Maintenance Manual ZAL40S Int Use

y
ZA40S
nl
Installation
ZAL40S
Engine type
se
Engine number
Fo
rI
nt
e
rn
a
lU
This manual is intended for the personal use of engine operators and
should always be at their disposal. The content of this manual shall neither
be copied nor communicated to a third person.
y
nl
O
se
lU
rn
a
Copyright 2004 by Wrtsil Corporation
nt
e
All rights reserved. No part of this publication may be reproduced or copied in any form or
by any means (electronic, mechanical, graphic, photocopying, recording, taping or other
information retrieval systems) without the prior written permission of the copyright owner.
Fo
rI
THIS PUBLICATION IS DESIGNED TO PROVIDE AN ACCURATE AND AUTHORITATIVE INFORMATION

WITH REGARD TO THE SUBJECT-MATTER COVERED AS WAS AVAILABLE AT THE TIME OF
PRINTING. HOWEVER, THE PUBLICATION DEALS WITH COMPLICATED TECHNICAL MATTERS
SUITED ONLY FOR SPECIALISTS IN THE AREA, AND THE DESIGN OF THE SUBJECT-PRODUCT IS
SUBJECT TO REGULAR IMPROVEMENTS, MODIFICATIONS AND CHANGES. CONSEQUENTLY, THE
PUBLISHER AND COPYRIGHT OWNER OF THIS PUBLICATION CAN NOT ACCEPT ANY
RESPONSIBILITY OR LIABILITY FOR ANY EVENTUAL ERRORS OR OMISSIONS IN THIS PUBLICATION
OR FOR DISCREPANCIES ARISING FROM THE FEATURES OF ANY ACTUAL ITEM IN THE
RESPECTIVE PRODUCT BEING DIFFERENT FROM THOSE SHOWN IN THIS PUBLICATION. THE
PUBLISHER AND COPYRIGHT HOLDER SHALL UNDER NO CIRCUMSTANCES BE HELD LIABLE FOR
ANY FINANCIAL CONSEQUENTIAL DAMAGES OR OTHER LOSS, OR ANY OTHER DAMAGE OR
INJURY, SUFFERED BY ANY PARTY MAKING USE OF THIS PUBLICATION OR THE INFORMATION
CONTAINED HEREIN.
Contact Informations
WRTSIL
Service Department
Wrtsil Italia S.p.A., Business Unit Service

Bagnoli della Rosandra, 334
34018 San Dorligo della Valle
Trieste --- ITALY
nl
24h Phone
Nights and weekends, please call mobile phone for service engineer or spare parts
se
+39 335 784 1217
SALES SUPPORT
lU
DIRECT DIAL NUMBERS
Fax: +39 040 319 5767
North, Central and East Europe
Wrtsil 64 engines
Phone: +39 040 319 5071

Americas
Wrtsil 38B engines
Phone: +39 040 319 5072
Phone: +39 040 319 5081
nt
e
rn
a
Fax: +39 040 319 5216
Phone: +39 040 319 5080
Middle East and South Asia
Wrtsil 26 engines
Phone: +39 040 319 5073
Phone: +39 040 319 5082
Southern Europe and Africa
Sulzer Z engines
Phone: +39 040 319 5074
Phone: +39 040 319 5083
Italy
GMT engines
Phone: +39 040 319 5075
Phone: +39 040 319 5084
rI
Fo
TECHNICAL SERVICE
The list of Wrtsil Network companies is available at www.wartsila.com web site.
Contact information
lU
se
nl
WRTSIL
Fo
rI
nt
e
rn
a
This page is intentionally left blank.
ii
0000--1/A1
Maintenance
=$6
)RU 3DUWLFXODU $WWHQWLRQ
7KLV PDQXDO LV SXW DW WKH GLVSRVDO RI WKH UHFLSLHQW VROHO\ IRU XVH LQ FRQQHFWLRQ ZLWK WKH FRUUHVSRQGLQJ W\SH RI 6XO]HU
GLHVHO HQJLQH
,W KDV DOZD\V WR EH WUHDWHG DV FRQILGHQWLDO
7KH LQWHOOHFWXDO SURSHUW\ UHJDUGLQJ DQ\ DQG DOO RI WKH FRQWHQWV RI WKLV PDQXDO SDUWLFXODUO\ WKH FRS\ULJKW UHPDLQV ZLWK
:UWVLO ,WDOLD 6S$ 7KLV GRFXPHQW DQG SDUWV WKHUHRI PXVW QRW EH UHSURGXFHG RU FRSLHG ZLWKRXW WKHLU ZULWWHQ SHUPLV
VLRQ DQG WKH FRQWHQWV WKHUHRI PXVW QRW EH LPSDUWHG WR D WKLUG SDUW\ QRU EH XVHG IRU DQ\ XQDXWKRUL]HG SXUSRVH
%HIRUH WKH RSHUDWRU LQWHQGV WR XVH WKH HQJLQH RU EHIRUH PDLQWHQDQFH ZRUN LV XQGHUWDNHQ WKH 2SHUDWLQJ ,QVWUXFWLRQV RU
WKH 0DLQWHQDQFH 0DQXDO UHVSHFWLYHO\ LV WR EH UHDG FDUHIXOO\
nl
7R HQVXUH WKH EHVW HIILFLHQF\ UHOLDELOLW\ DQG OLIHWLPH RI WKH HQJLQH DQG LWV FRPSRQHQWV RQO\ RULJLQDO VSDUH SDUWV VKRXOG EH
XVHG
,W LV WR EH HQVXUHG DV ZHOO WKDW DOO HTXLSPHQW DQG WRROV IRU PDLQWHQDQFH DUH LQ JRRG FRQGLWLRQ
7KH H[WHQW RI DQ\ VXSSOLHV DQG VHUYLFHV LV GHWHUPLQHG H[FOXVLYHO\ E\ WKH UHOHYDQW VXSSO\ FRQWUDFW
lU
se
7KH GDWD LQVWUXFWLRQV DQG JUDSKLFDO LOOXVWUDWLRQV HWF LQ WKLV PDQXDO DUH EDVHG RQ GUDZLQJV PDGH E\ :UWVLO ,WDOLD 6S$
DQG FRUUHVSRQG WR WKH DFWXDO VWDQGDUG DW WKH WLPH RI SULQWLQJ \HDU RI SULQWLQJ LV LQGLFDWHG RQ WLWOH SDJH
7KRVH VSHFLILFDWLRQV DQG UHFRPPHQGDWLRQV RI WKH FODVVLILFDWLRQ VRFLHWLHV ZKLFK DUH HVVHQWLDO IRU WKH GHVLJQ KDYH EHHQ
FRQVLGHUHG WKHUHLQ ,W PXVW EH UHFRJQL]HG WKDW VXFK GDWD LQVWUXFWLRQV DQG JUDSKLFDO LOOXVWUDWLRQV PD\ EH VXEMHFW WR
FKDQJHV GXH WR IXUWKHU GHYHORSPHQW ZLGHQHG H[SHULHQFH RU DQ\ RWKHU UHDVRQ
rn
a
7KLV PDQXDO LV SULPDULO\ LQWHQGHG IRU XVH E\ WKH HQJLQH RSHUDWLQJ DQG PDLQWHQDQFH SHUVRQQHO ,W LV DVVXPHG WKDW LW ZLOO
DOZD\V EH DW WKH GLVSRVDO RI VXFK SHUVRQQHO IRU WKH RSHUDWLRQ RI WKH HQJLQHV DQGRU IRU WKH UHTXLUHG PDLQWHQDQFH ZRUN
nt
e
7KLV PDQXDO KDV EHHQ SUHSDUHG RQ WKH DVVXPSWLRQ WKDW RSHUDWLRQ DQG PDLQWHQDQFH RI WKH HQJLQHV FRQFHUQHG ZLOO DOZD\V
EH FDUULHG RXW E\ SHUVRQQHO KDYLQJ WKH VSHFLDO NQRZOHGJH WUDLQLQJ DQG TXDOLILFDWLRQV QHHGHG WR KDQGOH LQ D ZRUNPDQ
OLNH PDQQHU GLHVHO HQJLQHV RI WKH FRUUHVSRQGLQJ VL]H WKH DVVRFLDWHG DX[LOLDU\ HTXLSPHQW DV ZHOO DV IXHO DQG RWKHU RSHU
DWLQJ PHGLD
rI
7KHUHIRUH JHQHUDOO\ DSSOLFDEOH UXOHV ZKLFK PD\ DOVR FRQFHUQ VXFK LWHPV DV SURWHFWLRQ DJDLQVW GDQJHU DUH VSHFLILHG LQ
WKLV PDQXDO LQ H[FHSWLRQDO FDVHV RQO\ ,W PXVW EH DVVXPHG WKDW WKH RSHUDWLQJ DQG PDLQWHQDQFH SHUVRQQHO DUH IDPLOLDU
ZLWK WKH UXOHV FRQFHUQHG
Fo
7KLV PDQXDO KDV EHHQ SUHSDUHG WR WKH EHVW NQRZOHGJH DQG DELOLW\ RI LWV DXWKRUV +RZHYHU QHLWKHU :UWVLO ,WDOLD 6S$
QRU WKHLU HPSOR\HHV DVVXPH DQ\ OLDELOLW\ XQGHU DQ\ OHJDO DVSHFW ZKDWVRHYHU LQ FRQQHFWLRQ ZLWK WKLV PDQXDO LWV
FRQWHQWV RU PRGLILFDWLRQV WR LW RU LQ FRQQHFWLRQ ZLWK LWV XVH LQFOXGLQJ SRVVLEOH QHJOLJHQFH
)XUWKHU FODLPV UHODWLQJ WR DQ\ GDPDJH ZKDWVRHYHU RU FODLPV RI RWKHU QDWXUH VXFK DV GHPDQGV IRU DGGLWLRQDO VSDUHV
VXSSOLHV VHUYLFH RU RWKHUV ZLOO QRW EH FRQVLGHUHG
:UWVLO ,WDOLD 6S$

%DJQROL GHOOD 5RVDQGUD
6DQ 'RUOLJR GHOOD 9DOOH
7ULHVWH ,WDO\
Wrtsil Italia S.p.A.
03.04
0001--1/A1
Maintenance
=$6
)RUHZRUG
7KH LQVWUXFWLRQV FRQWDLQHG LQ WKLV 0DLQWHQDQFH 0DQXDO DUH PHDQW WR FRQWULEXWH WRZDUGV FRUUHFWO\ KDQGOHG PDLQWH
QDQFH ZRUN WR EH FDUULHG RXW DW VSHFLILF LQWHUYDOV
,W KDV EHHQ DVVXPHG WKDW WKH VWDII SXW LQ FKDUJH RI VXFK ZRUN SRVVHVVHV WKH UHTXLUHG PHFKDQLFDO NQRZOHGJH DQG SUDFWLFH
,QGLFDWLRQV RQ WKH HQJLQH RSHUDWLRQ DV ZHOO DV WKH GHVFULSWLRQ RI WKH IXQFWLRQ RI VSHFLILF V\VWHPV DUH FRQWDLQHG LQ WKH
2SHUDWLQJ ,QVWUXFWLRQV ,Q WKLV PDQXDO \RX FDQ ILQG DOVR XQGHU JURXS DQG H[SODQDWLRQV WR WKH OD\RXW
DQG XVH RI WKH 2SHUDWLQJ ,QVWUXFWLRQV DV ZHOO DV RI WKH 0DLQWHQDQFH 0DQXDO
0RUH GHWDLOHG LQVWUXFWLRQV RQ WKH RSHUDWLRQ DQG PDLQWHQDQFH RI FRPSRQHQWV IURP VXEVXSSOLHUV FDQ EH JDWKHUHG IURP
WKH LQVWUXFWLRQ OHDIOHWV RI WKH UHVSHFWLYH PDQXIDFWXUHUV
2XWVLGH PDNHV DUH IRU H[DPSOH VXFK HQJLQH FRPSRQHQWV ZKLFK DUH QRW PDQXIDFWXUHG LQ DFFRUGDQFH ZLWK GUDZLQJV RI
:UWVLO ,WDOLD 6S$
7KH 0DLQWHQDQFH 0DQXDO LV VXEGLYLGHG LQWR WKH IROORZLQJ PDLQ GLYLVLRQV
nl
*HQHUDO JXLGHOLQHV IRU PDLQWHQDQFH

0DLQWHQDQFH VFKHGXOH
&OHDUDQFH DQG ZHDU WDEOHV WLJKWHQLQJ YDOXHV RI VFUHZHG FRQQHFWLRQV PDVVHV ZHLJKWV VHDO ULQJV
'HVLJQ JURXSV
se
7RROV OLVW

&RPPHQWV RQ WKHVH GLYLVLRQV
lU
7KH
*HQHUDO *XLGHOLQHV IRU 0DLQWHQDQFH
FRQWDLQ LQ DGGLWLRQ WR UHFRPPHQGDWLRQV RQ SUHFDXWLRQV WR EH WDNHQ DOVR
KLQWV RQ WKH ZRUN WR EH FDUULHG RXW
rn
a
,Q WKH
0DLQWHQDQFH 6FKHGXOH
JXLGLQJ YDOXHV DUH JLYHQ RQ LQWHUYDOV LQ ZKLFK VSHFLILHG PDLQWHQDQFH ZRUN RU VHUYLFLQJ
VKRXOG EH FDUULHG RXW
7KH
7DEOHV
LQIRUP DERXW QRUPDO DQG PD[LPXP SHUPLVVLEOH FOHDUDQFHV DQG RQ WKH WLJKWHQLQJ YDOXHV RI LPSRUWDQW
VFUHZHG FRQQHFWLRQV ZHLJKWV RI LQGLYLGXDO HQJLQH FRPSRQHQWV DV ZHOO DV WKH W\SH DQG XVH RI YDULRXV VHDOLQJ ULQJV
rI
nt
e
7KH
1RUPDO &OHDUDQFHV
OLVWHG LQ WKH FOHDUDQFH DQG ZHDU WDEOH JURXS FRUUHVSRQG WR GHVLJQ DQG PDQXIDFWXULQJ
YDOXHV RU WR WKH VHWWLQJV RQ WKH QHZ HQJLQH
7KH ODLG GRZQ PD[LPXP FOHDUDQFHV RU PD[PLQ GLPHQVLRQV DUH VXFK YDOXHV DV PD\ EH UHDFKHG DIWHU D OHQJWK\ RSHUDWLQJ
SHULRG ZKLFK KRZHYHU PD\ QRW EH DOORZHG WR EH H[FHHGHG RU IDOO EHORZ 2Q FRPSRQHQWV ZKHUH WKH FOHDUDQFH LV DGMXVW
DEOH E\ PRGLI\LQJ WKH WKLFNQHVV RI VKLPV GLVFV VSDFHUV HWF WKH YDOXH JLYHQ DV
1RUPDO &OHDUDQFH
VKRXOG DOZD\V EH DU
ULYHG DW RU VWULYHQ WR DWWDLQ :KHUH WKLV LV QRW SRVVLEOH ZRUQ SDUWV PXVW EH UHSODFHG E\ VWDQGDUG QHZ RQHV RU UHFRQGL
WLRQHG E\ VXLWDEOH PDWHULDO EXLOGXS
Fo
,I GXULQJ DQ RYHUKDXO FOHDUDQFHV DUH PHDVXUHG ZKLFK KDYH DOPRVW UHDFKHG WKH SHUPLVVLEOH OLPLW LW PXVW EH OHIW WR LQGL
YLGXDO MXGJHPHQW WR GHFLGH ZKHWKHU D FRPSRQHQW SDUW VKRXOG EH UHSODFHG RU UHPDLQ ILWWHG WLOO WKH QH[W RYHUKDXO 7KLV
GHSHQGV IRU H[DPSOH RQ WKH GXUDWLRQ RI WKH QH[W RSHUDWLRQ SHULRG WLOO WKH QH[W RYHUKDXO DQG ZKDW ZHDU KDV WR EH H[SHFWHG
EDVHG RQ H[SHULHQFH PDGH
'HWDLOHG LQVWUXFWLRQV DUH JLYHQ LQ WKH
'HVLJQ *URXSV
RQ WKH SURFHGXUH RI PDLQWHQDQFH ZRUN RQ FHUWDLQ HQJLQH SDUWV
7KH
7RROV /LVW
LV D FRPSLODWLRQ RI WRROV DQG GHYLFHV UHTXLUHG IRU WKH PDLQWHQDQFH ZRUN DQG ZKLFK DUH DV D UXOH VXSSOLHG
DORQJ ZLWK WKH HQJLQH
,QGLFDWLRQV LQ WKH WH[W DQG LOOXVWUDWLRQV LQ WKLV PDQXDO FRUUHVSRQG WR WKH VWDWXV DW WKH WLPH RI SULQWLQJ 0RGLILFDWLRQV DUH
WDNHQ LQWR FRQVLGHUDWLRQ LQ UHSULQWV
03.04
00021/A1
Maintenance
ZA40S
Table of Contents
Table of Contents
Group 0
For Particular Attention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0000-1/A1
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001-1/A1
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002-1/A1
General Guidelines for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003-1/A1
Safety Precautions During Maintenance Work
General Guidelines for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003-2/A1
Criteria for the Replacement of Bearing Shells
Numbering of Bearings and Cylinders, as well as Definition of Engine Sides . . . . . . . . . . . . . . . . . . . . . . . 0022-1/A1
Inspection / Service Intervals and Service Life of Engine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0030-0/A1
nl
Maintenance Schedule (for Engines Operating on Heavy Fuel Oil) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0030-1/A1

Inspection and Overhaul Intervals (Guidelines)
Engine Cross Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0030-1/A1

Masses (Weights) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0051-1/A1
Individual Components per Piece in kg
se
Dimensions and Material Specifications of ORings and Round Rubber Rings . . . . . . . . . . . . . . . . . . . . . 0328-1/A1
lU
Dimensions and Material Specifications of Piston and Rod Seal Rings

and Applicable ORings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0328-2/A1
Clearance and Wear Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0352-1/A1
rn
a

Crankshaft Main Bearing and Crankshaft Thrust Bearing
Cylinder Liner, Valve Rocker Arms
nt
e

Inlet and Exhaust Valve Guide, Crankpin Bearing
Rotating Piston
rI

Piston Rings and Oil Scraper Rings
Fo

Camshaft Bearing, Camshaft Thrust Bearing, Camshaft Drive,
Tooth Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NonReversible Engine
Camshaft Bearing, Camshaft Drive, Tooth Backlash . . . . . . . . . . . Reversible Engine
Starting Air Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with Control Disc
Starting Air Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NonReversible Engine
Reversing Servomotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reversible Engine
Valve Drive
Governor Drive
Mechanical Overspeed Trip and Safety CutOut Device
Wrtsil Switzerland Ltd
3.00
00021/A1
Maintenance
ZA40S
Table of Contents
Fuel Injection Pump
Lubricating Oil and Fuel Oil Booster Pump . . . . . . . . . . . . . . . . . . with EngineDriven Pumps
Cylinder Cooling Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with EngineDriven Pumps
Raw Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with EngineDriven Pumps
Fuel Nozzle Cooling Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . with EngineDriven Pumps
Tightening Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0355-1/A1

Tightening Values of Important Screwed Connections
nl
Taking Lubricating Oil Samples for Laboratory Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0356-1/A1
Group 1
Engine Housing (Frame) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001-1/A1

Replacement of Cylinder Head Studs
se
Crankshaft Main Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1201-1/A1

Loosening and PreTensioning of the Transverse Tie Rods and Main Bearing Studs
lU
Crankshaft Main Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1201-2/A1

Replacement of Crankshaft Main Bearing Shells (Standard Shell Bearing)
rn
a
Crankshaft Thrust Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1202-1/A1

Replacement of Bearing Shells and Thrust Ring Halves
Group 2
nt
e
Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2105-1/A1

Measuring Wear and Remachining of Cylinder Liner Bore
Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2105-2/A1
Removing and Fitting a Cylinder Liner
rI
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2701-1/A1

Removing and Fitting a Cylinder Head
Fo
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2701-2/A1

Replacing Valve Seats
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2701-3/A1
Grinding the Valve Seats of Inlet and Exhaust Valves
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2701-4/A1
Replacing the Insert Bush for the Fuel Injection Valve and Lapping the Seating Surfaces
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2701-5/A1
Replacing the Valve Guides for the Inlet and Exhaust Valves
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2701-6/A1
Pressure Test of Water Spaces
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2701-7/A1
Reconditioning a Relief Valve
Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2705-1/A1
Replacing the Rocker Arms of Inlet and Exhaust Valves
High Pressure Fuel Pipe and Fuel Delivery Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2716-1/A1
Removal, Reconditioning and Fitting
3.00
00021/A1
Maintenance
ZA40S
Table of Contents
Inlet and Exhaust Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2720-1/A1
Replacing Valve Springs as well as Removing and Fitting of Valves
Inlet and Exhaust Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2720-2/A1
Regrinding the Seats
Fuel Injection Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2722-1/A1
Removing, Dismantling and Assembling
Checking the Condition of Spraying and the Spraying Pressure
Cleaning and Reconditioning
nl
Starting Valve in the Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2728-1/A1

Removing from the Cylinder Head, Dismantling, Lappingin, Assembling and Fitting
Group 3
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3101-1/A1
Measuring Crank Deflections
se
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3101-2/A1
Loosening and Tightening the Coupling Bolts
lU
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3101-3/A1
Fitting the Counterweights
Torsional Vibration Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3130-1/A1
Taking a Silicon Fluid Sample
rn
a
Turning Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3212-1/A1

Maintenance
Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3302-1/A1
Inspection and Replacement of Crankpin Bearing Shells
nt
e
Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3302-2/A1

Loosening and PreTensioning the Studs of the Lower Connecting Rod Head
Rotating Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3401-1/A1
Removal and Fitting a Piston
rI
Rotating Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3401-2/A1

Dismantling and Assembling
Group 4
Fo
Piston Rings and Oil Scraper Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3402-1/A1

Removing and Fitting
Camshaft Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4101-1/A1

Checking Gear Tooth Backlash, Bearing Clearances and Adjusting Camshaft Driving Wheels
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4201-1/A1
Checking the Cams, Removing and Fitting the Camshaft
Cams on Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4211-1/A1
Replacing Original Cams by TwoPart Cams . . . . . . . . . . . . . . . . . . NonReversible Engine
Starting Air Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4301-1/A1
Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NonReversible Engine
Starting Air Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4301-1/A2
Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with Control Disc
ShutOff Valve for Starting Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4304-1/A1
3.00
00021/A1
Maintenance
ZA40S
Table of Contents
Inlet and Exhaust Valve Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4401-1/A1
Adjusting the Valve Clearance
Inlet and Exhaust Valve Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4401-2/A1
Reversing Servomotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4500-1/A1
Dismantling, Checking and Assembling . . . . . . . . . . . . . . . . . . . . . Reversible Engine
Regulating Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4501-1/A1
Removal and Fitting of the Spring Linkage Rod Springs
CutOut Servomotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4612-1/A1
Group 5
nl
Speed Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5101-1/A1

Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WOODWARD EGB58P
Speed Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5101-1/A2

Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WOODWARD PGA58
se
Speed Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5101-1/A3

Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WOODWARD PGGEG58
Governor Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5105-1/A1
lU
Mechanical Overspeed Trip and Safety CutOut Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5303-1/A1

Removing and Fitting the Spring
rn
a
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5501-1/A1

Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5501-2/A1
Adjusting and Checking
nt
e
Group 6
Charge Air Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6601-1/A1

Removal, Cleaning and Mounting
rI
Flap for Charge Air Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6730-1/A1

Fo
WasteGate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6735-1/A1
Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Variant 'A'
WasteGate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6735-1/A2
Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Variant 'B'
Group 7
Lubricating Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7101-1/A1
Dismantling and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with EngineDriven Pumps
Fuel Booster Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7102-1/A1
Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with EngineDriven Pumps
Cylinder Cooling and Raw Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7103-1/A1
Fuel Valve Cooling Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7105-1/A1
SCAMATIC Fine Filter for Cylinder Lubricating Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7203-1/A1
Function Check and Maintenance
Cylinder Lubricating Oil Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7220-1/A1
Flushing out the Housing
3.00
0002--1/A1
Maintenance
=$6
Table of Contents
*URXS
([KDXVW :DVWH*DWH $
6WDUWLQJ $LU 3LSHV $
Overhauling the Flame Traps and Relief Valves
*URXS
7RROV $
Explanation
+\GUDXOLF 3UH7HQVLRQLQJ -DFNV $
Storage, Care, Spares Stock and Sealing Rings
Fo
rI
nt
e
rn
a
lU
se
nl
7RROV $
Tools List
5 `
07.03
00031/A1
Maintenance
ZA40S
General Guidelines for Maintenance

Safety Precautions During Maintenance Work
The maintenance work which is required to be carried out on the engine at regular intervals is described in the Mainte
nance Schedule group 0030-1 of this manual and is to be understood as a general guide. The maintenance intervals are
dependent on the mode of operation, on the power as well as on the quality of the fuel used.
Experience will show whether the intervals may be extended or need to be shortened. The below mentioned recommen
dations regarding safety measures and maintenance work must be obeyed, they are not final.
4. General safety precautions

