SULZER

: ZA40

TABLE OF CONTENTS Of the Maintenance Manual

WmJp
SHEET

0000
1

PREFACE GENERAL GUIDE LINES FOR MAINTENANCE Precautionary measures for maintenance uork Recoacendations for uork procadure Criteria for the reneual of bearing shells NHMBERTNG OF BEARINGS AN0 CYLINOERS AN0 DEFINITION OF ENGINE SIOES MAINTENANCE SCHEOULE Inspection/service intervals and service life of engine components Schedule table Cross-section of engine .

0001 000211

0002/2 0022/1

0030/0 0030/1 6 f. 0030/7.

TABLES OF CLEARANCE AN0 WEAR Remark on tables of clearance and uear Crankshaft main bearing, crankshaft locating bearing Cylinder Dinar, valve rocker arm Inlet- b Exhaust valve guides, crank pin bearing Working piston Piston compression rings and oil scraper rings Camshaft bearings, camshaft locating bearing, camshaft drive, gear tooth backlash (non reversible engines) Canshaft bearings, camshaft drive, gear tooth backlash (reversible engines) Starting air distributor (non reversible engines) 0352/6 035217 035217 035218 035219 0352/10 0352/11 0352/12 0352113 0352114 0352/15 0355116 035511 0352/0 0352/1 035212 035213 0352/4 035215 035216

Starting air distributor (reversible engines) Reversible servo motor IreversibTe engines) Inlet/exhaust valve actuating gear Governor drive Mechanical overspeed safety Fuel injection pump

tut-out

Lubricating oil pump, fuel.booster pump (for engines uith built-on pumps) Cylinder cooling water pump (for engines with built-on pumps) Raw water pump (for engines with built-on puaps) Fuel nozzle cooling water pump (for engines with built-oil pumps) TIGHTENING INSTRUCTIONS WORK SHEETS Checking of lubricating oil by spot test Taking samples for laboratory analysis Engine block - Replacing cylinder head studs Crankshaft main bearings - Loosening and tightening the cross ties and main bearing studs - Replacing main bearing shells standard bearings)

0356/1 035612 lOOl/l 1201/1 1201/2

1487

OOOO/la

ZA40

Crankshaft locating bearing

- Replacing bearing shells and locating ring halves 120211 2105/1 2105/2 2701/.1 27Olf.2 2701/3 270114 270115 270116 270117

Cylinder liners

- Reasuring uear and renoving uear ridge - Renoving and fitting a cylinder liner

Cylinder head

- Renoving and fitting a cylinder head - Replacing valve seats - Regrinding of inlet and exhaust valve seats - Replacing insert bush for fuel injection valve and lapping the contact faces - Replacing guide bushes of inlet and exhaust valves - Pressure test of water space - Overhauling relief valves

Rocker ares

- Replacing rocker arms of inlet and exhaust valves 270511 2716/1

H.P. Fuel pipe and fuel delivery valves Inlet and exhaust valves

- Reeoving, overhauling refitting

- Replacing valve Springs and renoving and fitting valve spindles - Regrinding the sealing faces 272011 272012 2722il 272212 272213

Fuel injection valve

- Removing, dissantling and assebling - Testing spray pattern and spray-off pressure - Cleaning reconditioaing

Starting air valve in cylinder head Crankshaft

- Removal, dismantling, lapping assembling and fitting - Checking crank deflection - Loosening and tightening the coupling bolt nuts ; Fitting the counter weights 272811 310111 3101/2 3101/3 313011

Torsional vibration danper (HOLSET) Barring engine Connecting rod

- Taking a sasple of Silicone fluid .. . - Maintenance - Inspection and replacing crank pin bearing shells - Loosening and tightening the studs nuts of the crank pin bearing

3212/1

3302/1

Crank pin bearing

330212

10Q7

oOOO/lb

Piston

- Removal and fitting a piston - Dismantling and asseabli

340111 340112 3402/1

Piston compression and ail scraper rings Canshaft

- Removing and fitting

- Checking gear tooth back ash, bearing clearances and adjusting the camshaft drive wheels 4101/1

Camshaft

- Checking, cams, Removing and fitting camshaft 420111

Cams on caiashaft

- Replacing original (non split) cams by Z-piece-cams (only for non reversible engines) 4211/1 430111 4301/1

Starting.air distributor

- Disaantling and assenbling (non reversible engines - Dismantling and assetnbling (reversible engines)

Stop valve for starting air Inlet/exhaust valve actuating gear Reversible serve motor (only revarsible engines) Regulating linkage

- Disnantling and asseabling - Adjusting valve clearances - Dismantling and assembl-ing - Dismatling, checking and assembling

430411 440111 440112 45DO/l

- Removal and fitting the Springs in the spring linkage rod 4501/1

Cut-out serve motor Speed governor Governor drive Mechanical overspeed safety tut-out Fuel injection pump

- Diswantling and assenbli ng - Oil change - Dismantling and assembli ng - Removal and fitting spring

461211 5101/1,2,3 510511 5303/1

- Disaantling and asserbling - Adjusting pump on engine .

550111 550112 650111 6601/1 673Oil 6735il 710111

Exhaust

gas turbo charger

- Water rinsing in service - Renoval, cleaning fitting - Dismantle and assemble - Dismantle and assemble - Dismantling and asserpbling

Charge air cooler Flap to charge-air by-pass Waste gate Lubricating oil punp (For engines uith built-on pumps)

1987

0000/1c

ZA4CS

Fuel booster pump (For engines vith built-on pumps) Cylinder cooling puap and rav vater pump (For engines vith built-on pumps) Fuel nozzle cooling vater punp (for engines vith built-on pumps) SCAIATIC fine filter for cylinder lubricating oil Cylinder lubricators Starting air pipes

- Disaantiing and assenbling

710211

- Disnantling and assernbling

7103ll

- Oisaantling and assenbling

710511

- Operation check-out

720311

- Rinsing the casing - Overhauling flaae arresters and safety valves

722011 860011

TO0l.S Explanations -m Hydraulic tensioning jacks Tools list - Storing, servicing, spares stock-keeping, seal rings 9400/1 and f. 9400/0 9400/0a

SULZER z

40

ZA40

Checking of Lubricating Oil by Suot Test

I

GROUP
SHEET

0356
1

Even the best lubricating oil ages and becomes dirty in service. It must, therefore, be replaced at certain intervals by new oil. A simpl method for checking the condition of the oil is the so-called

Such a test should be carried out approxiaately every 500 service hours by proceeding as follows: When the oil has its normal service temperature and the oil pump some oil should be drained froa a cock in the oil piping system in order to clean the cock froc dirt collected possibly in it. -.. . ;i ,._.."< '; ,., ; : ._.,* - Only then should the oil necessary for the test be filled in a clean container (preferably glass). - Shake the container with oil sample well. - Oip a clean glass or metal rod (diam. = 3 to 5 ma) into the oil and let a drop fa11 in the middle of a filter paper. - Allow the filter paper to reaain in a horizontal position at normal room temperature for some hours (if possible on a hollow pad to ensure that the filter paper with the spot moistened with oil does not corne into contact uith any other natter). :,.. ._.-,: yw. ., & y .,fi3..'.& , '.< J .y . ; ~: 1. . _ . . ..y.';: . ..+a .*T. ;:. ..'. .;. _. .._. . '_ I' '- ..' . .-,. y. -. . _ ::.L. ..' .-c-, .:c .;.., ::. .,.. ':. :I)* '/_ :..,.' . tr .;.. . . * . f -.,..'\T: -i. : .Y' -.,.<'.. LL *,3..:- .I : .: . . . I. - In order to enable comparisons, the same filter paper quality should always be used (obtainable fror oil fircs). Froa the five spot tests shown at left, the gradua1 increase of oil contamination caribe seen clearly. . lests 1 and 2: The drap is froa an oil having only very few running hours. The dark spot is not very sharply outlined showing the oil is still in good condition. Test 3: The drop is froa an oil which was already in service for a relatively long time. A sharply outlined black spot is clearly visible, compared to the normal, bright colour of the oil. This oil cari,, houever, still be left in service. Test 4: This test already shows a clearly linited black zone in the centre. Oil which produces such a picture should be analysed. A certain irprovement could be obtained by replacing a part of the used oil by new oil. Test 5: Oil which produces such a picture nust be analysed at once bl -. ..I . ( s...4f a laboratory. The analysis Will show too high a degree of contanination. Such oil aust be replaced as soon as possible. (See sheet 0356/2). We recommend gluing the spot tests on a sheet of paper in the sequen. ce of the samples taken in order that the progress of contamination caribe clearly seen. For each spot test, indications regarding date of taking, running heurs, etc. should be recorded. The more experien. ce one gets with such spot tests, the better the capability of judgaent Nota: The oil spot test examples show oil cannot be seen on these pictures. on this sheet are only valid

..

y>~,--: * 1 : ,-...f++' .<~~.~--~~,, ..'; 2.. ..y,. . ->: :, .Y... _ <_ ..@ : : -> _

..

. I -. .<

_..
'., 5 . j'

~_ .-.... 4R .'.. : _ 7 ".. : 1

for evaluating the degree of contamination. The alkalinity of the

SUUER

ZA4Q

TAKING LUBRICATINGOIL SAMPLES FOR LABORATORY ANALYSIS

croup 0356 SHEET 2

After every 3000 operatinq heurs a sarple should be taken fror the engine lubricating oil and sent to a laboratory for analysis. The saaple eust be taken froc the oil in circulation and at noria1 service terperature fror a cock specially fitted for this purpose, and vhich is situated at the inlet of the main lub. oil pipe into the engine. Before taking the sample, drain about 2 litres into a container to reaove any possible dirt accueulation in the drain cock. Nov reaove the saeple oil (about 1 Litre) fror the engine into an absolutely clean container (61as is best). Hark the container uith the oil sarple with the follouing data:

Naae of Vesse1 or Plant Engine Type Engine No. or Cylinder No. Date of sarpling Running hours since last oil change Type of lubricating oil (Brand nase)

Honitorina the Lubricatina Oil Concerning the acceptable liott values for the oil, please refer to the recoerendat ions in section 0356 (Lubricating Oil) of the 'Instruction eanual and description'.

1987

SULZER

ENGINE BLOCK Replacement of Cylinder Head Stud Bolts

GROUP 1001 SHEET 1

.ZA40
1001s: Spanner Cleaning materials

KW 1 2 3

to Fiq. DF Sealing surface RR Annular space

Upper edge of engine block Cylinder head stud bolt Sealing conpound

The cylinder head stud bolts 2, stud bolts for short, aust be protected against corrosion at the louer end . The annular space 'RR' and the stud bolt shank nust be fully sealed off with a suitable sealing corpound, uithout cavities up to about the leva1 of the Upper edge of the engine block 1 (sec illustration). Note: - No filling aaterial may be added to the sealing conpound. - Only use a corpound vhich Will allow the stud bolts to he unscreued again uithout difficulty. Work Procedure durina Fittina and Sealinq: - Other than the corrosion protection oil already supplied, no lubricant or Toking the stud bolt 2. - Thoroughly clean and de-grease the sealing surfaces 'DF' befcrs fitting, e.g. uith white spirit, perchlor, acetone, etc. - Prime the sealing surfaces 'DF' with primer according to the ranufacturer's instructions. - Screw in the stud bolts 2 and tighten uith a torque of 50 -'. , 200 Nm. - As a sealant ue recomrend the following two component silicon compounts. - Fil1 the annular space 'RR' completely. In order to allow the sealing compound to be poured above the level of the top of the engine block 1, a ring of cardboard, putty or sirilar having an interna1 diareter of about 60 na has to be laid around the stud bolt shank until the sealing corpound has fully set. This is particularly important for 'V' engines. - The ring has to be removed after hardening. Riconrended Sealina Cowounds and Priners: No. of rardener Primer Supplier *

agent may be applied to the threads of

Type description of sealant RTV-HE 622A

coaponents

NE 6228

G 790,

Wacker Cherie AG Sonnenhalde 15 CH-4410 Liestal

Polastosil Y56

01-l

P-3

Polish product

Silcoset 105

A or D

no type de scription or DP

Wochendorf AG Auf dem Wolf 10 CH-4002 Base1

Similar products from other supplters l ay be used.

17.88

,
lOOl/la ~ealinn Conoound Reauirements: Requit-ad properties: - non- acidic, e.g. acetic acid; - resistant to oil, diesel oil, heavy fuel oil, water at a continuous temperature of about 1OO'C; - short hardening time (approx. 24 heurs); - flous easily SO that the annular space Will be corpletely filled without cavities; - binds val1 to prired aetal surfaces; - simple preparation and rixing; - no to minimum shrinkage; - the external surface ray not harden uith porosity; - the sealing compound must remain sufficiently elastic that the stud bolts may be unscrewed at any tims zf.40

SULZER

CRANlWUiFT MAIN BEARING

QROUP1201
1

:ZA40
Tools:

Loosening and Pre-Tensioning of the SHEET Transverse Tie Rods and Main Bearing Studs
Kev to Illustrations 9408.02 9408.09 1 2 Nain bearing caver Engine Housing 10 11 12 13 14 15 16 17 18 O-Ring Disc Round nut to iter 3

1 Hydraulic handpump uith accessories 2 HP Hoses 1 Feeler gauge 1 Oepth gauge 2 Hydr. jacks

3* Transverse Tie Rod 4* Rain bearing studs 5 6 7 8 9 * Round nut to item 4 Cylinder for Hydr.Jack Piston for hydr. jack Shaft seal ring Piston seal ring Tighten acc. Instructions

9408.15 9408.16 9410.01 1 Round bar 941O.Ola 1 Lifting device for hydr. 9412.10 pre-tensioning jacks 2 Hydr. Jacks 1 Round bar 1 Special spanner 9427.01 9427.01a 9431.03

Cylinder for Hydr. Jack Shaft seal ring Piston seal ring Piston for hydr. jack O-Ring Protection cap

TO loosen and pre-tension transverse tie rods and main bearing studs (short called R.Brg. Studs) for the reeoval and fitting of the main bearings proceed as follous: Reaoval 1. Loosen both transverse tie rods siaultaneously 2. Loosen both M.Brg. stud nuts simultaneously 3. Unscrew transverse tie rods 4. Lower bearing caver (Sheet 1201/2) Fittinq 1. Press bearing caver upuards (Sheet 120112) and hand fit round nuts 2. Screw-in transverse tic rods 3. Pre-tension both f4.Brg. stud nuts sinultaneously 4. Pre-tension both transverse tie rods simultaneously NOTES: - If a11 the crankshaft main bearings eust be reuoved, loosen first ino ami also the transverse tie rods in the tueediate vicinitL and later lift back the bearing caver, fi the transverse tic rods. If

only one of the rain bearings nust be reuoved, loosen the transverse tie rods of the specific boari. otherwise it is difficult to lower

- When screwing-on the piston 16 or 7 respectively of the Cylinder 13 or 6 respectively of the pretension jack (Fig. "Al' and 'A2'), the oil is being pushed back to the puup. TO permit the oil to flow back m the bleeder valve of the hand purp 9408.02 and connect the jacks uith the pum.p by hp hoses. (If.you want to screw the pSston-on wtthout draining the oil to the pu~p, opon the non return valve on the hose socket of the jack by pressing it inwards. The oil Will then flou out). - Before actuating the pump aake sure that the hose couplings are a11 coepletely tightened othrrvise the non return valve may not open, prevent the oil to reach the facks, and pro-tensioning is not achieved. LOOSENIN6 THE TRANSVERSE TIE ROOS Werkinq procedure: (Fig. "An and 'Al') - Renove protective cap from transverse tie rod. - Clean connecting surface of the disc 11 and screu one pre tensioning jacks 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 13 into the cylinders until thry land. - Screv both pre tensioning jacks back aaain unttl a aap of 2 ut appears between the cylinder 13 and the discs 11.

1987

:VII

ld

&A

_ 9uiJd up a pressure of 500 the nuts circumference.

to

620 bar ui?h the hand pump 9408.02 and maintain this pressure constant

until the tuo round nuts 12 have been loosened (uith the round bar 9427.Ola) by 4-5 hole spacinos on

- Relieve the pressure, by opening thi bleeder valve on the PU~P, - Remove pre-tensioning jacks and also the round nuts. LOOSENING THE CRANKSHAFT MAIN BEARING STUCS Please refer to notes on the obverse page! Working procedure: (Fig. "A" and "AZ")

until the pressure gauge shous 'zero'

- Use lifting device 9412.10 (fig. '6') to screu one pre-tensioning jack each onto the tua studs 4 unti the jack cylinders 6 are restcng against the bearing caver 1. - Screu-in the pistons 7 uith the round bar 9410.01a until they land. - Screu back both complete pre-tensioning jacks until a gap of 2 mm appears betueen the cylinder 6 and the bearing caver 1. - Build-up a pressure of 600 to 620 bar with the pump 9406.02 and keep pressure constant until you bave 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 bleeder valve on the pump, until the pressure gauge shows 'zero'. - Remove the pre-tensioning jacks uith the aid of the lifting device 9412.10 and screw the two round nuts 5 by about 130 ta 140 mm dounuards! (For the further procedure to louer the bearing caver pleass refer to sheet 1201/2). Attention! It is important to unscrew jacks (by 2 mm) as described for both the transverse tie rods and the bearing caver studs: If they are unscreved too much, the jacks cannot be removed as they jam against th nuts. If tha gap is too little the nuts cannot be loosened as they are still under pre-tension. PRE-TENSIONING MAIN BEARING STUOS Conditions at start of pre-tensioning: e The bearing covers are fitted according to the instructions on sheet 120112 and are held by two rounc nuts 5. - The transverse tie rods of the neighbouring bearings are not vet pre-tensioned. - The threads of the studs may net be lubricated uith MOLYKOTE-Paste. Workina Procedure of Pre-Tensioninq: - After the bearing caver is pressed upwards till fully seated against the engine hcusing (sec sheet 1207/2) and held in place by both nuts 5 screw the tuo pre-tensioning jacks 9410.01 onto the tuo stud with the aid of the lifting device 9412.10 (fig. '6') till their cylinders 6 are resting against the bearing caver. - Cannect the pre-tensioning jacks to the handpump Ve and SCreu the Pistons 7, using 9408.02 with the HP hoses 9408.09, open bleeder val

round

bar

9410,01a,

into

the

cylinders 6 until they land.

- Close

the

bleeder

valve

of the pump and pre-tension the studs preliminarly at a pressure of 100 bar.

Ho7d this pressure constant until you have tightened the nuts 5 uith round bar 94lO.Ola until they ar fu77y seated. (Check uith feeler gauge).

1967

1201/lb
- Release pressure ta 'Zero" and aeasure the protrusion "X' on the jacks and note carefully. (Please refer to adjacent sketch). - R.aise the pump pressure to 600 bar and hold constant until the nuts have been tightened uith the round bar for full seating. (Check seating uith the feeler gauge). - Release pressure to 'Zero" and seasure the protrusion "XI " and note carefully. The difference between protrusions "X" and "Xl" should theoretically be 1,31 mm. These check neasures are an additional safeguard to the pressure check of the pre-tensioning. - Vhen the measured elongation is closely enough correct, re. move the pre-tensioning jacks with the lifting device 9412.10 - For extra safety establish the vertical bearing clearance. PRE TENSIONING THE TRANSVERSE TIE ROTIS Conditions at start of Pre-Tensioninq - M.Brg.Studs must be tightened according to instructions. - The thread of the transverse tie rods mav not be lubricated with HOLYKOTE-Paste. - O-Ring 17 and disc 11 are fitted and the round nuts 12 are screwed onto the two opposing transverse tie rods requiring pre-tensioning. (Please refer to adjacent sketch). - The contact face of the disc 11 is clean. Note: The adjacent sketch shows a transverse tie rod with mounted protection cap 18. Workino procedure of Pre-Tensioninq: - Screw one pre-tensioning jack 9427.01 onto each of the two transverse tie rods until their cylinders 13 are fully seated on the discs 11. - Open bleeder valve of the hand pump and screu the piston 16 of the pre-tensioning jack, with the aid of special spanner 9431.03, into the cylinders 13 until they are fulle seated. - Close the bleeder valve of the puep and pre.tension the transverse tie rods preliainarily with 100 bar. Hold thfs pressure until you have tightened the nuts 12 uith the round bar until they are fully seated. (Check seating with the feeler gauge). - Release pressure to "Zero" and neasure the protrusfon "X" on both pre-tensioning jacks and note it carefully (please refer to adjacent sketch). - Raise the puap pressure to 600 bar and hold it constant until the nuts 12 are tfghtened till fully seated. (Check seating with feeler gauge). - Release tho pressure to 'Zero' and aeasure the protrusion 'Xl" and note it carefully. The difference between the measured values "Xl - X' should be theoretically 0,66 II uhen the pre-tensions is correct. These eeasures serve as additional safety check of the hydraulic pretensioning rethod. ) - If the established difference "X1 - X' is practically correct, reove the pre-tensioning jacks. - Grease the thread lightly to prevent corrosion and fit protective cap 18.

LA4C

l 4

. N

12

13

16

1987

31/ lc

ZALO

B 0

.?-lOj! 185.361

3. 87

SULZER

ZA40
Tools:

CRANj(SHAF"l' MAIN BEARINGS Replacement of Crankshaft Main Bearings Shells (Standard Shell Bearings)
Kev to Illustrations 1 2 3 4 5 Main bearing caver Engine casing Transverse tie rod Main bearing studs Round nut 19 20 21 22 23

CROUP 1201
SHEET 2

1 Hydr. Handpump with acessories 9408.02 2 HP Hoses 2 Hydraulic jacks . 1 Hydraulic jacks 2 Supports 1 Segment ZAV40 and ZAV40S 1 Segment ZAL40 and ZAL40S Condition at the start of Rork: 9408.09 9408.36 9408.38 9410.02 9412.01 9412.08

Counterweight Upper shell Louer shell Crankshaft Oil trough

- Transverse tie rods and main bearing studs of the bearing to be repaired as well as the transverse tie rods of the two adjacent main bearings have been slackened. (refer to sheet 1.201/1). - The transverse' tie rods of the bearing to be repaired have been unscrewed and reaoved. Workino procedure: - Screv the tuo round nuts 5 downwards, until a space of about 130 mm has been provided between the louer edge of the bearing caver and the connecting face of the nut. (see Fig. 'A'). - Fasten the two supports 9410.02 to the bearing caver 1 with tuo screus. - Place two hydraulic jacks 9408.36 between the supports and the counterweight 19, and connect them to the handpunp 9408.02 by high pressure hoses. - Actuate the purp to push the bearing cove'r from its guided position. (After pressing'it for abt. 110 ml the bearing caver Will slide down onto the round nuts 5 by its oun weight). - Remove the tvo hydraulic jacks and' the two supports 9410.02 froa the engine. The support must on no account be left fitted to the bearina caver as the counte?weiahts 19 would knock aaainst them Gina daeaae. uhen barrino the enoiner. (Fig. '8' and 'C')

- Place a hydraulic jack 9408.38 under the bearing caver and connect it to the hand puap. (THe bearinc caver and the bottom of the oil trough have been provided uith drilled recesses into which the hydraulic jacks fit). - Actuate the pump to lift the bearing caver sufficiently off the round nuts to permit unscreuing ther froc the studs. - Open the bleeder valve 'EV' of the hand pump allowing the bearing caver to descend as much as the jack permits. Removino The Bearine Shells (Fig. 'Cl) - In this position the lover bering shell, descending with the bearing caver cari be checked and if ne. cessary be removed. - The Upper bearing shell 20 caribe pushed out using the segment 9212.01 or 9412.06. Clean the segment well Press tt agafnst the journal and at the saee tiae upwards against the bearing sheT1. Attention! Safeguard the Upper shell with the hand froc falling out when pressing it out with the segment. Judgina The Bearina Shells For possibilitv of Re-use The possibility of re-using a bearing shell depends in principle on the condition of its running surface. Please refer on this matter to the recoenendations on sheet 0002/2.

1987

Crankshaft

Main bearinq She'ls for Undersize Journals

In case the surface of the journal becomes rough and requires regrinding thicker bearing shells uith undersize bores are required. The table below indicates the diameters to uhich the journals must be ground to fit stocked undersize bearing shells: (Al1 dimensions are in mm). Sheli/ 0 Shaft-0 / n Thickness 1 n Vertical Bearing Clearance Bearing Bore 0

I0esign

1 1

[[:::II;jil,,, Key No.

0,4

349,6

- 8,06

10,lZ

I
,2' 4 0,3 5

349,6

- >LJ
l 0,21 I

200

1,2

348,8

- ;,06

'0,52 I

- ;,02 Il

348,8

- U,fY
l

0,21

202 I 203

2,o
3,O 4,O

348

136 - 0 > oBg20 02 _

0,06 - 0 0 "842 - (02

348

+ 0,29 + 0,21

' d N

ui

347 346

204 + 205 206

lSg2 0
0,02 '2,42

- 0 I 06
580 345 - ii 06 > 0 - 0 >06

346

0,?9 + 0,2'

0,4
182
3,O 5,0

369,6 .

"*12

- 0 >02

368,8 _ ; 06
367 365 n' _ ;,06 _ iso6

lO,52

_ oo
n'

0, ,2' z 0, 37

'1s42 - 8,02 '2,42 _ i:,, .,J

Fittinq the. Bearino Shells (Fig. "Ca)

T
36986
l

0,31 + 0,2' + 36888 0,31 * 0,2' + 0,31 3617 + 0,21 3l i5 + * n 91 0,31

200 202 204 205

m l z 1

Note! Do not ever reduce the clearance by filing the nating faces of the bearing shells. The ends of the beariw shells protrude somewhat over the faces of the bearing caver or the bearing saddle. 'bis is aean to be and is necessary! - Push the Upper bearing shell with uel' lubricated running surface but dry back, by hand between journa 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 louer bearing shell with dry back and well lubricated running surface into the bearing caver - Using the hydraulic jack 9408.38 press the bearing caver opuards into its guide space in the engine casing, until it seats. - fit the two round nuts 5 onto the studs 4 till they are landed on the bearing caver. Remove the hydrau lit jack. - Fit the tuo transversal tie rods 3 into the bearing caver 1. - Proceed with pre-tensioning the H.Brg. Studs and the transversal tie rods in accordance uith the instructions on sheet 1201/1.

1987

>fW /7h

M *O-R---

:.;.;.;<.:. .:.:y.:. .:r:1:r:rt:t!t:1:;:t:ll \

N7-l

23-

9408.02<

EV

L-1OZ 185.399

9408. oz

SUMER

'ZA40
Tools: 1 1 1 1 1 1 1 Eye boit MT6 Dia1 gauge with aounting pedestal Hydraulic jack 9421.06 Hydr. Hand Purp HP Hose Segment Mandrel 9408.02 9408.09 9412.08 9412.09 9408.19 9408.17

CRANKSHAFT LOCATING BEARING Replacing Bearing Shells and Locating Ring Halves
Kev to Illustrations 1 Bearing housing 15 16 17 18 23 24 25 D K P S * GL Screws

GROUP 1202 SHEET 1

louer part 2 Upper locating ring half 2a Louer locating ring half 3 4 5 6 Bearing shell . Locating Bearing shaft End Positioning pins Oil catcher Upper part

Oil containing piece Fitted bolts Through bolts 1 Dia1 gauge Fig. 'A' and 'Dl

Flywheel Fig. 'B' Hydr. Jack 9421.06 and 'C' 1 Apply sealing corpound Head piece of steel rope Hydr. Hand Punp Clearance Tighten to specific values in instructions belou Threaded hole

1 Force amplifier 1 Torque urench Assorted spanners and Socket spanners

6a Oil catcher louer part 7 .Bearing housing Upper part 8 9 10 "11 End caver Crankshaft main bearing caver Caashaft drive gear uheel Screws Locating Bearing Screw Positioning pin (long) Positioning pin (short)

l lZ
13 14

O-W? 122.839

m-m

1007

Check the condition of the bearing shells and locating ring halves in accordance with the instructions in the maintenance schedule or according to the prescribed intervals of the classification society. Within a oeriod of 5 vears a11 the bearinqs must have been inspected at least once. Whether a bearing shell may be re-installed, depends mainly fron the condition of its running surface. Please refer to sheet 0002/2 for respective information. Locatinq Rihq Halves For these parts the same reconnendations apply as for the bearing shells, i.e. only such locating ring halves may be re-used, uhich are in good condition. It is also of the greatest importance that the ring halves are refitted in the same location from where they uere renoved. When removing the locating ring halves the shaft shoulders must also be inspected; They must be smooth and clean. Oversize Locatinq Rina Halves In case the shoulder of the locating bearing shaft,uhich was subjected to the load during operation,

has become rough and has therefore to be re-machined, then oversize locating ring halves have to be fit. ted. When re-machining the Shorlder as little material as possible should be tut off, but the distance betwee shaft shoulders susf,after machining correspond to one of fhe ('steps') dimensions 'L' in the table below. In accordance with the dimension 'L' oversize locating ,ring halves have to be selected and they have without fail to be fitted on that side where the shoulder had been re-machined! Shaft shoulder and locat ing ring half must be marked accordingly.

Index

Oversite mm

Length 'L' mm 150,8'y4

Axial clearance mm 0,20 - '0,44

l I

Rerachined shaft shoulder Locating Bearing Shaft

200

OS8

201

2,o
4,O

152

*OgO

0,20 - 0,44 0,20 - 0,44

,202

154

+;,04

-0.1 Thickness: 15 -o.,5

1987

LLVL/

IV

LA4U

Removjnp

the Searinp Shells and the Locatino Rina yalves Fig. 'A' on
preceding

York sequence: (Follou

Rage)

- 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 screus if necessary. - Remove a11 the screus 11 of the bearing housing Upper part 7 and loosen the two locating bearing screus 12 in two or three equal steps and remove. - Fit an eye bolt (H16) into the threaded hole housing Upper part off. (about 80 kg). - Remove both Upper locating ring halves 2 as uell as the Upper bearing shell. - Adjust a (micrometer)-dia1 gauge 23 on the top of the locating bearing shaft (Fig. 'B' place a hydraulit jack 25 under the flyuheel and uith it lift the shaft by about 0.15 mm. .(Fig. 'Cl). (Take tare that the shaft remains radially in the tenter!). - 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 locating bearing ring halves 2a out till you carilift them out. Attention! Before you attempt pulling the louer bearing shell or the louer locating ring haltes 2a out check and ensure that the shaft does net push axially against one of the locating rings. If necessary shift the crankshaft axially in the appropriate direction. The shaft must also be equally spaced in the tenter radially, as otherwise the bearing shell is jammed and carionly be removed with difficulty.

