the nuts have been tightened
X
with the round bar until fully seated.

- Open the relief valve on the pump and lower the pressure to 40 bar.
- Measure the projection 'X' of jack piston over jack cylinder with a
depth gauge and note them down (please refer to adjacent Fig.). 31
- Shut relief valve and actuate the pump raising the pressure to 600
bar. Hold the pressure constant until all the nuts 6 have been tightĆ 32
ened down until seated.
- Release the oil pressure to 40 bar and measure the projection jack 6
piston over cylinder 'X1' with the depth gauge and note them down. 95.7063

- Calculate the extension value X1 - X. For correctly preĆtensioned cylinder head studs, the difference between the
two measurements should be 1.4 ±0.1 mm. These measures serve as a safety check of the hydraulic preĆtensioning
method.
- If considerable differences are established in the measured values, then it is necessary to loosen the cylinder head
studs once more (please refer to group 2701-1) and to repeat the preĆtensioning procedure.
- When the stretching measure of all the studs corresponds approximately with the indicated value, remove all jacks,
the pump and close all open hose connections with sealing caps.
Remark Leaking hydr. jacks do not permit correct preĆtensioning of the studs. In such a case the defective
jack must be dismantled and equipped with new sealing rings. The piston 31 can be withdrawn from
the cylinder when the circlip is removed from the cylinder. When reassembling the jack particular
care must be taken when fitting the face seal.
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Replacing the OĆrings in the oil connecting piece without removing the cylinder head (please refer to Fig. 'E')
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The OĆrings 23 on the oil connecting piece 24 can be replaced without removing the cylinder head; for this proceed as
follows:
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- Loosen and remove screws 25 and 27.
- Flange 26 and oil connecting piece 24 can be removed laterally.
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- Remove the old OĆrings, smear a new set with engine lubricating oil and fit them.
- For fitting put both parts together and place them between cylinder head and engine housing (take care of cleanness
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of the seating faces).
- Fit and tighten screws 25 and 27.
a
Fitting the rocker arm cowling, please refer to group 2705-1

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Adjusting the valve clearances for inlet and exhaust valves, please refer to group 4401-1.
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1
A
3
16
4*
5
15 6
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7
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8
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14
13 se
12
9
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11
10
a
95.7204a
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B
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17
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18
10
20 21 22
95.7205a

C 9427.01 E
B 23
17
9427.01a
26
27 27
24 23
S
25 25
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28
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23
F 17
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29
se 30
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28
9427.02 95.7207
a
95.7206
9408.01
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D G
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9431.03
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17
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9427.09
20
9427.01
33 31 B
32
9427.01a
4 95.7209
6 S
95.7208

H J
ZAL40S ZAV40S
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9427.34
9408.17
9427.57
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9427.04 se
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95.7210
95.7211
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K
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ZAV40S ZAL40S
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9427.03
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9427.03
95.7212

Cylinder Head
Replacing Valve Seats

1 Spindle M24āxā365 9427.26 * 1Cylinder head 8 Valve seat
with two nuts 2Spring dowel pin 9 Bush
1 Upper sleeve, complete 9427.27 * 3, 3aNut M24 10 Straightedge
with ball bearing and nut 4OĆring
2 Cones 9427.30 * 5Double ring spanner
4 Clamping jaws 9427.31 * AF 46/50 AS Seat
with two OĆrings (66.04āxā5.33) 6 Valve guide bush S Clearance
1 Centring disc 9427.32 7 OĆring Z Shoulder
1 Spindle M24āxā600 9427.26b
Assorted spanners
*_assembled
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If the seat surface of valve seats is badly damaged or on which too much material was ground away during reconditioning,
replacement of the valve seat is necessary.
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The valve may lie in the seat maximum 1.5 mm deeper than in new condition.
For the replacement of the valve seats it is best to stand the cylinder head on its side. The valve guide bush 6 must not be
removed. se
Removing a valve seat (Fig. 'A')
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Gezeichnet für Auslassventil

A
a
DRAWN FOR EXHAUST VALVE

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1 2 3 9427.30 Z 9427.31 3a 9427.32 9427.27

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95.7213
6 4 9 8 9427.26
- Unscrew and separate the nuts 3 and 3a and the cones 9427.30 respectively until the extraction tool with the four
clamping jaws 9427.31 fitted can be pushed through the valve seat. (The OĆRings 4 are holding the clamping jaws
together).
- With the tool in place tighten nut 3a by hand, until the clamping jaws 9427.31 grip the valve seat on its bottom edge.
While tightening move the spindle 9427.26 simultaneously, axially to and fro until you feel that the shoulder of the
cone grips the valve seat at 'Z'. Only when this is the case tighten the nut 3a moderately with a spanner.
- Mount the centring disc 9427.32 and the upper sleeve with ball bearing and special nut 9427.27 and turn the special
nut with a spanner until the valve seat 8 has been withdrawn from its bore.

Remark If a valve seat holds exceptionally tight in the cylinder head, it is possible to loosen the valve seat by
the following method:
Apply a welding bead all around the seat periphery on the sloping seat surface.
When the valve seat cools, it shrinks and can readily be withdrawn. (While welding take care that no
weld spatter contacts the bore surface of the cylinder head).
Fitting a valve seat 8
Place the cylinder head on its side, permitting the valve seat to be fitted in a horizontal direction.
Inlet valve seat:
- Clean and degrease thoroughly the bore and the seating shoulder in the cylinder head.
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- Apply Loctite 648 to the sealing faces.
- Push the inlet valve seat by hand as far as possible into the bore in the cylinder head, then install the seat fitting device
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as shown in Fig. 'B' and pull the seat in until fully seated. (The valve guide bush 6 must be fitted for this procedure).
The inlet valve seat rests on the shoulder at 'AS' but must have a clearance at the point 'S'.
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Exhaust valve seat:
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- Clean thoroughly the bore and the seating shoulder of the bush 9 and the exhaust valve seat. Any unevenness or damĆ
age must be polished out.
- The radial sealing face of the exhaust valve seat as well as the corresponding bore in the cylinder head must be deĆ
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greased; then coat only the radial seating face of the exhaust valve seat with Loctite 648 as shown in Fig. 'C'.
- Before fitting oil lightly the OĆrings 7.
- Push the exhaust valve seat by hand as far as possible into the bore in the cylinder head, then install the seat fitting
a
device as shown in Fig. 'B' and pull the seat in until fully seated. (The valve guide bush 6 must be fitted for this proceĆ
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dure).
The exhaust valve seat rests on the shoulder at 'AS' but must have a clearance at the point 'S' (Fig. 'C').
- The proper fitting position must be checked as shown in Fig.' C'. For that place a straightedge on the sealing face of
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the cylinder head, and with a depth gauge measure the distance to the upper edge of the exhaust valve seat. The reĆ
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quired dimension is mentioned in Fig. 'C'.

- A pressure test must be carried out after replacement of an exhaust valve seat (see group 2701-6).
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Fitting a bush 9 for the exhaust valve seat

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Before fitting a new bush 9 clean and degrease thoroughly the radial sealing face of the bush and the corresponding bore
in the cylinder head.
Coat the bore in the cylinder head with Loctite 648 as shown in Fig. 'C'.
For fitting the bush it is to be cooled down to about -ā190_C in liquid nitrogen. The two cooling water bores in bush 9
must correspond with the bores in the cylinder head. The bush must rest on the shoulder at 'AS' but must have a clearĆ
ance at the point 'S'.
The proper fitting position must be checked as shown in Fig.' C'. For that place a straightedge on the sealing face of the
cylinder head, and with a depth gauge measure the distance to the upper edge of the bush. The required dimension is
mentioned in Fig. 'C'.

Gezeichnet für Auslassventil

B DRAW FOR EXHAUST VALVE
9427.26b 5 6 1 9427.26 S 7 AS
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95.7213
9427.27 9 8
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9427.32
S S
C se
9
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7
a
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8
x
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+0.4 +0.2
y = 11.8 - 0.3 x = 27 - 0.1
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10
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AS LOCTITE
NO LOCTITE
AS
LOCTITE
NO LOCTITE

Cylinder Head
Grinding the Valve Seats of Inlet and Exhaust Valves

1 Cylinder head turnĆover device 9427.17 1 Cylinder head
(only supplied against specific order) 2 Valve guide bush
1 Valve seat grinding machine 9427.18 3 Grinder spindle
1 Hand grip 9427.35 4 Valve seat
Marking blue 5 Nut
6 Brake (wooden staff, pipe
etc. for steadying)
7 Centering device
For information on the grinding of valve spindle seat please refer to group 2720-2
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Valve seats should only be ground with the valve seat grinding machine.
LappingĆin of the valve with valve seat using grinding paste is strictly forbidden!
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When is the grinding of valve seats indicated?
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- Every time new valve seats have been fitted in the cylinder head.
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- When new or reconditioned valve spindles are being fitted. An exception may be made, when the
valve seat surface is neither worn, corroded nor pitted.
- When the seat surface of the exhaust valve seats is badly impaired, on heavy fuel operation.
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(pitting, corrosion scars).
+ 2'
Inlet valve seats with a valve seat angle of 30° 0 are usually free from damage like pittings, or corrosion. However it can
happen that the seat surface becomes slightly embossed due to wear. As this does not impair the reliability of operation it
a
is usually not necessary to undertake this grinding operation, which reduces the lifespan of the valves. A condition for
this is of course that the valve in question is refitted to the same valve seat with unchanged seat surface. (Please refer to
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group 2720-2).
+ 2' + 2'
Exhaust valve seats for ZA40S engines may have valve seat angles of either 30° or 45° respectively. Valve seats of
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0 0
+ 2'
45° are fitted in ZA40S engines rated at 720 kW/cyl and also in engines with ER I / ER II at 660 / 600 kW/cyl. The
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0
criteria for grinding are the same for both types of valve seats.
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Grinding of valve seats
Fig. 'A' shows an example of how an electric driven seat grinding machine is used. Before starting the grinding operation
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the grinding device has to be mounted in the 30° or the 45° guide of the valve seat grinding machine tool No. 9427.18.
When grinding the valve seats care has to be taken to prevent grinding dust from entering the cylinder head. It is essential
that after completing the grinding the cylinder heads are thoroughly cleaned.
For the use of the grinding machine please refer to the instructions supplied with the machine.
A clean and smooth surface must be obtained with the grinding of the valve seat.
The valve seat grinding machine must be well centered in the valve guide bush as well as in the valve seat with the aid of
the inbuilt centering device 7. This is of paramount importance.
Experience has shown that chatter marks appear when valve seat surfaces are reĆground in the vicinity of engines or
machines producing vibrations. This phenomenon can be successfully prevented when the cylinder head is laid on a thick
rubber mat during the grinding operation. On board ship this grinding operation should never be attempted without
such a rubber mat.
To prevent the machine from twisting, a wooden staff or a pipe is inserted in a bore of the cylinder head.

For grinding of valve seats, only discs which are specified by the maker of the valve seat grinding machine are to be used.
Such discs may be ordered also through New Sulzer Diesel.
Cut: . . . . . . Coarse . . . . 0,1 mm

Fine . . . . . . 0,03 mm
Checking
A crack detection test by dye penetration must be carried out on the finish machined seat surface. No cracks are permitĆ
ted!
After completing the grinding check whether the new or reground valve (refer to group 2720-2) sits correctly on the
valve seat. To check this, apply some marking blue onto the valve spindle seat. The valve spindle is inserted into the guide
bush, the cylinder head being laid flat with combustion face upwards.
Move the spindle 3 to 4 times by about a 1/3 turn to and fro, if necessary use the hand grip 9427.35. Place this grip with the
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movable part of the strap folded down onto the clean surface of the valve plate (if the surface is rough, apply some oil). By
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folding the movable part of the strap upwards the grip fastens itself by suction to the valve plate (Fig. 'B').
If the angle tolerances on valve and valve seat have been adhered to, then the contact pattern on the seat surface of the
inlet valves amounts to 20- 80% of the seat width. The bearing imprint must run from the inner diameter outwards (see
O
Fig. 'a' Illustr. 'C'). Besides the imprint check, the gap between valve and seat can also be measured; As shown in Fig. 'c'
Illustr. 'C' this should be between 0.005 mm and 0.015 mm.
On correctly ground exhaust valves having seat angles of 30° or 45° respectively the contact pattern must be 50 - 100%
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of the seat width. Here, however, in contrast to the inlet valves, the bearing imprint must run from the outer diameter
inwards (see Fig. 'a' Illustr. 'D' and 'E').
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For inlet as well as for exhaust valve seats in the cylinder head it is important that the outer diameter of the valve seat
surface must be bigger than the outer diameter of the valve plate, and that the inner diameter of the valve seat is smaller
than the small diameter of the valve plate. Valve seats in the cylinder head may only be ground to the limit shown in Fig.
'b' Illustr. 'C', 'D', 'E'.
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9427.18
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+2
45 ° 0 +2
30 ° 0
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7
4
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3
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2
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1 B
9427.35
92.7079

0
Inlet Valve Seat
Ø 136 - 0.5
+ 0.3
Ø 116 0 max. Ø 138 mm
30 ° +20
a b
20 – 80%
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Exhaust Valve Seat

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Ø 131 +
-0.2 max. Ø 133 mm
30 ° +20
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a b
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50 – 100%
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D
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Exhaust Valve Seat for

ZA40S Engines with MCR = 720 kW/Cyl.
or Ratings ER I / ER II = 660 / 600 kW/Cyl.
Ø 131 +
-0.2 max. Ø 132.4 mm
45° +20
a b
50 – 100%
E
95.7226

Cylinder Head
Replacing the Insert Bush for the Fuel Injection Valve and Lapping the Seating Surfaces

1 Mandrel with centring disc 9427.10 1 Special nut 7 Insert bush
1 Cleaning tool 9427.11 2 Double end ring spanner 8 Nut M24
1 Spindle M24x880 9427.26c AF 46/50 9 Cleaning cloth
1 Upper sleeve 9427.27 3 Locking ring
1 Lower sleeve 9427.28 4 Ball thrust bearing
1 Centring disc 9427.32 5 Cylinder head F Seating surface for
1 Guide cone 9427.33 6 OĆring fuel injection valve
1 Double ring spanner
AF 46/50
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9427.26c
2
1 3 B
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4
9427.27
9427.28
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2
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5
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E1
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6
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E2
9427.33
8 9427.32
95.7214
Removing an insert bush (Fig. 'A')
- Fit the tool as shown in Fig. 'A' and turn the special nut 1 with spanner 2, until the insert bush 7 has been withdrawn
from its guide bore.
- Remove the insert bush and clean the guide bore in the cylinder head with a degreasing cleaning agent. Do not use
emery cloth except in exceptional cases and then only with greatest care to avoid enlarging the guide bores.

Fitting an insert bush (Fig. 'B')
- The guide bores and the seating surface in the cylinder head must be clean, dry and undamaged.
- Degrease the insert bush in the region 'E2' and coat it with Loctite 648. Mount the insert bush in the cylinder head and
fit the tool as shown in Fig. 'B'.
- Fit the OĆring 6 at 'E1' and smear the area with oil.
- Rotate the special nut 1 with the spanner 2 and press the insert bush into its guide bore until fully seated. Finally the
cylinder head must be subjected to a pressure test (please refer to group 2701-6).
Lapping in the seating surface for the fuel injection valve
The seating surface inside the insert bush must be inspected prior to each fitting of the fuel injection valve. It must not be
either dirty or damaged, as it has to seal against very high pressures. The sealing in this part must be metal to metal, i.e. no
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sealing ring may be fitted.
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Special tools are contained in the engine tools collection, to service this seating surface. They are to be used as described
below (Tool No. 9427.10 and 9427.11).
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- Insert the guide ring in the bore in the centre of the cylinder head (Fig. 'C').
- Put a few spots of grinding paste on the face of the mandrel, insert it into the inset bush and lap the seating surface by
turning the mandrel to and fro several times. se
- Fasten a soft cleaning cloth at the bottom end of tool 9427.11 and clean the setting surface with this device (Fig. 'D').
- If you carry out this reconditioning work with the cylinder head fitted, pay particular attention that no grinding paste
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or any other objects can enter the combustion chamber.
a
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9427.11
9427.10
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7 5
95.7215
3.00 2 z Wärtsilä Switzerland Ltd

Cylinder Head
Replacing the Valve Guides for the Inlet and Exhaust Valves

1 Spindle M24x600 9427.26a 1 Special nut M24 6 Nut M24
1 Spindle M24x760 9427.26c 2 Locking ring 7 Valve seat
1 Upper sleeve 9427.27 3 Ball thrust bearing 8 Double ended ring
1 Lower sleeve 9427.28 4 Cylinder head spanner AF 46/50
1 Centring disc 9427.32 5 Valve guide bush
1 Double ended ring
spanner AF 46/50
A B 8
9427.26a
9427.26c
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9427.27
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9427.28
5
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4 4
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6
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9427.32 95.7216
When valve guide bushes are worn beyond the permissible limit or are otherwise damaged, they must be replaced by new
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bushes, whereby the undermentioned procedure should be followed:
Removal of a valve guide bush (Fig. 'A')

- Fit the tool as shown in Fig. 'A' and rotate the special nut 1 with the double ended ring spanner 8 until the valve guide
bush has been withdrawn from its guide bore in the cylinder head 4, and can be put aside.
- Clean the bore and the seating surface in the cylinder head carefully. Use emery cloth only for extreme cases and then
only sparingly, to avoid any enlargement of the bore in the cylinder head.
Fitting a valve guide bush (Fig. 'B')

Valve seat 7 must be fitted!
- Check the bore in cylinder head 4 and valve guide bush 5 for cleanliness and possible damage, remedy if necessary.
- Smear oil or Thred Gard into the bore and the lower part of the valve guide bush; push the guide bush as far as possible
into the bore and tap lightly with a lead hammer. Ascertain that the valve guide bush is exactly aligned with the axis of
the bore in the cylinder head.
- Mount the tool as shown in Fig. 'B' and, by rotating the special nut 1 with the double ended ring spanner 8, push the
valve guide bush 5 into its bore until fully seated on its shoulder.
- Remove the tool and fit seal rings into the grooves in the valve guide bush bore (lubricate the bore with oil).

Cylinder Head
Pressure Test of Water Spaces
Tools: Key to Illustration:

1 Pressure testing device 9427.06 1 Cylinder head 6 Vent screw
1 Flange with hose coupling 9427.07 2 Uncooled valve seat 7 Screw M12
Assorted spanners 2a Cooled valve seat 8 Hose coupling piece
3 Insert bush 9 Gasket
4 OĆring
5 OĆring W Water spaces
Should, during operation or during an overhaul, a cylinder head show signs of water leakage (cracks, leaking valve seats
or insert bush), it becomes necessary to subject the water spaces to a pressure test at the next opportunity. Such a test
should definitely also be made when valve seats or insert bushes are replaced.
Working procedure:
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- Remove all the valves from the cylinder head and mount the pressure testing device 9427.06 equipped with two OĆ
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rings 4 in perfect condition in the bottom part of the cylinder head, and fasten it as shown in the illustration below.
- Fit the flange 9427.07 and fill the cylinder head with water, while the vent screw 6 remains open until all the air has
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escaped.
- Subject the cylinder head to a pressure of 7 bar shut the valve of the supply pipe and leave the pressure in the cylinder
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head constant for about 15 minutes. During this time the pressure in the water spaces may not diminish.
- If the water space is tight, loosen the vent screw 6, drain the water from the cylinder head and prepare the cylinder
head for assembly.
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8
9427.07 7
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9 6
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W W
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95.7217
9427.06 2 3 2a 4

Cylinder Head
Reconditioning a Relief Valve

1 Special spanner 9427.23 1 Distance ring 7 Ball
1 Ring spanner AF 46 2 Compression spring D Sealing face
1 Open end spanner AF 65 3 Spring casing P PunchedĆin blowĆoff
4 Valve body pressure value
5 Valve seat H Recess
6 Spring plate S Seat face
Relief valves which begin to leak in service must be removed and overhauled at the next opportunity, when the engine is
not in operation. In general all the relief valves should be dismantled and checked at every major overhaul of the engine.
Reconditioning a relief valve
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Working procedure:
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- Push the special spanner 9427.23 over the hexagonal spring casing 3 and turn it at the level of the recess 'H' till it fits
over the hexagon of the valve seat 5.
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- Unscrew the relief valve, using an open end spanner AF 65 and the special spanner 9427.23, from the cylinder head.
- To dismantle the relief valve unscrew the spring casing 3 and remove compression spring 2 together with spring plate
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6. Following this the valve body 4 can be pulled out of valve seat 5 together with ball 7.
Should reĆmachining have to carried out on the relief valve or P
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parts thereof be replaced, then the opening pressure must be
checked and if necessary reĆset with distance ring 1. By changĆ 1
ing the height of the distance ring the opening pressure can be 2
set i.e. when reducing the height, lower opening pressure, the
a
higher the distance ring the higher the opening pressure.

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To vary the opening pressure by about 1 bar, the ring height 3

has to be modified by about 0.1mm.
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Engine rating: Opening pressure:

up to 660 kW/cylinder . . . . . . . . 202 bar
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Before reĆassembling smear all parts including the M27x2

thread to the valve seat 5 lightly with a heat resisting lubricant.
For the reĆfitting in the cylinder cover no joint is to be used. 6
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Remark On engines of some stationary engines the

bores M27x2 in the cylinder covers are
closed with a screw plug instead of a relief H 4
valve being fitted. These screw plugs seal
metallically and have therefore to be 5
fitted without joints.
7
S M27x2
D 95.7218

Rocker Arms
Replacing the Rocker Arms of Inlet and Exhaust Valves

1 Torque wrench 9408.17 1 Main rocker arm 10 Vent valve
1 Socket spanner 9427.19 2 Aux. rocker arm 11 Tubular seal
1 Circlip tongs 3, 3a Circlip lock * 12 Nut
1 Eye screw M12 4 Main rocker pin 13 Ball head cups
Assorted spanners 4a Aux. rocker pin
5, 5a Distance bushes
6 Rocker gear housing RS Eye screws
7, 7a Plugs * Tightening according
8,8a OĆring to instruction
9, 9a Plugs
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1 2 3 4 5 6 3
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RS 9 8
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RS 3a 8a 4a 5a 8a 3a
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95.7219
10 9a 7a
To remove a rocker arm without removing the cylinder head or the rocker gear casing respectively, proceed as described
below:
- Bar the piston of the cylinder concerned to T.D.C. (firing stroke) when both valve groups are closed. (There must be
clearance between all the valves and their rocker arms).
- Remove the circlips 3 and 3a respectively with the circlip tongs.
- Using an eye screw (M12) pull out the plugs 7 and 9 and 7a and 9a respectively.

- Shift the pin 4 or 4a carefully and just enough to permit the removal of the respective rocker arm. When an auxiliary
rocker arm 2 has to be replaced it is recommended to first remove the main rocker arm 1.
- Fitting is done in reverse sequence, after first blowing through all the oil passages in the rocker arm pins and the
rocker arms with compressed air. Further ascertain that all the OĆrings 8 and 8a are still in perfect condition, otherĆ
wise replace them with new ones.
Regarding clearances please consult the Clearance Table group 0352-1.
- After completing the replacement of the rocker arms, start the lubricating oil pump and check whether oil is flowing
out of all the bearing bushes and also from the ball head cups 13. (During this check bar the engine with the turning
gear).
- If the rocker gear housing 6 has been removed check that the tubular seal 11 is correctly seated in its groove. The
landing surface on the cylinder head must be carefully cleaned.
- Place a washer under every nut 12.
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- Smear the thread of the studs, used to fasten the rocker gear housing, with oil, then fit the nuts 12 and tighten them in
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several equal steps with the aid of the socket spanner 9427.19 and the torque wrench 9408.17 to total 540 Nm.
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12*
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11
95.7220
13

High Pressure Fuel Pipe and Fuel Delivery Valve

Removal, Reconditioning and Fitting

1 Torque wrench 9408.17 1 Protecting pipe * 11 Allen screw
25ā-ā135 Nm 2 High pressure pipe 12 Cylinder head
1 Torque wrench 9408.17 *3 Cap nut 13 Valve casing
140ā-ā560 Nm 4 Delivery valve 14 Fuel injection pump
1 Fitting device 9427.20 5 Flange 15 Fuel stud
1 Spanner plate 9427.21 6 Plate 16 Cyl. pin
1 Socket spanner insert 9427.21a 7 Joint 17 Spring
AF 65 8 Screw
1 Socket spanner insert 9 OĆring * Tightening according
½" / AF 6 10 OĆring to instructions
1 Connecting piece 1" / ¾"
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During a major overhaul the delivery valves 4, built on to the fuel stud 15, should be dismantled and checked. Valve seats
which are no longer in perfect condition must be carefully lappedĆin with grinding paste. When the seat is again flawless
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the whole valve must be carefully washed in kerosene, white spirit or other cleaning fluid and then blown out with comĆ
pressed air. The best way to dismantle a delivery valve is to first remove it together with the fuel stud.
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Removal
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- Loosen both cap nuts 3 (Fig. 'A') and remove high pressure pipe 2 with the aid of spanner plate 9427.21 and torque
wrench 9408.17.
- Loosen and dismantle screws 8 to flange 5. Remove flange 5 and joint 7.
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- Set the socket spanner 9427.21a on the hexagon of the valve casing 13 and unscrew the fuel stud 15 with delivery valve
4 from the fuel injection valve.
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- Loosen the screws 11 and separate the valve casing 13 with delivery valve 4 and spring 17 from the fuel delivery conĆ
nection.
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Assembly
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- Hold the valve casing 13 with the threaded end downwards and insert delivery valve 4 with spring 17.
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- Wipe the end faces of the valve casing as well as the fuel stud with a clean cloth or the dry palm of the hand.
- Place fuel stud 15 on the valve casing 13 and clamp them together with fitting device 9427.20 (Fig. 'B') and tighten
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moderately.
- Smear the thread of screws 11 lightly with oil and tighten the screws evenly and crosswise to a final torque of 28 Nm.
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- Smear the thread of the fuel stud lightly with oil and screw it into the fuel injection valve inserted into the cylinder
head.
- Set socket spanner 9427.21a with connecting piece onto valve casing 13 and tighten with the aid of torque wrench
9408.17 to 300 Nm.

Fitting the high pressure fuel pipe
- Place joint 7 together with flange 5 onto cylinder head 12, but not yet tighten screws 8.
- Before fitting the high pressure pipe smear the OĆrings 9 lightly with oil.
- Smear the connecting thread of the valve casing 13 and of the fuel injection pump lightly with MOLYKOTE. Fit the
high pressure pipe but tighten first cap nut 3 only by hand.
- Tighten cap nuts with the aid of spanner plate 9427.21 and torque wrench 9427.17 to 130ā-ā150 Nm.
- Tighten screw 8 to flange 5.
12 *15 10 16 7 5 13 *3 1 (2)
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A
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17 4 *11 9 8
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B 15
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2
9427.20 1
8
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*3
13
6
9
14
Ablauf
DRAIN
00.7288


Replacing Valve Springs as well as Removing and Fitting of Valves

1 Tensioning device 9427.24 1 Clamp ring (2Ćparts) 12 Sleeve
2 Valve rotating device 13 Tensioning sleeve
ROTOCAP 14 Clamp sleeve (2Ćparts)
3 Inner spring 15 Threaded spindle
4 OĆring 16 Ball thrust bearing
5 Outer spring 17 Snap ring
6 Lower spring plate 18 Hand grip
7 Spring 19 Sleeve
8 Cylinder head 20 Lower part for
9 Guide bush TURNOMAT
10 Valve spindle 21 Guide for
11 Upper part for TURNOMAT
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TURNOMAT 22 Ball
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Replacing valve springs
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Remark Normally valve springs are replaced when the cylinder head is removed from the engine and placed
on its side.
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They can, however, also be replaced when the cylinder head is fitted on the engine. In such a case bar
the engine to bring the respective working piston to firing T.D.C. (all valves are then closed).
In both cases the removal of the valve springs follows the same procedure. It may happen that the
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valve spindle slides down onto the piston top when the springs are removed. To mount the spring
tensioning device for fitting, the valve spindle must be lifted up by hand. To prevent it slipping down
again attach a string to the spindle shank and pull the spindle up on this until the spring tensioning
device 9427.24 is mounted.
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Removing the springs
Valve springs 3, 5 and 7 are removed as follows:

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- Pull the rocker arm pin of the respective valve out sideways and remove the corresponding rocker arm (see sheet
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2705/1).
- For valves with ROTOCAP mount the spring tensioning device 9427.24 in such a way that the split clamp sleeve 14
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grips the valve shank on its end (see Fig. 'C'), then push the tensioning sleeve 13 downwards until the lower faces of
clamp sleeve 14 and tensioning sleeve 13 are flush (see Fig. 'A').
For valves with TURNOMAT the removal instructions for spring 7 are the same as already mentioned, with the only
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exception that for the removal sleeve 19 has to be used as shown in Fig. 'B' and 'C'.
- With hand grip 18 screw down sleeve 19 till the valve rotating device ROTOCAP 2 Fig. 'A' or the upper part of TURĆ
NOMAT 11 Fig. 'B' are sufficiently low, that clamp ring 1 can be removed.
- Turn the hand grip 18 back until the springs are fully slackened.
- Remove the tensioning device and remove the springs.
Fitting the springs
- The fitting of the springs is done analogously to the removal but in reverse sequence.
- The seating faces must be clean and undamaged for the springs 3, 5 and 7 as well as the lower spring plate 6 and the
valve rotating devices ROTOCAP or TURNOMAT.
- When carry out the tensioning procedure of the spring 7 for fitting the conical clamp ring halves 1 of the TURNOĆ
MAT, pay attention that the balls 22 engage with the guide grooves of the guide ring 21 (Fig. 'B' and 'C').

