Service Bulletin

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Wrtsil NSD Switzerland Ltd PO Box 414 Tel. +41 52 262 49 22
Wrtsil NSD Schweiz AG CH-8401 Winterthur Fax +41 52 212 49 17
Wrtsil NSD Suisse SA Switzerland Tlx 896 659 NSDL CH
1. Introduction 1
2. Pre-Adjusting of Fuel Pumps 1
3. Fuel Pump Adjustment 1
4. Deviations in Exhaust 2
Temperatures After Cylinder
5. Conclusion 3
6. Service Bulletins Published for 4
ZA 40S Engines
Contents: Page
ZAS37
25.02.2000
Technical Information to all Owners / Operators
of Sulzer ZA 40S Engines
Checking and Adjusting of
Fuel Injection Pumps
1 / 4 Service Bulletin ZAS-37
1. INTRODUCTION
With the different types of plungers also the adjustment values for the specific fuel pumps are
different. This Service Bulletin has been issued to support our clients in this matter and also to
give an overview of the different plunger types such as CIT (constant injection timing), VIT
(variable injection timing), Variable Damping Plungers and also how the adjustment must be
carried out.
This Service Bulletin should be kept in a separate file in the control room. The respective pages or
tables of the Service Bulletin with modifications to the Operating Manual, Maintenance Manual
or Code Book should be copied and filed in the respective Manual or Book.
2. PREADJUSTING OF FUEL PUMPS
Each time a fuel pump has been dismantled for overhaul and new parts have been fitted, the
pump must be preadjusted first. This can be done either outside of the engine, or with the pump
fitted on the engine. For easier handling we suggest to do the preadjustment of the fuel pump
outside the engine. For the adjustment outside of the engine a special tool (9444.01) which is
also used for dismantling the pump into its parts, as well as for the assembly has to be used. Very
important to get a correctly adjusted pump is also to have absolutely no air leakage between the
pump cover and the measuring device (945504).
3. FUEL PUMP ADJUSTMENT
All fuel pumps of an engine are adjusted such that the specified delivery stroke is achieved at a
load indicator position of 8.65 and at the same time the distance between the pump housing and
the clamping ring amounts to 10 0.03 mm. This fundamental adjustment with the specified
delivery stroke of the fuel pump must not under any circumstances be changed at a later date, as
it is a prerequisite for a balanced fuel delivery for all cylinders and, therefore, for a well
regulated engine.
All important values such as Load indicator position, Plunger identification No., Correction
value, Plunger diameter, and Specified delivery stroke for the different plunger and engine
types are listed in table 1 and 2. Actual detailed Adjusting Instructions are in possession of the
Service Personnel of our Network Companies and we recommend to call in one of our Service
Engineers for carrying out the fuel pump checking and adjusting.
LI Pos. Fuel Pump
Plunger
Engine Type Output
[kW/Cyl]
Speed
[rpm]
Plunger
diam.
[mm]
Specified delivery
stroke
[mm]
8.65 019
1)
ZA 40S
general
up to 750 500 / 510 / 514 35 15.88
8.65 617 ZA 40S
marine
up to 720 500 / 510 / 514 35 14.73
8.65 958 ZA 40S
general
up to 600 500 / 510 / 514 35 11.77
1)
Variable Damping plunger
Table 1: CIT plunger, including Variable Damping plunger
2 / 4 Service Bulletin ZAS-37
LI Pos. Fuel Pump
Plunger
Engine Type Output
[kW/Cyl]
Speed
[rpm]
Plunger
diam.
[mm]
Specified delivery
stroke
[mm]
Correction
value
8.65 542 ZA 40S
power plants
up to 720 500 / 510 / 514 35 14.73 2.07
8.65 466 ZA 40S
marine
up to 600 500 / 510 / 514 35 12.32 1.78
8.65 465 ZA 40S
power plants
up to 600 500 / 510 / 514 35 12.32 1.98
Table 2: VIT - plunger
4. DEVIATIONS IN EXHAUST TEMPERATURES AFTER CYLINDERS
Even a correctly adjusted engine with balanced fuel delivery and maximum cylinder pressures
within tolerances can, depending on the number of cylinders, exhibit individual temperatures
after cylinder which vary greatly from one another, as can be noted from the Acceptance Test
Results.