- It is the operator's duty to assure that all personnel is familiar with all safety, health as well as environment protection
rules released for operating and maintaining a diesel engine plant. In particular greatest attention has to be given to
the functionality, handling and dangers of cranes and lifting devices.
- The safety officer has to assure that all precautions have been taken in order to avoid dangerous situations.
nl
- The operator has to nominate a person responsible for assigning work tasks to every person who is participating on
maintenance work.
se
- Assure that fluids or gases draining or escaping during maintenance work cannot cause accidents, fires or explosions.
Keep the engine and the surroundings clean. Cleanliness increases the quality of the work and helps to prevent acci
dents. Before beginning with maintenance work the corresponding systems which are influenced by the maintenance
work must be relieved of pressure and/or drained if necessary. Keep a record of these activities such that it is visible to
everybody.
lU
- Certain media, i.e. fuels etc., are highly inflammable, therefore all precautionary measures have to be taken that they
do not get in contact with fires, glowing or hot parts. Smoking in the engine room is strictly forbidden.
Special attention has to be paid to the rules of fire fighting. Make absolutely sure that in case of fire alarm no fire
extinguishing gases can be released into the engine room while people are in it.
Emergency escapes are to be marked and personnel is to be instructed of what to do in case of fire.
rn
a
- Oils and other media can cause slippery surfaces. In order to avoid injury all surfaces which can be stepped on must be
kept clean and dry.
nt
e
5. Precautionary measures before beginning of maintenance work

Before starting any maintenance work on the engine (particularly on the running gear), take the following precautionary
measures:
- Installations with automatic controls: Set automatic control switch to OFF position.
rI
- Close stop valves of starting air receivers and vent the pipework to the engine.
Fo
- To prevent unintentional starting, as well as in reversible engines unintentional shifting of the camshaft, please refer
additionally to the instructions of the respective engine control.
- Open all indicator valves on the cylinder heads and leave them in this position until all maintenance work is com
pleted.
- Engage turning gear (gear pinion must be meshed) and lock the lever.
- If the engine had to be stopped due to overheating in the running gear or bearings, do not open the crankcase doors
immediately; wait at least 20 minutes.
6. Special safety measures

- Prior to turning the crankshaft with the turning gear, make sure that no person is inside the engine and no loose parts,
tools or devices can get jammed.
- At all times when somebody is inside the engine casing another person must stand by in order that he can give the
necessary aid if something unexpected happens to the person inside the engine. The person who is inside the engine
casing must be equipped with all safety gears which are required to prevent suffocation within the limited space and
atmospheric conditions.
2.97
00031/A1
Maintenance
ZA40S
- For maintenance work on the engine use the tools and devices intended for the particular job, which, as a rule, are
supplied with the engine (please refer to the tools list group 9400-3).
- Tools and devices should be made ready prior to use, make sure they are in perfect condition.
- Check hydraulic tools periodically for tightness and perfect functioning.
- The allowed load capacity of the engine room crane, the lifting tools, ropes and chains must be sufficient for the parts
to be lifted (see group 0051-1) pay attention to the weight distribution and attachment of the lifting tackle in order
that the part which must be lifted cannot tip over or crash down.
- Sharp edges, mating faces etc. as well as ropes are to be protected by wooden pieces, leather or special edge guards
which are placed between the part and the rope or chain.
- For your own safety keep away from under hanging loads never undersling hanging parts with your fingers or hands
and never embrace lifting ropes with your hands.
For further notes regarding safety precautions and warnings (general remarks) see also operating
instructions group 0200-1.
7. Recommendations for performing work

- Carry out all work carefully, observing utmost cleanliness.
se
Note
nl
- Removed parts must be secured in the engine room.
lU
- Protect running faces and sealing faces of removed parts by suitable means to prevent damages.
- Close all openings which form when certain parts are removed e.g. pipes, oil holes any opening etc. to prevent dirt
from entering the engine. (This includes also the pipes which are removed).
rn
a
- Check all repaired, overhauled or replaced parts for perfect functioning before starting the engine.
- Check all pipes, which have been removed, for tightness after they are refitted.
nt
e
- Clearances of moving parts must be checked periodically. Should the maximum permissible values (see Clearance
and Wear Table group 0352-1) have been reached or have even been exceeded, these parts must be replaced.
- Arrange to replace all parts taken from spares stock. When ordering new parts refer to Code Book, mention code
numbers and description.
rI
- When tightening studs, nuts or screws, take the utmost care not to damage their thread. They must be screwed in by
hand until metal to metal contact is achieved. Always use the prescribed lubricants on the threads (see group
0355-1).
Fo
- Adhere to tightening values wherever they are indicated. Use the specified lubricant on the threads (please refer to
the Tightening Instructions 0355-1).
- Fit locking devices correctly and carefully. Use locking plates and locking wires only once.
- Use Orings only once. The new Orings should comply with the requirements of group 0328-1.
- Where the reference 'D' (sealing compound) indicates that a sealing compound should be used in place of a gasket,
(for example on end casings, claddings, casings) use a product which does not harden and has good resistance to wa
ter, oil and fuel. Examples are indicated below.
2.97
00031/A1
Maintenance
ZA40S
- Before you apply the sealing compound, clean the sealing faces with a suitable solvent to remove grease and oil (for
example Trichlorethylene).
The engine manufacturer uses the following sealing compounds:
Hylomar SQ 32 M (blue)
Manufacturer:
Golden Hermetite
Manufacturer:
Hermetite Products Ltd.
Tavistock Road
West Drayton, Middlesex
England
Marston Lubricant LTD.

Rock Ferry Oil Works
Birkenhead, England
- Where the reference indicates 'fit with LOCTITE' without specifying any type, use one of the mentioned LOCTITE
threadlocking products.
LOCTITENo. 59 (violet) or LOCTITENo. 222 (violet)
nl
- For threads of screws and studs which are getting very hot, (for example exhaust pipe or turbocharger fastenings)
apply a high temperature resistant lubricant before assembly, to prevent a heat seizure.
Where the remark 'use high temperature resistant lubricant' appears, the manufacturers use one of the following
products:
Ultra Therm
Manufacturer:
Walter Zepf
Schmierungstechnik
an der Linde 12
D-78462 Konstanz a/B.
se
Thread Gard
Manufacturer:
Fo
rI
nt
e
rn
a
lU
Crane Packing Ltd.

Slough, Bucks
England
3 z
2.97
00032/A1
Maintenance
ZA40S
General Guidelines for Maintenance

Criteria for the Replacement of Bearing Shells
For the crankshaft main bearings as well as for the connecting rod bottom end bearings, bearing shells of the following
production types are used:
- Aluminium bearings with running layer No. 212.*)
- "Rillenlager" grooved bearings with running layer No. 336
For easy identification of the bearing shell type, their front faces are correspondingly marked (see Fig. 'A'). The last three
digits of the marking indicate the running layer of the bearing shell.
95.7183
nt
e
rn
a
lU
se
nl
rI
Depending on operating conditions, the running layer of a bearing is subjected to more or less wear.
Bearings are therefore considered as wear parts, and depending on operating conditions must be replaced sooner or
later. In order to ensure a trouble free operation and a long life of the bearings, the following points must be observed:
Fo
- Optimum lubrication of the bearings, prior to starting and while operating the engine.
- Optimum treatment of the lubricating oil by centrifuging.
- Perfectly working oil filters.
- Through cleaning of the crankcase after overhaul work, and adequately long flushing through of the oil piping system.
- Plugging the oil drillings in the crankshaft during overhaul work on the connecting rod bottom end bearing.
Remark
*) Crankshaft main bearings as well as connecting rod bottom end bearings with a running layer
No. 212 should be used for engines with a nominal output of more than 660 kW per cylinder.
1995
00032/A1
Maintenance
ZA40S
Criteria for the replacement of bearing shells

The following indications should facilitate a decision whether a bearing shell has to be replaced or can be fitted again for
further use. It is of paramount importance that in case of a refitting of used shells, they are installed in the same place i.e.
in the same bearing saddle or connecting rod as well as shaft journal, whereby the bearing shell should clamp lightly in
the saddle bore when assembling.
Before assembling a bearing shell its expanded dimension L1 and L2 (Fig. 'B') are to be measured. If a smaller dimension
is established than the values mentioned in Fig. 'B', the bearing shell is to be exchanged.
a) Aluminium bearing No. 212
A bearing shell with the above running layer No. may be refitted provided:
nl
1. The wear lies within the tolerance (see Fig. 'B').
2. The running surface and contact surface are good.
se
3. Only individual scratches or isolated beddedin dirt traces are observed in the running surface.
lU
A bearing shell with the above running layer No. must be replaced if:
1. The wear in the bearing centre lies outside the tolerance (see Fig. 'B').
2. The running surface is rough or damaged.
nt
e
rn
a
3. The running surface contains several grooves and several dirt indentations.
Main bearing shells
Bottom end bearing shells
15mm
Fo
15mm
rI
L1
95.7184
L2
Wear limit:
d0 d1 = max. 0.07 mm
Expanded dimension: L1 = min. 370 mm
d2 d3 = max. 0.10 mm
L2
= min. 365 mm
Additional criteria: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shell has to clamp

in bottom end bore.
8.96 / L-Mot.
00032/A1
Maintenance
ZA40S
b) "Rillenlager" grooved bearing No. 336

The bearing surfaces of a new grooved bearing shell correspond with the values given in Fig. 'C'. However, these values
are only meant as a general guide. The groove shape and dimensions may differ from one supplier to another.
C
20 33%
Aluminium web
80 67%
Overlay
33%
67%
95.7185
rn
a
lU
se
nl
Nickel barrier layer
nt
e
The following criteria are applicable for the replacement of grooved shells
Fo
rI
- A bearing shell must be replaced when, on the max. loaded area of the running surface, the Alweb has increased by
75% (see Fig. 'D'). This does not apply to running surface sections which show some wear caused during runningin by
small directional faults.
Aluminium
175%
Overlay
100%
95.7186
1995
00032/A1
Maintenance
ZA40S
- Should the overlay be worn from its grooves on more than 30% of the complete running surface, then a new bearing
shell must be fitted (Fig. 'E').
Aluminium
Missing overlay
95.7187
se
nl
or
lU
- Should, in a surface without overlay, 10% of the Alwebs be worn such that their width has increased by more than
75%, then a new bearing shell must be fitted.
- Should the Alwebs on either or both sides of the bearing be fully worn on a width of over 8 mm, then the bearing shell
must be replaced.
If cavitation traces are noticed ink the bearing shells of the connecting rod bottom end bearing as
depicted in Fig. 'F' then such bearing shells may again be fitted for reuse; provided however that the
bearing shells show none of the above mentioned wear limits.
Upper shell
Lower shell
Fo
rI
nt
e
Remark
rn
a
- Should the overlay be worn out of its grooves on either or both sides by more than 15% of the full running width, then
the bearing shell must be replaced.
95.7188
1995
4 z
00221/A1
Maintenance
ZA40S
Numbering of Bearings and Cylinders, as well as Definition of Engine Sides
Turbocharger
Bearing Number
Crankshaft Main Bearing

FUEL PUMP SIDE
2
7
FREE END
DRIVING END
Cylinder Number
Turbocharger
se
Camshaft Driving Wheel
nl
EXHAUST SIDE
Thrust Bearing
rn
a
DRIVING END
nt
e
FREE END
Inlet valve
FUEL PUMP SIDE
lU
Exhaust valve
FUEL PUMP SIDE
Inlet valve
EXHAUST SIDE
Fo
rI
Exhaust valve
EXHAUST SIDE
DIRECTION OF ROTATION VIEWED FROM DRIVING END
Camshaft
Crankshaft
95.7364
CLOCKWISE ROTATION
ANTI-CLOCKWISE ROTATION
1 z
L-Mot. / 1995
00300/A1
Maintenance
ZA40S
Inspection / Service Intervals and Service Life of Engine Components
Expected inspection and service lifetimes

As already mentioned in group 0003-1, the recommended intervals in the maintenance schedule, group 0030-1 serve
only as general g u i d a n c e.
The actually applicable intervals or lifetimes depend on the following points:
- Quality of fuel and lubricating oils (group 0356-1 of the Operating Instructions)
- Environmental and operating conditions
- Fuel and lubricating oil care
- Maintenance work
- Use of genuine spare parts
nl
- Engine load factor
se
Expected service life of engine components operating on heavy fuel oil
The actual service intervals are to be determined according to the actual operating conditions.
Operating hours
8'000
Inlet valve and valve seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24'000 - 36'000
lU
Fuel nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust valve and valve seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24'000 - 36'000 *)
rn
a
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48'000 - 60'000
12'000
Oil scraper rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12'000
Piston ring groove (rechroming) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36'000 - 48'000
nt
e
Piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48'000 - 60'000
Top end (spherical) bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48'000 - 60'000
Bottom end bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24'000 - 36'000
rI
Rotating mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24'000 - 36'000
Fuel pump plunger and guide bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24'000 - 36'000
Cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48'000 - 60'000
Fo
Main bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remark
*) Depending on actual fuel and lube oil operating conditions.
1 z
1995
0030--1/A1
Maintenance
=$6
0DLQWHQDQFH 6FKHGXOH IRU (QJLQHV 2SHUDWLQJ RQ +HDY\ )XHO 2LO

,QVSHFWLRQ DQG 2YHUKDXO ,QWHUYDOV *XLGHOLQHV
&RPSRQHQW
:RUN WR EH FDUULHG RXW
*URXS
,QWHUYDOV
*URXS
/RZ DQG KLJK WHPSHUD

WXUH ZDWHU FLUFXLW DV ZHOO
DV LQMHFWRU QR]]OH FRROLQJ
V\VWHP

&KHFN ZDWHU OHYHO

&KHFN SUHVVXUH WHPSHUDWXUH IORZ UDWH DQG
GHYLDWLRQ RI WHPSHUDWXUH
'HWHUPLQH FRROLQJ ZDWHU TXDOLW\ DV ZHOO DV
FRQFHQWUDWLRQ RI LQKLELWRU DQG 3+YDOXH
IROORZ LQVWUXFWLRQV RI LQKLELWRU PDQXIDFWXU
HUV
GDLO\
GDLO\
&OHDQ FRROLQJ V\VWHP
DV UHTXLUHG
&KHFN RLO OHYHO DQG ZKHQ QHFHVVDU\ WRS XS

GDLO\
&KHFN WKH SURSHU IXQFWLRQ RI OXEH RLO VHSDUD

WRUV DQG RI OXEH RLO ILOWHU
GDLO\
7DNH RLO VDPSOH IRU ODERUDWRU\ DQDO\VLV
&KHFN FRQWDPLQDWLRQ DQG RLO OHYHO ZKHQ QHF

HVVDU\ WRS XS
Fo
6WDUWLQJ DLU V\VWHP
&RQWURO DLU V\VWHP
se
lU
2LO FKDQJH
rI
)XHO RLO V\VWHP
&OHDQ FRROLQJ V\VWHP
nt
e
/XEULFDWLQJ RLO IRU VSHHG

JRYHUQRU DQG WXUERFKDU
JHU
GDLO\
rn
a
(QJLQH OXEULFDWLQJ RLO

nl
6HDZDWHU FRROLQJ V\VWHP

RQO\ LI SURYLGHG ZLWK
TXDUWHUO\

DV UHTXLUHG
GDLO\

RS KRXUV
RSHUDWLQJ KRXUV
GDLO\
DFFRUGLQJ WR LQVWUXF
WLRQV RI PDQXIDFWX
UHU

UHJXODWLRQ RI YLVFRVLW\
GDLO\
&KHFN WKH SURSHU IXQFWLRQ RI IXHO RLO VHSDUD

WRUV DQG RI IXHO RLO ILOWHU
GDLO\
7DNH IXHO RLO VDPSOH IRU ODERUDWRU\ DQDO\VLV

LPSRUWDQW IRU WKH VHOHFWLRQ RI WKH FRUUHFW
HQJLQH OXEULFDWLQJ RLO
DW HYHU\ EXQNHULQJ
RU DV UHTXLUHG
'UDLQ DLU UHFHLYHUV

RU FKHFN ZDWHU VHSDUDWRU
GDLO\
&KHFN DLU FRPSUHVVRU
ZHHNO\
&KHFN SUHVVXUH
GDLO\
&KHFN DLU GULHU DQG ILOWHU
ZHHNO\
1995
0030--1/A1
Maintenance
&RPSRQHQW
=$6
*URXS
,QWHUYDOV
&KHFN VDIHW\ V\VWHP DQG LWV SURSHU IXQFWLRQ
PRQWKO\
0RQLWRULQJ V\VWHP
&KHFN SURSHU IXQFWLRQ RI DOO WUDQVPLWWHUV DQG

WKHLU VHWWLQJ YDOXHV
KDOI \HDUO\
(QJLQH FRQWURO DQG

UHPRWH FRQWURO
&KHFN DOO IXQFWLRQV

DFFRUGLQJ WR 2SHUDWLQJ ,QVWUXFWLRQV
KDOI \HDUO\
(QJLQH GDWD
&RPSDUH DOO HQJLQH GDWD ZLWK WKH RIILFLDO

VKRS WULDO GRFXPHQWV
PRQWKO\
)RXQGDWLRQ EROWV
&KHFN WLJKWQHVV UHWLJKWHQ EROWV LI QHFHVVDU\
(QJLQH KRXVLQJ
5HSODFH F\OLQGHU KHDG VWXGV

DV UHTXLUHG
&UDQNVKDIW PDLQ EHDU

LQJ
&KHFN FRQGLWLRQ RI EHDULQJ VKHOOV UDQGRP LQ

VSHFWLRQ :LWKLQ D SHULRG RI WR \HDUV DOO
EHDULQJ VKHOOV VKRXOG KDYH EHHQ LQVSHFWHG DW
OHDVW RQFH

RS KRXUV
DFFRUGLQJ WR FODVVLIL
FDWLRQ VRFLHW\
&UDQNVKDIW WKUXVW EHDU

LQJ
&KHFN FRQGLWLRQ RI WKH EHDULQJ VKHOOV DQG WKH

WKUXVW ULQJ KDOYHV

RS KRXUV
DFF WR FODVV VRFLHW\
&KHFN D[LDO FOHDUDQFH
se
lU
rn
a
'UDLQ RII ZDWHU ZKHUH QR SHUPDQHQW ZDWHU

GUDLQDJH LV LQVWDOOHG
GDLO\
&KHFN SHUPDQHQW ZDWHU GUDLQDJH
GDLO\
rI

RSHUDWLQJ KRXUV
nt
e
&KDUJH DLU VSDFH
\HDUO\
*URXS
nl
6DIHW\ V\VWHP
Fo
&UDQNFDVH
&KHFN DOO VFUHZHG IDVWHQLQJV DQG ORFNLQJ GH

YLFHV
DV UHTXLUHG
9LVXDO LQVSHFWLRQ LQFO DOO VFUHZHG IDVWHQLQJV

RQ QHZ RU UHFHQWO\ RYHUKDXOHG HQJLQHV ILUVW
WLPH DIWHU DERXW UXQQLQJ KRXUV
KDOI \HDUO\
0HDVXUH ZHDU DQG JULQG RII ZHDU ULGJH

RS KRXUV
&KHFN FRROLQJ ZDWHU VSDFH E\ UHPRYLQJ RQH

F\OLQGHU OLQHU

RS KRXUV
&KHFN FRQGLWLRQ RI UXQQLQJ VXUIDFH

RS KRXUV
5HSODFH 2ULQJV

RS KRXUV
RU DV UHTXLUHG
5HSODFH DQWLSROLVKLQJ ULQJ $35

RQO\ IRU HQJLQHV ZLWK $35

RS KRXUV
*URXS
&\OLQGHU OLQHU
06.02
0030--1/A1
Maintenance
=$6
&RPSRQHQW
,QWHUYDOV
5HPRYDO
w
RS KRXUV
5HJULQG YDOYH VHDWV

RS KRXUV
2YHUKDXO UHOLHI YDOYH DGMXVW EORZRII SUHVVXUH
DV UHTXLUHG
0HDVXUH YDOYH JXLGHV

RS KRXUV
)LW QHZ 2ULQJV IRU YDOYH JXLGHV

RS KRXUV
5HSODFH 2ULQJV IRU H[KDXVW YDOYH VHDWV
3RVVLEO\ UHSODFH LQOHW DQG H[KDXVW YDOYH VHDWV DV

ZHOO DV YDOYH JXLGHV
&KHFN FRQGLWLRQ RI YDOYH URWDWLQJ PHFKDQLVP
5RFNHU DUP
&KHFN EHDULQJ EXVKHV DQG SLQV GHWHUPLQH

FOHDUDQFHV
+LJK SUHVVXUH IXHO SLSHV
&KHFN LI QHFHVVDU\ RYHUKDXO
)XHO GHOLYHU\ YDOYHV
&KHFN LI QHFHVVDU\ RYHUKDXO
,QOHW YDOYHV
2YHUKDXO LI QHFHVVDU\ UHJULQG VHDW VXUIDFHV E\

PDFKLQLQJ
)XHO LQMHFWLRQ YDOYH
nl
se
lU
rn
a
RU DV UHTXLUHG
DV UHTXLUHG

RS KRXUV

RS KRXUV

RS KRXUV

RS KRXUV

RS KRXUV

RS KRXUV
&KHFN YDOYHV VSLQGOH
2YHUKDXO LI QHFHVVDU\ UHJULQG VHDW VXUIDFHV E\

PDFKLQLQJ
&KHFN YDOYHV VSLQGOH
&KHFN VSUD\ SDWWHUQ RSHQLQJ SUHVVXUH DQG w

RS KRXUV
FKHFN DJDLQVW OHDNDJH
DV UHTXLUHG
2YHUKDXO LQMHFWLRQ QR]]OHV RU QR]]OH KROGHU LI
QHFHVVDU\

6WDUWLQJ DLU YDOYHV

RS KRXUV
rI
Fo
([KDXVW YDOYHV
nt
e
&\OLQGHU KHDG
*URXS
2YHUKDXO

RS KRXUV
HY
RSHUDWLQJ
KRXUV GHSHQGLQJ RQ
RSHUDWLQJ FRQGLWLRQ

RS KRXUV

RS KRXUV
1995
0030--1/A1
Maintenance
&RPSRQHQW
=$6
*URXS
,QWHUYDOV
*URXS

&KHFN FUDQN GHIOHFWLRQV

KDOI \HDUO\
&RXQWHUZHLJKWV RQ
FUDQNVKDIW

9LVXDO LQVSHFWLRQ RI VFUHZHG IDVWHQLQJV

&KHFN ZDLVWHG VWXGV ZLWK K\GU MDFNV IRU FRU
UHFW SUHWHQVLRQLQJ DQG LI QHFHVVDU\ UHWLJKWHQ
QXWV

\HDUO\
DV UHTXLUHG
7RUVLRQDO YLEUDWLRQ
GDPSHU
)OXLG GDPSHU
7DNH VLOLFRQ IOXLG VDPSOH DQG KDYH LW WHVWHG
EDVHG RQ WKH UHVXOWV RI WKH ILUVW VDPSOH WKH
LQWHUYDO IRU WDNLQJ IXUWKHU VDPSOHV ZLOO EH GH
FLGHG
6SULQJ GDPSHU
,QVSHFWLRQ

&KHFN RLO OHYHO

3HUIRUP RLO FKDQJH
&UDQNSLQ EHDULQJ
&KHFN FRQGLWLRQ RI EHDULQJ VKHOO UDQGRP LQ

VSHFWLRQ
:LWKLQ D SHULRG RI WR \HDUV DOO EHDULQJ
VKHOOV VKRXOG KDYH EHHQ LQVSHFWHG DW OHDVW
RQFH
5RWDWLQJ SLVWRQ
ILUVW WLPH DIWHU

RS KRXUV
nl
se
7XUQLQJ JHDU
lU
&UDQNVKDIW

RS KRXUV
EHIRUH HDFK VWDUW

RS KRXUV

RS KRXUV
5HPRYH DOO SLVWRQV DQG RYHUKDXO 0HDVXUH SLV

WRQ ULQJ JURRYHV 5HFRUG FRQGLWLRQ RI SLVWRQ
FURZQ SLVWRQ ULQJV SLVWRQ ULQJ JURRYHV DQG
SLVWRQ VNLUW
'LVPDQWOH SLVWRQ LQVSHFW FRROLQJ VSDFHV DQG
WRS HQG EHDULQJ