GL in the bearing housing Upper part 7 and lift the

r, r

9472.08\

It.
24

94-12.08

9412 08/(-.

1987

1202/lc

ZA40

F i t t i n q

the Bearinq Shells and the Locatinq Rinq Halves

(Fig. 'A', 'B' and 'C')

- Clean locating bearing shaft 4 and the bore of bearing housing louer part 1 carefully, lubricate the shaft journal 1ightTy. - Check whether the bearing shells and the locating ring halves are undamaged. - Check uhether the crankshaft is in such a position that axially sufficient space is available to fit the locating ring halves. If necessary shift the crankshaft slightly axially. - Using hydraulic jack 25 under the flyuheel lift it and the shaft until the (micrometer)-dia1 gauge 23 mounted above the shaft journal shous 0.15 mm. (Fig. 'B'). Take great tare that the journal is radially in the tenter. - Push the louer bearing shell as uell as the two louer locating ring halves by h a n d as far as possible betueen shaft journal and housing bore, note that the bearinq surface of the locating ring halves lie against the corresponding shaft shoulder. - Press segment 9412.08 against the shaft journal and slip in the lover bearing shell until the dividing faces protrude by,the same amount on both sides.

- Slide both locating bearing ring halves with the aid of mandrel 9412.09 in until the dividing faces
protrude by the same amount on both sides.

- Release the pressure in the jack 25 under the flyuheel and remove the tools.
- Apply oil lavishly on the shaft journal, use neu engine oil. - Apply sealing compound to the engines side of the bearing housing Upper part. (also a very thin coat of sealing compound on the horizontal separating faces).

- Place the Upper bearing shell 3 and the Upper locating ring halves 2 into the bearing housing Upper
part and secure them uith the locating pins 5. (Fitting condition: Bearing shell on its rear side dry, on the running surface coated with oil, bore of the locating bearing housing Upper part dry). Important! Before fittina them apolv molvcote-Daste G-n to the threads and landing faces of the screws 11 and 12, as the tightening torque values are only valid, if this lubricant is used.
w

Fit bearing housing Upper part 7 and fasten to the engine end plate uith the screus 11 uniformly, at first onlv liqhtly with about 100 Nm.

- Fit and tighten uniformly the tuo screus 12 in several equal steps uith a torque urench to 780 No. If you use the force multiplier contained in the engine tools the tightening value is 220 Nn. - Check that no clearance exists betueen the bearing housing Upper and louer part. - Tighten the screus 12 with a torque urench to the final value of 1230 Nm or uhen using the force mu tiplier to 350 Nm. - Finallly tighten the screws 11 also in several equal steps to the final value of 740 #m.

- Measure the axial clearance of the crankshaft with the locating r 'ing ha1ves fitted, by pressing the crankshaft with a hydraulic jacks alternately onto both end positions. 1ha axial movenent is seasured with a dia1 gauge (Please refer to clearance table 0352/1a). - Finally lock the screws 11 in pairs with locking wire (Fig. A).

1 I

.
1987

2A40

F i t t i n a - Clean and

the oil catcher (Fig. '0') carefully front and horizontal separating faces of oil catcher Upper and louer

degrease

part (6 and 6a) and aoolv sealina coeoound to these surfaces. - Fit oil catcher louer part 6a first, locate uith taper pins 14 and tighten uith the screus. - Place oil catcher Upper part 6 into position, fit locating bolts 17 and through bolt 18, - Apply LDCTITE to the threads of screws 15 and bolts 18. (Refer to DDD2/la). - Alternately tighten tho nuts of bolts 17 18 in verv SDall SteDS,

and 18, then of screus 15, again nuts of bolts 17 and be about 1 BD a11 round,

- The clearance 'S' betueen shaft and oil catcher should

1987

SU=ER

CYLINDER LINERS Measuring the Wear and Removing the Wear Ridge
KW 1 2 3 to Illustration$ Cylinder liner Inside microneter Keasuring rail

GROUP

210:

ZA40
Neasuring rail Inside microaeter

SHEET

1 -

9421.02 9421.03

Nilling tool for reiaoving the uear ridge (Supplied only against specific order) Nanual grinding machine

9421.09

The uear of the cylinder liners should be checked during every overhaul or uhenever a piston is removed. Neasure aluays cvlinder liners in fitted position and uhen enaine is cooled doun. TO permit corparisons uith previous measures it is inevitable that neasurina is aluavs done in the sane olace and that the measured values are noted in a log. TO this end use aluays the reasuring rail 3 (tool 9421.02) uhich is available in the engine tools. lt is SO designed that is cari siaply be hooked over the top face of the liner as shown in the sketch to the right. Neasure in the four points A,B,C and 0 in fi enaine axis and at riaht anales to it. Avoid measuring errors by preventing the inside micrometer being exposed to big terperature variations (froa hand heat, holding it for a long tiRa). Generally the most important uear occurs on point 'A'. For raxirur periissible inside dianeter please refer to clearance table 0352/2a. After a long operiting tiirea so-called uear ridge appears in the top part of the running surface. This uear ridge must 1: :: :: :: ::i .i .*

beground

off

during overhaul uithout daraqing the running surface in any uay. SometiBe the uear ridge must be reroved to permit uithdraual of the piston. If this is the case louer the pi'ston by barring the engine caver the piston and

the liner surface above it carefully to'prevent any grinding dust froc penetrating betueen piston an d cylinder liner. After the uear ridge is ground away the cylinder liner bore must bo cleaned very carefully to prevent it being scratched uhen the piston is uithdraun. Attention! Should a re-rachining of the running surface becoee necessary this aay not be done by turning it on a lathe, as thir vould impair the correct guiding of the piston. The machin ing ray only be done by honing the bore of the cylinder liner. For reioving the uear ridge as uell as for the honipg of the liner bore special devices aay be order *ed frai the engin@ aaker or possibly be rented against a fee.

1987

SULZER

ZAL40
1001s: 1 Hydr. Hand pump 1 Branch piece 1 Pressure gauge 2 HP Hoses 1 Torque wrench 1 Electr.Hand grinder (if necessary) 1 Pressure yoke 1 Suspension device 1 Shackle 1 Rope (capacity 1 t)

CYLINDER LINER Removing and Fitting a Cylinder Liner

GROUP SHEET

2105
2

Kev to Illustrations 9408.02 9408.03 9408.04 9408.09 9408.17 9421.01 9421.04 9421.08 1 2 *3 4 5 6 Cylinder liner O-Rings Screw t!20 Centering piece Screws Engine Casing 9 10 11 * 7,7a O-Rings (same dimensions) 8 Cylinder lubrication conduit Screws Crank pin bearing asserbly Screus Tighten according to instructions.

52

INote Reaardina Runninq-in of New Cylinder Liners When one or several cylinder liners have * been replaced it is necessary that they are 'run in', whereby the instructions section 0360 of the "Service instruction and Oescril ,tion Book" on 'Running-in The Engine After An Overhaul' have to be folloued. .

Preparatorv Work for the Kithdrawal of a Cvlinder Liner - Drain a11 the cooling water froa the engine. Remove the cylinder head and withdraw the piston of cylinder 1Sner concerned. - Barr the crankshaft until the crank of the liner concerned stands in T.D.C. - Shield the space below the liner concerned .with clean cardboard or sinflar to trap any falling dirt.

Removal - Loosen pipe connections 8 and remove the banjo bolts (Fig. 'A' and 'A,') - loosen screu 3 of the centering piece 4 and remove it (Fig. 'A' and 'A,').

- Turn the crack pin bearing to the position show

in Fig. 'E' (21G512b).

- Connect the jacking yo1.e 9421.04 by two HP hoses 9408.09 to the hand purp 94C8.02 acd fasten it uith the screus 11 to the crank pin tearing 10 as show in Fig. '6'. position as show in Fig. 'C'.

- Turn the crank pin tearing with fastened jacking yoke into the

- kctuate the hand pusp 9408.02 carefully paying attention that the yoke correctly mates the bottom of the cylinder linder. - Check aaain uhether the screu 3 (M 20) has actually been renoved! (Fig. 'A') - Continue puuping and jack the cylinder liner out of its guide (Ettention! the stroke of the jack in tt;eyoke is cnly 54 mm) - nount tbe suspension device 9421.08 on ?he cylinder liner top and fasten it vith the screus 9 (Fig. 'C' and 'El). (h'atch that the screws 9 tate with the holes in the cylinder lir;er collar). - Fzsten are shackle vith the rope at 'Ah' on the scspecsion device and pull tt,e cylinder liner (abt. 430 kg; out (illtistr. 'C'). - Remove the jacking yoke and the hydr. hand pu~p from the engine.

- Place the ren;ovedcylinder liner on an even surface and reaove the suspension device. - Clean tte landing surface on the engine casing and check uhether it is danaged. - Clean the guiding bores in the engine casing and if necessary smooth out with ea.erycloth. Fittinq - Cbeck ubether tte landing surface for tte cylicder liaer ar;d tbe guiding bores in tte engjne casing are clean acd srootb. Snear the landing surface on cylinder licer/engine casing vith sealing coapour,dHylorar SC32/M or Golden Herretite. - Equip ?he cylirder liner uith new heat resisting o-rings (pl.refer to operating rr.anLal section 0328) and srear t~ese as uell as the guiding surfaces 'F' in the engine frane with fresh engine lntricating oil. - #ount the suspension device 9421.08, fasten it uith the screvs 9 in the liner collar and lift the cylinder liner uith the crane on shackle and rope at the suspension point 'AH'. (Keight abt. 400 K - h'ith the cylfnder liner suspended at eye level tlow compressed air through the lubricating conduit bores at the tottor. - Louer the cylinder liner slouly and carefully into ihe engine casing. - Before ihe cylinder liner mates the guide bores turn it SO that the centering piece 4 when further louering uill fit into the provided bore on the cacshaft side. When guide bores are srcoothand uell tallow lubricated guides and O-Rings the cylinder liner ill slide doun on its oun ueight into the engine casing. If necessary tap the liner collar lightly uith a lead hasser. - Finally locate the liner with the screu 3 dipped in oil and join cylinder lutricating conduits on the Gottom end of tbe liner. Tighten the screu 3 uith50 Km. - If necessary lap the sealing surface on the liner collar with lapping ring 9421.01 and lapping paste. - Actuare the tand crank of the cylinder lutricatcr and ckeck that tt,eoil issues from both lubricating holes in the cylinder liner.

ZAL LO

\hY

-7 I

Y------l l
3. 87

SULZER

ZA40
1001s: 1 Hand pump with accessories 1 Oepth gauge 1 Torque urench 1 Round bar 8 Hydraulic jacks

Removing

CYLINDER HEAD and Fitting a Cylinder Head

~KW
SHEET

2701
1

Kev to Illustrations 1 9408.01 9408.16 9408.17 9427.01a 9427.01 9427.02 9427.03 9427.04 9427.09 9427.10 9427.11 9427.34 9427.57 2 3 Mut Rocker arn Cowling Thread protecting cap Cylinder head Studs O-Ring Mut for item 4 O-Rings Valve guides Valve seat O-Rings Pushrod cladding O-Rings Connecting piece Screws Tubular rubber ring Push rod Cylinder head 18 20 21 22 23 24 26 27 28 29 30 31 32 HP fuel pipe Cylinder liner Soft iron gasketv Insert bush O-rings Oil connecting piece Flange Spacer Engine casing Screu Centering pin Piston of hydr. jack Cylinder of hydr. jack

l 4
5

6
7 8 9 10 11 12 13

HP Hoses 1 Lifting device 2 Special nuts

25 Screw

2 Jacking screus 1 Mandrel 1 Cleaning tool 1 Lifting device 1 Socket spanner Assorted spanners

14
15 16 17

33 Hose coupling * Tighten to specification

A Major overhaul includes a thorough checking of the cylinder heads. This also covers an inspection of the water cooling spaces. When treated cooling water is used these spaces generally remain clear. Untreated cooling uater however usually causes scale formation vhich impairs the cooling effect. For the removal of this scale ue recommend consulting a specialist fira for chamical descaling. The surfaces in contact with the combustion ust be inspected for cracks. If cracks are suspected, and also after replacing valve seats and insert bushes, the water spaces have to be subjected to a uater pressure test (7 bar). (Plaase refer to sheet 270116). Valve seats uith water side leakage must be replaced. Damaged seat surfaces have to be reconditioned (please refer to instruction on sheets 2701/2 and 2701/3 respectively). The O-rings 7 of the valve guide bushes 8 must be replaced at each overhaul. The same applies to damaged or badly worn valve guide bushes 8 (Please refer to sheet 2701/5). Leaking insert bushes 22, also badly damaged ones must be replaced (Please refer to sheet 2701/4). Uneven or slightly damaged insert bushes 22 cari be reconditioned with the aid of too1'9427.10 and the prescribed grinding /lapping paste. (Please refer to sheet 2701/4). If the seating surface for the soft iron joint between cylinder head and cylinder liner is daaaged it cari be reconditioned with the help of lapping ring tool No. 9421.01 and grinding/lapping paste. The same tool caribe used for seating surfaces of cylinder head and ylinder liner.

REMOVING A CYLINDER HEAD Preparations --------B--- Grain the cylinder cooling water froa the engine and shut the shut-off cocks for the fuel valve cooling water. - Garr the crankshaft to bring the piston of the respective cyltnder to T.D.C. on the ftrfno stroke. This means the inlet and exhaust valves are closed. - Loosen the nuts 1 of the rocker arm cowling 2 in even steps of lifting device 9427.34 (Pl.ref.to Fig. 'J').

and lift

the couling

2 with

the help

1987

ZP40

- Reaove both push rods 16 and the screus 14 holding the connecting piece 13. - flnscrew and rerove HP fuel pipe 18 and plug the openings on the fuel valve as well as in the HP fuel pipe, using clean cloth. Separate a11 other pipe connections of (exhaust, Air, etc.) froc 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.

LOOSENING the Cvlinder Head Stud Nuts (Fig. C) Notes - When screuing the pistons 31 of the jacks 9427.01 onto the stud thread (Fig. '0') the oil is pressed out of the cylinder and cari return to the pump uhen the HP hoses are correctly connected to the jack whereby the non return valve on the jack is opened. If this valve is pressed in by hand on the unconnected jack the oil cari flou out. _ Do not start pumping before a11 the hose couplinos are correctly and firmlv ioined otherwise oil may not enter the jacks as the non returnvalve
l

does not open.

Work

Procedure

- Fit a jack 9427.01 on each of the 8 cylinder head studs, until the cylinders 32 touch the cylinder caver 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 coaplete iacks until at 'S' a oao of about 2 am exists. (Observe the notes above). - Connect a11 the short HP hoses 9427.02 according to Fig. 'C' and connect the two long HP hoses to the hand pump. - Actuate the pusp and pre-tension the eight cylinder head studs vi'th600-620 bar and hold this oressu. re constant. .- Unscrev a11 the nuts 6 by 4-5 hole spaces. - When a11 the nuts are in this position release the pressure to 'Zero', by opening the bleeder valve on the purp. .

- Disconnect the hose couplings between the eight jacks and rer'ovejacks and hoses. If they are not iwaediately reused, close the connecting openings uith closing caps. - Reove a11 the nuts 6. - Apply the jack screus 9427.09 and jack the cylinder head off the cylinder liner (Fig. '6'). - The cylinder head freed, fit the lifting device 9427.03 on the studs of the rocker arrs couling 2 and lift the cylinder head off by crane. (Please refer to Fig. 'RT' for ZV-and for ZAL engines). - Caver the open conbustion space with a wooden or cardboard lid to prevent foreign bodies to fa11 in. The sane should be done with the openings of the push rod claddings.

F i

t t i n Q

a Cvlinder Head

Pieparations (Fig. 'A' and '8') -----BB----- Clean the seating face on cylinder liner and cylinder head thoroughly. Any uneveness to be groung off with grinding device 9421.01 and grinding paste.

1987

27

Ol/lb

2640

_ Place a nev cylinder head (soft iron) gasket on the cylinder liner. (It should be a principle practice not ta re-use any jointings like gaskets, O-rings etc.) Check uhether the gasket lies flat. - Place new o-rings 10 into the grooves at the collar of the cylinder liner. Smear these before with en engine lub. oil. (Use aluays only original O-rings corresponding to SULZER specification, see sheet Q326-1 of the description and operating manual). - Ascertain that a11 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 botton of th'ecylinder head lightly with engine lub. oil. - Check combustion space for cleanliness and remove any foreign particles. - Check the drilling in the cylinder head 17 for centrjng dowel 30 and the drilling in flange 26 for the oil connecting piece 24 for cleanliness. Smear the drilling in the flange and the O-rings on the oil connecting piece lightly with engine lub. oil. 'rlork Seauence - fit the lifting device 9427.03 on the cylinder head and attach it to the crane. (Position loop as per Fig. 'K, ' for ZAV-S engines and 'K' for ZAL-S engines'. of rope

- Louer the cylinder head slouly over the cylinder head studs until the centering pin 30 and the oil connecting piece 24 have mated. In case the cylinder head does not slip down on its own weight to rest on the cylinder head gasket on the cylinder liner apply the tuo 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').

Pre

t e n s i o n i n Q

the Cvlinder Head Studs

- Clean the seating surface of a11 the nuts 6. Lubricate the thread of the studs and the seating surfaces with oil, do not use MOLYCOTE grease. - Screw down, by hand, a11 the nuts 6 until they seat and only then apply the round bar 9427.01a to "Tighten'. Renark: It is isportant that a11 the nuts run freely on their threads and that they cari be down by hand until seated. - Fit a11 the hydr. jacks 9427.01 on the cylinder head 32 are seated on the cylinder head. - The pistons 31 of the hydraulic jacks aust be screwed into the cylinders 32 until they are flush wit~ h their Upper edges at '8' ! If this point is not folloued the required stroke cannot be obtained by l the jack. Use the special spanner 9431.03 to screw doan the pistons 31. (Fig. '0'). Please refer tp the note on the previous page. - Connect the and purp 9408.01 by the HP hoses with the hydr. jacks 9427.01. - Shut the bleeder valve, actuate the pump and raise the pressure to 100 bar, Hold this pressure constant until a11 the nuts have been tightened with the round bar until fully seated. - Qpen the bleeder valve on the puop and louer the pressure ta 'Zero'. - Measure the projection 'X' of jack piston over jack cylinder uith a depth gauge and note them down. (Please refer to sketch on the side). - Shut bleeder valve and actuate the punp raisin9 the pressure to 600 bar, hold the pressure constant until a11 the nuts 6 have been tightened down until seated. - Release the oil pressure fully to 'Zero' and measure the projsc, tion jack piston over cylinder 'Xl' with the depth gauge and note thea down. I - Cylculate the tension value 'Xl' - 'Xl. For correctly pre-tensioned cylinder head studs the difference betueen the tuo measures should be about l... ~III. These reasures serve as additional but important check on the correctness of the pre-tension, screwed

studs,

screw them down until their cylinders

iA 40

- If considerable differences are established in the measured values, then it is necessary to de- tension the cylinder head studs once more (please refer to sheet 2701/Ta) and to repeat sioning procedure. - When the stretching measure of a11 the studs corresponds approxiaately with the indicated value, remove a11 jacks and the puap and close a11 open hose connections uith sealing caps. Note: Leaking hydr. jacks do not permit correct pre-tensioning of the studs. In such a case the defective jack must be dismantled and equipped with neu sealing rings. The piston 31 cari be withdrawn fron the cylinder, when the circlip is reaoved froa the cylinder. When reasseabling the jack particular tare nust be taken when fitting the face seal. Replacinq the O-Rinos in the Oil Connectino Piece uithout removino the Cvlinder Head (Please refer to Fig. 'E') The O-rings 23 on the oil connecting piece 24 caribe replaced with-out removing the cylinder head, for this proceed as follows: - Loosen the screws 25 and remove flange 26 and spacer 27. - Push connecting piece 26 downward and upward and replac'e first the louer then the Upper O-rings. - Remove the old O-rings smear a neu set uith engine lub. oil and fit them. - After replacing the O-rings 23 push the connecting piece 24 again into its central position then fit the spacer 27 and the flange 26 and tighten with the screus 25 moderately. Fittinq the Rocker Arm Cowlina, Please refer to sheet 2705/1 Adjustinq the Valve clearances for Inlet and Exhaust Valves, Please refer to sheet 4401/1. the pre-ten-

27O?/ld

ZA

40

0- 1OZ LU.363

0 - WZ IX.362

1982

701 /le

ZA

LO

t--db

9427.01

F--

1 il Ij II Il 11 II 4 b

9408.01

942z34

_* ,I . . \ I : ; 4

--

K 0
ZAL 2xL 40 40s

Cylinder Head Replacing Valve Seats

Group:

2701 2

Sheet: Tools: 1 Spindle M24 x 365 9427.26 * with two nuts 1 Upper sleeve, compl. with 9427.27 * bal1 bearing and nut 9427.30 * 2 Cones 4 Clamping jaws with 9427.31 * 2 O-Rings dimen. 66,04 x 5,33 1 Centering disc 9427.32 1 Spindle M24 x 600 9427.26b Assorted spanners * built up 1 2 3,3a 4 Key to Illustration: Cylinder head Rawl pin Nut M24 O-rings 5 6 7 8 9 D.E. Ring spanner AF 46/50 Valve guide bush O-rings Valve Seat Bush

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. (The valve may lie in the seat maximum 1.5 mm deeper as in new condition). For the replacement of the valve seats it is best to stand the cylinder head on its side. Thevalve guide bush 6 must ti be removed.

Removing a valve seat (Fig. A)

N
6

4 - 17.260.699

- Unscrew and separate the nuts 3 and 3a and the cones 9427.30 respectively until the extraction toolwith the four clamping jaws 9427.31 fitted cari be pushed through the valve Seat. (The O-Rings 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 fio until you feel that the cane grips with its shoulder the valve seat at X. Only when this is the case tighten the nut 3a -with a spanner.

- Mount the centering disc 9427.32 and the Upper sleeve with bal1 bearing and special nut 9427.27 and tum the
special nut with a spanner until the valve seat 8 bas been withdrawn, from its bore.

11.92

2701/2a

zA40 Should avalve seat hold exceptionally tightly in the cylinder head, causingproblemswith thewithdrawal, it is possible to loosen the valve seat with the following method: With an arc-welding set apply a welding bead a11around the seat periphery on the sloping seat surface. When the valve seat has cooled it has shrunk due the weld bead, and cari be readily withdrawn. Of course thevalve seat is then unusable. (While welding take tare that noweld spatter set on the bore surface of the cylinder head).

Note:

Fitting a valve seat (Fig. B)

Place the cylinder head on its side, permitting to fit the valve seat in horizontal direction. Clean the bore, and the seating surface in the cylinder head with great tare. Any unevenness or damage must be polished out. - Clean the sealing surfaces of the valve seat 8 and coat them with Loctite 648. - Smear the O-rings 7 with lubricating oil, then place them into the grooves in the valve seat 8. (Utilize new genuine O-rings!). - Push the valve seat by hand as far as possible into the bore in the cylinder head, then install the seat fitting device as shown in Fig. B and pull the seat in until fully seated. (The valve guide bush 6 must be ftted for this procedure). The valve seat rests on the shoulder at AS but must have a clearance at the point S. After the replacement of the valve seat it is recommended (Piease refer to sheet 2701/6). Remark to subject the cylinder head to a water pressure test.

Should a bush 9 have to be replaced in the exhaust valve bore in the cylinder caver, then the bush outer diameter as well as the corresponding bore in the cylinder caver must be degreased and then coated with Loctite 648 before fitting the bush. The two cooling water bores in bush 9 must correspond, after fitting, with the respective bores in the cylinder caver.

4-107.240.499

9427.27

9427.9

11.92

Cylinder Head Grinding the Valve Seats of Inlet and Exhaust Valves
Tools: Key to Fig. A

1 Cylinder head tum-over device (only supplied against specific order) 1 Valve seat grinding machine 1 Hand grip Marking blue

9427.17 9427.18 9427.35

1 Cyhnder head 2 Valve guide bush 3 Grinder spindle 4 Valve seat 5 Nut 6 Brake (wooden staff, pipe etc. for steadying) 7 Centring device

For information

on the grinding of valve spindle seat please refer to sheet 272012

Valve seat should onIy be ground with the valve seat grinding machine.

Lapping-in

of valve with valve seat using grinding paste should not be attempted.

When is the grinding of vaive seats indicated?

- Every time new valve se.ats have been fitted in the cylinder head. - When new or reconditioned valve spindles are being fitted. An exception may be made, when the valve seat surface is neither wom nor corroded, pitted. - When the seat surface of the exhaust valve seats is badly impaired, on heavy fuel operation. (pitting, corrosion stars).

Inlet valve seats with a valve seat angle of 30 + g are usually free from damage Iike pittings, or corrosion. However it cari happen that the seat surface becomes slightly embossed due to wear. As this does not impair the reliability of operation it is usually not necessary to undertake this grinding operation, which reduces the lifespan of the valves. 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 sheet 2720/2).

Exhaust valve seats for ZA4OS engines may have valve seat angles of either 30 + 0 or 45 + 0 respectively.

Valve seats of 45 + f are fitted in ZA4OS engines rated at 720 kW/@ and also in engines with ER 1 / ER II at 660 / 600 kW/cyl. The criteria for grinding are the same for both types of valve seats.
Grinding of valve seats

Illustration A shows an example how an electric driven seat grinding machine is used. Before starting the grinding operation 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 tare has to be taken to prevent grinding dust from entering the cyhnder 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.

9.92

2701/3a

ZA40

The valve seat grinding machine must be well centred in the valve guide bush as well as in the valve seat with the aid of the inbuilt centring device 7. This is of paramount importance. Experience has shown that chatter marks appear when valve seat surfaces are re-ground in the vicinity of engines or machines producing vibrations. This phenomenon cari 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 witbout 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.
eut:

Coarse; Fine;

= 0,l mm = 0,03 mm

Checking

On the finish machined seat surface a crack detection test by dye penetration must be carried out. No cracks are permitted! After completing the grinding check whether the new or reground valve (pl. refer to sheet 2720/2) sits correctly on the valve seat. Tb 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 IL3 tum to and fro, if necessary use the hand grip 9427.35. Place this grip with the movable part of the strap folded down onto the clean surface of the valve disc (if the surface is rough, apply some oil). By folding the movable part of the strap upwards the grip fastens itselfby suction to the valve disc. (Fig. B). If the angle tolerances on valve and valve seat have been adhered to, then the bearing portion on the seat surface of the inlet valves amounts to Xl- 80% of the seat width. The bearing imprint must mn from the inner diameter outwards (see Fig. a Illustr. C). Besides the imprint check the gap between valve and seat cari 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 bearing portion must be 50 - 100% of t.he 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). For inlet as well as for exhaust valve seats in the qlinder head it is important that the outer diameter of the valve seat surface must bc bigger than the outer diameter of the valve plate, and that the inner diameter of the valve seat is smallar 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.

7.93

-,

LA41

A 0

9427. la-------

blet valve seat

Exhaust valve seat

max. 0

\%
\Y
-0 CT

133 mm

.\

0
a

ZA4OS Engines wlth an output of 720 kW/cyl and wlth ER I / ER II = 660 / 600 kW/cyl. E 0
132,4 mm

max. 0

I I I I ;

-----

9.92 1
1

SULZER

ZA40
Tools: 1 Spindle R24x880 1 Upper sleeve 1 Louer sleeve 1 Centering disc 1 Guide cane 1 Double ring spanner AF 46/50

CYLINDER HEAD Replacing the Insert Bush for the Fuel Injection Valve and Lapping the Seating Surfaces

GROlJP 2701
SHEET

9427.26c 9427.27 9427.28 9427.32 9427.33

1 2 3 4 F

Special nut Double end ring spanner AF 46/50 Locking ring Bal1 thrust bearing Seating surface for fuel injection valve

5 6 7 8 9

Cylinder head O-Ring Insert bush Nut 124 Cleaning cloth

1 Mandrel with cen9427;10 tering disc 9427.11 1 Cleaning tool

Renovino an Insert Bush (Fig. 'A') - Fit the tool as show in Fig. 'A' and turn the special nut 1 with spanner 2, until the insert bush 7 has bren vithdrawn froa its guide bore.

- Remove the insert bush and clean the guide bore in the cylinder head with a degreasing cleaning agent. Do not use eaery cloth except in exceotional cases and then only uith greatest tare to avoid enlarging the guide bores.

Fittino an insert Bush (Fig. '8') r The guide bores and the seating surface in the cylinder head oust be clean, drv and undaraaed,

- Degrease the insert bush in the region 'E2' and coat it with a sealing compound. (Regarding sealing coapounds please refer to sheet 0002/la). - Fit the O-ring 6 at 'El' and smear the area with oil. - Mount the insert bush in the cylinder head and fit the tool as show in Fig. 'B'.

- 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 sheet 2701/6). Lapoino in the Seatinc Surface for the Fuel Iniector Valve The seating surface inside the insert bush musf be inspected prior to each fitting of the fuel injector 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 retal, i.e. no sealing rina mav be fitted, 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). - Insert the guide ring in the bore in the tenter of the cylinder head. (Fig. 'Cl). - Put a few spots of grinding paste on the face of the aandrel,insert it into the insert bush and lapp the seating surface by turning the nandrel to and fro several times. - Fasten a soft cleaning cloth at the bottom end of tool 9427.11 and clean the seating surface with this contraption . (Fig. '0'). - If you carry out this reconditioning uork with the cylinder head fitted, pay particular attention, that no grinding paste carienter the combustion chanber, not any other abjects.