- Smear the tapered clamp ring halves 1 with MOLYKOTE paste GĆn on all sides.
- Do not remove the tensioning device before having checked that the two clamp ring halves 1 are correctly inserted.
The spacing between the two halves should be about equal on both sides.
Removing the valves
- The removal of the valves demands the removal of the cylinder head from the engine (please refer to group 2701-1).
- Remove the valve springs as described before, then pull out the valveĆspindles.
- Inspect the seal faces of valve seat and valve body for damage and reĆgrind them if necessary using the grinding
machine (please refer to group 2701-3 and 2720-2).
Fitting the valves
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- Clean the valve guide bushes 9 thoroughly and fit new OĆrings 4.
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- Smear the valve spindles 10 well with oil and before fitting the springs check their easy movement within the guide
bushes 9.
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- Fit the valve springs in accordance with the instruction in the earlier paragraph.
- Fit the rocker arm and adjust the valve clearance.
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Ventil mit ROTOCAP 12 Ventil mit TURNOMAT

VALVE WITH ROTOCAP 19 VALVE WITH TURNOMAT
C 13
14
21
2
11
3
7
5
10
A 22 B
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Ventil mit ROTOCAP Ventil mit TURNOMAT
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VALVE WITH ROTOCAP VALVE WITH TURNOMAT
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18 18
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9427.24
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15
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17
15
16
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12
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17
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16 13
12 14
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13
19
14
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21
1 1
11
2
7
5
22
3
4 20
4
6
8
9
10
00.7289

Regrinding the Seats
Tools:
1 Valve seat grinding machine 9427.16 The instruction for the regrinding
(only supplied against of the valve seats is contained in
specific order) group 2701-3.
1 Marking template each 9427.36
for inlet and exhaust valve
Inking blue
The lapping together of valve spindle seat and valve seat with grinding paste must be avoided as a matter of strict princiĆ
ple.
Valve spindle seats which are considerably damaged by pitting or corrosion, must be reground with the machine. SuitaĆ
ble grinding machines are available in the engineering trade.The following angle tolerance for the seat surface of the
valve must be adhered to:
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+ 6'
Inlet valve for ZA40 and ZA40S engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = 30° + 4'
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0
Exhaust valve for ZA40 and ZA40S engines . . . . (MCR = 660 kW/cyl. or . . . . . . . . . . . . . . . . . . . . . . . . = 30°- 2'
ER I = 600 kW/cyl and ER II = 550 kW/cyl)
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Exhaust valve for ZA40S engines . . . . . . . . . . . . . (MCR = 720 kW/cyl. or . . . . . . . . . . . . . . . . . . . . . . . . = 45°- 2'
ER I = 660 kW/cyl and ER II = 600 kW/cyl)
0
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Make it a point to grind off only as much material as is absolutely necessary to obtain a clean smooth surface.
Grind only wet i.e. with cooling agent.
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To avoid chatter marks on the seating surface, place the grinding machine in a place which is free from vibrations set up
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by running machinery, engines or electric motors. If necessary place the grinding machine on a rubber matting.
A crack detection test by dye penetration must be carried out on the finish machined seat surface. No cracks are permitĆ
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ted!
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F
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On exhaust valves without anti Ć wear armouring, the seat

may not be ground deeper than the face 'F' on the valve plate.
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On inlet valves with anti Ć wear armouring, the valve plate

thickness after grinding must still measure at least 9 mm.
min. 9mm

When the grinding angle is exactly maintained an inking

check of an inlet valve with the valve seat fitted in the cylinder +6'
30°+4' 20 - 80%
head and equally ground will reveal a contact pattern of 20 -
80% of the seat width and beginning from the smaller diaĆ
meter.
Under the same conditions and with the same procedure as

described above, a marking check on an exhaust valve shows a 0
30°- 2' 50 - 100%
contact percentage of 50 - 100% of the seat width and runĆ
ning inward from the outer diameter.
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The above ruling also applies to ZA 40S engines with a MCR
of 720 kW/cyl, ER I = 660 kW/cyl and ER II = 600 kW/cyl.
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0
The exhaust valves of these engines have a seat angle of 45°. 45°- 2'
50 - 100%
When the marking check is carried out the contact area must
be 50 - 100% of the seat width starting from the outer diameĆ
ter and running inwards. se
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The seating surfaces of the inlet valves may not show any pitĆ straight edge
ting marks or corrosion scars, but have simply become hollow
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due to wear.
Such valves must not be reground but they have without fail wear
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to be fitted again to the same valve seat in the cylinder head in

which they operated before and which was not reĆ ground
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either.
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On the latest valve design this type of wear pattern will no longer
occur!
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valve plate
For the grinding of valves, only grinding discs which are specified by the maker of the valve grinding machine are to be
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used. Such discs may be ordered also through New Sulzer Diesel Ltd.
Grinidng sould be carried out only together with cooling agent.
InĆfeed advance: Rouging: about 0.025 mm infeed

grinding use both stone
halves alternately
Finishing: about 0.01 mm
On engines operating under unfavourable conditions for a

prolonged time, corrosion on the bottom of the valve plates
may occur. Valve plates on which a corrosion depth as listed
under 'a' (centre) and/or 'b' (outer diameter) has been meaĆ
sured must be replaced.
Inlet Valve . . . . . . . . . . . a = 2 mm . . . . b = 0,5 mm
a
Exhaust Valve . . . . . . . . a = 5 mm . . . . b = 2,5 mm

A welding repair of a corroded exhaust valve is normally not
recommended for cost reasons.

Fuel Injection Valve
Removing, Dismantling and Assembling

1 Torque wrench 9408.17 1 Spring tensioner 13 OĆring
(480 940 Nm) 2 Lock nut 14 Fuel stud
1 Torque wrench 9408.17 3 Nozzle holder 15 OĆrings
(25 135 Nm) 4 Spring plate 16 Securing snap ring
1 Stirrup with spindle 9427.15 5 Compression spring 17 Belleville washers
1 Lapping ring 9427.38 6 Push rod 18 Pressure flange
1 Socket spanner AF 65 9427.57 7 Insert bush * 19 Nut
1 Connecting piece 1" *8 Cap nut 20 Studs
1 Connecting piece ½" / ¾" 9 Locating dowel
1 Short extension piece ¾" x 8" 10 Nozzle body
1 Socket spanner insert ¾" x AF 24 11 Nozzle needle * Tightening according
12 OĆring to instructions
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Removing from the cylinder head (Fig. 'A')
A B
- Shut the shutĆoff valves for the nozzle
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cooling water inlet and return pipes to
the cylinder head.
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- Loosen and remove the fuel injection
pipe (see group 2716-1).
9427.15 - Unscrew the fuel stud 14 (Fig. 'C') with 9427.38
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fittedĆon delivery valve and store in a
clean place. 10
- Remove the nuts 19, with which the fuel
a
injection valve is fastened to the cylinder

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head, and lift off the flange 18 (Fig. 'C').

- Mount the stirrup with spindle (tool No.
3 9427.15) as shown in Fig. 'A' and pull the
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injection valve from the cylinder head.

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95.7222
- Check whether the sealing faces of the nozzle body 10 and the insert bush 7
are in order i.e. whether they show equal pressing marks.
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- If necessary lap the sealing face on the front of the nozzle body 10 with the
lapping ring 9427.38 and some lapping paste by hand, until it is clean and
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even over the whole circumference (see Fig. 'B').
95.7221

Dismantling the fuel injection valve (Fig. 'C')
- Clamp the fuel injection valve by the cap nut 8 in the vice.
- Loosen lock nut 2 and with a spanner loosen the spring tensioner just sufficiently to relieve all tension from the spring
5.
- Clamp the fuel injection valve in the vice by the upper end of the nozzle holder (nozzle pointing upwards) and loosen
the cap nut 8 using the socket spanner 9427.57, the 1" connecting piece and a ring spanner AF 65. Remove the cap nut
8.
- Lift off the nozzle body 10 with nozzle needle 11 and place aside in a clean place. (Take care that the nozzle needle
does not drop out!)
Remark The nozzle needles are lapped individually with their nozzle bodies; they form a unit together. It
must be strictly avoided to interchange nozzle needles and nozzle bodies!
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- Loosen the spring tensioner 1 fully and remove it; remove spring 5, spring plate 4 and push rod 6 downwards.
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1
C
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20
19*
18
17
2
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16
3
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15
4
5
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14
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13
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12
MOLYKOTE-G 8*
9
10
11
MOLYKOTE G-n
95.7223

Assembling the fuel injection valve
- For the assembly observe the utmost cleanliness and care.

- Clamp the nozzle holder 3 (without any inner parts) in the vice by the milled portion and with the nozzle seal face
pointing upwards.
- Check whether the inscription on the nozzle holder circumference (Specification) tallies with the indications in the
setting table of the engine.
- Wipe the sealing face of the nozzle body 10 and of nozzle holder 3 with the clean dry hand or wash them with PerchloĆ
rethylene, to obtain a clean dry sealing surface.
- Place the nozzle 10 carefully on the nozzle holder 3, taking care that the nozzle needle 11 does not drop out and that
the locating dowel 9 fits into the locating hole.
- Smear the thread of the cap nut 8 and the landing on the nozzle body 10
D
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(where the cap nut presses the nozzle body) with MOLYKOTE paste GĆn
(Fig. 'C').
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- Fit cap nut 8 and tighten by hand until it lands; then, using the torque
wrench 9408.17 with socket spanner 9427.57 and 1" connecting piece,
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tighten the cap nut to 590 Nm (Fig. 'D').
- Clamp the nozzle holder 3 with nozzle pointing downwards in the vice by
the cap nut 8. se
- Smear all the inner parts, 6, 5 and 4 carefully with clean engine oil and fit
9427.57
them as shown in Fig. 'C'. Screw the spring tensioner 1 in by hand then
8*
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tighten it to obtain the correct spaying pressure (see group 2722-2).
- Fuel injection valves which are not immediately installed must be stored
in a place where they are protected from damage and from dust and corĆ
a
rosion attack.
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Fitting the fuel injection valve into the cylinder head (Fig. 'C')
3
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- Equip the correctly adjusted fuel injection valve with new OĆrings 15 and
95.7224
12 and smear them with engine oil.
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- Check the bore and landings in the cylinder head for cleanliness and rust spots. (Should it become necessary to relap
the landings in the insert bush 7, please follow the instruction in group 2701-4).
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- Install the fuel injection valve and mount the flange 18, but do not yet tighten the nuts 19 (smear the threads of the
studs 20 with MOLYKOTE paste GĆn).
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- Fit the fuel stud 14 - with fitted delivery valve - from the side into the cylinder head and screw it by hand into the
nozzle holder (do not use any joints, but smear thread with oil).
- The lateral clearance of the fuel stud 14 must be distributed equally in respect to the bore in the cylinder head.
- Only then, tighten the fuel injection valve onto its seating with the two nuts 19 by compressing the belleville spring
stack 17 using the torque wrench. Tighten the nuts 19 alternately in several steps to a total of 250 Nm.
- Checking: Flange 18 must rest flush without clearance.
- After completing all the connections, the closed valves of the nozzle cooling water pipes can again be opened.
Remark If it becomes necessary to remove the belleville washer stacks 17, the securing snap ring 16 must first
be taken out. When reassembling the belleville washers take the utmost care always to place the
washers 17 in pairs in the same position. The washer stacks in turn must be fitted as shown in Fig. 'C'.

Checking the Condition of Spraying and the Spraying Pressure

1 Spray testing device 9427.40 1 Spring tensioner
(complete) 9427.41 45 2 Lock nut
assorted spanners 3 Pressure gauge damper valve
4 Nozzle holder
5 Cap nut
6 Fuel injection nozzle
7 Pressure gauge (0 500 bar)
8 Fuel tank
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8
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1 7
2
3 9427.43 se
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4
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9427.44
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9427.42
9427.45
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6
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95.7225
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9427.41
The fuel injection valves must be checked periodically as per maintenance schedule, or earlier if indications of faulty
combustion demands it, also after fitting a new fuel injection nozzle. The spray check has to be made with the spray teĆ
sting device 9427.40 and its components.
For this test use only absolutely clean gas oil, which may not be poured back into the fuel tank 8 after the test.
Prior to checking a fuel injection valve, clean the same carefully externally and remove any existing combustion residue
on the injection nozzle with a brass wire brush.
The fuel injection valve to be tested is placed on the spray testing device 9427.40 and connected to the pressure connecĆ
tion 9427.44 (without joint).

Judging a fuel injection valve
To correctly judge a fuel injection valve, the following checks must be carried out:
D Loosen lock nut 2 and then spring tensioner 1, to relieve the nozzle needle of the fuel injection valve completely of
tension.
Check by a few short pump strokes of spray testing device 9427.40 whether the fuel is equally distributed from all spray
holes of the fuel nozzle.
D Using spring tensioner 1, adjust the opening pressure of the fuel injection valve to the value mentioned in the setting
table (normally 400 ± 10 bar).
D To check sealing between nozzle needle and nozzle needle seat of the fuel injection valve, keep a pressure of 200 ± 20
bar constant, over a period of 5 seconds. During this time no dripping should be noticeable at the tip of the injection
nozzle.
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Attention Never hold fingers or hands directly against the spray holes of the injection nozzles due to the risk of
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accidents.
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Fuel injection valves checked according to the above mentioned criteria and proven flawless can be further used.
Deficient fuel injection valves must be dismantled (see group 2722-1 and 2722-3) and their injection nozzles replaced
by new or overhauled injection nozzles.
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Fuel injection valves which leak and drip have to be overhauled by the manufacturers or a specialized company.
Improper repair work on fuel injection valves can cause scrapping of the same.
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Adjusting the opening pressure
- Loosen the lock nut 2, move the pump lever up and down and at the same time tighten the spring tensioner 1 until the
opening pressure is read on the pressure gauge 20 (please note the required value, normally 400 ± 10 bar, in the setĆ
a
ting table).
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- Shut the pressure damping valve 3 and check with short fast pump strokes whether the fuel nozzle sprays equally.
When this condition is reached, tighten the lock nut 2 firmly, while holding the spring tensioner 1 steady with a spanĆ
ner.
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- After tightening the lock nut 2 check the opening spray pressure once more.
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Cleaning and Reconditioning

1 Tool case 9427.48 1 Nozzle holder
consisting of: 2 Bush (hard)
1 Checking disc 9427.50
1 Copper mandrel 9427.51
1 Wire brush 9427.52
1 Tube 9427.53
containing cleaning drills
and plug gauge
Fuel injection valves in which the fuel nozzles no longer function satisfactorily must be dismantled and cleaned thoĆ
roughly.
Blocked nozzle holes have to be freed on the dismantled nozzle with the nozzle needle removed using the drill contained
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in the tube 9427.53 of tool case 9427.48. After deblocking wash the nozzle body 10 out with gas oil or petroleum and blow
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it through with compressed air. Dip the nozzle needle in clean gas oil or petroleum and insert it in the nozzle body. The
nozzle needle must slide onto its seat under its own weight.
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For the cleaning of the nozzle interior do not use any pointed metallic utensils or tools, a wooden rod with a clean piece of
material is suited for this purpose.
The sealing face of the nozzle body must be checked.
Hold the bare nozzle body (without needle) with soft clamp jaws in the vice, sealing face upwards.
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Check the sealing face for flatness with the checking disc 9427.50 (Fig. 'A') whereby it is pressed against the sealing face
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of the nozzle body and at the same time apply a circular movement. The checking disc being of bronze will leave a yelloĆ
wish mark on the high spots.
During the check with the checking disc, the sealing face must be true or very slightly concave (higher on the edge than in
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the centre). Damaged or uneven sealing surfaces must be overhauled by a specialized firm.
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Finally wash the nozzle body thoroughly in gas oil or petroleum and blow it through with compressed air.
Assemble the fuel injection valve and adjust the spray pressure and check the spray condition (see group 2722-2).
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Should the function still not be satisfactory, replace the fuel nozzle by a new one or a reconditioned one. As a matter of
principle do not 'tinker' with the fuel nozzle as this may render a later repair impossible.
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We recommend sending fuel nozzles which do not function satisfactorily to a specialist firm or to New Sulzer Diesel
Winterthur for possible repair.
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A
9427.50

1

2

95.7111

Starting Valve in the Cylinder Head

Removing from the Cylinder Head, Dismantling, LappingĆin, Assembling and Fitting

1 Torque wrench 9408.17 1 Stud 13 Piston
(140ā-ā560 Nm) *2 Nut 14 OĆring
1 Extracting device 9427.15 3 Flange 15 Spring
1 Centering sleeve 9427.37 4 Control air pipe 16 Casing
1 Overhaul device 9427.47 5 OĆring 17 Soft iron joint
1 Socket spanner top 6 Snap ring 18 Rod seal
(¾" / AF 24) 7, 7a Cup spring (spring packet) 19 Piston seal ring
1 Socket spanner top 8 Valve casing 20 Spring
(¾" / AF 30) 9 Screw 21 Disc
1 Short extension 10 Pilot control valve
(¾" / 8") * 11 Nut * Tightening according
12 Valve spindle to instructions
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1
A 2* B
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3 4
5 6 se
7 9427.15
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7a
8
18
a
9
20 10
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19 11*
18
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14
19
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13
18
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15
12
16
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95.7227
17 95.7400
On the occasion of a general overhaul or if functional difficulties occur, remove the starting valves and recondition them.
Removal
- Loosen the nuts 2 and lift flange 3 off.
- Extract the starting valve complete with the spring packets 7 and 7a using the extracting device 9427.15 (Fig. 'B').
- Remove the soft iron joint 17.

- Should the removal be undertaken with the cylinder head fitted on the engine, close the opening in the cylinder head,
to avoid any foreign bodies falling into the combustion chamber.
- For further dismantling the starting valve loosen the screws 9 and remove them, after which the valve casing 8 can be
lifted off and the pilot control valve 10 removed with its spring 20.
- For turther dismantling clamp the valve spindle 12 at the milled face below the valve disc in the vice and loosen the nut
11.
- After removing the nut 11 the valve spindle can be slid out downwards
and the other inner parts removed upwards. 6
- After removing the parts check their condition.
- Faulty piston seal rings 19, rod seals 18, OĆrings 5 or 14 have to be reĆ
placed by new ones of the correct specification. When replacing the pisĆ
ton seal rings and the rod seals proceed with utmost care. Particularly do 7
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not stretch or deform the slide ring of this twoĆpart seal, as otherwise its
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fitting becomes extremely difficult.
- Do not dismantle the spring packets 7 and 7a. Should it be necessary for 7a
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important reasons, pay careful attention to the arrangement of the cup
springs (note the figure on the right).
LappingĆin se C
95.7228
- If the seat of the valve spindle has to be lappedĆin, fit the centring sleeve
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9427.37 as shown in Fig. 'C' into the casing 16.
- Using some lapping paste lapĆin the valve spindle onto the seat.
- Badly damaged seat surfaces should first be ground by machine
a
(( = 45_) and only afterwards lappedĆin with grinding paste.

16
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Assembly
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- The assembly of the valve is effected in reverse sequence analogous to the

dismantling.
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- Smear all the parts carefully with engine oil prior to fitting them in the
valve.
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- Apply MOLYKOTE GĆn to the thread; tighten the nut 11 with a torque
wrench to 180ā-ā190 Nm.
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- Fit a new OĆring 14 of correct specification smeared with oil into the
outer groove of the casing.
9427.37
95.7229

Fitting in the cylinder head

9427.47
- Before fitting the starting valve the sealing face in the D
cylinder head must be checked for damages. If necesĆ
sary recondition the sealing face with the overhaul deĆ
vice 9427.47. For the application of the mentioned tool
refer to Fig. 'D'.
A fine lapping paste must be applied for reconditioning,
whereby the disc 21 is used as a guide. A thorough cleanĆ
ing of the sealing face and the bore in the cylinder head
after completion is absolutely essential. 21
- Insert a new soft iron joint 17 into the bore in the cylinĆ
der head.
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- Smear the bore in the cylinder head with clean engine
oil and insert the complete starting valve onto the joint
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17.
- Smear the threads of the studs well with MOLYKOTE
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paste GĆn.
- Mount the flange 3 and tighten the nuts 2 with a torque
wrench, with a socket spanner top ¾" and extension se
¾"/8" in small equal steps to a total of 250 Nm.
- Check: Flange 3 must rest flush without clearance.
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00.7290
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Group 3
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Crankshaft
Measuring Crank Deflections
Tools:
1 Checking device 9431.01
We recommend that the crank deflections be measured whenever:

- A general overhaul is being carried out.
- Main bearing shells have been replaced.
- There are indications of engine foundation deformation.
- A breakdown has occurred or for other reasons where a check on the support of the crankshaft is required.
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The following points have to be noted when taking crank deflections:
- Measuring should always only be made on an engine which has cooled down.
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- All the running gear (pistons, connecting rods) should be in place.
- The dial gauge must always be fitted in the same position (see illustration on following page).
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- When dealing with a marine installation, it must be remembered that the loaded condition of the vessel should be as
nearly as possible the same at the time readings are taken.
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Measuring procedure
- The crankshaft is to be turned by the turning gear into such a position that the dial gauge (with about 1 mm of preĆtenĆ
a
sion) can be placed between two counterweights at measuring point 1, as shown in the illustration on the following
page, and set to '0'.
rn
- Then, with the aid of the turning gear, the crankshaft is turned in the normal running direction and stopped again so
that the value shown on the dial gauge at measuring points 2, 3, 4 and 5 can be read off and noted down.
e
- The noted values have to be recorded so that they can be compared with earlier or later measurements.
nt
- Where values are measured which lie outside those shown on the graphics 'A' and 'B', the cause has to be investigated,
whereby the crankshaft has to be uncoupled from driven equipment.
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- In addition to this, the engine holdingĆdown bolts have to be slackened off to determine if a permanent deformation
of the engine foundation has occurred.
Fo

Positions of the dial gauge during measuring

Position of dial gauge Position of dial gauge
at begining of measuring at end of measuring
1 5
2 4
3
Positioning the dial gauge
~30
(Tool 9431.01) Measuring positions
y
Counter- End Beginning
weight 5 1 Drawn for 8 cyl. engine
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FUEL PUMP SIDE
DRIVING END
FREE END
4 2
1 2 3 4 5 6 7 8
se EXHAUST SIDE 95.7230

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3 A NORMAL CRANKS and end crank No.
8 at the free end when neither torsional
vibration damper nor shaft is coupled up.
a
B END CRANKS (exception: crank at free

A
rn
mm end, see Fig. 'A').
2 1 LIMIT VALUES during engine erection

+0,10 +0,10 B (strive for small negative values with DieĆ
e
selĆalternator sets).
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2 2 LIMIT VALUES for engines in operaĆ

+0,05 +0,05 +0,05
1 tion (engine cooled down).
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+ 1 2 3 4 5 1 2 3 4 5 Should the measured values exceed the

0 limit values, readings should be taken
1 again under various conditions (e.g. difĆ
Fo
–
1 ferent machinery room temperatures,
–0,05 –0,05 slackenedĆoff holdingĆdown bolts or unĆ
der different loading conditions with maĆ
rine installations).
–0,10 –0,10
2 When the measured values still remain
outside the permissible limits, a closer inĆ
–0,15 vestigation has to be carried out and any
necessary corrections made. In such
1
–0,18 cases contact should be made with the
–0,20 engine builder.
–0,24 95.7231 Attention

–0,25 2
The crank limit values refer to the
coupled condition!

Crankshaft
Loosening and Tightening the Coupling Bolts

1 Hydr. hand pump 9408.01 1 Crankshaft
1 High pressure hose 9408.09 2 Crankshaft end piece
1 Hydraulic cylinder 9408.36 *3 Coupling bolt to shaft end piece
1 Special spanner 9431.02 *4 Coupling bolt to flywheel
5 Flywheel
6 Camshaft driving gear wheel
* Tightening according to instructions
To obtain a sufficiently firm connection, the coupling bolts for the flywheel and for the shaft end piece (locating bearing
shaft) must be very firmly tightened.
y
Due to space reasons the tightening of the above mentioned bolts by impact wrench and hammer is only conditionally
nl
possible. For this reason all bolts shall be tightened with the aid of a hydraulic cylinder 9408.36 and special spanner
9431.02. The utilization of these tools is shown in the illustrations overleaf.
O
The procedure for tightening the coupling bolts for the flywheel and for the shaft end piece is the same but for the sole
difference, that the length of the coupling bolts for the shaft end piece must be measured before and after final tighteĆ
ning. The bolt elongation from tightening shall amount to 0.36 ± 0.02 mm.
se
Threads and nut seating surfaces must be smeared with MOLYKOTE paste GĆn before tightening.
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Working Procedure:
First tighten all the nuts with the spanner - diagonally across - by hand as firmly as possible. Then tighten each bolt with
the aid of the hydraulic cylinder, the HPĆpump and the special spanner.
a
The tightening torque for the coupling bolts of the shaft end piece is 2300 Nm, or the preĆtensioning pressure on the
rn
pressure gauge is 100 bar for the HPĆpump.

The above tightening values are only valid if special spanner tool No. 9431.02 and hydraulic cylinder 9408.36 having a
piston area of 6.41 cm are utilized..
e
Should a hydraulic cylinder be used with a differing piston area then the correct preĆtensioning pressure can be calculaĆ
nt
ted according to the formula:

641
P (bar) =
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new piston area in cm 2

Loosening of the bolts is done in reverse sequence analogous to the tightening by using the same tools.
Fo

II I
2 5
6
1
3
9431.02
9408.36
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4
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O
se
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II
a
II - II
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nt
3 9431.02
I
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9408.36
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95.7232
9408.01 9408.09

Crankshaft
Fitting the Counterweights

1 Hydr. hand pump 9408.02 1 Crankshaft
1 Branch piece 9408.03 *2 Waisted stud
1 Pressure gauge 9408.04 3 Counterweight
2 HP hoses 9408.09 3a Counterweight
1 Special spanner 9431.03 4 Round nut
2 Hydraulic jacks 9433.07 5 Centering pin
1 Round bar Ø 8 mm 9433.07a 6 Cylinder
7 Piston
* PreĆtensioning according to instructions
y
The fitting of counterweights on the crankshaft is the same for engines type ZAL40S as for ZAV40S. A difference lies
nl
merely in the shape of the counterweights. The following instruction is valid therefore for both engine types.
Attention The engine may not be turned when the hydraulic jacks are mounted!
O
Working procedure:
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- The contact surfaces of crank web and counterweight must be clean, dry and undamaged. The same applies to the
centring pin 5, except it has to be smeared with oil.
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- Fit the two waisted studs 2 and tighten them to 50-100 Nm.
- After mounting the counterweight screw the round nuts 4 on to the studs until fully landed.
a
P r e Ć t e n s i o n i n g of the waisted studs

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- Mount the hydraulic jacks 9433.07 on the waisted studs 2 till the cylinder 6 is landed on the counterweight.
- Connect the hydraulic jacks to the hydr. hand pump 9408.02 by the HP hose 9408.09.
e
- With open relief valve of the hydr. hand pump, tighten the pistons 7, (using the special spanner 9431.03), onto the
nt
waisted stud 2, until the piston 7 and the cylinder 6 are flush with the outer front side (Fig. 'B').
- Close the relief valve on the hydr. hand pump and build up a pressure of 100 bar. Maintain this pressure until the
round nuts 4 have been tightened up by round bar 9433.07a till fully landed (check the landing with a feeler gauge).
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- Release the pressure to 40 bar and measure the protrusion 'X' on the jack and note it down (Fig. 'A').
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- Raise the pressure to 600 bar, hold the pressure constant until the round nuts are, as before, tightened until seated
(check seating with a feeler gauge!).
- Release the pressure to 40 bar and measure the protrusion 'X1' on the jack and note it down (Fig. 'A').
When the waisted studs are correctly preĆtensioned the elongation amounts to: X1 - X = 0.75 ± 0.05 mm.
If the stretch deviates considerably from this value, repeat the whole preĆtensioning procedure.

L o o s e n i n g the waisted studs
- Mount both hydraulic jacks 9433.07 on the waisted studs 2 until the cylinders 6 are landed on the counterweight.
- Connect the hydraulic jacks to the hydr. hand pump 9408.02 by the HP hose 9408.09.
- Open relief valve on the hydr. hand pump and screw pistons 7 with special spanner 9431.03 onto the waisted studs,
until piston 7 and cylinder 6 are flush with the outer face.
- Now screw both jacks back until a gap of about 2 mm appears between cylinder 6 and the counterweight at 'S' (Fig.
'B').
If the gap is too small it may not be possible to loosen the preĆtensioning jack after the release. If the space is too large
the stroke of the jack may not suffice for a full preĆtension of the waisted studs.
- Actuate the hydr. hand pump and build up a pressure of about 600 bar (possibly a few bar more) and loosen the round
nuts 4 by about one full turn.
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- Release the pressure to 'Zero' and remove the jacks.
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O
A
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X1
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X
7
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6
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4
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95.7063
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Fo

B
9408.09

9408.09 9431.03
ZA40S
9433.07
Fo
9431.03
9433.07
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9408.02
9408.03
nt
e 2* 7
3a 9408.04
3 rn
5
a
3 z
Maintenance
5
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1
1
se
O 95.7233
ZAL 4 6 S ZAV
nl
y
Gezeichnet für ZA
DRAWN FOR ZA
3101–3/A1
1995
Torsional Vibration Damper
Taking a Silicon Fluid Sample

1 Large screw driver 1 Torsional vibration damper
1 Flat punch 2 Screw plugs
1 Hand hammer 3 End cover of torsional vibration damper housing
1 Centre punch 4 Sealing ring
Various spanners C Silicon sampling tube
K Lock by centre punching
The service of a torsional vibration damper depends largely on the speed range in which the engine works. Friction on
the inner parts as well as changes in the characteristics of the silicon fluid can lead to a reduction in effect of the torsional
vibration damper. By periodically investigating the silicon fluid, the manufacturer of the damper can determine the geĆ
neral condition of same.
y
We therefore recommend that the silicon fluid should be investigated for the first time after about 12'000 running
nl
hours. The results of the first investigation will determine at what intervals further checks should be carried out.
Special 'sampling tubes' can be obtained from the manufacturer (see Fig. 'B').
O
Before fluid samples are taken or any work is carried out on the vibration damper, the relevant service instructions of the
damper manufacturer must be observed.
Taking a fluid sample

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Preparation:
Depending on the number of cylinders a torsional vibration damper may be fitted to the free end of the crankshaft as well
as to the free end of each camshaft.
a
- On engines which are equipped with a crankshaft having a torsional vibration damper fitted on the free end, the closĆ
rn
ing plate on the end casing at the free end or the corresponding pumps on engines having engineĆdriven pumps have to
be removed, before access can be gained to the screw plugs of the torsional vibration damper.
For the same reason the lateral camshaft closing plates have to be first removed for torsional vibration dampers fitted
e
to the camshaft.
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- Rotate the crankshaft or camshaft respectively until one of the screw plugs 2 is in the best accessible position (Fig. 'A').
- Using a flat punch, knock back the squeezed material in the slot, which serves as locking means.
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- Loosen the screw plug, but do not unscrew it yet, it must still seal.
- Rotate the crankshaft or camshaft respectively until the two screw plugs 2 lie approximately horizontally (see Fig. 'A').
Fo
- Leave the damper in this position for at least three hours. (If the fluid sample is to be withdrawn from a removed
vibration damper the same conditions apply as regards the positions and the waiting time). In both cases the vibration
damper must have cooled down to about room temperature.
- Prepare the sample container, i.e. remove the screw cap and examine the bore Ć which must be meticulously clean.
Attention The threads on the two ends are unequal on the Holset Damper (see Fig. 'B').

