Service Bulletin

ZAS35
09.06.99
1. Introduction 1
2. The Reason for a Plunger 1
with Variable Damping
3. Measurements prior to fitting 2
Variable Damping Plungers
4. Retrofit and Readjustment of the 2
Fuel Pump with Variable Damping
Plunger
5. Checklist for Subsequent 3
Re-adjustments
6. Engines with ABB DEGO II 4
Governor
7. Engines with Woodward 721 5
Digital Speed Control Governor
8. Service Bulletins Published for 5
ZA 40S Engines
2
8
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6
5
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7
1
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4
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Technical Information to all Owners / Operators
of Sulzer ZA 40S Engines
Contents: Page
Wrtsil NSD Switzerland Ltd PO Box 414 Tel. +41 52 262 49 22
Wrtsil NSD Schweiz AG CH-8401 Winterthur Fax +41 52 212 49 17
Wrtsil NSD Suisse SA Switzerland Tlx 896 659 NSDL CH
Variable Damping Plunger
Load indicator pos.
Delivery
stroke
(mm)
1 / 6 Service Bulletin ZAS-35
1. INTRODUCTION
This Service Bulletin informs you about the operational advantages of the variable damping plunger
as well as its fitting instructions, fuel injection pump adjustments and the required re-settings to be
carried out on the engine and various control systems.
This Service Bulletin should be kept in a separate file in the control room. The respective pages or
tables of the Service Bulletin with modifications to the Operating Manual, Maintenance Manual
or Code Book should be copied and filed in the respective Manual or Book.
2. THE REASON FOR A PLUNGER WITH VARIABLE DAMPING
The nominal lifetime of a fuel injection plunger and barrel can in some cases be negatively influenced
by increased wear depending on the engine operating conditions and load profile, as well as the
condition and adjustment of the fuel system.
We have received reports of the appearance of cavitation and erosion in one or more of the following
areas:
D cavitation / erosion in the spill bores of the fuel pump cylinder with possible subsequent fatigue
cracking of the cylinder and possibly also fuel pump cover
D cavitation damage at the upper end of the high pressure fuel pipe with possible subsequent fatigue
crack
Based on this knowledge and in order to improve the situation, the variable damping plunger was
developed as shown in enclosure ZAS-35/1 and, after long-term field testing, introduced as the
currently valid standard for new engines with a cylinder output of 660 kW or higher.
If damage as described above occurs to an appreciable extent, even though the adjustment of the fuel
system (pressure, temperature, circulating quantity, fuel preparation, etc.) is in accordance with the
recommendations given in the corresponding Service Bulletin, then it is recommendable in such
cases to retrofit the engines with fuel pump elements having the variable damping plunger. The
variable damping plunger prevents cavitation and erosion damage and increases the lifetime of the
fuel injection components. It is only available for engines with cylinder output of 660 kW or higher in
the CIT-version (Constant Injection Timing).
2.1. Effects of the Variable Damping Plunger on Engine Operation
D Engine parameters such as maximum cylinder pressure, specific fuel consumption, charge air
pressure and exhaust gas temperatures will remain practically the same after fitting variable
damping plungers. However, the characteristic of the engine load indicator will be different.
D No adjustment is necessary to fuel or valve cams.
D If the engine speed shows a tendency to oscillate under idling conditions this can be sufficiently
reduced by correcting the governor dynamic settings.
D The control edge of the variable damping plunger has a different gradient to that of the previous
standard plunger. Re-adjustment of the fuel injection pumps is therefore necessary, together with
all settings of the engine and speed governor which depend on the load indicator (LI) position.
Please refer to the fuel pump adjustment graph and load indicator comparison graph on
enclosures ZAS-35/2 and ZAS-35/3 respectively.
2 / 6 Service Bulletin ZAS35
3. MEASUREMENTS PRIOR TO FITTING VARIABLE DAMPING PLUNGERS
Wherever possible the following engine performance data should be recorded with the currently
fitted plungers at Service Load:
D load indicator position
D maximum cylinder pressures
D charge air pressure
D turbocharger speed (s)
D exhaust gas temperatures after cylinders / before and after turbine(s)
This performance data will be used as a reference for later comparison with variable damping
plungers fitted.
All load indicator dependent settings as mentioned in section 5 should also be known.