RS KRXUV
5HPRYH DQG UHSODFH E\ QHZ ULQJV

DW HDFK SLVWRQ RYHU

KDXO
&DPVKDIW GULYH
,QVSHFW FRQGLWLRQ RI JHDU WHHWK DQG PHDVXUH

WRRWK EDFNODVK

\HDUO\
&DPVKDIW
,QVSHFW FRQGLWLRQ RI FDPV

RS KRXUV
RU RQFH D \HDU RU
ZKHQHYHU RSSRUWXQH

5DQGRP LQVSHFWLRQ RI VRPH FDPVKDIW EHDULQJV

&KHFN D[LDO FOHDUDQFH

RS KRXUV
rI
nt
e
rn
a

Fo
3LVWRQ ULQJV DQG

RLO VFUDSHU ULQJV
*URXS
1995

RS KRXUV
\HDUO\
0030--1/A1
Maintenance
=$6
&RPSRQHQW
*URXS
,QWHUYDOV
6WDUWLQJ DLU GLVWULEXWRU
2YHUKDXO

RS KRXUV
6WDUWLQJ DLU VKXWRII

YDOYH
2YHUKDXO

RS KRXUV
3QHXPDWLF YDOYHV RQ WKH

HQJLQH
2YHUKDXO
,QOHW DQG H[KDXVW YDOYH

DFWXDWLQJ JHDU
$GMXVW YDOYH FOHDUDQFHV

IRU QHZ RU MXVW RYHUKDXOHG HQJLQHV ILUVW DI
WHU DERXW RSHUDWLQJ KRXUV
'LVPDQWOH DW UDQGRP D IHZ DFWXDWLQJ JHDU
KRXVLQJV DQG FKHFN LQGLYLGXDO FRPSRQHQWV
2YHUKDXO
)XHO LQMHFWLRQ SXPS UHJ

XODWLQJ OLQNDJH

&XWRXW VHUYRPRWRU
Fo
)XHO LQMHFWLRQ SXPS
y
nl
&KHFN IUHHGRP RI PRYHPHQW

2YHUKDXO HODVWLF URG

PRQWKO\
DV UHTXLUHG
2YHUKDXO

RS KRXUV
3HUIRUP RLO FKDQJH

IROORZ PDNHU
V LQVWUXFWLRQV
lU
rn
a
nt
e
w KDOI \HDUO\

&KHFN JHDU ZKHHOV

2YHUKDXO

\HDUO\

RS KRXUV

&KHFN IXQFWLRQ
2YHUKDXO

PRQWKO\

RS KRXUV
2YHUKDXO

RS KRXUV
DV UHTXLUHG
$GMXVW VHWWLQJ RQ HQJLQH

RS KRXUV RU
DV UHTXLUHG
rI
0HFKDQLFDO RYHUVSHHG
WULS DQG VDIHW\ FXWRXW
GHYLFH

RS KRXUV

RS KRXUV
*URXS
*RYHUQRU GULYH

RS KRXUV

se
5HYHUVLQJ VHUYRPRWRU
RQO\ IRU UHYHUVLEOH HQ
JLQHV
6SHHG JRYHUQRU

RS KRXUV

RS KRXUV
ZLWK SRRU DLU TXDOLW\
1995
0030--1/A1
Maintenance
&RPSRQHQW
=$6
*URXS
,QWHUYDOV
*URXS
([KDXVW JDV WXUERFKDU
JHU
&OHDQLQJ LQ VHUYLFH

GDLO\
ZHHNO\ RQH WR WKUHH
WLPHV
WR EH FDUULHG RXW HY
HU\ RQH WR WKUHH
GD\V
D EORZHU ZHW FOHDQLQJ

E WXUELQH ZHW FOHDQLQJ
F WXUELQH GU\ FOHDQLQJ

ZHHNO\ RQH WR WKUHH

WLPHV
GDLO\
ZKHQ a3 H[FHHGV
OLPLW YDOXH VWDWHG LQ
JURXS RI WKH
2S ,QVWUXFWLRQV
se

&OHDQLQJ LQ RSHUDWLRQ DW VHUYLFH ORDG

DSSOLHV WR HQJLQH ZLWK EXLOWRQ ZDVKLQJ V\
VWHP
9HQW ZKHUH QR SHUPDQHQW DLU YHQW LV LQVWDOOHG
5HPRYH DQG FOHDQ
nl
IROORZ LQVWUXF
WLRQV RI WXUER
FKDUJHU PDNHU
3HUIRUP RLO FKDQJH

2YHUKDXO
lU
&KDUJH DLU FRROHU

&KHFN ILOWHU
&OHDQ
IROORZLQJ LQVWUXFWLRQV RI ILOWHU PDQXIDFWXUHU
)ODS WR FKDUJH DLU E\

SDVV

)XQFWLRQDO FKHFN
2YHUKDXO

KDOI \HDUO\
DV UHTXLUHG
&KDUJH DLU ZDVWHJDWH

)XQFWLRQDO FKHFN YDULDQW

$

)XQFWLRQDO FKHFN YDULDQW
%

OXEULFDWH PRYDEOH SDUWV
2YHUKDXO

KDOI \HDUO\
PRQWKO\
&KHFN FRQGLWLRQ RI JHDU WHHWK RQ GULYLQJ JHDU

ZKHHO
2YHUKDXO SXPS


ZKHHO
2YHUKDXO SXPS


ZKHHO
2YHUKDXO SXPS

KDOI \HDUO\
ZKHQ a3 H[FHHGV
OLPLW YDOXH VWDWHG LQ
JURXS RI WKH
2S ,QVWUXFWLRQV
*URXS

Fo
rI
nt
e
rn
a
$LU ILOWHU RQ WXUERFKDU

JHU
/XEULFDWLQJ RLO SXPS

)XHO ERRVWHU SXPS

&\OLQGHU FRROLQJ ZD

WHU DQG UDZ ZDWHU
SXPS

DV UHTXLUHG
\HDUO\

RSHUDWLQJ KRXUV

\HDUO\

RSHUDWLQJ KRXUV

\HDUO\

RSHUDWLQJ KRXUV
&RPSRQHQW

0030--1/A1
Maintenance
=$6
)XHO YDOYH FRROLQJ ZD

WHU SXPS

*URXS

ZKHHO
2YHUKDXO SXPS

,QWHUYDOV

\HDUO\

RSHUDWLQJ KRXUV
5HPDUN

&KHFN IXQFWLRQ
D 2Q LQVWDOODWLRQV ZLWK FRQWLQXRXV IORZ
WKURXJK WKH ILOWHU
E 2Q LQVWDOODWLRQV ZKHUH RLO IORZV WKURXJK
WKH ILOWHU RQO\ ZKHQ VHSDUDWRU IDLOV
'LVPDQWOH DQG RYHUKDXO
&\OLQGHU OXEULFDWLQJ RLO

SXPS GULYH
'LVPDQWOH DQG RYHUKDXO
&\OLQGHU OXEULFDWLQJ RLO

SXPS
5LQVH FDVLQJ

Fo
*URXS
se
lU
IROORZ PDQXIDFWXU
HU
V LQVWUXFWLRQV
KDOI \HDUO\
)XQFWLRQ FKHFN
2YHUKDXO

KDOI \HDUO\
DV UHTXLUHG
2YHUKDXO IODPH WUDSV DQG VDIHW\ YDOYHV

RSHUDWLQJ KRXUV
nt
e
2LO PLVW GHWHFWRU

&KHFN LQGLFDWRU ODPS 6<67(0 21

&KHFN IXQFWLRQ
&OHDQ DQG RYHUKDXO
7RROV
3URWHFW K\GUDXOLF SUHWHQVLRQLQJ MDFNV IURP

FRUURVLRQ DQG GLUW
&KHFN SURSHU IXQFWLRQ DQG LWV FRPSOHWHQHVV
KDOI \HDUO\
\HDUO\
rI
6WDUWLQJ DLU SLSHV
ZHHNO\

*URXS
([KDXVW ZDVWHJDWH

rn
a
6&$0$7,& ILQH ILOWHU

IRU F\OLQGHU OXEULFDWLQJ
RLO
)RU QHZ HQJLQHV

LQLWLDOO\ DIWHU
DERXW RSHU
DWLQJ KRXUV
$SSOLHV RQO\ WR
HQJLQHVGULYHQ SXPSV
nl
GDLO\
PRQWKO\
IROORZ PDQXIDFWXU
HU
V LQVWUXFWLRQV

DIWHU HDFK XVH RU

EHIRUH VWRULQJ
\HDUO\
1995
0030--1/A1
Maintenance
nl
=$6
se
2705--1
lU
2720--1,--2
8600--1
1001--1
nt
e
3401--1,--2
4401--2
3402--1
3302--1
3302--2
Fo
3101--1,--2
4201--1
4211--1
rI
3302--2
2728--1
2722--1w3
2701--1w7
6601--1
5501--1, --2
2105--1, --2
rn
a
2716--1
4401--1
1201--2
1201--1
3101--3
95.7331
1995 / V-Mot.
00511/A1
Maintenance
ZA40S
Masses (Weights)
Individual Components per Piece in kg
1611
kg
Engine housing . . . . . . . . . . . . . . . . . 6 Cylinder with bearing covers and studs . . . . . . . . . . . . . . . . 20'970

Main bearing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Oil sump . . . . . . . . . . . . . . . . . . . . . . . 6 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1'180
Crankshaft thrust bearing . . . . . . . . . . . . . . . . . . . . one half, without shell and oil catcher . . . . . . . . . . . . 90
Casing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . to the camshaft space . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Cladding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . on free end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611
Cladding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . on free end (with enginedriven pumps) . . . . . . . . 1'030
Front plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . on driving end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 738
Front plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . on driving end, turbocharger at the free end . . . . . . 827
1001
1001
1001
1001
1008
1008
1008
1202
1607
1609
Description
nl
Design
Group
Cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493

Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . incl. valves (complete) . . . . . . . . . . . . . . . . . . . . . . . . 900
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . without valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 830
Fuel injection valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Starting valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Rocker gear housing . . . . . . . . . . . . . . . . . . . . . . . . incl. rocker arms, without cover . . . . . . . . . . . . . . . . 125
3101
3101
3101
3101
3130
3206
3301
3302
3401
Crankshaft . . . . . . . . . . . . . . . . . . . . . 6 Cylinder incl. counterweights approx. . . . . . . . . . . . . . . . . . . 8'300

Crankshaft . . . . . . . . . . . . . . . . . . . . . 8 Cylinder incl. counterweights approx. . . . . . . . . . . . . . . . . . 10'660
Crankshaft . . . . . . . . . . . . . . . . . . . . . 9 Cylinder incl. counterweights approx. . . . . . . . . . . . . . . . . . 11'840
Counterweight to crankshaft . . . . . . . . . . . . . . . . . depending on execution approx. . . . . . . . . . . . . . . . . 203
Vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . depending on execution up to . . . . . . . . . . . . . . . . . 2'000
Turning gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
Connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Bottom end bearing . . . . . . . . . . . . . . . . . . . . . . . . complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Rotating piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . complete (without connecting rod) . . . . . . . . . . . . . 310
4101
4201
4201
4201
4211
4301
4301
4301
4304
4401
4501
4503
4807
Camshaft drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . intermediate gear wheels . . . . . . . . . . . . . . . . . . . . . 385

Camshaft . . . . . . . . . . . . . . . . . . . . . . 6 Cylinder complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1'350
Fuel cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Starting air distributor . . . . . . . 6 + 8 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Starting air distributor . . . . . . . . . . . 9 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Starting air distributor . . . . . . . . . . . . . . . . . . . . . . (for reversible engines) . . . . . . . . . . . . . . . . . . . . . . . . 51
Starting air shutoff valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Starting air shutoff valve . . . . . 6 + 8 Cylinder with slow turning device . . . . . . . . . . . . . . . . . . . . . . . 65
Starting air shutoff valve . . . . . . . . . 9 Cylinder with slow turning device . . . . . . . . . . . . . . . . . . . . . . . 62
Valve actuating gear . . . . . . . . . . . . . . . . . . . . . . . . without push rod and casing . . . . . . . . . . . . . . . . . . . . 37
Reversing servomotor . . . . . . . . . . . . . . . . . . . . . . . (for reversible engines) . . . . . . . . . . . . . . . . . . . . . . . 380
Reversing valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . (for reversible engines) . . . . . . . . . . . . . . . . . . . . . . . . 50
Operating unit for local control stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
5103
5105
5303
5501
Speed governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Governor drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Overspeed safeguard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Fuel injection pump . . . . . . . . . . . . . . . . . . . . . . . . complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Fo
rI
nt
e
rn
a
lU
se
2105
2701
2703
2722
2728
2760
L-Mot. / 1995
00511/A1
Maintenance
ZA40S
Exhaust gas turbocharger . . . . . . . . . 6 Cylinder

Exhaust gas turbocharger . . . . . 8 + 9 Cylinder
Charge air cooler . . . . . . . . . . . . . . . . 6 Cylinder
Charge air cooler . . . . . . . . . . . . . 8+9 Cylinder
Air inlet casing . . . . . . . . . . . . . . . . . . 6 Cylinder
Air inlet casing . . . . . . . . . . . . . . 8 + 9 Cylinder
Air branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7201
Cylinder lubricator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8101
8145
8145
8145
Exhaust pipe section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Casing for exhaust pipes . . . . . . . . . . . . . . 6 Cyl. complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452
7103
7403
Lubricating oil pump . . . . . . . . . . . . . . . . . . . . . . . (with enginedriven pumps) . . . . . . . . . . . . . . . . . . . 330

Fuel booster pump . . . . . . . . . . . . . . . . . . . . . . . . . (with enginedriven pumps) . . . . . . . . . . . . . . . . . . . . 95
7505
Cooling water pump . . . . . . . . . . . . . . . . . . . . . . . . (with enginedriven pumps) . . . . . . . . . . . . . . . . . . . 142

(high temperature circuit)
Cooling water pump . . . . . . . . . . . . . . . . . . . . . . . . (with enginedriven pumps) . . . . . . . . . . . . . . . . . . . 184
(low temperature circuit)
Nozzle cooling water pump . . . . . . . . . . . . . . . . . . (with enginedriven pumps) . . . . . . . . . . . . . . . . . . . . 55
7507
nl
se
7506
VTR 354 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1'900

VTR 454 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3'250
with casing and water separator . . . . . . . . . . . . . . . 1'534
with casing and water separator . . . . . . . . . . . . . . . 1'850
with diffusor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
with diffusor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
connection engine housing / cylinder head . . . . . . . . 40
6502
6502
6601
6601
6601
6601
6701
lU
Complete engine . . . . . . . . . . . . . . . . 6 Cylinder without water, oil, gangway, . . . . . . . . . . . . . . . . . 59'000

flywheel, enginedriven pumps, reversing
device, EC40parts
rn
a

device, EC40parts
Fo
rI
nt
e

device, EC40parts
1995 / L-Mot.
2
0328--1/A1
Maintenance
ZA40S
Inner Diameter
in mm
Thickness
in mm
Group in
Code Book
Dimensions and Material Specifications of O-Rings and Round Rubber Rings
Component where the O-ring

or the rubber ring is installed
Material
NBR = Nitrile
FPM = Viton
MVQ = Silicone
Round rubber joints

1008---1 Oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 cylinder 7
*11400 NBR 50 Sh
Oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 cylinder 7
*14200 NBR 50 Sh
Oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 cylinder 7
*15600 NBR 50 Sh
nl
L
Rubber rings and O-rings
78.74
NBR 70 Sh
5.33
66.04
NBR 70 Sh
se
Horizontal tie rod for main bearing . . . . . . . . . . . . . . . . . . . . . .
5.33
1001---1 Horizontal tie rod for main bearing . . . . . . . . . . . . . . . . . . . . . .
6.99
443.36
FPM 75 Sh
Cylinder liner (above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.99
532.26
FPM 75 Sh
2701---1 Nut for cylinder head stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.33
78.74
NBR 70 Sh
Oil passage (engine housing / cylinder head) . . . . . . . . . . . . . . .
3.53
32.92
NBR 70 Sh
Oil passage (cylinder head / rocker arm housing) . . . . . . . . . . .
3.53
18.64
NBR 70 Sh
Bush for fuel injection valve . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.33
81.92
FPM 70 Sh
Valve guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.53
28.17
FPM 70 Sh
2716---1 High pressure fuel pipe and fuel delivery valve . . . . . . . . . . . . .
3.53
63.09
FPM 70 Sh
2722---1 Fuel injection valve / nozzle holder . . . . . . . . . . . . . . . . . . . . . . .
5.33
81.92
FPM 75 Sh
Fuel injection valve / nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.33
66.04
FPM 75 Sh
2728---1 Starting valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.33
100.97
FPM 70 Sh
Starting valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.53
18.64
NBR 70 Sh
2754---1 Valve seat for exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.53
120.24
FPM 70 Sh
Valve seat for exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.53
120.24
FPM 70 Sh
2760---1 Plug for auxiliary rocker arm . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.33
40.64
NBR 70 Sh
Plug for main rocker arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.33
78.74
NBR 70 Sh
3101---1 Intermediate piece for shaft extension . . . . . . . . . . . . . . . . . . . .
5.33
40.64
NBR 70 Sh
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.53
20.22
FPM 70 Sh
Screwed connection flywheel / vibration damper (GEISLINGER) 6.99
608.08
MVQ 50 Sh
Screwed connection flywheel / vibration damper (GEISLINGER) 6.99
380.37
MVQ 50 Sh
Fo
rI
nt
e
rn
a
lU
2103---1 Cylinder liner (below) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
L-Mot. / 12.04
Maintenance
Component where the Oring

Inner Diameter
in mm
ZA40S
Thickness
in mm
Group in
Code Book
03281/A1
Material
NBR = Nitrile
FPM = Viton
MVQ = Silicone
342.27
FPM 70 Sh
Piston crown . . . . . . . . . (P = 720 kW/cylinder) . . . . . . . . . . . . 6.99
342.27
FPM 70 Sh
Upper piston half . . . . . (P = 720 kW/cylinder) . . . . . . . . . . . . 6.99
227.97
FPM 70 Sh
4101-1 Journal pin for camshaft drive . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.99
148.59
NBR 70 Sh
4301-1 Slide valve / flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.33
40.64
Starting air distributor / guide flange . . . . . . . . . . . . . . . . . . . . . . 5.33
88.27
NBR 70 Sh
NBR 70 Sh
28.17
FPM 75 Sh
Precontrol valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
10
Rubber No. 750
Throttle nonreturn valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.53
28.17
FPM 70 Sh
4401-1 Housing for valve drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.99
148.59
NBR 70 Sh
Casing for push rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.33
100.97
NBR 70 Sh
4503-1 Reversing valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.33
40.64
NBR 70 Sh
4509-1 Fuel locking slide valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.53
32.92
NBR 70 Sh
Fuel locking slide valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.53
18.64
NBR 70 Sh
4604-1 3/2 way valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.53
28.17
FPM 75 Sh
Control valve to shutdown servomotor . . . . . . . . . . . . . . . . . . . . 5.33
53.34
NBR 70 Sh
Control valve to shutdown servomotor . . . . . . . . . . . . . . . . . . . . 5.33
40.64
NBR 70 Sh
Control valve to shutdown servomotor . . . . . . . . . . . . . . . . . . . . 2
10
Rubber No. 750
1.78
3.68
NBR 70 Sh
Pressure sensor for control / sealing flange for connecting block 1.78
6.07
NBR 70 Sh
4612-1 Shutdown servomotor / cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.53
34.52
NBR 70 Sh
Shutdown servomotor / cylinder . . . . . . . . . . . . . . . . . . . . . . . . . 5.33
53.34
NBR 70 Sh
Shutdown servomotor / flange . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.33
40.64
NBR 70 Sh
Shutdown servomotor / cylinder . . . . . . . . . . . . . . . . . . . . . . . . . 3.53
24.99
NBR 70 Sh
Shutdown servomotor / guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.33
66.04
NBR 70 Sh
Shutdown servomotor / housing . . . . . . . . . . . . . . . . . . . . . . . . . 5.33
46.99
NBR 70 Sh
Shutdown servomotor / flange . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.99
126.37
NBR 70 Sh
Fo
rI
nt
e
rn
a
lU
se
4304-1 Throttle nonreturn valve for shutoff valve . . . . . . . . . . . . . . . . 3.53
NBR 70 Sh
nl
177.17
Starting air distributor / housing . . . . . . . . . . . . . . . . . . . . . . . . . . 6.99
3401-1 Piston crown . . . . . . . . . (P = 660 kW/cylinder) . . . . . . . . . . . . 6.99
4608-1 Pressure sensor for control / needle valve in connecting block
1995 / L-Mot.
Inner Diameter
in mm
Thickness
in mm
Group in
Code Book
03281/A1
Maintenance
ZA40S

NBR = Nitrile
FPM = Viton
MVQ = Silicone
NBR 70 Sh
Local control stand / valve connection . . . . . . . . . . . . . . . . . . . . . 2
10
Rubber No. 750
4807-2 Local control stand / valve connection . . . . . . . . . . . . . . . . . . . . . 2
10
Rubber No. 750
5303-1 Intermediate wheel shaft to overspeed safety cut out . . . . . . . . 3.53
37.69
NBR 70 Sh
5501-1 Fuel injection pump / housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
158.12
MVQ 50 Sh
Fuel injection pump / cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.33
91.44
FPM 75 Sh
Fuel injection pump / cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.33
66.04
FPM 75 Sh
4.42
nl
4807-1 Local control stand / valve connection . . . . . . . . . . . . . . . . . . . . . 2.62
Material
10
Rubber No. 750
7005-1 Pump attachment / lubricating oil pump . . . . . . . . . . . . . . . . . . . 6.99
393.07
NBR 70 Sh
Pump attachment / fuel transfer pump . . . . . . . . . . . . . . . . . . . . 6.99
291.47
NBR 70 Sh
Pump attachment / nozzle cooling water pump . . . . . . . . . . . . . 6.99
215.27
NBR 70 Sh
Pump attachment / cylinder cooling water pump . . . . . . . . . . . . 6.99
291.47
NBR 70 Sh
7201-1 Drive of cylinder lubricating pump / flow control valve . . . . . . . 3.53
18.64
NBR 70 Sh
Flow valve / base plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.53
18.64
NBR 70 Sh
148.59
NBR 70 Sh
Fuel transfer pump / sealing disc . . . . . . . diesel oil . . . . . . . . 5.33
43.82
NBR 70 Sh
Fuel transfer pump / driving shaft . . . . . . diesel oil . . . . . . . . 3.53
37.69
NBR 70 Sh
Fuel transfer pump / cover . . . . . . . . . . . . heavy fuel oil . . . . . 6.99
148.59
FPM 70 Sh
Fuel transfer pump / sealing disc . . . . . . . heavy fuel oil . . . . . 5.33
43.82
FPM 70 Sh
Fuel transfer pump / driving shaft . . . . . . heavy fuel oil . . . . . 3.53
37.69
FPM 70 Sh
7505-1 Cylinder cooling water pump / cover . . . . . . . . . . . . . . . . . . . . . . 6.99
227.97
NBR 70 Sh
Cylinder cooling water pump / bearing housing . . . . . . . . . . . . . 6.99
177.17
NBR 70 Sh
7506-1 Raw water pump / cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.99
291.47
NBR 70 Sh
Raw water pump / bearing housing . . . . . . . . . . . . . . . . . . . . . . . 6.99
177.17
NBR 70 Sh
177.17
NBR 70 Sh
91.44
NBR 70 Sh
rn
a
lU
se
6730-1 Flap for bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fo
rI
nt
e
7403-1 Fuel transfer pump / cover . . . . . . . . . . . . diesel oil . . . . . . . . 6.99
(high temperature circuit)
(low temperature circuit)

7507-1 Nozzle cooling water pump / cover . . . . . . . . . . . . . . . . . . . . . . . . 6.99
Nozzle cooling water pump / bearing housing . . . . . . . . . . . . . . . 5.33
L-Mot. / 1995
03281/A1

Inner Diameter
in mm
ZA40S
Thickness
in mm
Group in
Code Book
Maintenance
Material
NBR = Nitrile
FPM = Viton
MVQ = Silicone
40.64
FPM 70 Sh
Washing plant for charge air cooler, intermediate flange . . . . . 5.33
40.64
NBR 70 Sh
Oil main piping / connecting flange on engine housing . . . . . . . 6.99
164.47
NBR 70 Sh
8701-1 Fuel oil pressure retaining valve . . . . . . . . . . . . . . . . . . . . . . . . . . 3.53
28.17
FPM 70 Sh
Connecting piping to shutoff cock of fuel piping . . . . . . . . . . . . 3.53
34.52
FPM 70 Sh
Control piping / connecting block . . . . . . . . . . . . . . . . . . . . . . . . . 1.78
3.68
NBR 70 Sh
6.07
NBR 70 Sh
1603-1 Cover to crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
*1850
MVQ 50 Sh
Cover to camshaft space . . . . . . . . . . . . . . . . . . . . 6-9 cylinder 15
*3300
MVQ 50 Sh
Cover to camshaft space . . . . . . . . . . . . . . . . . . . 9 cylinder only 15
*1850
MVQ 50 Sh
2762-1 Cover on rocker arm housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
*2220
MVQ 50 Sh
Rocker arm housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
*2220
MVQ 50 Sh
*575
MVQ 50 Sh
se
9323-1 Pressure sensor for remote indication . . . . . . . . . . . . . . . . . . . . . 1.78
NBR 70 Sh
nl
6.07
9322-1 Pressure sensor for alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.78
8301-1 Cyl. cooling water piping / connecting piece on cyl. head . . . . . 5.33
nt
e
rn
a
lU
Tubular joints
Fo
rI
6701-1 Air connection to cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Orings on tools
9408.36
Hydraulic jack 150 mm stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.62
9.19
NBR 70 Sh
9427.06
Pressure test cylinder cover, sealing ring . . . . . . . . . . . . . . . . . . . 6.99
532.26
MVQ 50 Sh
9427.31
Fitting or mounting device, valve seat . . . . . . . . . . . . . . . . . . . . . 5.33
66.04
NBR 70 Sh
*) Length of joint
1995 / L-Mot.
4 z
03282/A1
Maintenance
ZA40S
Dimensions and Material Specifications of Piston and Rod Seal Rings and Applicable ORings
2728-1 Starting valve / piston . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting valve / housing . . . . . . . . . . . . . . . . . . . . . . . . .
PSR
RSR
85x81x3.8
50x54x3.8
4301-1 Starting air distributor / piston . . . . . . . . . . . . . . . . . . .