Drawing a sample (see Fig. 'A' and 'B')
- Unscrew the prepared screw plug 2 and in its place screw in immediately the sampling tube 'C' which is held ready.
- Wait till the silicon fluid flows out of the open sampling tube end. Depending on the viscosity of the silicon fluid this
may take some time. The process can be accelerated by the following:
1) Rotate the damper so that the sampling tube is as low as possible.
2) Remove the second screw plug 2 for a short period.
- As soon as the silicon fluid begins to flow out, close the sampling tube with the one screw cap.
- Unscrew the sampling tube from the damper casing (hold vertical) and fit immediately the screw plug 2 with a new
sealing ring 4. Avoid unnecessary leakage of silicon fluid.
- Fit the second screw cap on the sampling tube and finally tighten both moderately.
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- Tighten the screw plugs 2 with a torque of about 2,5 mkp and lock it by caulking metal into the slot with a powerful
blow of a centre punch at 'K'.
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Attention The special sampling tube permits drawing a specific quantity of silicon fluid from the damper. The
O
total numbers of samples should be limited to 10 times.
The filled sample tube has to be labelled and sent to the following address for examination:
Carl Hasse & Wrede GmbH
Mohriner Allee 30-42
se Holset Engineering Co. Ltd.
131 Parkinson Lane
D-12347 Berlin 47 Halifax HX1 3RD
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Germany England
The label must contain the following information:
Engine type, Engine No. Number of operating hours of the vibration damper, also
a
its manufacturing serial number (this number is stamped into the cover in the vicinity of the warning
plate).
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A
nt
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2
Fo
95.7234

B Proben – Behälter / SAMPLE CONTAINER
Holset
3/8”BSF
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Hasse & Wrede
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M10x1
C se C
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M10x1
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5/16”BSF
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2 2
Fo
3 3
4 4 K
F
K 93.7153

Turning Gear
Maintenance

Assorted open end and ring spanners 1 Operating lever
2 Locking pin
3 Thrust ring
4 Spacer ring
5 Spacer ring
6 Oil drain plug
7 Cover for oil filling
8 Pinion
8a Pinion shaft
9 Oil level glass
10 Compression springs
11 Ball thrust bearings
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AS Axial clearance
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F Grease lubricated shaft
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- Before starting the turning gear check the oil level. The level in the oil level glass 9 must be at least at the mark 'Min'.
For topping up use Hypoid gear oil class SAE 90, (no thinner oil may be used under any circumstances).
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The oil should have good high pressure, corrosion protecting and antifoaming properties.
For filling oil remove the cover 7.
- The shaft 8a, on which the pinion 8 is shifted for engagement and disengagement with the flywheel gear rim, must
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always be well greased. (Serves also as rust protection).
- About every 5 years drain the oil through the drain plugs 6 and replace it with 18 litres of fresh oil (for oil type see
above).
a
- If a lengthy duty is foreseen for the turning gear (for example an engine overhaul) grease the pinion teeth 8 with MOĆ
rn
LYKOTE grease.
- When replacing the ball bearings, make sure during fitting that the spacer ring 5, opposite the ball bearing housing
e
protrudes by 0.15 -00.05 mm, when it is pressed against the shaft shoulder.
nt
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Fo

1
1995
2
3212–1/A1
Fo
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nt
e rn 7
F a
2 z
Maintenance
8a
AS=
0.3 – 0.6 10
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max.
8 min.
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9
O
nl
y 5
95.7235 95.7236
ZA40S

6 3 11 4 11
Connecting Rod
Inspection and Replacement of Crankpin Bearing Shells

1 Hydr. hand pump 9408.02 1 Stud (long)
with ancillaries 2 Stud (Short)
1 Hydr. cylinder (jack) 9408.35 3 Crankpin bearing upper part
1 Removal device 9433.02 4 Crankpin bearing lower part
2 Pin to removal device 9433.02a 5 Main bearing cover
1 Underlay to the 9433.02b 6 Yoke
removal device 7 Engine housing
2 Lowering devices 9433.03 8 Adjusting nuts
2 Roller for the lowering 9433.03a 9 Retaining device
devices 10 Securing screw
11 Screw
12 Screw
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13 Connecting rod
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Bearing shells of the crankpin bearing can be removed and fitted without pulling out the working piston.
O
Procedure for the removal
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- Loosen all the nuts of studs 1 and 2 as described in group 3302-2. Do not yet remove the nuts but leave them handĆ
tight.
- Turn crankshaft to bring the piston of respective cylinder to ignition TDC. This is absolutely essential to prevent the
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working piston touching a possible open valve, when it has to be lifted when the crankpin bearing upper part has to be
inspected.
- On both sides of the crankpin bearing upper part 3 screw in one ring screw each together with the steel rope of lowerĆ
a
ing device 9433.03. At the same time mount also the two rollers 9433.03a needed to lower crankpin bearing lower part
rn
4.
- Remove now all nuts of studs 1, then lower crankpin bearing lower part 4 with the aid of two lifting tackles, mounted
on the engine exterior. Lower with care, so as not to damage the threads of studs 1.
e
- Mount removal device 9433.02 as shown in the illustration. For this screw in the two pins 9433.02a fully into the correĆ
nt
sponding threaded holes in the main bearing cover 5. Fasten joke 6 of removal device 9433.02 with two screws 11 to
engine housing 7. Adjust retaining device 9 with adjusting nuts 8 in such a way that the removal device comes to lie
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lightly against crankpin bearing upper part 3.

- Place hydraulic cylinder 9408.35 together with underlay 9433.02b on to support of removal device 9433.02 as shown in
the illustration.
Fo
- Connect hydraulic cylinder by high pressure hose to hydraulic hand pump 9408.02 and by actuating the pump lever
raise crankpin bearing upper part 3 together with connecting rod 13.
Attention Lift the connecting rod with crankpin bearing upper part only just sufficiently that the bearing
shell can be removed.
In this position secure the connecting rod and crankpin bearing upper part by tightening securing
screw 10 firmly.
Before reĆfitting used bearing shells check their condition carefully (see group 0002-2, 'Criteria for the replacement of
bearing shells'). Unduly worn or defective bearing shells must on no account be reĆfitted, but must be replaced by new
ones. Any machining, scraping or filing of the bearing shells must absolutely be avoided!
Should it become necessary to reĆgrind a worn roughened crankpin, then thicker bearing shells must be fitted, to suit the
reduced pin diameter. The following table advises on standard undersize bearing shells, the reĆgrinding diameter for the
crankpin as well as the article denomination of the respective bearing shell undersize (dimensions are in mm).

Reduction of Crankpin Shell thickness Vertical bearing Bore diameter Article

crankpin diameter clearance vertical denomination
diameter (shells fitted)
0.4 349.6 0 7.6 0 349.6 + 0.29 200

-0.06 - 0.02 + 0.22
1.2 348.8 0 8 0 348.8 + 0.29 202

-0.06 - 0.02 + 0.22
0 0 + 0.29
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3.0 347 8.9 0.22 - 0.35 347 204
- 0.06 - 0.02 + 0.22
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5.0 345 0 9.9 0 345 + 0.29 205
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- 0.06 - 0.02 + 0.22
8.0 342 0
- 0.06
11.4 0
- 0.02
se 342 + 0.29
+ 0.22
206 *
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* Undersized bearing shells with article denomination 206 may only be fitted after consulting New Sulzer Diesel Ltd.
Working procedure for fitting

a
For fitting the bearing shells the shell rear side and the bore in the crankpin bearing body must be free from any damage.
rn
Smear the running surface of the bearing shells lavishly with clean engine lubricating oil.
- Fit the upper bearing shell equally spaced axially and radially into crankpin bearing upper part 3. Make sure that the
small tongue of the shell fits into the recess in the crankpin bearing upper part.
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- Actuate hydr. hand pump 9408.02 to slightly raise connecting rod 13 together with crankpin bearing upper part 3, then
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loosen securing screw 10.

- Slowly lower the oil pressure by the relief valve of hydr. hand pump, till the bearing shell together with crankpin bearĆ
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ing upper part and connecting rod rests on the crankpin.

- Remove hydraulic jack 9408.35, the underlay 9433.02b as well as removal device 9433.02 with the pins 9433.02a.
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- Mount the bearing shell to the crankpin lower part 4 in the same manner as in upper part 3 described above.
- Using lowering device 9433.03 and rollers 9433.03a, lift crankpin bearing lower part with its bearing shell till it rest
against the crankpin.
- Fit the four nuts to studs 1.
- Tighten nuts of studs 1 as described in group 3302-2.
- Tighten nuts of studs 2 as described in group 3302-2.
Remark The nuts of studs 1 should always be tightened before the ones of studs 2.
After completion of work remove all tools from the crankcase.

For a final check measure the bearing clearance on the fully fitted bearing and compare it with the values in Clearance
and Wear Table 0352-1.
12.96 / L-Mot. 2 Wärtsilä Switzerland Ltd

13
9433.02 10 9433.02b II - II
7 3
6 9433.03
11
8
1
9
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5
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4
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9408.02 9408.35 9433.03a
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3
10
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11
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6 9433.02b
7
9433.02 12 4 5
9408.35
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12
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12
9433.02a
95.7237a
II
Wärtsilä Switzerland Ltd 3 z L-Mot. / 12.96

Connecting Rod
Loosening and PreĆTensioning the Studs of the Lower Connecting Rod Head

1 Hydr. hand pump 9408.02 1 Connecting rod C Arrangement of the hydr.
1 Branch piece 9408.03 2 Crankpin bearing jacks for preĆtensioning
1 Pressure gauge 9408.04 upper part the studs to the connecting
2 HPĆhoses 9408.09 2a Crankpin bearing rod.
2 Hydr. jacks 9433.01 lower part D Arrangement of the hydr.
1 Round bar 9433.01a 3 Piston of jack jacks for preĆtensioning
4 Cylinder of jack the studs of the bearing.
* 5 Stud T Bearing body separation
6 Round nut
7 Compression shim * Tightening according
to instructions
y
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Remark To prevent damage to the components, the crankshaft may not be rotated after the preĆtensioning
jacks are mounted!
O
Lubrication of the stud threads in addition to the oil which is already present is not necessary.
Loosening se
Attention If the long studs have to be slackened (inspection or removal of lower crankpin bearing shell), the
short studs must always be slackened as well.
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In case the short studs have to be slackened (withdrawal of a piston), the long studs must not be
slackened.
a
The procedure for slackening the studs to the connecting rod (short studs) is the same as for the studs of the crankpin
bearing (long studs).
rn
Turn the crankshaft to a position corresponding to the one in Fig. 'C' or Fig. 'D'.
e
Working procedure:
nt
- Clean the contact faces of the preĆtensioning jacks.
- Screw the preĆtensioning jacks 9433.01 crosswise onto two diagonally opposite studs 5, till their cylinders 4 rest against
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the foot of the connecting rod or the bottom end connecting rod head.
Fo
- Connect the preĆtensioning jacks by HPĆhoses 9408.09 with the hydr. hand pump 9408.02.
- Open relief valve on hydr. hand pump, and screw the pistons 3 of the preĆtensioning jacks in, till they land on the cylinĆ
ders of the preĆtensioning jacks (see Fig. 'A').
- Now turn the preĆtensioning jacks back a little until a gap of about 2 3 mm appears between the preĆtensioning jack
and the connecting rod foot or the crankpin bearing body. If the clearance is too small, there may be difficulty unĆ
screwing the preĆtensioning jacks. If it is too large, the jack stroke may not suffice to stretch the studs by the required
amount.
- Build up a pressure of 600 bar (or a little more) with the hydr. hand pump and unscrew the two nuts of the studs by
about 4 5 hole intervals.
- Release the pressure to 'zero', remove the preĆtensioning jacks and repeat the same procedure on the other two studs.

PreĆtensioning
Attention In case the long and short studs were slackened (see under loosening), the long studs must always be
tightened before the short ones.
1. Studs to the connecting rod (short studs)

- Clean the contact faces of the nuts 6, screw them on and tighten them with the round bar 9433.01a until landed.
- Screw preĆtensioning jacks 9433.01 crosswise onto two diagonally opposite studs till their cylinders 4 are landed.
- Connect the jacks with the hydr. hand pump 9408.02 by the HPĆhoses 9408.09.
- Open the relief valve of the hydr. hand pump and screw the pistons 3 completely into the jacks until they rest on the
cylinder of the jacks (see Fig. 'A').
- Build up a pressure of about 100 bar with the hydr. hand pump and keep this pressure constant.
y
- Tighten the round nuts 6 with the round bar until they are firmly seated (check seating with feeler gauge).
- Release the pressure to 40 bar.
nl
- Measure protrusion 'X' of piston and make a note of it (see Fig. 'B').
- Raise tensioning pressure to 600 bar. Keep this pressure constant and tighten the nuts 6 with the round bar until they
O
are firmly seated (check seating).
- Release pressure to 40 bar and measure protrusion 'X1' of piston on both preĆtensioning jacks and make a note of it
se
(see Fig. 'B'). When the waisted studs are correctly preĆtensioned the elongation amounts to: X1 - X = 0.50 ± 0.1
mm.
- If the measured elongation deviates considerably from the above figure, repeat the whole procedure.
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- Release the pressure to 'zero' and finally preĆtension the other two studs in the same way.
2. Studs to bottom end connecting rod bearing body (long ones)

a
Preparations and work sequence are similar to the studs for top end bearing body (short ones) as described under 1).
- In order to ensure a correct seating of all bearing components, mount the preĆtensioning jacks crosswise on two oppoĆ
rn
site studs and connect them to the hydraulic hand pump. Raise first a pressure of 600 bar and keep this pressure for a
short period of time. Following this lower the pressure to 200 bar and keep this pressure constant, till nuts 6 have been
tightened to their seatings.
e
- Release pressure to 'zero' then mount the jacks onto the two studs not yet preĆtensioned. Tighten these equally in
nt
accordance with the above described process, whereby these studs also have to be preĆtightened first to 600 bar and
this pressure kept for a short period. Following this lower the pressure again to 200 bar and tighten nuts 6 till seated.
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- In this condition, i.e. all four studs preĆtensioned with 200 bar, no gap may remain between the two bearing body
halves at 'T' (see Fig. 'D').
- Release pressure to 40 bar and measure protrusion 'X' of piston on both preĆtensioning jacks and make a note of it
Fo
(see Fig. 'B').

- Raise a pressure of 600 bar on both jacks, keep this pressure constant and tighten the nuts 6 until they are fully seated
(check nut seating by feeler gauge).
- Release pressure to 40 bar and measure protrusion 'X1' (Fig. 'B') and record it.
- The difference 'X1' - 'X' is the elongation which should amount to 0.8 ± 0.05 mm.
- Release the pressure to 'zero' and reĆmount both jacks on the studs previously preĆtensioned to 200 bar. Raise again
the pressure to 200 bar and tighten nuts 6 till fully seated.
- Release pressure to 40 bar and measure protrusion 'X' of piston on both preĆtensioning jacks and make a note of it
(see Fig. 'B').
- Raise pressure to 600 bar tighten nuts 6 till fully seated (check seating by feeler gauge).
- Release pressure to 40 bar and measure protrusion 'X1' on both jacks (Fig. 'B').
- The difference 'X1' - 'X' is the elongation which should amount to about 0.8 ± 0.05 mm. In case of substantial deviĆ
ation the preĆtensioning procedure must be repeated on all four studs.
- After completion of the preĆtensioning, release pressure to zero and remove the preĆtensioning jacks (see respective
instructions). Close open connections by dust caps, then store preĆtensioning jacks and hydr. hand pump with hoses in
a clean dry space.

3
A
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9433.01
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4
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5*
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6
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95.7238
a
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B
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Fo
X1
6
95.7063

C
9433.01
9433.01a
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1
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2
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9408.09 9408.04
7 9408.02
D 7
a
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9408.02

Rotating Piston
Removal and Fitting a Piston

1 Wear ridge milling tool 9421.09 1 Piston 6 Piston ring
1 Carbon removing machine 9421.10 2 Connecting rod 7 Oil scraper ring
(for carbon removal in upper 3 Studs 8 Cylinder liner
part of cylinder liner) 4 Connecting rod head 9 Compression shim
1 Guide rod 9434.05 5 Screw
1 Eye screw 9434.08
1 Insertion funnel 9434.10
As the compression shim 9 is subject to wear, it is Piston removal (Fig. 'A')

Remark necessary to check them for fretting and cracks durĆ
ing every piston overhaul. Damaged compression - Drain cylinder cooling water from
the engine.
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shims must be replaced, however as a rule, shims 0.5
mm thick must be replaced by new ones during every - Remove the cylinder head of the
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piston overhaul. cylinder concerned
(please refer to group 2701-1).
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5 9434.08
- Possibly developed wear ridge in
A 1 the cylinder liner, to be removed
with the wear ridge milling tool
se 9421.09. For this follow the
instructions on group 2105-1.
- On cylinder liners, the uppermost
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portion is provided with a fine
thread. The combustion residues
must first be removed by the carĆ
a
bon removing machine 9421.10

(see group 2105-1) before the
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2
piston may be pulled.
- Slacken preĆtension of connecting
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rod studs 3 hydraulically, remove

9
3 their nuts
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4
9434.05 - Ensure that the cylinder liner 8 is
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fastened by the screw 5.

- Turn the crankshaft till the piston
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is in T.D.C., screw eye screw

9434.08 into the piston top. (if
necessary clean the threaded hole
of carbon with a threading tap,
(M20).).
95.7240
- Fasten the guide rod 9434.05 onto the connecting rod head 4.
- Connect the piston to the crane with a shackle and a rope (weight of piston about 450 kg).
- Pull the piston slowly out of the engine with the crane, while holding the connecting rod head steady with the rod
9434.05 until the connecting rod 2 has been lifted out of the studs.
- Clean the removed piston carefully and measure the ring grooves (please refer to Clearance and Wear Table group
0352-1). For the cleaning of the piston use only tools which cannot damage the piston.
Attention After pulling the piston the four studs 3 must be immediately removed!
The crankshaft may not be barred while studs 3 are fitted, as there is the risk of damage to the cylinĆ
der liner 8, as well as to the studs.

Fitting the piston (Fig. 'B')
- Clean the cylinder liner bore carefully and liberally apply engine oil all over its bore.
- Turn the crank to T.D.C. and fasten the guide rod 9434.05 onto the connecting rod head 4.
- Clean the piston 1 carefully and attach it to the crane hook with eye screw 9434.08, shackle 9421.10 and a rope.
- Fit new piston and oil scraper rings to the piston (please refer to group 3402-1) and turn the rings so that their ends
are offĆset by 180_ degrees.
- Smear piston and rings with clean engine oil.
- Check the insertion funnel 9434.10 carefully for ridges or scratches, apply engine oil liberally on its taper bore and
place it on the cylinder liner. (Ridges in the insertion funnel would damage the piston and (sealing) surfaces of the
rings).
- Lower the piston carefully into the cylinder liner, until the foot of the connecting rod is just above the studs 3. Turn the
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piston with the connecting rod until the marking on the foot of the connecting rod is on the same side as the one on the
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connecting rod head.
- Check the contact surfaces of connecting rod foot and connecting rod head, they must be clean and free from oil.
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- Place the connecting rod head 4 with the aid of guide rod 9434.05 so that its top surface is parallel to the bottom surĆ
face of the connecting rod foot.
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- Now lower the piston fully, while taking care that the foot of the connecting rod slides over the studs 3 in the connectĆ
ing rod head without jamming.
- Remove the guide bar 9434.05.
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- Unscrew the eye screw 9434.08

B 9434.10
9434.08 from the piston crown and reĆ
move the insertion funnel
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6 1
9434.10.
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9434.10
8 - Fit the connecting rod nuts by
hand onto the studs 3 until they
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are seated (do not grease the

thread).
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- Turn the crankshaft until the pisĆ

ton is in B.D.C.
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7
- PreĆtension the connecting rod
2 waisted studs according to
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instructions
- Fit the cylinder head (please refer
to group 2701-1) and connect
the various pipes.
3
- Fill the cylinder cooling water
into the engine and ready the enĆ
9434.05 gine for operation.
4
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Wärtsilä Italia S.p.A. 3 ` L-Mot. / 06.02

Rotating Piston

1 Torque wrench 9408.17 1 Piston crown 16 Screw with
(480 940 Nm / ¾") 2 Piston ring locking plate
1 Ring screw M20 9434.08 2a Piston rings 17 Retaining plate
1 Piston clamping device 9434.09 3 OĆrings 18 Spherical head
2 Clamping bolts 9434.11 3a OĆring 19 Oil scraper ring
2 Ring screw 9434.12 4 Upper spherical shell 20 Centring pin (long)
2 Jacking screws 9434.13 5 Guide bush 21 Pin
2 Centring rings (wood) 9434.14 6 Ratchet pawl 22 Centring dowel
2 Ring screws M12 7 Ratchet ring 23 Stop piece
2 Jacking screws M20 8 Ring spring 24 Cyl. pin
1 Socket spanner AF 24 9 Ring 25 Ring screw
assorted open end and 10 Piston skirt 26 Wooden underlay
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ring spanners 11 Lower spherical shell 27 Nozzles
12 Supporting ring
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*13 Waisted screw OB Bore for inner
14 Spring guide piece cylinder lubrication
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15 Spring * Tightening according
to instructions
Remark
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Depending on the output and design execution of the engine, variations in the design of the piston
may be fitted see Fig. 'A', whereby on a given engine, only pistons of the same design execution may
be fitted.
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· Variant 1: For engines with an output of 600 kW/Cyl. and 660 kW/Cyl.
· Variant 2: For engines with an output of 720 kW/Cyl.
· Variant 3: Piston with inner cylinder lubrication for the complete power range.
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The following description is valid for the dismantling of a piston of all three variants.
When assembling a piston, be sure to pay attention to utmost cleanliness.
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1. Replacing a piston crown (Fig. A, B, C, D and E)

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Procedure for dismantling

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- Screw ring screw 9434.08 into the top of piston crown and suspend the piston with rope on crane (Fig. 'B').
- Fix the two centring ring halves 9434.14 with two clamping bolts 9434.11 (Fig. 'B' and 'C').
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- Turn piston and place it into the piston clamping device 9434.09, tighten its bolts moderately, so that later the piston
cannot turn (Fig. 'D').
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- Loosen all eight waisted screws 13 and remove them. Clamping bolts 9434.11 can remain in place (Fig. 'D').
- Fit a jack screw 9434.13 through each of the two holes 'b' (Fig. 'C') into the upper spherical shell 4 and tighten alterĆ
nately until the piston skirt 10 is separated from piston crown 1 (Fig. 'E') i.e. until the jacking screw 9434.13 lands on
supporting ring 12.
- The inner parts of the piston are thereby fastened together firmly, so that the piston skirt can be lifted off the piston
crown 1 with all inner parts.
Procedure for assembling
Before assembling a piston upper part check nozzles 27 of variants 2 and 3 (see Fig. 'A') for free passage.
- Place new piston crown 1 into the piston clamping device 9434.09 and tighten its bolts moderately (Fig. 'E').
- Fit new OĆrings 3 and 3a into the grooves of the piston crown and the upper spherical shell (use only original OĆrings)
and grease or oil them liberally.

- Place the complete piston skirt 10 onto the piston crown 1, match the holes for the waisted screws 13 with the threaded
holes in the piston crown.
- Smear the head landings and the thread of the eight waisted screws 13 with oil and screw them in by hand.
- Unscrew both jacking screws 9434.13, remove them and tighten the eight waisted screws 13 alternately and diagonally
until the upper spherical shell 4 rests against the piston crown 1.
Attention A gap of 1.0-1.4 mm always remains between piston crown 1 and piston skirt 10, i.e. also after fully
tightening the waisted screws 13.
- Tighten the eight waisted screws 13 with a torque wrench 9408.17 and suitable socket spanner insert (AF 24) first of all
to 120 +
-0
20
Nm (preĆtightening).
- Mark the position of each screw head to the piston skirt with a marking pen. Pay attention to the marks on the screw
collar (4 x 90_), then finally tighten the screws by an angle of 90_.
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The total torque is about 620 Nm, but the tightening must be carried out as described above.
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- After having thus fully tightened the screws 13, turn the piston back to its original position and suspend it on the crane
with ring screw 9434.08 and rope (Fig. 'B').
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- Remove the two clamping bolts 9434.11 as well as the centring ring halves 9434.14, and prepare the piston for fitting
into the engine (please refer to group 3401-1).
2. Dismantling and assembling a piston

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Working procedure for dismantling
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- Screw in the ring screw 9434.08 into the piston crown 1 and suspend the piston by a rope on the crane (Fig. 'B').
- Mount the two halves of the wooden centring device 9434.14 with the clamping bolts 9434.11 (Fig. 'B' and 'C').
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- Turn piston and place it into the clamping device 9434.09, tighten its bolts moderately, so that later the piston cannot
turn (Fig. 'D').
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- Loosen all eight waisted screws 13 and remove them. Clamping bolts 9434.11 can remain in place (Fig. 'D').
- Attach the connecting rod with a rope to the crane and lift it vertically out of the piston, the lower spherical shell 11
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and the supporting ring 12 are lifted along with it (Fig. 'F').
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- Remove the ring 9 and the ring spring 8 and place them aside.
- To prevent its getting lost later on, remove stop piece 23 off ratchet ring 7 and keep in a safe place (Fig. 'F')
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- To lay the connecting rod down without difficulty, we recommend to replace the two clamping bolts 9434.11 (Fig. 'F')
by the two ring screws 9434.12 (Fig. 'H').
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Attention Take the greatest care not to damage the spherical head of the connecting rod and the lower spheriĆ
cal shell 11.
- Fit two jacking screws 9434.13 through two threaded holes (M24) in the piston skirt and screw them in by hand until
they rest against the shoulder of the upper spherical shell 4 (Fig. 'G'). Fit ring screw M12 into the top ends of the
jacking screws and attach them by a rope to the crane.
- Tighten both jacking screws simultaneously, whereby the piston skirt 10 is separated from the piston crown 1 (Fig.
'G').
After the two parts are separated lift the piston skirt 10 off the piston crown (Fig. 'J' and 'K').
Attention The ratchet ring 7 must remain lying on the upper spherical shell 4. If necessary tap it out with a piece
of wood.
- If the ratchet mechanism has to be dismantled, remove the screws 16 after bending the locking plates up. Remove the
retaining plate 17 and push out the ratchet pawls 6 with their springs 15 and the spring guide piece 14. The same apĆ
plies to the guide bush 5.
- Assemble the ratchet mechanism in reverse sequence, clean all parts with great care before fitting and smear with oil
moderately. For locking the screws 16 use new locking plates.

- Check the two ratchet pawls for ease of movement by rotating them around their axis and pushing them inwards
against the force of the springs.
- If the lower spherical shell 11, which consists of two halves, has to be removed, fit two screws M20 for each half shell
into the supporting ring 12. From the opposite side drive in two clamping bolts 9434.11. By tightening the clamping
bolts against the M20 screws, you will press the respective spherical shell half 11 off the supporting ring 12 (please
refer to Fig. 'M').
This dismantling is best achieved by fixing the connecting rod to the floor and using two wooden blocks 26 as a working
base (Fig. 'M').
Attention The two spherical shell halves 11 are marked together. They may only be used as a unit. Single shell
halves may not be replaced, also not interchanged with another piston!
Replacement of spherical shell
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The spherical shells need not be replaced if the running surface is worn and the lead bronze becomes visible.
They must however be replaced, when bits break out of the lead bronze or when it is badly scratched by foreign parĆ
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ticles.
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3. Assembling a piston
Assembling the lower spherical shell
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- Raise the connecting rod to vertical and fix it in this position (Fig. 'M').
- Place two wooden blocks 26 of equal height on either side of the connecting rod.
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- Heat the supporting ring 12 in an oil bath or in a furnace to 120 150_C and place it on the wooden blocks. Clean the
bore and the landing with a clean cloth.
- Fit the two spherical shell halves 11 into the supporting ring 12, paying attention to the correct position of the dowel
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pin 22 (Fig. 'M' and 'C', 'A', III-III).

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- From below immediately screw in four clamping bolts 9434.11 through the supporting ring 12 into the spherical shell
halves to ensure their correct position. Do not remove the clamping bolts nor the jacking screw M20 until the supportĆ
ing ring has cooled down.
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Assembling the piston
- Place the piston crown into the clamping device 9434.09 and tighten its bolts moderately (Fig. 'O').
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- Fit new OĆrings 3 and 3a into the grooves in the piston crown and the upper spherical shell and smear them with grease
or oil (Fig. 'A' and 'O').
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- Place upper spherical shell 4 onto the piston crown 1. Pay attention to the centring pin position (Fig. 'O').
- Place the ratchet ring 7, with cylindrical pin 24 pointing upwards, on the upper spherical shell (Fig. 'O').
- Check oil bore 'OB' for inner cylinder lubrication (see Fig. 'A' variant 3) for free passage.
- Fit two jacking screws 9434.13 into the piston skirt and lower it, hanging on the crane, over the parts fitted before (Fig.
'N' and 'O').
- As soon as the centring pin 20 mates the corresponding hole, reach with the hand into the piston skirt from above and
adjust the ratchet ring 7 so that the position of the pin 21 to cylindrical pin 24 and to the machining 'AF' respectively,
corresponds to Fig. 'P'.
- Only now lower the piston skirt 10 completely, which possibly requires some strokes with a lead hammer (Fig. 'Q').
Attention A gap of 1.0-1.4 mm will always remain between piston skirt and piston crown 1.
- Now place the stop piece 23 onto the cylindrical pin 24, then fit the ring spring 8, then the ring 9 (please refer to Fig. 'P'
and 'O').
- Attach the connecting rod, spherical head 18 downwards with the lower spherical shell 11 and supporting ring 12, on
two ring screws 9434.12 and a rope on the crane (Fig. 'R').