SULZER

CYLINDER HEAD Replacing the Valve

Guide for the and Exhaust Valves Inlet

ZA40
1001s:
1 Spindle H24x600 1 Spindle R24x760 1 Upper sleeve 1 Louer sleeve 1 Centering disc

OROUP 2701 SHEET 5

Kev to Illustrations 9427.26a 9427.26c 9427.27 9427.29 9427.32 1 2 3 4 Special nut t!24 Locking Ring Bal1 thrust bearing Cylinder head 5 6 7 B Valve guide bush Nut H24 Valve Seat Double ended Ring spanner AF 46/50

1 Double ended ring spanner AF 46150

When valve guide bushes are nom Removal

beyond fhe permissible limit or are otheruise damaged,they musf be procedure should be followed:

replaced by neu bushes, uhereby the undementioned of a Valve Guide Bush (Fig. 'A')

- Fit the tool as show

in Fig. 'A' and rotate the special nut 1 uith the spanner B until the valve in the cylinder head carefully, Use emery cloth gnlv for

guide bush has been uithdrauo from its guide bore in the cylinder head 4, and cari be put aside. - Clean the bore and the seatfng surface extreme cases and then only sparingly, to avoide any enlargement of the bore in the cylinder head. F i t t i n a a Valve ouide Bush (Fig. '9') (Valve Seat 10 must be fitted!)

- Check bore in cylinder caver 4 and valve guide bush 5 for cleanliness and possible darage, remedy if necessary. - Smear oil into the bore and the louer part of the valve guide bush, push the guide bush as far as possible into the bore and tap l'ightly uith a lead hammer. Aseertainthat the valve guide bush is exactly aligned uith the axis of the bor in the cylinder head. - Rount the tool as shown in Fig. '9' and by rotating the special nut 1 uith the spanner B 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 uith oil), 1987

SUUER

CYLINDER HEAD

OROUP 2701
SHEET 6

: ZA40
Tools: 1 Pressure testing device 1 Flange with hose coupling Assorted Spanners

Pressure Testing the Water Spaces

KW 9427.06 9427.07 3 4 5 1 2

to Illustrations 6 7 8 9 W Vent screw

Cylinder head Uncooled valve seat

Screu N12
Hose coupling piece Gasket Water spaces

2a Cooled valve seat Insert bush O-Rings O-Ring

Should during operation or during an overhaul a cylinder head show signs of uater Teakage (Cracks, leaking valve seats or insert bush), it becomes necessary ta subject the water spaces to a pressure test, at the next opportunity. Such a test should definitely also be nade when valve seats or insert bushes are replaced. Work Procedure: - Reaove ail the valves fror the cylinder head and aount the pressure testing device 9427.06 squipped uith tw'oO-rings 4 in Perfect condition in the bottom part of the cylinder head, and fasten it as show in the illustration below.

- Fit the flange 9427.07 and fil1 the cylinder head with uater, uhile the vent screw 6 reaains open until a11 the air has escaped. - Subject the cylinder head to a pressure of 7 uater spaces nay not dieinish. prepare the cylinder head for the assembly. shut the valve of the supply pipe and leave the ..

pressure in the cylinder head constant for about 15 Minutes. During this tire the pressure in the

- If the water space is tight, loosen the vent screv 6, drain the uater fror the cylinder head and

9127.06

/3- 107 18S.083

1987

SULZER

ZA40
1001s: 1 Special spanner 1 Ring spanner 1 Open end spanner 1 Pipe plug spanner

CYLINDER HEAD Reconditioning of Relief

*IWJP 2701
Valves
SHEET

Kev to Illustration 9427.23 AF 46 AF 65 AF 13 1 2 3 4 5 Spacer ring Compression spring Spring casing Valve body Valve Seat D P H S Sealing face Punched-in blouoff pressure value Recess Seat face

Relief valves uhich begin to leak in 'service musf be reeoved and overhauled at the next opportunity, uhen the engine is not in operation. In gneral a11 the relief valves should be disnantled and checkei at every major overhaul of the engine. Reconditionino a relief valve Work Procedure -------------.

- 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. - Unscreu the relief valve, using an open end spanner AF 65 and the special spanner 9427.23, from the cylinder head. - TO diseantle the relief valve unscrew the spring casing.3, remove spring 2, whereupon the valve bod: 4 cari be removed for inspection. - Grind-in the valve body on the valve seat with grinding paste until a clean seating surface 'St uithout flaus is obtained. - Badly daeaged seating faces eust be rpachined on a lathe (45' Seat angle) and finally lapped -in. - In the end adjust the blow-off pressure which is staped at 'PI into the spring casing, by altering the thickness of the spacer ring 1. Enaine Capacity till 440 KW/Cyl. till 550 KW cyl. till 600 KW/cyl. Blow-Off pressure 162 bar 182 bar 202 bar

Yhen you reduce the thickness of the spacer ring you reduce the blow-off pressure, by increasing the spacer ring thickness you increase the bleu-off pressure. 70 alter the pressure by about 1 bar ths spacer ring thickness rust be changed by about 0.1 mm. - Do not use a joint for fitting the relief valve into the cylinder head.

SULZER

ZA40
Tools: 1 Socket spanner 1 Torque urench 1 Circlip tongs 1 Eye screu 112 Assorted spanners

ROCKER ARMS Replacing the Rocker Arms of the Inlet and Exhaust Valves
Kev to Illustrations 9427.19 9408.17 1 Main rocker arm . 8,8a O-Ring 9,9a Plugs 10 Vent valve 11 "12 13 RS Tubular seal Nut Bal1 head cups

CROUP
SHEET

27G5
1

2 Aux. rocker arms 3,3a Circlip lock 4 Main rocker axle 4a Aux. rocker axle 5,5a Distance bushes

6 Rocker gear housing 7,7a Plugs

Eye screus 'tighten to specification

TO remove a rocker arm without remov,ing the cylinder head or the rocker gear casing respectively, proceed as described below: - Bal1 the piston of the cylinder concerned to T.O.C. (Firing stroke) uhen both valve groups are closed. (There musf be clearance betueen a11 the valves and their rocker arms). - Remove the circlips 3 and 3a respectively with the circlip tongs. - Dsing an eye screu (H12) pull out the plugs 7 and 9 and 7a and 9a respectively.

1987

705/la

ZA40

- Shift the axle 4 or 4a carefully and just enough to permit the reeoval of the respective rocker arm. When an auxiliary rocker arm 2 must be replaced it is recoaeended to first remove the main : rocker ara 1. - Fitting is done in reverse sequence, after first blowing through a11 the oil passages in the rocker arm axles and the rocker arms with coapressed air. Further ascertain that a11 the O-rings 8 and 8a are itill in Perfect condition, otherwise replace thea with neu ones. Regarding clearances please consult the clearance table 035212. - After completing the replacement of the rocker arms, start the lubricating oil pump and check whether oil is flouing out of a11 the bearing bushes and also froa the bal1 head cups 13. (During this check barr the engine with the barring 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 - Place a washer under every nut 12. - Smear the thread of the sfuds, used to fasten the rocker gear housing, uith oil, then fit the nuts 12 and tighten them in several equal steps uith the aid of the socket spanner 9427.19 and the torque wrench 9408.17 to total 540 Nn. the cylinder head must be carefully cleaned.

1987

SULZER

ZA40
1001s: 1 Fitting device 1 Spanner plate 1 Torque urench 25 ; 135 Na 1 Torque urench 140 ; 560 Nm 1 Socket spanner insert t*/AF 6 1 Socket spanner insert 3/4'/AF 55

HIGH PRESSURE FUEL PIPE AN9 FUEL DELIVERY VALVERemoval, Reconditioning and Fitting
KW 9427.20 9427.21 9408.17 9408.17 1 2 3 4 5 6 7 +8 10 11 12
l

GROUP SHEET

27%
1

to Illustratiotis 13 14 Valve casing Claap-and seal ring Fuel delivery connection Cap nut O-Ring Nut Allen screu Spring for 20 Cyl. pin Fuel injection puap Cylinder head

Protecting hose High pressure pipe Cap nut O-Ring Casing Allen screu Y. spring washer Joint Nut Screw Spring washer Casing

l 15
16 17

l 18 l 19
21 22 P Z

'20 Oelivery valve

TO be tightened according to instruction.

Ouring a major overhaul the fuel dalivery valves 20 built onto the fuel delivery connection 15, should be disaantled and checked. Valve seats which are no longer in Perfect condition rust be carefully lapped-in uith grinding paste. When the Seat is again flawless the whole valve eust be carefully washed in kerosene, uhite spirit or other cleaning fluid and then bloun out uith corpressed air The best uay to disaantle a fuel delivery valve is to first remove it together with the fuel delivery connection. Work Procedure: Oisaantling ----------- Loosen both cap nuts 3 and 16 and push them backvards over the protecting hose 1. - Loosen screvs 6 and 10, renove thea and push the casings 5 and 12 also back over the protecting hose 1. - Loosen the nuts 8 and 18, until the High pressure pipe 2 cari be reaoved. - Set the socket spanner AF 55 on the hexagon of the valve casing 13 and unscreu the fuel delivery connection 15 uitb delivery valve 20 froa the fuel injection valve. - Loosen the screus 19 and sparate the valve casing 13 with valve 20 and spring 21 froc the fuel delivery connection. Asseabling ---------- Hold the valve casing 13 with the threaded end dounwards and insert valve 20 and spring 21. : Wipe the end faces of the valve caiing as val1 as the delivery connection uith a clean cloth or the dry palr of the - Place fuel delivery conn.ection 15 on the valve casing 13 and claep thea together uith fitting device 9427.20 (pl.refer to Fig. 'Br on the reverse) and tighten aoderatelv, - Saear the thread of screus 19 uith oil and tighten the screus evenly and crossuise to a final _ torqur of 28 NR,

- Smear the thread of the fuel delivery connection 15 with oil, - Place the clamp and seal ring 14 on the delivery connection 15 and screw it into the fuel injection valve inserted into the cylinder head. - Set socket spanner insert AF 55 onto hexagon of valve casing 13 and tighten with a torque of 290 NB. Fitting the Fuel High pressure pipe ---_------_------------------------ Push protecting hose 1 back over high pressure pipe 2. - Push the casings 5 and 12 back over the protecting hose to obtain access to the nuts 8 and 18. Fit and tiphten these until fullv seated, onto the high pressure pipe. - Place joint 7 onto the casing of the fuel injection PumP. - Smear the connecting thread of the delivery valve casing and of the fuel injection pump uith oil, fit the high pressure pipe but tighten first nuts 8 and 18 onlv bv hand. - Tighten nut 18 on the delivery valve casing 13 uith torque trench and plate spanner 9427.21 to total 170 Nm. - Tighten nut 8 onto the connection of the fuel injection pump uith 170 N~I. - After tightening nuts 8 and 18, there must be a clearance of about 2 to 4mm between the fuel injection pump 'PI and nut 8, respectively allen screw 19 and nut 18. - Tighten the two casings 5 and 12 with the screws 6 and 10 respectively moderatelv. - Finally fit and tighten the cap huts 3 and 16 moderately.

Inlet - and Exhaust- Valves

Replacing Valve Springs as well as Removing and Fltting of Valves
Tools: Key to Illustration on the reverse:

Group:

2720
1

Sheet

1 Ibnsioning device

9427.24

1 2 3 4 5 6 7 8 9 10

Clamp ring (2-parts) Upper spring plate Inner spring O-ring Outer spring Lower spring plate Spring Cylinder head Guide bush Valve spindle

11 12 13 14 15 16 17 18 19 20

Upper part for TURNOMAT Sleeve Tensioning sleeve Clamp sleeve (2-parts) Threaded spindle Bal1 thrust bearing Snapring Hand grip Sleeve Lower part for TURNOMAT

Replacing valve springs

Remark Nonnally valve Springs are replaced when the cylinder head is removed of the engine and placed on its side. They cari however also be replaced when the cylinder head is fitted on the engine. In such a case ban the engine to bring the respective working piston to firing-T.D.C. (a11valves are then closed). In both cases the removal of the valve Springs follows the same procedure. It may happen that the valve spindle slides down onto the piston top when the Springs are removed. Tb mount the spring tensioning device for fitting, the valve spindle must be lifted up by hand. Ib 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.

Removing the Springs

Valve Springs 3,5 and 7 are removed as follows: - Pull the rocker arm axle of the respectivevalve sideways out and remove the correspondingrocker 2705/1). arm (see sheet

- For valves without TURNOMAT mount the spring tensioning device 9427.24 in such a way that the split clamp sleeve 14 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). In the case of valvespdthTURNOMAT the removal instructions for spring 7 are the same as already mentioned, with the only exception, that for the removal sleeve 19 has to be used as shown of Fig. B and C. - With hand grip 18 screw down sleeve 19 till the Upper spring plate 2 Fig. Aor the Upper part of TURNOMAT 11 Fig. B are sufficiently low, that clamp ring 1 cari be removed. - Ibm the hand grip 18 back, until the Springs are fully slackened. - Remove the tensioning device and remove the Springs.

Fitting tbe Springs

- The fitting of the Springs is done analogous to the removal but in reverse sequence. - Make sure the seating faces for the Springs 3,5 and 7 as well as the spring plates 2 and 6 of the Upper and lower part of TURNOMAT 11 resp. 20 are clean and undamaged.

11.92

2720lla - Smear the tapered clamp ring halves 1 with Molycote paste G-n on a11sides.

zA40

- 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 sheet 2701/1). - Remove the valve Springs as described before, then pull out the valve-spindles. - Inspect the seal faces of valve seat and valve body for damage and re-grind machine (please refer to sheet 2701/3 and 2720/2). them if necessary using the grinding

Fitting the valves

- Clean the valve guide bushes 9 thoroughly and fit new O-rings

4. within the guide

- Smear thevalve spindles 10 well with oil and hefore fitting the Springs check their easymovement bushes 9. - Fit the valve Springs in accordance with the instruction in the earlier paragraph. - Fit the rocker atm and adjust the valve clearance.

1987

vmwohwVALVE WITHOUT TURNOMAT

vualmnnJmonm VALVE wmi TURNOMAT

11 7

10

B 0
Ventil mit Tbmomat VALVE WITH TURNOMAT

Ventil ohne lbmomat VALVE WITHOUT TURNOMAT

Inlet and Exhaust Valve

Group:

2 720 2

Regrinding the Seat Face

Sheet:

Tools:

The instruction for the regrinding of the valve seat seal faces is contained in sheet 270113. 9427.16 9427.36

1 Valve grinding machine (Only supplied against specific order) 1 Marking template each 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 principle.

Valve spindle seats which are considerably damaged by pitting or corrosion, must be reground with the machine. Suitable grinding machines are available in the engineering trade.The following angle tolerance for the seat surface of the valve must be adhered to: Inlet valve for ZA40 and ZA4OS engine Exhaust valve for ZA40 and ZA4OS engines (MCR= 660 kW/cyl, ER l= 600 kW/cyl and ER II= 550 kW/cyl) Exhaust valve for zA4OS engines (MCR= 720 kW/@, ER I= 660 kW/cyl and ER II= 600 kW/@) = 30 ;t: =3o-y = 45y.

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. TO avoid chatter marks on the seating surface, place the grinding machine in a place which is free from vibrations set up by running machinery, engines or electric motors. If necessary place the grinding machine on a rubber matting. On the finish machined seat surface a crack detection test by dye penetration ried out. No cracks are permitted! must be car-

On exhaust valves without anti - wear hard surfacing the seat may not be ground deeper than the fa F on the valve body.

On Met valves with anti - wear hard sudacing the valve body thickness after grinding must still measure at least 9 mm.

373nrh

z.A40

When the grinding angle is exactly maintained

an inking check of an inlet valve with the valve seat fitted in the cylinder head and equally ground Will reveal a bearing proportion of 20 - 80% of the seat width and beginning from the smaller diameter.

- 80%

Under the same conditions and with the same procedure as described above, a marking check on an exhaust valve shows a bearing percentage of 50 - 100% of the seat width and running inward from the outer diameter.

The above ruling also applies to ZA 40s engines with a MCR of 720 kW/@, ER 1 = 660 kW/cyl and ER II = 600 kW/cyl. The exhaust valves of these engines have a seat angle of 45. When the marking check is carried out the contact area must be 50 - 100% of the seat width starting from the outer diameter and running inwards.

The seating surfaces of the inlet valves may not show any pitting marks or corrosion stars, but have simply become hollow due to wear. Such valves must not be reground but they have without fail to be fitted again to the same valve seat in the cylinder head in WC& &y operated before and which wa net re- ground either. On t!&&& mrl valve &&n&&ypthis of wear oattern

.,.

For the grinding of valves, only grinding discs which are specified by the maker of the valve grinding machine are to be used. Such discs may be ordered also tluoughNew Sulzer Diesel LAd. Grinding should be carried out only together with cooling agent. In - feed advance: Roughing; Finishing; abt. 0,025 mm infeed grinding, use both stone halves altemately abt. 0,Ol mm l

On engines operating under unfavourable conditions for a prolonged time, corrosion on the bottom of the valve heads may occur. Valve heads on which a corrosion depth as listed under a (centre) and/or b (outer diameter) has been measured must be replaced. Inlet Wve Exhaust Valve a= a= 2mm 5mm b= b = O,!jmm 2,51nm
I l

A welding repair of a corroded exhaust valve is normaIly not recommended for cost reasons.
9 .92

SULZER

FUEL INJECTION VALVE

OROlJP

2722
1

ZA40
Tools: 1 Torque wrench (480 ; 940 Nm) 1 Torque wrench (25 .i 135 Na) 1 Stirrup with

Removing, Dismantling and Assembling

SHEET

Kev to Illustrations 9408.17 Il 9427.15 1 Spring tensioner 2 Lock nut 3 Nozzle holder 4 Spring plate 5 Compression spring 6 Push rod 7 Insert bush 11 Nozzle needle 12 O-ring 13 O-ring 14 Pressure connection 15 O-rings 16 Securing snap ring 17 Belleville uashers 18 Pressure flange +19 uut 20 Studs Tighten to instructions

spindle 9427.38 1 Lapping ring 1 Socket spanner AF65 9427.57 1 Connecting piece 1" 1 Connecting piece 1/2"/3/4" 1 Short extension piece 3/4" X 8" 1 Socket spanner insert 3/4" X AF 24 assorted open end spanners Kolycote past G-n Lapping paste

l Cap nut 8
9 Locating dowel 10 Nozzle body
l

Removinq from the cvlinder head (Fig

'A')

- Shut the shut-off valves for the nozzle cooling uater inlet and return pipes to the cylinder head. - Loosen and retnove the fuel injection. pipe (see sheet 271611). - Unscrew the pressure connection 14 vith fitted-on pressure (Fig. 'C'). valve and store in a clean place. - Remove the nuts 19, with which the fuel injection valve is fastened to the cylinder head, and lift off the flange 18 (Fig. 'C'). - Mount the stirrup uith spindle (Tool No, 9427.15) as show in Fig. 'A' and pull the injection valve from the cylinder head. - Check whether the seating faces of the nozzle body 10 and the insert bush 7 is in order 1.e. uhether they show equal pressing marks. - If necessary lapp the sealing face on the front of the nozzle body 10 uith the lapping ring 9427.38 and soae lapping paste by hand, until it bears clean over the whole circusference (see Fig. IBI).

lOR7

7777/1s

ZA40

ismantlino the Fuel Iniection Valve (Fig.

C)

CTanp the fuel injection valve by the cap nut 8 in the vise. Loosen lock nut 2 and with a spanner loosen the spring tensioner just sufficiently to relieve a11 tension from the sorino 5. Clamp the fuel injection valve in the vise by the Upper end of the nozzle holder (nozzle pointing upuards) and loosen the cap nut 8 using the socket spanner 9427.57, the 1" connecting piece and a ring spanner AF 65. Reaove the cap nut 8. Lift off the nozzle body 10 with noztle needle 11 and place aside on a clean place. (Take tare that the noztle needle does not drop out.)! Remark : The nozzle needles are lapped individually with their noztle bodies, they fora a unit together. It nust be strictly avoided to interchange nozzle needles and nozzle bodies! Loosen the spring tensioner 1 fully and remove it, remove spring 6, spring plate 4 and push rod 6 downwards.

MOLYKOTE-

G+ 1

1987

.sembljno the Fuel iniection Valve For the assebly observe the utmost cleanliness and tare. Clamp the nozzle holder 3 (without any inner parts) in the vise by the milled portion and with the nozzle seal face pointing upwards. Check vhether the inscription on the noztle holder circumference (Specification) tallies with the indications in the control report of the engine. Wipe the sealing face of the nozzle body 10 and of nozzle holder 3 ufth the clean dry hand or uash them with perchlorethylene, to obtain a clean drv sealino surface. Place the nozzle 10 carefully on the nozzle holder 3, taking tare that the nozzle needle 11 does not drop out and that the locating doue1 9 fits into the locating hole. Srear the thread of the cap nut 8 and the landing on the nozzle body 10 (where the cap nut presses the notzle body) uith MOLYCOTE-Daste G-n. (Fig. 'Cl). Fit cap nut 8 and tighten by hand until it lands, then using the torque wrench 9408.17 with socket spanner 9427.57 and connecting piece l", tighten the cap nut to 590 NB. (Fig. '0'). Clamp the nozzle holder 3 with nozzle pointing downwards in the vise by the cap nut 8. Smear a11 the inner parts 6, 5, 4 4 carefully uith clean engine oil and fit them as show in Fig. 'C'. Screw the spring tensioner 1 on by hand then tighten it to abtain the correct spraying pressure (Sec sheet 2722/ 2). Fuel injection valves which are not immediately installed must be stored in a place where they are protected froc damage and from dust and corrosion attack. ttina the Fuel Iniection Valve into the Cvlinder Head. (Fig. 'C') Equip the correctly adjusted fuel injection valve with neu O-rings 15 and 12 and saear them with grease or engine oil. 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 follou the instructions on sheet (2701/4!) Install the fuel injection valve and mount the flange 18, but do not vet tiahten the nuts 19 (m the threads of the studs 20 vith MCLYCOTE-Paste G-n) Fit the fuel pressure connection 14- uith fitted pressure valve- froa the side into the cylinder head and screu it by hand into the nozzle holder (do not use any joints, but -smear thread with oil.) Adjust the fuel pressure connection 14 sideuise SO that the clamp- and seal rings (see sheet 2716/1) caribe fitted in centred position. - Only then, tighten the fuel injection valve onto its seating uith the tvo nuts 19 by corpressing the Belleville spring stack 17, and using the torque wrench alternately in saall equal steps until a hta1 of 180 Nm. - Checking: Flange 18 oust rest flush without clearance, if necessary tighten nut 19 till paximu 200 Na further. - After coapleting a11 the connections, the closed valves of the nozzle cooling uater pipes cari again be opened. Rerark If it becoaes necessary to remove the Belleville washer stacks 17, the securing snap ring 16 ad firs .

be taken.out, When reassebling the Belleville uashers take the utmost tare always te place the washer 17 in pairs in the same position. he uasher stacks in turn oust be fitted as show in Fig. 'C!.

10.88

SULZER

FUEL INJECTION VALVE

OROUP 2722 SHEET

Checking the Condition of Spraying and the

ZA40
1001s: 1 Spray testing device (complete) assorted spanners 9427.40 9427.41 G 45

Spraying Pressure
Key to Illostrations 1 Spring tensioner 2 Lock nut 3 Pressure gauge damper valve 4 Nozzle holder 5 Cap nut 6 Nozzle body 7 Pressure gauge (0 - 500 bar) 8 Fuel tank.

The fuel injection valves must be checked periodically as per maintenance plan, or earlier if indications of faulty combustion demands it, also after fitting a neu nozzle. The spray check bas to be nade with the spray testing device 8427.40 and its components. For this test use only absoluterly clean gas oil, which mav not be poured back into the fuel tank 8 after the test. The valve to be tested is placed on the spray testing device 9427.40 and connected to the pressure connection 9427.44 (uithout joint). Check firtt uith a feu hard short strokes the sorav oattern of the fuel uhereby the pressure gauge daRthe pressure gauge daaper valve 3 and check with slow equal strc per valve 3 is kept closed, Then open kes of the punp handle at vhat oressure the nozzle of the fuel injection valve opens. (observe the pre: sure gauge 7). The required opening or spray pressure is given in the control report of the enaine. It amounts generally to 320 + 10 bar but the value of the control report oust be followed. The pressure gauge 7 oust be calibrated froa tine to time to ensure correct indications.

1987

2722/2a Judqeinq the Condition of a Fuel Iniection Valve

ZE40

A fuel injection valve sprays correctly when the fuel is atotnized equally froc a11 the spray holes of the fuel noztle at the required opening pressure. During this a loud 'chatter' should be heard, and ai the end of.the pemp stroke no fuel uay m out of the fuel noztle. A check on equal atomizaztion cari be made by holding a piece of paper horizontally under the fuel nozzle and by a single short puap stroke induce the injection valve to spray. On the 'spray pattern' thus abtained it cari be easily determined whether any of the spray holes are partly or fully blocked. Attention! Never actuate the pump when a finger or a hand is held against the fuel notzle! (Risk of Accident) Fuel injection valves which do not spray correctly musf be disantled and their nozzle replaced (sec. sheet 272211 and /3)

Adiustinq the Openina Pressure - Loosen the lock nut 2, move the puap lever up and down and at the same fine tighten the spring tensioner 1 until the required opening pressure is read on the pressure gauge 20. - Shut the pressure danping valve 3 and check uith short fast puap strokes whether the fuel nozzle sprays equally, and thereby produces a 'chatter'. When this condition is reached, tighten the lock nut 2 firnly, while holding the spring tensioner 1 steady with a spanner . - After tightening the lock nut 2 check the opening spray pressure once more.

7987

SULZER

FUEL INJECTION VALVE QRoup Cleaning and Reconditioning

ZA40
Tools: 1 Jo01 case 1 Lapping plate 1 Lapping powder

SHEET

2722 3

Kev to Illustrations on sheet 2722/3a

9427.40 3427.54
9427.55

10 Nozzle holder 18 Bush (hard)

Fuel injection valves on uhich the fuel nozzles do no longer "spray" satisfactorily must be disnantled and cleaned thoroughly. Blocked nozzle holes have ta be freed on-.the dismantled nozzle with the nozzle needle removed using the drill contained in the drill quiver 9427.53 of tool case 9427.48. After deblocking uash the nozzle body 10 out with kerosene or white spirit and blow it through uith compressed air. Oie the noSle needle in clean Diesel fuel or kerosene and insert it in the nortle body.The nozzle needle must slide onto its Seat by its oun ueight. The sealing face of the noztle body musf be checked. If necessary this face has to reconditioned with the aid of the lapping disc 9427.49. in the fo]lowing manner: - Apply lapping powder and kerosene on the lapping plate 9427.54 and first lap the lapping disc 9427.49 true flat. (F.ig.'D'). - Hold the bare nozzle body (without needle) uith soft clamp jaus in the vise, sealing face upwards, - Apply soee lapping paste (lapping powder with kerosene) to the smaller surface of the lapping disc (Fig.'A') and lap the sealing. face of the nozzle body by a circular movement first in the inner zonE clean. This is necessary, because it is knoun by experience that the sealing face becones slightly cenvex with longer operation. (higher in the tenter than' touards the edge.) .- After a whi'lecheck the face for flatness with the face plate 9427.50 (Fig.*B'). The face plate aust also be lapped flat on the lapping plate before using it. For the face check press the face plate against the sealing face of the nozzle body and at the sane time apply a circular movement. The face plate being of bronze it Will leave a yellowish mark on the high spots. - When the face is no longer convex;.continue lapping it with the larger surface of the lapping disc until a clean sealing face is obtained. (Fig.'C'). The circular novements should not extend far over the edge as the face would again become convex. - On the final check uith the face plate the sealing face musf be true flat or very slightly concave (higher on the edge than in the centre). - Finally J& sed air. the nozzle body thoroughly in kerosene or white spirit and bleu it through with conpres-

- The lapping plate 9427.54 has to be planed flat (follow profile indication of Fig.'D'), fror tire to time. - Assemble the fuel injection valve and adjust the spray pressure and check the spray pattern (see sheet 2722/2). - Should the atomization of fuel still not be satisfactory, replace the fuel nozzle by .a neu one or a reconditioned one. AS a matter of principle do not 'tinker' with the fuel noxxle as this may render a later repair impossible.

