TECHNICAL

BULLETIN

Wärtsilä 4-stroke T-ZA40S.0055.GB

Technical Services Issue 1, 2 September 2015

Upgrade from external to internal

At your convenience
lubrication
Information to all Owners and Operators of Sulzer Concerned components
engines with external lubrication: Piston crown, piston skirt, upper and lower
ZA40S spherical bearing, injection nozzle, thrust
bearing for rotating piston, lubricating oil
system

Introduction
Some of the current ZA40S engines are
equipped with an external lubrication
system. However, an internal lubrication
system provides a more efficient
lubrication of the components with a
reduction of particulate emissions and lube
oil consumption.

Validity
Until further notice

Before taking any action, always check the

available on line systems for the latest
revision of this document. Any locally
stored or printed version is considered to
be an uncontrolled document.

Note
It is suggested to perform an upgrade
during a planned major overhaul.

Wärtsilä Italia S.p.A. Services

Bagnoli della Rosandra, 334 Tel: +39 040 319 5000
34018 San Dorligo Della Valle (TS) ITALY Fax: +39 040 319 5647
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Contents
Page
1 Introduction 2
2 Application field 2
3 Main benefits achieved 2
4 Modification of the components 3
5 Ordering parts 5
6 Contacts 7

1 Introduction
The purpose of this recommended modification is to replace the cylinder liner
lubricating system from an external one to an internal one. In order to achieve this
result, some engine components need to be changed.
The modification of the lubrication system can benefit the engine, in terms of
emissions, component expected lifetime and overall engine performance.

2 Application field
Engine reference type: ZA40S.
Required configuration: Standard 660 and 720kW/Cyl.

3 Main benefits achieved

The main benefits achieved from an internal lubrication modification can be
summarized in the following list:

 A more simple circuit (less pipelines, both inside and outside engine).
 Elimination of possible lubricating pollution, caused by external sources (main cause
of phenomena found on cylinder liner, piston rings and piston skirt).
 Elimination of certain components subject to adjustment, fine setting and overhaul
with consequential elimination of human error which may cause serious
consequential damages.
 Elimination of the daily service tank.
 Reducing lubricating oil consumption.
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4 Modification of the components

4.1 Piston assembly
For the modification of the piston, see Figure 1.

1
1

3 3

1. Piston Crown 4. Spherical bearing upper part

2. Cooling nozzle 5. Spherical bearing lower part
3. Piston skirt

Figure 1: Piston components subject to modification

The internal lubrication system of the piston consists of:

 A bore cooled steel crown with combined oil spray and shaker cooling, with three
piston ring grooves and one oil scraper ring on the piston crown.

 A spheroidal graphite cast iron piston skirt with a more convex running surface
profile at the top and bottom edges.
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4.2 Modification on the lubricating oil system

In the external lubricating oil system, the oil used to lubricate the working surface of the
piston/liner is supplied by a daily tank (refilled automatically by a pipeline from the oil
purifier, or done manually), that feeds the lubricating oil tanks located on the engine.
From these boxes, the linkage to the flow control valve needs to be carefully adjusted
as well. The correct quantity of oil flows from the bottom of the cylinder liner passing
through suitable orifices, and is injected between the sliding part of the piston and liner.

On the other hand, in an internal lubricating oil system, the oil used to lubricate the
working surface of the piston/liner is supplied directly by the oil sump. The oil passes
through the internal orifices in the connecting rod, piston crown, piston skirt and is
directly injected between the sliding parts, see Figure 2.

1. Oil drain tank 7. Flushing oil filter

2. Lubricating oil suction filter 8. Automatic temperature regulating valve
3. Lubricating oil pump 9. Lubricating oil cooler
4. Automatic temperature regulating valve 10.Separator supply pump
5. Lubricating oil cooler 11.Pre-heater
6. Lubricating oil automatic filter 12.Separator

Figure 2: Lubricating oil system modification

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4.3 Cylinder liner

The cylinder liner for internal lubrication is different from the external one, because of
the presence of lubricating oil ducts that allow the oil to flow from the lower part of the
liner and inject it between the sliding surfaces. In the internal lubrication, the oil flows
directly from the connecting rod to the piston and from the piston to the cylinder liner.
The liner designed for the external lubrication can also be re-used for internal
lubrication, by previously closing the lubrication oil duct by means of proper threaded
plugs.
The liner can only be re-used if the wear limits are respected.
For what concerns the wear limits, please refer to the proper chapter in the
maintenance manual “clearance and wear table 0352-1/A1”.

Oil flow

Internal
External

Figure 3: External lubrication principle compared to internal

5 Ordering parts
All the components that must be replaced in order to perform the upgrade to the
internal lubrication are listed in Table 1.

NOTE:
It is suggested to perform the modification in correspondence with the main
maintenance act

When upgrading to the internal lubrication configuration, you can take also in
consideration to apply the bulletins T-ZA40S.0038.GB and T-ZA40S.0052.GB, about
installing the Anti-Polishing Ring (APR) and the “Dry Package”. Contact Wärtsilä for
further information.
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Table 1: Components to replace

Description SPN EPN Q.ty / cyl. Comments

Piston crown KS34003 001 (*) 1 -
Piston skirt KS34007 001 1 -
Upper spherical bearing KS34008 001 1 -
Lower spherical bearing KS34014 001 1 -
Nozzle KS34021 001 16 -
Thrust bearing KS34034 001 1 -
Cylinder liner KS21404 001 (*) 1 Option (**)

(*) In case you also apply the bulletins T-ZA40S.0038.GB and T-ZA40S.0052.GB, the
components can be different. Contact Wärtsilä for further information.
(**) To be replaced only in case wear limits are respected.

CAUTION:
Before ordering the piston crown, be aware of the liner configuration. If the APR is
installed, the correct piston crown must be ordered.

5.1 Summary of the elements

For the summary of the elements to be removed and replaced, see Figure 4.

Figure 4: Elements to be replaced (+) or removed (-)

(*) If the liner wear figures are still in the allowed limit, the cylinder liner lubricating
bores can be plugged by using rods and plugs.

WARNING:
Always assure that the engine is stopped and the starting air is closed before starting
the overhaul.

All the rotating piston components have to be inspected and the wear limits checked. If
the wear limits of the components (according to the maintenance wear table) are
respected, the components can be used again.
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6 Contacts
6.1 How to contact Wärtsilä
For questions about the content of this Technical Bulletin, or if you need Wärtsilä
assistance, services, spare parts and/or tools, please contact your nearest Wärtsilä
representative.
If you don’t have the contact details at hand, please follow the link “Contact us” – “24h
Services” on the Wärtsilä webpage:
www.wartsila.com

© 2015 Wärtsilä Italia S.p.A. – All rights reserved

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omissions for information contained herein. Information in this publication is subject to change without notice.

Unless otherwise expressly set forth, no recommendation contained in this document 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.

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