- Clean spherical head 18 and spherical shells 4 and 11 with a clean rag and apply oil by hand, turn the ratchet pawl 6 so
that its leading edges stand vertically (Fig. 'R').
- Now insert connecting rod into the piston, guide the ratchet pawl 6 to match with ratchet ring 7 (Fig. 'S' and 'T').
When the spherical head of the connecting rod lies in the upper spherical shell 4, check the ratchet action by turning
the connecting rod around its axis. This will be possible in one direction, whereby a well audible 'Chatter' is caused.
The connecting rod should not turn in the other direction.
- Remove the ring screws on the ends of special ring screws 9434.12 and fit the 'assembly' consisting of spherical shell 11
and supporting ring 12 into the piston, paying attention to the position of centring dowel 22 (Fig. 'A', III-III), please
refer to Fig. 'R' and 'A', III-III.
- Remove special ring screws 9434.12.
- Smear the head landing surface and the thread of waisted screws 13 with oil then screw them in by hand.
- Tighten all eight waisted screws 13 with a torque wrench 9408.17 and socket insert (AF 24) first of all to 120 + 20
Nm
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-0
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(preĆtightening).
Mark the position of each screw with reference to the piston skirt with a marking pen. For this take the four markings
on the cylindrical heads of the screws into consideration (4 x 90_). Now tighten the screws fully by the angle of 90_
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(Fig. 'U').
Checking clearances se
After completed assembly, check with the feeler gauge, whether sufficient clearance exists between the spherical
connecting rod head and the lower spherical shell 11 (min. 0.07, max. 0.23 mm). The wooden centring ring must not
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be fitted yet for this checking (Fig. 'U)'
Checking the ratchet (rotating) mechanism

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Test the rotating mechanism to ensure the proper working of same as follows: The connecting rod should be turned
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against the normal direction of rotation of the piston until the pawl fully engages in a tooth, then the connecting rod
must be pushed in the opposite direction of rotation to check if the ratchet mechanism is truly engaged.
This action must be repeated tooth by tooth until a full turn of the connecting rod is completed.
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After this check fit wooden centring ring 9434.14 and fasten it by two clamping screws 9434.11 (Fig. 'U').
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Now the piston can be turned and attached to the crane by a rope and prepared for fitting into the engine (Fig. 'B').
Piston fitting see group 3401-1.
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Variant 1 A Variant 2 27
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1 I-I Variant 3
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22
95.7073
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1995
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9434.08
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a Gezeichnet für ZA40

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ZA40S
13 b DRAWN FOR ZA40

F H
9434.12
9434.14
12
9434.11 11
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9434.14
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12
11
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13
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Gezeichnet für ZA40

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DRAWN FOR ZA40

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25
9
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9434.13
8
23
24 7
10
7 10
4
4
3
1 1
3 9434.09
95.7243

K L
18
14
5
16
17
15
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9434.13
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10
M
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DRAWN FOR ZA40
Fo
9434.11
J
7 11
12 M 20
20 M 20
4
3 26
1
9434.09
95.7244

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AF
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21
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24
O
23
9434.13
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10
9
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8
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DRAWN FOR ZA40

21
7
O
7
24 10 10
1–1.4 mm
20
4
AF
3
1
1
9434.09
95.7245

9434.12
9434.14
12
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11
nl
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DRAWN FOR ZA40
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S 18
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6
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9
8 9434.14
Fo
7
9434.11 9434.11
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12
9 13
21 11
7 18
10 10
4 13
1
1
9434.09
95.7246
1995 10z Wärtsilä Switzerland Ltd

Removing and Fitting

1 Piston ring expander 9434.18 1 Piston ring 4 Garter spring
2 Piston rings
3 Oil scraper ring Cr Chrome layer
A
1 1
2 2
2 Cr 962 or 059 Top 2
3
Special layer
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Cr 1
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Piston with Piston with
inner lubrication external lubrication
231 Top
Cr se
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2
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579 Top
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Cr
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96.7225 96.7233
4 3
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Remark Piston rings of various design can be fitted into the uppermost groove of the piston crown (see Fig.
'A').
Should new piston rings and oil scraper rings be fitted, the running surface of the cylinder liner must
be honed first with the honing machine 9421.11 (see sheet 2105/1).
Use the piston ring expander 9434.18 (Fig. 'C') for removing and fitting piston rings. This tool contained in the engine
tool kit prevents overĆexpanding the rings, which would make them lose their shape.
Oil scraper rings have less tension and can be easily expanded by hand. However here also the ring must be expanded just
sufficiently as is absolutely necessary.
Jammed piston rings should first be eased with a suitable solvent instead of trying to force them out, with the result that
ring grooves in the piston are damaged. (Place the piston upside down into a carbon solvent solution).
The ring grooves must be thoroughly cleaned before fitting the rings. All carbon deposits in the bottom of the grooves
must be removed carefully. A piece from an old piston ring sharpened at one end is an excellent tool for this.

Although the flanks of the piston ring grooves are hard chrome plated, they must be checked for wear by measurement
(please refer to the Clearance Table 0325-1). It may be necessary to reĆchrome the flanks to restore them to their origiĆ
nal dimension.
In principle new piston rings and oil scraper rings must be fitted to the pistons at every overhaul of the engine, please
consider to use only original spare parts!
The piston rings and oil scraper rings are usually fitted to the thoroughly cleaned piston when it is hanging on the crane.
To fit piston rings always use piston ring expander 9434.18. This avoids overstressing the piston rings.
The marking TOP stamped on one of the ring ends has to be facing upwards! The number next to the marking TOP is the
last three digits of the corresponding drawing number (identification number). Only such piston rings and oil scraper
rings may be fitted which bear the appropriate identification numbers as listed in Fig. 'A'.
Newly fitted piston rings must not stick in their grooves.
Before fitting the oil scraper ring, first remove the garter spring from the ring. Open the garter spring by pulling apart the
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junction and introduce it into the lowest ring groove for the oil scraper ring. There push the ends together i.e. the garter
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spring is closed (please refer to Fig. 'B where the garter spring is shown in the open position).
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Now expand the oil scraper ring slightly and carefully by hand and slide it into its ring groove. The ends of the scraper ring
and garter spring should be offset from each other.
Note that the marking on the oil scraper ring end must also be facing upwards.
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Remark Oil scraper ring and garter spring are one unit, as the garter spring is matched to the corresponding
scraper ring. The two parts may therefore not be replaced individually.
Regarding clearances between ring and ring groove please refer to the Clearance and Wear Table,
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group 0352-1.
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gespannt C
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STRETCHED
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ungespannt
NOT STRETCHED
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9434.18
95.7083

Group 4
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Camshaft Drive
Checking Gear Tooth Backlash, Bearing Clearances and Adjusting Camshaft Driving Wheels

1 Feeler gauge 9408.15 1 Drive gear wheel on Fig. A View on camshaft
1 Torque wrench 9408.17 crankshaft drive gear wheel
(140 560 Nm / ¾") 2 Large intermediate gear Fig. B Longitudinal section
1 Short extension ¾" / 8" wheel of gear train of
1 Socket spanner insert 3 Small intermediate gear nonĆreversible engine
¾" / AF17 wheel Fig. C Longitudinal section
1 Straight edge 4 Camshaft gear of gear train of
(about 500 mm long) * 5, 5a Screws reversible engine
1 Depth gauge 6 End plate (driving end) M M3 Marks for correct
(measuring range about 450 mm) 7 Spacer ring position of gear wheels
Assorted double end spanners 8 Stop ring (only installed in
nonĆreversible engines) * Tightening according
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9 Oil jet nozzle to instructions
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Whenever an opportunity occurs but definitely during an overhaul, check the condition of the gear train teeth profile
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and measure the tooth backlash and the bearing clearances (please refer to Clearance and Wear Table group 0352-1).
Early detection of any tooth damage can, by prompt replacement of the gear wheels, prevent serious damage.
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Use this opportunity to also check whether the spray nozzles in the gear train space spray oil onto the gear wheels when
the lubricating oil and the preĆlubricating pump is running. Oil must also flow from the journals of the intermediate gear
wheels.
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The radial clearance of the intermediate gear wheel can be measured with the feeler gauge after removing the end plate
6 and the spacer 7.
Should it have been necessary to loosen the screws 5 or 5a, retighten them with a torque wrench at 350 Nm and secure the
a
screws with locking wire. The threads of both screws and their landing faces are to be smeared with oil.
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Adjusting the camshaft drive gear wheels (see Fig. 'A')

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Bar the crankshaft until the mark 'M' on the driving gear wheel 1 is in the topmost vertical position, which means that the
crank web next to the flywheel points vertically upwards.
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The two marks 'M2' on the large intermediate gear wheel 2 must be situated to the left and right of the mark 'M1' on the
drive gear wheel on the crankshaft.
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The camshaft gear 4 has to be so positioned that the distance 'K' from the mark 'M3' on the toothed rim to the upper edge
of the engine housing measures 432 mm. For checking this distance place a straight edge onto the engine casing.
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Remark for replacing a large intermediate gear wheel
Should a large intermediate gear wheel 2 have to be replaced, heat it to about 80 100_ C and quickly fit it in the correct
position on the small gear wheel 3 to line up the cylindrical dowel pin. Provisionally tighten some of the screws 5 before
the gear wheel has cooled.

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K = 432 mm
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9
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M3
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2
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M2
M O.T.P.
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T.D.C.
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M1
1 M
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95.7247
Gezeichnet für ZAL40

DRAWN FOR ZAL40

nicht umsteuerbar
NON-REVERSIBLE
I-I
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8
umsteuerbar
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REVERSIBLE
4
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6
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2
5*
3
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5a*
7
95.7248
Gezeichnet für ZAL40

DRAWN FOR ZAL40
95.7249

Camshaft
Checking the Cams, Removing and Fitting the Camshaft

1 Hydr. hand pump 9408.02 1 Camshaft
1 Branch piece 9408.03 *2 Screw
1 Pressure gauge 9408.04a 3 Cover of camshaft bearing
2 HPĆhoses 9408.09 4 Dowel pin
1 Torque wrench 9408.17 5 Underlay (copper, hard wood, aluminium)
1 Force multiplier 9408.19 6 Stopper ring for locating bearing
1 Socket spanner insert (only for nonĆreversible engines)
1" / AF 46
2 Hydr. jacks 9408.35 H Wooden underlay about 30 mm thick
2 RollĆout rails 9442.20
2 Supports with screws 9442.21 * Tightening according to instructions
2 Wooden spacer pieces 9442.22
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1 Eye screw M16
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Whenever the casing cover to the camshaft is removed, take the opportunity to visually inspect the condition of the runĆ
ning surface of the cams as well as the tooth profiles of the camshaft drive gear wheels. If cams are found damaged inveĆ
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stigate whether possibly springs or other parts in the housing for valve actuation or in the fuel injection pumps are defecĆ
tive.
In the course of an overhaul check in addition the radial and axial clearance in the camshaft bearings (consult Clearance
se
and Wear Table group 0352-1). If clearances are excessive remove the bearing shells and if necessary replace them.
Concerning inspection of a vibration damper on the camshaft please refer to group 3130-1.
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Removing the camshaft
- Remove all the valve push rods.

a
- Remove the fuel injection pumps and the valve actuating gear housing or lift them and support them on a wooden
underlay of about 30 mm thickness 'H'.
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- Remove the camshaft casing covers and their frames.

- Separate all the equipment driven by the camshaft from the end of the camshaft.
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- Remove those two bearing covers 3 where afterwards the rollĆout rails 9442.20 are fitted (use eye screw M16). It deĆ
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pends on the number of cylinders the engine has, on which bearings the rollĆout rails are mounted. The rails must be so
arranged that the camshaft is evenly supported.
(Fig. 'C' shows the arrangement for a nonĆreversible 8 cylinder engine).
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- Loosen the bearing screws of all the other bearings by about one turn.
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- Remove the bearing shells of the two bearings where the covers have already been removed to fit the rollĆout rails. To
do this, ease the camshaft off its bearings slightly, by two hydraulic jacks 9408.35 placed in the immediate vicinity of
these bearings with underlays 5 to protect the shaft, and applying pressure with the hand pump 9408.02. When placing
the jacks and underlays make provision that the shaft is pressed slightly away from the engine.
- Mount the two rollĆout rails 9442.20 and supports 9442.21 at the two bearings where covers and bearing shells were
removed, and press the rails against the shaft while tightening the fastening screws 7.
- Should the engine tilt towards the camshaft side (because of the ship listing during unloading etc.) use the hand cranks
of the rollĆout rails until their holding jaws are about 1 mm away from the camshaft to prevent its rolling out unexpectĆ
edly, while still permitting removal of the other bearing shells.
- Remove all the remaining bearings shells.
- Check again that the camshaft is not held anywhere. Turn the crank counterclockwise, thus easing back the jaws of the
rollĆout rails and pull the camshaft out on the rails.

- To move the shaft away attach it with two ropes in such a way that it hangs horizontally and does not bend.
F i t t i n g the camshaft
Conditions for fitting:

- All the valve push rods are removed, the valve actuating gear casings and fuel injection pumps either removed or
raised and placed on wooden underlays 'H' of about 30 mm thickness.
- The crankshaft must be in the position where the crank of cylinder No. 1 stands vertically upwards (please refer to
group 4101-1).
Fitting
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- Mount two rollĆout rails 9442.20 and supports 9442.21 on the engine casing (it depends on the number of cylinders the
engine has, at which of the camshaft bearing the rails are mounted).
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- Place the camshaft 1 onto the rollĆout rails 9442.20.
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- Clean the bearing areas on the camshaft and the bore of the camshaft bearing shells with a clean cloth.
- By rotating the cranks of the rollĆout rails clockwise push the camshaft in until the camshaft gear wheel is just about to
engage the teeth of the intermediate gear wheel. (Note the mark on the face of the camshaft gear wheel).
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- Adjust the camshaft axially, so that it can be rolled in unhindered.
- Roll the camshaft into its bearings, making sure that the camshaft gear wheel engages the intermediate gear in the
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right position. (Observe the check dimension 'K' as per group 4101-1).
- Fit the bearing shells with clean dry outer surface and running surface of shell and shaft well oiled, leaving out the two
where the rollĆout rails are mounted. The bearing shells must be so placed that the dowels 4 of the bearing covers can
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fit into the corresponding milled holes at the joining faces.

Axially the bearing shells should be approximately flush with each other.
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- To fit the bearing shells it is necessary to slightly raise the camshaft with the aid of the hydraulic jack 9408.35 placed in
the immediate vicinity of the respective bearing. For the protection of the camshaft it is essential to place a soft metal
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(copper, aluminium) underlay 5 between the jack and the shaft.

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- Mount the bearing covers 3 and fit the screws (with locking plates) by hand. Coat thread and head landing surfaces
with MOLYKOTE paste GĆn.
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Attention Take care that the dowel 4 in the cover fits correctly into the machined holes.
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- Dismantle the two rollĆout rails 9442.20 and supports 9442.21 and fit the two remaining bearings.
- Remove all the tools used for fitting.

T i g h t e n i n g the bearing cover screws
- First tighten all screws in several steps with a torque wrench and a socket spanner 1" with 150 ± 10 Nm followed by
final tightening with an angle of 60 65_ using a force multiplier.
- Check the radial clearance of all bearings with feeler gauge 9408.15 with greatest care. The axial clearance is checked
by pushing the camshaft axially from one stop to the other.
Remark For reversible engines the reversing servomotor must first be fitted before the axial clearance can be
measured!
- If all clearances radially and axially are within the tolerances given in the clearance table, secure the screws of the
bearing covers with the locking plates.
- ReĆfit the starting air distributor, the fuel injection pumps and the valve actuating gear.
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- Bar the crankshaft with the turning gear and check that with lubricating and preĆlubricating pump running the oil
flows out from all the camshaft bearings.
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- To seal the frame of the engine casing, onto which the camshaft casing covers will later be fitted, clean them with a
degreasing agent (benzine, acetone etc.) and smear them with a sealing compound.
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II - II
A
4201–1/A1
1995 / L-Mot.
B
H
III - III III I II
1
Fo
2*
3 IV IV
4 I
5
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9408.35
9408.09
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9408.04a e
II
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4 z
9408.02 9408.03 9442.22 9442.20 9442.21 5 9408.35 9442.22 1 7 X 9442.21
Maintenance
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C IV - IV
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9442.21 1 9442.21
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9442.20 9442.20 6
Gezeichnet für 8ZAL40
ZA40S
DRAWN FOR 8ZAL40

Cams on Camshaft
Replacing Original Cams by TwoĆPart Cams NonĆReversible Engine

1 Torque wrench 9408.17 1, 1aSupports 14 Waisted screws
1 Socket spanner insert 2Stops 15 Brace
(AF17 or AF30) 3Carriage
1 Pneumatic grinder 4Air stop valve O Upper cam half
for cutting cams 5Grinding disc P Identification mark
6Feeding crank U Lower cam half
7Pneumatic grinder Z Dowel pin
8Camshaft Fig. 'A' Fuel cam
9Clamping screws Fig. 'B' Valve cam
10Guide rods Fig. 'C' Arrangement of
11Grip for side to side grinder on free end
movement of carriage 3 Fig. 'D' Arrangement of
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12 Clamping screws grinder on driving end
13 Original cams
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14 Should it become necessary to replace a cam eiĆ
A
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ther for the fuel pump or for the valve actuation,
this can be done for nonĆreversible engines, by
fitting in place of the defective one a new split
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U P
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(twoĆpart) cam. This is done as described below:
- Remove the fuel pump or the valve actuating
Z gear of the respective cam.
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- Bar the crankshaft until the centre of the cam
profile of the defective cam faces upwards so
that the parting cut will be made at the thinĆ
a
nest section (see Fig. 'C' and 'D').

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- Mount the device for cutting the cams as

shown in Fig. 'C' and 'D', whereby the two
supports 1 and 1a must be clamped onto the
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camshaft.
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14 B - Connect the pneumatic grinder 7 to an air

supply system of 6 to 7 bar.
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- Locate the two stops 2 in such a way that the

O carriage 3 when moved back and forth cannot
U P touch any neighbouring parts.
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Z - Mark the position of the cam to be replaced

on the camshaft with a felt tip pen. Use the
identification mark on the respective cam face
95.7251
as a basis:
EX = Exhaust, IN = Inlet, B = Fuel.
Mark for Exhaust cams

Mark for Inlet cams
- The working area and the adjacent space must be carefully covered with a suitable material so that no grinding dust
can find its way into the engine. The covering material must be nonĆcombustible to trap the stream of sparks.
- Immediately adjacent to the defective cam the camshaft should be protected from possible damage by a steel sheeting
of about 0.2 mm.

- After starting the grinder, the carriage 3 is moved to and fro, while the feed depth is adjusted by turning the crank 6 in
very small steps. In this manner a groove is cut in the cam until the remaining thickness of the cam is about 0.2 mm.
- Bar the crankshaft until the cam to be replaced is so positioned that a second groove can be cut exactly opposite the
first.
- The cam cutting device can now be removed entirely. Drive a steel wedge gently into the groove with a hammer to
break the cam apart.
- Before fitting the split (twoĆpart) cam the camshaft must be thoroughly cleaned and degreased. Take exceptional care
not to wipe out the marking previously made on the camshaft.
If the mark has been inadvertently wiped off, the cam must be positioned so that it corresponds to the information in
the setting table.
- The split (twoĆpart) cam is placed on the camshaft in such a way that the mark on its face corresponds with the one
made on the crankshaft before cutting the defective cam. The arrow on the face of the cam indicates the sense of
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rotation of the camshaft.
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- Smear the thread and the landing face of the heads of screws 14 with MOLYKOTE paste GĆn and tighten the screws in
by hand, only to the extent that the cam cannot shift any more. Axially the cam must be located in such a way that the
rollers actuating push rods or fuel pumps protrude equally on either side.
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- Prior to tightening the screws, their exact length must be measured and noted.
- Arrange the gaps between the two cam halves evenly, then firmly tighten the screws alternately in several steps acĆ
cording to values in the following table: se
Figure Screw elongation [mm] Tightening torque [Nm]
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'A' Fuel cam l = 0.33 ± 0.01 about 950
'B' Valve cam l = 0.27 ± 0.01 about 610
a
Attention The deciding factor for correct tightening is the specified screw elongation and it may never be exĆ
rn
ceeded!
Remark The device for cutting original cams is not part of the standard engine tool kit. It must be specially
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ordered from Wärtsiläe NSD Ltd.

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The cam replacement must only be carried out by experienced personnel which has been specially
trained for this work.
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Fo

Antriebseite
DRIVING END
95.7252
9 1a
5
2
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13
6
5
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11
2
9
3
9
7
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9
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2
9
12
13
1, 1a
2
8 9
8
15
Freies Ende
FREE END

Dismantling and Assembling NonĆReversible Engine

1 Torque wrench 9408.17 1 Oil slinger 9 Casing
(140 560 Nm) 2 Cam 10 OĆring
1 Grip screw M5 3 Flange 11 Camshaft
Various spanners 4 OĆring 12 Dowel pin
5 Control slide valve 13 Screw
5a Spring 14 Screw
5b Roller 15 Dowel pin
5c Roller pin
*6 Screw M Adjusting mark
7 Shaft K Check drilling
8 Cover P Locating mark (drill point)
8a Joint * Tightening according
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8b Screw to instructions.
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The starting air distributor generally requires no maintenance. However, approximately every fourth year during a geĆ
neral overhaul it is recommended to remove the control air slide valves 5 and to clean and check them. The clearances
O
should checked and compared with the Clearance and Wear Table group 0352-1. Also verify whether any parts require
replacement.
Removing the control slide valves

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Remark The control slide valves 5 can only be removed after the roller pins 5c have been taken out.
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Working procedure:
a
- Shut off the control air supply.

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- Loosen the screw 8b and remove cover 8.

- Loosen the screw 6 and lift cam 2 off its shaft.
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- Loosen screw 14 and remove the covers 3.

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- Press each control slide valve 5 lightly inwards against the force of spring 5a and at the same time pull the roller pin 5c
out with a grip screw (M5) and remove the roller 5b.
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- The control slide valves can now be removed.
Attention Take great care not to drop either the roller or the control slide valve on the floor!
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Fitting the control slide valves
- Smear all components lightly with oil.

- Fit each control slide valve 5 with its spring 5a into its bore and press it inwards until the roller pin 5c can be fitted
through roller and valve body.
- When all the control slide valves are fitted, place the cam 2 onto the shaft 7 and initially tighten the screw 6 slightly by
hand. (The screw thread should be smeared with oil).
- Turn the cam around till the check drilling 'K' coincides with the locating mark 'P' (drill point).
- Tighten screw 6 with a torque wrench 9408.17 to 250 Nm. In this position the mark 'M' on the face of the cam must be
in line with the axis of control slide valve cylinder No. 1 of the engine, when the piston of cylinder No. 1 is in ignition
T.D.C.
- Make sure the control slide valves are sliding easily in their bores, by pushing them inwards several times against the
force of the springs 5a. The control slide valve must return immediately to the original position.

- Fit the covers 3 equipped with new OĆrings 4 and tighten the screws 14.
- Fit cover 8 and tighten the screws 8b firmly.
Remark As long as the starting control air distributor is not under pressure, there is a clearance of about 1 mm
between the roller 5b and the cam head circle.
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II I-I
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14 3 S K 1 2 3 14

ZA40S
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4
5
5a
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5c
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K
a II
12 6*
3 z
7
Maintenance
8
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8b
8a
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M 9
11 15 10
O 13
I 95.7253
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2 K
Gezeichnet für 8ZA40 7
DRAWN FOR 8ZA40
P
4301–1/A1
1995

Dismantling and Assembling with Control Disc

1 Torque wrench 9408.17 1 Camshaft 14 Screw
(25-135 Nm) *2 Screw 15 Slotted countersunk
3 Cover head screw
4 Control disc 16 OĆring
5 Shaft 17 Washer
6 Washer 18 Check disc
7 Housing 19 DU bush
8 Cross intermediate piece 20 End casing
9 Ball 21 Intermediate shaft
10 Ring 22 Screw
*11 Nut M16
12 OĆring * Tightening according
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13 Spray disc to instructions
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The starting air distributor generally requires no maintenance. However, during a overhaul or yearly, it is recommended
to remove the control disc and to clean and check them. The clearances should checked and compared with the ClearĆ
O
ance and Wear Table group 0352-1. Also verify whether any parts require replacement.
Dismantling for checking clearances and surfaces

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If only the rotating parts, i.e. their surfaces, are to be checked, proceed as follows:
- Turn the crankshaft by means of the turning gear, so that the piston of cylinder 1 is 5° ( before ignition T.D.C..
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- Shut off the control air supply.
- Remove the inspection cover 1 for the starting air distributor.
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A
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20 20 7 3
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96.8567
96.8576
3 12 18 17 2*
- Loosen the screws 2 and remove them together with the washers 17 (Fig. 'A').
- Remove cover 3 and check if the washer 6 is still tight.
- Mark the position of the control disc 4 with regard to the housing 7.

- Draw the shaft 5 and the control disc 4 completely out of the housing 7, avoiding that the DU bushes 19 be damaged by
the cross intermediate piece 8. A spring dowel pin connects the cross intermediate piece to the shaft 5 (Fig. 'B').
- Check if the ball 9 is still in the shaft.
- Check whether the surfaces of the check disc 18 and the control disc 4 are worn.
I-I
B
1 13 20 21 8 7 19 3
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I 16
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22 4
18
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10
11*
II 6
II se
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5
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2*
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17
II - II
12
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7 12 3 15
18
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97.7597
7
20 14
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Assembling after checking without replacing parts

- If during checking the crankshaft has not been turned, the nut 11 has not been loosened, and no parts have been reĆ
placed, then lubricate the shaft 5 as well as the cross intermediate piece 8 and the control disc 4, and reassemble them
carefully.
- After assembling check the position of the control disc with the mark made beforehand.
- Install OĆring 16 and fit the cover 3 with the lubricated screws 2 and washers 17.
- Tighten the screws 2 crosswise and evenly with a torque of 80-85 Nm.
Should it be necessary to replace also the DU bushes 19 or the OĆring 12, then loosen first the control air pipes 13 from
the housing 7.
Afterwards, loosen the screws 14 and remove them together with the housing 7.

If the friction surfaces of the check disc 18 or of the control disc are badly scratched, or if the running layer of the check
disc is worn, the parts must be replaced.
Proceed as follows:
- Loosen the nut 11, the shaft 5 being fitted, and remove the nut together with the ring 10.
Attention For a clockwise rotation engine the nut 11 has a leftĆhand thread. For a counterĆclockwise rotation
engine the nut 11 has a rightĆhand thread.
- The cone of the control disc is loosened by a light blow with a lead hammer on the end of the shaft 5.
- Dismantle the control disc together with the shaft.
- Loosen the slotted countersunk head screws 15 of the check disc 18 and remove them.
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- Remove the check disc.
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Assembling and adjusting after replacing parts
- Apply a nonĆhardening sealing compound on the bearing area between the end casing 20 and the housing 7, and
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install OĆring 12.
- Fit the housing with the dowel pins and tighten the screws 14.
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- Screw down the check disc 18 on the housing 7 with the slotted countersunk head screws 15.
Attention The slotted countersunk head screws 15 must be secured with LOCTITE No. 0243.
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- Lubricate the shaft 5 including the cross intermediate piece 8 and carefully install it in the housing 7 without damaging
the DU bushes. The cross intermediate piece and the intermediate shaft 21 must mesh.
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- Push the control disc 4 onto the cone of shaft 5, lubricate the thread M16 of the shaft, and screw on the nut 11, taking
into account the leftĆhand or the rightĆhand thread.
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- Fit ring 10 and nut 11. Tighten the nut slightly by hand, so that the control disc can still be moved on the cone.
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Adjusting of the control disc

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- Turn the crankshaft by means of the turning gear, so that the piston of Cyl. 1 (or Cyl. 1R for VĆMot.) is 5° ( before
ignition T.D.C..
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- Press the control disc slightly against the check disc 18, and turn it in the rotation direction of the camshaft until the
opening of the control disc just begins to release the slot on the check disc belonging to Cyl. 1 (Fig. 'C').
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C rechtsdrehend linksdrehend
RIGHT TURNING LEFT TURNING
97.7595

- Tighten the nut 11 with a torque of 90-100 Nm.

- Check again the position of the control disc.
Checking the clearances and final assembly (Fig. 'D')

- Press the control disc 4 against the check disc until it stops.
- Measure the axial clearance between cross intermediate piece 8 and intermediate shaft 21, x1+x2ā=ā0.8-3.0 mm (see
also clearance table, group 0352-1).
- Check whether the shaft 5 not seizes up. For this, move the shaft slightly back and forth while making one revolution
with the crankshaft.
- Fit the cover 3 temporarily and press the control disc against the check disc.
- Check the clearance x = 0.7-1.7 mm between the ball 9 and the washer 6.
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- Remove the cover 3 and install OĆring 16 in the groove of the housing 7.
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- Lubricate the thread of the screws 2.
- Fit the cover 3 together with the screws 2 and the washers and tighten them with a torque of 80-85 Nm.
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- Fit the inspection cover for the starting air distributor with a nonĆhardening sealing compound, and reconnect the
control air pipes (Fig. 'A').
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x2
97.7598
2* 21 8 7 5

ShutĆOff Valve for Starting Air

2 Threaded spindles M10 9443.02 1 ShutĆoff valve casing 6 NonĆreturn valve piston
(complete) 2 Spring 7 Threaded plug
1 Pliers type 'J' 3 Threaded plug 8 Screw
for inside circlip 3a Circlip 9 NonĆreturn valve casing
1 Lead drift 3b CuĆjoint 10 Valve seat
2 Wooden underlays 4 Piston sealing ring complete
(about 60x60x250 mm) 5 ShutĆoff valve piston D Use sealing compound
Various d.e. spanners and
socket spanners
Sealing compound
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10 9 8
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95.7255
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Provided the starting air is clean, that no foreign particles can enter the valve and that no defects become evident, disĆ
mantling the valve every fourth year is sufficient.
Before you start with dismantling the valve, the shutĆoff valves on the starting air vessels must be closed. The pressure
gauge for the starting air may not show any pressure. The main starting air pipe and the control pipe must be disconnecĆ
ted from the shutĆoff valve for starting air.