4. RETROFIT AND RE-ADJUSTMENT OF THE FUEL PUMP
WITH VARIABLE DAMPING PLUNGER
Due to the difference in gradient of the plunger control edge, the effective delivery stroke of the
variable damping plunger should be set to 15.88 mm with a load indicator position of 8.65 compared
to a stroke of 14.73 mm for the previous plunger, see enclosure ZAS-35/2. The new values together
with the change to variable damping plungers must be recorded in the engine setting table(s).
Re-adjustment is basically carried out with the same device (included in the set of tools) as for the
previously used CIT (constant injection timing) plunger.
Adjustment of the pumps must be carried out with accurate pressure gauges and a working air
pressure of at least 7 bar.
Note:
Mixing of old and new plunger types is strictly forbidden. Only complete engines are to be
retrofitted with the variable damping plungers and never just individual cylinders.
Multi-engine installations: Engines connected to the same gearbox should be retrofitted at the same
time whenever possible. If two engines operate with different plungers, then balanced load sharing is
difficult to achieve as the Load Indicator Position of the two engines will not be identical. In
exceptional cases, e.g. for a short time during the retrofit, the load sharing has to be adapted. A service
engineer from Wrtsil NSD could be consulted for this work.
Engines fitted with VIT (variable injection timing): As already mentioned there is no retrofit
available.
3 / 6 Service Bulletin ZAS-35
5. CHECKLIST FOR SUBSEQUENT RE-ADJUSTMENTS
Generally speaking, all functions and limits that depend on engine Load Indicator position have to be
considered for re-adjustment after fitting variable damping plungers.
Based on the following list, you have to check the functions and limits applicable for your particular
installation.
For the actual re-adjustments you should use the load indicator comparison graph as shown in
enclosure ZAS-35/3.
Basis: All fuel pumps re-adjusted as specified in Section 4.
Function and Limits Actually
Installed
Yes/No
Original Setting Re-setting for
Variable
Damping Plunger
1 Mechanical Limits at the engine
2 Starting fuel limiter mechanical
3 Maximum load limit mechanical
4
5 Mechanical Speed Governor
6 Charge air pressure fuel limiter (smoke
limiter)
1)
7 Speed setting fuel limiter (torque limiter)
1)
8 Speed droop
2)
9 Load (Pitch) control
1)
10 Load indicating switches
11
12 Electric Speed Governor
13 Start fuel limit
14 Clutch fuel limit
15 Charge air pressure fuel limiter (smoke
limiter)
1)
16 Speed dependent fuel limiter (torque
limiter)
1)
17 Maximum fuel limit
18 Slave limit at clutching (min. level load up
ramp of 2
nd
engine connected to a com
mon gear box)
19 Minimum unload level (min. level load
down ramp unloading one engine only
while parallel working to a common gear
box)
20 Break point load up / down ramp
21 Speed droop
2)
4 / 6 Service Bulletin ZAS35
Function Actually
Installed
Yes/ No
Original Setting Re-Setting for
Variable
Damping Plunger
22 Actuator feed back signal
1) 3)
23
24 Electric Actuator
25 Maximum actuator pos. limit switch
26
27 Control System EC 40 or similar in other
Control systems
Denis 21 (Load Indicator Limit Switches)
28 Overload indication EC 40
29 Overload used external EC 40 (e.g. Pitch
reduction)
30 Engine running without fuel (dragging) if
failure of Woodward actuator (direct
acting) in parallel operation
31 Charge air by-pass flap control
32 Charge air preheating at low load
33
34 CP Propeller Load Control
35 Load Indicator feed back signal
1) 4)
36 Load curve
1) 4)
37 Charge air pressure load limit
1)
38
39 Monitoring and Alarm System
40 Overload alarm
41
42 Control System
43 Feed forward functions by Load Indicator
pos. e.g. HTCW temperature control
44
45 Any other Load Indicator dependent
Function
46
Foot notes: 1) Curve characteristic
2) Will be smaller without resetting
3) To be determined from case to case if actuator feed back signal and/or
governor internal fuel values need to be adjusted.
4) For unchanged service condition relating to allowable load versus engine
speed, the load indicator feed back signal and/or the whole load curve need
re-adjustment.
