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com ,

DATA &
SPECIFICATIONS

Wärtsilä 4-stroke D-ZA40S.0002.GB

Technical Services Issue 3, 6 June 2019

Hydraulic tightening procedure for

At your convenience *
thrust bearing
Distribution to operators and owners of installations Engines concerned
concerned All WÄRTSILÄ® ZA40S reference types.

Reference
Wärtsilä ZA40S Manual chapter 1202-1/A2 in attachment.

Introduction
The purpose of this document is to
provide information concerning the
updated hydraulic tightening procedure
for thrust bearings.

Validity
Until further notice.
Before taking any action, always check
the available online systems for the latest
revision of this document. Any locally
stored or printed version is an
uncontrolled document.

Note
From issue 2 the differences are:
· Reference to Spare Part Notice.
· Some minor enhancement.

* At your convenience: Action is necessary or recommended, but can be taken at your convenience, for example
during maintenance.

Wärtsilä Italia S.p.A. Tel: +39 040 319 5000 www.wartsila.com

Bagnoli della Rosandra, 334
34018 San Dorligo Della Valle (TS) ITALY
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DATA & SPECIFICATIONS

D-ZA40S.0002.GB, Issue 3, Page 2 / 2

1 Introduction
The engines that change the thrust bearing tightening system from mechanical to
hydraulic need a different process to replace thrust bearing shells.
This document provides the manual chapter that contains the information of the hydraulic
tightening procedure to be followed.
All the parts involved in the modification are available on the Spare Part Notice bulletin:
P-ZA40S.0020.GB.

Elongation evaluation must be carried out with the dial gauge magnetic base fixed on
the engine frame. This elongation measurement is valid for the crankshaft thrust bearing
only. Please refer to the figure F page 7 in the attachment.

ATTENTION:
Do not install the dial gauge as in Figure F, in section 1202-1/A2, since the elongation
measured shown is affected by an elastic part adaptation.

2 Attachments

Please update your manual with the chapter here attached and discard the Chapter
1202-1/A1.

Chapter 1202-1/A2

3 Contacts
If technical support is needed, please create a TechRequest in Wärtsilä Online Services.
For services, spare parts and/or tools, please contact your nearest Wärtsilä
representative or the Customer Support Centre (CSC):
www.wartsila.com/services/support/customer-support-centre-csc

© 2019 Wärtsilä Italia S.p.A. – All rights reserved

No part of this publication may be reproduced or copied in any form or by any means (electronic, mechanical, graphic, photocopying, recording,
taping or other information retrieval systems) without the prior written permission of the copyright holder. Wärtsilä Italia S.p.A. makes no
representation, warranty (express or implied) in this publication and assumes no responsibility for the correctness, errors or omissions for
information contained herein. Information in this publication is subject to change without notice. Wärtsilä does not assume any liability for the
consequences of the owner’s/operator’s actions, inactions, and/or decisions made or based upon the information provided herein.
Unless otherwise expressly set forth, no recommendation contained in this document or any of its appendices is to be construed as provided
due to a defect of the product, but merely as an improvement of the product and/or the maintenance procedures relating thereto. Any actions
by the owner/operator as a result of the recommendations are not covered under any warranty provided by Wärtsilä and such actions will
thus be at the owners/operators own cost and expense.
NO LIABILITY WHETHER DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL, IS ASSUMED WITH RESPECT TO THE
INFORMATION
© 2019 WärtsiläCONTAINED
Italia S.p.A.HEREIN. THIS
– All rights PUBLICATION
reserved – PleaseISread
CONFIDENTIAL
the completeAND INTENDED
disclaimer at theFOR
endINFORMATION PURPOSES
of this document.
ONLY.
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ZA40S Maintenance 1202--1/A2

Crankshaft Thrust Bearing

Replacement of Bearing Shells and Thrust Ring Halves

Tools: Key to Illustrations:

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
1 Dial gauge with mounting pedestal * 11 Screws
13 Positioning pin (long) D Apply sealing compound
14 Positioning pin (short) S Clearance
GL Threaded hole

I --- I II --- II
A
2 6 11* 15 7 GL 8 2 3 10 16 26*
11* I 27

18
D
17
III III

13
D 14

5 I

2a 6a D 1 2a 3 4 9

III --- III

11*
D 5

II
5
95.7199
II

Wärtsilä Italia S.p.A. 1

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1202--1/A2 Maintenance ZA40S

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 re-installed, 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 re-
used, which are in good condition. It is also of the greatest importance that the ring halves are refitted in the same loca-
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.