The reason for such deviations is the effect of gas pressure waves within the single pipe exhaust
system (SPES) and also on the position at which temperature measurement takes place. The
temperature sensor is only acted upon for a short time by the exhaust gas as the exhaust valves
opens, whereas it is influenced for a much longer period of time after the scavenging phase. The
sensors of different cylinders are, therefore, acted upon in different ways due to the
complicated interaction of the gas flows from each cylinder during scavenging.
The exhaust gas temperature after cylinder cannot be taken as a binding indication of the
output being produced by a particular cylinder.
Under no circumstances can it be used to adjust individual cylinders to give a constant
temperature after cylinder by differing the fuel delivery quantity or delivery begin.
This applies not only to initial running on the test bed but also later in service. The negative
effect which incorrect increased adjustment of an individual fuel pump can have on the exhaust
valve and seat, and thus on the lifetime of the valve, is shown in the enclosure ZAS-37/2.
Conversely manual reduction of the fuel pump setting of an individual cylinder due to a
supposedly too high exhaust temperature will create such a negative effect on all the remaining
cylinders that their output will be increased accordingly.
The large increase in temperature at the centre of the exhaust valve plate and at the valve seat
due to the increase in load indicator position of a cylinder is not allowed as it questions the
reliability of the exhaust valve in heavy fuel oil service.
The readings of exhaust gas temperature after cylinder are useful as a longterm indication of a
malfunction or changed conditions, if the deviation of each individual cylinder from the average
value is monitored over a period of time. This is the only purpose of this temperature
measurement arrangement.
3 / 4 Service Bulletin ZAS-37
5. CONCLUSION
After the engine has been regulated according to the instructions previously mentioned,
balancing of the maximum cylinder pressures within the nominal value 2 bar is only allowed as
follows:
ADJUSTMENT OF: ALLOWED:
Fuel pump cam Yes
Valve drive cam No
Fuel pump No
Clamping ring No
Regulating linkage No
Compression shims No
As previously explained, a correctly adjusted engine can exhibit deviations in the individual
exhaust temperatures after cylinder. Despite the measured temperature of some cylinders
being higher than others, the turbocharging system (charge air pressure, valve timing etc.) is
laid out such that the excess air required for complete fuel combustion at an acceptable
combustion chamber temperature level is sufficient for all cylinders.
The practice of balancing exhaust temperatures after cylinder by adjustment of any of the above
components is strictly forbidden.
This would cause an imbalance in the output of each cylinder and, in addition to the negative
effects on thermal loading, could also have serious consequences regarding the torsional
vibration behaviour of the crankshaft.
5.1. Control Sheet for Fuel Pumps, Inlet and Exhaust Valves
Enclosure ZAS-37/1 Setting Table 1
After adjusting the fuel pumps on the engine it is always useful to write the adjusting values
down in the Valve Setting Table sheet for later reference.
Enclosures: ZAS37/1 Setting Table 1
ZAS37/2 8 ZAL40S Test with higher load indicator position
on one cylinder (cyl.1)
Wrtsil Switzerland Ltd has issued this Service Bulletin with their best knowledge and ability.
However, Wrtsil Switzerland Ltd can not take any liability for any or all information contained
in this or any other Service Bulletin.
Changes of any nature to the form and or to the content of this or any other Service Bulletin as
published by Wrtsil Switzerland Ltd, are not permitted.