Starting air distributor / cylinder . . . . . . . . . . . . . . . . . .
Starting air distributor / thrust washer . . . . . . . . . . . . .
PSR
RSR
RSR
100x95x3.8
75x79x3.8
25x27x1.8
4304-1 Shutoff valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shutoff valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutoff valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PSR
PSR
PSR
120x115x3.8
30x27x2.8
20x18x1.8
4503-1 Piston of reversing valve . . . . . . . . . . . . . . . . . . . . . . . .
PSR
50x46x3.8
4604-1 Control valve of cutout servomotor / piston . . . . . . . .
PSR
50x46x3.8
4612-1 Cutout servomotor / piston . . . . . . . . . . . . . . . . . . . . .

Cutout servomotor / piston . . . . . . . . . . . . . . . . . . . . .
PSR
PSR
50x46x3.8
140x135x3.8
5303-1 Overspeed safeguard / piston . . . . . . . . . . . . . . . . . . . .

Overspeed safeguard / cylinder . . . . . . . . . . . . . . . . . . .
PSR
RSR
45x42x2.8
25x27x1.8
x
x
5501-1 Fuel injection pump, rack . . . . . . . . . . . . . . . . . . . . . . .
RSR
24x26x1.8
6730-1 Flap for bypass / rack . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flap for bypass / rack . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flap for bypass / support . . . . . . . . . . . . . . . . . . . . . . . .
PSR
PSR
PSR
50x46x3.8
0x27x2.8
30x27x2.8
x
x
x
6735-1 Wastegate / piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PSR
140x135x3.8
Nitrile NBR
7010 Shore A
x
x
x
x
x
x
x
x
nl
se
lU
rn
a
nt
e
rI
Fo
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
Rod Seal Ring (RSR)

(nominal dimensions di x da x b)
Piston Seal Ring (PSR)

(nominal dimensions da x di x b)
Cylinder
Bush
Support ring
Seal ring
Seal ring
Viton FPM
705 Shore A
Nominal
Dimensions
Support Ring
PTF/Bronze
Component where the Piston Seal Ring (PSR) or

the Rod Seal Ring (RSR) is installed.
PTF/MoS2 /Glass
Abbreviation
Group in
Code Book
Seal Ring
Support ring
b
Piston
Rod
di
di da
da
L-Mot. / 1995
Maintenance
ZA40S
Pretensioning jack to crankshaft main bearing / pis

ton
Pretensioning jack to crankshaft main bearing / cyl
inder
PSR
RSR
220x214x5.8
120x125x3.8
9427.01
Pretensioning jack to cylinder head / piston

Pretensioning jack to cylinder head / cylinder
PSR
RSR
9433.01
Pretensioning jack to connecting rod / piston

Pretensioning jack to connecting rod / cylinder
9433.07
Pretensioning jack to crank web counterweights /

piston
Pretensioning jack to crank web counterweights /
cylinder
Nitrile NBR
7010 Shore A
9410.01
Support Ring
PTF/Bronze
Nominal
Dimensions
x
x
140x135x3.8
90x94x3.8
x
x
x
x
PSR
RSR
110x105x3.8
60x64x3.8
x
x
x
x
PSR
RSR
120x115x3.8
60x64x3.8
x
x
x
x
se
nl
x
x
Fo
rI
nt
e
rn
a
lU
Tool where the Piston Seal Ring (PSR)

or the Rod Seal Ring (RSR) are used.
PTF/MoS2 /Glass
Abbreviation
Tool No.
in Group 9400-2
Seal ring
Viton FPM
705 Shore A
03282/A1
1995 / L-Mot.
2 z
03521/A1
Maintenance
ZA40S
Clearance and Wear Table
The normal clearances given in the following clearance and wear tables correspond to those resulting from manufactu
ring tolerances or clearances as adjusted on the new engine.
The laid down maximum clearances resp. max/min. dimensions are such values as may be reached after a lengthy opera
ting period, which however may not be allowed to be exceeded or fall below. On components where the clearance is
adjustable by modifying the thickness of shims, discs, spacers etc. the value given as 'Normal Clearance' should always be
arrived at, or striven to attain. Where this is not possible, worn parts must be replaced by standard new ones or recondi
tioned by suitable material buildup.
Fo
rI
nt
e
rn
a
lU
se
nl
If during an overhaul clearances are measured which almost have reached the permissible limit it must be left to indivi
dual judgement to decide whether a component part should be replaced or remain fitted till the next overhaul. This de
pends for example from the duration of the next operation period till the next overhaul and what wear has to be expected
based on experience made.
1995
03521/A1
Maintenance
ZA40S

nl
95.7160
rn
a
lU
se
nt
e
Crankshaft Thrust Bearing
Fo
rI
95.7161
1995
03521/A1
Maintenance
ZA40S
Key No.
Group

Part description
Direction of
measuring
Nominal
dimension
mm
Maximum clearance
(due to wear)
mm

1
Journal
Outer
Diameter
350
Bearing shells (studs tightened ac

cording to instructions)
Inner
Diameter
350 + 0.35
+ 0.27
0
- 0.06
Ovality . . . . . max. 0.05

Parallelism . . max. 0.025
Diameter . . . max. -0.10
1201
Bearing shells (studs tightened ac

cording to instructions)
I.D.
350 + 0.29
+ 0.21
vertical
Shaft end piece
0
- 0.06
Ovality . . . . . max. 0.05

I.D.
350 + 0.36
+ 0.29
For reuse of bearing shells,

please note group 0003-2
vertical
0.29 0.42
axial (total)
0.20 0.44
nt
e
1202
rI
Crankshaft axial clearance

(both thrust rings installed)
Shaft end piece
O.D.
350
Oil catcher
I.D.
350
Clearance
all around
1.0
Fo
1202

please note group 0003-2
350
Thrust bearing shells (bearing

screws tightened according to
instructions)
Bearing clearance
0.21 0.35
O.D.
rn
a
Ovality . . . . . max. 0.05

nl
350
O.D.
Bearing clearance
1202
0
- 0.06
Journal
se
lU
1201
0.80
L-Mot. / 1995
03521/A1
Maintenance
ZA40S

125mm
Cylinder Liner
95.7162
rn
a
lU
se
nl
Fo
rI
nt
e
Valve Rocker Arms
95.7163
1995
03521/A1
Maintenance
ZA40S
Key No.
Group

Part description
Direction of
measuring
Nominal
dimension
mm
I.D.
400 + 0.057
0
Maximum clearance
(due to wear)
mm
Cylinder Liner
2105
Cylinder liner
Measuring point A
Diameter . . . max. 401.5
Measuring point B, C, D
I.D.
Diameter . . . max. 400.4
400
Ovality . . . . . max.
0.5
Measuring point A
nl
(see also group 2105-1
Valve Rocker Arm

Main rocker pin
O.D.
90
Bearing bush (fitted)
I.D.
90
se
lU
2705
radial
rn
a
Clearance
3
Main rocker arm axial clearance
2705
Auxiliary rocker pin
rI
nt
e
2705
Fo
Clearance
2705
+ 0.090
+ 0.036
0.036 0.112
Auxiliary rocker arm

axial clearance
axial (total)
0.5 1.0
O.D.
50
I.D.
50
radial
+ 0.064
+ 0.025
0.025 0.080
axial (total)
0.5 1.0
0.15
0.15
1995
03521/A1
Maintenance
ZA40S

Valve with Turnomat
nl
1
Crankpin Bearing
Fo
rI
nt
e
45
35
rn
a
se
lU
25
50
172
Valve with Rotocap
95.7165
3.00
03521/A1
Maintenance
ZA40S
Direction of
measuring
Nominal
dimension
mm
Maximum clearance
(due to wear)
mm
Valve spindle
(measuring point see Fig.)
O.D.
28
min. 27.85
Valve guide bush
I.D.
28
Key No.
Group

Part description
Inlet and Exhaust Valves
2701
0.06-0.11
0.30
nl
Clearance
(measuring point see Fig.)
Crankpin Bearing
Crankpin
O.D.
Bearing clearance
Crankpin
nt
e
Bearing shells
(bearing studs tightened accord
ing to instructions)
vertical
O.D.
350
350 + 0.29
+ 0.22
Parallelism . . max.
0.08
0.03

see group 0003-2
0.22 - 0.35
350
0
- 0.06
Parallelism . . max.
0.08
0.03

I.D.
350 + 0.35
+ 0.28

see group 0003-2
Fo
rI
I.D.
rn
a
Bearing shells
(bearing studs tightened accord
3302
0
- 0.06
se
lU
3302
3.00
03521/A1
Maintenance
ZA40S

Rotating Piston
nl
The specified clearances are identical

for both piston designs.
see
page 10
and 11
1
Piston with
external lubrication
rn
a
lU
Piston with
inner lubrication
se
see
page 10
and 11
Fo
rI
nt
e
5
see
page 10
and 11
95.7166
96.7225
1995
03521/A1
Maintenance
ZA40S
Key No.
Group

Rotating Piston
Part description
Direction of
measuring
Nominal
dimension
mm
Maximum clearance
(due to wear)
mm
O.D.
398.85
Cylinder liner
I.D.
400 + 0.057
0
Clearance
radial (total)
Piston skirt
O.D.
399.75
Cylinder liner
I.D.
400 + 0.057
0
0.250 0.357
O.D.
30
I.D.
30
radial (total)
0.020 0.062
0.15
Clearance between ratchet ring

and upper bearing cup
(waisted bolts connecting piston
crown to skirt, tightened accord
ing to instruction)
axial
0.15 0.50
0.60
Clearance between lower bearing

cup and spherical head of connect
ing rod
(waisted bolts connecting piston
crown to skirt, tightened accord
ing to instruction)
radial
0.07 0.23
0.35
Ratchet pawl
Clearance
4
3401
Fo
rI
3401
nt
e
Guide bush
rn
a
radial (total)
lU
Clearance
3401
1.150 1.307
nl
Piston crown (measuring point at

lower edge of piston crown)
3401
se
3401
Rotating Piston
1995
03521/A1
Maintenance
ZA40S

Arrangement of the piston rings and

oil scraper rings see group 34021
nl
lU
nt
e
rn
a
se
Fo
rI
5
6
96.7249
1995
10
10
03521/A1
Maintenance
ZA40S
Key No.
Group

Part description
Direction of
measuring
Nominal
dimension
mm
Maximum clearance
(due to wear)
mm
Piston Ring
3402
10
Piston ring (ring height)
axial
10
Clearance
axial
0.17-0.225
0.50
Piston ring groove
depth
13.5
All piston rings to be re

placed at every piston over
haul.
Piston ring
width
13
measured in a
ring of
1.4 0.2
Piston ring gap
Piston ring groove (groove height)

Piston ring (ring height)
3402
axial
Piston ring groove

Piston ring (ring width)
Piston ring gap
nt
e
3402
depth
rn
a
Clearance
400 + 0.05 D.
0
axial
8
axial
width
measured in a
ring of
max. groove height 10.45
nl
axial
3402
+ 0.20
+ 0.17
0
- 0.025
Piston ring groove (groove height)
se
3402
lU
3402
+ 0.20
- 0.17
0
- 0.025
max. groove height 8.45
0.17-0.225
13.5
+0 2
13 - 0.2
0.3
2.2 0.2
400 + 0.05 D.
0
Oil Scraper Ring
axial
9 + 0.040
+ 0.020
Oil scraper ring (ring height)
axial
Clearance
axial
9 - 0.013
- 0.053
0.033-0.093
Oil scraper ring groove
depth
13
3402
Scraping edge
height
3402
10
Oil scraper ring gap
Fo
3402
rI
Oil scraper ring groove

(groove height)
3402
measured in a
ring of
+ 0.45
+ 0.30
0.8 0.07
1.0
1 0.2
4.0
400 + 0.05 D.
0
11
3.00
03521/A1
Maintenance
ZA40S

Camshaft Bearing, Camshaft Thrust Bearing, Camshaft Drive, Tooth Backlash
NonReversible Engine
nl
se
95.7190
rn
a
lU
nt
e
Fo
rI
95.7168
95.7169
1995 / L-Mot.
12
03521/A1
Maintenance
ZA40S
Key No.
Group

Camshaft Bearing, Camshaft Thrust Bearing, Camshaft Drive, Tooth Backlash
Part description
Direction of
measuring
Nominal
dimension
mm
Maximum clearance
(due to wear)
mm
Camshaft Bearing
1
Camshaft
O.D.
Bearing shells
(bearing screws tightened accord
I.D.
Clearance
140
140 + 0.195
+ 0.13
radial
0.13 0.22
axial (total)
0.2 0.3
Camshaft / stop ring

Camshaft Drive
Bearing journals
O.D.
I.D.
180
se
Clearance
lU
4101
0.4
nl
Camshaft Thrust Bearing

4101
0.26
4101
radial
Intermediate gear wheel
4101
Intermediate gear wheel / cam

shaft gear wheel
4101
Driving gear wheel on crankshaft

(split gear),
intermediate gear wheel
0.4 0.8
0.9
tooth backlash
0.16 0.32
0.5
tooth backlash
0.22 0.39
0.45
Fo
rI
nt
e
0.25
axial (total)
rn
a
4101
180 + 0.04
0
0.10 0.17
13
L-Mot. / 1995
03521/A1
Maintenance
ZA40S

Camshaft Bearing, Camshaft Drive, Tooth Backlash
Reversible Engine
se
nl
95.7190
rn
a
lU
nt
e
Fo
rI
1
6
95.7170
95.7169
1995 / L-Mot.
14
03521/A1
Maintenance
ZA40S
Key No.
Group

Camshaft Bearing, Camshaft Drive, Tooth Backlash
Part description
Reversible Engine
Direction of
measuring
Nominal
dimension
mm
Maximum clearance
(due to wear)
mm
Camshaft Bearing
1
Camshaft
O.D.
Bearing shells
(bearing screws tightened accord
I.D.
Clearance
radial
140
140 + 0.195
+ 0.13
0.13 0.22
0.26
4101
(Please refer to page 20 and 21:

Reversing Servomotor)
lU
se
nl
Camshaft Axial Clearance
Camshaft Drive
3
Bearing journal
Intermediate gear wheel

(axial clearance)
4101
Intermediate gear wheel / cam

shaft gear wheel
Fo
rI
4101
4101
Driving gear wheel on crankshaft

(split gear)
O.D.
180
I.D.
180 + 0.04
0
0.10 0.17
0.25
0.4 0.8
0.9
radial
nt
e
Clearance
rn
a
4101
axial (total)
tooth backlash 0.16 0.32
0.5
tooth backlash 0.22 0.39
0.45
15
L-Mot. / 1995
03521/A1
Maintenance
ZA40S

Starting Air Distributor
with Control Disc
Fo
rI
nt
e
rn
a
lU
se
nl
96.8567
10
10
3.00
+0
+ 0.03
+0
+ 0.03
16
03521/A1
Maintenance
ZA40S
Key No.
Group

with Control Disc
Part description
Nominal
dimension
mm
Direction of
measuring
Maximum clearance
(due to wear)
mm

10
+ 0.05
+ 0.02
Cross intermediate piece
radial
10
0
- 0.03
Clearance
radial
Shaft
O.D.
24
DU bush
I.D.
24
Clearance
radial
Intermediate shaft / cross

intermediate piece
4301
Ball / disc
axial
rn
a
4301
- 0.065
- 0.098
+ 0.071
- 0.010
0.20
0.055-0.169
0.80-3.0
0.70-1.70
Fo
rI
nt
e
axial
nl
0.02-0.08
0.10
radial
Slot in intermediate shaft

and shaft
se
4301
lU
4301
17
3.00
03521/A1
Maintenance
ZA40S

rn
a
lU
se
nl
Fo
rI
nt
e
95.7172
1995
18
03521/A1
Maintenance
ZA40S
Direction of
measuring
Nominal
dimension
mm
Pilot control valve
O.D.
30
Casing
I.D.
30
Clearance
radial
0.020 0.062
Roller pin
O.D.
10
Roller bush
I.D.
Key No.
Group

Part description
Maximum clearance
(due to wear)
mm
10
Roller
axial (total)
0.01 0.084
0.3 0.7
Fo
rI
nt
e
rn
a
radial
lU
Clearance
4301
nl
4301
se
4301
Staring Air Distributor
19
1995
03521/A1
Maintenance
ZA40S

Reversing Servomotor
lU
se
nl
Reversible Engine
Fo
rI
nt
e
rn
a
95.7173
1995
20
03521/A1
Maintenance
ZA40S
Key No.
Group

Reversible Engine
Part description
Direction of
measuring
Nominal
dimension
mm
Maximum clearance
(due to wear)
mm
Camshaft
O.D.
140
Bearing bush
I.D.
140 + 0.195
+ 0.13
0.13 0.22
Clearance
2
Piston / locating rings

(central stud pretightened ac
cording to instruction)
axial (total)
0.324 1.024
0.3
Fo
rI
nt
e
rn
a
lU
se
4500
radial
nl
4500
21
1995
03521/A1
Maintenance
ZA40S
se
nl

Valve Drive
rI
nt
e
rn
a
lU
Fo
95.7174
1995
22
03521/A1
Maintenance
ZA40S
Key No.
Group

Valve Drive
Part description
Direction of
measuring
Nominal
dimension
mm
Maximum clearance
(due to wear)
mm
Valve drive
0.6 + 0.1
0
Exhaust valve
1.2 + 0.1
0
Inlet valve
O.D.
120
Housing
I.D.
120
Clearance
radial
0.036 0.106
Roller pin
O.D.
42
Bearing bush
I.D.
42
radial
0.025 0.080
nl
Guide piston
4401
Valve clearance (cold engine)
se
4401
Clearance
4
Bearing bush / guide piston
4401
Locating discs / guide piston
axial (total)
rn
a
4401
lU
4401
0.10
0.2 0.4
0.26 0.54
Fo
rI
nt
e
axial (total)
0.15
23
1995
03521/A1
Maintenance
ZA40S
lU
se
nl

Governor Drive
rn
a
1 6
4
Fo
rI
nt
e
95.7175
1995 / L-Mot.
24
03521/A1
Maintenance
ZA40S
Key No.
Group

Governor Drive
Part description
Direction of
measuring
Nominal
dimension
mm
Maximum clearance
(due to wear)
mm
radial
+ 0.070
+ 0.045
0.045 0.086
0.15
axial (total)
0.25 0.45
Governor Drive
O.D.
I.D.
Clearance
2
Bevel gear / bearing bush
5105
Bevel gear shaft
O.D.
I.D.
Driving spur gear wheel
5105
Camshaft gear / driving spur gear

wheel
5105
Bevel gears
radial
+ 0.070
+ 0.045
0.045 0.086
axial (total)
0.25 0.45
0.16 0.32
0.4
0.1 0.2
0.3
tooth backlash
rn
a
5105
44
44
se
Clearance
44
lU
5105
44
Vertical shaft
nl
5105
Fo
rI
nt
e
tooth backlash
0.15
25
L-Mot. / 1995
03521/A1
Maintenance
ZA40S

5
6
Fo
rI
nt
e
rn
a
lU
se
nl
95.7176
1995 / L-Mot.
26
03521/A1
Maintenance
ZA40S
Key No.
Group

Part description
Direction of
measuring
Nominal
dimension
mm
Maximum clearance
(due to wear)
mm
radial
+ 0.070
+ 0.045
0.045 0.086
0.15
axial (total)
0.3 0.65
Mechanical Overspeed Safety

CutOut Device
O.D.
I.D.
Clearance
5303
Shaft / bearing bush
5303
Shaft of intermediate gear
O.D.
I.D.
Shaft intermediate gear / inter

mediate gear
5303
Camshaft gear / intermediate gear
5303
Intermediate shaft / driving gear
axial (total)
0.2 0.55
tooth backlash
0.16 0.32
0.4
tooth backlash
0.16 0.32
0.4
44
se
44
0.8
radial
0.15
Fo
rI
nt
e
rn
a
5303
44
+ 0.070
+ 0.045
0.054 0.095
lU
Clearance
44
Pin shaft
nl
5303
27
1995
03521/A1
Maintenance
ZA40S

Fuel Injection Pump
rI
Fo
7a
7
nt
e
rn
a
lU
se
nl
5
4
95.7177
1995
28
03521/A1
Maintenance
ZA40S
Direction of
measuring
Nominal
dimension
mm
Pump plunger
O.D.
35
Plunger guide
I.D.
35
Clearance
radial
0.014 0.016
Control rack
O.D.
30
Housing (bore)
I.D.
30
Clearance
radial
0.040 0.094
Guide piston
O.D.
130
Pump housing
I.D.
130
Key No.
Group

Fuel Injection Pump
Part description
Maximum clearance
(due to wear)
mm
Fuel Injection Pump
5501
Clearance
radial
0.043 0.123
Bearing bush
O.D.
60
Roller
I.D.
60
radial
0.03 0.09
5501
lU
Clearance
Roller pin
Clearance
5501
Roller pin
Clearance
nt
e
Guide piston (bore)
0.15
0.15
0.1
O.D.
50
I.D.
50
radial
0.025 0.080
O.D.
50
I.D.
50
radial
0.009 0.050
0.08
rn
a
Bearing bush
0.023
nl
5501
5501
se
5501
0.1
Axial clearance, bearing bush
axial
0.2 0.4
0.5
5501
7a
Total clearance between guide pis

ton and roller with locating discs
axial
0.26 0.54
0.7
Fo
rI
5501
29
1995
03521/A1
Maintenance
ZA40S

Lubricating Oil and Fuel Oil Booster Pump
with EngineDriven Pumps
Lubricating Oil Pump
lU
3a
rn
a
se
nl
95.7178
Fuel Oil Booster Pump
Fo
rI
nt
e
7
5
95.7179
4
6
1995 / L-Mot.
30
03521/A1
Maintenance
ZA40S
Key No.
Group

Lubricating Oil and Fuel Oil Booster Pump
Part description
Direction of
measuring
Nominal
dimension
mm
Maximum clearance
(due to wear)
mm
0.2

O.D.
I.D.
Clearance
radial
+ 0.060
+ 0.020
0.08 0.139
axial
0.20 0.296
Total clearance between pump

transport wheels and pump housing
7101
Tooth backlash between pump driv tooth backlash

ing gear wheel and driving gear
wheel on crankshaft
7101
3a
Tooth backlash between pump tooth backlash

transport wheels
Cog wheel shaft
Clearance
0.16 0.32
0.34 0.49
0.4
0.4
0.55
lU
nt
e
rn
a
Fuel Booster Pump

4
75
se
7101
7102
75
Shaft
nl
7101
O.D.
40
I.D.
40
radial
+ 0.039
0
0.050 0.105
0.15
axial
0.10 0.15
0.20
Total clearance between cog wheels

and pump housing
7102

wheel on crankshaft
0.16 0.32
0.4
Tooth backlash between cog wheels tooth backlash
0.10 0.20
0.25
7102
Fo
rI
7102
31
L-Mot. / 4.97
03521/A1
Maintenance
ZA40S

Cylinder Cooling Water Pump
se
nl
Fo
rI
nt
e
rn
a
lU
95.7180
1995
32
03521/A1
Maintenance
ZA40S
Key No.
Group

Part description
Direction of
measuring
Nominal
dimension
mm
Maximum clearance
(due to wear)
mm
0.15

1
Shaft sleeve
O.D.
I.D.
70
Clearance (shaft nut tightened)
radial
+ 0.125
+ 0.095
0.075 0.124
70
Axial clearance between bearing

bush and pump drive gear wheel
(shaft nut tightened)
axial
0.34 0.48
7103
Tooth backlash between pump

drive gear wheel and driving gear
wheel on crankshaft
tooth backlash
0.16 0.32
7103
Impeller
Impeller
Inlet cover
se
0.4
I.D.
188.3 + 0.1
0
0.350 0.496
O.D.
180
I.D.
180.3 + 0.1
0
0.343 0.483
radial
Fo
rI
Clearance
nt
e
188
radial
rn
a
Clearance
7103
O.D.
lU
Pump housing
0.6
nl
7103
7103
33
1995
03521/A1
Maintenance
ZA40S