Oversize thrust ring halves

If the shoulder of the thrust bearing shaft, which was subjected to the load during operation, has become rough and has
therefore to be re-machined, then oversize thrust ring halves have to be fitted.
When re-machining the shoulder as little material as possible should be removed, but the distance between shaft shoul-
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
fitted on that side where the shoulder had been re-machined! Shaft shoulder and locating ring half must be marked ac-
cordingly.

Oversize Length ’L’ Axial clearance

Index
mm mm mm

200 0.8 150.8 + 0.04 0.20 --- 0.44

0
201 2.0 152 + 0.04 0.20 --- 0.44
0
202 4.0 154 + 0.04 0.20 --- 0.44
0

Re-machined
shaft shoulder
Thrust Bearing Shaft

95.7200

Standard ring half

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

2014 2 Wärtsilä Italia S.p.a.

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ZA40S Maintenance 1202--1/A2

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 studs.

--- 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 2 --- 3 mm appears between the pre-tensioning jack and
the bearing housing upper part.

--- Build up a pressure of 600 bar (or a little more) with the hydraulic hand pump and unscrew the two nuts of
the studs by about 4 --- 5 hole intervals.

--- Release the pressure to ’zero’ and remove the hydraulic jacks.
--- 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!
--- Use segment 9412.08 --- pressing it against the shaft --- to push the lower bearing shell out (Fig. ’B’) and remove it.
--- Use mandrel 9412.09 to press both thrust bearing ring halves 2a out till you can lift them out.

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 crank-
shaft axially in the appropriate direction. The shaft must also be equally spaced in the centre radially,
as otherwise the bearing shell is jammed and can only be removed with difficulty.

Wärtsilä Italia S.p.A. 3 2014

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1202--1/A2 Maintenance ZA40S

I --- I II
B C
23
9412.08 24
9412.09

3 9412.08

25

II 2a
9412.09 9408.09

9408.02
I

9412.08

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 shoul-
der.
--- Press segment 9412.08 against the shaft journal and slip in the lower bearing shell until the dividing faces protrude by
the same amount on both sides.
--- 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.
--- Release the pressure in jack 25 under the flywheel and remove the tools.
--- Apply oil lavishly on the shaft journal; use new engine oil.
--- Apply sealing compound to the engine side of the bearing housing upper part. (Also a very thin coat of sealing com-
pound on the horizontal separating faces).

2014 4 Wärtsilä Italia S.p.a.

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ZA40S Maintenance 1202--1/A2

--- Place the upper bearing shell 3 and the upper thrust ring halves 2 into the bearing housing upper part and secure them
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.

Attention! Before fitting them apply MOLYKOTE paste G-n to the threads and landing faces of the screws 11,
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
with about 100 Nm.
--- 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.
--- Connect the jacks with the hydr. hand pump 9408.02 by the HP hoses 9408.09.

--- 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’).
--- Build up a pressure of 600 bar with the hydraulic hand pump and release to zero for part adaptation.
--- Build up a pressure of 100 bar with the hydr. hand pump and keep this pressure constant.
--- Tighten the round nuts 27 with the round bar until they are firmly seated.
--- Release the pressure to 40 bar.
--- For each jack fix the magnetic base on an external surface (like engine end cover) and point the dial gauge on the
piston 28 upper face as shown in figure.
--- Set zero on dial gauge.
--- Raise tensioning pressure to 600 bar. Keep this pressure constant and tighten the nuts 27 with the round bar until they
are firmly seated (check seating).
--- Release pressure to 40 bar. When the waisted studs are correctly pre-tensioned the elongation measured on the dial
gauge amounts to: 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.
--- 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 hy-
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’).

Attention! Do not install the dial gauge like figure F since elongation measured as shown in figure F is affected
by part elastic adaptation.

Wärtsilä Italia S.p.A. 5

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1202--1/A2 Maintenance ZA40S

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
I I --- I
15

D
18

17 17
II
II

14 14

6a
I

II --- II

95.7202
17

2014 6 Wärtsilä Italia S.p.a.

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ZA40S Maintenance 1202--1/A2

E
9433.01
26*
27

9408.09
9408.04

9408.02
00.7286

9408.03

F
X1

29 29
28 28

26*

27

Wärtsilä Italia S.p.A. 7 z