4 / 4 Service Bulletin ZAS-37
6. SERVICE BULLETINS PUBLISHED FOR ZA 40S ENGINES
We have so far published the following Service Bulletins which are valid for ZA 40S type engines:
ZAS-1.2 dated 02.02.96 Cylinder Liner Overhaul
ZAS-2.1 dated 29.08.97 Overhaul of Cylinder Head
ZAS-3 dated 10.06.93 Oil Scraper Rings
ZAS-4.4 dated 26.02.99 Piston Rings
ZAS-5 dated 03.12.93 Instruction for Testing of Fuel Injection Nozzles
ZAS-6.1 dated 23.02.96 Piston Rotating Mechanism
ZAS-7 dated 05.04.94 Adjustments and Maintenance Requirements on Oil Mist Detector
ZAS-8.1 dated 16.05.97 Turnomat for Exhaust Valves and Rotocap for Inlet Valves
ZAS-9 dated 01.06.94 Exhaust Pipe Expansion Bellows
ZAS-10 dated 01.08.94 High Temperature Cooling Water System
ZAS-11.1 dated 31.03.98 Cylinder Liner with a Thread
ZAS-12 dated 01.03.95 New Spindle Design for Pressure Control Valve KS 87085
ZAS-13.1 dated 18.12.98 Inlet Valves
ZAS-14.1 dated 27.02.98 High Pressure Fuel Pipe
ZAS-15.1 dated 30.01.98 Fuel Injection Nozzle Specification
ZAS-16 dated 10.08.95 Flow Control Valve KS 72126 for Cylinder Lubrication
ZAS-17.3 dated 18.05.99 VTR ..4 Turbochargers After Sales Service Information issued by ABB
ZAS-18.1 dated 27.02.98 Tightening Instructions
ZAS-19 dated 17.11.95 New Piston Ring Fitting Tool
ZAS-20 dated 17.11.95 New Spring Cage KS 28042 for Rocker Gear
ZAS-21 dated 22.03.96 Differences in the Drive for the Cylinder Lubrication between
Engines with 660 kW/Cyl. and 720 kW/Cyl.
ZAS-22 dated 08.11.96 Adjustments of Fuel Oil Systems
ZAS-23 dated 19.11.96 Modification to the Oil Mist Detector
ZAS-24 dated 28.01.97 Alphabetical Index of Topics of Service Bulletins
ZAS-25 dated 16.05,97 Tightening Instructions for the Connecting Rod Big End Bearing
ZAS-26 dated 30.05.97 ABB Type VTR..4 Turbochargers
Cleaning of Turbine and Blower Side
ZAS-27 dated 29.08.97 Lubricating Oil Treatment and Requirements
ZAS-28 dated 29.08.97 Assessment of Main and Connecting Rod Bearings
ZAS-29 dated 29.08.97 Undersized Bearings and Reconditioning of Crankshafts
ZAS-30 dated 31.10.87 ABB Type VTR..4 Turbochargers Cooling Water Arrangement
ZAS-31 dated 31.10.97 Flushing Instructions
ZAS-32.1 dated 13.12.99 Fuel Injection Pump
ZAS-33 dated 31.03.98 Shim between Connecting Rod and Big End Bearing
ZAS-34 dated 26.08.98 Hand Rails for Enginemounted Platforms
ZAS-35 dated 09.06.99 Variable Damping Plunger
ZAS-36 dated 11.10.99 Exhaust Pipe at Support for ByPass Arrangement
ZAS-37 dated 25.02.00 Checking and Adjusting of Fuel Injection Pumps
Should you not be in possession of the above mentioned documentation suitable for your plant, kindly contact
your local Wrtsil NSD representative for your copy.
Service Bulletin Enclosure ZAS-37/1
Fuel Pumps: Adjusted with Load Indicator at Position 8.65
Service Bulletin Enclosure ZAS-37/2
8 ZAL40S Test with higher load indicator position on one cylinder (Cyl. 1)
100 % Load 5'760 kW (720 kW / Cyl.)
Speed 514 rev / min
T
Eac
(C)
430
0.2 0.4 0.6 0.8 1.0 0
420
410
400
390
380
370
1.5 3 4.5 6 7.5 x (mm)
+60
+40
+20
0
1.5 3 4.5 6 7.5
0.2 0.4 0.6 0.8 1.0 0
x (mm)
LI - Difference of load indicator position between
Cyl. 1 and the other cylinders
+60
+40
+20
0
T
Eac
- Exhaust temperature after cylinder
T
VC
- Mean temp. at exh. valve centre Cyl. 1
T
VS
- Mean temp. at exh. valve seat Cyl. 1
T
VC
T
VS
T
Eac
Mean Cyl. 2 - 8
T
VC
(C)
T
VS
(C)
x (mm)
LI
LI