Raw Water Pump
se
nl
lU
Fo
rI
nt
e
rn
a
1995
34
95.7181
03521/A1
Maintenance
ZA40S
Key No.
Group

Raw Water Pump
Part description
Direction of
measuring
Nominal
dimension
mm
Maximum clearance
(due to wear)
mm
0.15
Raw Water Pump

Shaft sleeve
O.D.
I.D.
radial
+ 0.125
+ 0.095
0.075 0.124
0.34 0.48
Axial clearance between bearing

bush and pump driving gear wheel
(shaft nut tightened)
axial
7104
Impeller
O.D.
Pump housing
I.D.
Impeller
O.D.
210
210.3 + 0.1
0
0.350 0.496
radial

wheel on crankshaft
195
195.3 + 0.1
0
0.350 0.496
0.16 0.32
0.4
Fo
rI
nt
e
7104
I.D.
rn
a
Suction cover
Clearance
0.6
se
radial
lU
Clearance
4
70
nl
7104
7104
70
7104
35
1995
03521/A1
Maintenance
ZA40S

Fuel Nozzle Cooling Water Pump
Fo
rI
nt
e
rn
a
lU
se
nl
1995
95.7182
36
03521/A1
Maintenance
ZA40S
Part description
Direction of
measuring
Nominal
dimension
mm
O.D.
I.D.
radial
axial
Axial clearance between driving

gear wheel and bearing bush
7105
Tooth backlash between pump

driving gear wheel and driving
gear wheel on crankshaft
tooth backlash
0.15
0.30 0.44
0.6
0.16 0.32
0.4
Fo
rI
nt
e
rn
a
7105
+ 0.08
+ 0.05
0.050 0.096
38
se
38
Shaft sleeve
lU
nl

7105
Maximum clearance
(due to wear)
mm
Key No.
Group

37z
1995
0355--1/A1
Maintenance
ZA40S
6WUHWFK RU
VKLIW PP
7UDQVYHUVH WLH URG IRU FUDQNVKDIW

=$/6 0
PDLQ EHDULQJ =$96

6WXG IRU FUDQNVKDIW PDLQ EHDULQJ 0[

&UDQNVKDIW WKUXVW EHDULQJ

+RUL]RQWDO VFUHZ
+RUL]RQWDO VFUHZ
9HUWLFDO VFUHZ
9HUWLFDO VWXG
DOWHUQDWLYH H[HFXWLRQ

0
2
0
.
se
0
0
0[
0[
nl
'HVLJQDWLRQ
6SHFLILHG
OXEULFDQW
7LJKWHQLQJ
DQJOH %

7KUHDG VL]H
7LJKWHQLQJ
WRUTXH 1P
+\GUDXOLF
SUHWHQVLRQ EDU
'HWDLOHG LQIR
LQ JURXS
7LJKWHQLQJ ,QVWUXFWLRQV
7LJKWHQLQJ 9DOXHV RI ,PSRUWDQW 6FUHZHG &RQQHFWLRQV
lU
)UHH HQG YHUWLFDO VFUHZHG FRQQHFWLRQ

0[
SODWH ORZHU SDUW SODWH XSSHU SDUW =$/6

&\OLQGHU OLQHU IDVWHQLQJ VFUHZ 0

&\OLQGHU KHDG VWXG 0

6WXG IRU URFNHU DUP KRXVLQJ QXW 0

)XHO VWXG 0[

&DS QXW IRU IXHO +3 SLSH 0[

&DS QXW IRU IXHO +3 VKRUWHU W\SH SLSH 0[

6FUHZ IRU GHOLYHU\ YDOYH 0

)XHO LQMHFWLRQ YDOYH

&DS QXW IRU IXHO QR]]OH 0[
1XW IDVWHQLQJ IXHO YDOYH WR F\OLQGHU 0
KHDG

0
0

Fo
rI
nt
e
rn
a

6WDUWLQJ YDOYH
1XW RQ YDOYH VSLQGOH 0

1XW IDVWHQLQJ YDOYH WR F\OLQGHU KHDG
0
&UDQNVKDIW
&RXSOLQJ EROW WR IO\ZKHHO 0[
&RXSOLQJ EROW WR WKUXVW EHDULQJ VKDIW
=$/6 0[
=$96
&RXSOLQJ EROW WR YLEUDWLRQ GDPSHU 0[

06.02
0355--1/A1
ZA40S
6WUHWFK RU
VKLIW PP
6SHFLILHG
OXEULFDQW
6WXG IRU FRXQWHUZHLJKW RQ FUDQNVKDIW
0[

6KRUW VWXG RQ FRQQHFWLQJ URG IDVWHQLQJ

FRQQHFWLQJ URG WR FUDQNSLQ EHDULQJ
0[

/RQJ VWXG LQ FUDQNSLQ EHDULQJ IDVWHQLQJ

FUDQNSLQ EHDULQJ XSSHU WR ORZHU SDUW
QRWH DOVR LQGLFDWLRQV LQ JURXS
0[

5RWDWLQJ SLVWRQ ZDLVWHG VFUHZ IDVWHQ

LQJ SLVWRQ FURZQ WR SLVWRQ VNLUW
0

6FUHZV D IRU =$/6 UHVS IRU

=$96 IDVWHQLQJ EHDULQJ MRXUQDO RI LQWHU
PHGLDWH JHDU ZKHHO RI FDPVKDIW GULYH
0

6FUHZ IRU FDPVKDIW EHDULQJ FRYHU 0

E
nl
O

se

yE
r )L[LQJ VFUHZ WR YLEUDWLRQ GDPSHU 0

r )L[LQJ VFUHZ WR YLEUDWLRQ GDPSHU 0

RQO\ IRU F\OLQGHUV HQJLQH

)XHO FDP SLHFHV VFUHZ 0

,QOHW DQG H[KDXVW FDP SLHFHV VFUHZ 0

2
2

&HQWUDO VFUHZ IRU VWDUWLQJ DLU GLVWULEXWRU 0

RQO\ QRQUHYHUVLEOH HQJLQH

6FUHZ YDOYH DFWXDWLQJ KRXVLQJ 0

:DLVWHG VWXG RI UHYHUVLQJ VHUYRPRWRU

RQO\ UHYHUVLEOH HQJLQH

6FUHZ RI JRYHUQRU GULYH =$96 0

6FUHZV RI JRYHUQRU GULYH =$96 0

2
2

6FUHZ RI JRYHUQRU GULYH

6FUHZ RI JRYHUQRU GULYH =$// 0

6FUHZ RI JRYHUQRU GULYH =$96

6FUHZ WR IXHO SXPS FRYHU 0

6FUHZ IDVWHQLQJ IXHO LQMHFWLRQ SXPS WR 0

HQJLQH FDVLQJ
06.02
Fo
rI
nt
e
lU
rn
a
'HVLJQDWLRQ
7LJKWHQLQJ
DQJOH %

7KUHDG VL]H
7LJKWHQLQJ
WRUTXH 1P
+\GUDXOLF
SUHWHQVLRQ EDU
'HWDLOHG LQIR
LQ JURXS
Maintenance
0[
=$/6 0

:LWK HQJLQHGULYHQ SXPSV

:DLVWHG EROW WR OXEULFDWLQJ RLO SXPS
0
=$/6

0[

E

0
.
2

Fo
rI
nt
e
rn
a
lU

6SHFLILHG
OXEULFDQW
6WUHWFK RU
VKLIW PP
7LJKWHQLQJ
DQJOH %

1P PP
VKLIW
se
6KDIW RI QR]]OH FRROLQJ ZDWHU SXPS 0
1XW WR H[KDXVW ZDVWHJDWH 0

nl
6FUHZ WR IXHO ERRVWHU SXPS 0
1P PP
VKLIW
:DLVWHG VWXG WR OXEULFDWLQJ RLO SXPS

0[
=$96
6KDIW RI F\OLQGHU FRROLQJ DQG UDZ ZDWHU

SXPSV
7LJKWHQLQJ
WRUTXH 1P

'HVLJQDWLRQ
+\GUDXOLF
SUHWHQVLRQ EDU
7KUHDG VL]H
'HWDLOHG LQIR
LQ JURXS
0355--1/A1
Maintenance
ZA40S
7KH YDOXHV LQ PDUNV WKH VFUHZ EROW RU VWXG RQ WKH UHIHUHQFHG LOOXVWUDWLRQ
/XEULFDQW 0
02/<.27( SDVWH *Q 2 2LO . 12 DGGLWLRQDO OXEULFDQW FRUURVLRQ
+
+HDW UHVLVWLQJ OXEULFDQW
SUHYHQWLYH FDQ EH OHIW LQ WKUHDG
9DOXHV ZLWK :KHQ XVLQJ SRZHU PXOWLSOLHU UHGXFH DSSOLHG IRUFH E\ WLPHV 7RRO
7LJKWHQLQJ DQJOH 7KH WLJKWHQLQJ DQJOH VLJQLILHV WKH DQJOH E\ ZKLFK WKH QXW RU VFUHZ LV WLJKWHQHG DIWHU LW
KDV EHHQ WLJKWHQHG WR D VSHFLILHG VWDUWLQJ SRLQW
3.00
3.00 / V--Mot.
50 ... 100 Nm
600 + 20
0
On threads and contact

surfaces of bolts and
nuts.
MOLYKOTE PASTE G-n
OIL LUBRICATION
On threads and contact

surfaces of bolts and
nuts.
NO ADDITIONAL LUBRICATION
(Anti-corrosion oil can remain

in thread)
600 Nm
350 Nm
O
O
se
641
new piston area in cm2
nl
*
1 X
780 Nm Read off power

multiplier 220 Nm
Control: Gap clearance = 0
1230 Nm Read off power
multiplier 350 Nm
Oil pressure 100 bar (2300 Nm)
740 Nm
350 Nm
Alternative design
250 Nm
OIL PRESSURE 600 + 20

0 bar
Control dimension
L = 1.0 +
-- 0.1 mm
See procedure for control dimension
2. Protrusion X to be determined.
Elongation of bolt
L = 0.39 + 0.02 mm. Oil pressure
-100 bar - equivalent to 2300 Nm
Tightening instructions given on

the separate pump assemblies
With engine-driven pumps:
CYLINDER
PISTON
PROCEDURE FOR OBTAINING THE CONTROL DIMENSION OF HYDRAULICALLY

TENSIONED STUDS
HYDR. JACK
1. Pretensioning pressure on hydr. jack 100 bar (Note! stud of lower connecting
rod bearing and main bearing pretensioned to 600 bar to be released
to 200 bar). Nut to be tightened firmly. Pressure to be released to 40 bar.
X
Read off power multiplier 590 Nm
2060 Nm
O 50 ... 100 Nm

0 bar
Pretensioning to 200 bar
Control dimension L = 0.8 +
-- 0.05 mm
On first assembly of engine, all bolt connections which are coated

3. Tensioning of studs to 600 bar, nut to be tightened firmly.
Pressure to be released to 40 bar.
with MOLYKOTE paste G-n have to be tightened to instructed torque
values, subsequently to be loosened again. Afterwards the contact
4. Protrusion X1 to be determined.
surfaces have to be recoated with MOLYKOTE G-n and to be tighL = X1-- X
tened to instructed torque values again.
5. Control dimension
the formula P (bar) =
220 + 20
0 Nm
90 + 10
0 Nm
130-150 Nm Joint faces to be dry
O
O
28 Nm
M16
M12
O 140+ 10
0 Nm
Joint faces to be dry
Pretightening with 120+ 20

0 Nm
Followed by final tightening with an
angle of 90 -- mark on collar
150 Nm
70 Nm
O
590 Nm
22 Nm
300 Nm

0 bar
-- 0.1 mm
lU
100 bar for hydr. cylinder with a piston

area of 6.41 cm2
For hydr. cylinder with a different piston area
the oil pressure should be determined acc. to
rn
a
250 Nm
For checking: Flange must be touching
cylinder cover
nt
e
rI
180-190 Nm
Maintenance
95.7549

0 bar
-- 0.05 mm

0 bar
Pretensioning to 200 bar
-- 0.1 mm
bar
K OIL PRESSURE
-- 0.1 mm
290 Nm
Fo

0 bar
Control dimension L = 1.4 + 0.1 mm
-See procedure for control dimension
Pre tightened with 150 +

-- 10 Nm
Completly tightened with a torque
angle of 60 ... 65
540 Nm
0355--1/A1
ZA40S
03561/A1
Maintenance
ZA40S
Taking Lubricating Oil Samples for Laboratory Analysis
In the course of time, even the best quality lubricating oil tends to change it properties due to ageing, oxidation and con
tamination. Therefore in intervals of approx. 3000 operating hours a sample should be taken from the engine lubricating
oil and sent to a laboratory for analysis. The sample must be taken from the oil in circulation and at normal service tem
perature from a cock specially fitted for this purpose, and which is situated at the inlet of the main lubricating oil pipe into
the engine.
Before taking the sample, drain about 2 litres into a container to remove any possible dirt accumulation in the drain cock.
Now remove the sample oil (about 1 litre) from the engine into an absolutely clean container (glass is best).
Mark the container with the oil sample with the following data:
- Name of Vessel or Plant
nl
- Engine type
- Engine No. or cylinder No.

- Date of sampling
se
- Operating hours of lubricating oil and of engine
lU
- Oil brand
Monitoring the lubricating oil
rn
a
The condition of the lubricating oil charge or its alteration during operation can be assessed on the basis of some analysis
data. With regular checks a deterioration can be detected at an early stage and remedial measures taken.
The test should at least cover the following characteristics:
nt
e
- Viscosity
- Flash point
- Insolubles
rI
- BN
- Water content and nature of water
Fo
Possibly also contamination by fuel and metal content might be included.

The significance of such analysis results can best be assessed if they are considered as a whole and in relation to the past
analytical history of the oil.
In the course of time, even the best quality lubricating oil changes its properties in such a way that a change of the oil
charge must be considered. However, it is not possible to give a fixed time interval for this purpose since this is influenced
by the operating conditions and the efficiency of the oil treatment.
A rather sudden change of one or the other of these parameters can indicate abnormal operating conditions or failures
in the system. In such a case it would be of little help just to change the oil without investigating the cause.
The values for used lubricating oil indicated in the relevant group 0110-1 of the Operating Manual are given for general
guidance. Normally, the oil is still fit for further use if the parameters are within the limits indicated.
1 z
1995
Group1
Betrieb
ZA40S
Fo
rI
nt
e
rn
a
lU
se
nl
Group 1
10011/A1
Maintenance
ZA40S
Engine Housing (Frame)

Replacement of Cylinder Head Studs
Tools:
Key to Illustrations:
Spanner
Cleaning materials
1 Upper edge of engine

housing
2 Cylinder head stud
3 Sealing compound
DF Sealing surface
RR Annular space
The cylinder head studs 2, studs for short, must be protected against corrosion at the lower end. The annular space 'RR'
and the stud shank must be fully sealed off with a suitable sealing compound, without cavities, up to about the level of the
upper edge of the engine housing 1 (see illustration).
- No filling material may be added to the sealing compound.

- Only use a compound which will allow the studs to be unscrewed again without difficulty.
Remark
se
- Thoroughly clean and degrease the sealing surfaces 'DF' before fitting
(e.g. with white spirit).
- Other than the corrosion protection oil already supplied, no lubricant or

locking agent may be applied to the threads of the stud 2.
nl
Working procedure during fitting and sealing
- Prime the sealing surfaces 'DF' with primer according to the manufac
turer's instructions.
lU
DF
- Screw in the studs and tighten with a torque of 50-200 Nm. Utilize al
ways stud driver or two locked nuts. Tools like pipe wrench etc. which
would damage the stud shank must never be used.
RR
rn
a
- As a sealant we recommend the following two component silicon com

pounds.
nt
e
- Fill the annular space 'RR' completely. In order to allow the sealing
compound to be poured above the level of the top of the engine housing
1, a ring of cardboard, putty or similar having an internal diameter of
about 60 mm has to be laid around the stud shank until the sealing com
pound has fully set. This is particularly important for ZAVS engines.
95.7191
rI
- The ring has to be removed after hardening.
Fo
Recommended sealing compounds and primers

Type description
of sealant
No. of
components
Hardener
RTVME 622A
ME 622B
Polastosil M56
OL1
Silcoset 105
A or D
Primer
G 790
P3
Supplier
Wacker Chemie (Switzerland) Ltd.
Lautengartenstr. 23
PO Box 4002 Basel
CH-4052 Basel BS
Polish product
no type description or OP Wachendorf Ltd.

Auf dem Wolf 17
PO Box 4002 Basel
CH-4052 Basel BS
Similar products from other suppliers may be used.
1995
10011/A1
Maintenance
ZA40S
Sealing compound requirements

Required properties:
- nonacidic, e.g. acetic acid;
- resistant to oil, diesel oil, heavy fuel oil, water at a continuous temperature of about 100 _C;
- short hardening time (approx. 24 hours);
- flows easily so that the annular space will be completely filled without cavities;
- binds well to primed metal surfaces;
- simple preparation and mixing;
- minimum to not shrinkage;
- the external surface may not harden with porosity;
Fo
rI
nt
e
rn
a
lU
se
nl
- the sealing compound must remain sufficiently elastic so that the stud bolts may be unscrewed at any time.
1995
2 z
12011/A1
Maintenance
ZA40S

Loosening and PreTensioning of the Transverse Tie Rods and Main Bearing Studs
Tools:
9408.02
9408.09
9408.15
9408.16
9410.01
9410.01a
9412.10
Bearing cover
Engine housing
Transverse tie rod
Main bearing stud
Round nut to item 4
Cylinder for hydr. jack
Piston for hydr. jack
Shaft seal ring
Piston seal ring
Oring
Disc
12
13
14
15
16
17
18
Round nut to item 3

Cylinder for hydr. jack
Shaft seal ring
Piston seal ring
Piston for hydr. jack
Oring
Protection cap
* Tightening according to
instructions
nl
9427.01
9427.01a
9431.03
1
2
*3
*4
5
6
7
8
9
10
11
1 Hydraulic hand pump

with accessories
2 HP hoses
1 Feeler gauge
1 Depth gauge
2 Hydr. jacks
1 Round bar
1 Lifting device for hydr.
pretensioning jacks
2 Hydr. jacks
1 Round bar
1 Special spanner
To loosen and pretension transverse tie rods and main bearing studs for the removal and fitting of the main bearings
proceed as follows:
Fitting
se
Removal
1. Loosen both transverse tie rods
simultaneously
rn
a
3. Unscrew transverse tie rods
2. Screwin transverse tie rods
lU
2. Loosen both main bearing stud nuts

simultaneously
1. Press bearing cover upwards (group 1201-2)

and hand fit round nuts
4. Lower bearing cover (group 1201-2)
4. Pretension both transverse tie rods

simultaneously
nt
e
Remarks
3. Pretension both main bearing stud nuts

simultaneously
rI
- If all the crankshaft main bearings must be removed, loosen first all the transverse tie rods. If only one of the main
bearings must be removed, loosen the transverse tie rods of the specific bearing and also the transverse tie rods in the
immediate vicinity, otherwise it is difficult to lower and later lift back the bearing cover.
Fo
- When screwingon the piston 16 or 7 of the cylinder 13 or 6 respectively of the pretension jack (Fig. 'A1' and 'A2'), the
oil is being pushed back to the hydraulic hand pump. To permit the oil to flow back open the relief valve of the hydrau
lic hand pump 9408.02 and connect the pretensioning jacks with the hydraulic hand pump by HP hoses.
If you want to screw the piston on without draining the oil to the hydraulic hand pump open the nonreturn valve on
the hose socket of the pretensioning jack by pressing it inwards. The oil will then flow out.
- Before actuating the hydraulic hand pump make sure that the hose couplings are all completely tightened otherwise
the nonreturn valve may not open, preventing oil from reaching the pretensioning jacks, thus not achieving correct
pretensioning.
L o o s e n i n g the transverse tie rods
Working procedure: (Fig. 'A' and 'A1')
- Remove protection cap from transverse tie rod.
- Clean connecting surface of the disc 11 and screw one pretensioning jack 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 16 into the cylinders until they land.
- Screw both pretensioning jacks back again until a gap of 2 mm appears between the cylinder 13 and the discs 11.
1995
12011/A1
Maintenance
ZA40S
- Build up a pressure of 600 to 620 bar with the hydraulic hand pump 9408.02 and maintain this pressure constant until
the two round nuts 12 have been loosened (with the round bar 9427.01a) by 4-5 hole spacings on the nuts circumfer
ence.
- Relieve the pressure by opening the relief valve on the hydraulic hand pump, until the pressure gauge shows 'zero'.
- Remove pretensioning jacks and also the round nuts.
L o o s e n i n g the crankshaft main bearing studs
Please refer to notes on the obverse page!
Working procedure: (Fig. 'A' and 'A2')
- Use lifting device 9412.10 (Fig. 'B') to screw one pretensioning jack each onto the two main bearing studs 4 until the
jack cylinders 6 are resting against the bearing cover 1.
nl
- Screwin the pistons 7 with the round bar 9410.01a until they land.
- Screw back both pretensioning jacks until a gap of 2 mm appears between the cylinder 6 and the bearing cover 1.
- Buildup a pressure of 600 to 620 bar with the hydraulic hand pump 9408.02 and keep pressure constant until you have
unscrewed both round nuts 5 by 4-5 hole spacings (on nut circumference) by using the round bar 9410.01a.
se
- Relieve the pressure by opening the relief valve on the hydraulic hand pump, until the pressure gauge shows 'zero'.
lU
- Remove the pretensioning jacks with the aid of the lifting device 9412.10 and screw the two round nuts 5 by about 130
to 140 mm downwards! (For the further procedure to lower the bearing cover please refer to group 1201-2).
rn
a
Attention
nt
e
It is important to unscrew the round nuts as described for both the transverse tie rods and the bearing cover studs. If the
round nuts are unscrewed too much, the jacks cannot be removed as they jam against the round nuts.
If the round nuts are unscrewed too little, they cannot be loosened after releasing, as the transverse tie rod studs or main
bearing studs are still under pretension.
P r e t e n s i o n i n g main bearing studs
rI
Conditions at start of pretensioning:
- The bearing covers are fitted according to the instructions in group 1201-2 and are held by two round nuts 5.
Fo
- The transverse tie rods of the respective bearing as well as of the neighbouring bearings are not yet pretensioned.
- The threads of the main bearing studs must not be lubricated with MOLYKOTE paste.
Working procedure of pretensioning:
- After the bearing cover is pressed upwards till fully seated against the engine housing (see group 1201-2) and held in
place by both round nuts 5, screw the two pretensioning jacks 9410.01 onto the two main bearing studs with the aid of
the lifting device 9412.10 (Fig. 'B') till their cylinders 6 are resting against the bearing cover 1.
- Connect the pretensioning jacks to the hydraulic hand pump 9408.02 with the HP hoses 9408.09, open relief valve
and screw the pistons 7, using round bar 9410.01a, into the cylinders 6 until they land.
- Close the relief valve of the hydraulic hand pump and pretension the main bearing studs initially at a pressure of 600
bar. Hold this pressure constant. Subsequently the pressure has to be reduced to 200 bar and kept at this level, till the
round nut 5 has been tightened firmly till full seating (check seating with the feeler gauge). With the above mentioned
procedure a full seating of all bearing components is ensured.
1995
12011/A1
Maintenance
ZA40S
- Release pressure to 40 bar and measure the protrusion 'X' on the jacks
and note carefully (please refer to adjacent figure).
- Raise the pressure to 600 bar and hold constant until the round nuts have
been tightened with the round bar for full seating (check seating with the
feeler gauge).
4*
- Release the pressure to 40 bar and measure the protrusion 'X1' and note
it carefully.
- The difference between protrusions 'X1' and 'X' should be 1.2 0.1 mm.
These measures serve as a safety check of the hydraulic pretensioning
method.
- When the measured elongation is approximately correct, remove the
pretensioning jacks with the lifting device 9412.10.
- For extra safety establish the vertical bearing clearance.
5
6
7
X
X1
y
nl
Conditions at start of pretensioning:
3* 18
12 11
se
- Main bearing studs must be tightened according to instructions.