5 / 6 Service Bulletin ZAS-35
Note:
The above list is not conclusive.
The above re-settings are of importance to avoid overloading of the engine as the Load Indicator
Position with new Variable Damping Plungers will be lower at the upper load range.
Following the above re-adjustments, performance data at service load as under section 3 should be
taken again for comparison, especially in regard of turbocharger speed, charge air pressure firing
pressures etc. to verify the above re-adjustments to be correct. In case of larger deviations e.g. mean
firing pressure larger than 3 bar, respective corrections have to be made.
6. ENGINES WITH ABB DEGO II GOVERNOR
The actual (original) engine Voltage / Load Indicator Characteristic as shown as an example in
enclosure ZAS-35/4 has to be established first. This characteristic is expected to be similar for
engines in a system (smaller deviations are possible).
The respective ABB test protocol and manuals may assist you in your work.
The established Voltage / Load Indicator Characteristic in combination with the Load Indicator
Comparison Curve ZAS-35/3 now form the base for the re-adjustment of the load indicator
dependent adjustment values measurable at the governor test points.
Example: New Smoke Limit at 0 charge air pressure (SFL) :
from ZAS-35/4: SFL was 5.25 VLoad indicator Pos. 4.0 (example only)
from ZAS-35/3: Previous Load indicator Pos. 4.0 new Load Indicator Pos. 4.5
from ZAS-35/4 New Load Indicator Pos. 4.5 new SFL 5.9 V (example only)
7. ENGINE WITH WOODWARD 721 DIGITAL SPEED CONTROL
The actual (original) Actuator Output Load Indicator Characteristic as shown as an example in
enclosure ZAS-35/5, has to be established first for each engine and actuator.
The respective Woodward Setting Protocol and manuals may assist you in your work.
The established Actuator Output Load Indicator Characteristic in combination with the Load
Indicator Comparison Curve ZAS-35/3 now form the base for re-adjustment of the load indicator
dependent setting of the Woodward Governor DSC 721.
Example: New Charge Air Limiter at 0 bar charge air pressure (charge air at P1 [%]).
from ZAS-35/5: P1 was 38% Load Indicator Pos. 4.0 (example only)
from ZAS-35/3: Previous Load Indicator Pos. 4.0 new Load Indicator Pos. 4.5
from ZAS-35/5: New Load Indicator Pos. 4.5 new 42% (example only)
If questions arise, please contact Wrtsil NSD and / or the governor manufacturer or control system
supplier to avoid misunderstandings during adjustment of the engine or governor parameters.
Wrtsil Switzerland Ltd has issued this Service Bulletin with their best knowledge and ability.
However, Wrtsil Switzerland Ltd can not take any liability for any or all information contained
in this or any other Service Bulletin.
Changes of any nature to the form and or to the content of this or any other Service Bulletin as
published by Wrtsil Switzerland Ltd, are not permitted.
6 / 6 Service Bulletin ZAS35
8. SERVICE BULLETINS PUBLISHED FOR ZA 40S ENGINES
We have so far published the following Service Bulletins which are valid for ZA 40S type engines:
ZAS1.2 dated 02.02.96 Cylinder Liner Overhaul
ZAS2.1 dated 29.08.97 Overhaul of Cylinder Head
ZAS3 dated 10.06.93 Oil Scraper Rings
ZAS4.4 dated 26.02.99 Piston Rings
ZAS5 dated 03.12.93 Instruction for Testing of Fuel Injection Nozzles
ZAS6.1 dated 23.02.96 Piston Rotating Mechanism
ZAS7 dated 05.04.94 Adjustments and Maintenance Requirements on Oil Mist Detector
ZAS8.1 dated 16.05.97 Turnomat for Exhaust Valves and Rotocap for Inlet Valves
ZAS9 dated 01.06.94 Exhaust Pipe Expansion Bellows
ZAS10 dated 01.08.94 High Temperature Cooling Water System
ZAS11.1 dated 31.03.98 Cylinder Liner with a Thread
ZAS12 dated 01.03.95 New Spindle Design for Pressure Control Valve KS 87085
ZAS13.1 dated 18.12.98 Inlet Valves
ZAS14.1 dated 27.02.98 High Pressure Fuel Pipe
ZAS15.1 dated 30.01.98 Fuel Injection Nozzle Specification
ZAS16 dated 10.08.95 Flow Control Valve KS 72126 for Cylinder Lubrication
ZAS17.3 dated 18.05.99 VTR ..4 Turbochargers After Sales Service Information issued by ABB
ZAS18.1 dated 27.02.98 Tightening Instructions
ZAS19 dated 17.11.95 New Piston Ring Fitting Tool
ZAS20 dated 17.11.95 New Spring Cage KS 28042 for Rocker Gear
ZAS21 dated 22.03.96 Differences in the Drive for the Cylinder Lubrication between
Engines with 660 kW/Cyl. and 720 kW/Cyl.