We recomaend.sending fuel nezzles vhich do not kinterthur for possible repair.

spray

satisfactorily

to a specialist

fit-a

or to SULZER

1987

27W3a

ZA40/240

A 0
94

gszz49 9427.50

C ,O

1982

SULZER

AIR

STARTING VALVE ON THE CYLINDER HEAD

ZA40
Tools: 1 Torque wrench (140-560 Nm) 1 Extracting device 1 Centring sleeve 1 Socket spanner top (3/4"/AF 24) 1 Socket spanner top (3/4"/AF 30) 1 Short extension (3/4'i8')

Removing from the Cylinder Head, Dismantling, Lapping-in, Assembling and Fitting

GROUP SHEET

2728
d

Kev to illustrations 9408.17 9427.15 9427.31 1 Stud '2 Nut 3 Flange 4 Control air Pipe 5 O-ring 6 Snap ring 7,7a Belleville 8 Valve casing 9 Screu 10 Pilot control valve "11 Nut 12 Valve spindle 13 Piston 14 O-ring 15 Spring 16 Casing 17 Soft iron joint 18 Rod seal 19 Piston seal ring 20 Spring l Tighten to instruc ion

washerstack

3 -107 185.077

On the occasion of a general overhaul or when unsatisfactory performance marrants it, remove the air starting valves and recondition them. Removal - Loosen the nuts 2 and lift flange 3 off. - Extract the air starting valve complete device 9427.15 (as shoun in Fig.'B'). - Remove the soft iron joint 17.

with the Belleville uasher stack7 and 7a using the extractin

1987

2728/1a - Should the removal be undertaken uith the cylinder head fitted on the engine, close the opening in the cylinder head immediately uith a suitzble lid, to avoid any foreign bodies falling into ihe combustion chacber. - For further dismantlinq of the air starting valve loosen the screws 9 and remove them, after uhich the valve casing 8 caribe lifted off and the pilot control valve 10 removed with its spring 20. - For dismantling additional parts clamp the valve spindle 12 at the milled face below the valve disc and loosen the nut 11. - After removinq the nut 11 the valve spindle caribe slid out downwards and the other inner parts removed upuards. - After removinq the parts check theiS condition. - Faulty piston seal rings 19, rod seals 18, O-rings 5 or 14 have to be replaced by neu ones of the correct specification. When replacinq the piston seal rings and the rod seals proceed with utmost tare. Particularly do net stretch or deform the slide ring of this tuoparts seal, as otheruise its fitting becomes extremely difficult. - Do net dismantle the Belleville washer stacks 7 and 7a. Should it be necessary for important reasons, pay careful attention to the arrangement of the uashers (please note the sketch on the right.) Lappina-in - If the seat of the valve spindle must be lapped-in, fit the centring sleeve 9427.37 as show in Fiq.'C' into the casinq 16. 4 - 102 llL.380

- Using some lapping paste lap-in the valve spindle onto the Seat. - Badly daeaged seat surfaces should first be ground by machine ( Assembly - The assembly of the valve is effected in reverse sequence analo+ gous to the dismantling. - Smear a11 the parts carefully uith enqine oil prier to fitting then in the valve. - Tighten the nut 11 uith a torque trench at 290 Nm, after applying fl onto the thread. - Fit a nev O-ring 14 of correct specification smeared with oil into the outer groove of the casing. Fittinp in the Cvlinder Head - insert a neu soft iron joint 17 into the bore in the cylinder head. - Smear the bore in the cylinder head uith clean engine oil and insert the complete air starting valve onto the joint 17. - Smear the thread of the studs well with Molykote G-n. - Mount the flange 3 and tighten the nuts 2 uith a forque trench, uith a socket spanner top 3/4" and extension 3/4"/8" in small equal steps to a total of 250 NM. - Checking: Flange 3 must rest flush without clearance9427.37 - 45') and only afferwards lapped-in uith grinding paste.

1.93

SULZER

Crankshaft

WmJP
SHEET

3101
1

ZA40
TO01 s: 1 Checking device 9431.01

Checking Crankshaft Deflections

We reconunend that the crankshaft deflections be aeasured uheneuer: - A general overhaul is being carried out. - Main bearing shells have been replaced. - There are indications of engine foundation deforaation. - A breakdown has occurred or for other reasons uhere a check on the support of the crankshaft is required. The follouing points have to be noted when taking crankshaft deflections: - Neasuring should always only be made on an engine which has cooled doun. - Al1 the running gear (pistons, connecting rods) should be in place; - The dia1 gauge ust always be fitted in the same position (see illustration on follouing page) - When dealing with a marine installation, it must be remembered that the loaded condition of the vesse1 should be as nearly as possible the sare at the tiae readings are taken.

Measurino urocedure - The crankshaft is to be turned by the turning gear into such a position that the dia1 gauge (uith about 1 IDI of pre-tension) cari be placed betueen two counterweights at reasuring point 1, as shown in the illustration on the following page, and set to '0'. - Then, uith the aid of the turning gear, the crankshaft is turned in the normal running direction and stopped again SO that the value show on the dia1 gauge at aeasuring points 2, 3, 4 and 5 cari be read off and noted dom. - The noted values have to be recorded SO that they cari be compared with earlier or later measurements. - Where values are measured which lie outside those show on the graphies 'A' and 'B', the cause has

to be investigated uhereby the crankshaft has to be uncoubled froc driven equipaent. - In addition to this, the engine holding-down bo'ltshave to be slackened off to determine if a pereanent deforaation of the engine foundation has occurred.

1987

Positions of the dia1 qauqe durinq measurinq

Position of dia1 gauge

Position of dia1 gauge at end of measuring

Positioninq the dia1 qauqe (tool No. 9431,Ol) Q, ,, . .,. neasurinq posif)ons End Beqinning

Draun for 8 cyl. engine Canshaft side

Exhaust side

NORMAL CRANKS and end crank no. 8 at the free end uhen neither torsional vibration damper nor shaft

mm +o. 10 +O. 70

is coupled up. END CRANKS (exception: crank at free end, see 'A'). LIHIT VALUES during engine erection (strive for small negative values uith diesel-alternator sets).

+0.05 m-

+o 05

-0
1

LIMIT VALUES for engines in service (engine cooled doun). Should the measured values exceed the limit values, readings should be taken again under various conditions (e.g. different machinery room temperatures, slackened-off holding-down bolts or under different loading conditions uith marine installations).

ao -005

-070

-0.15 - C?l8 -020

When the measured values still remain outside the permissible limits, a closer investigation has to be carried out and any necessary corrections made. In such cases contact should ba made with the engine builder.

-025 ~

Please note The crank limit values refer to the coupled condition! 4-107.121.301 1997

I,
1

SULZER

Crankshaft Loosening and Tightening the Coupling Bolts

Group:

3707 2

ZAL40
Tools:

Sheet:
Key to Illustrations:

1 Hydr. hand pump 1 High pressure hose 1 Hydraulic cylinder 1 Special spanner

9408.01 9408.09 9408.36 9431.02

l l

1 2 3 4 5 6

Crankshaft Crankshaft end piece Coupling bolt to shaft end piece Coupling bolt to flywheel Flywheel Camshaft driving ear wheel according to instructions

* Tightening

TO obtain a sufficiently firm compound, the coupling bolts for the flywheel and for the shaft end piece (locating bearing shaft) must be very frimly tightned. Due to space reasons the tightening of the above mentioned bolts by impact wrench and hammer is only conditionally possible. For this reason a11bolts shall be tightened with the aid of a hydraulic cylinder 9408.36 and special spanner 9431.02. The utilization of these tools is epicted in the illustrations overleaf. 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 the final tightening. The bolt elongation from tightening shall amount to 0,36 f 0,02 mm. Threads and nut seating surfaces must be smeared with Molycote paste G-n before the tightening.

Working

Procedure:

First tighten a11the nuts with the spanner - diagonnally accross - by hand as firmly as possible. Then tighten each bolt with the aid of the hydraulic cylinder, the HP pump and the special spanner. The tightening torque for the coupling bolts of the shaft end piece is 2300 Nm, or the pre-tensioning on the pressure gauge is 100 bar for the HP-pump. The above tightening values are only valid if special spanner tool No. 9431.02 respectively 9408.36 having a piston area of 6,41 cm* are utilized.. hydraulic pressure cylinder

Should a hydraulic cylinder be used with a differing piston area then the correct pre-tensioning be calculated to the below printed formula: P(bar) Loosening = 641 new piston area in cm2

pressure cari

of the bolt is done in reverse sequence

analogous to the tightening by using the same tools.

10.88

9431. 9408.

l- nZ 240.178

SUUER

CilANKSHAFT

Group:

5191

ZA40
Tools: 1 Hydr. hand pump 1 Branch piece 1 Pressure gauge 2 HP hoses 1 Spec. spanner 2 Hydraulic jacks 1 Round bar 0 8 9408.02 9408.03 9408.04 9408.09 9431.03 9433.07 9433.07a

Fitting the Counter weights

Sheet:

Kev to Illustrations 1 2 3 Crankshaft Waisted stud Counter ueight

3a Counter ueight 4 Round nut 5 6 7 * Centering pin Cylinder TO pre.tensioning jack Piston Pre-tension acc. to instructions

The fitting of counter weights on the crankshaft is.the same for engines type ZAL40S as for ZAV40S. A difference lies merely in the shape of the counterweights. The following instruction is valid therefore for both engine types. Attention! The engine may net be turned when the hydr. jacks are mounted! Workinp Procedure: - The contact surfaces of crank veb and counterweight must be clean, dry and undamaged. The same applies to the centering pin 5, except it has to be saeared with oil. - fit the tuo waisted studs 2 and tighten them uith 50 ; 100 Nm. - Xfter mounting the counter weight screw the round nu.ts 4 up unto the studs until fully landed. PreT e n s i o n i n a of the Waisted Studs

- Mount the hydraulic jacks 9433.07 on the uaisted studs 2 till their cylinders 6 are landed on the counter ueight. - Connect the hydr. jacks to the hand pump 9408.02 by the HP hose 9408.09. - With open bleed valve of the pump, tighten the pistons 7, (using the spanner 943l.O3), onto the uais. ted stud 2, until the piston 7 and the cylinder 6 are flush uith the outer front side. (Fig.'B') - Close the bleed valve on the 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 uith a feeler gauge). - Release the pressure to 'Zero' and measure the protrusion 'X' on the jack and note it down. (Fig. A). - 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 'Zero' and measure the protrusion 'X1' on the jack and note it down (Fig. A), When the waisted studs are correctly pre-tensioned the elongation X1 - X = about 0.72 mm. If the stretch-measure deviates considerably from this elongation repeat the whole pre-tensioning procedure.

1987

3101/3a

ZA40

L o o s e n i n q

the Waisted Studs

Y lount both hydr. jacks on the waisted studs 2 until their cylinders 6 are landed on the counter weight. - Connect the hydr. jacks to the hand pump 9408.02 by the HP hose 9408.09. - Open the bleed valve on the punp and screv the pistons 7 with the spanner 9431.03 onto the waisted studs, until the piston 7 and cylinder 6 are flush with the outer face. - Now screu both jacks back until a space of about 2 mm appears betueen the cylinder 6 and the counter weight at 'S' (Fig. '8'). (If the space is too small it may not be possible to release the pre tensioning jack after the release. If the space is too large the stroke of the jack may not suffise for a full pre-tension, of the waisted studs. - Actuate the pump and build up a pressure of about 600 bar (possibly a feu bar more) and loosen the round nuts 4 by about one full turn. - Release the pressure to 'Zero' and remove the Jacks.

1987

SULZER

ZA40
1001 s:
1 Large screu driver 1 Flat caulking tool 1 Hand hamner 1 Center punch Various spanners

Torsional Vibration Damper 'HOLSET' Manufacture Taking a Silicone.Fluid Sample

Kev to Fias, 1 Torsional vibration damper Closing screws End caver of torsional vibration danper housing 4 C K Rubber ring Silicone sanpling tube Secure the closing screus 2 by spreading metal into the slot with a tenter punch

CROUP 3130
SHEET 1

2 3

The service life of a torsional vibration daaper is dependent to a great extent on the speed range in uhich the engine works. Friction on the inner parts as vell as the changes in the characteristics of the silicone fluid cari lead to a reduction in effect of the torsional vibration daaper. By periodically investigating the silicone fluid, the manufacturer of the damper cari deternine the general condition of same. We therefore recommend that the silicone fluid should be investigated for the first time after about 20 - 22'000 running hours. The results of the first investigation vil1 deterrine at vhat intervals. further checks should be carried out. Special 'sampling tubes' cari be obtained fron HOLSET (sec Fig. 'B'). Takino a Fluid Sample Preparation *-----s---- The closing plate on the end casing at the free end or the corresponding puaps on engines having engine-driven punps have to be removed before access cari be gained to the closing screvs. - Turn the crankshaft SO that the tvo closing screvs 2 in the end caver of the torsional vibration damper lie approximatelv horitontallv (sec Fig. 'A'). - Leave the torsional vibration daaper to sit in this position for at (Where a sample

is to be taken frai a torstorral vibration daaper vhich has been reroved, the same conditions are valid vith regard to position and waiting time). In both cases the torsional vibration damper should be cooled doun to about room tempearature. - Prepare the sanpling tube, i.e. remove the closing caps and check their bores. These oust be perfectly clean. Warning: The threads are not the same at both ends. Takina a Sanple - Using a caulking tool, knock back the upset material, for locking purposes, frai the-s'iot at 'K' of one of the closing screris. - Unscrev closing screu 2 and imrediately screu in the sampling tube 'Cr vhich is held ready. - As soon as silicone fluid begins to issue frai the open end of the saapling tube, fit on and tighten the closing cap. - Unscrev the sampling tube (hold vertically) and immediat ly screu the closing screu 2 (uith rubber ring 4) back i Any unnecessary loss of silicone fluid oust be avoided. - Screw on and tighten the sarpling tube's second closing cap.

313Wla

7A4D

- Tighten with

the closing punch The

screu

2 with a torque

of about

35 Nm and

lock

the slot

uith

a poverful

blow

a tenter note:

at 'K': special saapling from tube the pernits a known vibration specif damper a tightl y fixed label and sent to the c quantity of silicone fluid

Important

to be removed The filled

torsional has

sanpling address

tube for

to be given

follouing

investigation: Engineering CO. Ltd.

HOLSET

PO Box A9 Turnbridge Huddersfield Great The follouing information type damper near has to be put No., Britain HDl 6RD

on the label: Number of running No. hours (this of the tor-sional on the

Engine caver

Engine as uell the uarning

vibration

as the production

serial

is stamped

plate).

Note:

Should

it not

be possible proceed tube

to fil1

the sampling

tube

with

silicone

fluid

in the previously

described - Leave connect 3.5 bar

manner,

as follows: screwed opening This in position and unscrew nitrogen filtered the second closing screw 2. Now

the sanpling up a pipe air may (50 lbs/inz)

to this into

and bleu
nust

nitrogen and

through

it at a pressure

of approx.

the housing.

(Should be dry

not be available, houever.

as a necessity

compressed - As soon viously

be used. fluid

as silicone described.

appears

at the outer

end

of the sampling

tube proceed

as pre-

1987

SULZER

ZA40
Tools: Assorted open end and ring spanners

TURNING DEVICE (BARRING ENGINE) Maintenance

GROlJP 3212
SHEET 1

Kev to Illustrations (On reverse of this sheet) 1 2 3 4 5 6 7 Operating lever Locking pin Thrust ring Spacer ring Spacer ring Oil drain plug Cover f. oil filling

8 Barring pinion Ba Pinion shaft 9 10 11 AS F Oil level glass Compression Springs Bal1 thrust bearings Axial clearance Grease lubricated shaft

- Before starting the barring engine check oil level. The level, in the oi'l level glass 9 must be at least on the mark 'Min'. For toppino UQ use Hvpoid Gear oil class SAE 90, (no thinner oil say be used under any circumstance) corrosion .protecting and antifoaaing properties. The oil should have good high pressure, For filling oil remove the caver 7. - The shaft 8a, on which the barring pinion 8 is shifted for engagement and disengagement uith the flywheel gear riut,oust 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 & (For oil type see above) for the barring engine (for exanple an engine overhaul) grease the

- If a lengthy duty is forese&

pinion teeth 1 uith MOLYCOTE-Grease. - When replacing the bal1 bearings, make suhe during fitting, that the spacer ring 5, opposite the bal1 bearing housing, protrudes by 0..15-o o5 PR, when it is pressed against the shaft shoulder. .

1987

/lU

?A. LO 9

SULZER

Connecting Rod Inspection and Replacement of Crank Pin Bearing Shells

houp:

3302
1

ZAL ho
m:
l Hydr. hand pump with ancillaries I Hydr. cylinder (jack) I Removal device ! Pin to removal device I Underlay to the removz11 device 2 Lcuaring devicea

Sheet:

Kev to Illustrations: 9408.02 9408.35 9433.02 9433.02a 9433.02b 9433.03 1 2 3 4 5 6 7 8 9 10 11 12 Stud Crank pin bearing Upper part Crank pin bearing l.ower part Main bearing caver Yoke Engine housing Adjusting nuts Retaining device Securing screw Screw Screw Connecting rod

! Roller for the lowering 9433.03a devices

Bearing shells of the crank pin bearing cari be removed and fitted without pulling out the working piston. Procedure for the Removal: - Loosen a11 the nuts of studs 1 as described on sheet 3302/2. Do not yet remove the nuts. - Turn crankshaft to bring the piston of respective cylinder to ignition TDC. This is absolutely essential to prevent the working piston touching a possible open valve, when it has to be lifted when crank pin bearing Upper part has to be inspected. -.Screw-in one ring screw each together with the steel rope of louering device 9433.03.At the same timt mount also the two rollers 9433.03a needed to louer crank pin bearing louer part 3. - Remove now a11 nuts of studs 1, then louer crank pin bearing lower part 3 with the aid of two liftin! tacklea, mounted on the engine exterior. Lower with tare, SO as not to damage the threads of studs 1. - Mount removal device 9433.02 as shou in the illustration,forthis screw-in the tuo pins 9433.02a full into the corresponding threaded holes in the main bearing caver 4. Pajten yoke 5 of removal device 9433.02 with two screws 10 to engine housing 6. Adjust retaining device 8 uith adjusting nuts 7 in such a uay that the removal device cornes to lie lightly against crank pin bearing Upper part 2. - Place hydraulic cylinder 9408.35 together with underlay 9433.02b on to support of removal device 9433.02 as shown in the illustration. - Connect hydraulic cylinder by high pressure hose to hydraulic hand pump 9408.02 and by actuating the pump lever raise crank pin bearing Upper part 2 together with connecting rod 12. Attention! Lift the connectina rod with crank oin bearina uooer part onlv iust sufficiently that the bearinq shell cari be removed. Irithis position Secure the connectina rdd and crank Din bearina uoper oart by tiahteninq securina screw 9 firnly. Before re-fitting used bearing shells check their condition carefully (see sheet 000212 criteria for tt replacement of bearing shells). Unduly uorn or defective bearing shells must on no account be re-fittec but must be replaced by neu ones. Any machinina. scrapina or fillinq of the bearinq shells must absolu. telv be avoided! Should it become necessary to re-grind a uorn roughened crank pin, then thicker'bearing shells must be fitted, to suit the reduced pin diineter. The table below advises on standard undersize bearing shells, the re-grinding diameters for the crank pin as well as the article denomination of the respective bearing shell undersize. (Dimensions are in mm).

1988

Rcduction of crankpin B 0,4

Crank pin b 349,6 - 8 ,06

Shcll Thickncss

Vertical bcaring clearancc

Oore 4 vertikal (shclls fitted) 349 >6 + OP*' 0,22 348,8 ? "*' + 0,22

Article denomination

7,6 - B ,02

200

1,2
3,O

348,8 - (06

- 8,02

202

347

- 8 ,06

8,9 - 8,02

0,22;0,35

347

0,29 + 0,22 + 0,29 + 0,22 +

l

204

5,O

345 342

- El,06 - 8,06

9,9 - 8,02 11,4 - 8 ,02

345 342

205 206*

890

0,29 0,22

* Undersized bearing shells xith article denomination 206 may only be fitted after consulting SULZER. lorkinq Procedure for Fittinq: 'or fitting the bearing shells the shell rear side and the bore in the crank pin bearing body must be free 'rom any damage. imear the running surface of the bearing shells lavishly with clean engine lubricating oil. Fit the Upper bearing shell equally spaced axially and radially into crank pin bearing Upper part 2. make sure that the small tonque of the shell fits into the recess in the crank p3n bearing Upper part. . Actuate hydr. hand pump 9408.02 to slightly raise connecting rod 12 together with crank pin bearing Upper part 2, then loosen securing screw 9. . Slowly louer the oil pressure by the relief valve of hydr. hand pump, till the bearing shell together with crank pin bearing Upper part and connecting rod rests on the crank pin. .,Remove hydraulic jack 9408.35, the underlay 9433.02b as well as removal device 9433.02 with the pins 9433.02a. Mount the bearing shell to the crank pin above. . Using lowering device 9433.03 and rollers 9433.03e to lift crank pin bearing louer part w.ith its bearitig shells till it rests against the crank pin. Fit the four nuts to studs 1, thea tigkten the nuts as described in sheet 3302/2. After completion of work remove a11 tools from the crankcase. 'or a final check measure the bearing clearance on the fully fitted bearing and compare it with the values n clearance table 0352/3a. louer part 3 in the same manner as in Upper part 2 described

1988

3302 / lb

ZAL40

9408.02

9408.35

kkhW-rP408.K

11

;d
I

P433.02a

SlJLZER

.ZA40
Tools: 1 Hydr. Hand pump 1 Branch piece 1 Pressure gauge 2 HP hoses Z!Hydr.jacks 1 Round bar 9408.02 9408.03 9408.04 9408.09 9433.01 9433.01a

CONNECTING ROD Slackening and Pre-Tensioning the Studs in the Crank Pin Bearing
Kev to illustrations 1 2 Connecting rod Crank pin bearing C

GROUP
SHEET

3302
2

ArraDgement of the hydr. jacks for pre-tensioning the Studs to the connecting rod. .

upper part 2a Crank pin bearing louer part 3 4 Piston Cylinde i Stud Round nut of jack T
l

Arrangement of the hydr. jacks for pre-tensioning the studs of the bearing. Bearing body separation Tighten according to instruction

l5
6 7

Compression shim

Remark: TO prevent damage to the components, the crankshaft may not be rotated after the pre-tensioning jacks are mounted! Additional lubrication of the stud threads is not necessary.

Slackeninq The procedure for slackening the studs to the connecting rod (short studs) is the same as for the studs of the crank pin bearing (long studs). Turn the crankshaft to a position corresponding the one in Fig. 'C' or Fig. '0'.

Workina Procedure: - Clean the contact faces for the pre-tensioning jacks. - Screw the pre-tensioning jacks 9433.01 cr~sswise onto two diagonally opposite studs 6, till their cylinders 4 rest against the foot of the connecting rod or the bottom end connecting rod head. - Connect the jacks by high pressure hoses 9408.09 uith the pump 9408.02. - Open bleed valve on pump, and screu the pistons 3 of the jacks in, till they land on the cylinders of the jacks. (sec Fig. 'A). - Now turn the jacks back a little until between the jack and the connecting rod foot or the crank pin bearing body a space of about 2-3 mm appears. (When the clearance is too small, there may bs difficulty unscrewing the jacks. When it is too large the jack stroke nay not suffice to stretch the studs by the required measure. - Build up a pressure of 600 bar (or a feu more) with the pump and unscreu the tuo nuts of the studs by about 4-5 hole intervals. - Release the pressure to 'zero', remove the jacks and repeat the same procedure on the other tuo stud

19R7

33G2/2a

Lk4u

Pre

Tensioninq

1) Studs to the ConnectinqRod (short studs) _ Clean the contact faces of the nuts 6, screr them on and tighten then with the round bar 9433.Ola until landed. - Screw pre-tensioning jacks 9433.01 crosswiseonto two diagonallyoppositestuds till their cylinders4, are landed.

- Connect the jacks with the pump 9408-02 by the HP hoses 9408.09.
- Open the bleed valve of the pump and screw the pistons3 completelyinto the jacks. - Build up a pressure of about 100 bar with the pump and keep this pressureconstant. - Tighten the round nuts 6 with the round bar until they are firmly seated (check seating with feeler gauge). - Release the pressure to 'zero'. - Measure protrusionof piston (dimension'X') and make a note of it. (sec Fig. 'B'). - Raise tensioningpressure to 600 bar, Keep this pressureconstantand tighten the nuts 3 with the round bar until they are firmly seated (check seating). - ldeasure protrusionof piston (dimension'Xl' and make a note of it (sec Fig. '8'). When the pre-tensionis correct the elongationshould be: X1 - X = 0.50 mm. - If the measured elongationdeviatesconsiderably from the above figure, repeat the whole procedure. - Finally pre-tensionthe other two studs in like manner.

2) Studs to Bottom End ConnectinqRod Bearinq Body (Long ones) Preparations and work sequenceare similar to the studs for top end bearing body (short ones) as described under 1). - After nounting pre-tensioning jacks crosswiseonto two opposite studs and joining them to the pump, raise a pressureof 200 bar, keep this pressureconstantuntil nuts 6 have been tightenedtill seated. - Release pressureto zero then mount the jacks onto the two not pre-tensiond studs, and pre-tensionthese equally at 200 bar. - Tighten nuts 6 till seated. - Release pressure to zero then measure projection'X' on both pre-tensioning jacks and record them as 'X' (Fig. 'B'). - In this conditionno qap may renain betmeen the two bearing body halves at 'T'. - Raise a pressureof 600 bar on both jacks, keep this pressureconstanttill nuts 6 have been tightened till fully seated. (Check nut seating by feeler gauge).

- Release

pressure

to zero

and measure

projections

X, .

(Fig.

B)

and record

it.

- The difference IX,' 1 'X' is the elongationrhich should amount to about 0.85 mm. - Re-mount both jacks on the studs previouslypre-tensioned 200 bar. Raise again the pressure to 200 bar and to tighten nuts 6 till fully seated.

4.88

- Release pressureto zero measure on the jacks projection 'X' and record them. - Raise pressureto 600 bar tighten nuts 6 till fully seated (Check seating by feeler gauge). - Release pressureto zero and measure projection 'X,' on both jacks. (Fig. 'B'). - The difference IX,' - 'X' is the elongationrhich should amount to about 0.85 mm. In case of substantialdeviatior the pre-tensioning proceduremust be repeated on a11 four connectingrod bottom end bearing body studs. - After completion of the pre-tensioning removethe pre-tensioning jacks (sec respectiveinstructions). Close open connectionsby dust caps, then store jacks and pump with hoses in a clean dry space.

/' /

b- 107.185359

4.88

102 / 2c

ZAL CO *

9433.

3.87

SULZER

I PISTON Removal and Fitting I

a

:ZAL40
1001s: 1 Guide rod 1 Ring screw 1 Bull ring 1 Rope Shackle 9434.05 9434.08 9434.10

Piston

I
Screw

GROlJP 3401
SHEET 1

Kev to Illustrations 1 2 3 4 Piston Connecting rod Studs Crank pin bearing 5 6 7 8

Compression Rings Oil scraper rings Cylinder liner .,PISTON REHOVAL (Fig. 'IA') Drain cylinder cooling water frotn the engine. Remove the cylinder head of the cylinder concerned. (Pl. refer to sheet 2701/1). Slacken pre-tension of connecting rod studs 3 hydraulically, remove their nuts (pl. refer to sheet 3302/2),

- Ascertain that the cylinder

liner 8, is fastened by the screu 5. Barr the crankshaft till thc piston is in T.O.C., screu ring screu 9434.08 into the piston top. (if necessary clean the threaded hole of coke with a threading tap, (820). Fasten the guide rod 9434.0! onto the Bearing body 4. Connect the piston to the crne with a shackle and a rope. (weight of biston about 450 kg). - Pull the piston slouly out of the engine with the crane, while holding the crank pin bearing body
steady with the rod 9434.05 until the connecting rod 2 has been lifted out of the studs.

- Clean the renoved ces 0352/5a). For

piston carefully the cleaning of

and ineasure the ring grooves. the piston use onlv tools uhich

(pl. refer to the table of clearancannot damae the ptston,

1987

1407/la

ZAL40

FITTING THE PISTON (Fig. 'fi') - Clean the cylinder liner bore carefully and apply engine oil a11 over its bore liberally. -.Barr the crank to T.D.C. and fasten the guide rod 9434.05 onto the crank pin bearing body 4. - Clean the piston 1 carefully and attach it to the crane hook with ring 9421.10 and a rope. - Fit ney piston compression and oil scraper rings on the piston (Pl. refer to sheet 3402/1) and tur the rings SO that their ends are off-set by 180'degrees. - Saear piston and rings with clean engine oil. - Check the 'Bull ring' 9434.10 carefully for ridges or skratches, apply engine oil liberally on its taper bore and place it on the cylinder liner. (Ridges in the 'Bull Ring' uould daage the (sealin surface of the rings). - Louer the piston carefully into the cylinder liner, until the foot of the connecting rod is just above the studs 3. Turn the piston with the connecting rod until the marking on the foot of the CO necting rod is on the same side as the one on the crank pin bearing body. - Check the contact surfaces, of connecting rod foot and crank pin bearing body, they must be clean and free from oil. - Place the crank pin bearing body 4 with the aid of guide rod 9434.05 SO that its top surface is pa rallel to the bottom surface of the connecting rod foot. - Nou louer the piston fully, while taking tare that the foot of the connecting rod slides over the studs 3 in the bearing body without janming. - Rerove the guide bar 9434.05. - Unscrew the ring screw 9434.08 from the piston ' croun and remove the 'Bu1 Ring' 9434.10. - Fit the connecting rod nu by hand onto the studs 3 until they are seated. (0 not apease the thread). - Barr the crankshaft until the piston is in B.D.C. - Pre-tension the connectin rod waisted studs accordi to instructions (pl. refe to sheet 3302/2). w Fit the cylinder head (pl refer to sheet 270111) an connect the various pipes - Fil1 the cylinder cooling water into the engine and ready the engine for oper tion. screu 9434.08, shackle

1987

SULZER

ZA40
1001s: 1 Torque urench (480 ; 940 Ne/3/4") 1 Ring screu 120 1 Piston claeping device 2 Claaping bolts 2 Ring screu 2 Jacking screus 2 Centering rings 2 Ring screus Ml2 2 Jacking screus M20 1 Socket spanner AF 24 Assorted open end and Ring spanners 9434.11 9434.12 9434.13 9434.14 9434.08 9434.09 9408.17

PISTON Dismantling and Assembling

GROUP SHEET

3401
2

Kev to Illustrations 1 2 3 4 5 6 7 8 9 10 11 12 Piston croun Coepression rings O-Rings Upper spherical shell Guide bush Ratchet pawl Ratchet ring Ring spring Ring Piston skirt Louer spherical shell Supporting ring haisted screv
l

14 15 16 17 18 . 19 20 21 22 23 24 25 26

Spring guide piece Springs Screu uith locking plate Retaining plate Spherical head Oil scraper ring Centering pin (long) Pin Centering doue1 Stop piece Cyl. pin Ring screu Wood underlay

l 13

Tighten according to instruction.

1907

Explanation: Paragraph 1 describes the procedure to replace merely the piston croun. Paragraph 3 describes the complete dismantlinq procedure of the piston. Paragraph 3 describes the assenbling of a dismantled piston. In a11 these cases work must be done with great cape, to avoid daaage to any of the coaponents. Befo re assembling the parts oust a11 be thoroughly cleaned.

