Wrtsil Italy, Service

Subject Engine type Ref. Date Document No. DLC Issue Page
High pressure fuel pipe ZA40S WIT-S 18.02.2003 T-ZA40S.0014.GB 162 03 1/5
Wrtsil Italia SpA Bagnoli della Rosandra, 334 Telephone : +39 040 319 5000
Service 34018 San Dorligo Della Valle (TS) ITALY Fax : +39 040 319 5647
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ZAS-14.3
High-pressure Fuel Pipe
1 Introduction
This Technical Bulletin supersedes previous Service Bulletin ZAS-14.2 and its purpose is to declare
superseded previous high-pressure pipe Type 808.
It still informs you about different types of high-pressure fuel pipe together with tightening instructions and
guidelines to be observed when changing the type of high-pressure fuel pipe on a cylinder unit.
2 Superseded Fuel Pipe Types
2.1 Original Type 714
The following Type 714 high-pressure pipe was originally introduced on the first ZA40S engines in 1986.
Its main features were: flat seal between pressure pipe, fuel stud and fuel pump cover as well as a
corrugated protection tube with metal gauze jacketed around the high pressure pipe.
It has been superseded because of possible friction between corrugated protection tube and pipe. Type
714 is not interchangeable with Type 723.
2.2 Intermediate Type 808
The first type of high-pressure fuel pipe introduced with conical seal was Type 808 in 1995. It also
presents a solid protection tube surrounding the pipe.
Type 808 type has already a double shielded high-pressure fuel pipe and it has been declared
superseded because of a tendency for cavitation at upper end. Type 808 is interchangeable with
Type 723 under the specific conditions of paragraph 4.2 of the present document.
2.3 Alternative Type 111
The retrofit package Type 111 was also introduced in 1995 in order to profit from the benefits of the new
Type 808 design, without changing the fuel pump cover.
It has been declared superseded because of the tendency for cavitation at the upper end might be
increased. Type 111 is not interchangeable with Type 723.
Wrtsil Italy, Service
Subject Engine type Ref. Date Document No. DLC Issue Page
High pressure fuel pipe ZA40S WIT-S 18.02.2003 T-ZA40S.0014.GB 162 03 2/5
Wrtsil Italia SpA Bagnoli della Rosandra, 334 Telephone : +39 040 319 5000
Service 34018 San Dorligo Della Valle (TS) ITALY Fax : +39 040 319 5647
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3 Present Fuel Pipe Type 723
Type 723 high-pressure fuel pipe is the present standard, introduced since February 1998.
Compared to Type 808, the Type 723 has:
(a) a shorter pipe, and
(b) an inner diameter of the pipe enlarged
(from 6 mm) to 7 mm in order to
minimise any tendency for cavitation at
the upper end.
4 Up-grading recommendations
4.1 Summary of present status
Type Status Remarks
714 Superseded Original type, no longer available
808 Superseded Intermediate type, no longer available
111 Superseded Alternative retrofit set for Type 714, no longer available
723 Present standard -
4.2 Conditional maintenance for existing superseded types
If the installed fuel pipe is a superseded type and doesn't show any leaking or cavitation problems,
it can be kept on the engine only if applying the following conditional maintenance follow-up.
Wrtsil Italy, Service
Subject Engine type Ref. Date Document No. DLC Issue Page
High pressure fuel pipe ZA40S WIT-S 18.02.2003 T-ZA40S.0014.GB 162 03 3/5
Wrtsil Italia SpA Bagnoli della Rosandra, 334 Telephone : +39 040 319 5000
Service 34018 San Dorligo Della Valle (TS) ITALY Fax : +39 040 319 5647
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4.2.1 Parameters to follow
In order to identify if a problem exist on the installed superseded fuel pipe, the fuel pressure should
be followed-up and within the limits, as per Technical Bulletin T-ZAS-22:
Fuel oil service pressure at engine inlet....................................................................................................8-10 bar
Dp across the engine fuel injection pump at engine stand-still - 550 kW.................................... 0.8 bar
- 600 kW.................................... 0,9 bar
- 660 kW.................................... 1,1 bar
- 720 kW.................................... 1,3 bar
In case of deviation from the above information, the hereunder conditional recommendations of
your installed fuel pipe should be performed.