- The thread of the transverse tie rods must not be lubricated with MOLY
KOTE paste.
- Oring 17 and disc 11 are fitted and the round nuts 12 are screwed onto
the two opposing transverse tie rods requiring pretensioning (please re
fer to adjacent figure).
- The contact face of the disc 11 is clean.
P r e t e n s i o n i n g the transverse tie rods
lU
17
The adjacent figure shows a transverse tie rod with

mounted protection cap 18.
Working procedure of pretensioning:
rn
a
Remark
95.7063
nt
e
- Screw one pretensioning jack 9427.01 onto each of the two transverse
tie rods until their cylinders 13 are fully seated on the discs 11.
- Open relief valve of the hydraulic hand pump and screw the piston 16 of
the pretensioning jack, with the aid of special spanner 9431.03, into the
cylinders 13 until they are fully seated.
- Close the relief valve of the hydraulic hand pump and pretension the
transverse tie rods initially with 100 bar. Hold this pressure until you
have tightened the round nuts 12 with the round bar until they are fully
seated (check seating with the feeler gauge).
- Release pressure to 40 bar and measure the protrusion 'X' on both pre
tensioning jacks and note it carefully (please refer to adjacent figure).
- Raise the pressure to 600 bar and hold it constant until the round nuts 12
are tightened till fully seated (check seating with feeler gauge).
- Release the pressure to 40 bar and measure the protrusion 'X1' and note
it carefully.
- The difference between protrusions 'X1' and 'X' should be
on ZALS engines 0.7 0.1 mm
on ZAVS engines 0.9 0.1 mm
when the pretension of the transverse tie rods is correct. These mea
sures serve as a safety check of the hydraulic pretensioning method.
- If the established value is practically correct, remove the pretensioning
jacks.
- Grease the thread lightly to prevent corrosion and fit protection cap 18.
Fo
rI
95.7192
X1
12
13
16
3*
95.7063
1995
12011/A1
Maintenance
9412.10
ZA40S
A1
9427.01
2
3
9410.01
16
10
11
12 13
16
15
14
95.7194
nl
95.7193
13 16
9427.01
9427.01
9408.09
9431.03
rn
a
lU
9408.09
se
Fo
rI
nt
e
3
4
9410.01
9410.01a
95.7195
9408.02
A2
4 z
4
9410.01
1995
1
5
6
95.7196
12012/A1
Maintenance
ZA40S

Replacement of Crankshaft Main Bearing Shells (Standard Shell Bearing)
Tools:
1 Hydraulic hand pump

with accessories
2 HP hoses
2 Hydraulic jacks
1 Hydraulic jacks
2 Supports
1 Segment ZAVS
1 Segment ZALS
9408.02
9408.09
9408.36
9408.38
9410.02
9412.01
9412.08
1
2
3
4
5
Main bearing cover

Engine housing
Transverse tie rod
Main bearing studs
Round nut
19
20
21
22
23
Condition at the start of work
Counterweight
Upper shell
Lower shell
Crankshaft
Oil sump
nl
- Transverse tie rods and main bearing studs of the bearing to be removed as well as the transverse tie rods of the two
adjacent main bearings have been slackened (refer to group 1201-1).
- The transverse tie rods oft he bearing to be removed have been unscrewed and removed.
se
Working procedure
lU
- Screw the two round nuts 5 downwards, until a space of about 130 mm has been provided between the lower edge of
the bearing cover and the connecting face of the nut (see Fig. 'A').
- Fasten the two supports 9410.02 to the bearing cover 1 with two screws.
rn
a
- Place two hydraulic jacks 9408.36 between the supports and the counterweight 19, and connect them to the hand
pump 9408.02 by HP hoses.
- Actuate the pump to push the bearing cover from its guided position. After pressing it for about 110 mm the bearing
cover will slide down onto the round nuts 5 by its own weight.
nt
e
- Remove the two hydraulic jacks and the two supports 9410.02 from the engine. The supports must on no account be
left fitted to the bearing cover as the counterweights 19 would knock against them causing damage, when turning the
engine (Fig. 'B' and 'C').
rI
- Place a hydraulic jack 9408.38 under the bearing cover and connect it to the hand pump. The bearing cover and the
bottom of the oil sump have been provided with drilled recesses into which the hydraulic jacks fit.
- Actuate the pump to lift the bearing cover sufficiently off the round nuts to permit unscrewing them for the main
bearing studs.
Fo
- Open the venting valve 'EV' of the hand pump allowing the bearing cover to descend as much as the jack permits.
Removing the bearing shells (Fig. 'C')
- In this position, the lower bearing shell 21, descending with the bearing cover, can be checked and if necessary be
removed.
- The upper bearing shell 20 can be pushed out using the segment 9412.01 or 9412.08. Clean the segment well, press it
against the journal and at the same time upwards against the bearing shell.
Attention
Safeguard the upper shell by hand, to prevent it from falling out when pressing it out with the seg
ment.
Judging the bearing shells for possibility of reuse

the possibility of reusing a bearing shell depends in principle on the condition of its running surface. Please refer in this
matter to the recommendations in group 0003-2.
1995
12012/A1
Maintenance
ZA40S
Crankshaft main bearing shells for undersize journals

If the surface of the journal becomes rough and requires regrinding, thicker bearing shells with undersize bores are re
quired. The table below indicates the diameters to which the journals must be ground to fit stocked undersize bearing
shells: (All dimensions are in mm).
Undersize
Shaft diameter
Shell thickness
Vertical bearing
Bearing
bore diameter
Clearance
refer to
Design
Key No.
(vertical)
diameter
0
-0.06
10.12
0
- 0.02
0,8
349.2
0
- 0.06
10.32
0
- 0.02
1.2
348.8
0
-0.06
10.52
0
- 0.02
2.0
348
0
- 0.06
10.92
3.0
347
0
- 0.06
4.0
346
5.0
345
0.4
369.6
nl
349.6
349.6 + 0.29
+ 0.21
200
5.0
1995
202
348
+ 0.29
+ 0.21
203
rn
a
lU
se
348.8 + 0.29
+ 0.21
0.21-0.35
nt
e
0
- 0.02
0
- 0.02
347
+ 0.29
+ 0.21
204
0
- 0.06
11.92
0
- 0.02
346
+ 0.29
+ 0.21
205
0
- 0.06
12.42
0
- 0.02
345
+ 0.29
+ 0.21
206
0
-0.06
368.8 0
-0.06
0
367
-0.06
0
365
-0.06
10.12
369.6 + 0.31
+ 0.21
368.8 + 0.31
+ 0.21
367 + 0.31
+ 0.21
365 + 0.31
+ 0.21
200
0
- 0.02
10.52 0
- 0.02
11.42 0
- 0.02
12.42 0
- 0.02
0.21-0.37
202
204
ZAVS
3.0
201
11.42
rI
1.2
349.2 + 0.29
+ 0.21
Z
ZALS
0,4
Fo
(Shell fitted)
205
12012/A1
Maintenance
ZA40S
Fitting the bearing shells (Fig. 'C')
Remark
Never reduce the clearance by filling the mating faces of the bearing shells. The ends of the bearing
shells protrude somewhat over the faces of the bearing cover or the bearing saddle. This is meant to
be and is absolutely necessary!
- Push the upper bearing shell, with well lubricated running surface but dry back, by hand between journal 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 lower bearing shell with dry back and well lubricated running surface into the bearing cover.
- Using the hydraulic jack 9408.38, press the bearing cover 1 upwards to the stop in the engine housing.
- Fit the two round nuts 5 onto the main bearing studs 4 till they are landed on the bearing cover. Remove the hydraulic
jack.
nl
- Fit the two transverse tie rods 3 into the bearing cover 1.
Fo
rI
nt
e
rn
a
lU
se
- Proceed with pretensioning the main bearing studs and the transverse tie rods in accordance with the instructions in
group 1201-1.
1995
1995
9410.02
9408.36
9408.09
EV
23
1 22
9408.09
9408.36
se
lU
19
9410.02
rn
a
nt
e
rI
Fo
9408.02
19
nl
I-I
22
95.7197
19
12012/A1
Maintenance
ZA40S
12012/A1
Maintenance
ZA40S
ca. 130mm
B
20
4
2
23
se
nl
21
20
Fo
21
EV
rI
9412.01
9412.08
4
2
9408.02
nt
e
rn
a
lU
9408.38
23
1
9408.38
95.7198
9408.02
5 z
EV
1995
12021/A1
Maintenance
ZA40S

Replacement of Bearing Shells and Thrust Ring Halves
1
2
2a
3
4
5
6
6a
7
8
9
10
* 11
* 12
13
14
Bearing housing lower part

Upper thrust ring half
Lower thrust ring half
Bearing shell
Thrust bearing shaft end
Positioning pins
Oil catcher upper part
Oil catcher lower part
Bearing housing upper part
End cover
Main bearing cover
Camshaft drive gear wheel
Screws
Thrust bearing screw
Positioning pin (long)
Positioning pin (short)
I-I
se
2 3
10 16
rn
a
nt
e
6a D
2a 3 4
12*
II - II
11*
I
12*
18
D
17
III
III
13
14
rI
Fo
2a
Screws
Oil containing piece
Fitted bolts
Fig. 'A'
Through bolts
and 'D'
Dial gauge
Flywheel
Fig. 'B'
Hydr. jack 9421.06 and 'C'
Stud
Nut
Piston
Cylinder
D Apply sealing compound

S Clearance
GL Threaded hole
lU
2 6 11* 15 7 GL 8
15
16
17
18
23
24
25
* 26
27
28
29
Hydr. hand pump 9408.02

Branch piece
9408.03
Pressure gauge
9408.04
HP hoses
9408.09
Torque wrench
9408.17
Force amplifier
9408.19
Segment
9412.08
Mandrel
9412.09
Hydraulic jack
9421.06
Hydraulic jacks
9433.01
Round bar
9433.01a
Eye bolt M16
Dial gauge with mounting pedestal
nl
1
1
1
2
1
1
1
1
1
2
1
1
1
Tools:
III - III
Remark
Depending on the execution,

hydraulically tensioned studs
26 are used instead of thrust
bearing screws 12.
Pay attention to the section
'Loosening and tensioning of
studs 26'!
11*
D
II
5
95.7199
II
3.00
12021/A1
Maintenance
ZA40S
Check the condition of the bearing shells and thrust ring halves in accordance with the instructions in the Maintenance
Schedule or according to the prescribed intervals of the classification society. Within a period of 5 years all the bearings
must have been inspected at least once.
Whether a bearing shell may be reinstalled, depends mainly on the condition of its running surface. Please refer to
group 0003-2 for respective information.
Thrust ring halves
For these parts the same recommendations apply as for the bearing shells, i.e. only such thrust ring halves may be re
used, which are in good condition. It is also of the greatest importance that the ring halves are refitted in the same loca
tion from where they were removed.
When removing the thrust ring halves, the shaft shoulders must also be inspected; they must be smooth and clean.
nl
Oversize thrust ring halves
If the shoulder of the thrust bearing shaft, which was subjected to the load during operation, has become rough and has
therefore to be remachined, then oversize thrust ring halves have to be fitted.
When remachining the shoulder as little material as possible should be removed, but the distance between shaft shoul
ders must, after machining, correspond to one of the ('steps') dimensions 'L' in the table below.
200
0.8
201
2.0
202
4.0
Length 'L'
mm
150.8 + 0.04
0
+ 0.04
152
0
+ 0.04
154
0
Fo
Axial clearance
mm
nt
e
Oversize
mm
rI
Index
rn
a
lU
se
Oversize thrust ring halves have to be selected in accordance with the dimension 'L' and they have, without fail, to be
fitted on that side where the shoulder had been remachined! Shaft shoulder and locating ring half must be marked ac
cordingly.
0.20 - 0.44
0.20 - 0.44
0.20 - 0.44
Thrust Bearing Shaft
Re-machined
shaft shoulder
95.7200
Oversize ring half

on re-machined side
1995
Standard ring half

Thickness: 15 0.10
0.15
12021/A1
Maintenance
ZA40S
Removing the bearing shells and the thrust ring halves

Working sequence: (follow Fig. 'A' on preceding page)
- 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 screws if necessary.
- Remove all the screws 11 of the bearing housing upper part 7 and loosen the two thrust bearing screws 12 in two or
three equal steps and remove.
- Fit an eye bolt (M16) into the treaded hole 'GL' in the bearing housing upper part 7 and lift the housing upper part off
(about 80 kg).
- Remove both upper thrust ring halves 2 as well as the upper bearing shell.
- Adjust a (micrometer) dial gauge 23 on the top of the thrust bearing shaft (Fig. 'B'). Place a hydraulic jack 25 under the
flywheel and with it lift the shaft by about 0.15 mm (Fig. 'C'). Take care that the shaft remains radially in the centre!
nl
- Use segment 9412.08 - pressing it against the shaft - to push the lower bearing shell out (Fig. 'B') and remove it.
Before you attempt to pull the lower bearing shell or the lower thrust ring halves 2a out, check and
ensure that the shaft does not push axially against one of the thrust rings. If necessary shift the crank
shaft axially in the appropriate direction. The shaft must also be equally spaced in the centre radially,
as otherwise the bearing shell is jammed and can only be removed with difficulty.
II
I-I
rn
a
23
lU
se
Attention
- Use mandrel 9412.09 to press both thrust bearing ring halves 2a out till you can lift them out.
9412.08
24
9412.09
nt
e
Fo
rI
9412.08
25
II
2a
9408.09
9412.09
9408.02
I
9412.08
95.7201
2a
1995
12021/A1
Maintenance
ZA40S
Fitting the bearing shells and the thrust ring halves (Fig. 'A', 'B' and 'C')
- Clean thrust bearing shaft 4 and the bore of bearing housing lower part 1 carefully, lubricate the shaft journal lightly.
- Check whether the bearing shells and the thrust ring halves are undamaged.
- Check whether the crankshaft is in such a position that sufficient space is available axially to fit the thrust ring halves.
If necessary shift the crankshaft slightly axially.
- Using hydraulic jack 25 under the flywheel lift it and the shaft until the (micrometer) dial gauge 23 mounted above the
shaft journal shows 0.15 mm (Fig. 'B'). Take great care that the journal is radially in the centre.
- Push the lower bearing shell as well as the two lower thrust ring halves by hand as far as possible between shaft journal
and housing bore. Ensure that the bearing surface of the thrust ring halves lie against the corresponding shaft shoul
der.
nl
- Press segment 9412.08 against the shaft journal and slip in the lower bearing shell until the dividing faces protrude by
the same amount on both sides.
- Release the pressure in jack 25 under the flywheel and remove the tools.
se
- Apply oil lavishly on the shaft journal; use new engine oil.
- Slide both thrust bearing ring halves in with the aid of mandrel 9412.09 until the dividing faces protrude by the same
amount on both sides.
- Apply sealing compound to the engine side of the bearing housing upper part. (Also a very thin coat of sealing com
pound on the horizontal separating faces).
Important!
rn
a
lU
- Place the upper bearing shell 3 and the upper thrust ring halves 2 into the bearing housing upper part and secure them
with the locating pins 5.
Fitting condition: Bearing shell on its rear side dry, on the running surface coated with oil, bore of the thrust bearing
housing upper part dry.
Before fitting them apply MOLYKOTE paste Gn 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.
nt
e
- Fit bearing housing upper part 7 and fasten to the engine end plate with the screws 11 uniformly, at first only lightly
with about 100 Nm.
rI
- Fit and tighten uniformly the two screws 12 in several equal steps with a torque wrench to 780 Nm. If you use the force
multiplier contained in the engine tools, the tightening value is 220 Nm.
- Check that no clearance exists between the bearing housing upper and lower part.
Fo
- Tighten the screws 12 with a torque wrench to the final value of 1230 Nm or when using the force multiplier to 350 Nm.
- Finally tighten the screws 11 also in several equal steps to the final value of 740 Nm.
- Measure the axial clearance of the crankshaft with the thrust ring halves fitted, by pressing the crankshaft with a hy
draulic jack alternately into both end positions. The axial movement is measured with a dial gauge (please refer to
Clearance and Wear Table 0352-1).
- Finally lock the screws 11 in pairs with locking wire (Fig. 'A').
1995
12021/A1
Maintenance
ZA40S
Fitting the oil catcher (Fig. 'D')

- Clean and degrease carefully front and horizontal separating faces of oil catcher upper and lower part (6 and 6a) and
apply sealing compound to these surfaces.
- Fit oil catcher lower part 6a first, locate with taper pins 14 and tighten with the screws.
- Place oil catcher upper part 6 into position, fit locating bolts 17 and through bolt 18.
- Apply LOCTITE to the treads of screws 15 and bolts 18 (refer to group 0003-1).
- Alternately tighten the nuts of bolts 17 and 18, then of screws 15, again nuts of bolts 17 and 18 in very small steps.
- The clearance 'S' between shaft and oil catcher should be about 1 mm all round.
se
18
6
lU
17
17
II
rn
a
II
14
nt
e
14
rI
Fo
6a
15
nl
I-I
II - II
95.7202
17
1995
12021/A1
Maintenance
ZA40S
Loosening and tensioning of studs 26 (Fig. 'E')

Loosening
- Clean the contact faces of the hydraulic jacks.
- Screw the hydraulic jacks 9433.01 onto the studs 26 till their cylinders 29 rest on the bearing housing upper part 7.
- Connect the hydraulic jacks by HP hoses 9408.09 with the hydr. hand pump 9408.02.
- Open relief valve on hydr. hand pump, and screw the pistons 28 of the hydraulic jacks in, till they land on the cylinders
of the hydraulic jacks (see Fig. 'E').
- Now turn the hydraulic jacks back a little until a gap of about 2-3 mm appears between the pretensioning jack and
the bearing housing upper part.
nl
- Build up a pressure of 600 bar (or a little more) with the hydr. hand pump and unscrew the two nuts of the studs by
about 4-5 hole intervals.
se
- Release the pressure to 'zero' and remove the hydraulic jacks.
lU
Tensioning
- Clean the contact faces of the nuts 27, screw them on and tighten them with the round bar 9433.01a until landed.
rn
a
- Screw hydraulic jacks 9433.01 onto the studs 26 till their cylinders 29 are landed.
- Connect the jacks with the hydr. hand pump 9408.02 by the HP hoses 9408.09.
nt
e
- Open relief valve on hydr. hand pump, and screw the pistons 28 of the hydraulic jacks in, till they land on the cylinders
29 of the hydraulic jacks (see Fig. 'E').
- Build up a pressure of 100 bar with the hydr. hand pump and keep this pressure constant.
- Tighten the round nuts 27 with the round bar until they are firmly seated (check seating with feeler gauge).
rI
- Release the pressure to 40 bar.
- Measure protrusion 'X' of piston 28 and make a note of it (see Fig. 'E').
Fo
- Raise tensioning pressure to 600 bar. Keep this pressure constant and tighten the nuts 27 with the round bar until they
are firmly seated (check seating).
- Release pressure to 40 bar and measure protrusion 'X1' of piston on both hydraulic jacks and make a note of it. When
the waisted studs are correctly pretensioned the elongation amounts to: X1 - X = 1.0 0.1 mm.
- If the measured elongation deviates considerably from the above figure, repeat the whole tensioning procedure.
- Release the pressure to 'zero' and remove the hydraulic jacks.
3.00
12021/A1
Maintenance
ZA40S
X1
29
28
nl
26*
9433.01
26*
27
rn
a
lU
se
27
Fo
rI
nt
e
9408.09
9408.04
9408.02
00.7286
9408.03
7 z
3.00
Group2
Betrieb
ZA40S
Fo
rI
nt
e
rn
a
lU
se
nl
Group 2
21051/A1
Maintenance
ZA40S
Cylinder Liner
Measuring Wear and Remachining of Cylinder Liner Bore
Tools:
1
1
1
1
1
Measuring rail
Measuring tool
Setting gauge
Wear ridge milling tool
Carbon removing machine
(for carbon removal in upper
part of cylinder liner)
1 Honing machine
9421.02
9421.03
9421.03a
9421.09
9421.10
1 Cylinder liner
2 Top piston ring
9421.11
9421.02
9421.02
125
9421.03
lU
rn
a
se
nl
The wear of the cylinder liners should be checked during every overhaul or whenever a piston is removed. Always mea
sure cylinder liners in situ and when engine is cooled down.
To permit comparisons with previous measures it is inevitable that measuring is always done in the same place and that
the measured values are noted in a log.
To this end always use the measuring rail 9421.02 (Fig. 'A') which is available in the engine tools. It is so designed that it
can simply be hooked over the top face of the liner. Measure at the four points A, B, C and D in the engine axis and at
right angles to it.
Avoid measuring errors by preventing the measuring tool 9421.03 being exposed to large temperature variations. The
setting gauge 9421.03a must be used for calibrating the measuring tool.
Generally the most important wear occurs at point 'A'. For maximum permissible inside diameter please refer to Clear
ance Table group 0352-1.
nt
e
175
Fo
175
rI
360
00.7287
3.00
21051/A1
Maintenance
ZA40S
After a long operating time a socalled wear ridge appears in the top part of the running surface. During overhaul this
wear ridge must be ground off carefully with the wear ridge milling tool 9421.09 without damaging the running surface in
any way. It is possible that the wear ridge must be removed to permit withdrawal of the piston. If this is the case, lower the
piston by barring the engine and cover the piston and the liner surface above it carefully to prevent any foreign particles
from penetrating between piston and cylinder liner.
For removal of the wear ridge on the cylinder liner milling tool 9421.09 must always be used. The removal of wear ridges
should be carried out after the first piston removal and after the first replacement of piston rings, whereby the machi
ning has to be done as shown in Fig. 'B'.
A repetition of the machining of the wear ridge may be necessary after a longer operating period or after replacing a
piston.
After completing the remachining, the cylinder liner bore must be cleaned very carefully in order to avoid scratch marks
on the piston.
nl
On cylinder liners which are provided with a fine thread in the uppermost portion, the hard combustion residue must be
removed prior to pulling the piston. For removal of the combustion residue the carbon removing machine 9421/10 must
be used (Fig. 'C'). For this work the space above the piston has to be well covered, so that no combustion residue can
enter between piston and cylinder liner bore.
se
In order to avoid damaging the fine thread it is necessary to carefully centre it in the cylinder liner 1, before starting ma
chine 9421/10.
When removing combustion residue, be sure to pay attention not to damage the fine thread. Combustion residue within
the thread itself has not to be removed.
lU
Avoid removing combustion residue by using wire brushes, scrapers, pointed utensils etc.
rn
a
After having removed the combustion residue, the inner diameter of the cylinder liner in the region of the fine thread
mm.
must measure 400 +0
-0.1
After having removed the combustion residue, the cylinder liner bore must be thoroughly cleaned.
nt
e
Should a piston have been removed and equipped with new piston rings and oil scraper rings, then the cylinder liner bore
must be honed with the honing machine 9421.11. Possible hard wear areas must be levelled by honing. During this work,
it isabsolutely necessary to prevent machining residues from entering the crankcase. To prevent this, the best means is to
place a suitablle dirty oil catcher bowl into the crankcase of the respective cylinder.
After honing, the cylinder liner bore has to be washed with clean Diesel fuel or kerosine using a clean paint brush.
Note
1995
rI
Reworking of the cylinder liner's running surface may only be carried out by honing. Under no cir
cumstances may the bore of cylinder liner be simply cylindrically rebored by turning out, as other
wise the guidance of the piston is impeded.
Fo
Attention
For the utilization of the honing machine mentioned above, the working instruction of the respective
manufacturer must be followed.
21051/A1
Maintenance
ZA40S
402,5mm
after machining
nt
e
rn
a
lU
se
1.5mm
TDC
nl
prior to machining
rI
9421.10
Fo
1
0
400 -0,1
1
95.7085
3 z
1995
21052/A1
Maintenance
ZA40S
Cylinder Liner
Removing and Fitting a Cylinder Liner
Tools:
Hydr. hand pump
Branch piece
Pressure gauge
HP hoses
Torque wrench
Device for lapping
Pressure yoke
Suspension device
Fixing plate
Shackle
Rope (capacity 1000 kg)
9408.02
9408.03
9408.04
9408.09
9408.17
9421.01
9421.04
9421.08
9433.08
1
2
*3
4
5
6
7, 7a
8
Cylinder liner
Orings
Screw M20
Centring piece
Screws
Engine housing
Orings
Cylinder lubrication pipe
9
10
11
12
13
Screws
Connecting rod head
Screws
Screws
Counterweight
* Tightening according
to instructions
1
1
1
2
1
1
1
1
1
1
1
nl
Remark regarding runningin of new cylinder liners
When one or more cylinder liners are replaced, these have first to be runin, whereby the instructions of the Operating
Manual in group 0300-1 'Runningin the Engine after an Overhaul' have to be followed.
se
Preparatory work for the removal of a cylinder liner
lU
- Drain all the cooling water from the engine. Remove the cylinder head and withdraw the piston of the cylinder liner
concerned (see group 2701-1 and 3401-1).
- Bar the crankshaft until the crank of the liner concerned stands in T.D.C.
rn
a
- Cover the space below the cylinder liner concerned with clean cardboard or similar to ensure that no foreign particles
can enter the crankcase.
Removal
nt
e
- On engines equipped with pistons without inner lubrication, loosen pipe connections 8 and remove the banjo bolts
(Fig. 'A').
- Loosen screw 3 of the centring piece 4 and remove it (Fig. 'A').
rI
- Turn the connecting rod head 10 to the position shown in Fig. 'B'.
- Connect the jacking yoke 9421.04 by two HP hoses 9408.09 to the hydraulic hand pump 9408.02 and fasten it with the
screws 11 to the connecting rod head 10 as shown in Fig. 'B'.
Fo
- Turn the connecting rod head with fastened jacking yoke into the position as shown in Fig. 'C'.
- At the same time fasten the fixing plate 9433.08 by screws 12, as shown in Fig. 'A1', to connecting rod head 10. The
fixing plate must come to lie on counterweight 13. The fixing of the connecting rod head is necessary for safety reasons
in order to prevent an inadvertent turning of the connecting rod head with the pressure yoke fitted.
- Actuate the hand pump 9408.02 carefully paying attention that the yoke correctly mates the bottom of the cylinder
liner.
- Check again whether the screw 3 has actually been removed (Fig. 'A').
- Continue pumping and jack the cylinder liner out of its guide.
(Attention! The stroke of the jack in the yoke is only 54 mm)
- Mount the suspension device 9421.08 on the cylinder liner top and fasten it with the screws 9 (Fig. 'C' and 'E'). Watch
that the screws 9 mate with the holes in the cylinder liner collar.
- Fasten one shackle with the rope at 'AH' on the suspension device and pull the cylinder liner (about 450 kg) out (Fig.
'C').
- Remove the jacking yoke, the hydr. hand pump as well as the fixing plate 9433.08 from the engine.
L-Mot. / 1995
21052/A1
Maintenance
ZA40S
- Place the removed cylinder liner on an even surface and remove the suspension device.
- Clean the landing surface on the engine housing and check whether it is damaged.
- Clean the guiding bores in the engine housing and if necessary smooth out with emery cloth.
Fitting
- Check whether the landing surface for the cylinder liner and the guiding bores in the engine housing are clean and
smooth.
- Smear the landing surface on cylinder liner/engine housing with sealing compound Hylomar SQ32/M or Golden Her
metite.
- Equip the cylinder liner with new heat resisting Orings (please refer to Operating Instructions group 0328-1) and
smear these as well as the guiding surfaces 'F' in the engine housing with fresh engine lubricating oil.
nl
- Mount the suspension device 9421.08, fasten it with the screws 9 in the liner collar and lift the cylinder liner with the
crane on shackle and rope at the suspension point 'AH' (weight about 450 kg).
se
- Lower the cylinder liner slowly and carefully into the engine housing.
- With the cylinder liner suspended, blow compressed air through the lubricating oil bores at the bottom (only for en
gine equipped with pistons without inner lubrication).
lU
- Before the cylinder liner mates the guide bores, turn it so that the centring piece 4 when further lowered will fit into
the bore provided on the camshaft side. With smooth and well lubricated guide bores 'F' and Orings, the cylinder
liner the cylinder liner will slide down under its own weight into the engine housing. If necessary tap the liner collar
lightly with a lead hammer.
rn
a
- Finally locate the liner with the screw 3 dipped in oil and attach cylinder lubricating pipes to the bottom end of the
liner (only for engine equipped with pistons without inner lubrication). Tighten the screw 3 with 150 Nm.
- If necessary lap the sealing surface on the liner collar with lapping ring 9421.01 and lapping paste.
Fo
rI
nt
e
- Actuate the hand crank of the cylinder lubricator and check that the oil issues from both lubricating holes in the rele
vant cylinder liner (only for engine equipped with pistons without inner lubrication).
1995 / L-Mot.
21052/A1
Maintenance
ZA40S
I-I
1
3*
4
5
II
II
2
6
7a
rn
a
A1
lU
5 3* 4
se
nl
nt
e
Fo
rI
9421.04
10
10
9433.08
13
95.7075
13
12
L-Mot. / 1995
1995 / L-Mot.
4 z
11
9421.04
AH
9421.08
9408.02
10
9421.04
9408.03
9408.09
se
9408.04
lU
9421.08
rn
a
nt
e
rI
Fo
nl
95.7203
9421.04
9421.08
10
21052/A1
Maintenance
ZA40S
27011/A1
Maintenance
ZA40S
Cylinder Head
Removing and Fitting a Cylinder Head
1
2
3
*4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
20
Nut
Rocker arm cowling
Thread protecting cap
Cylinder head studs
Oring
Nut for item 4
Orings
Valve guides
Valve seat
Orings
Push rod cladding
Orings
Connecting piece
Screws
Tubular rubber ring
Push rod
Cylinder head
HPfuel pipe
Cylinder liner
21
22
23
24
25
26
27
28
29
30
31
32
33
Soft iron gasket