1. R e D 1 a c i n a

a Piston Crown (Fig. A, B, C, 0 & E)

Procedure for Oisnantling: ------_--_-_-------------- Screw ring screw 9434.08 into the top of piston croun and suspend (Fig. 'B'). - Fix the tuo centering ring halves 9434.14 with tuo claaping bolts 9434.11. (Fig. 'B' and 'Cl). - Turn piston 'upside doun' into the piston clamping device 9434.09, tighten its bolts noderately . the piston should later not turn. (Fig. '0'). - Loosen a11 eight waisted screws 13 and reiove. Claaping bolts 9434.11 cari remain in place (Fig. '0'). - Fit a jack screw each 9434.13 through the two holes 'b' (Fig. 'C') into the Upper spherical she11 4 and tighten alternately until the piston skirt 10 is separated from piston croun 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 firnly, SO that the piston skirt ca n be lifted off the piston croun 1 with a11 inner parts. Procedure for Assembling --------____------------ Place neu piston croun 1 into the piston clarping device 9434.09 and tighten its bolts moderately (Fig. 'El). - Fit two n'y O-Rings 3 into the grooves of the piston crown (use only original O-rings) and grea se or oil them liberally. - Place the coaplete piston skirt 10 onto the piston crovn 1, match the holes for the waisted screus 13 uith the threaded holes in the piston croun. - bear the head landings and the thread of the eight waisted screws 13 with oil and screw them in by hand. - Unscrew both jacking screvs 9434.13, reaove them and tighten the 'eight waisted screus 13 alter nately and diagonally, until the Upper spherical shell 4 rests against the piston crown 1. Attention! Betveen piston crown 1 and piston skirt 10 a space of 1 - 1,4 II rerains alwavs, i.8. also after fully tightening the waisted screus 13. - Tighten the eight waisted screus 13 with a torque wrench 9408.17 and suitable socket spanner in lsert (AF 24) to start with, to 120 r 6' NB. (Pre-tightening). - Mark the position of each screu head to the pistonoskirt with a Parking pen or like scriber. Pa ,Y attention fg the sarks on the screu collar (4 x 90 ), then finally tighten the screvs bv an anale of 90 . (The total torque is about 620 Na, but the tightening must be carried out as described above). - After having thus fully tightened the screus 13, turn the piston back ta its original position and suspend it on the crane uith ring screu 9434.08 and rope. (Fig. 'B') - Rerove the tuo clamping bolts 9434.11 as uell as the centering ring halves 9434.14, and prepare the piston for fitting into the engine. (Please refer to sheet 3401/1). the piston uith rope on crane.

741-I-l /3h

Z?40

2. D i s m a n t 1 i n q

and Assemblinq a Piston

Working Procedure for Dismantling ______--_-----------------------_ Screv in the ring screw 9434.08 into the piston croun 1 and suspend the piston by a rope on the crane (Fig. 'B'). - Mount the tuo halves of the uooden centering device 9434.14 with the clamping bolts 9434.11. (Fig. 'B' b 'C'). - Upend the piston and place it 'upsi de down' into the clamping device 9434.09. tighten its bolts moderately, SO that the piston cannot turn (Fig. '0'). - Loosen a11 eight uaisted screws 13 and remove. (Claaping bolts 9434.11 cari remain in place Fig. ID'). - Attach the connecting rod uith a rope to the crane and lift it vertically out of the piston, the louer spherical shell 11 and the supporting ring 12 are lifted along with it. (Fig. 'FI). - Remove the ring 9 and the ring spring 8 and place them aside. - TO prevent its getting lest later on, remove stop piece 23 off ratchet ring 7 and glace in a safe place. . (Fig. 'F')

- TO lay the connecting rod down without difficulty, ue recomaend to replace the tuo clamping bolts 9434.11 (Fig. 'F') by the two ring screus 9434.12 (Fig. 'H'). Attention! Take the greatest tare not to daaage the spherical head of the connecting rod and the louer spherical shell 11. - Fit tuo jacking screws 9434.13 through two threaded holes (M 24) in the piston skirt and screu thea in by hand until they rest against the shoulder of the Upper spherical shall 4. (Fig. 'G'). Fit ring screw Ml2 into the top ends of the jacking screus and attach them by a rope ta the cran - Tighten both jacking screws simultaneously, uhereby the piston skirt 10 is separated from the pi.ston crown 1 (Fig. 'GI). . - After the two parts are separated lift the piston skirt 10 off the piston crown. (Fig. 'J' 1 'K'). ATTENTION: The ratchet ring 7 nust remain lying on the Upper spherical shell 4, if it is lifted with the piston skirt it aay fa11 out suddenly. (if necessary tap it out uith a piece of wood). - If the ratchet mechanisa aust be disaantled, remove the screws 16 after bending the locking plates up. Reaove the retaining plate 17 and the ratchet pauls 6 with-their Springs 15 and the spring guide piece 14 be pushed out. The same applies to the guide bush 5. l - Assemble the ratchet mechanism in reverse sequence, clean a11 parts with great tare before fitting and smear uith 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 louer spherical shell 11, which consists of two halves, oust be removed, fit two screws 120 for each half shell into the supporting ring 12. Froc the opposite side drive in tuo clarpin bolts 9434.11. By tightening the clarping belts against the Il20screvs, you uill press the respective spherical shell half 11 off the supporting ring 12. (Please refer te Fig. 'Ml). This dismantling is best achieved by fixing the connecting rod to the floor and osing two wooden blocks 26 as working base (Fig. 'MI). Attention1 The fwo spherical shell' halves 11 are marked together. They may only be used as a unit. Single shell halves may another piston! Replacement of Spherical shells - The spherical shells need not be replaced if the running surface is uorn and the lead bronze becomes visible. - They rust houever be replaced, when bits break out of fhe lead bronze or uhen it is badly scratched by foreign particles. & be replaced, also not interchanged uith

1987 1 1

3. Workinq Procedure for Assesblinq a Piston Assembling the lower spherical shell ___-----_-------_------------------- Raise the connecting rod to vertical and fix it in this position. (Fig. 'Il'). - Place two wooden blocks 26 of squal height on either side of the connecting rod. - Heat the supporting ring 12 in an oil bath or in a furnace to 120 - 15O'C and place it on the uooden 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 cor rect'position of the doue1 pin 22. (Fig. 'Il'6 'C', 'A', 11-11)

- Froa below iseediately screw in four clamping bolts 9434.11 through the supporting ring 12 into the spherical shell halves ta ensure their correct position. Do not remove the clanping bolts until the supporting ring has cooled dom.

Assemblinq the Piston - Place the piston croun into the clamping device 9434.09 and tighten its bolts moderately. . (Fig. '0'). - Place new O-Rings 3 into the grooves in the piston croun and suear then uith grease or oil. (Fig. '0'). - Place Upper spherical shell 4 onto the piston croun 1. (Pay attention to the centering pin position (Fig. '0'). - Place the ratchet ring 7, uith cylindrical pin 24 pointing upuard, on the Upper spherical shell. (Fig. '0'). - Fit two jacking sc'reus9434.13 into the piston skirt and louer it,.hanging on the crane, over the parts fitted before. (Fig. 'N' 6 '0'). - As soon as the centering pin 20 mates the corresponding hole, reach with the hand into the pis. ton skirt fron 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. 'Pl. - Only nou lower the piston skirt coapletely, which possibly requires some strokes uith a lead hawner. (Fig. 'QI). (Attention! Betueen piston skirt and piston croun 1 a gap of 1 - 1.4 wn uill alvays remain). - 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. 'PI 8 '0'). - Attach the connacting rod, spherical head 18 dounuard uith the louer spherical shell 11 and supporting ring 12, on tu0 ring screws 9434.12 and a rope on the crane. (Fig. 'RI) - 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 their leading edges stand vertically. (Fig. 'RI 6 'St). - NON insert connecting rod inta the piston, guide the ratchet paul 6 to match uith ratchet ring 7. (Fig. 'S' C '1'). 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 uill be possible in one dibec tien, whereby a uell audible 'Chatter' is caused. In the other direction the connecting rod should not turn. - Remove the ring screus on the ends of special ring screus 9434.12 and fit the 'asserbly" consisting of spherical shell 11 and supporting ring 12 into the piston, pay attention to the position of centering doue1 22 (Fig. 'A', II-II). (Please refer to Fig. 'R' and 'A', II-II). - Rerove special ring screus 9434.12. - Smear with oil the head landing surface and the thread of waisted screus 13 then screu then in bv hand,

1987

3401/2d

ZA40

- (Pre-tighten) a11 eight uaisted screws 13 with a torque urench 9408.17 and socket insert (AF24) d first to 120 'i" Nm. - Mark the position of each screu with reference to the piston skirt uith a marking pen or like scriber For this take the four narkings on the cylindrical heads of the screus into consideration. (4 x 90*). Now tighten the screus fully by the angle of 90'. (Fig. 'LT').

- Checkinq clearances After coapleted asseably, check vith the feeler gauge, whether sufficient clearance exists between the spherical connecting rod head and the louer spherical shell 11. (It should be Hin.O,07 , Max. 0,23 en).(The wooden centering ring oust net be fitted yet for this checking). (Fig. 'U'). - Checkinq the Ratchet Mechanism For axis. - Fit the wooden centering ring 9434.14 and fasten it with two clamping bolts 9434.11. (Fig. 'U') V Now reverse the piston, attach it to the crane uith ring screu and rope and prepare it for fittinq into the engine. (Fig. 'B') (Fitting the piston sheet 3401/1). extra safety check the function of the ratchet again by turning the connecting rod through its

3407/2e

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SULZER

Piston COMPRESSION and OIL SCRAPER RINGS Removing and Fitting

GROUP
SHEET

3402
1

.ZA40
1001s. A 1 Piston ring expander 9434.18

Kev to Illustrations 1 2 3 4 5 6 Guide tube Sliding tube Heavy spring dowel pin Pin Jaus Spring Sleeve

a
9

Compression ring Oil scraper ring

8a Compression ring 9a Garter spring Cr Chrome layer PI X20 Plasma

ZA40 Cr PI X20 2A4OS

: 207 TOP : 248 TOP

+a%-

ZA40 ZA4OS

: 240 TOP : 579 TOP

a&-

Use the piston ring expander 9434.18 for removing and fitting comoression rinas. lhis tool contained in the engine tool kit prevents over-expanding the rings, which would make then loose their shape. Oil scraper rings have a lesser tension and caribe easily expanded by hand. However here also the ring must be expanded just sufficiently to guide it over the piston skirt. Jammed Compression Rings should first be eased with a suitable solvent instead of trying to force them ouf, with the result that ring and 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. Al1 carbon deposits in the bottoa of the grooves must be removed carefully. A piece from an old piston ring sharpened at one end is an excellant tool for this. Although the flanks of the piston ring grooves are hard chrome plated, they nust be checked for uear by aeasurement (please refer to the clearance table 0325/5a) it may be necessary to re-chrome the flanks to restore them to their original dimension. In principle neu compression and oil scraper rings should be fitted to the pistons at every overhaul of the engine.

3402/1a

ZP40

The piston compression and oil scraper rings are usuallv fitted ta the thorouohlv cleaned piston uhen it is hanging on the crane. - Fit first the lowest colpression ring, then the central one and last the topmost compression ring. The rings have to be expanded with the ring expander 9434.18 until the limit stop engages (please refer to the sketch at the end of the sheet). Each ring is guided horizontally to its groove and th stop is disengaged. - The narking 'TOP' stamped on one of the ring ends has to be facing upuards: (The nuaber next to the marking 'TOP' are the last three digits of the drauing number). - The piston rings must not stick in their grooves, this is important and aust be checked. The oil scraper rinq is fitted from below into its groove. First remove the garter spring 9a from the ring open it by pulling apart the junction and introduce it into the groove at the piston skirt botto There push the ends together i.e. the garter spring is closed (please refer to the sketch below this paragraph, where the garter spring is shown in open position).

Nov expand the oil scraper ring slightly and carefully by hand and slide it over the piston skirt intI its groove. The ends of scraper ring and garter spring should be offset from each other. Note that the markina on the oil scraper rina end musf also be facing upuards. Remark: Oil scraper ring and garter spring are one as the garter spring is matched to the corresponding scraper ring. The tuo parts may therefore not be reolaced individuallv. Regarding clearances betueen ring and groove please refer to the clearance table, sheet 0352/5a.

SULZER

ZAL40
Tools. L 1 Feeler gauge

CAMSHAFT DRIVE Checking the Gear Tooth Backlash, Bearing Clearances as well as Adjusting the Camshaft Drive Gear Wheels

GROUP SHEET

4101
1

Kev to Illustrations (Overleaf and Sheet 4101/1b) 9408.15 1 2 3 Drive Gear Wheel on crankshaft Large interaediate Gear wheel Small internediate gear wheel Fig. C Fig. A Fig. B View on camshaft drive gear wheel Longitudinal section of gear train of non reversible engine Gtudinal section of gear train of reversible M;M3 engine Marks for correct position of gear uheels
l

9408.17 1 Torque urench (140-560 NUI/~/~") 1 Short extension 3/4"/8' 1 Socket spanner insert 3/4"/AF 17 1 Straight edge (About 500 mm long) 1 Depth gauge (neasuring range abt. 450 mm Assorted double end spanners

l 5,5a
6 7 8

4. Canshaft gear Screus End plate (Flyuheel end) Spacer ring Stop ring (only installed in non reversible 9 engines) Oil jet nozzle

TO be tightened according instruction.

Whenever an opportunitv'occurs but definitely during an overhaul, check the condition of the gear train teeth profile and measure the tooth backlash and the bearing clearances (Please refer to clearance table 035216). Early detection of any tooth danage, cari,, prompt replaceaent of the gear wheels, prevent serious by damage. Use this opportunity to also check, whether the spray nozzles in the gear train space, spray oil onto the gear wheels uhen the lubricating oil and the pre-lubrication pump is running. Oil aust also flou fror the journals of the intersediate gear wheels. The radial clearance of the intermediate gear wheel cari be measured uith the feeler gauge after renoving the end plate 6 and the spacer 7. Should it have been necessary to loosen the screus 5 or 5a, retighten them uith a torque urench at 350 Nm and secure the screws with locking vire. The threads of both screws and their landing faces are to be smeared with fi Adiustina the Carshaft Drive Gear Wheels (Please refer to Fig. 'A') Barr the crankshaft until the mark 'M' on the driving gear wheel 1 fs in fbpmost vertical position, which means that the crank ueb next to the flywheel points verticallv upwards, The two Harks 'M2' on the large intermediate gear wheel 2 must be situated to left and right of the . mark 'Ml' on the driving gear wheel on the crankshaft. The camshaft gear 4 has to be SO positioned that the distance 'K' fror the mark '113'on the toothed rim to the upper edge of the engine casing measures 432 mm. For chacking this distance place a straight edge onto the engine casing.

Remark for

Replacina a Larae Interaediate Gear Wheel

Should a large interaediate gear wheel 2 have to be replaced, heat it to about 8Q-1DO'C and quickly fit it in the correct position on the small gear uheel 3 to line up the cylindrical doue1 pin. Provisionally tighten some of the screu 5 before the gear wheel has cooled.

1987

Gezeichne DRAWN

t fr FOR

ZAL 40 ZALGO

A 0

ZAL LO

l- 102 121.367

3.87

ZAL409

ZAL 40, ZAL 40s nicht umsteuerbar NOk REVERSIBLE

B 0
I-I

6 ZAL 40, ZALLOS umsteuerbar REVERSIBLE

8 ----

C 0

.?AL 40

l- w7121.369

d
3.87

SUCZER

CAMSHAFT

ZAL40
Tools: 1 Hydr. Hand pump 1 Branch piece 1 Pressure gauge 2 HP Hoses 1 Torque wrench 1 Force multiplier 1 Socket spanner insert l"/AF 46

Checking the Cams Removing and Fitting the Camshaft

Kev to Illustrations 9408.02 9408.03 9408.04a 9408.09 9408.17 9408.19 1 Camshaft

GROUP

4201
1

S=IEE7

*2
3 4 5 6 H *

Screw
Cover of Caashaft bearing Doue1 pin Underlay (Copper, hard uood, Aluminium) Fitting ring for locating bearing (only for non reversing engines) Wooden underlay about 30 mm thicb Tighten according to instructions.

9442.20 2 Roll-out rails 2 Supports uith screws 9442.21 2 Wood spacer pieces 2 Hydr. jacks 1 Eye screu Ml6 9442.22 9408.35

Whenever the casing caver to the cawshaft is removed, take the opportunity to inspect visually the condition of the running surface of the cams as well as the tooth profiles of the camshaft drive gear wheels. If cams are found damaged investigate whether possibly Springs or other parts in the housing for valve actuation or in the fuel injection pumps are defective. In the course of an overhaul check in addition the radial and axial clearance in the carshaft bearing (consult clearante table 0352/6).Wh en clearances are excessive remove the bearing shells and if necessary replace thm. R e m o v i n q the Camshaft '(Pl.refer ta sheet 42Ol/lc) .

- Remove a11 the valve push rods. - Remove the fuel injection pumps and the valve actuating gear housing or lift thea and support them on a wooden underlay of about 30 mm thickness 'HI. - Remove the caashaft casing caver and their fraaes. - Oisconnect a11 the gear driven off the end of the camshaft, froo the camshaft. - Remove those tuo bearing covers 3 where afterwards the roll-out rails 9442.20 are fitted. (Use eye screu M16). It depends on the number of cylinders the engine has, on which bearingt the roll-oi rails are mounted. The rails must be SO arranged that the camshaft is evenly supported. (Fig. 'C' shows the arrangeent for a non reversible 8 cylinder engine). - Loosen the bearing screws of a11 the other bearinas bv about one turn, - Remove the bearing shells of the two bearings where the covers have already been reroved to fit the roll-out rails. TO do this, ease the carshaft off its bearings slightly, by tuo hydraulic jack: 9408.35 placed in the imediate vicinity of these bearings with underlays 5 to protect the shaft, and applying pressure uith the hand puap 9408.02. klhenplacing the jacks and underlays make provision that the shaft is pressed slightly avay froo the engine. - lount the two roll-out rails 9442.20 and supports 9442.21 at the two bearings where

covers

and

bearing shells were reaoved, and press the rails against the shaft while tightening the fastaning screws 7. - Should the engine tilt touards the camshaft side (because of the ship listing during unloading etc. use the hand cranks of the roll-out rails until their holding jaws are about 1 mm away from the camshaft to prevent its rolling out unexpectadly, while still peraiting removal of the other bearing shells. - Reoove a11 the remaining bearings shells.

ZA40

- Check again that the camshaft is not held anywhere. Turn the crank counterclockwise, thus easing back the jaus of the roll-out rails and pull the camshaft out on the rails. - TO move the shaft off attach it with tuo ropes in such a uay that it hangs horizontally and does not bend.

F i t t i n q

the Camshaft

Conditions for Fittinq - Al1 the valve push rods are removed, the valve actuating gear casings and fuel injection pumps either removed or raised and placed on uooden 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 Sheet 4101/1). Fittinq (Please refer to Illustration on sheet 42Ol/lc) - Mount two roll-out rails 9442.20 and supports 9442.21 on the engine casing (it depends on the number of cylinders the engine has, by which of the camshaft bearing the rails are mounted). - Place the camshaft 1 onto the roll-out rails 9442.20. - Clean the bearing areas on the camshaft and the bore of the camshaft bearing shells with a clean ~10th. - Gy rotating the cranks of the roll-out rails clockuise 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). - Adjust the camshaft axially, that it cari be rolled in unhindered. - Roll the camshaft into its bearings, make sure that the camshaft gear wheel engages the intermediatt gear in the right position. (Observe the check dimension 'K' as per sheet 410111). - Fit the bearing shells with clean dry outer surface and running surface of shell and shaft well oiled, leaving out the two where the roll-out rails are mounted. The bearing shells must be SO placed that the dowels 4 of the bearing covers cari fit into the corresponding milled holes at the joining faces. Axially the bearing shells should be approximately flush with each other. - TO fit the bearing shells it is necessary to slightly raise the canshaft with the aid of the hydraulic jack 9408.35 placed in immediate vicinity to the respective bearing. For the protection of the camshaft it is essential to place a soft metal (copper, Aluminium) underlay 5 between the jack and the shaft. - Hount the bearing covers 3 and fit the screws (with locking plates) bv hand, Coat thread and head landing surfaces with HOLYKOTE Paste G-n, Attention! Take tare that the dowel 4 in the caver fits correctly into the machined holes. - Dismantle the two roll-out rails 9442.20 and supports 9442.21 and fit the two remaining bearings. - Remove a11 the tools used for the fitting.

T i q h t e n i n q

the Eearinq Cover Screws

- First tighten a11 screws moderately by hand with a spanner, then alternatelv in several steps with a torque wrench and a force multiplier and socket spanner 1" to a total of 740 Nn for ZA40. For ZAS-engies pretighten a11 screws with 150*i$Nrs followed by final tightening uith an angle of 60~65' - Check the radial clearance of a11 bearings with feeler gauge 9408.15 with greatest tare, The axial clearance is checked by pushing the camshaft axially fron.one stop to the other. (Rote! For reversible engines the reversing servomotor must first be fitted before the axial clearance caribe measured!). - If a11 clearaoces radially a n d axially are within the tolerances given in the clearance table, secure the screws of the bearing covers with the locking plates.

7 an

4201/lb

ZP4J

- Re-fit the Starting control air distributor, the fuel injection pumps and the valve actuating gear. - Barr the crankshaft with the barring engine and check that uith lubricating and pre-lubricating purp .running the oil flous out froc a11 the canshaft bearings. - TO seal the fraie of the engine casing, onto which the carrshaft casing covers uill later be fitted, clean ther with a degreasing agent (benzine, aceton etc.) and smear theo with a sealing conpound.

1987

4201 /lc
t

ZAL 40

SULZER

,,nZ,Ar~ .o
Tools: Various spanners Pneumatic grinder for cuttiag cams.

CAMSHAFI CAMS Replacing original Cams by Split (2-piece) Cams

Kev to Illustrations 1,la Supports 2 3 4 5 6 7 B 9 stops Carriage Air stop valve Grinding disc Feeding crank Pneumatic grinder Caashaft Clamping screvs 12 13 14 0 U 10 11 Guide rods Grip for side to side aovement of carriage 3 Clamping screws Original cams kaisted screus Upper cars half Louer cars half P Z
l

GROUP SHEET

4211
1

A B C D

Fuel cam Valve cam Arrangement of grinder on free end Arrangement of grinder on driving end Identification narks Doue1 pin On front page of sheet

Should it become necessary to replace a cam ,either for the fuel puap or for the inlet/ exhaust valve actuation, this cari be done for non reversible engines, by fitting in place of the defective one a new split (Z-piece) cam. This is done as described belou; - Reaove the fuel pump or the valve actuatin gear of the respective cam. - Barr the crankshaft until the tenter of. the cas profile of the defective ca@ faces upwards SO that the parting cuts vil1 be made at the thinnest sections (Please refer to the illustration on sheet 4211/lb). - Mount the device for cutting the cams as show in the illustration on sheet 4211/lt vhereby the tua supports 1 and la must be clamged onto the camshaft. - Connect the pneuaatic grinder 7 to an air supply systen of 6 to 7 bar. - Locate the tuo stops 2 in such a way that the carriage 3 when moved back and forth cannot touch any neigh-bouring parts. - Mark the position of the cam to be replace on the carshaft with a felt tip pen. Use the identification mark A,E or B on the i ED 4 1 - 10Z18s.392

cas

face

as a bais.

(A = Exhaust,

E = Inlet, B = Fuel). - The working area and the adjacent space must be carefullv covered uith a suitable material SO that no grinding dust cari fine its way into the engine. The covering I& rial ust be nonconbustible to trap the stream of sparks.

- Imaediately adjacent to the defective cas the camshaft should be protected froa possible daaage 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 tut in the cam until the remaining thickness of the cam is about 0.2 mm,

1987

t211/la

n.

umstb.

ZA40

- Barr the crankshaft that the cam to be replaced is SO positioned, that a second groove caribe tut exactly opposite the first. _ The cam cutting device carinov be removed entirely. Drive a steel uedge gently into the groove uith a hammer to break the cam apart. - Before fitting the split (2-piece) cam the camshsft must be thoroughly cleaned and degreased. Take exceptional tare not to uipe'out the marking made on the camshaft previously. If the mark has been inadvertently wiped off, the cam must be positioned,that it corresponds to the information in the control records. - The split (2-piecej'cars 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 can.The arrou on the face of the cam indicates the sense of rotation of the camshaft. - Smear the thread and the landing face of the heads of screus 14 uith MDLYKDTE

Paste G-n and drive the screvs in by hand, only to the extent that the cam cannot shift any more. Axially the cam must be located in such a way taht the rollers actuating push rods or fuel plunger protrude equally on either side. - Prier to tightening the screw their exact length must be measured and noted. - Arrange the gaps between the txo cam halves evenly, then tighten the screws alternately in several steps firmly. - For both executions acc. Fig. 'A' and 'B' of the ZA 40 engines the screw elongation must be 0.27 mm (eq. to abt. 610 Nmj. - For ZA 40 S engines acc. to fig. 'A' the screw elongation must be 0.27 mm(eq. to abt. 610 Nm), for execution acc. to Fig. 'B' the screw elongation is 0.33 mm (eq. to abt. 960 Nm). Determinant for correct tightening is the specified screw elongation! Remark: The device for cutting original cams is not part of the standard engine tool kit. it must be specially ordered from SULZER. The cam replacement must only be carried out by experienced personnel which has been specially trained for this work.

1987

8 1

Freies FREE

Ende EN0

:..*.. . 1
E
I 1
Antriebseite DRIVING END
w7/7

-01swn

eu

-.

/117+

_---. J

SULZER

Non Rev. Engines 1001 s: 1 Torque wrench (140-560 Nm) 1 Grip screu M5 Various spanners 9408.17 1
2

ZA40

STARTING CONTROL AIR DISTRIBUTOR Dismantling and Assembling

MmJp
SHEET

4301
1

Key to Illustrations Oil slinger Cam Flange O-Ring Control slide valve 7
8

Shaft Cover

14 15 M K P
l

Screw Dowel pin Adjusting mark Check drilling Locating Mark (Drill point) TO be tightened acc. to Instruction

3 4 5

8a Joint 8b Screw 9 10 11 12
13

5a Spring 5b Roller 5c Roller pin

Casing O-Ring Camshaft Doue1 pin Screu

l 6

Screw

The starting control air distributor requiresogenerally no maintenance, houever approximately every fourth year during a general overhaul it is recommended to remove the control air slide valves 5, to clean and-check them. The clearances should checkad, compared with the clearance table D352/7 also verify whether any parts require replacement. Removinq the Control Slide Valves 5 Remark: The control slide valves cari onlv be removed. after the roller pins 5c have been taken out, Work procedure: - Shut off the control air supply. - Loosen the screu 8b and remove caver 8. - Loosen the screu 6 and lift cam 2 off its shaft. - Loosen screu 14 and remove the covers 3. - Press each control slide valve 5 lightly, against the force of spring 5a, inwards and at the same time pull the roller pin 5c out uith a grip screu (M5), and remove the roller 5b. - The control slide valves carinou be removed. Attention! Take great tare not to drop either the roller or the control slide valve on the floor!

Fittinq the Control Slide Valves - Smear a11 components lightly with oil. - Fit each control slide valve 5 uith its spring 5a into its bore and press it invards until the roller pin 5c cari be fitted through roller and valve body.

- When a11 the control slide

valves are

fitted, place the cas 2 onto the shaft 7 and, first'only

_
uith the locating

tighten the screu 6 slightly by hand. (The screu thread should be saeared with oil).

- Turn the cas around till the check drilling 'K' coincides

aark IP' (Drill point).

- Tighten screv 6 with a torque vrench 9408.17 to 250 Nm, (In this position the mark III1on the face

of the ma ust be in line with the axis of control slide valve Cylinder No. 1 of the engine, uhen
the piston of cylinder No. 1 is in firing stroke T.D.C. - Make sure the control slide valves are sliding easily in their bores, by pushing ther inuards seve-

rai tires against the force of the swings 5a. The contra1 slide valve rust return imediately to the original position.

1987

b301/la
- Fit the covers 3 equipped uith new D-rings 4 and tighten the screus 14. - Fit caver 8 and tighten the screus 8b firmly.

non rev.

ZF4C

Eemark: - 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.

1987

Gezeichnet fr 8 -2~1. Mo Drawn for S-Cyl. Engine

v SULZER

STARTING CONTROL AIR DISTRI3CTOR WmJp Dismantling and Assembling

SHEET

4301
1

Reversible Tools: 1 Grip screu M5 1 Plastic or lead mallet Various spanners 1 2 Oil slinger Cam 9 10 12 13 14 15 16 17 18 KW 8 to Illustrations Protection caver C tube Shaft seal ring Screw Screu Thrust disc Cylinder Piston seal Piston Piston ring Special bearing bushes The starting control air distributor generally requires no maintenance, however approximately every fourth year during a general overhaul it is recoamended to disnantle it into its components to clean and check it. Oismantlinq Remark: The control slide valve 5 cari onlv be removed. after the roller pin 5c is pulled ouf, Working Procedure: - Shut off the control air supply. - Loosen the screu 12 and reaove protection caver and tube 8. - Tap gently with a plastic or lead aallet alternately from two sides on the cylinder 14, to loosen the guide flange 20 from the casing 22 and the coaplete displacement mechanism consisting of the parts 11, lla, 13, 14, 16, 18 and 20 cari be withdrawn. This assembly cari be corpletely dismantled into its coaponents if found necessary, after loosening screus 6 and 10 and reroving thea. - Loosen screu 3a and remove the caver 4. - Press each control slide valve 5 lightly, against the force of spring 5a, inuardsand tine pull the roller pin 5c out with a grip screu (H5) and remove roller 5b. - The control slide valves 5 carinow be removed together with their Springs 5a. Attention! Take great care not to drop either the roller 5b nor the control slide valves 5 on the floor. Assemblinq Remark: The metal to metal sealing faces (marked '0' on the sketch) have to be coated thinly vith a sealing compound for assenbling. - Lubricate a11 components with oil. - Shaft- and Piston seal rings as well as a11 O-rings, which are no longer in Perfect condition must be replaced by neu ones. - At first, the control slide valves 5 complete with Springs 5a are inserted into their bores. - Place the rollers 5b into the control slide valves, press the latter slightly tnwards to permit fitting the roller pins 5c. at the same 19 20 21 22 23 24 25 H 0 O-Ring Guide flange Screw Casing O-Ring Doue1 pin Doue1 pin Locating mark Use sealing compound for asserbling

ZA40

3 Cover 3a Screw 4 5 O-Ring Control slide valve

11,lla Bearing rings

5a Spring 5b Roller 5c Roller pin 6 7 Screw Shaft (splined)

1987

4301/la

reversible

zb40

- The displacement nechanise, consiting of parts 11, lla, 13, 14, 15,18 and 20 is pushed fully asseabled, cam forward, onto the splined shaft 7, note the line mark on the cao, (refer to 'tl' and the illustration ) must be in lina with the axis of control slide valve of cylinder No. 1 of the engine, when the piston of cylinder No. 1 is in T.D.C. firing position..The cylinder nupIber is stanped on the casing. - Fit protection caver and tube 8 and tighten it with the screus 12. - flake sure the control sli-devalves are sliding easily in their bores by pushing them inwards several times against the force of the Springs 5a. The control slide valves must return imediately to the original position. - Finally replace the caver 3, fitted uith O-rings 4, and tighten ffrmly uith screvs 3a.