Dismantling
- Place the complete valve with the screws 8 facing upwards on a work bench. (The weight is about 56 kg).
- Mark the position of the three parts 1, 9 and 10 on the circumference.
- Loosen all the screws 8 equally by about five turns and observe whether the valve seat 10 separates from casing 1 or the
casing 9 separates from valve seat 10. If this does not occur, tap lightly around the casing with a lead drift until they
have separated; it can happen that these parts stick together on account of the sealing compound used for the previous
mounting.
- Loosen the four screws 8 fully and remove them.
- Remove all inner parts, clean and check them.
- Traces of former sealing compound must be thoroughly removed from the faces of casings 1 and 9 as well as from the
valve seat 10.
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- Should the complete piston sealing ring 4 no longer be in perfect condition, it must be replaced together with its OĆ
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ring.
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Assembling (see Fig. 'B')
Smear all parts with the exception of the faces marked by 'D' on the illustration with oil immediately before assembling
the valve. se
The piston sealing ring 4, consisting of an OĆring and a sliding ring, has to be fitted with great care (without overĆstretĆ
ching it) into the shutĆoff valve piston 5, after which the other components are assembled as described below.
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- Remove the circlip 3a and the threaded plug 3 from the shutĆoff valve casing 1.
- Fit the spring 2 and the shutĆoff valve piston 5 into the shutĆoff valve casing 1.
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- Insert a threaded spindle 9443.02a into the shutĆoff valve piston 5 and tighten the nut 9443.02c thereby pulling the
piston into the casing 1, paying special attention to slidingĆin the piston sealing ring 4 into its bore.
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- Place the air shutĆoff valve 1 on two wooden underlays 'H' and apply a thin coat of sealing compound onto the sealing
faces marked 'D'.
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- Seat the valve seat 10 onto the shutĆoff valve casing 1 (note the correct position with respect to the screw holes and the
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marks made prior to dismantling the valve).

- Insert the nonĆreturn valve piston 6 with its spring 2 into the nonĆreturn valve casing 9 and prestress with the second
threaded spindle 9443.02.
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- Apply a light coat of sealing compound on the sealing faces marked 'D' of the nonĆreturn valve casing 9, and place this
onto the vale seat 10 (note the correct positioning).
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- Insert screws 8 and tighten equally and firmly with a socket spanner (AF 17), then remove the two threaded spindles
9443.02.
- Fit the threaded plug 3 with a cuĆjoint 3b, tighten firmly and secure with a circlip 3a.
- Refit the fully assembled air shutĆoff valve onto the engine.

B 9443.02a
9443.02c
9443.02b
8 7
2
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9443.02c
9443.02a 9443.02b

Inlet and Exhaust Valve Drive
Adjusting the Valve Clearance

2 Feeler gauges 9408.15 1 Valve spindle 8 Ball socket
1 Allen key AF 10 2 Valve spindle 9 Main rocker arm
1 Allen key AF 14 3 Special screw M33 10 Auxiliary rocker arm
1 Ring spanner AF 32 4 Lock nut AF 50 11 Roller
1 Ring spanner AF 50 5 Ball socket 12 Cam
6 Special screw M20
7 Lock nut AF 32 G Cam base circle
3 4 5 9 6 7 10 8
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11
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1 9408.15
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95.7257
95.7258
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The valve clearance has to be checked and reĆadjusted every time the cylinder head or the rocker arms are removed.
Should loud clicking noises be heard which appear to come from the rocker arm housing while the engine is running, stop
the engine and check the valve clearance, as possibly some valves have excessive play.
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Check and adjust the valve clearance in general on the cooled down engine.
For checking the clearance bar the crankshaft until the roller 11 of the valve actuating gear for the cylinder concerned sits
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on the base circle of the cam.

The following clearances are normal for a cooled down engine:
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INLET VALVE = 0.6 + 00.1 mm EXHAUST VALVE = 1.2 + 0.1

0 mm
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The valve clearance is adjusted as described below

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- Loosen the lock nuts 4 and 7 and turn the special screws 3 and 6 right back.
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- Push feeler gauge (0.6 mm for inlet valves or 1.2 mm for exhaust valves) fully between the ball socket 5 and the valve
spindle 1 or 2 respectively.
- Tighten special screw 3 lightly with Allen key AF 14, until the feeler gauge is slightly gripped, but can still be moved by
pulling. (The spring pressure is clearly felt).
- Leave the feeler gauge clamped in this way, hold the special screw 3 with the Allen key and tighten at the same time the
lock nut 4 firmly.
- Leave the feeler gauge clamped in valve 1. Push the second feeler gauge (of the same thickness) fully under the ball
socket 8 of valve 2.
- Tighten special screw 6 until the feeler gauge is gripped lightly.
- Hold special screw 6 with Allen key AF 10 and tighten the lock nut 7 with ring spanner AF 32 firmly.
- Pull out both feeler gauges.
Remark After tightening the lock nut the feeler gauges should be a good fit and should be movable back and
forth.

Inlet and Exhaust Valve Drive

1 Torque wrench ¾" 9408.17 1 Guide housing 16 Retaining pin
(140 560 Nm / ¾") 2 Guide piston 17 Roller pin
1 Dismantling tool 9444.01 3 Spherical end pin 18 Circlip
1 Special jack screw 9444.02 4 Spring 19 Thrust disc
2 Jack screws M 12 5 OĆring 20 Roller
1 Grip screw M 6 6 Circlip 21 Bush
1 Socket head insert 7 Spring plate 22 Engine casing
(¾" / AF 30) 8 Dowel pin 23 Special (ball head) screw
Various spanners 9 Casing for push rod 23a Lock nut
10 OĆrings 24 Special (ball head) screw
11 Connecting piece 24a Lock nut
12 Cylinder head * 25 Screw
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13 Push rod N Cam
14 Main rocker arm * Tightening according
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15 Auxiliary rocker arm to instructions
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A 23
24
23a 24a
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4
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5 1
N 16 95.7259
1 M 16 During a general overhaul or if it becomes necĆ

2 18 essary, the valve actuating gear has to be disĆ
17 21 mantled, checked and cleaned, as described
overleaf:
18
19
19 20

Dismantling
- Turn the crankshaft until the roller lies on the base circle of the cam.
- Slacken the lock nuts 23a and 24a and screw the special (ball head) screws 23 and 24 right back.
- Sway the push rod 13 sideways and remove it.
- Remove the shroud for push rod 9.
- Loosen the screws 25, fastening the valve actuating gear to the engine casing and remove them.
- Withdraw the complete valve actuating gear and place on the work bench. (If necessary use two jack screws M12 to
jack the (valve actuating gear) guide housing 1 off the engine casing. The required threaded holes have been provided
in the flange.
- Mount the dismantling tool 9444.01 as shown on
Fig. 'B'. B
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- Screw in the spindle of the dismantling tool until the
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retaining pin 16 is relieved and withdraw the pin usĆ
M 16
2 M6
ing a grip screw (M6).
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- Unscrew the spindle of the dismantling tool until
the spring pressure has slackened and remove the 16
tool. 1
- Remove all the internal parts and check on their
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condition.
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- Should it be necessary to remove the spherical end
pin 3, screw the special jack screw 9444.02 from beĆ
low into the guide piston 2 and push the spherical
end pin 3 out.
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- The roller 20 can be removed by taking the circlip 18 9444.01

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off on one side and pushing the roller pin out. (Take
care that the roller bush 21 does not fall out of the
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roller!).
- Clean all the removed parts well and check them for
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reĆuse (please also refer to the Clearance Table

group 0352-1).
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95.7260
Assembling
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- Liberally oil all the parts before assembling and fit them in reverse order to the dismantling sequence.
- To fit the retaining pin 16, press the guide piston into the guide housing 1, with dismantling tool 9444.01, as far as
necessary.
- Replace the OĆring 5 each time the valve actuating gear is dismantled.
- Before fitting the complete valve actuating gear, the landing surfaces of housing 1 and engine casing must be cleaned
well.
- Coat the threads and landing faces of screws 25 (fastening the guide housing) with oil and tighten to 290 Nm.
- After the parts have all been assembled, adjust the valve clearance as described on group 4401-1.

Reversing Servomotor
Dismantling, Checking and Assembling Reversible Engine

1 Hydr. hand pump 9408.02 1 Engine casing 20 Bearing bush
1 Branch piece 9408.03 2 Casing 21 Camshaft
1 Pressure gauge 9408.04 3 OĆring 22 Circlip
1 HPĆhose 9408.09 4 Cylinder 23 Compression spring
1 Feeler gauge 9408.15 *5 Flywheel disc 24 Slide valve
1 Depth gauge 9408.16 6 Piston 25 Taper dowel pin
1 Special spanner 9431.03 7 Guide ring 26 Screw
1 Hydr. jack 9433.07 8 Screw 27 Screws
1 Support plate 9445.01 9 Locating bearing ring 28 Dowel pin
2 Eye screws M12 10 Stop collar
2 Jack screws M12 11 Control ring AG Jacking thread
12 Cover D Apply sealing compound
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** 13 Waisted stud for assembling
14 Round nut * Shape and weight vary
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15 Connecting piece according to number of
16 Dowel pin cylinders
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17 OĆring ** Tightening according
18 Bearing rings to instructions
19 Dowel pin
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The reversing servomotor needs no maintenance during operation. It should, however, be dismantled, cleaned and
checked during a general overhaul. Worn or damaged parts must be replaced.
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Attention The camshaft must be in the end position towards the 'free end', when dismantling the reversing serĆ
vomotor. If this is not the case, start the engine for a short time in the corresponding sense of rotaĆ
tion. If this is no longer possible, remove all the actuating casings of the fuel pumps, inlet and exhaust
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valves, then push the camshaft by hand axially till the stop at the 'free end'.
Under no circumstance may the camshaft be shifted by a chain puller or a hydr. jack or similar deĆ
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vice while the engine is at standstill.

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1. Dismantling
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Working procedure:
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- Separate all the pipework from the reversing servomotor (place a container underneath).
- Loosen and remove the screws 26 and press off and remove cover 12 with the aid of jack screw M12.
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- Slacken the waisted stud 13 with the aid of hydr. jack 9433.07 and unscrew and remove round nut 14 (please refer to
section 3.1).
- ScrewĆin eye screw M12 into the cylinder 4 and attach it to the crane with a rope (Fig. 'C').
- Fasten support plate 9445.01 to the connecting piece 15 with the screws 27 and to the cylinder with two screws 26 (Fig.
'C' and 'D').
- Loosen and remove all the screws 8 and, using two of these screws (M20), press off the cylinder 4 including the parts
fastened by support plate 9445.01 from casing 2.
- If it is necessary to remove also the flywheel disc 5 from the camshaft, fit an eye screw M12 into the flywheel disc and
attach it to the crane by a rope (weight max. 65 kg).
- With the aid of two grip screws M12 and suitable spacers remove the two taper dowels 25, then apply two jack screws
M12 and press the disc off the camshaft.
- To remove the casing 2 from the engine casing use two of the screws (M20) 8 as jack screws in the threaded holes
provided in the casing for this purpose and press off the casing 2 until it is free of the dowel pins 28.
- Use an eye screw M12 and rope to attach the casing to the crane (about 120 kg) and remove it.

- To dismantle the parts which were pulled off together with the cylinder 4, remove circlip 22, then slide them off conĆ
necting piece 15 for cleaning and checking (Fig. 'A' and 'C').
Pay particular attention to the running surfaces of locating bearing rings 9 and 18. Heavy wear of the locating bearing
rings increases the axial clearance of the camshaft (please refer to Clearance Table group 0352-1).
2. Assembling
2.1 Preparations:
- Clean all the components carefully and, just prior to fitting them, smear them lightly with oil.
- Blow through all the oil bores with compressed air.
- Replace the OĆrings 2 and 17 by new genuine original OĆrings.
- Screw in the waisted screw 13 until its stop in the camshaft.
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- The camshaft must be pushed to its end position at the 'free end'.
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2.2 Working procedure:
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- Apply sealing compound to the sealing surface on the engine casing.
- Push the casing 2 over the camshaft making sure that the dowel pins 28 fit their holes (Fig. 'B').
- Fit OĆring 3 (Fig. 'B').
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- Mount the flywheel disc 5 with fitted rings 9 and 18 onto the camshaft, fit the two taper dowels 25 and tap in moderĆ
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ately. Remove the eye screw.
- Fit the cylinder 4 with all the parts shown in Fig. 'C', which are held by the support plate 9445.01.
- Fit screws 8 and tighten equally.
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- Remove the support plate 9445.01 and screw in the round nut 14 onto the waisted stud 13, until it is seated.
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- Using the hydraulic jack 9433.07, preĆtension the waisted stud 13 to 600 bar (please follow exactly the instructions
in section 3.2 and on Fig. 'E').
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- After tensioning check the axial clearance (please refer to Clearance Table group 0356-1).
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- Fit the cover 12 with a new OĆring 17 and tighten the screws 26.
- ReĆconnect all the pipes to the reversing servomotor, and to check tightness start the lubricating oil pump.
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3. Loosening and preĆtensioning the waisted stud (Fig. 'E')

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3.1 Loosening:
- Mount the preĆtensioning hydraulic jack 9433.07 onto the stud 13 until its cylinder 'Z' is seated.
- Connect the piston 'K' by HPĆhose 9408.09 with the hydr. hand pump 9408.02.
- Open the relief valve on the hydr. hand pump screw in the piston 'K' with the aid of special spanner 9431.03 until it
is seated in the cylinder 'Z'.
- Unscrew the complete preĆtensioning jack until a clearance of about 2 mm exists between cylinder and connecting
piece 15 at 'X'.
- Close the relief valve on the hydr. hand pump and preĆtension the waisted stud 13 to about 600 bar (or a little
more).
- Unscrew the round nut 14 with a round bar by about ¾ turns and release the pressure by opening the relief valve on
the hydr. hand pump.
- The round nut should now be loose, the preĆtensioning jack and the round nut can be removed.

3.2 PreĆtensioning (Fig. 'E')

- After fitting the various parts according to section 2, fit the round nut 14 onto the waisted stud 13 ensuring that the
landing faces are clean and the thread not specially lubricated.
- Fit the preĆtensioning jack 9433.07 onto the waisted stud till the cylinder 'Z' is seated on the connecting piece 15
(check seating with the feeler gauge).
- Connect the piston 'K' by HPĆhose 9408.09 with the hydr. hand pump.
- Open the relief valve on the hydr. hand pump and screw the piston 'K' with the special spanner 9431.03 into the
cylinder until it lands. (The faces of cylinder and piston are then flush at 'Y' and there is no clearance at 'X').
- Close the relief valve on the hydr. hand pump and raise a pressure of 100 bar.
- Hold this pressure constant while the round nut 14 is tightened
until seated (check the seating with the feeler gauge).
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- Release the pressure to 40 bar and measure protrusion 'X' and X1
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note it down (please refer to the adjacent Fig.).
- Raise the pressure to 600 bar, hold it constant while the round 14 Z K
X
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nut is tightened until it is seated (check the seating with feeler
gauge).
- Lower the pressure to 40 bar and measure the protrusion 'X1'
and note it down.
- Calculate check measurement nL (X1 - X).
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When the preĆtensioning has been correctly carried out this difĆ
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ference should be 0.7 ± 0.1 mm. The establishment of the check
measurement (nL) serves solely as an additional, but important
check on the tensioning. 95.7063
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1995
1 2 3 4 5 6 7 R 8
A
4500–1/A1
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9
26
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AG 11
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25
12
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Maintenance
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ZA40S
95.7261

28

ZA40S
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9445.01
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27
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18 15
Maintenance
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AG 19 10
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95.7262
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4500–1/A1
1995
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9433.07 9431.03
9408.09
9408.02 9408.04
95.7263
9408.03

Regulating Linkage
Removal and Fitting of the Spring Linkage Rod Springs

1 Depth gauge 9408.16 1, 1a Linkage joint
1 Special tool 9446.01 B 2 Circlip
Various open end spanner 3 Connecting piece
4 Springs
5, 6 Spring plate
7 Ring (2Ćpiece)
Spring removal
Should it be necessary to dismantle the spring linkage rod which serves as the connection between the governor and the
regulating linkage, the special tool 9446.01 B included in the tool kit has to be used to tension the springs 4.
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Before unbolting the linkage joint 1, dimension 'X' has to be determined and noted down. After removing the linkage
joints, the tool has to be fitted as shown in Fig. 'A' and the springs 4 put under tension until the circlip 2 can be removed.
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The connecting piece 3 can now be removed and the springs 4 unloaded (see Fig. 'B').
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Spring fitting
The reverse procedure to that of removal is used when fitting the connecting piece 3.
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The bores of the spring plates 5 and 6 are to be smeared with MOLYKOTE paste GĆn before fitting.
The linkage joint 1 has to be screwed back in until the previously determined dimension 'X' is reached exactly and then
secured with the lock nut.
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9446.01 B 1 5 6 3 1a
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MOLYKOTE paste G-n 4 7 2
95.7267

CutĆOut Servomotor

2 Threaded bars M16 x 500 1 Casing (oneĆpart) 11 OĆring
with nuts 9446.03 1a Casing (twoĆpart) 12 Valve guide
Various spanners 2 Spring 13 Piston
3 Slide valve 14 Cylinder
3a Valve body 15 Piston seal
4 Spring 16 OĆring
5 Spring plate 17 Flange
6 Piston 18 Fuel pump control shaft
7 Piston seal 19 Lever
8 Flange 20 Screw
9 Rod seal 21 OĆring
10 Snap ring 22 Clamp screw
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If the control air is well filtered and dewatered, the cutĆout servomotor requires practically no maintenance. During a
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more important engine overhaul or when functional defects have been noticed, it is recommended to dismantle the cutĆ
out servomotor and to clean it.
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Prior to dismantling, the clamp screw 22 has to be loosened and the lever 19 pushed sideways. After this proceed as
described below.
- Loosen and remove two diagonally opposed screws 20 (Fig. 'B'). se
- Fit in their place the two threaded bars 9446.03 and screw their nuts until landed on flange 17 (Fig. 'C').
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- Loosen the two remaining screws 20 and remove them.
- Loosen alternately the two nuts of the threaded bars 9446.03, paying attention that the bars themselves do not rotate,
instead the flange 8 and the piston 6 are lifted off the casing 1.
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- After the spring 2 is completely released, remove the two threaded bars and with them piston 6, flange 8 and spring 2.
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- Finally also slide valve 3, valve body 3a and spring 4 can be withdrawn.
Assembling is done in the reverse sequence to dismantling.

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- All the parts have to be clean and lightly smeared with oil prior to fitting them. The OĆrings must all be replaced by new
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genuine original ones.

- Use the two threaded bars 9446.03 for compressing the spring and fitting the piston 6 and the flange 8 (Fig. 'C').
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- Pay particular attention and care when inserting the piston 6 and the flange 8 into the casing 1, to prevent any damage
to the seal rings 7.
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- When the spring is sufficiently compressed, fit two screws 20 and tighten them.
- Remove the threaded bars and fit and tighten also the other two screws 20.
- Finally fit the lever 19 in its original position and fasten it with the clamp screw 22.
Remark
In cases where the cutĆout servomotor is equipped with a staring fuel limiter as shown in Fig. 'A1' the same instructions
apply. In addition, however, the piston 13 has to be equipped with a new OĆring and before assembling the OĆring 16
must be fitted.
If the casing is in two parts as shown in Fig. 'A2', the OĆring 21 must also be replaced.

1 2 3 4 5 6 7
A
8
9
19
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3a 11 10 20 18 22
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A2 6 7 13 14 15 16 17 20
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2 6 7 9 9446.03
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95.7266

Group 5
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Speed Governor
Oil Change WOODWARD EGBĆ58P
Key to Illustrations:
1 Access to needle valve of mechanical governor 9 Serrated governor output shaft
2 Oil level indication 10 Cooling oil outlet
3 Cooling oil inlet 11 Oil filler neck
4 Oil drain cock 12 Setting knob for SPEED DROOP
5 Connection for oil to booster inlet 13 Speed setting motor
6 Serrated drive shaft 14 Setting knob for power limitation
7 Connection for oil from booster outlet 15 Setting knob for speed (r.p.m.)
8 Feedback needle 16 Access to feedback
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EGB-58P
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13 11
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3 9 6
95.7268
Fitting and removal of the governor on the engine
When lifting off or replacing the governor, care has to be taken to ensure that the splines at the lower end of the governor
shaft do not get damaged.
Furthermore, when the governor is being replaced, the shaft must slide into the drive without binding.
Pipework and rods must be connected up stressĆfree.

Maintenance
Information concerning maintenance work, maintenance intervals and repairs is to be taken from the WOODWARD
publications which are supplied with the governor and engine.
In principle, repairs should only be made to the governor by experts from a WOODWARD service station (or specially
trained personnel). At the same time it is essential that the governor test records to be found in the engine acceptance
trial documentation be made available according to which the governor must be correctly adjusted.
We highly recommend that a complete governor, already exactly set up for the engine, be held as a spare ready to be
exchanged when necessary.
Oil change
Under good running conditions the oil can remain in the governor for up to 6 months (approx. 3000 h) or more. Should,
however, blackening or ageing of the oil be determined, it has to be renewed immediately.
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The old governor oil is to be drained off when the engine is hot and at a standstill by opening the oil drain cock 4.
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After this, fill the governor up to the upper mark on the oil level sight glass with lightweight flushing oil or clean Diesel oil
(gas oil) and run the engine at reduced speed for about one min. In order to prevent the flushing fluid from entering the
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booster and then remaining in the oil, the air pipe connection to the booster has to be removed before starting the flusĆ
hing process and reconnected afterwards.
During this short run of the engine the speed should be altered frequently so that the governor oscillates. This can be
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done by pulling the emergency stop lever (on the regulating linkage) towards the zero position and then immediately
releasing it.
The flushing or gas oil is to be drained from the governor afterwards.
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After a flushing process has been completed successfully, fill the governor with new, clean oil (for oil specification see
WOODWARD bulletin).
When the engine is running, the oil level should lie between the two marks on the oil level sight glass.
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After putting the governor back into service, the system has to be vented as described in the section 'Adjusting the droop
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feedback' in the WOODWARD bulletin.

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Speed Governor
Oil Change WOODWARD PGA58
1 Charge air connection for fuel limitation 11 Governor hood
2 Oil level indicator 12 Oil filling connection
3 Governor output position indicator 13 Overspeed checking device
4 Splined drive shaft 14 Electrical connection
5 Splined governor output shaft 15 Connection for pneumatic speed setting
6 Oil filter 16 Oil inlet connection
7 Oil connection for booster outlet No. 1 17 Oil drain connection
8 Oil drain cock 18 Oil connection for booster outlet No. 2
9 Oil connection for booster inlet 19 Knob for manual speed setting
10 Feedback needle valve
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PGA58
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13
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12
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11 14
19
15
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16 18
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2 17
6 10
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5
4
95.7269

Maintenance
Oil change
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The old governor oil is to be drained off when the engine is hot and at a standstill by opening the oil drain cock 8.
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(gas oil) and run the engine at reduced speed for about one min. In order to prevent the flushing fluid from entering the
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booster and then remaining in the oil, the air pipe connection to the booster has to be removed before starting the flusĆ
hing process and reconnected afterwards.
During this short run of the engine the speed should be altered frequently so that the governor oscillates. This can be
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done by pulling the emergency stop lever (on the regulating linkage) towards the zero position and then immediately
releasing it.
The flushing or gas oil is to be drained from the governor afterwards.
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WOODWARD bulletin).
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Speed Governor
Oil Change WOODWARD PGGĆEG58
1 Oil connection to oil cooler inlet 11 Governor hood
2 Oil level indicator 12 Oil filling connection
3 Governor output position indicator 13 Oil connection from oil cooler outlet
4 Splined drive shaft 14 Electrical connection
5 Splined governor output shaft 15 Knob for manual speed setting
6 Oil filter 16 Knob for load limit
7 Oil connection for booster outlet No. 1 17 Knob for 'speed droop'
8 Oil drain cock 18 Oil connection for booster outlet No. 2
9 Oil connection for booster inlet 19 Oil drain plug
10 Feedback needle valve
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PGG-EG 58
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12
11
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6 16
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17
18
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13
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96.7781
5 4 7 19 9 8 1

Maintenance
Oil change
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The old governor oil is to be drained off when the engine is hot and at a standstill by opening the oil drain cock 8 and by
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unscrewing the oil drain plug 19.
The oil in the oil cooler and starting booster must also be drained. Remove and clean the oil filter 6. After cleaning fit the
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filter straight away since it is essential that it be in place when carrying out the following procedure.
(gas oil) and run the engine at reduced speed for about one min.
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During this short run of the engine the speed should be altered frequently so that the governor oscillates.
Afterwards drain off the flushing or gas oil in the same way as the old oil from the governor, starting booster and oil
cooler.
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WOODWARD bulletin).
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Governor Drive

1 Torque wrench 9408.17 *1 Screw (2Ćpiece execution) 10 Bevel gear
(25 135 Nm / ½") 2 Shaft upper part 11 Bevel gear
1 Socket spanner insert (2Ćpiece execution) * 12 Screw
(Driver ½", AF 10) 2a Shaft lower part
(2Ćpiece execution) D Apply sealing compound
3 Shaft (1Ćpiece execution) OF Dry, oilĆfree for assembling
4 Casing SP Spray hole
5 Bearing bushes OE Oil inlet
6 Bearing bushes
7 Cylindrical pin
* 8 Screw * Tightening according
9 Spur gear wheel to instructions
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An annual visual check of the gear
wheels is recommended. this necessitates
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the removal of the corresponding housĆ
ing covers on the engine.
1*
D
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and the bearing bushes must be checked
for wear (please refer to Clearance and
2 Wear Table group 0352-1).
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3
2a For the replacement of the gear wheels
or the bearing bushes, the speed control
4 5 governor and the complete governor
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SP drive must be removed.

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OE 6
OF
OF Dismantling
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7
D
- Remove the locking wires securing the
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screws 8 and 12.

- Loosen the screws 8 and 12 and reĆ
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move them.
8* 95.7270
- Withdraw shaft 3 (on the 1Ćpiece type)
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or the parts 2 and 2a (on the 2Ćpiece

12* 11 10 SP 9 type) upwards and remove the bevel
gear 11.
- Pull off spur gear wheel 9, push in bevel gear 10 and remove it.
- The bearing bushes 5 and 6 are pressed in. To withdraw them use suitable tools. It is recommended to replace the
bushes in pairs; better still both pairs (5 and 6).
- The lubricating holes must be blown through with compressed air, ensure also that the spray holes 'SP' are clear.

Assembling
- For assembling the governor drive proceed in the reverse sequence to dismantling. For this all the parts must be clean
and show no wear or damage.
- Shafts and gear wheels as well as the bearing bushes to be smeared with clean oil.
- The faces of shafts and gears, marked 'OF' in the illustration, must be dry and oilĆfree.
- Fit first the shaft 3 or 2 and 2a respectively and afterwards the bevel gear shaft 10.
- Lift shaft 3 or 2 and 2a respectively a little to permit fitting the bevel gear 11.
- Smear the thread of screws 8 and 12 with oil, fit them and tighten to 70 Nm.
- Check the axial clearances of the two shafts (please refer to the Clearance Table group 0352-1) and if found in order
lock the screws with locking wire.
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- Use sealing compound to seal the casing 4 towards the engine casing and also the governor casing towards the goverĆ
nor drive casing 4.
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Tightening the screws 1
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Where the shaft is in two parts 2 and 2a, tighten the screws 1 with a torque of 22 Nm using oil as lubricant on thread and
landing face.
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Removing and Fitting the Spring

1 Ring spanner with 9408.40 1 Fuel control shaft 16 Cylinder for load limiter
extension arm 2 Clamp screw 17 Piston rings
1 Spring compressing device 9446.01A 3 Lever for safety cutĆout 18 Latch
1 Screwdriver device 19 CutĆout piston
various open end and 4 Cover 20 CutĆout shaft
ring spanners * 5 Spring 21 Adjusting screw
6 CutĆout push rod 22 Bearing flange
* in ZALĆ40S engines only 7 Cover 23 Spring
one spring is installed 8 Casing 24 Spring case
9 Threaded plug 25 Steel balls
10 Intermediate gear wheel 26 Springs
11 Driving gear 27 Shaft
12 Gear wheel on camshaft
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13 Load limiter lever
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14 Torsion spring D Use sealing compound
15 Piston for load limiter for assembling
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During an engine overhaul the condition of the
tooth profile of the drive gear wheels 10 and 11 of
the safety cutĆout device has to be checked, for
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which the cover 7 must be removed (Fig. 'C').
Through the same aperture the condition of the
4
cutĆout push rod shoulder 6, on which the latch 18
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catches, can be inspected. This shoulder may not

be either rounded nor damaged.
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Use a screwdriver and unlatch the latch 18, by

pushing it off the cutĆout push rod 6. This must be
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done while the safety cutĆout and the fuel injection

regulating linkage is still fully assembled.
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To prevent a strong recoil of shaft 27 during the cutĆ

out check of the mechanical overspeed safety cutĆ
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5
out device, hold against the front side of shaft 27
with a ring spanner and extension arm 9408.40.
A B
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For tensioning the mechanical overspeed safety

cutĆout device use the ring spanner with extension
6 arm 9408.20 as well.
Attention Due to risk of accidents the

cover 4 may never be removed
as long as the spring 5 is under
tension and the cutĆout push
rod 6 is not secured by the
spring compression device
9446.01A (Fig. 'A' and 'C').
By unlatching the latch 18 the spring 5 is partly reĆ

leased.
95.7271
9446.01A

Removal of the spring
- Remove the threaded plug 9 (Fig. 'c') and screw in spring compressing device 9446.01A into the rear end of the cutĆ
out push rod 6 (Fig. 'A').
- Turn the grip of the device 9446.01A in a clockwise direction until the spring 5 is compressed (Fig. 'A').
- Loosen the screw 2, which clamps the lever 3, and push the lever sideways away (Fig. 'C').
- Remove the cover 4 (Fig. 'A').
- Turn the grip of the device 9446.01A back in a counter clockwise direction, until the spring is decompressed (Fig. 'B').
- If it is necessary to remove the shaft 20, first decompress the spring 5, then remove the remote tachometer transmitter,
then the flange 22 (Fig. 'D').
- The complete shaft 20 including driving gear 11 and cutĆout piston 19 etc. can now be withdrawn.
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Remark Do not move the adjusting screw 21 unless absolutely necessary. If it cannot be avoided, mark its posiĆ
tion accurately beforehand, so that it can be restored to its original position.
If necessary the complete shaft must be mounted into an infinitely variable lathe, to establish the
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correct cutĆout point. (The correct cutĆout data can be obtained from the shop trial documents of the
engine). The cutĆout point can be adjusted by turning the adjusting screw 21 (please also refer to the
Operating Instructions group 5303-2).
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IV
C
I II I-I
II - II

ZA40S
1 1 13 3 14 1 13 15 16
2
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27
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3
4
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27
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3
VI
SH I
Maintenance
10
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IV III IV
SH
III - III
11
6 V V
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7 O 7
20
95.7272
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8 9 D 12 III 19 18 9
5303–1/A1
L-Mot. / 1995
IV - IV D D
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10
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D 11 20
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24
VII - VII 21
VII
VII 18
22
26 25 26
95.7273
6 24 23

Fuel Injection Pump


1 Torque wrench 9408.17 1 Pump housing 25 Thrust disc
(140-560 Nm) 2 Guide piston 26 Bush
1 Torque wrench 9408.17 3 Lower spring plate 27 Circlip
(480-940 Nm) 4 Tappet 28 Roller pin
1 Withdrawing device 9444.01 5 OĆring 29 Rod seal
1 Eye nut (ZALĆS) 9455.12 6 Upper spring plat 30 Dowel pin
1 Suspension device (ZAVĆS) 9455.13 7 Regulating rack 31 BackĆup ring
1 Grip screw M6 8 Clamp ring
2 Jack screws M12 9 Regulating sleeve A Supply chamber
* 10 Screw B Return chamber
11 Pump cover J Carrier
12 OĆring K Piston for pneumatic
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13 Deflector screw safety shutĆdown
14 Pump cylinder AS For M12 jack screws
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15 Pump plunger LF Leakage fuel
16 Cover to pneumatic LO Leakage fuel outlet
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shutĆdown device M Alignment marks
17 Set screw M1 Alignment marks
18 Return spring ON Relief groove
19
20
Circlip
Guide pin
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SO1
Oil inlet
Connecting bore for oil
21 Roller ZN Circumferential groove
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* 22 Screw for lub. and seal oil
23 Set screw * Tightening according
24 OĆring to instructions
A I-I II - II
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10*
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11 LF
B 12
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13
A
14
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9 15 23
16 24
III 8 III LO
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ON SO1
ZN
7
17 30
6 M1
5
18
J 19
4 SO
3 25
20 26
2 21 27
1 21
28
95.7278

Removing the fuel injection pump from the engine
(For simplicity sake the fuel injection pump will in this group be called pump for short)
- Bar the crankshaft, so that the roller 21 rests on the cam base circle.
- Close the shutĆoff valves for the fuel inlet and return
pipe of the relevant pump.
- Loosen all the screws 10, then tighten them again by
hand until seated. ZAL40S ZAV40S
- Loosen and remove the four screws which fasten the
pump onto the engine. 9455.12 B
9455.13
- Use two jack screws (M12) to separate the pump casing
form the engine casing and lift it until the dowel pin 30
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is no longer engaged.
(The pump can be pushed out of its guide by barring the
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engine crankshaft, whereby the cam lifts the pump.
This has to be done carefully and only when all the conĆ
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nections to the pump are removed).
- Attach pump to crane with suspension device 9455.12 95.7279
or 9455.13 and pull it out fully and move it away. Please se
refer to Fig. 'B').
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Dismantling the pump (Fig. 'A')
It will seldom be necessary to dismantle a pump into all its component parts. Usually partial dismantling suffices to replaĆ
ce some worn parts. However, the complete dismantling procedure is described below for information.
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It would be of advantage to construct a device permitting the pump to be mounted vertically with the cover upwards or
downwards, fastening it with screws similarly to the manner it is fastened on the engine.
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Working procedure:
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- Fix the pump to a work bench with the cover downwards. C

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- Mount the withdrawing device 9444.01 as shown in Fig.