Insert bush
Orings
Oil connecting piece
Screw
Flange
Screw
Engine casing
Screw
Centring pin
Piston of hydr. jack
Cylinder of hydr. jack
Hose coupling
9408.01
9408.16
9408.17
9427.01
9427.01a
9427.02
9427.03
9427.04
9427.09
9427.10
9427.11
9427.34
9427.57
nl
Hand pump with accessories

Depth gauge
Torque wrench
Hydraulic jacks
Round bar
HPhoses
Lifting device
Special nuts
Jacking screws
Mandrel
Cleaning tool
Lifting device
Socket spanner
Assorted spanners
1
1
1
8
1
7
1
2
2
1
1
1
1
to instructions
se
Tools:
rn
a
lU
A major overhaul includes a thorough check of the cylinder heads. This also covers an inspection of the cooling water
spaces. When treated cooling water is used these spaces generally remain clear. Untreated cooling water, however,
usually causes scale formation which impairs the cooling effect. For the removal of this scale we recommend consulting a
specialist firm for chemical descaling.
The surfaces in contact with the combustion must be inspected for cracks. If cracks are suspected, and also after replac
ing valve seats and insert bushes, the water spaces have to be subjected to a water pressure test (7 bar), (please refer to
group 2701-6).
Valve seats with water side leakage must be replaced. Damaged seat surfaces have to be reconditioned (please refer to
instruction in groups 2701-2 and 2701-3 respectively).
nt
e
The Orings 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 group 2701-5).
Leaking insert bushes 22, also badly damaged ones, must be replaced (please refer to group 2701-4).
rI
Uneven or slightly damaged insert bushes 22 can be reconditioned with the aid of tool 9427.10 and the prescribed grin
ding/lapping paste (please refer to group 2701-4).
Fo
If the seating surface for the soft iron gasket between cylinder head and cylinder liner is damaged it can be reconditioned
with the help of lapping device tool No. 9421.01 and grinding/lapping paste. The same tool can be used for seating surfa
ces of cylinder head and cylinder liner.
R e m o v i n g a cylinder head
Preparations:
- Drain the cylinder cooling water from the engine and shut the shutoff cocks for the fuel valve cooling water.
- Bar the crankshaft to bring the piston of the respective cylinder to T.D.C. on the firing stroke. This means the inlet and
exhaust valves are closed.
- Loosen the nuts 1 of the rocker arm cowling 2 in even steps and lift the cowling 2 with the help of lifting device 9427.34
(please refer to Fig. 'J').
- Remove both push rods 16 and the screws 14 holding the connecting piece 13.
1995
27011/A1
Maintenance
ZA40S
- Unscrew and remove HPfuel pipe 18 and plug the openings on the fuel valve as well as in the HPfuel pipe, using clean
cloth. Separate all other pipe connections (exhaust, air, etc.) from 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.
L o o s e n i n g the cylinder head stud nuts (Fig. 'C')
Remarks
When screwing the pistons 31 of the jacks 9427.01 onto the stud thread (Fig. 'D') the oil is pressed
out of the cylinder and can return to the pump when the HPhoses are correctly connected to the
jack, whereby the nonreturn valve on the jack is opened. If this valve is pressed in by hand on the
unconnected jack the oil can flow out.
nl
Do not start pumping before all the hose couplings are correctly and firmly joined otherwise oil may
not enter the jacks as the nonreturn valve does not open.
Working procedure:
se
- Fit a jack 9427.01 on each of the 8 cylinder head studs, until the cylinders 32 touch the cylinder head 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 complete
jacks until at 'S' a gap of about 2 mm exists (observe the notes above).
- Connect all the short HPhoses 9427.02 according to Fig. 'C' and connect the two long HPhoses to the hand pump.
- Unscrew all the nuts 6 by 4 5 hole spaces.
lU
- Actuate the pump and pretension the eight cylinder head stud with 600-620 bar and hold this pressure constant.
rn
a
- When all the nuts are in this position release the pressure to 'Zero', by opening the relief valve on the pump.
- Disconnect the hose couplings between the eight jacks and remove jacks and hoses. If they are not immediately re
used, close the connecting openings with closing caps.
- Remove all the nuts 6.
nt
e
- Apply the jack screws 9427.09 and jack the cylinder head off the cylinder liner (Fig. 'G').
- The cylinder head freed, fit the lifting device 9427.03 on the studs of the rocker arms cowling 2 and lift the cylinder
head off by crane (please refer to Fig. 'K' for ZALS and Fig. 'K1' for ZAVS engines).
Fo
rI
- Cover the open combustion space with a wooden or cardboard lid to prevent foreign bodies falling in. The same
should be done with the openings of the push rod claddings.
F i t t i n g a cylinder head
Preparations: (Fig. 'A' and 'B')

- Clean the seating face on cylinder liner and cylinder head thoroughly. Any unevenness is to be ground off with grind
ing device 9421.01 and grinding paste.
- Place a new cylinder head soft iron gasket on the cylinder liner. (It should be a principle practice not to reuse any
gaskets, joints or Orings etc.) Check whether the gasket lies flat.
1995
27011/A1
Maintenance
ZA40S
- Place new Orings 10 into the grooves at the collar of the cylinder liner. Smear these before with engine lub. oil. Al
ways use only original Orings corresponding to our specification, see group 0328-1.
- Ascertain that all 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 bottom of the cylinder head lightly with
engine lub. oil.
- In order to have the oil connecting piece 24 (see Fig. 'E') correctly centred when cylinder head 17 is placed in position,
loosen first screws 25 and 27 before positioning the cylinder head.
- Check the drilling in the cylinder head 17 for centring pin 30 and the drilling in flange 26 for the oil connecting piece 24
for cleanliness. Smear the drilling in the flange and the Orings on the oil connecting piece lightly with engine lub. oil.
- Check combustion space for cleanliness and remove any foreign particles.
Working sequence:
nl
- Fit the lifting device 9427.03 on the cylinder head and attach it to the crane. Position of rope loop as per Fig. 'K' for
ZAL engines' and 'K1' for ZAVS engines.
se
- Lower the cylinder head slowly over the cylinder head studs until the centring pin 30 and the oil connecting piece 24
have mated. If the cylinder head does not slip down under its own weight to rest on the cylinder head gasket on the
cylinder liner apply the two 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').
P r e t e n s i o n i n g the cylinder head studs
lU
- After fitting the cylinder head tighten screws 25 and 27 of the oil connecting piece 24 again (Fig. 'E').
rn
a
- Clean the seating surface of all the nuts 6. Lubricate the thread of the studs and the seating surfaces with oil, do not use
MOLYKOTE paste.
- Screw down, by hand, all the nuts 6 until they seat and only then tighten them with round bar 9427.01a.
It is important that all the nuts run freely on their threads and that they can be screwed down by hand until seated.
nt
e
- Fit all the hydr. jacks 9427.01 on the cylinder head studs, screw them down until their cylinders 32 are seated on the
cylinder head.
rI
- The pistons 31 of the hydraulic jacks must be screwed into the cylinders 32 until they are flush with their upper edges at
'B'! As a result of nonobservance the required stroke cannot be obtained by the jack. Use the special spanner 9431.03
to screw down the pistons 31 (Fig. 'D'). Please refer to the note on the previous page.
- Shut the relief valve, actuate the pump and raise the pressure to 100
bar. Hold this pressure constant until all the nuts have been tightened
with the round bar until fully seated.
X1
Fo
- Connect the hand pump 9408.01 by the HPhoses with the hydr. jacks
9427.01.
- Open the relief valve on the pump and lower the pressure to 40 bar.
- Measure the projection 'X' of jack piston over jack cylinder with a
depth gauge and note them down (please refer to adjacent Fig.).
31
- Shut relief valve and actuate the pump raising the pressure to 600
bar. Hold the pressure constant until all the nuts 6 have been tight
ened down until seated.
32
- Release the oil pressure to 40 bar and measure the projection jack
piston over cylinder 'X1' with the depth gauge and note them down.
6
95.7063
1995
27011/A1
Maintenance
ZA40S
- Calculate the extension value X1 - X. For correctly pretensioned cylinder head studs, the difference between the
two measurements should be 1.4 0.1 mm. These measures serve as a safety check of the hydraulic pretensioning
method.
- If considerable differences are established in the measured values, then it is necessary to loosen the cylinder head
studs once more (please refer to group 2701-1) and to repeat the pretensioning procedure.
- When the stretching measure of all the studs corresponds approximately with the indicated value, remove all jacks,
the pump and close all open hose connections with sealing caps.
Leaking hydr. jacks do not permit correct pretensioning of the studs. In such a case the defective
jack must be dismantled and equipped with new sealing rings. The piston 31 can be withdrawn from
the cylinder when the circlip is removed from the cylinder. When reassembling the jack particular
care must be taken when fitting the face seal.
Remark
nl
Replacing the Orings in the oil connecting piece without removing the cylinder head (please refer to Fig. 'E')
The Orings 23 on the oil connecting piece 24 can be replaced without removing the cylinder head; for this proceed as
follows:
- Loosen and remove screws 25 and 27.
se
- Flange 26 and oil connecting piece 24 can be removed laterally.
- Remove the old Orings, smear a new set with engine lubricating oil and fit them.
lU
- For fitting put both parts together and place them between cylinder head and engine housing (take care of cleanness
of the seating faces).
rn
a
- Fit and tighten screws 25 and 27.
Fitting the rocker arm cowling, please refer to group 2705-1
Fo
rI
nt
e
Adjusting the valve clearances for inlet and exhaust valves, please refer to group 4401-1.
1995
27011/A1
Maintenance
ZA40S
3
4*
5
6
16
nl
15
14
se
13
lU
12
rn
a
11
9
10
95.7204a
rI
Fo
17
nt
e
18
10
20
22
21
95.7205a
1995
27011/A1
Maintenance
ZA40S
9427.01
23
17
9427.01a
26
27
23
25
27
24
25
nl
28
23
se
17
29
lU
28
95.7207
95.7206
9408.01
rI
nt
e
17
Fo
9431.03
rn
a
9427.02
9427.01
30
9427.09
20
33
31 B
32
9427.01a
4
95.7209
S
95.7208
1995
27011/A1
Maintenance
ZA40S
J
ZAL40S
ZAV40S
9427.34
9408.17
nl
9427.57
I-I
se
9427.04
lU
4
17
K1
95.7211
K
ZAL40S
rI
ZAV40S
nt
e
rn
a
95.7210
Fo
9427.03
9427.03
95.7212
7 z
1995
27012/A1
Maintenance
ZA40S
Cylinder Head
Replacing Valve Seats
Tools:
1 Spindle M24x365
with two nuts
1 Upper sleeve, complete
with ball bearing and nut
2 Cones
4 Clamping jaws
with two Orings (66.04x5.33)
1 Centring disc
1 Spindle M24x600
Assorted spanners
9427.26 *
1
2
3, 3a
4
5
Cylinder head
Spring dowel pin
Nut M24
Oring
Double ring spanner
AF 46/50
6 Valve guide bush
7 Oring
9427.27 *
9427.30 *
9427.31 *
9427.32
9427.26b
AS Seat
S Clearance
Z Shoulder
nl
*_assembled
8 Valve seat
9 Bush
10 Straightedge
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 than in new condition.
se
For the replacement of the valve seats it is best to stand the cylinder head on its side. The valve guide bush 6 must not be
removed.
lU
Removing a valve seat (Fig. 'A')
Gezeichnet fr Auslassventil
DRAWN FOR EXHAUST VALVE
rn
a
2 3 9427.30
Z 9427.31 3a
9427.32
9427.27
Fo
rI
nt
e
95.7213
9 8
9427.26
- Unscrew and separate the nuts 3 and 3a and the cones 9427.30 respectively until the extraction tool with the four
clamping jaws 9427.31 fitted can be pushed through the valve seat. (The ORings 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 fro until you feel that the shoulder of the
cone grips the valve seat at 'Z'. Only when this is the case tighten the nut 3a moderately with a spanner.
- Mount the centring disc 9427.32 and the upper sleeve with ball bearing and special nut 9427.27 and turn the special
nut with a spanner until the valve seat 8 has been withdrawn from its bore.
3.00
27012/A1
Remark
Maintenance
ZA40S
If a valve seat holds exceptionally tight in the cylinder head, it is possible to loosen the valve seat by
the following method:
Apply a welding bead all around the seat periphery on the sloping seat surface.
When the valve seat cools, it shrinks and can readily be withdrawn. (While welding take care that no
weld spatter contacts the bore surface of the cylinder head).
Fitting a valve seat 8

Place the cylinder head on its side, permitting the valve seat to be fitted in a horizontal direction.
Inlet valve seat:
- Clean and degrease thoroughly the bore and the seating shoulder in the cylinder head.
- Apply Loctite 648 to the sealing faces.
nl
- Push the inlet 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 fitted for this procedure).
The inlet valve seat rests on the shoulder at 'AS' but must have a clearance at the point 'S'.
se
Exhaust valve seat:
- Clean thoroughly the bore and the seating shoulder of the bush 9 and the exhaust valve seat. Any unevenness or dam
age must be polished out.
lU
- The radial sealing face of the exhaust valve seat as well as the corresponding bore in the cylinder head must be de
greased; then coat only the radial seating face of the exhaust valve seat with Loctite 648 as shown in Fig. 'C'.
- Before fitting oil lightly the Orings 7.
rn
a
- Push the exhaust 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 fitted for this proce
dure).
The exhaust valve seat rests on the shoulder at 'AS' but must have a clearance at the point 'S' (Fig. 'C').
nt
e
- The proper fitting position must be checked as shown in Fig.' C'. For that place a straightedge on the sealing face of
the cylinder head, and with a depth gauge measure the distance to the upper edge of the exhaust valve seat. The re
quired dimension is mentioned in Fig. 'C'.
rI
- A pressure test must be carried out after replacement of an exhaust valve seat (see group 2701-6).
Fo
Fitting a bush 9 for the exhaust valve seat

Before fitting a new bush 9 clean and degrease thoroughly the radial sealing face of the bush and the corresponding bore
in the cylinder head.
Coat the bore in the cylinder head with Loctite 648 as shown in Fig. 'C'.
For fitting the bush it is to be cooled down to about -190_C in liquid nitrogen. The two cooling water bores in bush 9
must correspond with the bores in the cylinder head. The bush must rest on the shoulder at 'AS' but must have a clear
ance at the point 'S'.
The proper fitting position must be checked as shown in Fig.' C'. For that place a straightedge on the sealing face of the
cylinder head, and with a depth gauge measure the distance to the upper edge of the bush. The required dimension is
mentioned in Fig. 'C'.
3.00
27012/A1
Maintenance
ZA40S
Gezeichnet fr Auslassventil
DRAW FOR EXHAUST VALVE
9427.26
AS
nl
9427.26b
8
9427.32
se
95.7213
9427.27
lU
rn
a
nt
e
+0.4
+0.2
x = 27 - 0.1
10
Fo
rI
y = 11.8 - 0.3
AS
NO LOCTITE
LOCTITE
AS
LOCTITE
NO LOCTITE
3 z
3.00
27013/A1
Maintenance
ZA40S
Cylinder Head
Grinding the Valve Seats of Inlet and Exhaust Valves
Tools:
1 Cylinder head turnover device

9427.17
(only supplied against specific order)
1 Valve seat grinding machine
9427.18
1 Hand grip
9427.35
Marking blue
1
2
3
4
5
6
Cylinder head
Valve guide bush
Grinder spindle
Valve seat
Nut
Brake (wooden staff, pipe
etc. for steadying)
7 Centering device
For information on the grinding of valve spindle seat please refer to group 2720-2
Valve seats should only be ground with the valve seat grinding machine.
When is the grinding of valve seats indicated?
se
- Every time new valve seats have been fitted in the cylinder head.
nl
Lappingin of the valve with valve seat using grinding paste is strictly forbidden!
- When new or reconditioned valve spindles are being fitted. An exception may be made, when the
valve seat surface is neither worn, corroded nor pitted.
+ 2'
lU
- When the seat surface of the exhaust valve seats is badly impaired, on heavy fuel operation.
(pitting, corrosion scars).
rn
a
Inlet valve seats with a valve seat angle of 30 0 are usually free from damage like pittings, or corrosion. However it can
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. A 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
group 2720-2).
nt
e
Exhaust valve seats for ZA40S engines may have valve seat angles of either 30
+ 2'
0
+ 2'
0
or 45
+ 2'
0
respectively. Valve seats of
rI
45
are fitted in ZA40S engines rated at 720 kW/cyl and also in engines with ER I / ER II at 660 / 600 kW/cyl. The
criteria for grinding are the same for both types of valve seats.
Grinding of valve seats
Fo
Fig. 'A' shows an example of 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 care has to be taken to prevent grinding dust from entering the cylinder 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.
The valve seat grinding machine must be well centered in the valve guide bush as well as in the valve seat with the aid of
the inbuilt centering device 7. This is of paramount importance.
Experience has shown that chatter marks appear when valve seat surfaces are reground in the vicinity of engines or
machines producing vibrations. This phenomenon can 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 without
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.
1995
27013/A1
Maintenance
ZA40S
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.
Cut: . . . . . . Coarse . . . . 0,1 mm
Fine . . . . . . 0,03 mm
Checking
lU
se
nl
A crack detection test by dye penetration must be carried out on the finish machined seat surface. No cracks are permit
ted!
After completing the grinding check whether the new or reground valve (refer to group 2720-2) sits correctly on the
valve seat. To 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 1/3 turn 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 plate (if the surface is rough, apply some oil). By
folding the movable part of the strap upwards the grip fastens itself by suction to the valve plate (Fig. 'B').
If the angle tolerances on valve and valve seat have been adhered to, then the contact pattern on the seat surface of the
inlet valves amounts to 20- 80% of the seat width. The bearing imprint must run from the inner diameter outwards (see
Fig. 'a' Illustr. 'C'). Besides the imprint check, the gap between valve and seat can 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 contact pattern must be 50 - 100%
of the 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').
Fo
rI
nt
e
rn
a
For inlet as well as for exhaust valve seats in the cylinder head it is important that the outer diameter of the valve seat
surface must be bigger than the outer diameter of the valve plate, and that the inner diameter of the valve seat is smaller
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'.
1995
27013/A1
Maintenance
ZA40S
+2
0
rn
a
45
lU
se
nl
9427.18
nt
e
+2
0
rI
30
Fo
2
1
B
9427.35
5
92.7079
1995
27013/A1
Maintenance
136
116
ZA40S
Inlet Valve Seat
0
- 0.5
+ 0.3
0
max. 138 mm
30 +20
20 80%
nl
rn
a
lU
se
Exhaust Valve Seat
nt
e
131 +
-0.2
a
max. 133 mm
30 +20
rI
50 100%
Fo
Exhaust Valve Seat for

ZA40S Engines with MCR = 720 kW/Cyl.
or Ratings ER I / ER II = 660 / 600 kW/Cyl.
131 +
-0.2
max. 132.4 mm
45 +20
50 100%
95.7226
1995
27014/A1
Maintenance
ZA40S
Cylinder Head
Replacing the Insert Bush for the Fuel Injection Valve and Lapping the Seating Surfaces
Tools:
1
1
1
1
1
1
1
1
Mandrel with centring disc

Cleaning tool
Spindle M24x880
Upper sleeve
Lower sleeve
Centring disc
Guide cone
Double ring spanner
AF 46/50
9427.10
9427.11
9427.26c
9427.27
9427.28
9427.32
9427.33
1 Special nut
2 Double end ring spanner
AF 46/50
3 Locking ring
4 Ball thrust bearing
5 Cylinder head
6 Oring
F Seating surface for

fuel injection valve
9427.26c
nl
7 Insert bush
8 Nut M24
9 Cleaning cloth
3
4
se
9427.27
lU
9427.28
rn
a
Fo
rI
nt
e
E1
6
7
E2
9427.33
8
95.7214
9427.32
Removing an insert bush (Fig. 'A')

- Fit the tool as shown in Fig. 'A' and turn the special nut 1 with spanner 2, until the insert bush 7 has been withdrawn
from its guide bore.
- Remove the insert bush and clean the guide bore in the cylinder head with a degreasing cleaning agent. Do not use
emery cloth except in exceptional cases and then only with greatest care to avoid enlarging the guide bores.
1995
27014/A1
Maintenance
ZA40S
Fitting an insert bush (Fig. 'B')