1987

--.L W7lSl-R

-1 LA41

, D

SULZER

STARTING AIR STOP VALVE Dismantling and Assembling

QROlJP4304
SHEET 1

ZA40
Tools: 2 Threaded spindles Ill0 (Complete) 1 Pliers type 'J' for inside circlip 1 Lead drift 2 Wood underlays (Abt. 60x60~250 mm) Various d.e. spanners and socket spanners Sealing compound

Kev to Illustrations 9443.02 1 2 3 Stop valve casing Spring Threaded plug 6 7 8 9 10 0 Non return valve piston Threaded plug Screw Non return valve casing Valve seat Use sealing compound

3a Circlip 3b CU-joint 4 5 Piston sealing ring compl. Stop valve piston

10

--

Provided the starting air is clean, that no foreign particles carienter the valve and that no defects becoae evident, disaantling the valve everv fourth vear is sufficient. Before you start with dismantling the valve, the shut-off valves on the starting air vessels must be

closad.

The pressure gauge for the starting air nay not show any pressure. The main starting

air pipe and the control pipe eust be disconnected from the starting air stop valve.

1987

I 7AfIl-l

Oismantlinq - Place the conplete valve uith the screws 8 facing upwards, on a uork bench. (The ueight is abt. 56 Kg). - llark the position of the three parts 1, 9 and 10 on the circurference. - Loosen a11 the screus 8 equally by about five turns and watch uhether 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 carihappen that these parts stick together on account of the sealing compount used for the previous mounting. - Loosen the four screus 8 fully and remove them. - Remove a11 inner parts, clean and check ther. - Traces of former sealing conpound musf be thoroughly reaoved from the faces of casings 1 and 9 as well as from the valve Seat 10, - Should the piston sealing ring compl. 4 no longer be in Perfect condition, it must be replaced, at the sae time its O-Ring.

.
Assemblinq-(Please refer to Fig. '6' on sheet 4304/1b) Saear a11 parts with exception of the faces aarked by '0' on the illustration, with oil immediitsly before assembling the valve. The piston sealing ring 4, consisting of an O-Ring and a sliding ring has to be fitted with great tare, (uithout over-stretching it) into the stop valve piston 5, after which the other components are assembled as described below. - Remove the circlip 3a and the threaded plug 3 froc the stop valve casing 1. - Fit the spring 2 and the stop valve piston 5 into the stop valve casing 1. - Insert a threaded spindle 9443.02a into the stop valve piston 5 and tighten*the nut.9443.02c.: thereby .pulling the piston iito the casing 1, paying special attention to sliding-in the pistoi sealing ring 4 into its bore. - Place the air stop valve 1 on tuo wooden underlays 'H' and apply a thin coat of sealing compound onto the sealing faces marked 'Or. - Seat the valve seat 10 onto the stop valve casing 1 (note the correct position vith respect to the screu holes and the narks made prior to dismantling the valve). - Insert the non return valve piston 6 with its spring 2 into the non return valve casing 9 and prestress with the second threaded spindle 9443.02. - Apply a light coat of sealing coapound on fhe sealing faces sarked '0' of the non return valve casing 9, and place this onto the valve seat 10. (note the correct positioning). - Insert screws 8 and tighten equally with a socket spanner (AF 17) firaly, then remove the two threaded spindles 9443.02. - Fit the threaded plug 3 with a cu-joint 3b tighten firsty and secuie vith a circlip 3a. - Refit the fully assembled air stop valve onto ttieengine.

1987

B 0
u.
8 2 9

,944302a

--IF

10 -E

SULZER

INLm- AJ'JD EXHAUST- VALVE ACTUATION Adjusting the Valve

Clearance

GROUP

4401
1

ZA40
Tools: 2 Feeler gauges 1 Allan key 1 Allan key 1 Ring spanner 1 Ring spanner 9408.15 AF 10 AF 14 AF 32 AF 50

SHEET

Kev to Illustrations 1 2 3 4 Valve spindle Valve spindle Special screv Il33 Lock nut AF 50 5 6 7 8 Bal1 socket Special screv H20 Lock nut AF 32 Bal1 socket 9 10 11 12 6 Main rocker arm Aux. rocker arm Roller Cam Car base circle

34

59

67

10

9108.15

I - 107

185.376

The Valve clearance has to be checked and re-adjusted every time the cylinder head or the rocker arms had to be removed. Should loud clicking noises be heard vhich appear to coe from the rocker arm housing vhile the engine is running, stop the engine and check the valve clearance as possibly some valves have excessive play. Check and adjust the valve clearance in general on the cooled dovn enaine. For checking the clearance barr the crankshaft until the roller 11 of the valve actuating gear for the cylinder concerned sits on the base circle of the cari,, The folloving clearances are normal for cooled dovn enoine: INLET VALVE - 0.6 + 0.' mm EXHAUST VALVE = 1.2 ' i*' mm

The Valve Clearance is adiusted as described belov: - Loosen the lock nuts 4 and 7 and turn the special screvs 3 and 6 far back. - Push feeler gauge (0.6 tm for Inlet Valves or 1.2 ma for Exhaust Valves) fully betveen the bal1 socket 5 and the valve spindle 1 or 2 respectively. ' - Tighten special screv 3 lightly vith Allan key AF 14, until the feeler gauge is slightly gripped, but cari still be moved by pulling. (The spring pressure is clearly felt). - Leave the feeler gauge clamped in this vay, hold the special screv 3 vith the Allan key and tfghten at the same time the lock nut 4 firrly. - Leave the feeler gauge clarped in valve 1. Push the second feeler gauge (of the saae thickness) fully under the bal1 socket 8 of valve 2. - Tighten special screv 6 until the feeler gauge is gripped lightly. - Hold special screv 6 uith Allan key AF 10 and tighten the lock nut 7 vith ring spanner AF 32 firaly. - Pull out both feeler gauges. Remark: After tightening the lock nut the feeler gauges should be a good fit and should be rovable back and forth.

1987

SULZER

INLEFC- AND EXEAUST- VALVE ACTUATING GEAR Dismantling and Assembling

GROlJP
SHEET

4401
2

ZA40
1001s: 1 Torque wrench 314" 9408.17 (140 - 560 Na/3/4") 9444.01 1 Disinantling tool 1 Special jack screw 2 Jack screus M 12 1 Grip screu M 6 1 Socket head insert (3/4"/AF 30) Various spanners 9444.02

Kev to Illustrations 1 2 3 4 5 6 7 8 9 10 11 Guide housing Guide piston Sphere end pin Spring O-Ring Circlip Spring plate Dowel pin Shroud for push rod O-Rings Connecting piece 12 13 14 15 16 17 18 19 20 21 22 Cylinder head Push rod Main rocker ara Aux. Rocker arm Retaining pin Roller pin Circlip Thrust disc Roller Bush Engine casing 23 Special (bal1

head) screu 23a Lock nut 24 Special (bal1 head) screu 24a Lock nut l 25 Screw N
l

Caw Tighten according to instruction.

ZA

CO/O-1OZ

PL.

verhaul or if it becornesnecessary, he valve actuating gear has to be disrantled, checked and cleaned, as described overleaf:

19A7

4401/2a

Disrantlinq - Turn the crankshaft until the roller lies on the base circle of the cam. - Slacken the lock nuts 23a and 24a and screu the special (bal1 head) screws 23 and 24 right back. - Sway the push rod 13 side ways and remove it. - Reeove the Shroud for push rod 9. - Loosen the screws 25, fastening the valve actuating gear to the engine casing and remove them.

Nithdraw the coeplete valve actuating gear and place on the uork bench. (If necessary use two jack screus Ml2 to jack the (valve actuating gear) guide housing 1 off the engine casing; The required threaded holes have been provided in the flange). Hount the dismantling tool 9444.01 as show on Fig. 'B'.

- Screu in the spindle of the dismantling tool

until the retaining pin 16 is relieved and withdraw the pin usjng a grip screu (H6). Unscreu the spindTe of the dismantling tool until the spring pressure has sleckened and reaove the tool. Remove a11 the interna1 parts and check on their condition. Should it be necessary to renove the sphere end pin 3, screu the special jack screu 9444.02 from below into the guide piston 2 and push sphs end pin 3 out. The roller 20 caribe renoved by taking the circlip 18 off on one sida and pushing the roller pin out. (Take tare that the roller bush 21 does not fa11 out of the roller!). Clean a11 the removed parts uell and check them for m-use (Please .also refer to the clearance table 0352).

1- wi! m.m

Asserblinq - Liberally oil a11 the parts before asserbling and fit them in reverse order ta the dismantling sequence. - TO fit the retaining pin 16, press the guide piston into the guide housing 1, uith disaantling tool 9444.01, as far as necessary. - Replace the O-Ring 5 each ti-eethe:alve actuating gear is disrantled.

- Before fitting the coeplete valve actuating gear the landing surfaces of housing 1 and engine casing must be cleaned uell. - Coat the threads and landina faces of screus 25 (fastening the guide housing) uith oil and tighten to 290 Nr, - After the parts have a11 been assembled, adiust the valve clearaim as described in sheet 440111.

1987

SULZER

REVELRSING SERVO MOTOR

CROUP
SHEET

4500
1

ZA40
Reversible 1001s: 1 Hydr. Hand pump 1 Branch piece 1 Pressure gauge 1 HP Hose 1 Feeler gauge 1 Depth gauge 1 Special spanner 1 Hydr. Jack 1 Support plate 2 Eye screus Ml2 2 Jack screws Ml2

Dismantling, Checking and Assembling

KW 9408.02 9408.03 9408.04 9408.09 9408.15 9408.16 9431.03 . 9433.07 9445.01 1 2 3 4 5 6 7 8 9 10 11 12 ""13 14 15 16 17 18 Engine casing Casing O-Ring Cylinder

to Illustrations 19 20 21 22 23 24 25 26 27 28 AG Doue1 pin Bearing bush Camshaft Circlip Compression spring Slide valve Taper doue1 pin Screw Screus Dowel pin Jacking thread assembling * Shape and weight vary according to nueber of ** cylinders Tension acc. to instruction

Flywheel disc* Piston Guide ring Screu Locating bearing ring Stop collar Control ring a Cover Najsted Stud Round nut Connecting piece Doue1 pin O-Ring Bearing rings

Various d.e. spanners and ring spanners

El Apply sealing conpound for

The reversing servo mofor needs no maintenance during operation. It should however be disaantled, cleaned and checked during a maior overhaul. Worn or daaaged parts aust be replaced. Attention! The canshaft musf be in the end position towards the "free end", when dismantling the reversing servofaotor. If this is not the case, start the engine for a short tiae in the corresponding sense of rotation. If this is no longer possible, remove a11 the actuating casings of the fuel puaps and inlet/ exhaust valves, then push the caashaft by hand axially till the stop at the "free end". Under no circuistance rnav the canshaft be shifted bv a chain ouller or a hvdr. iack or similar device while the ensine is at stand still,

l.DISMANTLING Nork Procedure: - Separate a11 the pipework froa the reversing servo motor (Place a container underneath). - Loosen and reuove the screus 26 and jack-off and remove caver 12 uith the aid of jack screu M12. - Slacken the waisted stud 13 with the aid of hydr. jack 9433.07 and unscreu and remove round nut 14. (Please refer to Section 3.1). - Screu-in eye-screw Ml2 into the Cylinder 4, and attach it to the crane with a rope. (Fig. 'Cl). - Fasten support plate 9445.01 to the connecting piece 15 with the screus 27, and to the cylinder with two screus 26. (Fig. 'Cl and 'Dl). - Loosen and remove a11 the screws 8, and using tuo of these screus (M20) jack off the cylinder 4 including the parts fastened by support plate 9445.01 froa casing 2.

1981

- In case it is necessary to reaove also the flywheel disc 5 fron the camshaft, fit an eye screu Ml2 into the flywheel disc and attach it to the crane by a ropo. (Weight nax. 65 Kg). - With the aid of tuo grip screvs Ml2 and suitable spacers reove the tuo taper douels 25, then apply tuo jack screus Ml2 and press the disc off the caeshaft. - TO remove the casing 2 froc the angine casing use tvo of the screus (H20) 8 as jack screws in the threaded holes provided in the casing for this purpose and jack off the casing 2 until it i free of the dowel pins 28. - Use an eye screu Ml2 and rope to attach the casing to the crane (about 120 kg) and remove it. - TO disrnantle the parts which vere pulled off'together vith the cylinder 4, reaove circlip 22, then slide them off connecting piece 15 for Cleaning and checking. (Fig. 'A' and 'Cl). Pay particular attention to the running surfaces of locating bearing rings 9 and 18. Heavy uear of the locating bearing rings increases the axial clearance of the caashaft (Please refer to clearance table 035216).

2.

ASSEHBLING

2.1 Preparations - Clean a11 the coiponants carefully and, just prior to fitting thea, smear ther lightly with oil - 810~ through a11 the oil leading bores with compressed air. - Replace the O-Rings 2 and 17 by neu genuine original O-Rings. - Screw in the waisted screu-13 until its stop in the carshaft. - The camshaft must be pushed to its end position on the "Free End'.

2.2 Workino Procedure - Apply sealing coepound to the sealing surface on the engine casing. - Push the casing 2 over the carshaft aaking sure that the doue1 pins 28 fit their holes (Fig. 'B'). - Fit O-Ring 3 (Fig. 'B'). - Mount the flywheel disc 5 with fitted rings 9 and 18 onto the camshaft, fit the two taper dowels 25 and tap in moderately. Renove the eye screu. - Fit the cylinder 4 with a11 the parts shoun in Fig. 'C', which are held by the support plate 9445.01. - Fit screws 8 and tighten equally. - Remove the support plate 9445.01 and screu in the round nut 14 onto the waisted stud 13, until it is seated. - Using the hydraulic jack 9433.07, pre-tension the uaisted stud 13 to 600 bar (Please follou exactly the instructions in section 3.2, and on Fig. 'El). - After tensioning check the axial clearance (please refer to clearance table 0352/6). - Fit the caver 12 with a neu O-Ring 17 and tighten the screus 26. - Re-join a11 the pipes to the reversing serve motor, and to check tightness start the lubricating oil purp.

1987

45oO/lb 3.
S L A C K E N I N G ck en in g AND P R E- T E N S I 0 N I N G

Reversible
the Waisted Stud (fig. 'E')

Zh40

3.1Sla

- Mount the pre-tensioning hydraulic jack 9433.07 onto the stud 13 unti1 its cylinder 'Z' is seated. - Connect the piston 'K' by HP-hose 9408.09 with the hand puutp9408.02 . - Open the bleeder valve on the hand purp screu in the piston 'K' with the aid of special spanner 9431.03 until it is seated in the cylinder 'Z'. - Unscrew the conplete jack until a clearance of about 2 II exists between cylinder and connecting piece 15 at 'X'. - Close the bleeder valve on the (hydr.) hand puap and pre-tension the uaisted stud 13 to about 600 bar (or a little eore). - Unscrew the round nut 14 with a round bar by about 3/4 turns and release the hydr. pressure by opening bleede valve on the hand puep. - The round nut should nou be loose, the hydr. jack and the round nut cari be removed.

3.2

P r e - T e n s i o n i n q (Fig. 'E') - After fitting the various parts acc. to section 2. Fit the round Fut 14 onto the waisted stud 13 ascertain that the landing faces are clean and the thread not specially lubricated. - Fit the pre-tensioning jack 9433.07 onto the uaisted stud till the cylinder 'i!!is seated on the connecting piece 15. (Check seating with the feeler gauge). - Connect the piston 'K' by HP-Hose 9408.09 with the hand-puop. - Open the bleeder valve on.the hand pu~pp and screu 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 bleeder valve on the hand pump and raise a pressure of 100 bar.. - Hold this pressure constant until the round nut 14 has been tightened until seated (Check the seating with the feeler gauge). - Release the pressure to tero and measure protrusion 'X' and note it doua. (Please refer to sketch on the right. - Raise the pressure to 600 bar and hold constant until the round nut has been tightened till it is seated (check the seating with feeler gauge). - Louer the pressure to zero and reasure the protrusion 'XT' and note it down. - Calculate check digit AL difference should be about cf Filec!,~k digit (Xl-X). When the ,pre0,661~'. The UstabTihmeht serves solely as additional,

tensioning has been correctly carried out this

!AL)

fut important check on the tensioning,

1987

500 / lc

umstb. ZA 4

\ 0 =I ru

ums tb. ZA f.0

1

x70/

le

umstb.

ZA4 0

u-

15-

ZA40/

3-

rw:785.373

SULZER

ZA40
1001s: 1 Depth gauge 1 Special tool spanners 9408.16 9446,Ol B

Regulatinn Linkafze Removal and Fitting of the Spring Linkage Rod Springs
Kev ta Fios. l,la Linkage joint 2 3 4 5,6 7 Circlip Connecting piece Springs Spring plate Ring (Z-piece)

GROUP
SHEET

4501
1

Various openended

Sorino Renoval Should it be necessary to diseantle the spring linkage rod uhich 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. Before unbolting the linkage joint 1, dimension 'X' has to be deterrined and noted doun. After removing the linkage joints, the tool has to be fitted as show on Fig. 'A' and the Springs 4 put under tension until.the circlip 2 caribe reaoved. The connecting piece 3 cari nou be removed and the Springs 4 unloaded (see Fig. 'B'). Serins Fittinq The reverse procedure fo that of removal is used uhen fitting the connecting piece 3. The bores of the spring plates 5 and 6 are to be sreared uith HOLYKOTE paste G-n before fitting. The linkage joint 1 has to be screued back in until the previously deterained dimension IX' is reached exactly and then secured with the lock nut.

63

la

MOiYKOTE 0 a

G-n

1987

SULZER

CUT- OUT SERVO MOTOR Dismantling and Assembling

GROUP SHEET

4612
1

2A40
Tools: 2 Treaded bars Ml6 x 500 with nuts Various spanners

Kev to Illustrations 1 9446.03 2 3 4 5 6 7 8 9 10 11 Casing (one piece) Spring Slide valve Spring Spring plate Piston Piston seal Flange Rod seal Snap ring O-Ring 12 13 14 15 16 17 18 19 20 21 22 Valve guide Piston Cylinder Piston seal O-Ring Flange Fuel pump control shaft Lever Screw O-Ring Clamp screu.'

la Casing (tu0 piece)

3a Valve body

If the control air is well filtered and de watered, the tut-out servomotor requires practically no maintenance. Ouring a more important engine overhaul or uhen functional defects have been noticed, it is recommended to dismantle the tut-out servo rotor and to clean it. Prior to the dismantlinq the clamp screu 22 has to be loosened and the lever 19 pished sideuays. After this proceed as described below. - Loosen and remove two diagonally opposed screus 20. (Fig. 'B').

- Fit in their place the tua threaded bars 9446.03 and screu their nuts until landed on flange 17. (Fig. 'C'). - Loosen the two remaining screus 20 and remove them. - Loosen alternately the two nuts of the threaded bars 9446.03, paying attention that the bars themselves do not rofate, instead the flange 8 and the piston 6 are lifted off the casing 1. - After the spring 2 is c'ompletelyreleased remove the two threaded bars and with them piston 6 flange 8 and spring 2. - Finally also slide valve 3, valve body 3a and spring 4 cari be with-drawn. The Asseablinq is done in reversed sequence to the disrantling.

- Al1 the parts have to be clean and lightly saeared with oil prier to fitting them. The O-Rings ust a11 be replaced by neu qenuine oriainal ones. - Use the tua threaded bars 9446.03 for compressing the spring and fitting the piston 6 and the flange 8. (Fig. 'C'). - Pay particular attention and tare when inserting the piston 6 and the flange 8 into the casing 1, to prevent any darage to the seal rings 7. - Uhen the spring is sufficiently coapressed, fit tuo screus 20 and tighten them. - Rerove the threaded bars and fit and tighten alto the other tuo screus 20. - Finally fit

the lever

19 in its original position and fasten it with the clamp screw 22.

Remark: In cases uhere the tut-out servo motor is equipped with a starting fuel limiter as show in Fig. 'Al' thr sam instructions apply. In addition houever the piston 13 has to be equipped uith a neu O-ring and before assembling the O-Ring 16 rust be fitted. If the casing is in tuo parts as show in Fig. 'Ap' the O-Ring 21 must also be replaced.

1987

il21

la

-.-.-.

.--___
-19

--

la

ZAL LO / 0- 107 Q~C.396

6 ??

$446.03

SULZER

ZAL40
1 2 3 4 5 Shut-down Solenoid Speed setfing motor Oil cup Load indicating pointer Governor drive casing

SPEED CONTROL GOVERNOR R.P.M. GOVERNOR Woodward Type UG 40 D Oil Change

Kev to Illustrations 6 7 8 9 10 11 Starting aid booster Cable connection Oil levd sight glass Governor output shaft Speed droop setting knob Load limiting knob 14 15 11 12 13

or
GROUP SHEET

5101
1

Load limiter knob Speed setting knob Speed setting indicator Plug for feed back needle valve Oil drain plug

UG 100

Removina'and Fittinq the Governor on the Enaine .

When lifting off or eounting the governor take tare ensuring that the serrations at the louer end of the governor shaft do not get daaaged. Furthernore the governor shaft musf slide into the governor drive shaft serrations without binding. Pipe work and rods aust be connected stress free.

lOP7

Maintenance Information concerning the maintenance work, maintenance intervals and repairs is to be taken from the WOODWARD Publication vhich is supplied separately with the governor or the engine respectively. In principle repairs on the governor should only be carried out by experts from a WOODWARD service station (or by specially trained personnel). For these repairs it is essential that the governor test records contained in the engine acceptance triais be made available to the repairers, as based on these the governor cariagain be correctly adjusted. We highly recommend that a complete governor already adiusted to the enpine be kept in stock as a spare which is ready to replace the fitted one if necessary.

Dil Chanoe Under good running conditions the oil cari remain in the governor for up to 6 months (about 3000 h) or even more. Should hovever, blackening or ageing of the oil be observed, it oust be changed iamediately. The old oil musf be drained off when the engine is at screwing the oil drain plug 15. After replacing the plug fil1 the governor to the Upper mark on the oil level sight glass 8 with a low viscosity flushing oil or clean Diesel oil and run the engine at reduced speed for about 1 minute. In order to prevent the flushing oil fror entering the booster and thus remaining in the lubricating oil, disconnect the air pipe to the booster and connect it again after the flushing is coaple. ted. During this short period of operation the engine speed should be altered frequently SO that the governor is hunting. TO achieve this, pull the emergency stop lever (on the regulating linkage) toward: the zero position and release it ianediately: Drain the flushing oil from the governor. After the flushing process has been copleted, fil1 the governor with fresh clean oil (for oil spe. cification please refer to WOODWARD Bulletin 03014 K). Mhen the engine is r u n n i n g the oil level should lie between the tuo marks on the standstill but still hot, by un-

oil level sight glass. After putting the governor back into commission, the systeu has to be vented as described in the section "Adjusting the droop feedback" in the YOODWARD bulletin 03014 K.

SUUER ZA

SPEED GOVERNOR

Group:

5101
2

40

WOODWARD EG-B50P Oil Change

Key to Illustrations

siationary engine

Sheet:

1 2 3 4 5 6 7

Access

to needle valve of mechanical governor

9 10 11 12 13 14 15 16

Serrated governor output shaft Cooling oil outlet Oil filler neck Setting knob for "SPEED DRDDP" Speed setting motor Setting knob for pouer limitation Setting knob for speed (RPM) Access to feedback .

Oil level indication Cooling oil inlet Oil drain cock Connection for oil to booster inlet Serrated drive shaft Connection for oil from booster outlet

8 Feedback needle

Fittina and Removal

of the Governor on the Enoine

When lifting off or replacing the governor, tare has to be taken to ensure that the splines at the lower end of the governor shaft do not get damaged. Purthermore, uhen the governor is being replaced, the shaft must slide into the drive uithout binding. Pipework and rods

must be connected up stress free.

1987

Waintenaoce Information concerning the maintenance uork, maintenance intervals and repairs is to be taken froc

the WOOOHARD publications which are supplied with the governor and engine. In principle, repairs should only be rade to the governor by experts froa a WOOOWARD service agency (or specially trained personnel). At the sare tiee it is essential that the governor test records t0 be found in the engine acceptance tria1 documentation be made available according to uhich the governor eust be correctly adjusted. We highly recomeend that a corplete governor, already exactlv set 2 for the engine, be held.as a spare ready to be exchanged uhen necessary.

Oil Chanqe Under good running conditions the oil cari remain in the governor for up to.6 nonths (approx. 3000 h or more. Should, houever, blackening or ageing of the oil be determined, it has to be reneved imaediately. . standstill by

The old governor oil is ta be drained off uhen the engine is hot and at a opening the oil drain cock 4.

After this, fil1 the governor up to the Upper mark on the oil lave1 sight glass with lightueight flushing oil or clean diesel oil (gas oil) and run the engine at reduced speed for about 1 min. In order to prevent the flushing fluid from entering the booster and then remaining in the oil, the ail pipe connection to the booster has to be removed before starting the flushing process and reconne; ted afteruards. Ouring this short run of the engine the speed should be altered. frequently SO that the governor oscillates. This caribe done by pulling the emergency stop lever (on the regulating linkage) touatd: s the zero position and then imrediately releasing it. The flushing or gas oil is to be drained from the governor afteruards. After a flushing process has been coapleted successfully, fil1 the governor with neu, clean oil (for oil specification see WOODWARD bulletin). Mhen the engine is r u n n i n g, the oil level should lie between the tuo marks on the

oil level sight glass. After putting the governor back into service, the systea has to be vented as described in section 'Adjusting the droop feedback" in the 1100DVARD bulletin.

1987

SUUER

SPEED GOVERNOR WOODWARD PGA58 Oil Change

Kev to Fias.

Gros:
Sheet:

5101 3

ZA40

1 2 3 4 5 6 7

Charge air connection for .fuel limiting Oil level indicator Governor output position indicator Splined drive shaft Splined governor ootput shaft Oil filter Oil connection for booster outlet No. 1

8 9 10 11 12 13 14 15

Oil drain cock Of1 connection for booster inlet Feed-back needle valve Governor hood Oil filling connection Overspeed checking device Electrical connection Connection for pneumatic speed setting _

16 17 18 19

Oil inlet connection Oil drain connection Connectian for booster outlet No. 2 Knob for manual speed setting

PGA 58

18

Fittino and Removal of the Governor on the Enqine When lifting off or replacing the governor, tare has to be taken to ensure that the splines at the lover end of the governor shaft do not ge damaged. Furthermore, uhen the governor is being replaced, the shaft nust slide into the drive without binding. Ripework and rods nust be connected up stress free.

1987

L01/3a

ZA40

Raintenance Inforration concerning the maintenance York, maintenance intervals and repairs is to be taken froc the WOOOWARO publications, uhich are supplied uith the governor and engine. In principle, repairs should only be aade to the governor by experts froc a ROOORARO service agency (or specially trained personnel). At the sare tire it is essential that the governor test records t be found in the engine acceptance tria1 docurentation be rade available according to uhich the governor rust be correctly adjusted. We highly recoerend that a coeplete governor, already exactly se 2 for the engine, be held as a spara ready to be exchanged uhen necessary.

Oil Chanae Under good running conditions the oil cari rerain in the governor for up to 6 l onths (approx. 3000 h or more. Should, however, blackening or ageing of the oil be deterrined, it has to be reneued irmediately. The old governor oil is to be drained off uhen the engine is hot and at a by opening the oil drain cock 8. After this, fil1 the governor up to the Upper aark on the oil level sight glass vith lightueight flushing oil or clean diesel oil (gas oil) and run the engine at reduced speed for about 1 rin. In order to prevent the flushing fluid froc entering the booster and then reeaining in the oil, the air uioe connection to the booster has to be reroved before starting the flushing process and reconnected afteruards. Ouring this short run of the engine the speed should be altered frequently SO that the governor oscillates. This cari be done by pulling the emergency the zero position and then iemediately releasing it. The flushing or gas oil is to be drained froc the governor afteruards. After a flushing process has been completed successfully, fil1 the governor uith neu, clean oil (for oil specification, see WOOOWARO bulletin. When the engine is r u n n i n gS the oil level should lie betueen the tuo earks on stop lever (on the regulating linkage) tocard standstill

the oil level sight glass. After putting the governor back into service, the system has to be vented as described in section 'Adjusting the droop feedback' in the WOOOYARD bulletin.