ZAS22 dated 08.11.96 Adjustments of Fuel Oil Systems
ZAS23 dated 19.11.96 Modification to the Oil Mist Detector
ZAS24 dated 28.01.97 Alphabetical Index of Topics of Service Bulletins
ZAS25 dated 16.05,97 Tightening Instructions for the Connecting Rod Big End Bearing
ZAS26 dated 30.05.97 ABB Type VTR..4 Turbochargers
Cleaning of Turbine and Blower Side
ZAS27 dated 29.08.97 Lubricating Oil Treatment and Requirements
ZAS28 dated 29.08.97 Assessment of Main and Connecting Rod Bearings
ZAS29 dated 29.08.97 Undersized Bearings and Reconditioning of Crankshafts
ZAS30 dated 31.10.87 ABB Type VTR..4 Turbochargers Cooling Water Arrangement
ZAS31 dated 31.10.97 Flushing Instructions
ZAS32 dated 31.03.98 Fuel Pump
ZAS33 dated 31.03.98 Shim between Connecting Rod and Big End Bearing
ZAS34 dated 26.08.98 Hand Rails for Engine-mounted Platforms
ZAS35 dated 09.06.99 Variable Damping Plunger
Should you not be in possession of the above mentioned documentation suitable for your plant, kindly contact your local
Wrtsil NSD representative for your copy.
Enclosures: ZAS-35/1 Pump plunger with variable damping arrangement
ZAS-35/2 Adjustment of previous plunger and new variable damping plunger
ZAS-35/3 Load indicator comparison curve
ZAS-35/4 Voltage/Load Indicator Characteristic for ABB-Governor DEGO II
ZAS-35/5 Actuator Output / Load Indicator Characteristic for
Woodward - Governor DSC 721
Fuel Pump Plunger with Variable Damping Arrangement
Throttled passage
to first step release
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1
Damping Groove
D
D
D
D
D
D
Control edge
Variable Damping Plunger (277. 992)
0
0 8.65 Load indicator position
The delivery stroke adjustment 15.88 mm at 8.65
load indicator position is mandatory
Delivery
stroke
(mm)
15.88
Previous Plunger (188. 616)
Load indicator position 0
0
8.65
14.73
Adjustment of previous Plunger and new Variable Damping Plunger
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Delivery
stroke
(mm)
ReAdjustment
Engine LI with Variable Damping Plunger
277.992 *)
Equivalent LI - Value with Variable Damping Plunger
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The comparison curve is to be used
for re-adjusting of all LI-dependent
settings of the engine and systems
*) Check number stamped
on the concerned plunger
Engine LI with previous Plunger
CIT 188.616*)
Load Indicator Comparison Curve
between previous CIT Plunger
and Variable Damping Plunger
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This comparison curve represents
mean values.
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*) This information serves as an example
only. The actual (original) adjustement
curve has to be established for each
installation, but can be left as it is.
Voltage / Load Indicator Characteristic
for ABB - Governor DEGO II
Example only of an
engine - adjustment
curve*)
Actuator Position Value (T3)
Engine Load Indicator Position LI
Small offset from zero possible
Normally approx. 10V at 100% Load
1
0
0
%

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%

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Engine Load Indicator Position LI
Actuator Output / Load Indicator Characteristic
for Woodward- Governor DSC 721
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*) This information serves as an example only.
The actual (original) adjustment curve
has to be established for each engine and actuator
respectively, but can be left as it is.
Example only of an engine
adjustment curve *)
1
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%

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Woodward Actuator Output
(actually governor actuator control output signal)
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%

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)