'C' and, by turning its spindle, push the guide piston 2 20
in, until the pin 20 can be withdrawn with the grip screw 2
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(M6).
- Relieve the withdrawing device 9444.01 and remove it.
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M6
- Withdraw the guide piston 2 along with the parts 3, 4, 15
and 18 upwards.
- Grasp the pump plunger 15 by hand and swing it
strongly to and fro (as shown in Fig. 'D'). This will cause
the spring plate 3 to be lifted slightly off the guide pisĆ
ton 2. When the clearance is large enough, the pump 9444.01
plunger 15 can be pushed out between the lower spring
plate 3 and the tappet 4.
- For the removal of the lower spring plate 3, place an unĆ
usable pump plunger in place of the one just removed,
clamp it in a vice, and pull hard on the guide piston. 95.7280

- The roller 21 can be removed together with bush 26 and thrust discs 25, after removing the circlip 27 and pushing the
roller pin 28 out.
Attention The bush 26 is loose in the roller 21 and it, as well as the thrust discs 25, can fall out.
- Should it become necessary to replace tappet 4, press it out with a round bar
from below. D
- To remove the upper spring plate 6 and the regulating sleeve 9, loosen the locatĆ
ing screw 17.
- If it is necessary to remove also the regulating rack 7, it is important to deterĆ
mine its exact position beforehand either by measuring or by a mark, before the 15
clamp ring 8 is removed.
- After removing the cover 16, the regulating rack 7 can be pushed out of the
pump housing.
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- Now remove the screws 10, which were slackened off at the beginning, and lift 3
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4
off the pump cover 11 from the housing, by using the jacking screw (M12). 2 19
- Unscrew the locating screw 23 and push the pump cylinder 14 out with a piece of
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hard wood or a lad punch.
Attention The pump cylinder 14 and the pump plunger 15 are a matched
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pair and may not be interchanged. They are also not supplied
individually. The pump plunger must be protected from any
kind of damage. It should therefor be pushed back into its corĆ
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responding cylinder as soon as it has been removed.
95.7281
The removed parts can now be cleaned and their condiĆ IV - IV

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tion checked. (Please also refer to the Clearance and 22*

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Wear Table group 0352-1).

The various bores in the pump housing must be blown out 1
with compressed air.
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Assembling the pump (see Fig. 'A')
PreĆassembling conditions:
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- All the parts must be absolutely clean and undamaged.

- Assemble the parts in a clean and dust free place.
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- Replace all the OĆrings 5, 12 and 24 by new ones.

- The copper joint rings of the screws 13 and 23 must eiĆ
ther be annealed or replaced by new ones. 9 III - III
Assembling: II AS K 16
- Place the pump housing 1 on a work bench with the 8 7
head facing upwards.
- Insert the pump cylinder 14, with OĆring 24 fitted, into
the pump housing 1, line up the milled slot in the pump
cylinder with the hole for the locating screw 23, screw in ’0’ ’10’
the locating screw and tighten it firmly.
Dip the pump cylinder in clean diesel I I

Remark IV
oil prior to inserting it into the housĆ
ing. 29
IV 95.7282
AS II

- Invert the pump housing and place it with head downwards on the work bench.
- Insert the fuel regulating rack 7 and fit the cover 16 with its joint. Push the clamping 8 exactly to its position prior to
dismantling and clamp it firmly with its clamp screw.
- Insert the regulating sleeve 9 (toothed end first) in such a way that the mark on one tooth of the regulating rack 7
comes to lie between the two marks of the regulating sleeve 9 (please refer to Fig. 'E').
- Fit the upper spring plate 6 and insert locating screw 17 (with a copper joint) and tighten it (please refer to Fig. 'A').
- Place the spring 18 onto the upper spring plate 6 and note where the mark is on the edge of the regulating sleeve 9 (see
mark 'M1').
- Fit roller 21 with bush 26 and thrust discs 25 into the guide piston 2 and push the roller pin 28 through. Insert both
circlips 27 into the grooves on the roller pin. All these parts must be well oiled before fitting.
- Insert the pump plunger 15 between the lower spring plate 3 and the tappet 4, and tap it down with a lead punch or a
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hard wood block,until the circlip 19 snaps into the groove. (A clearance of 0.01 to 005 mm must remain between pump
plunger and lower spring plate i.e. the pump plunger must be free to rotate without jamming).
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- Grip the previously completed guide piston 2 from behind, dip the pump plunger 15 in clean Diesel oil, then insert the
guide piston with the plunger first. The mark 'M1' on the pump plunger carrier 'J' must line up with the corresponding
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marks in the slot of the regulating sleeve 9 and the milled groove in the guide piston 2 must lie on that side of the pump
where the hole for the locating pin 20 (Fig. 'A') is located in the housing.
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- Using device 9444.01 push the guide piston into the pump housing until the locating pin 20 can be inserted (Fig. 'C').
Should it be felt that the guide piston meets with resistance before the locating pin 20 can be inĆ
Attention
serted, this means that the carrier 'J' of the pump plunger has come up against the regulating sleeve.
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The device 9444.01 must then be partially released and the pump plunger slightly turned by moving
the regulating rack 7. Now tighten the device, gently attempting to push the guide piston into its
housing until the pin 20 can be inserted.
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Under no circumstances may simply more force be applied when solid resistance is suddenly felt
during this fitting.
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- Release the device 9444.01 and remove it. Now invert F

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the pump again with its head facing upwards.

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- Fit the pump cover 11 with inserted backĆup ring 31 and

OĆring 12 (see Fig. 'F') onto the pump (note position of
the connecting hole for the leak fuel pipe and the backĆ 11
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up ring). Always use a new OĆring for the assembly!

- Apply oil to the screws 10 on thread and head landing,
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insert them and tighten equally in steps to a torque of LF

140 Nm. 31
On the fully assembled pump, the fuel regulating rack 7
must be free to be moved to and fro without sticking. 12
00.7300

Preservation
Should a pump have to be put into storage for any length of time, the spaces 'A' and 'B' (Fig. 'A' I-I) have to be filled with
a thin Vaseline oil and the pump has to be stored upright. All openings must be closed with plastic plugs.
Mounting the pump on the engine
- Bar the crankshaft until the cam profile of the respective pump faces downwards.
- Check to ensure that the landing surfaces and guide elements in the engine casing and the pump are in perfect condiĆ
tion.
- Smear the guide elements with oil and carefully mount the pump, whilst ensuring that the dowel pin 30 as well as the
regulating rack engage properly (do not use any sealing compound).
- Smear the threads and head landings of the screws 22 (Fig. 'E' IV-IV) with oil and tighten the screws diagonally, in
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equal stages to a final torque of 600 Nm.
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- By moving the connecting members between the regulating linkage and pump regulating rack to and fro, ensure that
nothing is sticking.
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- Connect the pipes to the pump and open the shutĆoff valves of the fuel inlet and return pipes.
- Connect the fuel high pressure pipe up and fit the protection hose.
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- When starting the engine up check the pump for any leakage or possible abnormal heating.
Remark Where new parts have been fitted during the pump overhaul (pump plunger and cylinder), the
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clamp ring 8 on the fuel regulating rack of the pump fitted on the engine must be reĆadjusted (please
refer to group 5501-2).
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Fuel Injection Pump

Adjusting and Checking

1 Withdrawing device 9444.01 1 Pump housing 35 Dial gauge (8455.06)
1 Adjusting device (complete) 9455.02 7 Regulating rack 36 Tensioning nut
1 Intermediate piece 9455.09 8 Clamp ring 37 Clamping piece
1 Gauge 9455.10 9 Regulating sleeve 38 Waisted bolt
Various spanners Fig. 'A' group 5501-1 39 Measuring cylinder
13 Deflector screws (9455.03)
Fig. 'A' group 5501-1 40 Nozzle
14 Pump cylinder 41 Measuring pin (9455.05)
15 Pump plunger 42 Pressure gauge 0-10 bar
16 Cover (9455.07)
30 Gasket 43 Pressure gauge 0-6 bar
31 Locking plug (9455.04) (9455.08)
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32 Spring piston
33 Nozzle C Clamping device for
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34 Air hose coupling measuring pin (9455.05)
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As a rule the manufacturer adjusts the fuel injection pumps (called injection pumps for short) in such a manner that they
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deliver the same amount of fuel at a certain position of the regulating rack.
An injection pump has to be adjusted if:
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- the pump cylinder 14 with pump plunger 15, the regulating rack 7, or
the regulating sleeve 9 have been exchanged;
- the clamp ring 8 on the regulating rack 7 has been moved.
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Depending on the requirements on the engine, several design variants of pump plungers 15 may be built in the injection
pumps. However, only use one design variant of pump plungers in the same engine.
Pump plungers with the designation
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S CIT (Constant Injection Timing) or

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S VIT (Variable Injection Timing) are used.

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They in turn are marked with an execution number.

The table below shows the pump plunger executions and the relevant adjusting values of the injection pumps.
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Pump plunger Execution No. Delivery stroke Load indicator Correction factor
(mm) (Pos.)
CIT .019 15.88 8.65 -
.617 14.73 8.65 -
.958 11.77 8.65 -
VIT .542 14.73 8.65 2.07
.466 12.32 8.65 1.78
.465 12.32 8.65 1.98
For the executions, as well as for the adjusting data of the injection pumps refer to the engine setting table. The data
listed in this table must be used for checking and adjusting a injection pump.
A check or an adjustment of the injection pump can be done either outside of the engine (section A), or with the injecĆ
tion pump fitted on the engine (section B).

Remark The injection pump covers 16 can have two different connection threads for the highĆpressure pipes:
- old execution M27x1.5
- new execution M39x3
If the cover 16 shows an M39x3 connection thread, mount an intermediate piece 9455.09 on
the cover 16 before fitting the adjusting device 9455.02. Check the correct length of the meaĆ
suring pin 41! During the whole adjusting procedure the latter must protrude from the top
edge of the connection thread.
Alte Ausführung Neue Ausführung

OLD EXECUTION
A NEW EXECUTION
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9455.02
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9455.09
30
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30 41
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16
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A) Adjusting and checking of an injection pump outside the engine
S Injection pump with CIT plunger:
Example with execution No. .019: Delivery stroke 15.88 mm (refer also to the table)
Adjusting procedure:
1) Plug the leakage oil connection with the locking plug 31 of the adjusting device 9455.02 (Fig. 'C'). The fuel inlet or
return connections must remain open.
2) Place the measuring pin 41 on the pump plunger 15 and fit the adjusting device with the gasket 30 as shown in Fig.
'C'. The device is to be screwed down moderately with four waisted bolts 38.
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3) Connect the air hose to the adjusting device. The necessary air pressure at the pressure gauge 42 must be constantly
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6-9 bar.
4) Screw down the withdrawing device 9444.01 to the pump housing 1 as shown in Fig. 'B'.
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5) Bring the pump plunger 15 up with the spindle of the withdrawing device 9444.01, until the pressure gauge 43 shows
the maximum pressure (e.g. 4 bar), see 'a' in Fig. 'E'. Note down the pressure value!
6) se
Bring the pump plunger down with the aid of the withdrawing device until the pressure gauge 43 does not indicate
pressure any more; see 'b' in Fig. 'E'.
7) Run the pump plunger up until the pressure gauge 43 indicates exactly half of the maximum pressure measured
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before (e.g. 2 bar). Set dial gauge 35 to '0' with weak preĆtension ('c' in Fig. 'E').
8) Continue to run up the plump plunger until the dial gauge 35 indicates the specified delivery stroke (e.g. 15.88 mm),
see 'd' in Fig. 'E'.
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9) Loosen the clamp ring 8 (Fig. 'D') to the regulating rack 7, and move the latter until the pressure gauge 43 indicates
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half of the maximum pressure (e.g. 2 bar), see 'e' in Fig. 'E'.
In this position the clamp ring 8 is to be fitted without any clearance between pump housing 1 and clamp ring 8 with
the aid of the gauge 9455.10 (Fig. 'D').
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B
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1
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9444.01

Check: - Return the pump plunger to the initial position until the pressure gauge 43 indicates zero pressure ('f'
in Fig. 'E').
- Bring the pump plunger up until the pressure gauge 43 indicates exactly half (e.g. 2 bar) of the max.
pressure (e.g. 4 bar). Set dial gauge 35 to '0' with weak preĆtension. Start of delivery ('g' in Fig. 'E').
- Continue to run up the plunger until the pressure gauge 43 again indicates only half of the maximum
pressure (e.g. 2 bar), end of delivery. Read the delivery stroke from the dial gauge 35 (e.g. 15.88 mm),
see 'h' in Fig. 'E'.
The measured delivery stroke must correspond to the value listed in the engine setting table.
Admissible difference ± 0.02 mm. If the difference is bigger repeat the adjusting procedure.
- After checking mark the clamp ring 8 to the regulating rack 7 with an oilĆresistant paint drop (Fig. 'D').
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S Injection pump with VIT plunger:
Example with execution No. .466: Delivery stroke 12.32 mm and correction factor 1.78
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(refer also to the table)
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The same preparations are to be made as described in above items 1 to 4.
5) Bring the pump plunger 15 up with the spindle of the withdrawing device 9444.01 (Fig. 'B'), until the pressure gauge
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43 shows the maximum pressure (e.g. 4 bar), see 'a' in Fig. 'F'. Note down the pressure value.
6) Bring the pump plunger down with the aid of the withdrawing device until the pressure gauge 43 does not indicate
pressure any more; see 'b' in Fig. 'F'.
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7) Run the pump plunger up until the pressure gauge 43 indicates exactly half of the maximum pressure measured
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before (e.g. 2 bar). Set dial gauge 35 to '0' with weak preĆtension ('c' in Fig. 'F').
8) Continue to run up the plunger until the pressure gauge 43 again indicates half of the maximum pressure (e.g. 2
bar). Read the measured delivery stroke from the dial gauge 35 (e.g. 11.62 mm), see 'd' in Fig. 'F'.
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9) The dimension difference is calculated from the delivery stroke in the setting table:
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e.g. 12.32 mm
minus measured delivery stroke e.g. 11.62 mm
dimension difference = 0.70 mm
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In case of a negative dimension difference the correction becomes negative.

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The correction value is calculated from the dimension difference:

e.g. 0.70 mm x correction factor (see table)
e.g. 1.78 = 1.25 mm
The correspondent delivery stroke adjustment is calculated from the measured delivery stroke:
e.g. 11.62 mm
plus correction value e.g. 1.25 mm
final value = 12.87 mm
10) Depending on the calculated final value, bring the pump plunger up or down till the final value, e.g. 12.87 mm, has
been reached (see dial gauge 35, 'e' in Fig. 'F').
11) Loosen the clamp ring 8 (Fig. 'D') to the reglating rack 7, and move the latter until the pressure gauge 43 indicates
half of the maximum pressure (e.g. 2 bar), see 'f' in Fig. 'F'.
In this position fit the clamp ring 8 by means of the gauge 9455.10 without any clearance between pump housing 1
and clamp ring 8 (Fig. 'D').

Check: - Return the pump plunger to the initial position until the pressure gauge 43 indicates zero pressure ('g'
in Fig. 'F').
- Bring the pump plunger up till the pressure gauge 43 indicates exactly half (e.g. 2 bar) of the maximum
pressure (e.g. 4 bar).
Set dial gauge 35 to '0' with weak preĆtension. Start of delivery ('h' in Fig. 'F').
- Continue to run up the pump plunger until the pressure gauge 43 again indicates only half of the max.
pressure (e.g. 2 bar), end of delivery.
Read the delivery stroke from the dial gauge 35 (e.g. 12.32 mm), see 'i' in Fig. 'F'.
The measured delivery stroke must correspond to the value listed in the setting table.
Admissible difference ± 0.02 mm. If the difference is bigger repeat the adjusting procedure.
- After checking mark the clamp ring 8 to the regulating rack 7 with an oilĆresistant paint drop (Fig. 'D').
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Fitting of an adjusted injection pump on the engine
nl
After the injection pump has been adjusted and fitted as described in Group 5501-1, the regulating rack is to be adjuĆ
O
sted.
Set the load indicator to position 8.65 and lock it (see also items 7 to 9 "Adjusting and checking of an injection pump on
the engine").
se
By means of the gauge 9455.10 adjust the position of the regulating rack 7 (Fig. 'D'). The gauge 9455.10 must be seated
without any clearance between pump housing 1 and clamp ring 8. The thickness 10 ± 0.03 mm of the gauge corresponds
to the setting value. The clamp ring must not be moved.
Use the adjusting screws (Fig. 'D') to carry out and obtain the setting mentioned above. After that the screws must lie on
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the stop levers without any clearance, as shown in Fig. 'D'. After setting the adjusting screws secure them with lock nuts.
Attention The torsion springs of the regulating linkage must not be additionally preĆtensioned.
a
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B) Adjusting and checking of an injection pump on the engine

e
S Injection pump with CIT plunger:

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Example with execution No. .019: Delivery stroke 15.88 mm (refer also to the table)
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1) Close the shutĆoff cock for the fuel inlet and return piping.
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2) Disconnect the fuel pressure pipe from the injection pump.

3) Remove one deflector screw 13 from the pump housing.
4) Screw the fuel leakage pipe off the pump cover and plug the open connection with locking plug 31 of the adjusting
device 9455.02 (Fig. 'C').
5) Turn the engine until the roller of the injection pump is on the cam base circle.
6) Place the measuring pin 41 on the pump plunger 15 and fit the adjusting device with the gasket 30 as shown in Fig.
'C'. The device is to be screwed down moderately with four waisted bolts 38.
7) Loosen the elastic rod between speed control and regulating linkage.
8) Loosen the clamp screw of the lever to the shutĆdown servomotor and move the lever on the regulating shaft axially
until the latter can be turned freely (see group 4612-1).
9) Set the load indicator to Pos. 8.65 by means of the emergency shutĆoff lever, and lock the regulating linkage in this
position.
10) Connect the air hose to the adjusting device.
The necessary air pressure at the pressure gauge 42 must be constantly 6-9 bar.

Remark For all measurements the camshaft is to be turned forward only (considering the clearances).
If it has been turned too far, turn it back and then forward again up to the relevant measuring point.
11) Turn the engine slowly forward until the pressure gauge 43 indicates the maximum pressure (e.g. 4 bar), see 'a' in
Fig. 'E'. Note down the pressure value!
12) Slowly turn the engine backward until the pressure gauge 43 does not indicate any pressure any more, see 'b' in Fig.
'E'.
13) Turn the engine forward until the pressure gauge 43 indicates exactly half of the maximum pressure measured beĆ
fore (e.g. 2 bar).
Set dial gauge 35 to '0' with weak preĆtension ('c' in Fig. 'E'). This position means start of delivery.
14) Continue to turn the engine forward until the dial gauge 35 indicates the specified delivery stroke (e.g. 15.88 mm),
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see 'd' in Fig. 'E'.
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15) Move the regulating rack 7 (Fig. 'D') by means of the two adjusting screws at the stop levers, till the pressure gauge
43 indicates half of the maximum pressure (e.g. 2 bar), see 'e in Fig. 'E'. Fasten the screws with lock nuts.
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16) In this position fit the clamp ring 8 by means of the gauge 9455.10 without any clearance between pump housing 1
Attention se
The torsion springs of the regulating linkage must not be additionally preĆtensioned. The adjusting
screws (Fig. 'D') must lie on the stop levers without any clearance.
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Check of CIT pump plungers:
- Turn back the engine until the roller of the injection pump is on the cam base circle.
a
- Set dial gauge 35 to '0' with weak preĆtension.

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- Turn the engine forward until the pressure gauge 43 indicates exactly half of the maximum pressure = start of delivĆ
ery. Note down the measured stroke = idle stroke.
e
From the scale of the flywheel read the angle with regard to the ignition T.D.C., and note it down too = start of
delivery in crank angle degrees.
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- Continue to turn the engine forward until the pressure gauge 43 again indicates half of the maximum pressure =
end of delivery. Read the measured stroke = total stroke from the dial gauge 35 and note it down.
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Subtract the idle stroke from the measured total stroke. The result is the delivery stroke in mm.
The delivery stroke calculated in this way must correspond to the value mentioned in the setting table or to the
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relevant value in the table above; tolerance ± 0.02 mm.

- From the scale of the flywheel read the angle with regard to the ignition T.D.C., and note it down too = end of delivĆ
ery in crank angle degrees.
- After checking mark the clamp ring 8 to the regulating rack with an oilĆresistant paint drop (Fig. 'D').
After adjusting and checking an injection pump remove the gauge 9455.10 which has possibly been fitted.
The elastic rod between speed control and regulating linkage, as well as the lever for the shutĆdown servomotor are to be
refitted.

S Injection pump with VIT plunger:
Example with execution No. .466: Delivery stroke 12.32 mm and correction value 1.78
(refer also to the table)
The same preparations are to be made as described in above items 1 to 10 (see "Adjusting and checking of an injection
pump on the engine", paragraph "Injection pump with CIT plunger").
11) Turn the engine slowly forward until the pressure gauge 43 indicates the maximum pressure (e.g. 4 bar), see 'a' in
Fig. 'F'. Note down the pressure value!
12) Slowly turn the engine backward until the pressure gauge 43 does not indicate any pressure any more, see 'b' in Fig.
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'F'.
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13) Turn the engine forward until the pressure gauge 43 indicates exactly half of the maximum pressure measured beĆ
fore (e.g. 2 bar).
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Set dial gauge 35 to '0' with weak preĆtension ('c' in Fig. 'F').
14) Continue to turn the engine forward until the pressure gauge 43 again indicates half of the maximum pressure (e.g.
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2 bar). Read the measured delivery stroke from the dial gauge 35 and note down the value (e.g. 11.62 mm), see 'd' in
Fig. 'F'.
15) The dimension difference is calculated from the delivery stroke in the setting table:
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e.g. 12.32 mm
minus measured delivery stroke e.g. 11.62 mm
dimension difference = 0.70 mm
a
In case of a negative difference the correction becomes negative.

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The correction value is calculated from the dimension difference, e.g. 0.70 mm x correction factor:
e.g. 1.78 = 1.25 mm
e
The correspondent delivery stroke adjustment is calculated from the measured delivery stroke:
e.g. 11.62 mm
nt
plus correction value e.g. 1.25 mm

final value = 12.87 mm
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16) Depending on the calculated final value, turn the engine forward or backward till the final value, e.g. 12.87 mm, has
been reached (see 'e' in Fig. 'F').
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17) Move the regulating rack 7 (Fig. 'D') by means of the two adjusting screws at the stop levers, till the pressure gauge
43 indicates half of the maximum pressure (e.g. 2 bar), see 'f in Fig. 'F'.
Fasten the adjusting screws with lock nuts.
18) In this position fit the clamp ring 8 by means of the gauge 9455.10 without any clearance between pump housing 1
Attention The torsion springs of the regulating linkage must not be additionally preĆtensioned. The adjusting
screws (Fig. 'D') must lie on the stop levers without any clearance.
Check of VIT pump plungers:
- Checking of the above adjustment is to be carried out as described in "Adjusting and checking of an injection pump
on the engine", paragraph "Check of CIT pump plungers".

DRAWN FOR ZA40

C
35
(9455–06)
9455.02 36
43 (9455–08)
37 (9455–07) 42
39
34 (9455–03) 38
II II
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33 40
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32 41
(9455–04) 31 (9455–05)
30
14
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15
31 II - II
a
(9455–04) C
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D 1
1 Oil-resistant paint drop
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8
No clearance
7
7
Lock nut 8
9455.10
Adjusting screw
Stop lever
Adjusting screw
Torsion spring
Lock nut

Adjusting procedure for injection pump with CIT pump plunger

E
The adjustment takes place in alphabetical order
b f
Pressure gauge 43 Pressure gauge 43
CIT pump plunger
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Start position
End position
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Dial gauge 35 Dial gauge 35
value not important value not important
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c se g
Pressure gauge 43 Control edge Pressure gauge 43
alU Delivery stroke

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adjusted to ’0’ adjusted to ’0’

e
a e
nt

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value not important 15.88 mm
d h

value e.g. 15.88 mm 15.88 mm

Adjusting procedure for injection pump with VIT pump plunger

F
The adjustment takes place in alphabetical order
b g
Start position
End position
VIT pump plunger
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value not important value not important
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c h
Pressure gauge 43 se Pressure gauge 43
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Delivery stroke
measured

adjusted to ’0’ adjusted to ’0’
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Delivery stroke
a f
e
nt

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value not important 12.87 mm
d e i
Pressure gauge 43 Pressure gauge 43 Pressure gauge 43
Dial gauge 35 Dial gauge 35 Dial gauge 35

value e.g. 11.62 mm 12.87 mm 12.32 mm

Group 6
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Charge Air Cooler
Removal, Cleaning and Mounting

4 Shackles 1 Expansion belows 12 Tubestack plate
Various spanners 2 Diffusor 13 Gasket
Ropes 3 Screws 14 Sealing flange
4 Eye screws 4 Bracket 15 Screws
5 Air inlet housing 16 Sealing ring
5a Air cooler (Rubber 10 mm Ø)
5b Water trap 17 Tubestack
6 Screws
7 Flow reversing chamber AP Suspension points
8 Connection chamber (for cooler removal)
9 Casing of charge air cooler D Use sealing compound
10 Drain connection DR Drainage
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11 Gasket V Vent
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--- Check daily on the running engine whether the nozzle in the drain connection is unclogged, i.e. whether air is coming
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out. A clogged nozzle must e freed immediately. Should water issue with the air, check whether it is condensate or
water from the cooling system (possibly leaking cooler tubes).
--- The cooler must be cleaned if:
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a) The pressure drop of the air through the cooler exceeds the value fixed in the Operating Data Sheet table (see
Operating Manual, group 0230---1/A2).
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b) The temperature difference of the cooling water between cooler inlet and cooler outlet has risen to 12_C.
(These values refer to normal running load).
It is not always necessary to remove the cooler for the cleaning operation.
a
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Cleaning of the cooler
Water side:
e
The water side of the charge air coolers can be cleaned without dismantling the cooler. To this end the connection cham-
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ber 8 and the flow reversing chamber 7 (Fig. ’A’) must be removed, whereupon the tubes can be pushed through with tube
brushes and a liberal application of water.
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--- Sediments which cannot be removed from the tubes with the brushes, must be cleared by immersing the cooler in a
chemical solvent. Consult a specialist firm for this undertaking and follow its recommendations carefully. After such a
chemical cleaning operation, it is necessary to rinse the cooler with a neutralizing agent very thoroughly.
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(As a rule the cooler manufacturers provide special cleaning instructions, which contain all the details required).
Air side:
--- On engines equipped with a permanent charge air cooler washing device, the cooler can be ’washed’ periodically in
operation.
Where this installation does not exist it is best to remove the cooler form the engine and place it in a chemical cleaning
bath. After the cleaning the cooler must be rinsed, carefully ’neutralized’ and finally be blown through with com-
pressed air.
As cleaning agent the product of a well known firm should be used like for example:
ALTREX, HENKEL, ACC, etc.
It goes without saying that the instructions for preparing the baths and the actual cleaning procedure of the various firms
must be followed carefully.
After re-assembly of the cooler it must be subjected to a pressure test at 4 bar.