1987

SULZER

GOVERNOR DRIVE

GfwUP 5105
SHEET 1

ZAL40
Tools: 1 1 Torque urench 9408.17

Dismantling

and Assembling

Kev to Illustrations '1 2 Screw Shaft Upper Z-piece exacution 9 10 11 Spur gear wheel Elevel gear Bevel gear Screw Apply sealing coapound Dry, oil free for assembling Spray hole Oil inlet

(25-135 Na/+") Socket spanner insert (Driver 3", AF 10)

part 2a Shaft louer 3 4 5 6 7 part 1 Shaft (l-piece execution) Casing Bearing bushes

l 12
D OF SP OE

Bearing bushes Cylindrical pin Screw

l 8

+ Tighten acc. to instruction

An annual visual check of the gear wheels is recomaended..This neces. sitates the removal of the corresponding housing covers on the engine. During a major overhaul the gear uheels and the bearing bushes must be checked for uear (please refer to clearance table 0352/11). For the replacement of the gear wheels or the bearing bushes, the speed control governor and the complete governor drive ved. Dismantlinq - Reaove the locking wires securiny the screes 8 and 12. - Loosen the sctews B and 12 and remove then. - Withdrau shaft 3 (on the 1-piece type) or the parts 2 and 2a (on the 2-piece type) upwards and re. -Pull off Spur gear wheel 9, push in bevel gear10 and reeove it. move the bevel gear il.

ustbe

remo-

- The bearing bushes 5 and 6 are pressed in. TO withdraw thea use suitable tools. It is recomrended 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.

1987

Assemblinq - For assenbling the Governor drive proceed in reverse sequence to the dismantling, for this a11 the parts must be clean and shou no uear or damage. - Shafts and gear wheels as well as the bearing bushes to be smeared uith clean oil. - The faces, rarked OF in the illustration, of shafts and gears aust be drv and oil free, - Fit first the shaft 3 or 2 and 2a respectively and afteruards 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 oiJ fit then and tighten to 70 Nm,

- Check the axial clearances of the two shafts (please refer to the clearance table 0352/11) and if found in order lock the screus uith locking vire. - TO seal the casing 4 touards the engine casing and also the governor casing touards the governor drive casing 4 use sealing compound.

Tiqhteninq the screws 1. Yhere the shaft is in two parts 2 and 2a, tighten the screws 1 with a torque of 22 Nn, use oil as lubricant on thread and landing face.

1987

SULZER

MECHANICAL OVERSPEED TRIP AND SAF'ETYCUT-OUT DEVICE Removing and Fitting the Spring
Kev to Illustrations 9446.OlA 1 2 3 Fuel control shaft Clamp screu Lever for safety cutout device Cover Spring or Springs Cut-out push rod . Cover Casing Threaded plug Intermediate gear uheel Driving gear Gear wheel on camshaft Load limiter lever Torsion spring4 15 16 17 18 19 20 21 22 23 24 25 26 D

GROUP SHEET

5303
1

2A40S
Tools: 1 Spring cospressing device 1 Screw driver Various open end and ring spanners "In ZAL engines only one spring is installed.

Piston for load limiter Cylinder for load limiter Piston rings Latch Cut-out piston Cut-out shaft Adjusting screu Bearing flange Spring Spring case Steel balls

4
+5 6

7
8 9 10 11 12 13 14

Springs Use sealing coapound for asseabling

Gurino an enoine overhaul the condition 0' the tooth profile of the drive gear wheelr 10 and 11 of the safety tut-out device har to be checked.,;for which the caver 7 must be removed. (Fig. 'Cl). Through the saoe aperture the condition of the tut-out pus1 rod shoulder 6, on which the latch 18 catches, caribe inspected. This shoulder may not be either rounded noF damaged. Use a screw driver and unlatch the latch 18, by pushing it off the tut-out push rot 6. This must be done while the safety tut. out and the fuel injection regulating linkage is still fullv assembled. Attention! Due to risk of accidents the caver 4 may never be reaoved as long as the spring 5 is under tension and the tut-out push rod 6 is not secured by the spring compression device 9446.OlA (Fig. 'A' and 'C'). By unlatching the latch 18 the spring 5 i: being partlv released,

l- 1OZ 081.L62

9446. OlA
1987

5303/1a
Removal of the Sorinq Attention! For as long as the spring 5 is removed, the crankshaft may not be barred!

2A4G

- Renove the threaded plug 9 (Fig. 'Cl) and screu in spring corpressing device 9446.01A into the rear end of the tut-out push rod 6. (Fig. 'A'). - Turn the grip of the device 9446.OlA in clockuise rotation until the spring 5 is compressed (Fig. 'A'). - Loosen the screw 2, vhich claaps the lever 3, and push the lever side-vays away. (Fig. 'Cl). - Remove the caver 4 (Fig. 'A'). - Turn the grip of the device 9446.014, back in counter clockwise rotation, until the spring is decompressed. (Fig. '8'). - If it is necessary to remove the shaft 20, decompress first the swing tachometer transmitter, then the flange 22. (Fig. '0'). - The complete shaft 20 including driving gear 11 and tut-out piston 19 etc. carinou be withdraun. 5, then remove the remote

Reeark: m o v e the adjusting screu 21 unless absolutely necessary. If it cannot be avoided, 00 not mark its position accurately beforehand, SO that it caribe restored to its original position. If necessary the complete shaft must be mounted into an infinitely variable lathe, to establish the correct tut-out point. (The correct tut-out data caribe obtained from the acceptance test document of the engine). The tut-out point cari be adjusted by turning the adjusting screu 21 (please also refer to the Instruction Manual page 5303-2).

f! c1

u Ll

_-______--_--__

1982

303 / lc

ZAL 40

1p-E

(5303

/lb)

0
D

q-~/5303/lbl 11

20

26

25

26

ZAL CO/O-

102 X211.386

SULZER

FUEL INJECTION PUMP Dismantling and Assembling

WmJp
SHEET

5501
1

: ZA40

Tools: 1 Torque wrench {25-135 Nm/f") 9408.17 1 torque wrench (140-560 Nm/3/4") 1 Withdrawing de- 9444.01 vice 1 Jack screw 1 Hounting flange 9444.02 9455.01 9408.17 1 2 3 4 5 6 7 8 9 Pump housing Guide piston Louer spring plate Tappet O-Ring Upper spring plate Regulating rack Clamp ring Regulating sleeve Screu Pufflp caver O-Ring Oeflector screws Pump barre1 Pump plunger Cover to pneum. shut-down device Set screu Return spring fi I

Kev to Illustrations 19 20 21 '22 23 24 25 26 27 28 29 30 A B J K LF LO Circlip Guide pin Roller Screu Set screu O-Ring Thrust disc Bush Circlip Roller pin Rod seal Doue1 pin Inlet chanber Run back chamber Carrier Piston for pneum. safety shut-down Leakage fuel Leakage fuel outlet U-II
l

Il Alignment narks MT Alignaent marks ON Relief groove SO Oil inlet SO1 Connecting bore for AS ZN oil For Ml2 jack screws Circunferential groove for lubr. and seal oil ' Tighten according to instruction.

1 Eye nut (ZL-Eng.19455.12 1 Suspension de9455.13 vice (ZV-Engine) 1 Grip screw M 6 1 Set of socket spanner insert (*"/AF 8) 1 Socket spanner insert (3/4" AF 30) 1 Short extension 3/4"/8" 2 Jack screws W 12

l lO
11 12 13 14 15 16 17 18

ti

1982

ZA40

Removino the Fuel Iniection PUIDP from the Enoine (For simplicity sake the fuel injection puap uill in this group be called PUMP for short). - Barr the crankshaft, SO that the roller 21 rests on the cam base circle. - Close the shut-off valves for the fuel inlet-' and return- pipe of the relevant pump. - Loosen a11 the screus 10, then turn ther in again until seated. - Loosen and remove the four screws which fasten the pump onto the engine. - Use two jack screus (Ml21 to separate the pump casing from the engine casing and lift it until the douel pin 30 is no longer engaged. (The pump cari be pushed out of its guide by barring the engine crankshaft, whereby the carilifts the pump. This has to be done carefully and only whenall the connections ta the pump are severed). - Attach pump to crne uith suspension device 9455.12 or 9455.13 and pull it out fully and move it away. (veight about 67 kg). Please refer to Fig. "8'). Disaantlino the PU~D (Please refer to Fig. IA')

ZAL4O

ZAV40

ZbO

b-101 72; m

It uill seldom be necessary to djsmantle a pump into a11 its conponent parts. Usually partial dismantling suffices to replace some wearing parts. However for information the complete disaantling procedure is described below. It would be of advantage to construct a device permitting the punp to be mounted vertically with th head upwards or dounuards, fastening it with screus similarly to the aanner it is fastened on the engine. Workino Procedure - Fix the puap to a uork bench with the head dounwards. t tlount the uithdrawing device 9444.01 as shown in Fig. !C' and, by turning its spindle push the guide piston 2 in, until the pin 20 caribe withdraun with the grip screb

tM).
- Relieve the withdrawing device 9444.01 and remove it. - 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 show in Fig. 'Dl). This ut11 cause the spring plate 3 to be lifted slightly off the guide piston 2. When the clearance is large enough the purp plunger 15 cari be pushed out between the louer spring plate 3 and the tappet 4. - For the reroval of the louer spring plate 3, place an unusable DURD plumer and pull hard on the guide piston. in place of the one just removed, clamp it in a vise

1982

5501/lb

'ZA40

- The roller 21 cari be rernovedtogether with bush 26 and thrust discs 25, after renoving the circlip 27 and pushing the roller pin 28 out. (Warning! The bush 26 is Toose in the roller 21 and it as well as the thrust discs 25 cari fall

out).
- TO remove the tappet 4, the special jack screu 9444.02 must be screwed into the guide piston 2 from belou. - TO remove the Upper spring plate 6 and the regulating sleeve 9, loosen the locating screw 17. - If it is necessary to rerove also the regulating rack 7, it is important to determine its exact position beforehand either by measuring or by a mark, before the clamp ring 8 is removed. - After removing the caver 16 the regulating rack 7 cari be pushed out of the pump housing. - New remove the screws 10, which uere slackened off at the beginning, and lift off the pump caver 11 from the housing, by using the jacking screu (M12). - Unscrev the locating screu 23 and push the pump barre1 14 out uith a piece of hard wood or a lead punch. Attention! The
DUIIID

barre1 14 and th'epump plunoer 15 are a until

and mav not be interchanoed, They are also not supplied individually. The pump plunger must be protectd froa any kind of daaage. It should therefore be pushed back into its corresponding barre1 as soon as it has been removed. The reaoved parts can'now be cleaned and their condition checked. (Please also refer to the clearance table 0352112). The varios bores in the pump housing must be bloun out with compressed air. Asseablina the Pumo (Please refer to Fig. 'A') Pre-Assembling Conditions _-_---_-_----_------_____ - Al1 the parts must be absolutely clean and undanaged, - Assemble the parts in a clean and dust free place. - Replace a11 the O-Rings 5,12 and 24 by neu ones. - The copper joint rings of the screws 13 and 23 ust either be annealed or replaced by neu ones. Assembling ---------- Place the punp housing 1 on a work bench uith the head facine uowards. - Insert the puap barre1 14, with Oring 24 fitted, into the pump housing 1, line up the rilled slot in the punp barre1 with the hole for the locating screw 23, screw in the loacting screu and tighten it firly. Remark! Dip the pump barre1 in clean Diesel Oil prior to inserting it into the housing. 1982

E 0

16

- Invert the purp housing and place it with head dounuards on the uork bench. - Insert the fuel regulating-rack 7 and fit the caver 16 Kth its joint. Push the clarp ring 8 exac-

tly to its position prior to disrantling and clamp it firmly uith its clarp screu. .- Insert the regulating sleeve 9 (toothed end first) in such a uay that the mark on one tooth of betueen the two marks of the regulating sleeve 9 the regulating rack 7 cornesto lie (Please refer to Fig. 'El). - Fit the Upper spring plate 6 and insert locating screu 17 (with a copper joint) and tighten it. (Pl. refer to Fig. 'A'). - Place the spring 18 onto the Upper spring plate 6 and note vhere the mark is on the edge of the regulating sleeve 9. (Note rark 'Bit). - Fit roller 21 uith bush 26 and thrust discs 25 into the guide piston 2 and push the roller pin 28 through. Insert both circlips 27 into the oiled before fittinq, - Insert the purp plunger 15 betueen the louer spring plate 3 and the tappet 4, and tap it doun uith a lead punch or a hard uood block, until the circlip 19 snaps into the groove. (Between pump plunger and louer spring plate a clearance of 0.01 to 0.05 IIPmust remain i.e. the pump plunger rust be free to rotate without jaaming. - Grip the previously corpleted guide piston 2 froc behind, dip the puap plunger 15 in clean diesel fuel, then insert the guide piston vith the plunger first. The mark 'Hl' on the pump plunger carrier 'J' rust line up uith the corresponding same aarks in the slot of the regulating sleeve 9 and the ailled groove in the guide piston 2 must lie on that side of the pump uhere the hole for the locating pin 20 (Fig. 'A') is located in the housing. - Using device 9444.01 push the guide piston' into the pu~p housing until the locating pin 20 cari be inserted (Fig. 'C'). Important! Should it be felt that the guide piston meets with resistance before the locating pin 20 cari be inserted, this means that the carrier 'J' of the puap plunger has corne up against the regulating sleeve. The device 9444.01 rust then be partially released and the pump plunger slightly turned by moving the regulating rack 7. Now tightening the device, gently, attempt to push the guide piston into its housing until the pin 20 cari be inserted. Under no circuistances may simblv aore force be apoiied when solid resistance is suddenw Iv felt during this fitting. - Release the device 9444.01 and reaove it. Nov invert the puap again with its head facino upuards, - Now check uhether the longitudinal slot in the purp plunger Upper part lies approximately in front of the fuel inlet hole in the pump barrel, when the regulating rack 7 is pulled out to its stop. If this is the case the components are correctly asserbled. - Fit the pump caver 11 uith inserted rubber ring 12 onto the pump, (note position of the connecting hole for the leak fuel pipe!). - Place the rounting yoke 9455.01 on the purp caver and tighten slightly uith tuo screus 10. (Fig. 'FI). - Apply oil to a11 other screws 10 on thread and head _ landina insert thea and tighten equally, in steps to a torque of 60Nm, At the sare tire tighten alsi the screws holding the yoke slightly. - With a11 screus tightened, remove the yoke 9455.01 and tighen the tuo last screus in the saae mariner (fig. 'F@I. Oq the fully assembled pump the fuel regulating rack 7 rust be free to be moved to and fro uithout stickin& ' grooves on the roller pin. Al1 these parts aust be uell

9fs5.01

1982

5501/ld

z;140

Preservation Should a puap have to be put into storage for any length of tire, the spaces 'A' and 'B' (Fig. 'A', 11-11) have to be filled uith a thin Vaseline Oil and the purp has to be stored upright. Al1 openings eust be closed uith plastic plugs.

Hountina the Pus~ on the Enaine

- Bair the crankshaft until the cap profile of the respective pump faces dounuards. - Check to ensure that the landing surfaces and guide elerents in the engine casing and the pump are in Perfect condition. - Smear the guide elements with oil and carefully eount the pump, uhilst ensuring that the doue1 pin 30 as vell as the regulating rack engage properly. (00 net use any sealing compound). - & the threads and head landings of the screus 22 (Fig. 'E' IV-IV) uith screus across, in equal stages to a final torque of NB 290, oil and tighten the

- By eoving the connecting meabers betueen the regulating linkage and pump regulating rack to and fro, ensure that nothing is sticking. - Connect the pipes to the punp and open the shut. off valves of the fuel inlet and return pipes. - Connect the fuel high pressure pipe up and fit the protection hose, - When starting the engine up check the pump for any leakage or possible abnorsal heating. Reaark: Where neu parts have been fitted during the pump overhaul (puap plunger and barrel), the clanp ring 8 on the fuel regulating rack of the puep fitted on the engine oust be re-adjusted (Please refer to sheet 5501/2).

1982

SULZER

240 ZA40
1001s: 1 Adjusting device (cosplete) 1 Gauge Various spanners

Fuel
Adjustment

Injection the

PumP Engine

of

Pump on the

WmJP 5501
SHEET 2

Key to Fiqs. 9455.02 9455.10 1 7 8 9 13 14 15 30 31 32 33 34 PUB~ housing Regulating rack Clarp ring Requlating sleeve Deflector screu /. PUB~ barre1 Puip plunger Gasket Locking screu (9455.04) Spring piston Nozzle Air hose coupling B C sec Fig. 'A' sheet 5501/1 35 36 37 38 39 40 41 A Dia1 gauge (8455.06) Tensioning nut Clarping piece Waisted boit Heasuring cylinder (9455.03) Nozzle Heasuring pin (9455.05) Pressure gauge O-10 bar (9455.07) Pressure gauge O-6 bar (9455.08) Clarping device for measuring pin (for 9455.05)

A purp has to be adjusted after: a) The purp barre1 14 with pump plunger 15, the regulating rack 7 or the regulating sleeve 9 have had to be rectlaced. b) The clamp ring 8 on the regulating rack 7 has been moved. . The purps have been SO adjusted by the manufacturers that they uill a11 deliver the sare quantity of fuel at a particular position of the fuel regulating rack. The adjustrent procedure principle cari be seen illustrated on sheet 5501/2c. In addition, the stroke and pressure progression for pump adjustment is show graphically on the sale page.

Adiustino the Pua~ on the Engine (Note: With reversing engines it has to be ensured, that the camshafts are in AHEAD position before starting fo rake the adjustnenti). York procedure ---w----s----- Close the

fuel

inlet and outlet pipe shut-off valves.

- Remove the high-pressure fuel pipe together uith the protection tube froc the puap. - Remove the purp housing deflector screu 13. - Uncouple and remove the fuel leakage pipe fron the purp caver. Close off the thus created opening with the bolt 31 of the adjusting.device (Fig. 'A'), - Turn the engine until the purp roller lies on the cal base ctrcle, - Set the reasuring pin 41 on the purp plunger 15 and mount the adjusting device as show on fig.

'A'. (Do not forget the gasket 30). The device is to be clamped on moderatrly tightly uith four bolts. Use the threaded holes into uhich norrally go the bolts clarping the protection tube of the high-pressure fuel pipe. - Oisconnect the spring link betuern thr governor and regulating rod at one end and put the lever to the ECIERGENCY STOP position in such a vay that the enaine joad indfcator is at Posit?on '8.51, Loc,k the rod in this position. - Connect UP a corpressed air hose to the adjusting device. (A non-return valve is fitted to the air hose coupling 34 (Fig. 'A') SO that the supply need not be continually tut off). Required constant air pressure - 6-9 bar.

1982

1501/2a

ZA40

- lut-n the engine slovly foruards and read off on pressure gauge 'B' (Fig. 'A') uhat the indicated hiohest oressure reached is and note it doun, In this position the inlet and outlet ports in the purp barre1 14 are closed off by the purp plunger 15 (deliverv strokel. The hiqhest pressure is attained when the pressure gauge needle reaains constant as the engine is turned. - Turn the engine back until the puap plunger 15 lies at B.D.C. (roller rests on base circle of cam). - Set the radial gauge 35 to z~po uith about 1 II of pre-tension. - Turn the engine foruards until the pressure indicated on the pressure gauge 'B' is exactlv half of that weviouslv reaistered, This position reans start of deliverv. (Should the engine have been turned too far, it has to be first of a11 turned back and then brought forvard again to the require' position). The value indicated on the dia1 gauge 35 at this position has to be read off and noted doun (= free stroke). Read off and note doun the anale on the flyuheel graduated scale of the cylinder concerned uith reference to firing T.D.C. The value refers to the start of delivery reasured in crankshaft degrees. - Turn the engine forwards until the pressure indicated on the pressure gauge 'B' indicates exactly half the hiohest value again. This reans end of deliverr, Read off and note doun the value indicated on the dia1 gauge 35 (- total stroke). Subtract the measured free stroke value fror the measured total.stroke value. The result represents the delivery stroke in mm. - Should the delivery stroke determined by this method not compare uith the value of delivery stroke given in the control records for that particular pwp, the correction dimension has to be determine uhich is 4/5 of the difference betueen the measured and specified stroke. The correction dimension is added to the measured stroke uhen this stroke is smaller than specified, or subtracted uhen the eeasured stroke is qreater than specified. - In this uay, the correct dimension cari be calculated uhereby the engine is to be turned first of ai' backuards and then foruards again until the dia1 gauge 35 indicates the calculated value. - The fuel regulating rack is roved in such a way uith the tuo adjusting screus on the forked lever until the pressure on the pressure gauge IBr is half of the hiqhest oressure read off earlier. Important: The torsional Springs may not be given any additional pre-tensioning in this uay. The adjusting screws should touch the regulating shaft limit levers uith no clearance and no clearance should exist betueen the pins and slots of the limit levers (see Fig. '8'). - Hou turn the engine back until the pump plunger is at B.D.C. (roller on base circle of car) uhere the previausly described check for the delivery stroke is to be repeated, During this check a11 thi data (free stroke, start of delivery in crankshaft degrees, end of delivery in crankshaft degrees and the corresponding values indicated on the dia1 gauge in mm) and note it doun. - The measured delivery stroke must compare with the value given in the control records (permissible tolerance 2 0.02 mm). - When this check shous the correct stroke, the fuel regulating rack clamp ring has to be adjusted SO that there is a gap of 10 + 0.03 mm betueen the ring and the purp housing, this being the thickness of the setting gauge 9455.10 to be found in the tool kit (see Fig. '8'). - The position of the clamp ring on the fuel regulating rack has to be marked uith a drop of oilresistant, coloured Paint SO that it caribe seen later uhether it has moved or not.

- The adjusting screus on the operating levers of the regulating shaft have to be secured first of a11 uith lock nuts and then uith a locking plate. - Remove the adjusting device and insert the measuring rod 41 in the bore of the measuring cylinder. Remove the bolt 31 from the pump caver and use it to fix the measuring rod 41 in the measuring cylinder (see Fig. 'A'). - Upon completion of the adjustment York, the connection has to be made good again betveen the regulating shaft and the governor.

1987

ZA40

Gezeichnet DRAWN

fr FOR

IA40 IA40

32

Ii

i @ - +

Il

--.-AL- 4% --_-

l-107.024.362

.. ...... .. . ..

*..... ..... .. .:.:::::::::B ...r.:.:.:.: ......::::::::::.. ...:.:,::. 0 ::::::: .. .._. . ... .~.~.-.~_~.-.~ .., .. .. .. . ...- .... . . .. . ... :::. .. f... .. . .. .. ..-::. .. :. .::.-. @
Set ting gauge .::. . . t 1.; : 9455.10 I

I 1 I

... :.:.:.y: ...

Pin

SiOr 4-107.240.212 i-;

5501/2C

ZA40

Principleof the adjustingdevice

SUPPlY press. w El3

Press. plunaer

A
i

Compr.air cb.EN

I 1f!w

Principleof the double-chaaber punp

Fuel e9

Stroke and pressure progression

ZLOICB,. 77,

Pressure in plunge4 chamber

Camsdii%+

Principlediagram for the adjustingdevice

o-x)702L387

1979

SULZER

EXHAUST

CAS

TURBOCHARGER VTR 454

Group: Sheet:

6501 1

ZA40
Key
1 2 3 4 5 6 "7 8 9 10 11 12 13 14 15 16 17 to illustrations Water tank Air pipe froc charge air cooler Injection pipe to blouer Cover Quick coupling Press knob Shut-off valve Nozzle Grip screw Hash uater pipe (Turbine) Air outlet housing Blower casing Gas inlet casing Gas outlet casing. Drain pipe Drain cock Sealing air pipe

Water Rinsing in Service

Reaark:
l

The shut-off valve 7 aust be SO installed that the arrow on its case is pointing against the flou of the water. Otherwise the valve seat is coaing in direct contact with the exhaust gases and would be destroyed,

figures 'A' and '8' show the scheoatic arrangement of the water piping on an engine having the turbocharger on the darper side (free end). On engines where the turbocharger is arranged on the flywheel end - a few minor modifications eust be rade to the piping arrangement. These are however of no consequence for the in-

tructions below.

Washinp the GLOWER in Service The periodical washing of the blower in service should be done generally daily or at least everv 25 to 75 service hours. By jnjeting water the blower caribe cleaned in service as long as the dirt accumulation has not progressed too far. If the dirt coating has becore excessive and hardened, cleaning cari only be done after disrantling the blower. The water, in this cleaning aethod, does not act as a solvent, but rather carries away the deposit by the aechanical action of the irpinging water droplets. It is therefore recomended to use only clean uater without any solvent additives. The water should also not contain any cooling water treatrent agent which could fore a deposit on the blower. The frequent washing of the blouer prevents or delays heavy fouling, but does not replace the normal overhaul, when the turbocharger is coapletely disaantled (please refer to the separate instruction book for the Exhaust Gas. Turbocharger). Washinq Procedure (Fig. 'A') The engine has to be at runnina teaperature and operate af normal load i-e. the blower rust revolve at hiqh speed. - Loosen the g!ip screw 9 and lift off caver 4. - Fil1 the water tank 1 until about 10 II below the edge with Flean water. - Replace the caver 4 and fasten with grip screw 9. - Compress Knob 6 and hold it down until the uater has been injected (about 4 - 10 seconds). The effect of the injection caribe noted either by the rise of the charging pressure or by a lowering of the exhaust gas temperature. Should the washing.shou no resulfs, the process cari be repeated & the earliest 10 minutes later, After the cleaning of the blover the enqine should continue to run for at least 5 Minutes on load.

1987

Washina the TURBINE in Service (fig. 'B') Dirt accumulation in the Turbine results mainly in a rite of the scavenging pressure and of the exhaus gas temperature before the turbine, and in extreme cases by 'surging". The dirt accumulation is aainly influenced by the quality of the fuel consumed, the periods between washings in service oust therefore be adjusted to suit the prevailing conditions. The uashing in service is intended to prevent or delay a heavy fouling of the turbine. It does not however replace a thorough cleaning during an overhaul (please refer to the separate instruction book for the Exhaust Gas Turbocharger). The Cleaning in service is best carried out on a routine basis. At the beginning, once weekly, but always before going over ta an extended period on load (in ships.for ex.before the start on a longer voyage. In stationary plants before en extended period on continuous load). During very long period on continuous load, the engine power must be reduced slightly at intervals for the washing of the turbine. The drain cock 16 must be opened daily at least once for a short time to prevent its clogging. Cleaninq Procedure (fig. 'A' and 'B') - Adjust engine pouer output SO that the turbocharger speed corresponds as near as possible to the value indicated by the turbocharger manufacturer, or that the exhaust gas teroerature before turbine lies beloa 3OO'C. - Open the drain cock 16 (Fig. 'El')and check whether exhaust gas issues froa the end of the drain pipe 15. (The drain cock aust remain open till the end of the washing period). - Connect the

Quick (acting) coupling 5 (Fig. 'A') to the uash water pipe 10.

- Open the shut-off valve 7 and spray water into the turbine for abt. 10 to 20 ainutes (the norzle 8 determines the uater flou) (water pressure about 0,5 to 1,0 bar). - Check the condition of the issuing water at the outlet of the drain pipe. The cleaning procedure may be considered as completed when the outflowing water is clear. - Shut the shut-off valve 7. If no more water flows from the drain pipe, close the drain cock 16 as well. - Disconnect the quick coupling 5 from the wash water pipe, to prevent any unintentional injection of water during the on load period of the engine. - After completion of the washing the engine aust run for at least 5 minutes or longer at the same or higher load SO that any water remaining in the turbine cari evaporate and the inner parts dry up completely. - In order to establish the effectiveness of the cleaning operation, take the readings of temperature and pressure and compare them with those prior to the washing, whereby it is important that the rea dings are taken at the same running conditions (service load),.

lOQ7

50 l/ lb

ZAGO

Geadnef

A 0

fr ZAL40

DRA WAf

FUR ZAL#&

B
._

2 i x, II

Il

4- n7. 2co.m

3.87

SULZER

ZA40
Tools: 4 Shackles Various spanners Ropes 4 eye screus 1 2 3 4 5

CHARGE AIR COOLER Removal, Cleaning and Mounting

CROUP
SHEET

6601
1

Kev to Illustrations Expansion bellous Diffusor Screws Bracket Air inlet housing 8 9 10 11 12 13 14 15 Connections chamber Casing of charge air cooler Drain connection Gasket Tube stack plate Gasket Sealing flange Screws D DR v 17 AP 16 Sealing ring (Rubber 10 am 0) Tube stack Suspension points !for cooler reroval) Use sealing compound Drainage vent

5a Air-cooler 5b Mater trap 6 7 Screws Flou reversing chaber - Check 0 a i 1 y

on the running engine whether the nozzle in the drain connection is unclogged, systea. (possibly leaking cooler

i.e. whether air is coming oui. A clogged nozzle must be freed imnediately. Should water issue with the air, check uhether it is condensate or water from the cooling tubes). - The cooler aust be cleaned if: a) The pressure droo of the air throuah the cooler exceeds 400 a WC (Water column), b) The tenoerature difference of the cooling water between cooler inlet and Cooler outlet has risen to lZ"C, (these values refer to normal running load). tt is not aluays necessary to reaove the cooler for the cleaning operation. C 1 e a n i n q Iater side The uater sida of the charge air coolers cari be cleaned uithout disiantlino the cooler. TO this end the connections chamber 8 and the flou reversing chamber 7 (Fig. "A") must be reaoved, whereupon th tubes caribe pushed through with tube brushes and liberal application of water, - Sedinents uhich cannot be removed froa the tubes uith the brushes, oust cleared by iniaersing the cooler in a cheiical solvant. Consult a spoctalist firn for this undertaking and follow its recoemendations carefully. After such a chemical cleaning operation, it is necessary to rinse the cooler with a neutralizing agent very thoroughly. (As a rule the cooler manufacturers provide special cleaning instructions, which contain a11 the details required). Air Side - On enginge equipped uith a permanent charge air cooler washing device the cooler cari be 'washed" periodically 'In service'. Where this installation does not exist it is best to remove the cooler fror the enqine and placed in a chemical cleaning bath. After the cleaning the cooler rust be rinsed, carefully 'neutralised' and finally be blown through with'corpressed air. As cleaninq aqent the product of a uell known firm should be used like for exaaple: ALTREX, HENKEL, ACC etc. lt goes uithout saying that the instructions for preparing the baths and the actual cleaning procedure, of the various firis must be followed carefully. After refitting the cooler it l ust be subjected to a test pressure of 4 bar A of the Cooler

1987

6601/la
D i s m a n t 1 i n P the Charoe Air Cooler

ZA40

_ Shut off the uater flou to the cooler and drain the cooler. (Dpen the cock at "DR', or remove the threaded plug respectively). - Disconnect a11 the pipes from the cooler. - Renove the expansion bellous 1, the diffusor 2 and the air inlet housing 5. - Loosen the screws 3 of the bracket 4 and remove thes. - Rerove a11 but a feu of the screus 6. - Attach a shackle at "AP" on either end of the bracket 4. Fix the shackles with ropes to the crne. - Resove the remaining screus 6 and pull the cooler horizontally sufficiently away from the charge air cooler casing 9, that it caribe rested on the floor. - For further disaantling remove the screus 15, which fasten the sealing flange 14 (Fig. "C"). - Remove the sealing flange 14 and sealing ring (Rubber ring) 16, and place the cooler uoriqht with the connections chamber 8 topmost on the floor. - Drive four eye screws, equally spaced into thethreaded ber 8 and attach them with ropes to the crane hook. holes of the connections of connections char

- Withdraw the tube stack 17 from the casing with the crane. - TO clean the inside of the cooler tubes, remove the flou reversing chamber 7 and the connections chamber 8 from the tube stack 17. (As to cleaning agents, please refer to the last chapter of the follouing sheet). - Defective cooler tubes caribe put out of action by soldering both ends or by blanking thea off with tapered hardwood plugs. The number of blanked-off tubes may not exceed 10% of a11 the-tubes. . - The cleaned cooler must be subjected to a pressure test at 4 bar. A s s e

rn*1 b

i n Q

the Charqe Air Cooler

- Fit the flow reversing chamber 7 and the connections chaaber 8 to the cleaned cooler tube stack. (Use only neu joints!). - Place the cooier asing vertically on tuo wood underlays, and set the gasket 13 on the flange (connecting chamber end). Attach the tube stack by ropes to the crane and lover it (flou reversing chaaber first) into the casing, slouly SO as not to daoage the gasket 13. - After fastening the tube stack to the casing with the screws, place the coaplete cooler into a horizontal position. - Place gland ring 16 over the neck chamber 7 protruding out of the casing over the gland frame 14, uhich is fastened to the casing by screus 15. - The complete cooler is attached with shackles and ropes to the crane and is rounted to the charge air cooler casing 9, in reverse sequence to the dismantlfng, and fastened with the screus. For the sealing between the charge air cooler and the casing use sealing compound.