4.2.2 Condition checking
for Type 714
Control of the flat sealing surfaces: check if leaking.
Control of inner pipe: check if crack are present on the internal pipe surface resulting from a
friction between corrugated protection tube and fuel pipe.
for Type 808
Control of inner pipe: check if traces of cavitation are present inside the pipe at the upper end.
for Type 111
Control of inner pipe: check if traces of cavitation are present inside the pipe at the upper end.
4.2.3 Corrective action
If one of the above mentioned problem is found, the installed high-pressure fuel pipe should be up-
graded for a 723-Type.
5 Tightening instructions
Please find in the following table an overview of the tightening torques suitable for the different types.
Type Fuel stud (1) Delivery valve bolts (2) High pressure pipe cap nut (3)
714 290 Nm 28 Nm 170 Nm
111 290 Nm 28 Nm 250 Nm
808 300 Nm 28 Nm 250 Nm
723 300 Nm 28 Nm New 130-150 Nm (*)
(*) Notice: The threads of the 723 cap nut should be lubricated with Molykote 1000 or Copper Slip.
All other threads in this table remain oil lubricated.
Wrtsil Italy, Service
Subject Engine type Ref. Date Document No. DLC Issue Page
High pressure fuel pipe ZA40S WIT-S 18.02.2003 T-ZA40S.0014.GB 162 03 4/5
Wrtsil Italia SpA Bagnoli della Rosandra, 334 Telephone : +39 040 319 5000
Service 34018 San Dorligo Della Valle (TS) ITALY Fax : +39 040 319 5647
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Important All joint faces should be dry and clean.
6 Conversion from Types 714, 111, and 808 to present Type 723
6.1 Fuel Pipe up-grading
6.1.1 Solution for 714-Type and 111-Type
The 714-Type and 111-Type can be upgraded as per following indications:
Replacement of fuel injection pipe, fuel stud with delivery valve and accessories ........... KS27245
Replacement of fuel pump cover ..................................................................................................... KS55008
Replacement of fuel pump cover o-ring ......................................................................................... KS55036
Replacement of back-up ring ............................................................................................................. KS55038
6.1.2 Solution for the 808-Type
The 808-Type can be upgraded as per following indications:
Replacement of fuel pressure pipe................................................................................................... KS27248
Replacement of existing compression spring ............................................................................... KS27270
Replacement of fuel pump cover ..................................................................................................... KS55270
Replacement of fuel pump cover o-ring ......................................................................................... KS55036
Replacement of back-up ring ............................................................................................................. KS55038
The pump cover can also be up-graded by machining as per Technical Bulletin T-ZAS-32.
Index to Figure
(1) Fuel stud
(2) Delivery valve bolts
(Allen screw M8x20)
(3) High pressure pipe cap nut
Wrtsil Italy, Service
Subject Engine type Ref. Date Document No. DLC Issue Page
High pressure fuel pipe ZA40S WIT-S 18.02.2003 T-ZA40S.0014.GB 162 03 5/5
Wrtsil Italia SpA Bagnoli della Rosandra, 334 Telephone : +39 040 319 5000
Service 34018 San Dorligo Della Valle (TS) ITALY Fax : +39 040 319 5647
qb`ekf`^i
_riibqfk
6.2 Tool up-grading
If the fuel pump is equipped with the conical seal pump cover, the adjusting device 9455.02 can
only be used if the following tool parts are added:
Additional flange and gasket ............................................................................................................... 9455.09
Measuring pin (174 mm instead of 143 mm)........................................................................... 9455.05.004
6.3 Spare part kits
Up-grading set of parts are presented in the Spare Part Notice P-ZAS-01, paragraphs 3.1 and 3.2.
7 Distribution
Wrtsil Italy Service Wrtsil Service Network Owners of engines concerned
8 Liability
NO LIABILITY WHETHER DIRECT, INDIRECT, SPECIAL INCIDENTAL OR CONSEQUENTIAL, IS
ASSUMED WITH RESPECT TO THE INFORMATION CONTAINED HEREIN. THIS PUBLICATION IS
CONFIDENTIAL AND INTENDED FOR INFORMATION PURPOSES ONLY.
9 Validity
This general instruction is valid until further notice.