Dismantling the charge air cooler
- Shut off the water flow to the cooler and drain the cooler. (Open the cock at 'DR', or remove the threaded plug respecĆ
tively).
- Disconnect all the pipes from the cooler.
- Remove the expansion bellows 1, the diffusor 2 and the air inlet housing 5 (Fig. 'A' and 'B').
- Loosen the screw 3 of the bracket 4 and remove them.
- Remove all but a few of the screws 6.
- Attach a shackle at 'AP' on either end of the bracket 4. Fix the shackles with ropes to the crane.
- Remove the remaining screws 6 and pull the cooler horizontally sufficiently away from the charge air cooler casing 9,
that it can be rested on the floor.
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- For further dismantling remove the screws 15, which fasten the sealing flange 14 (Fig. 'C').
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- Remove the sealing flange 14 and sealing ring 16, and place the cooler upright on the floor with the connection chamĆ
ber 8 uppermost.
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- Attach four eye screws, equally spaced into the threaded holes of the connections of connection chamber 8 and attach
them with ropes to the crane hook.
- Withdraw the tubestack 17 from the casing with the crane.
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- To clean the inside of the cooler tubes, remove the flow reversing chamber 7 and the connection chamber 8 from the
tubestack 17.
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- Defective cooler tubes can be put out of action by soldering both ends or by blanking them off with tapered hardwood
plugs. The number of blankedĆoff tubes may not exceed 10% of all the tubes.
- The cleaned cooler must be subjected to a pressure test at 4 bar.
a
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Assembling the charge air cooler
- Fit the flow reversing chamber 7 and the connection chamber 8 to the cleaned cooler tubestack (use only new joints!).
e
- Place the cooler casing vertically on two wooden underlays, and set the gasket 13 on the flange (connecting chamber
end). Attach the tube stack by ropes to the crane and lower it (flow reversing chamber first) into the casing, slowly so as
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not to damage the gasket 13.

- After fastening the tubestack to the casing with the screws, place the complete cooler into a horizontal position.
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- Place gland ring 16 over the flow reversing chamber 7 protruding out of the casing over the gland frame 14, which is
fastened to the casing by screws 15.
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- The complete cooler is attached with shackles and ropes to the crane and is mounted to the charge air cooler casing 9,
in reverse sequence to the dismantling, and fastened with the screws. For the sealing between the charge air cooler
and the casing use sealing compound.
- Tighten all the screws 3, so that the bracket 4 is again fastened to the support (Fig. 'A').
- Finally connect all the water pipes to the connection chamber 8.

Remark on the use of chemical cleaning agents
If the degree of dirt deposit in the cooler necessitates a cleaning with chemical solvents, ensure firsts without any doubt
that the cooler materials are not attacked by them. For the air side cleaning, products of the following firms may for
example be used:
ALTREX . . . . by Wyandotte Chemical Corporation
ACC . . . . . . . . by Drew Chemical Corporation
Regarding the mixtures and the application follow strictly the instruction of the suppliers.
To remove sediments in the inside of the tubes chemically, we recommend to consult the cooler manufacturers. Before
using chemical agents the supplier should contact the cooler manufacturers. If difficulties are encountered regarding
the application, ask New Sulzer Diesel Ltd. indicating the cooler make and type.
Remark
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Detailed information concerning the operation, maintenance and repair of charge air coolers is provided in a separate
Instruction Manual issued by the cooler manufacturers.
Since in most cases GEA coolers are provided, it is advisable to obtain the Instruction Manuals directly from GEA at the
O
following address:
GEA Luftkühlergesellschaft Happel GmbH u. Co.
43-45 Königsallee se
D 44789 Bochum (Germany)
Should a cooler of other manufacture be fitted, the instruction material must be obtained from the respective manufacĆ
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turer.
It is also possible to order such Instruction Manuals from the engine builder or supplier. For this, the following informaĆ
tion is to be provided:
a
Engine type and number

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Engine supplier
Cooler make and type
e
Desired language
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A B
I II
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2
3
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4 AP
4
AP
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II
V
9
5b
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8
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7
D 6 5a DR D
a
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Kühler am Freien Ende

COOLER ON FREE END
10
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11 12 13 17 14 15 16
95.7274
8 11 7

B A
I II
2
4
II 4 3
AP AP
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V
5 7
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5b
8
9 se
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D DR 5a 6 D
a
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Kühler auf Antriebseite

COOLER ON DRIVING END
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10
C
16 15 14 17 13 12 11
95.7275
7 11 8

Flap for Charge Air Bypass


4 Open end spanner AF 41 1 Sleeve
2 Valve flap
3 Allen screw
4 Flange
5 Limit feeler
6 Shaft
7 Spur gear wheel
8 Cylinder
9 Spur rack
10 Piston seal ring
11 Piston seal ring
12 Solenoid valve
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A halfĆyearly functional check of the charge air bypass flap must be carried out.
For this check the control air piping to the flap controls has to be removed during an operating stop. In this condition the
O
flap can be checked for ease of movement. This can be done with the aid of an open end spanner which is applied on the
sleeve 1 (see illustration). With its help the flap can be moved from fully open to fully closed and vice versa. Should the
flap jam in any position or be hard to move, it must be dismantled in the following manner:
- Remove flap as complete unit from the bypass.
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- Loosen the screws to valve flap 2 and remove them. Remove the valve flap together with the two spring dowel pins.
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- Loosen and remove Allen screw 3. Remove sleeve 1.
- Take off limit feeler 5, loosen fastening of flange 4, remove flange. The shaft 6 can now be removed together with the
spur gear wheel 7.
a
- Loosen fastening to cylinder 8 and remove cylinder.

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- Remove spur rack.

e
Assembling
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The assembling of the bypass flap is done analogously to dismantling but in reverse sequence. Attention must be paid
that during assembly the marks on the spur gear wheel 7 mate with the mark on the spur rack 9.
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Further attention must be paid that after assembling the valve flap 2 does not touch the housing bore in any position.
Before assembly, all moving parts are to be smeared lightly with MOLYKOTE paste.
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Remark Leakages at the vent (see Fig.) indicate defective piston seal rings 11 and 12.
If only the piston seal rings 10 and 11 must be replaced, withdraw first the spur gear wheel 7 from the
shaft 6. For that the valve flap remains in situ.
Attention must be paid that during assembly the marks on the spur gear wheel mate with the mark on
the spur rack.

II - II I
2 II
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10
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9 III III
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1
se 5
11
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8
a
12
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II
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III - III
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Entlüftung
VENT
6 7 1
4
I 00.7302

WasteĆGate
Dismantling and Assembling Variant 'A'

1 Testing device 9408.26 1 Flange 8,8a Test connection
for pneumatic fittings 2 Screw 9 Limit switch
and wasteĆgate 3 Pressure piece 10 Stop plate
4 Piston 11 Piston seal ring
5 Valve 12 Piston seal ring
6 Grooved cone piece 13 O-ring
7 Spring 14 Pressure reducing valve
Should, in the course of the halfĆyearly function check of the wasteĆgate, the valve be jammed in any position or does not
open properly, then the wasteĆgate has to be dismantled in the following manner:
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- Remove wasteĆgate as a complete unit.
nl
- Loosen screwed connection to flange 1 and remove flange.
- Loosen and remove screw 2 together with its bush.
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- Loosen screwed connection to pressure piece 3 and remove the latter.
- With the aid of a wooden piece press hard on piston 4, till it is metallically seated. Simultaneously press onto valve disc
5 with sufficient force to keep the valve closed. The two grooved cone pieces 6 can then be removed.
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- Slowly relieve pressure on piston 4.
- Piston 4, valve 5 and the spring 7 can now be removed.
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Assembling
a
The assembling of the wasteĆgate is carried out analogous to the dismantling but in reverse sequence. The stop plate 10
for the valve stroke limitation as well as the regulating air pressure on the pressure reducing valve 14 may not be varied,
rn
as they have been set in correspondence with the turbocharger specification. The set values are entered in the setting
table.
Before assembly, all parts shall be lightly smeared with MOLYKOTE paste.
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14
7
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8a
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12
13
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10 10
4
2 6
II
11 2
95.7277 9
8 8
3

WasteĆGate
Dismantling and Assembling Variant 'B'

1 Testing device 9408.26 1 Housing 7 Check nut
for pneumatic fittings 2 Cover 8 Screws
and wasteĆgate 3 Piston 9 Guide ring
4 Pressure regulating valve 10 Piston seal ring
5 Stroke limiting screw 11 Outer compr. spring
6 Gasket 1 mm thick 12 Inner compr. spring
The wasteĆgate must be subjected to a monthly function check on the running engine. Should any faults appear or should
the lamp WASTEĆGATE FAILURE light up in the control room then the wasteĆgate has to be overhauled as described
below:
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- Loosen screws 8 to cover 2. Specially long screws are built in for deĆtensioning springs 11 and 12.
nl
Attention Stroke limiting screw 5 must not be adjusted !
- Dismantle piston 3. Clean piston as well as housing 1.
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- Check piston seal ring 10 and guide ring 9 and replace them if necessary.
- After reassembling smear piston lightly with oil and check its easy movement in the casing.
se
Assembling
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Assembling is carried out analogous to dismantling but in reverse sequence.
Attention Should gasket 6 (1 mm thick) need to be replaced, ensure that a gasket of the same thickness is again
a
fitted.
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Before assembling smear all moving parts lightly with clean engine oil.
Remark The holding pressure of the wasteĆgate is adjustable on pressure regulating valve 4. For this adjustĆ
e
ment utilize the tools contained in testing device 9408.26. With the aid of these adjusting tools the
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holding pressure can be correctly set. (Please refer to group 6735-1 of the Operating Manual). The
setting data is recorded in the setting table.
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4
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2
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7
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5
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8
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95.7284
3 9 10 11 12 6

Group 7
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Dismantling and Reassembly with EngineĆDriven Pumps

1 Depth gauge 9408.16 1 Pilot valve 13 Pump transport wheel
1 Torque wrench 9408.17 2 Pump housing (driven)
(480 940 Nm) 3 Bolt M16 x 50 14 Gasket
1 Puller 9471.01 4 Bearing cover 15 Shim
2 Jacking screws M16 5 Drive wheel 16 Cover
4 Eye bolts M16 6 Thrust ring 17 Spring
Various open end 7 Waisted bolt 18 Dowel pins
and ring spanners 8 OĆring
9 Bearing bushes G Place for eye bolt M16
10 Pump transport wheel K Drilling for measuring the
(driver) wheel displacement on the
11 Cover pump shaft
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12 Gasket, 1 mm thick
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With a new engine the gear teeth profiles of the pump drive wheel 5 have to be inspected after a few weeks in service.
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During a general overhaul the pump has to be dismantled and inspected. Heavily worn parts must be renewed (see CleaĆ
rance and Wear Table group 0352-1).
Dismantling
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- Drain pump.
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- Separate the pipe connections from the pump and close off their openings with blank flanges (e.g. wood) in order to
prevent the entry of foreign bodies.
a
- Remove all the set bolts clamping the pump to the engine except one.
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- Screw in four M16 eye bolts into the pump housing at 'G' (see Fig. 'B') and hang the pump (approx. 332 kg) on a lifting
hoist.
- Now remove the remaining set bolt and press off the pump from the engine with two M16 jacking screws until it is no
e
longer centred by the dowel pins 18.

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- Take away the pump and set it on a flat surface for further dismantling.
- Remove cover 16 and withdraw the pilot valve 1 and spring 17.
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Attention Do not lose the shim 15.

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- Remove both the covers 11 and turn the pump round until the drive wheel points upwards.
- Slacken off the waisted bolt 7 and remove it together with the thrust ring 6.
- Fit on the puller 9474.01 as shown in Fig. 'C' and evenly tighten its M16 bolts hard until the drive wheel 5 is released
from the shaft. If necessary, strike the rear face of the puller once or twice hard with a hammer in order to aid release.
After loosening the drive wheel 5, further dismantling is carried out as follows:
- Remove the drive wheel 5.
- Unscrew the bolts 3 and lift off the cover 4 (Fig. 'A').
- It is now possible to withdraw the pump transport wheels 10 and 13 and to inspect them (see also Clearance and Wear
Table group 0352-1).
- Should the bearing bushes 9 have to be removed, they have to be pressed out of the housing and bearing cover and the
new ones pressed in with a suitable tool.

Reassembly
- Oil all bare parts immediately before assembly.

- Slide both the pump transport wheels 10 and 13 into the housing 2 as shown on Fig. 'A' and then put on the bearing
cover 4 which is then located by dowel pins.
- Evenly tighten the bolts 3 and secure them with locking wire (2 mm diameter).
- Set the drive wheel 5 onto the shaft, whereby the tapered part of the shaft and the bore of the wheel must be clean and
dry.
- Mount the thrust ring 6. Smear the thread and landing surfaces of the bolt 7 with MOLYKOTE paste GĆn and screw it
home onto the thrust ring by hand. The initial tightening is done with the aid of a torque wrench to a torque of 50 Nm
(= starting position).
- Using a depth gauge through one of the holes 'K', measure the distance 'X' (= Outside edge of thrust ring to face of
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drive wheel) and note it down (Fig. 'D').
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- Tighten the bolt 7 further until the axial displacement of the gear wheel along the shaft comes to 1.3 ± 0.05 mm which
has to be determined by measuring the distance 'X' several times.
(Theoretically the final tightening torque would be about 700 Nm. However, the measurable displacement is the deĆ
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termining factor).
- The bolt 7 must not be secured.
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- Before fitting the pump on the engine a new OĆring 8 has to be inserted in the groove on the pump flange.
- When fitting the complete pump on the engine, its correct position is determined by the dowel pins 18 (Fig. 'B').
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I-I
9 II
8 A
10
7
K
11
6
12
13
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5
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4 14
3 15
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2
16
1 se 17
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Fuel Booster Pump
Dismantling and Assembling with EngineĆDriven Pumps

1 Depth gauge 9408.16 1 Valve body (relief valve) 18 Pump cog wheel (driving)
1 Torque wrench 9408.17 2 Stop 19 Screw
(140 560 Nm / ¾") 3 Spring 20, 20a Shaft seal
1 Puller 9474.01 4 Joint 21 Backing ring
1 Round bar 9474.02 5 Screw 22 Driving gear wheel
1 Socket spanner ½" AF30 6 Holes for dowel pins 23 Press ring
2 Jacking screws M16 7 OĆring * 24 Screw
1 Eye screw M12 8 Circlip 25, 25a Dowel pin
Various open end 9 OĆring 26 Screw
and ring spanners 10 Sealing disc
11,11a OĆring G Threaded hole
12 Bearing housing for eye bolt M12
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13 OĆring AG Threaded hole
14 Pump casing for jack screw M16
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15,15a,15b Bearing bushes
16 Pump cog wheel (driven) * Tightening according
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17 Bearing cover to instructions
On a new engine the tooth profile of the pump driving gear wheel must be inspected after a few weeks of engine operaĆ
tion. se
During a general overhaul the pump must be dismantled and checked for wear. Worn parts must be replaced (see CleaĆ
rance and Wear Table group 0352-1).
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Dismantling
- Drain the pump.

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- Disconnect the pipes from the pump casing and close its openings with blanks (for example wood) to prevent any
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foreign bodies from entering.

- Remove the screws fastening the pump to the engine with the exception of one screw.
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- Fit an eye bolt M12 in the pump casing at 'G' (see Fig. 'C') and attach the pump (about 95 kg) to the crane.
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- Now remove the last screw holding the pump to the engine. Fit two jack screws M16 at 'AG' and press the pump away
from the engine until it is no longer positioned by the dowel pins (Fig. 'A').
- Move the pump for dismantling to a work bench.
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- Loosen the screw 24 and remove it with press ring 23.

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- Fit the puller 9474.01 as shown on Fig. 'D' and tighten its two screws M16 equally and firmly, until the driving gear
wheel 22 has been pulled of the shaft. If necessary tap the centre of the puller hard once or twice with an iron hammer,
to aid the withdrawal.
After the removal of the driving gear wheel proceed with dismantling as follows:
- Remove the screws 26 (Fig. 'C') and pull the bearing housing 12 off the pump casing 14.
- Pull the OĆring 7 off the shaft.
- Loosen and remove the screws 19 and lift the bearing cover 17 off the pump casing 14.
- Remove pump cog wheels 16 and 18.
- If the shaft seals 20 have to be replaced, remove circlip 8 and backing ring 21.
- The sequence of dismantling the remaining parts is obvious from the Figs. 'A' and 'D'.
- Should it be necessary to replace the bearing bushes 15, remove the old ones with a suitable tool and press in the new
bushes with great care.

Assembling
- Clean all the parts carefully and, immediately before assembling the pump smear them with fresh oil.
The OĆrings 7, 9, 11, 11a and 13 as well as the shaft seal rings 20 and 20a must be replaced by new ones.
When fitting the shaft seal rings 20 and 20a as well as the sealing disc 10 into the pump casing be sure that also the
backing ring 21 and the circlips 8 are in place!
- Fit pump cog wheels 16 and 18 into the pump casing, fit the bearing cover 17 and insert and tighten the screws 19 all
equally and firmly.
- Fit OĆring 7 onto the driving shaft.
- Place OĆring 11 in the groove, mount the bearing housing 12, insert and tighten the screws 26 equally and firmly and
lock the screws finally with locking wire.
- Fit the driving gear wheel 22 onto the driving shaft. (The tapered part of the shaft as well as the tapered bore in the
driving gear wheel must be specially clean and dry).
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- Fit press ring 23, smear the screw 24 on thread and head landing with oil and screw in by hand until seated and tighten
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at first to about 20 Nm (= initial position).
- Measure with a depth gauge through one of the holes 'K' the distance 'X' (= outer edge press ring to front face of
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driving shaft) and note the dimension (Fig. 'E').
- Tighten the screw 24 further, until the driving gear wheel 22 has been shifted on the shaft by 0.45 ± 0.05 mm, which
must be checked by repeated measuring of the distance 'X'. se
The tightening torque is theoretically 190 Nm but the measurable shifting is the decisive factor.
- The screw 24 does not have to be locked.
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- Before fitting the pump to the engine, place the OĆring 13 into the groove of the pump flange.
- When fitting the pump on the engine the correct position is determined by the dowel pins (Fig. 'A') which must engage
with the holes 6 in the pump casing.
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A I-I IV - IV
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9474.01 24*
(SW30)
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95.7288
7102–1/A1
1995
Cylinder Cooling and Raw Water Pump

1 Hydr. hand pump 9408.01 1 Round nut 13 Bolts M16 x 50
1 Depth gauge 9408.16 2 Drive wheel 14 OĆring
1 Special spanner 9431.03 3 Sleeve 15 Cover
1 Tensioning jack 9433.07 4 Locking wire 16 Shaft
2 Jacking screws M16 5 Bolts M16 x 130 17 Impeller
2 Eye bolt M16 6 Bearing housing 18 OĆring
6a Dowel pin 19 Bearing bushes
7 OĆring 20 Piston sealing ring
8 Shaft sealing ring (GACO) 21 Rod sealing ring
9 Bush 22 Piston
10 Spacer ring 23 Cylinder
11 Rotary mechanical seal
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12 Pump housing L Leakage drain
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M16
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Gezeichnet für ZV40/48
DRAWN FOR ZV40/48
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1 2 3 4 5 6 7 8 9 10 11
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17
0.34 0.48
18
19 L
6a 95.7292
The following instructions are valid for both the cylinder cooling water and the raw water pump.
The only difference between the two pumps lies in the choice of material, form and position of the pump housing and in
the size of the impeller 17.

With a new engine the gear teeth profiles of the pump driving gear wheel 2 have to be inspected after a few weeks in
service.
During a general overhaul the pump has to be dismantled and the parts inspected. Heavily worn parts must be renewed
(see also Clearance Table 0352/14 and /15).
Should leakage from the pump leakage drain 'L' sharply increase when in service, this indicates that one or both of the
shaft sealing rings 8 and 11 no longer seal properly. Renewal of such a seal requires the dismantling of the pump and the
following to be done beforehand:
- Drain the pump and remove all the pipe connections.
- Remove all set bolts clamping the pump to the engine except one.
- Connect the pump to a lifting hoist with a rope (weight: cylinder cooling water pump 142 kg / raw water pump 184 kg).
- Now remove the remaining bolt.
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- Press off the pump from the engine, using two M16 jacking screws, take it away and place it on a work bench for further
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dismantling.
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Dismantling
- Screw the tensioning jack 9433.07 onto the thread of the shaft 16 and connect it up to the hydr. hand pump 9408.01.
Using the special spanner 9431.03, screw down the piston of the tensioning jack until the faces of the piston 22 and the
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cylinder 23 are level. Unscrew the complete hydraulic jack by about a half to a full turn (Fig. 'B').
- Tension the shaft 16 with a pressure of 620 bar and unscrew the round nut 1 by one turn.
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- Fully release the pressure. Remove the tensioning jack, round nut 1 and drive wheel 2 from the shaft.
- Unscrew the bolts 13 and remove cover 15.
- Withdraw the impeller 17, shaft 16, bushes 9 and rotary mechanical seal 11 from the pump.
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- Slacken off and remove the bolts 5. Separate the bearing housing 6 from the pump housing and remove the sleeve 3
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and the shaft sealing ring 8.

- Clean all the parts and check them for wear (see also Clearance and Wear Table 0352/13a).
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Reassembly
Preparation:
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All the individual parts must be clean and then oiled just before fitting.
The OĆrings 7 and 14 as well as the shaft sealing ring 8 have to be replaced by new ones before commencing reassembly.
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This also applies to the spacer ring 10 and the rotary mechanical seal 11.
Attention It is absolutely essential that during assembly the faces of the following parts are clean, dry and unĆ
damaged:
Shaft 16, impeller 17, bush 9, sleeve 3, driving gear wheel 2 and round nut 1.
Working procedure:
- Slide the sleeve 3 into the bearing bushes 19 and fit the shaft sealing ring 8.
- Fit the bearing housing 6 to the pump housing 12; tighten the bolts 5 evenly and hard and secure them with locking
wire (ensure beforehand that also the OĆring 7 has been laid into the bearing housing flange).
- Fit the spacer ring 10 into the pump housing.
- Slide the impeller 17 and bush 9 with the rotary mechanical seal onto the shaft 16 and assemble together.
- Smear the OĆring 14 lightly with oil and insert it in the groove in the cover, fit the latter and tighten the bolts 13 evenly
and hard.

- Screw the round nut 1 fully down without lubricating its thread.
- Screw down the hydr. tensioning jack 9433.07 with the special spanner 9431.03 so that the outer faces of the piston and
cylinder are level with each other and then connect it up to the hydr. hand pump 9408.01 (Fig. 'B').
- Tension the shaft with 100 bar, hold this presĆ 20 21
sure constant and screw the round nut 1 fully
down, then release the pressure to 40 bar.
- Measure the protrusion of piston 22 (dimension
'X') of the tensioning jack and note it down
(starting position).
1
- Increase pressure to 600 bar and keep it
constant until the round nut has been tightened
and is firmly seated.
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- Release pressure to 40 bar and measure the proĆ
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trusion of piston 22 (dimension 'X1') of the tenĆ
sioning jack. 22
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When the bolt tensioning has been correctly carĆ 9408.01
ried out, the checking dimension amounts to:
'X1' - 'X' = 1.4 ± 0.1 mm
The axial clearance of the shaft will be, with a new
pump and after tensioning shaft, about 0.34 to 0.48
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mm and this has to be checked. X
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When fitting the pump onto the engine, ensure X1
that the OĆring 18 has first been inserted in the
flange of the bearing housing 6. 23
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95.7293
(9433.07)
The pipes must be connected up to the pump
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stressĆfree.
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Fuel Valve Cooling Water Pump

1 Depth gauge 9408.16 1 Nut 14 OĆring
1 Torque wrench 9408.17 2 Drive gearwheel 15 Cover
(140 560 Nm / ¾") 3 Sleeve 16 Shaft
1 Socket head insert 4 Locking wire 17 Impeller
¾" / 30 across flats 5 Bolts M12 x 110 18 OĆring
2 Jacking screws M16 6 Bearing housing 19 Bearing bushes
Various open end 7 OĆring 20 Dowel pin
and ring spanners 8 Shaft sealing ring (GACO) 21 Split pin 3.2 x 22
9 Bush
10 Spacer ring
11 Rotary mechanical seal LS Bearing clearance
(GULLIVER GV38C) L Leakage drain
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12 Pump housing S Axial clearance
13 Bolts M12 x 40 X Checking dimension
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1 2 3 4 5 6 7 8 9 10 11 12
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21 ’LS’ 19
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S
20
L
18 95.7296
With a new engine the gear teeth profiles of the pump drive wheel 2 have to be inspected after a few weeks in service.
During a general overhaul the pump has to be dismantled and inspected. Heavily worn parts must be renewed (see
Clearance and Wear Table group 0352-1).
Should leakage from the pump leakage drain 'L' sharply increase when in service, this indicates that one or both of the
shaft sealing rings 8 and 11 no longer seal properly. Renewal of such a seal requires the dismantling of the pump and the
following to be done beforehand:
- Drain the pump and remove all the pipe connections.
- Remove all but one of the set bolts clamping the pump to the engine.

- Connect the pump to a lifting hoist with a rope (weight = 55 kg).

- Now remove the remaining mounting bolt.
- Press off the pump from the engine, using two M16 jacking screws, take it away and place it on a work bench for furĆ
ther dismantling.
Dismantling
- Remove the bolts 13 and the cover 15.

- Remove the split pin 21 and unscrew the nut 1, holding the hexagon at the impeller end of the shaft with a spanner.
- Remove the drive wheel 2 and withdraw the impeller 17 together with the shaft 16.
- The pump housing 12 can be separated from the bearing housing 6 after removing the bolts 5. Now all the internal
parts can be removed.
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Reassembly
Reasembly follows the dismantling procedure, only in the reverse order whereby the following points must be particularĆ
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ly noted:
- The bearing bushes 19 have to be lightly oiled. However, the parts 2, 3, 9, 16 and 17 must be dry before assembly.
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- The shaft sealing rings 8 and 11 as well as the OĆrings 7, 14 and 18 must be replaced by new ones.
- Ensure that the dowel pin 20 engages correctly.
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- The bolts 5 have to be secured with locking wire (diameter 2 mm) after tightening.
The nut 1 has to be tightened as follows:
- Lubricate the thread of the shaft 16 with oil.
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- Screw the nut 1 fully down onto the shoulder of the drive wheel 2, which must be possible by hand.
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- Using the torque wrench, tighten the nut 1 to an initial torque of 30+ 50 _ Nm (= starting point) then determine and
note down the dimension 'X' by means of the depth gauge 9408.16
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- The nut 1 has then to be tightened by a further ( 95+ 50 _ . Measure the distance 'x' again and note it down as 'X1'.
- When the pump has been correctly assembled and the nuts has been tightened according to instructions:
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X1 - X = 0.66 0.70 mm
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Axial clearance 'S' = 0.30 0.44 mm

Bearing clearance 'LS' = 0.045 0.091

SCAMATIC Fine Filter for Cylinder Lubricating Oil
Function Check and Maintenance

Various spanners 11 Securing screw 24 Joint
12 Lock washer 25 Screw plug
13 Joint 26 Connection union
14 Screw with nut and lock nut 27 Protective sheathing
15 Sealing ring 28 Corset
16 Lock washer 29 Screws
17 Hexagonal head screw
18 Sealing ring A Oil inlet
19 Cover B Oil outlet
20 Special sealing ring C Sludge drain
21 Filter insert D Oil outlet from actuating
22 Filter housing mechanism
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23 Sealing ring E Sludge chamber
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14 15 16 17 18 19 Function check
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se When the filter is working properly, the noise
coming from the actuating mechanism can be
clearly heard in operation (about 20 times per
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minute). In installations where oil flows continuĆ
ously through the filter when it is in operation, a
A check for correct working should be made every
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week by listening to it.

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In installations where the filter is only necessary

when the oil level in the header tank sinks below a
certain level, an operational check has only to be
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made quarterly. To do this, the level in the header

27 tank has to be appropriately lowered and the
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shutĆoff cock before the filter opened since it can

21 only work when oil flows through it.
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28
Servicing
22
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The sludge chamber 'E' of the filter housing is

29 connected to the engine casing by a pipe which alĆ
lows periodic deĆsludging. Should it be discovĆ
13 ered, however, that the cylinder lubricating oil
E 23 pumps are sludging up frequently, the filter has to
12 be dismantled, cleaned and inspected. It may be
11 24 necessary to wash the filter and this should be
25 done as follows:
26 B
95.7297
- Drain the filter.
- Separate the oil outlet pipe 'D' from the filter.
C - Unscrew the screws 14 and lift off cover 19 verĆ
tically along with all its attached parts.
- Remove the two screws which hold the protective sheathing 27 at the top of the flange of the filter insert 21 (not
shown on the illustration) and pull off the protective sheathing axially.