LLni

/lh

i:4D

- Tighten a11 the screus 3, SO that the bracket 4 is again fastened to the support (Fig. 'A'). - Finally connect a11 the water pipes to the connections chaaber 8.

Remark on the Use of Chemical Cleaninq Aqents If the degree of dit-t deposit in the cooler necessitates a cleaning uith chemical solvents, ascertain firts without any doubt that the cooler materials are not attacked by thea. For the air side cleaninq products of the following firrs aay for example be used: ALTREX By Wyandotte Chemical Corporation ACC By Orew Chenical Corporation

Regarding the mixtures and the application follow striclty the instruction of the suppliers. TO reaove sedioents in the inside of the tubes chemically, ue recomiend to consult the cooler manufacturers. Bedore using chemical agents the manufacturers should contact the cooler aanufacturers. If difficulties are encountered regarding the application, ask SULZER indicating the cooler aake anc type. Information .

Detailed information concerning the operation, maintenance and repair of charge air coolers is provided in aseparate instruction manual issued by the cooler manufacturers. Since in most cases "GEAR coolers are provided, it is advisable to obtain the instructions manuals directly from GEA at the following address: GEA Luftkhlergesellschaft Happe1 GmbH u. CO. 43-45 Konigsallee D 4630 B o c h u m Federal Republic of Germany

Should a cooler of other manufacture be fitted, the instruction material must be obtained froc the respective manufacturer. It is also.possible to order such instruction manuals froc the engine builder or supplier. For this, the following information is to be provided: Engine type and number Engine supplier Cooler make and type Desired language

sol/

lc

ZA40

Khler am Frein COOLER ON FREE

Ende END

A 0 I

B 0 t

4 - 10 i! 240.196

3.87

66011

Id

Kil& auf Antriebsetie COOLER ON ORIVING EN0

A 0
N

\I~c-----_-c---2 .-vw -----u

SlJum

G~OUP:

ZA40

Flap for Change Air By-Pass Dismantling and Assembling

Sheet:

6730
1

1001s: 1 Open end spanner AF 41 1 2 3 4 5 6 7 Sleeve

Kev to:lllustrations 8 9 10 11 12 . Cylinder Spur rack Piston seal ring Piston seal ring Electric valve

Valve flap 'Allen' screw Flange Limit feeler Shaft Spur gear wheel

A half yearly functional check of the charge air by-pass flap must be carried out. For this check the control air piping to the flap controls have to be removed during a operating stop. In this condition the flap cari be check for case of movement. This cari be done with the aid of an open end spanner uhich is applied on the sleeve 1 (sec illustr.). With its help the flap cari be moved from fully open to fully shut 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 by-pass. - Loosen the fastening to valve flap 2 and remove them. Remove the valve flap together uith the two heavy roll pins. - Loosen and remove 'Allen' screu 3. Remove sleeeve 1. - Take off limit feeler 5, loosen fastening of flange 4, remove flange. The shaft 6 cari nov be removed together with the spur gear wheel 7. - Loosen fastening to cylinder 8 and remove cylinder. - Remove Spur rack.

Assemblinq: The assembltng of the by-pass flap is done analogous to dismantling musf

but in reverse sequence. Attention be paid that during assembly the marks on the spur gear wheel 7 mate with the mark on the spur

rack 9. Further attention must be paid that after assembling the valve flap 2 does not touch the housing bore in any Posit?on. Before the assembly a11 moving parts to be smeared lightly with molycote paste.

1987

I 2

et-!-l

. ! 0

o- wz 2&0.lrn

3.87

SULZER

WSTE

GATE (Variante

A)

~mppe:6735
Blatt: 1

z440
r001s: 1Testing device for pneumatic valving 9408.26

Dismantling

and Assembling

Key to illustrations: 1 2 3 4 5 6 7 8,8a Flange Screw 9 Pressure piece 10 Piston 11 Valve 12 Grooved cane piece 13 Spring 14 Test connection Limit key Stop plate Piston seal ring Piston seal ring O-ring Pressure reducing valve

Should in the course of the half-yearly function check of the waste gate the valve be jammed in any position or does not open properly. than the waste gate has to be dismantled in the following manner: - Remove waste gate as complete - Loosen - Loosen - Loosen screwed connection unit. flange.

to flange 1 and remove with its bush.

and remove screw 2 together screwed cormection

to pressure

piece 3 and remove the latter.

- With the aid of a wooden piece press hard on piston 4, till it is metalhcally seated. Simultaneously press onta valve disc 5 with sufficient force to keep the valve closed. The two grooved cane pieces 6 cari then be removed. - Slowly relieve pressure on piston 4. - Piston 4, and valve 5, and the spring 7 cari now be removed.

Assembling:

The assembling of the waste gate is canied 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, as they have been set in correspondance with the turbocharger speciffcation. The set values are entered in the timing records. Before assembling them, ail the parts shall be lightly smeared with Molycote paste.

(Variante

A)

7.90

L71C/l.,

7.AA

(Variante A)

7.90

SULZER

WA!933 GATE (Variante

Dismantling

B)

~ru~~e:6735
Blatt: I

n40
roo1s:

and Assembling

Key to illustrations:

1 Testing device for pneumatic valving and waste gate

9408.26

1 2 3 4 5 6

Housing Cover

Piston Pressure regulating vaive Stroke limiting screw Gasket 1 mm thick

7 8 9 10 11 12

Check nut Screws Guide ring Piston seal ring Outer compr. spring Inner compr. spring

Half yearly the waste gate must be subjected to a function check on the running engine. ShouId any faults appear or should the lamp WASTE GATE FAILURE light up in the control room then the waste gate has to >e overhauled as described below: - Loosen screws 8 to caver 2. Specially long screws are built in for de-tensioning Attention! Stroke limiting screw 5 may not be adjusted l Springs 11 and 12.

- DismantIe piston 3. Clean piston as well as housing 1. - 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.

Assembling:

Assembling is carried Attention!

out analoguos to dismanthng

but in reverse sequence. ensure that a gasket of the same thickness is

Should gasket 6 (1 mm thick) need to be replaced, again fitted.

Before assembling smear a11 moving parts lightly with clean engine oil.

Remark:

The holding pressure of waste gate is adjustable on pressure regulating valve 4. For this adjustment utilize the tools contained in testing device 9408.26. With the aid of these adjusting tools the holding pressure cari be correctIy set. (Please refer to sheet 6735 of the operating manual). The setting data are recorded in the timing records.

3
(Variante B) 1990

ZA40

f-102240.377

.-

(Variante

B)

SULZER ZAL

40

LUBRICATING OIL PUMP Zismantling and Reassembly

~~OlJP
SHEET

7101
1

li;fle$i!?2 driven pumps Tools: 1 Depth gauge 1 Torque trench (480-940 Nm) 1 Puller . 9471.01 2 Jacking screws Ml6 4 Eye bolts Ml6 Various openended and ring spanners 9 10 11 9408.16 9408.17 1 2 3 4 5 6 7 8 Pilot valve Pump housing Bolt Ml6 x 50 Bearing caver Drive uheel Thrust ring Waisted bolt '0' ring 363.07 x 7 (Nitrile, Shore hardness = 60-70) Bearing bushes Pump transport wheel (driver) Cover 14 15 16 17 18 G K Key to Fios. 12 13

Gasket, 1 mm thick Pump transport uheel (driven) Gasket Shim Cover Spring Dowel pins Place for eye bolt Ml6 Drilling for measuring the uheel displacement on the pump shaft

Wtth a new enqine the gear teeth profiles of the pump drive uheel 5 have to be inspected after a few ueeks in service. During a qeneral overhaul the pump has to newed (see clearance table D352/13). Dismantlinq - Drain punp. - 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. - Remove a11 the set bolts clamping the pump ta the engine except one. - Screw in four Ml6 eye bolts into the pump housing at '6' (see Fig. 'B') and hang the pump (approx. 332 kg) on a lifting block. - Now remove the remaining set bolt and jack off the pump from the engine with tuo Ml6 jacking screws until it is no longer centered by the doue1 pins 18. - Take away the pump and set it on a flat surface for further dismantling.

bedismantled

and inspected. Heavily worn parts must be re-

- Remove caver 16 and withdrau the pilot valve 1 and spring 17. (Attention: Do not lose the shim 15). - 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 shoun on Fig. 'C' and evenly tighten its Ml6 bolts hard until the drivf wheel 5 is released from the shaft. When necessary, strike the rear face of the puller once or tuicf hard with a hammer in order to aid release. After looseninq the drive wheel 5, further dismantling is carried out as follows: - Remove the drive wheel 5. - Unscrew the bolts 3 and lift off the caver 4 (Fig. 'A'). - Unscrew the bolts 3 and lift off the caver 4 (Fig. 'A'). - Tt is nov possible to withdraw the pump transport wheels 10 and clearance table 0352/13). - Should the bearing bushes 9 have to be removed, they have to be pressed out of the housing and bearing caver and the new ones pressed in with a suitable tool. 13 and to inspect them (see also

)
1982

7101/la
Reassembly - Oil a11 bright parts immediately before assembly.

uith enqine-driven oumos ZL40/ZAL40

- Slide both the pump transport uheels 10 and 13 into the housing 2 as show put on the bearing caver 4 uhich is then located by doue1 pins. - Evenly tighten the bolts 3 and secure them uith locking wire (2 mm dia.)

on Fig. 'A' and then

- Set the drive uheel 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 G-n and screu it home onto the thrust ring bv hand. The initial tightening is done uith the aid of a torque urench 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 drive uheel) and note it doun (Fig. 'Cl'). - Tighfen the bolt 7 further until the axial displacesent of the gearuheel along the shaft cornesto 1.3 - 0.05 'RD which has to be deterrnined by measuring the distance 'X' several times. (Theoreti& the final tightening torque would be about 700 Nm, houever, the measurable disolacement is the deteraining factor). - The bolt 7 nust not be secured. - Eefore fitting the pump on the engine a new '0' ring 8 has to be inserted in the groove on the punp flange. - When fitting the complete pump on the engine, its correct position is determined by the doue1 pins 18 (Fig. 'ET').

1982

.-. -. -. kl

SULZER

ZA40
Kith built-on Pumps Tools:

FUEL BOOSTER PUMP Dismantling and Assembling

GROUP SHEET

7102
1

Key to Illustrations 9408.16 1 2 3 4 5 6 7 8 9 10 12 13 Valve body (relief valve) stop Spring Joint Screw Holes f. dowel pins O-Ring Circlip O-Ring Sealing disc Bearing housing O-ring 16 17 18 19 21 22 23 Pump cog uheel (driven) Bearing caver Purp coq uheel (driving) Screw Backing ring Oriving gear uheel Press ring Screw Screw Threaded hole for eye screu B12 Threaded hole for jack screw il16

1 Oepth gauge

1 Torque wrench 9408.17 140-560 Nm/3/4') 9474.01 1 Puller 9474.02 1 Round bar 1 Socket spanner i' AF30 2 Jack screvs Ml6 1 Eye screw Ml2 Various open end and ring spanners

20,20a Shaft seal

l 24
26 G AG

25,25a Doue1 pin

11,lla O-ring

14 Pump casing 15,15a,15b Bearing bushes l Tighten to instructions

On a new enqine the tooth profile of the punp driving gear vheel ust be inspected after a few veeks of engine operation. Ouring a aeneral overhaul the pump must be disaantled and checked for wear. Horn parts musf be replaced (Check vith clearance table 0352/13). Oisnantlinq - Drain the punp - Oisconnect the pipes froa the pump casing and close its openings vith blanks (for exarple Wood) to prevent any foreign bodies to enter. - Remove the screws, fastening the pump to the engine - with exception of one screv. - Fit an eye screv N12 in the pump cssing at '6' (Sec Fig. 'Cl) and attach the puap (abt. 95 kg) to the crane. - Nov remove the last screu holding the pump to the engine. Fit two jack screvs Ml6 at 'A6' and jack the pump away froa the engine until it is no longer positioned by the dowel pins (Fig. 'A'). - Move the puap for dismantling to a vork bench. - Loosen the screu 24 and remove i.t with press ring 23. .

- Fit the puller 9474.01 as shown on Fig. '0' and tighten its tvo screws M 16 equally and firmly, until the driving gear vheel 22 has bee pulled off the shaft. If necessary tap the tenter of the puller hard once or twice with an iron hammer, to aid the withdraval. After the removal of the driving gear vheel proceed with disaantling as follovs: - Renove the screus 26 (Fig. 'C') and pull the bearing housing 12 off the purp casing 14. - Pull the O-Ring 7 off the shaft. - Loosen and remove the screws 19 and lift the bearing caver 17 off the purp casing 14. - Remove puep cog wheels 16 and 18. - Tf the shaft seals 20 must be replaced, remove circlip 8 and hacking ring 21. - The sequence of disaantling the reraining parts is obvious froa the Figs. 'A' and '0'. - Should it be necessary to replace the bearing bushes 15, remove the old ones uith a suitable tool and press in the nev bushes vith great cape.

1987

Euilt-on

pumps

ZP4C

Assenblino - Clean a11 the parts carefully and, imaediately before assembling the pump srear then uith fresh oi' The O-rings 7, 9, 11, lia and 13 as well as the shaft seal rings 20 and 20a rust be replaced by neu 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 hacking ring 21 and the circlips 8 are in place! - Fit punp~cog wheels 16 and 18 into the pump casing, fit the bearing caver 17 and insert and tighten the screus 19 a11 equally and firmly. - Fit O-Ring 7 onto the driving shaft. - Place O-Ring 11 in the groove, mount the bearing housing 12, insert and tighten the screus 26 equally and firmly and lock the screws finally with locking vire, - Fit the drfving gear wheel 22 onto the driving shaft. (The tapered part of the shaft as uell as the tapered bore in the drivinq qear wheel nuss be specially clean and dry)-. - Fit press ring 23, smear the screw 24 on thread and head landing with oil and drive the screu in by hand until seated and tighten at first to about 20 NB ( - Initial position). - Measure with a depth gauge through one of the holes 'K' the distance 'X' (- outer edge press ring to front face of driving shaft) and note the dimension (Fig. 'El). - Tighten the screw 24 further, until the driving gear wheel 22 has been shifted on the shaft by 0.45 + 0.05 mm, which aust be watched by repeated aeasuring of the distance 'X'. . TThe tightening torque is theoretically 190 Na but the measurable shifting is the decisive criteric - The screu 24 does not have to be locked. - Before fitting the pump to the engine, place the+O-ring 13 into the groove of the pump flange. - When fitting the pump on the engine the correct position is determined by the doue1 pins (Fig. 'A') which must engage with the holes 6 in the pump casing.

OZ/lb

ongeb. fimpen

ZAL

\ i

SULZER

ZA40
uith eng.driven pups 1001s: 1 Hydr. hand pump uith accessories 1 Depth gauge 1 Special spanner 1 Tensioning jack 2 Jacking screvs 2 Eye bolt Il16 Various openended and ring spanners

Cylinder Coolinn and Raw Water Puma Dismantling and Reassembly

Kev to Fias, 9408.01 9408.16 9431.03 9433.07 1 2 3 4 5 6 7 8 9 10 11 12 Round nut Drive uheel Sleeve Locking wire Bolts H16 x 130 Bearing housing Rubber '0' ring 177.17 x 7 Shaft sealing ring (6~C0) Bush Spacer ring Rotary mechanical seal Puep housing 21 22 23 L 13 14 15 16 17 18 Bolts H16 x 50 Rubber '0' ring 291.47 x 7 Cover Shaft lapeller Rubber '0' ring (as item 14)

*mp
SHEET

7103
1

6a Doue1 pin

19 Bearing bushes
20 Piston sealing ring Rod sealing ring Piston Cylinder Leakage drain 1 for tensioning jack 9433.07

Gezeichne t fr ZV40/48 DRAW FDR ZV40/48

1 1

34

67+89

10

11

The following instructions are valid for both the cylinder cooling water and the rau uater PUB~. The only difference between the tuo pumps lies in the choit. of aaterial, forr and position of the pump housing and Jn the size of the impeller 17. Figure 'A' illustrates a rau water pump for the ZV40/48 engine.

1987

7103/la
ueeks in service.

eng.-driven

pumps

2b4C

With a neu engine the gear teeth profiles of the puap drive uheel 2 have to be inspected after a feu

During a general overhaul the purp has to be dismantled and the parts inspected. Heavily uorn parts must be reneued (see also clearance table 0352/14 & 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. Reneual of such a seal requires the disaantling of the punp and the following to be done beforehand: - Drain the pump and remove a11 the pipe connections. - Reaove a11 but one of the set bolts clamping the pump to the engine. - Connect the puap to a lifting block with a rope (weight of pump, see table of weights 0051 in the service instructions). - Now resove the remaining mounting bolt. - Jack off the punp froa the engine, using two Ml6 jacking screws, take it away and place it on a work bench for further dismantling. Oismantling ------m-s-m - Screu the tensioning jack 9433.07 onto the thread of the puap shaft 16 and connect it up to the hydr. hand pump 9408.01. Using the special spanner 9431.03, screu down the piston of the tensioning jack until the faces of the piston 22 and the cylinder 23 are level. Unscrew the corplete hydraulic jack by about a half to a full turn (Fig. 'El'). - Tension the pump shaft uith a pressure of approx. 670 bar and unscreu the round nut 1 by one turn. - Fully release the pressure. Reaove the tensioning jack, round nut 1 and drive wheel 2 froa the shaft - Unscrew the bolts 13 and remove caver 15. - Withdraw the inpeller 17, pump shaft 16, bushes 9 and rotary mechanical seal 11 froc the punp. '- Slacken off and reove the bolts 5. Separate the bearing housing 6 froa the puap housing and remove the sleeve 3 and the shaft sealing ring 8. - Clean a11 the parts-and check them for uear (see also clearance table 0352/13a). Reassembly Preparation ---s------Al1 the individual parts aust be clean and then oiled just before fitting. The rubber '0' rings 7 and 14 as well as the shaft sealing ring 8 have to be replaced by neu ones before commencing reassembly. This also applies to the spacer ring 10 and the rotary nechanzl Important! It is absolutely essential that during assembly the faces . of the follouing parts are clean. dry and undamaoed:. shaft 16, impeller 17, bush 9, sleeve 3, gearuheel 2 and round nut 1. Work Procedure ----w-s--s-m- Slide the sleeve 3 into the bearing bushes 19 and fit the shaft sealing ring 8. - Fit the bearing housing 6 to the ptusp housing 12; tighten the bolts 5 evenly and hard and secure thea with locking wire (ensure beforehand that also the rubber '0' ring 7 has been laid into the bearing housing flange). - Fit the spacer ring 10 into the pump housing. - Slide the irpeller 17 and bush 9 uith the rotary mechanical seal onto the shaft 16 and asserbly together. - Grease the rubber '0' ring 14 and insert it in the groove in the caver, fit the latter and tighten the bolts 13 evenly and hard. seal 11.

1987

.2-t----

-__---

- Screu the round nut 1 fully doun uithout lubricatino its thread, - Screv doun the hydr. tensioning jack 9433.07 vith the special spanner 9431.03 SO that .the outer faces of the piston and cylinder are level uith each other and then connect it up to the hydr. hand purp 9408.01 (Fig. '6'). - Tension the shaft uith 100 bar, hold this piessre corstant and screu the round nut 1 fully doun, then fully release the pressure. - Keasure the dimension 'X' that the piston lies proud of the tensioning jack and note it doun (starting position). - Repeat again uith 600 bar then eeasure and note dom the dirension 'Xl'. When the boit tensioning has been correctly carried ouf, the checking dirension, i.e. Xl - x-1*4 mm ,

The axial clearance of the shaft uill be, uith a neu purp and after tensioning shaft, about 0.34 to 0.48 mm and this has to be checked. When fitting the puap onto the engine, ensure that the rubber '0' ring 18 has first been inserted in the flange of the bearing housing 6. The pipes oust be connected up to the purp stress free.

1967

SULZER

ZA40
with eng.driven pumps

Fuel Injector Cooling Water Pump Dismantling and Reassembly

I
7

GROUP 7105
1

SHEET

Key to Fios. Depth gauge Torque spanner (140-560 Nm/3/4") Socket head insert 3/4A/30 across flats Jacking screws Ml6 Various openended and ring spanners 8 9 10 11 9408.16 9408.17 1 2 3 4 5 6 7 Nut Orive gearwheel Sleeve Locking wire Bolts Ml2 x 110 Bearing housing Rubber '0' ring 91.44 x 5.33 Shaft sealing ring 19 20 (GACO) Bush Spacer ring Rotary mechanical seal (CULLIVER GV38C) 12 Pirmp housing 21 IS L S X 15 16 17 18 13 14 Bolts Ml2 x 40 Rubber '0' ring 177.17 x Cover Shaft Impeller Rubber '0' ring 215.27 x 7 Bearing bushes Oowel pin Split pin 3.2 x 22 Bearing clearance Leakage drain Axial clearance Checking dimension

With a neu engine the gear teeth profiles of the pump drive wheel 2 have to be inspected after a few ueeks in service. During a general overhaul the pump has to be dismantled and inspected. Heavily uorn parts must be renewed (see clearance table 0352/16). Should leakage from the pump leakage drain 'L' sharply increase uhen in service, this indicates that one or both of the shaft sealing rings 8 and 11 no longer seal properly. Reneval 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.

7105/la

eng.-driven

pumps

ZA40

- Connect the pump to a lifting block with a rope (weight - 55 kg). - Now remove the remaining mounting bolt. - Jack off the pump from the engine, using two Ml6 jacking screws, take i t away and place it on a work bench for further dismantling. Dismantlinq - Remove the bolts 13 and the cover 15. - Remove the split pin 21 and unscrew the nut 1, holding the hexagon at the water end of the shaft by 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. Reassembly Reassembly follows the dismantling procedure, only in the reverse order whereby the following points must be particularly noted: - The bearing bushes 19 have to be lightly oiled. However, the parts 2, 3, 9, 16 A 17 must be drv before assembly. - The shaft sealing rings 8 and 11 as well as the '0' rings 7, 14 and 18 must be replaced by new ones. - Ensure.that the dowel pin 20 engages correctly.

- The bolts

5 have to be secured with locking wire (dia. 2 mm) after tightening.

The nut 1 has to be tiqhtened as follows: - Lubricate the thread of the shaft 16 with oil. - Screw the nut 1 fully down onto shoulder on the drive wheel 2, which must be possible by hand. - Using the torque spanner, tighten the nut 1 to an initial torque of 3O'iNm ! -starting point) then determine and note down the dimension 'X' by means of the iepth gauge 9408.16. - Following the nut 1 has to be tightened by further 495+; note it down as 'Xl'. h'henthe pump has been correctly assembled and the nut has been tightened to instructions Xl . Measure the distance 'X' again and

- X = 0.66 - 0.70mm
= 0.3 - 0.44 mm

Axial clearance IS'

Bearing clearance 'LS' = 0.045 - 0.091 mm

nn

SULZER

SCAMATIC Fine Filter for Cylinder Lubricating Oil

~f?OUP 7203
SHEET 1

ZA4Q

1
Tools: Various spanners

Checking Operation and Servicing

Key to Fiq. 11 12 13 14 15 16 17 18 19 20 21 22 Securing screw Lock uasher Joint Screw uith nut and lock nut Sealing ring Lock washer Hex. head screu Sealing ring Cover Special sealing ring Filter insert Filter housing 28 29 A El f 0 E 23 24 25 26 27 Sealing ring Joint Screw plug Connection union Protective sheathing Corset Screws Oil inlet Oil outlet Sludge drain Oil outlet from actuating mechanism Sludge chamber

Operational Check When the filter is working properly, in operation the noise coming from the

ac-

tuating mechanism can be clearly heard (about 20 times per minute). In installations uhere oil flows continuously thtoug the filter when it is in operation a chec for correct working should be made every week by listening to it. In installations where the filter is only necessary uhen the oil level in the heade tank sinks below a certain level, an operational check has only to be made quarte ly. To do this, the level in the header tank has to be appropriately lowered and the shut-off cock before the filter opened since it can only work when oil flows

-21
-28

through it. Servicinq The sludge chamber 'E' of the filter hous ing is connected to the engine casing by a pipe which allows periodic de-sludging. Should it be discovered, however, that the cylinder lubricating oil pumps are sludging up frequently, the filter has to be dismantled, cleaned and inspected. It may be necessary to wash the filter and this should be done as follows: - Drain the filter.
25

- Separate the oil outlet pipe '0' from the filter. - Unscrev the screws 14 and lift off COVE lg'vertically ched parts. along with all its atta-

- 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.

1987

!03/la

z:4i,

- Unscrew the screws 29 and carefully remove the corset 28 axially. It is now possible to wash the filter element in paraffin or diesel oil and blow it out with compressed air. (Namino: 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 clean cloth soaked in petrol or gas oil can be used to clean the outer surface of the filter by wiping it along the direction 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 bottom of same with the rubber ring 23 slides off the guide neck in the housing 22 without any undue force.

SULZER

Cylinder Flushing

Lubricatina out the

Oil Pums Housing

mOUP
SHEET

7220
1

ZA40
Tools: 1 Screudriver stroke 1 2 3 4

Kev to Fie oust caver Storke adjustrent screu Housing caver Stroke operating disc Housing Stroke control disc Main piston PUB~ element Control plunger 14 15 16 17 18 Gear shaft Baseplate Drive shaft Shaft seal Cylinder lubricating oil puep shaft coupling piece uith helical .gear uheel 10) 19 20 A B 11 12 Hand crank Oil outlet connection lla Corpression spring C E Freewheel Freeuheel rollers Suction pipe Delivery pipe Oil drain screw Vent screu uith built-in relief valve The cylinder lubricator should be rinsed through everv 6 ronths. Work Procedure: - With the engine at a standstill, shut off the oil supply and drain the housir 5 by renoving the oil drain screu 'Cl. - Reeove the housing vent screw 'E' and pour a feu litres of paraffin or clean diesel oil through each housing. - After flushing out the oil sludge in this uay, slouly open the rupply shutoff cock in order to flush out any remaining flushing fluid. - On corpletion of this, screu the oil drain screu 'C' back in and tighten it. - Screw in the air vent screw 'E' as far as it uill go and then slacken it back by about tuo turns. - Open the supply shut-off cock slightly until a11 the air has been purged froc the pwps and oil flovs fror the air vents 'E'.Tightenthe vents and fully open the supply shut-off cocks. Before starting up the engine, turn the hand cranks 11 until the flou control check glasses indicate that a11 the cylinder lubricating oil pump eleeents ar .-. uorking properly. (Follou the instructions of the purp suppliers).

5 6 7 8 9

2- m. 080.336

1987

SULZER

STARTING AIR PIPES Overhauling the Flame Traps and Safety Valves

OROUP

8600
&

ZA40
TO01s:
Various open end and ring spanners

SHEET

Kev to Illustrations A Flare Trap ---------1 Casing Upper part 2 Casing louer part 3 Flaue trap insert 4 Copper joint 5 Screu plug H 60x 2 8 Safety Valve -----------6 Pressure adjusting spacer 7 Spring 8 Spring casing 9 Valve body 10 Valve seat .

Ouring a general overhaul the flame traps (Fig. 'A') uhich are fitted in the connections of the starting air pipes, oust be checked and if necessary cleaned. TO get access to the interior for cleaning, unscreu the plug 5. The holes in the insert 3

lust be pushed through (0 6 aa).

Replace the old copper joint 4 by a neu one. Suear the thread of the plug 5 for locking uith LOCTITE No. 221, then fit it uith copper joint 4 in place and tighten firaly. Oisrantle the safetv valve (Fig. '8' by unscrewing spring.case 8, check valve body 9 and Seat 10 and if necessary regrind and lap {-angle of Seat is 45O), The blou-off pressure of 35 bar cari be adjusted by changing the thickness of the spacer 6. For adding off one bar change spacer thickness by 0.42 WR.

27x2

1987