- Unscrew the screws 29 and carefully remove the corset 28 axially. It is now possible to wash the filter element in parafĆ
fin or Diesel oil and blow it out with compressed air.
Attention When dismantling and reassembling, it is essential to ensure that nothing touches the outer surface
of the filter which could cause damage to it).
- A clan cloth soaked in petrol or gas oil can be used to clean the outer surface of the filter by wiping it along the direcĆ
tion of the wire spool. Never wipe in the axial direction and never use a brush to do this!
It is essential to ensure that the filter outer surface is not jarred in any way during reassembly. The lock washers have to
be replaced under every screw fitted inside the filter.
When guiding in the complete filter insert, ensure that the bottom of same with the rubber ring 23 slides over the guide
neck in the housing 22 without any undue force.
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Cylinder Lubricating Oil Pumps
Flushing out the Housing

1 Screwdriver 1 Dust cover 14 Gear shaft
2 Stroke adjustment screw 15 Baseplate
3 Housing cover 16 Drive shaft
4 Stroke operating disc 17 Shaft seal
5 Housing 18 Cylinder lubricating oil pump
6 Stroke control disc shaft (coupling piece with helical
7 Main piston gear wheel 10)
8 Pump element 19 Freewheel
9 Control plunger 20 Freewheel rollers
10 Helical gear wheel on gear shaft
11 Hand crank A Suction pipe
E 11a Compression spring B Delivery pipe
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12 Oil outlet connection C Oil drain screw
13 Gasket E Vent screw with builtĆin relief valve
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The cylinder lubricator should be rinsed
se through every 6 months.
Working procedure
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- With the engine at a standstill, shut off the
oil supply and drain the housing 5 by removĆ
1 11a ing the oil drain screw 'C'.
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2 12 - Remove the housing vent screw 'E' and

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pour a few litres of paraffin or clean Diesel

oil through each housing.
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- After flushing out the oil sludge in this way,

slowly open the supply shutĆoff cock in orĆ
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4 13 der to flush out any remaining flushing

fluid.
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5 - On completion of this, screw the oil drain

screw 'C' back in and tighten it.
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6 - Screw in the air vent screw 'E' as far as it will

7 go and then slacken it back by about two
turns.
8 14
- Open the supply shutĆoff cock slightly until
all the air has been purged from the pumps
9 15 and oil flows from the air vents 'E'. Tighten
A the vents and fully open the supply shutĆoff
cocks.
Before starting up the engine, turn the hand
cranks 11 until the flow control check
glasses indicate that all the cylinder lubriĆ
cating oil pump elements are working propĆ
95.7298
erly. (Follow the instructions of the pump
C supplier).
10 20 19 18 17 16

Group 8
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EXHAUST GAS
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CONTROL AIR
CHARGE AIR
Steuerluft
Ladeluft

Starting Air Pipes
Overhauling the Flame Traps and Relief Valves
1 Casing upper part 6 Cover
2 Casing lower part 7 Spring
3 Flame trap insert 8 Socket screw
4 Copper joint 9 Valve body
5 Screw plug 10 Housing
Flame trap
During a general overhaul the flame traps (Fig. 'A') which are fitted in the connections of the starting air pipes, must be
checked and if necessary cleaned.
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To obtain access to the interior for cleaning, unscrew the plug 5. The holes in the insert 3 must be pushed through.
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Replace the old copper joint 4 by a new one.
Smear the thread of the plug 5 for locking with LOCTITE No. 221.
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Relief valve
The relief valve to starting air piping (Fig. 'B') can be dismantled after socket screw 8 has been removed. If necessary the
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seat surface 45 in housing 10 can be re-machined. The seat surface of valve body 9 is spherically machined.
Should re-machining be carried out or parts of the relief valve be replaced then the opening pressure of 33 bar must be
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verified by a check.
The opening pressure can be reduced by machining the spring landing on cover 6 or increased by machining the cover
landing on housing 10, whereby 1 mm stroke difference amounts to about 1.8 bar difference in the opening pressure.
Before assembling smear all internal parts lightly with MOLYKOTE paste.
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A B
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95.7286
4
10 9 7 6
5

Group 9
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Tools
Explanation
All the tools required for the normal maintenance of the engine are listed on the following group 9400---2/A1 onwards.
Listed are also such special tools which are only rarely used and which do not form part of the standard tool kit of the
engine. These tools can be obtained against a special order. A third type of tools are listed which are only made available
on a loan basis. Such tools are identified by a special note in the third column of the tools list.
The information in the third column indicates for what purpose the tool has to be used.
The code numbers in the first column are the same as the tools numbers given in the work sheets. When ordering a tool,
do not forget to give this identifying number and for general tools such as spanners etc. indicate the type and size.
The engine builder reserves to right to alter tools, to remove them from the tools list, or to add new ones to it and no
claims for reimbursement or supplementary delivery can be considered.
The governing factor for the scope of tools delivered is the agreement made upon closing the contact.
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Wärtsilä Italia S.p.A. 1 z 06.04

Hydraulic PreĆTensioning Jacks
Storage, Care, Spares Stock and Sealing Rings
1 Cylinder 4 Piston seal ring (complete)
2 Piston 5 Rod seal ring (complete)
3 Circlip
ØD
3
G 2 NPT / 8 ” 3 1 4
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5
a
95.7289
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3
G 2 NPT / 8 ” 3 1 4
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H
95.7290
5
Ød

The hydraulic preĆtensioning jacks forming part of the engine tool kit are to be stored, when not in use, in a clean dry
place, where they are protected from any sort of damage and from corrosion attack by a coating of lubricating grease.
(The connections are to be closed by dust caps). During prolonged storage or when used very frequently, the OĆrings of
the rod and piston seal rings can become hard, thus not sealing well any longer. We therefore recommend storing a quanĆ
tity of these sealing elements (in plastic bags for protection) so that the hydraulic tools are always able to perform well.
When fitting new slide rings please proceed with utmost care, to avoid damaging them, stretching them or deforming
them. Below please find the sealing ring dimensions of the preĆtensioning jacks for ZALĆS and ZAVĆS engine .
Dimension
Tool No. Application D d H G Pos. 4 Pos. 5
9410.01 Studs of the crankshaft main 240 165 162 M90 x 6 220 x 214 x 5.8 120 x 125 x 3.8
bearing
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9427.01 Studs of the cylinder head and 158 110 142 M60 140 x 135 x 3.8 90 x 94 x 3.8
transverse tie rods
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9433.01 Studs of the crankpin bearing 128 69.6 se
145 M39 x 3 110 x 105 x 3.8 60 x 64 x 3.8
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9433.07 Studs for the counterweights 140 96 95 M42 x 3 120 x 115 x 3.8 60 x 64 x 3.8
on the crankshaft
Central screw in the reversing
a
servomotor
· (only for reversible engine)
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Cooling water pump, oil pump

· (with engineĆdriven pumps)
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Tools
Tools List
General Application
Open end / ring spanners

2 pieces each of following AF in mm:
10, 13, 14, 17, 19, 22, 24, 27, 30, 32, 36,
41, 46, 50, 55 and 60
93.7461
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Single open end spanner Type 100
2 Pieces AF 65 mm se 93.7462
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Cranked double end ring spanners

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2 Pieces AF 13/17 mm
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95.7291
Fo
Allen key (wrenches) Type 460

2 pieces each of following AF in mm:
4, 5, 6, 8, 10, 14, 17 and 22 93.7465

Socket spanner Type 410

95.7299
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Jointed pin hole spanner
1 Piece X = 320 mm
(for setting the cams on the
camshaft)
se 95.7300
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Socket tool set ½” driver

1 Set of sockets with accessories
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in case AF 12 to 32
95.7294
Socket tool set ¾” driver

1 Set of sockets with accessories
in case AF 22 to 50
95.7295

V 1”
Spanner socket
Driver 1”
1 Pieces AF 46 mm
1 Pieces AF 60 mm
95.7301
Spanner socket with insert
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Driver ½”
1 Pieces AF 6 mm
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1 Pieces AF 8 mm
1 Pieces AF 10 mm 95.7302
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1 Pieces AF 14 mm
1 Pieces AF 17 mm V 1/2”
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1 Piece AF 17 mm
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95.7303
V 3/4”
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Adapter piece
1 Piece 1” x ¾”
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1 Piece ¾” x 1”
1 Piece ½” x ¾”
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95.7304
3/4”
Crow foot spanner 3/8” driver

1 Piece AF ¾”
95.7305
3/8”
V
Driver ¾”
1 Piece AF 55 mm
95.7306

Fitting tongs
for SEEGER circlip
1 Piece Type J1
1 Piece Type J2
1 Piece Type J3
95.7307
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1 Piece Type A1
1 Piece Type A2
se 95.7308
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Screws Type B4
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5 Pieces M 8 x 80
5 Pieces M 10 x 100
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5 Pieces M 12 x 100
5 Pieces M 16 x 130 95.7309
5 Pieces M 20 x 150
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Ring screws
5 Pieces each of
M10, M12, M16, M20, M24, M30
93.7472

Screwdrivers Type 110

2 Pieces X= 4 mm
2 Pieces X = 5.5 mm
2 Pieces X = 6.5 mm
X
2 Pieces X= 8 mm 95.7310
2 Pieces X = 10 mm
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Grip screws
2 Pieces
2 Pieces
2 Pieces
M 6 x 150 mm
M 8 x 150 mm
M 10 x 150 mm
se 95.7311
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1 Combination pliers
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95.7312

Engine suspension device

(for fully assembled engines)
consisting of:
9405.01 2 Suspension pins for ZAL-S

X = 200 mm
95.7313
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4 Suspension pins for ZAV-S
X = 330 mm se
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95.7314
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9405.02 8 Special studs with

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8 Nuts M42 x 3 for ZAL-S

X = 674 mm 95.7315
16 Special studs with
16 Nuts M42 x 3 for ZAV-S

X = 314 mm
This pre-tensioning device is not part of

the engine tool kit
(it is supplied only against special order)

Special Tools 9408.09
9408.01 1 Hydraulic hand pump

Make: ENERPAC Type P-39 9408.04
complete with accessories comprising: Oil filling screw 9408.04a
95.7316
9408.10
9408.02 Venting valve
9408.03
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9408.02 1 Hydraulic hand pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Upon special order a pneu-
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matically actuated hydraulic
pump type ENERPAC can
be supplied with accessories.
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9408.03 1 Branch piece with two coupling sockets
9408.04 1 Pressure gauge

0---1’000 bar
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9408.04a 1 Pressure gauge
0---160 bar
a
9408.09 2 HP hoses
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9408.10 1 Double nipple NPT 3/8” with

copper joints
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9408.14 1 Peak pressure indicator

0---250 bar
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9408.15 1 Feeler gauge 93.7485
9408.16 1 Depth gauge

(measuring range 330 mm)
93.7487

Torque wrenches
9408.17 1 Piece 25 w 135 Nm
1 Piece 140 w 560 Nm
1 Piece 480 w 940 Nm 93.7477
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9408.19 1 Force multiplier ¾” x 1”
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95.7318
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9408.20 1 Articulated grip 10”

3/8” square
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95.7319
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9408.25 1 Plug-in ratchet

X = 73 mm
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95.7320
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a
9408.26 Testing device
for pneumatic fittings and waste-gate
a) Air pump
b) Pressure gauge 0 w 4 bar c
c) Pressure gauge 0 w 6 bar
d) Pressure gauge 0 w 15 bar f
e) HP-hose
f) Setting tool
91.7079
b e d

9408.35 2 Hydraulic jacks (ram)

16 mm stroke
· Make ENERPAC type RC---50 or
· RARIPRESS type BM---4---RG
X = 65 mm
95.7321
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9408.36 2 Hydraulic jacks
with spherical head pieces:
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· Make ENERPAC type RC 55
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(133 mm stroke, 6.41 cm2 piston area) or
· RARIPRESS type BS---46---RM
(150 mm stroke, 7.07 cm2 piston area)
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95.7322
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9408.37 1 Hydraulic jack

with flat head pieces:
· Make ENERPAC type RC 55
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(133 mm stroke) or
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(150 mm stroke) 95.7323
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· Make ENERPAC type RC---1010
(260 mm stroke) or
(260 stroke)
95.7324
9408.40 1 Ring spanner with extension arm for X

engaging and releasing the mechanical
overspeed and safety cut-out device
AF 36 mm
X = 735 mm
95.7113

9410.01 2 Hydraulic jacks for the

studs of the crankshaft main bearings Ø 10
9410.01a 1 Round bar Ø 10 x 150 mm
150
95.7325
Ø 240
9410.02 2 Supports for propping up the hydraulic
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jacks when removing the crankshaft
main bearing covers
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95.7326
(inclusive of 2 screws each)
230
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9412.01 1 Segment for removing and fitting the
crankshaft main bearing shells
ZAV-S
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95.7327
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1 Device for the removal and fitting of the

lower shell of the thrust bearing
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as well as of the main bearing shells of:

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ZAL-S
consisting of:
95.7328
9412.08 1 Segment
9412.09 1 Mandrel 95.7329

X = 300 mm X
9412.10 1 Lifting device for hydraulic

pre-tensioning jack
X
X = 1’500 mm
95.7330

9421.01 1 Device for lapping the sealing faces on

cylinder liners and cylinder heads
(the hand grip may be fitted on either
side as required)
95.7340
558
9421.02 Measuring rail

for measuring cylinder liner bore
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95.7341
nl
870
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9421.03 1 Measuring tool X
for measuring the cylinder liner bore
X = 965 mm se
9421.03a 1 Setting gauge
X
00.7305
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for calibrating the measuring tool
X = 400 mm
00.7304
a
rn
450
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9421.04 Pressure yoke

nt
with 2 two hydr. jacks 9421.06

9421.06
for withdrawing the cylinder liner
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95.7342
Fo
9421.08 1 Suspension strap 95.7343

for removing and fitting of cylinder liner
288
9421.09 1 Milling tool

for removal of the wear ridge
in the cylinder liner
95.7344
X = 400 mm X
(Design execution Wärtsilä
or Chris Marine)

9421.10 1 Carbon removing machine

for carbon removal in upper part of cyl-
inder liner
(only for cylinder liner with fine thread,
it is supplied only upon special order)
X = 200 mm
95.7114
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X
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9421.11 1 Honing machine
for honing of the running surface of the
cylinder liner se
X = 1436 mm
(design execution Wärtsilä
or Chris Marine, it is supplied only
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upon special order)
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X
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95.7119
X
9421.12 2 Fitting tool
for spring dowel pin in cylinder liner
(non-standard tool)
X = 500 mm 95.7120
X
9421.13 1 Extraction tool
for spring dowel pin in cylinder liner
(non-standard tool)
95.7115
X =726 mm

1 Device for pre-tensioning

the studs of the cylinder head
9427.01a 1 Round bar

Ø 8 x 120 mm
600 mm
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158
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9427.02 7 HP-hoses
3/8” x 600 mm se
Ø8
120 95.7345
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9427.03 1 Lifting and suspension bracket

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for cylinder heads

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95.7346
Fo
145
9427.04 2 Special nuts M60

SW65
for pressing the cylinder head down
while fitting it
95.7347
9427.05 1 Extraction device

for the sleeves of the cylinder head nuts
95.7348
66
1 Device for pressure test

of the cylinder head
consisting of:
95.7349
9427.06 1 Sealing ring with two O-rings

548
9427.07 1 Flange with hose coupling half and
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gasket
105
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95.7350
9427.09 2 Jacking screws

se 700
for separating the cylinder head from

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the cylinder liner
95.7351 M24
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9427.10 1 Lapping mandrel

with centring disc for the reconditioning
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of the seat surface of the fuel injection 95.7352

valve in the cylinder head
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Fo
9427.11 1 Cleaning tool

for the seat surface of the fuel valve in
95.7353
the cylinder head
365
9427.15 1 Stirrup with spindle

for the removal of fuel injection valve
and starting valves
95.7354
9427.16 Valve seat grinding machine

for the seats of inlet and exhaust valve
spindles
(It is supplied only upon special order)
95.7355
1350
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835
nl
9427.17 1 Turn-over device for cylinder heads
This device is not supplied with the en-
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gine
(It is supplied only upon special order)
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95.7356
nt
ca. 415
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9427.18 1 Valve seat grinding machine

for the seats of inlet and exhaust valves
in the cylinder head
Fo
95.7357

9427.19 1 Socket spanner

for nuts of rocker gear housing
X = 100 mm
95.7358
9427.20 1 Fitting device

for fitting the fuel delivery valve
on the fuel stud
X = 150 mm
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X
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00.7306
9427.21 1 Spanner plate

for tightening cap nuts of the fuel HP
pipes with a torque wrench AF 50 mm
se
X = 120 mm
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95.7360
a
9427.21a 1 Socket spanner

for tightening the fuel stud AF 65 mm
rn
X = 84 mm
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nt
95.7124
X
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Fo
95.7451
9427.22 1 Mandrel
for fitting the valve seats
X = 170 mm
95.7452
9427.23 1 Special socket spanner
for relief valve in the cylinder head
X = 620 mm

9427.24 1 Device for the tensioning

of the valve springs during the removal
and fitting of inlet and exhaust valves
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95.7458
se 80
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Ø 80
rn
9427.25 1 Combination tool

for the removing and fitting of:
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--- Insert bushes for the fuel injection

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valve
--- Guide bushes for the inlet and ex-
haust valves
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9427.27
--- Valve seats of the inlet and exhaust
122
valves
Fo
consisting of:
M24
9427.26 1 Spindle M24 x 365 9427.26
(a, b, c)
9427.26a 1 Spindle M24 x 600
9427.26b 1 Spindle M24 x 760

9427.28
225
9427.26c 1 Spindle M24 x 880
9427.27 1 Upper sleeve with ball bearing and nut

AF 46 mm
9427.29
9427.28 1 Lower sleeve
95.7459
9427.29 1 Nut M24
Ø 110

97
Accessories for the combination tool 9427.25:
9427.30 2 Cones
for the withdrawal of the inlet and ex-
haust valve seats
95.7460
y
112
nl
9427.31 4 Clamping jaws with two rubber rings
for the withdrawal of the inlet and ex-
haust valve seats
O
se
95.7461
lU
170
9427.32 1 Centring disc for:
a
--- Fitting of fuel injection valve insert

rn
bushes
--- Fitting of valve guide bushes
--- Withdrawal and fitting of inlet and
e
exhaust valve seats

nt
95.7462
rI
52
Fo
9427.33 1 Guide cone

for fitting the insert bushes for fuel in-
jection valves into the cylinder heads
95.7463
452
9427.34 1 Lifting bracket

for dismantling and fitting of the com-
plete rocker gear housing
95.7464

9427.35 1 Hand grip

for turning inlet or exhaust valves when
checking the seating surface for correct
contact, or for the correct angle of the
seating surface
X = 120 mm
95.7465
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nl
9427.36 Marking template
each for checking theseating surface of
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inlet or exhaust valves
0’
· Exhaust valve 30_ ---2’
· Inlet valve 30_

+6’
+4’
0’
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· Exhaust valve 45_ ---2’
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(only for engines with:
95.7466
MCR = 720 kW/Cyl. or ratings
ER I = 660 kW/Cyl.; ER II = 600 kW/Cyl.) X
a
X = 140 mm
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9427.37 1 Sleeve
for centring starting air valve during lapping-in
nt
X = 110 mm
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Fo
95.7467
9427.38 1 Ring
for relapping the seating shoulder of the 95.7468
fuel injection nozzles

X
X = 45 mm
9427.39 3 Handwheels for indicator valve

X = 112 mm
94.7076
X
9427.40 1 Spray testing device

for fuel injection nozzles
consisting of: 9427.43
9427.41 1 Base plate with clamps
9427.42 1 BOSCH nozzle testing device

EFEP-67D with pressure gauge and
test oil container
9427.44
9427.43 1 HP-delivery pipe 9427.42
y
9427.44 1 Connecting nipple 9427.45
nl
9427.45 1 Collecting tray
O
se 9427.41
95.7469
lU
9427.47 1 Overhaul device

a
for reconditioning the starting valve seat

in the cylinder head
rn
00.7307
X = 561 mm
X
e
nt
rI
Fo
9427.48 1 Tool box 9427.52

for servicing the fuel nozzles
consisting of:
9427.50 1 Checking disc Ø 48x20 mm
9427.51 1 Copper mandrel Ø 13x70 mm 9427.51
9427.52 1 Wire brush

95.7470
9427.53 1 Tube containing: 9427.53

5 Cleaning drills
1 Plug gauge
for rejection check of the nozzle holes 9427.50

9427.57 1 Socket spanner

for the cap nut of the fuel injection valve
Ø 90
V 1”
95.7471
225
y
nl
O
9431.01 1 Set of gauges
for checking the crankshaft deflection
(in a case)
se 364
93.7505
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SW 60
a
rn
9431.02 1 Special spanner

for the nuts of the coupling bolts of the
flywheel and of the torsional vibration
e
95.7472
damper
370
nt
rI
Fo
9431.03 1 Special spanner

for the hydraulic jacks for pretensioning
the studs of the cylinder heads, the
crankshaft counterweights and the trans-
verse tie rods
95.7473
370

9431.04 1 Mounting device

for fitting the damper
(This device is not supplied with the engine)

95.7474
y
nl
O
for pre-tensioning the studs of the
crankpin bearing assembly
(for pump and HP hoses please refer to
se
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tool No. 9408.01)
a
rn
95.7475
128
e
nt
rI
9433.01a 1 Round bar Ø 8 x 120 mm

Fo
95.7476
Ø8
120

9433.02 1 Removal device

for the removal of the crankpin bearing
shells with fitted rotating piston
(only for ZAL-S)
493
9433.02a 2 Pins to removal device
(only for ZAL-S)
145
y
nl
95.7477
O
9433.02b 1 Underlay
se
to the removal device fitted between 95.7478
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hydraulic cylinder and crankpin bearing
upper part
a
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rI
9433.03 2 Lowering devices

consisting of a steel rope together with
Fo
eye bolt 95.7479

1980
9433.03a 2 Roller for the lowering devices

95.7480
75

9433.04 1 Removal rail

for removal of crankpin bearing lower part
(only for ZAV-S)
X = 678 mm
95.7481
y
nl
O
se
lU
for removal of crankpin bearing shells
with fitted rotating piston
(only for ZAV-S)
a
X = 560 mm
e rn
nt
95.7482
rI
Fo
9433.07 2 Hydraulic jacks for pre-tensioning:

--- Studs of crankshaft counterweights
--- Central bolt of reversing servomotor
(only for reversible engines)
--- Water and lubricating oil pump
(only with engine-driven pumps)
X = 140 mm X
95.7483
9433.07a 1 Round bar Ø 8 x 120 mm

9433.08 1 Fixing plate

for connecting rod head during removal
of cylinder liner
(only for ZAL-S)
X = 208 mm
X
95.7121
y
nl
O
se
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9433.09 1 Fixing plate

a
for connecting rod head during removal

of cylinder liner
rn
(only for ZAV-S)

X = 240 mm
e
95.7122
nt
rI
X
Fo

9434.01 1 Device for the removal c

and fitting of a rotating piston
(only for ZAV-S) a b
consisting of:
a) 1 Attaching device
b) 1 Guide rod
c) 1 Anchor shackle 95.7484
470
y
nl
9434.02 1 Prop for the removal and fitting of a
rotating piston with (only for ZAV-S)
O
a) 1 Slide piece
X = 540 mm
X
a
se
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9434.05 1 Rod with two screws M12 x 40 95.7485

a
for guiding the crankpin bearing assem-
130
bly during removal and fitting of a rotat-
rn
ing piston
e
95.7486
nt
Ø 25
rI
Fo
9434.08 1 Ring screw M20

for suspending the piston
M20
95.7487
9434.09 1 Piston clamping device

(for the dismantling and assembling of
the piston)
95.7488
9434.10 1 Insertion funnel

for fitting the rotating piston
95.7489
549

Tooling for dismantling and assembling

a rotating piston
consisting of:
9434.11 Locking screw

for fastening centring ring halves 9434.14
(quantity depends on the number of cylin- 95.7490
ders and installation)
X = 240 mm X
y
9434.12 2 Ring screws
for fixing lower spherical shell when fit-
nl
ting the connecting rod 95.7491
X = 425 mm X
O
9434.13 4 Jacking screws
se
for separating piston skirt form its crown
lU
(for two pistons) 95.7492
X = 455 mm X
a
rn
9434.14 Centring ring

consisting of two halves each for the
e
fixation of the connecting rod

nt
(quantity depends on the number of cylin-

ders and installation)
X = 248 mm
rI
95.7493
Fo
X
9434.18 1 Piston ring expander
for removal and fitting of piston rings
and oil scraper rings
X = ca. 400 mm
95.7127
9442.01 1 Device for removing and fitting cams,

pressure rings, camshaft drive gear
wheels and the piston of the reversing
servomotor
(This device is not supplied with the en-
gine; it is only supplied upon special or- 95.7494
der)
It consists of:
y
9442.01 1 Tapered shaft
nl
O
95.7495
se
lU
9442.03 1 Displacement tube
with nut on ball bearing
95.7496
a
e rn
nt
rI
M42
Fo
95.7497
9442.07 1 Threaded spindle
M42
9442.08 1 Collar nut M42
95.7498

Accessories for device 9442.01:
9442.09 1 Spanner for the nut 9442.08
95.7499
9442.10 2 Brackets for removal of cams
y
95.7500
nl
480
O
9442.11 2 Threaded rods
with two nuts each and two washers se 95.7501
M24
a lU
e rn
9442.12 1 High pressure pump

nt
with electric drive

(it is only supplied upon special order)
rI
845
Fo
95.7502
9442.15 1 High pressure hose B---5000---A

connecting high pressure pump and 95.7503
cams
5285

9442.17 1 Gauge
for checking the cam position
X = 315 mm
X
95.7504
y
nl
1 Device for removing and fitting the camshaft
consisting of:
O
95.7505
9442.20 2 Roll-out rails with cranks

se
a lU
e rn
nt
331
rI
9442.21 2 Supports
with two screws M20 x 130 each
Fo
95.7506
9442.22 2 Wooden underlays

for supporting the hydraulic jack
9408.35
300
further: ZAV-S
ZAL-S
2 Hydraulic jacks (see tool No. 9408.35)
95.7507
35

M10 a b c
9443.02 2 Threaded spindles M10
for dismantling and assembling the shut-
off valve for starting air
a) Spindle
b) Washer
c) Nut 95.7510
160
y
nl
9443.03 1 Device
for fitting the housing of the starting air
O
distributor (with control disc)
se 97.7566
lU
9444.01 1 Withdrawing device

for the guide piston of the exhaust valve
a
and fuel pump drives

X = 165 mm
e rn
nt
rI
95.7511
X
Fo
260
9444.02 1 Jacking screw

for the ball head of the valve drive
95.7512
M16
9445.01 1 Holding plate

for the dismantling and assembling of
the reversing servomotor
(only for reversible engines)
95.7513
290

9446.01 1 Special device M16 M12

· (combination ’A’) for tensioning spring A
of the overspeed trip,
· (combination ’B’) tensioning spring of
the elastic rod between the governor 95.7514
and the fuel regulating linkage
B
y
696
nl
O
9446.03 2 Threaded rods M16x500 M16
with nuts, for tensioning the spring of 95.7515
the cut-out servomotor
se
a lU
rn
9455.02 1 Adjusting device

for setting the fuel injection pumps
consisting of: 9455.06
e
nt
9455.03 1 Holder 9455.08

9455.07
9455.04 1 Locking plug
rI
9455.05
9455.03
9455.05 1 Measuring pin
Fo
9455.04
9455.06 1 Dial gauge
9455.07 1 Pressure gauge 0---10 bar
9455.08 1 Pressure gauge 0---6 bar 95.7517
9455.09 1 Intermediate piece

for adjusting device 9455.02
30
(required for fuel injection pump, if the 00.7308

cover shows an M39x3 connection
thread)

9455.10 1 Gauge
for setting the fuel injection pumps
95.7518
y
nl
9455.11 3 Spacers
95.7519
O
for cutting out individual fuel injection
pumps
X = 71 mm
se
a lU
e rn
9455.12 1 Eye nut

for attaching the fuelinjection pump
nt
when removing and fitting it

rI
95.7520
Fo

95.7521
for suspending the fuel injection pump a
during fitting and removal
(only for ZAV-S)
a) 2 Screws
b) 1 Ring screw
X = 290 mm

9465.16 1 Connecting piece

for measuring the exhaust gas back pres-
sure
00.7309
150
y
nl
O
9471.01 1 Puller
for the driving gear wheel of the lubri-
cating oil ump
se
23
lU
consisting of:
1 Puller flange
a
4 Screws M16
rn
95.7522
e
ZAL-S = 150
ZAV-S = 165
nt
rI
Fo
150
9474.01 1 Puller
for the driving gear wheel of the fuel
booster pump
consisting:
1 Puller flange
2 Screws M16
95.7523
2 Clamping segments
3.00 34 z Wärtsilä Italia S.p.A.

Maintenance Manual ZAL40S Int Use

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Maintenance Manual ZAL40S Int Use

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ZA40S

¤ Copyright 2004 by Wärtsilä Corporation

by any means (electronic, mechanical, graphic, photocopying, recording, taping or other

THIS PUBLICATION IS DESIGNED TO PROVIDE AN ACCURATE AND AUTHORITATIVE INFORMATION

SALES SUPPORT TECHNICAL SERVICE

North, Central and East Europe Wärtsilä 64 engines

Americas Wärtsilä 38B engines

Middle East and South Asia Wärtsilä 26 engines

Southern Europe and Africa Sulzer Z engines

Italy GMT engines

The list of Wärtsilä Network companies is available at www.wartsila.com web site.

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Wärtsilä Italia S.p.A. 1 ` 03.04

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Wärtsilä Italia S.p.A. 1 ` 03.04

Clearance and Wear Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0352-1/A1

Clearance and Wear Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0352-1/A1

Clearance and Wear Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0352-1/A1

Clearance and Wear Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0352-1/A1

Clearance and Wear Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0352-1/A1

Tooth Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NonĆReversible Engine

Wärtsilä Switzerland Ltd 1 3.00

Clearance and Wear Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0352-1/A1

Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2105-1/A1

Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2105-2/A1

Removing and Fitting a Cylinder Liner

Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2701-2/A1

Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2701-3/A1

3.00 2 Wärtsilä Switzerland Ltd

Inlet and Exhaust Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2720-1/A1

Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3302-1/A1

Inspection and Replacement of Crankpin Bearing Shells

Removal and Fitting a Piston

Dismantling and Assembling

Removing and Fitting

Wärtsilä Switzerland Ltd 3 3.00

Inlet and Exhaust Valve Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4401-1/A1

Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5501-2/A1

Adjusting and Checking

Charge Air Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6601-1/A1

Removal, Cleaning and Mounting

3.00 4 Wärtsilä Switzerland Ltd

Wärtsilä Italia S.p.A. 5 ` 07.03

4. General safety precautions

kept clean and dry.

5. Precautionary measures before beginning of maintenance work

6. Special safety measures

Wärtsilä Switzerland Ltd 1 2.97

the Tightening Instructions 0355-1).

2.97 2 Wärtsilä Switzerland Ltd

Wärtsilä Switzerland Ltd 3 z 2.97

- Optimum treatment of the lubricating oil by centrifuging.

Wärtsilä Switzerland Ltd 1 1995

Criteria for the replacement of bearing shells

a) Aluminium bearing No. 212

Main bearing shells Bottom end bearing shells

Wear limit: d0 – d1 = max. 0.07 mm d2 – d3 = max. 0.10 mm

8.96 / L-Mot. 2 Wärtsilä Switzerland Ltd

b) "Rillenlager" grooved bearing No. 336

80 – 67% Overlay 67%

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