- The guide bores and the seating surface in the cylinder head must be clean, dry and undamaged.
- Degrease the insert bush in the region 'E2' and coat it with Loctite 648. Mount the insert bush in the cylinder head and
fit the tool as shown in Fig. 'B'.
- Fit the Oring 6 at 'E1' and smear the area with oil.
- 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 group 2701-6).
Lapping in the seating surface for the fuel injection valve
nl
The seating surface inside the insert bush must be inspected prior to each fitting of the fuel injection 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 metal, i.e. no
sealing ring may 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 centre of the cylinder head (Fig. 'C').
se
- Put a few spots of grinding paste on the face of the mandrel, insert it into the inset bush and lap the seating surface by
turning the mandrel to and fro several times.
- Fasten a soft cleaning cloth at the bottom end of tool 9427.11 and clean the setting surface with this device (Fig. 'D').
rn
a
lU
- If you carry out this reconditioning work with the cylinder head fitted, pay particular attention that no grinding paste
or any other objects can enter the combustion chamber.
rI
nt
e
9427.11
Fo
9427.10
5
9
95.7215
F
3.00
2 z
27015/A1
Maintenance
ZA40S
Cylinder Head
Replacing the Valve Guides for the Inlet and Exhaust Valves
Tools:
9427.26a
9427.26c
9427.27
9427.28
9427.32
9427.26a
1
2
3
4
5
Special nut M24

Locking ring
Ball thrust bearing
Cylinder head
Valve guide bush
B
9427.26c
2
3
6 Nut M24
7 Valve seat
8 Double ended ring
spanner AF 46/50
Spindle M24x600
Spindle M24x760
Upper sleeve
Lower sleeve
Centring disc
Double ended ring
spanner AF 46/50
nl
1
1
1
1
1
1
se
9427.27
9427.28
5
rn
a
lU
rI
nt
e
7
9427.32
95.7216
Fo
When valve guide bushes are worn beyond the permissible limit or are otherwise damaged, they must be replaced by new
bushes, whereby the undermentioned procedure should be followed:
Removal of a valve guide bush (Fig. 'A')
- Fit the tool as shown in Fig. 'A' and rotate the special nut 1 with the double ended ring spanner 8 until the valve guide
bush has been withdrawn from its guide bore in the cylinder head 4, and can be put aside.
- Clean the bore and the seating surface in the cylinder head carefully. Use emery cloth only for extreme cases and then
only sparingly, to avoid any enlargement of the bore in the cylinder head.
Fitting a valve guide bush (Fig. 'B')
Valve seat 7 must be fitted!
- Check the bore in cylinder head 4 and valve guide bush 5 for cleanliness and possible damage, remedy if necessary.
- Smear oil or Thred Gard into the bore and the lower part of the valve guide bush; push the guide bush as far as possible
into the bore and tap lightly with a lead hammer. Ascertain that the valve guide bush is exactly aligned with the axis of
the bore in the cylinder head.
- Mount the tool as shown in Fig. 'B' and, by rotating the special nut 1 with the double ended ring spanner 8, 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 with oil).
1 z
1995
27016/A1
Maintenance
ZA40S
Cylinder Head
Pressure Test of Water Spaces
Tools:
Key to Illustration:
1 Pressure testing device

1 Flange with hose coupling
Assorted spanners
9427.06
9427.07
1
2
2a
3
4
5
Cylinder head
Uncooled valve seat
Cooled valve seat
Insert bush
Oring
Oring
6
7
8
9
Vent screw
Screw M12
Hose coupling piece
Gasket
W Water spaces
Should, during operation or during an overhaul, a cylinder head show signs of water leakage (cracks, leaking valve seats
or insert bush), it becomes necessary to subject the water spaces to a pressure test at the next opportunity. Such a test
should definitely also be made when valve seats or insert bushes are replaced.
Working procedure:
nl
- Remove all the valves from the cylinder head and mount the pressure testing device 9427.06 equipped with two O
rings 4 in perfect condition in the bottom part of the cylinder head, and fasten it as shown in the illustration below.
- Fit the flange 9427.07 and fill the cylinder head with water, while the vent screw 6 remains open until all the air has
escaped.
se
- Subject the cylinder head to a pressure of 7 bar shut the valve of the supply pipe and leave the pressure in the cylinder
head constant for about 15 minutes. During this time the pressure in the water spaces may not diminish.
nt
e
rn
a
lU
- If the water space is tight, loosen the vent screw 6, drain the water from the cylinder head and prepare the cylinder
head for assembly.
9427.07
8
7
6
W
5
rI
Fo
95.7217
9427.06
2a
1 z
1995
27017/A1
Maintenance
ZA40S
Cylinder Head
Reconditioning a Relief Valve
Tools:
1 Special spanner
1 Ring spanner
1 Open end spanner
9427.23
AF 46
AF 65
1
2
3
4
5
6
Distance ring
Compression spring
Spring casing
Valve body
Valve seat
Spring plate
7 Ball
D Sealing face
P Punchedin blowoff
pressure value
H Recess
S Seat face
Relief valves which begin to leak in service must be removed and overhauled at the next opportunity, when the engine is
not in operation. In general all the relief valves should be dismantled and checked at every major overhaul of the engine.
Reconditioning a relief valve
nl
Working 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.
- Unscrew the relief valve, using an open end spanner AF 65 and the special spanner 9427.23, from the cylinder head.
1
2
rn
a
lU
Should remachining have to carried out on the relief valve or

parts thereof be replaced, then the opening pressure must be
checked and if necessary reset with distance ring 1. By chang
ing the height of the distance ring the opening pressure can be
set i.e. when reducing the height, lower opening pressure, the
higher the distance ring the higher the opening pressure.
se
- To dismantle the relief valve unscrew the spring casing 3 and remove compression spring 2 together with spring plate
6. Following this the valve body 4 can be pulled out of valve seat 5 together with ball 7.
nt
e
To vary the opening pressure by about 1 bar, the ring height

has to be modified by about 0.1mm.
rI
Engine rating:
Opening pressure:
up to 660 kW/cylinder . . . . . . . . 202 bar
Fo
Before reassembling smear all parts including the M27x2

thread to the valve seat 5 lightly with a heat resisting lubricant.
For the refitting in the cylinder cover no joint is to be used.
Remark
On engines of some stationary engines the

bores M27x2 in the cylinder covers are
closed with a screw plug instead of a relief
valve being fitted. These screw plugs seal
metallically and have therefore to be
fitted without joints.
5
7
1 z
M27x2
95.7218
3.00
27051/A1
Maintenance
ZA40S
Rocker Arms
Replacing the Rocker Arms of Inlet and Exhaust Valves
Torque wrench
Socket spanner
Circlip tongs
Eye screw M12
Assorted spanners
9408.17
9427.19
Main rocker arm

Aux. rocker arm
Circlip lock
Main rocker pin
Aux. rocker pin
Distance bushes
Rocker gear housing
Plugs
Oring
Plugs
10
11
* 12
13
RS Eye screws
to instruction
Vent valve
Tubular seal
Nut
Ball head cups
6 3
1
2
3, 3a
4
4a
5, 5a
6
7, 7a
8,8a
9, 9a
1
1
1
1
nl
Tools:
RS 9
RS 3a 8a 4a
5a
8a
3a
Fo
rI
nt
e
rn
a
lU
se
95.7219
9a
10
7a
To remove a rocker arm without removing the cylinder head or the rocker gear casing respectively, proceed as described
below:
- Bar the piston of the cylinder concerned to T.D.C. (firing stroke) when both valve groups are closed. (There must be
clearance between all the valves and their rocker arms).
- Remove the circlips 3 and 3a respectively with the circlip tongs.
- Using an eye screw (M12) pull out the plugs 7 and 9 and 7a and 9a respectively.
1995
27051/A1
Maintenance
ZA40S
- Shift the pin 4 or 4a carefully and just enough to permit the removal of the respective rocker arm. When an auxiliary
rocker arm 2 has to be replaced it is recommended to first remove the main rocker arm 1.
- Fitting is done in reverse sequence, after first blowing through all the oil passages in the rocker arm pins and the
rocker arms with compressed air. Further ascertain that all the Orings 8 and 8a are still in perfect condition, other
wise replace them with new ones.
Regarding clearances please consult the Clearance Table group 0352-1.
- After completing the replacement of the rocker arms, start the lubricating oil pump and check whether oil is flowing
out of all the bearing bushes and also from the ball head cups 13. (During this check bar the engine with the turning
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 the cylinder head must be carefully cleaned.
- Place a washer under every nut 12.
lU
se
nl
- Smear the thread of the studs, used to fasten the rocker gear housing, with oil, then fit the nuts 12 and tighten them in
several equal steps with the aid of the socket spanner 9427.19 and the torque wrench 9408.17 to total 540 Nm.
rI
Fo
nt
e
rn
a
12*
11
95.7220
13
1995
2 z
27161/A1
Maintenance
ZA40S
High Pressure Fuel Pipe and Fuel Delivery Valve

Removal, Reconditioning and Fitting
Tools:
9408.17
9408.17
9427.20
9427.21
9427.21a
1
2
*3
4
5
6
7
8
9
10
Protecting pipe
High pressure pipe
Cap nut
Delivery valve
Flange
Plate
Joint
Screw
Oring
Oring
* 11
12
13
14
15
16
17
Allen screw
Cylinder head
Valve casing
Fuel injection pump
Fuel stud
Cyl. pin
Spring
to instructions
1 Torque wrench
25-135 Nm
1 Torque wrench
140-560 Nm
1 Fitting device
1 Spanner plate
1 Socket spanner insert
AF 65
" / AF 6
1 Connecting piece 1" / "
nl
During a major overhaul the delivery valves 4, built on to the fuel stud 15, should be dismantled and checked. Valve seats
which are no longer in perfect condition must be carefully lappedin with grinding paste. When the seat is again flawless
the whole valve must be carefully washed in kerosene, white spirit or other cleaning fluid and then blown out with com
pressed air. The best way to dismantle a delivery valve is to first remove it together with the fuel stud.
se
Removal
- Loosen both cap nuts 3 (Fig. 'A') and remove high pressure pipe 2 with the aid of spanner plate 9427.21 and torque
wrench 9408.17.
lU
- Loosen and dismantle screws 8 to flange 5. Remove flange 5 and joint 7.
rn
a
- Set the socket spanner 9427.21a on the hexagon of the valve casing 13 and unscrew the fuel stud 15 with delivery valve
4 from the fuel injection valve.
- Loosen the screws 11 and separate the valve casing 13 with delivery valve 4 and spring 17 from the fuel delivery con
nection.
nt
e
Assembly
- Hold the valve casing 13 with the threaded end downwards and insert delivery valve 4 with spring 17.
- Wipe the end faces of the valve casing as well as the fuel stud with a clean cloth or the dry palm of the hand.
rI
- Place fuel stud 15 on the valve casing 13 and clamp them together with fitting device 9427.20 (Fig. 'B') and tighten
moderately.
Fo
- Smear the thread of screws 11 lightly with oil and tighten the screws evenly and crosswise to a final torque of 28 Nm.
- Smear the thread of the fuel stud lightly with oil and screw it into the fuel injection valve inserted into the cylinder
head.
- Set socket spanner 9427.21a with connecting piece onto valve casing 13 and tighten with the aid of torque wrench
9408.17 to 300 Nm.
1995
27161/A1
Maintenance
ZA40S
Fitting the high pressure fuel pipe

- Place joint 7 together with flange 5 onto cylinder head 12, but not yet tighten screws 8.
- Before fitting the high pressure pipe smear the Orings 9 lightly with oil.
- Smear the connecting thread of the valve casing 13 and of the fuel injection pump lightly with MOLYKOTE. Fit the
high pressure pipe but tighten first cap nut 3 only by hand.
- Tighten cap nuts with the aid of spanner plate 9427.21 and torque wrench 9427.17 to 130-150 Nm.
- Tighten screw 8 to flange 5.
*15
10 16
7 5
13 *3
1 (2)
nt
e
rn
a
lU
se
nl
12
17
4 *11 9
A
8
Fo
rI
15
2
1
9427.20
8
*3
13
6
7
9
14
Ablauf
DRAIN
00.7288
3.00
2 z
27201/A1
Maintenance
ZA40S

Replacing Valve Springs as well as Removing and Fitting of Valves
9427.24
1 Clamp ring (2parts)

2 Valve rotating device
ROTOCAP
3 Inner spring
4 Oring
5 Outer spring
6 Lower spring plate
7 Spring
8 Cylinder head
9 Guide bush
10 Valve spindle
11 Upper part for
TURNOMAT
Sleeve
Tensioning sleeve
Clamp sleeve (2parts)
Threaded spindle
Ball thrust bearing
Snap ring
Hand grip
Sleeve
Lower part for
TURNOMAT
21 Guide for
TURNOMAT
22 Ball
Replacing valve springs
Normally valve springs are replaced when the cylinder head is removed from the engine and placed
on its side.
They can, however, also be replaced when the cylinder head is fitted on the engine. In such a case bar
the engine to bring the respective working piston to firing T.D.C. (all valves 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. To mount the spring
tensioning device for fitting, the valve spindle must be lifted up by hand. To 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.
rn
a
lU
se
Remark
12
13
14
15
16
17
18
19
20
nl
1 Tensioning device
Tools:
Removing the springs
nt
e
Valve springs 3, 5 and 7 are removed as follows:
- Pull the rocker arm pin of the respective valve out sideways and remove the corresponding rocker arm (see sheet
2705/1).
Fo
rI
- For valves with ROTOCAP 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').
For valves with TURNOMAT 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 in Fig. 'B' and 'C'.
- With hand grip 18 screw down sleeve 19 till the valve rotating device ROTOCAP 2 Fig. 'A' or the upper part of TUR
NOMAT 11 Fig. 'B' are sufficiently low, that clamp ring 1 can be removed.
- Turn the hand grip 18 back until the springs are fully slackened.
- Remove the tensioning device and remove the springs.
Fitting the springs
- The fitting of the springs is done analogously to the removal but in reverse sequence.
- The seating faces must be clean and undamaged for the springs 3, 5 and 7 as well as the lower spring plate 6 and the
valve rotating devices ROTOCAP or TURNOMAT.
- When carry out the tensioning procedure of the spring 7 for fitting the conical clamp ring halves 1 of the TURNO
MAT, pay attention that the balls 22 engage with the guide grooves of the guide ring 21 (Fig. 'B' and 'C').
3.00
27201/A1
Maintenance
ZA40S
- Smear the tapered clamp ring halves 1 with MOLYKOTE paste Gn on all sides.
- 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 group 2701-1).
- Remove the valve springs as described before, then pull out the valvespindles.
- Inspect the seal faces of valve seat and valve body for damage and regrind them if necessary using the grinding
machine (please refer to group 2701-3 and 2720-2).
Fitting the valves
nl
- Clean the valve guide bushes 9 thoroughly and fit new Orings 4.
- Smear the valve spindles 10 well with oil and before fitting the springs check their easy movement within the guide
bushes 9.
- Fit the valve springs in accordance with the instruction in the earlier paragraph.
Fo
rI
nt
e
rn
a
lU
se
- Fit the rocker arm and adjust the valve clearance.
3.00
27201/A1
Maintenance
ZA40S
Ventil mit ROTOCAP
12
Ventil mit TURNOMAT
VALVE WITH ROTOCAP
19
VALVE WITH TURNOMAT
13
14
21
11
7
10
22
Ventil mit TURNOMAT

VALVE WITH TURNOMAT
18
se
18
nl
Ventil mit ROTOCAP

VALVE WITH ROTOCAP
3
5
Fo
rI
nt
e
15
rn
a
lU
9427.24
15
17
16
12
17
16
13
12
14
13
14
19
21
11
22
20
4
8
9
10
00.7289
3 z
3.00
27202/A1
Maintenance
ZA40S

Regrinding the Seats
Tools:
1 Valve seat grinding machine 9427.16
(only supplied against
specific order)
1 Marking template each
9427.36
for inlet and exhaust valve
Inking blue
The instruction for the regrinding

of the valve seats is contained in
group 2701-3.
The lapping together of valve spindle seat and valve seat with grinding paste must be avoided as a matter of strict princi
ple.
nl
Valve spindle seats which are considerably damaged by pitting or corrosion, must be reground with the machine. Suita
ble grinding machines are available in the engineering trade.The following angle tolerance for the seat surface of the
valve must be adhered to:
+ 6'
Inlet valve for ZA40 and ZA40S engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = 30 + 4'

0
se
Exhaust valve for ZA40 and ZA40S engines . . . . (MCR = 660 kW/cyl. or . . . . . . . . . . . . . . . . . . . . . . . . = 30- 2'
ER I = 600 kW/cyl and ER II = 550 kW/cyl)
0
lU
Exhaust valve for ZA40S engines . . . . . . . . . . . . . (MCR = 720 kW/cyl. or . . . . . . . . . . . . . . . . . . . . . . . . = 45- 2'
ER I = 660 kW/cyl and ER II = 600 kW/cyl)
Grind only wet i.e. with cooling agent.
rn
a
Make it a point to grind off only as much material as is absolutely necessary to obtain a clean smooth surface.
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.
nt
e
A crack detection test by dye penetration must be carried out on the finish machined seat surface. No cracks are permit
ted!
rI
Fo
On exhaust valves without anti wear armouring, the seat

may not be ground deeper than the face 'F' on the valve plate.
min. 9mm
On inlet valves with anti wear armouring, the valve plate

thickness after grinding must still measure at least 9 mm.
1995
27202/A1
Maintenance
ZA40S
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 contact pattern of 20 80% of the seat width and beginning from the smaller dia
meter.
20 - 80%
+6'
30+4'
Under the same conditions and with the same procedure as

described above, a marking check on an exhaust valve shows a
contact percentage of 50 - 100% of the seat width and run
ning inward from the outer diameter.
30- 2'
O
0
50 - 100%
se
45- 2'
lU
The above ruling also applies to ZA 40S engines with a MCR

of 720 kW/cyl, ER I = 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 diame
ter and running inwards.
nl
50 - 100%
rn
a
The seating surfaces of the inlet valves may not show any pit
ting marks or corrosion scars, 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
which they operated before and which was not re ground
either.
straight edge
nt
e
wear
rI
On the latest valve design this type of wear pattern will no longer
occur!
Fo
valve plate
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 through New Sulzer Diesel Ltd.
Grinidng sould be carried out only together with cooling agent.
Infeed advance:
Rouging:
about 0.025 mm infeed

grinding use both stone
halves alternately
Finishing: about 0.01 mm
Inlet Valve . . . . . . . . . . . a = 2 mm . . . . b = 0,5 mm

Exhaust Valve . . . . . . . . a = 5 mm . . . . b = 2,5 mm
On engines operating under unfavourable conditions for a

prolonged time, corrosion on the bottom of the valve plates
may occur. Valve plates on which a corrosion depth as listed
under 'a' (centre) and/or 'b' (outer diameter) has been mea
sured must be replaced.
A welding repair of a corroded exhaust valve is normally not

recommended for cost reasons.
1995
2 z
27221/A1
Maintenance
ZA40S
Fuel Injection Valve

Removing, Dismantling and Assembling
1
2
3
4
5
6
7
*8
9
10
11
12
Spring tensioner
Lock nut
Nozzle holder
Spring plate
Compression spring
Push rod
Insert bush
Cap nut
Locating dowel
Nozzle body
Nozzle needle
Oring
13
14
15
16
17
18
* 19
20
Oring
Fuel stud
Orings
Securing snap ring
Belleville washers
Pressure flange
Nut
Studs
to instructions
nl
1 Torque wrench
9408.17
(480 940 Nm)
1 Torque wrench
9408.17
(25 135 Nm)
1 Stirrup with spindle
9427.15
1 Lapping ring
9427.38
1 Socket spanner AF 65
9427.57
1 Connecting piece 1"
1 Connecting piece " / "
1 Short extension piece " x 8"
1 Socket spanner insert " x AF 24
Tools:
Removing from the cylinder head (Fig. 'A')
se
- Shut the shutoff valves for the nozzle

cooling water inlet and return pipes to
the cylinder head.
- Loosen and remove the fuel injection

pipe (see group 2716-1).
- Unscrew the fuel stud 14 (Fig. 'C') with
fittedon delivery valve and store in a
clean place.
lU
9427.15
9427.38
10
rn
a
- 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 with spindle (tool No.
9427.15) as shown in Fig. 'A' and pull the
injection valve from the cylinder head.
Fo
rI
nt
e
95.7222
- Check whether the sealing faces of the nozzle body 10 and the insert bush 7
are in order i.e. whether they show equal pressing marks.
- If necessary lap the sealing face on the front of the nozzle body 10 with the
lapping ring 9427.38 and some lapping paste by hand, until it is clean and
even over the whole circumference (see Fig. 'B').
95.7221
1995
27221/A1
Maintenance
ZA40S
Dismantling the fuel injection valve (Fig. 'C')

- Clamp the fuel injection valve by the cap nut 8 in the vice.
- Loosen lock nut 2 and with a spanner loosen the spring tensioner just sufficiently to relieve all tension from the spring
5.
- Clamp the fuel injection valve in the vice by the upper end of the nozzle holder (nozzle pointing upwards) and loosen
the cap nut 8 using the socket spanner 9427.57, the 1" connecting piece and a ring spanner AF 65. Remove the cap nut
8.
- Lift off the nozzle body 10 with nozzle needle 11 and place aside in a clean place. (Take care that the nozzle needle
does not drop out!)
The nozzle needles are lapped individually with their nozzle bodies; they form a unit together. It
must be strictly avoided to interchange nozzle needles and nozzle bodies!
Remark
se
20
19*
18
lU
17
16
rn
a
nt
e
15
4
5
6
Fo
rI
14
13
nl
- Loosen the spring tensioner 1 fully and remove it; remove spring 5, spring plate 4 and push rod 6 downwards.
12
MOLYKOTE-G
8*
9
10
11
MOLYKOTE G-n
95.7223
1995
27221/A1
Maintenance
ZA40S
Assembling the fuel injection valve

- For the assembly observe the utmost cleanliness and care.
- Clamp the nozzle holder 3 (without any inner parts) in the vice by the milled portion and with the nozzle seal face
pointing upwards.
- Check whether the inscription on the nozzle holder circumference (Specification) tallies with the indications in the
setting table of the engine.
- Wipe the sealing face of the nozzle body 10 and of nozzle holder 3 with the clean dry hand or wash them with Perchlo
rethylene, to obtain a clean dry sealing surface.
- Place the nozzle 10 carefully on the nozzle holder 3, taking care that the nozzle needle 11 does not drop out and that
the locating dowel 9 fits into the locating hole.
- Fit cap nut 8 and tighten by hand until it lands; then, using the torque
wrench 9408.17 with socket spanner 9427.57 and 1" connecting piece,
tighten the cap nut to 590 Nm (Fig. 'D').
nl
- Smear the thread of the cap nut 8 and the landing on the nozzle body 10
(where the cap nut presses the nozzle body) with MOLYKOTE paste Gn
(Fig. 'C').
se
- Clamp the nozzle holder 3 with nozzle pointing downwards in the vice by
the cap nut 8.
9427.57
- Smear all the inner parts, 6, 5 and 4 carefully with clean engine oil and fit
them as shown in Fig. 'C'. Screw the spring tensioner 1 in by hand then
tighten it to obtain the correct spaying pressure (see group 2722-2).
lU
8*
rn
a
- Fuel injection valves which are not immediately installed must be stored
in a place where they are protected from damage and from dust and cor
rosion attack.
nt
e
Fitting the fuel injection valve into the cylinder head (Fig. 'C')
- Equip the correctly adjusted fuel injection valve with new Orings 15 and
12 and smear them with engine oil.
3
95.7224
rI
- 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 follow the instruction in group 2701-4).
Fo
- Install the fuel injection valve and mount the flange 18, but do not yet tighten the nuts 19 (smear the threads of the
studs 20 with MOLYKOTE paste Gn).
- Fit the fuel stud 14 - with fitted delivery valve - from the side into the cylinder head and screw it by hand into the
nozzle holder (do not use any joints, but smear thread with oil).
- The lateral clearance of the fuel stud 14 must be distributed equally in respect to the bore in the cylinder head.
- Only then, tighten the fuel injection valve onto its seating with the two nuts 19 by compressing the belleville spring
stack 17 using the torque wrench. Tighten the nuts 19 alternately in several steps to a total of 250 Nm.
- Checking: Flange 18 must rest flush without clearance.
- After completing all the connections, the closed valves of the nozzle cooling water pipes can again be opened.
Remark
If it becomes necessary to remove the belleville washer stacks 17, the securing snap ring 16 must first
be taken out. When reassembling the belleville washers take the utmost care always to place the
washers 17 in pairs in the same position. The washer stacks in turn must be fitted as shown in Fig. 'C'.
3 z
1995
27222/A1
Maintenance
ZA40S

Checking the Condition of Spraying and the Spraying Pressure
Tools:
9427.40
9427.41 45
1
2
3
4
5
6
7
8
Spring tensioner
Lock nut
Pressure gauge damper valve
Nozzle holder
Cap nut
Fuel injection nozzle
Pressure gauge (0 500 bar)
Fuel tank
9427.43
rn
a
se
1
2
lU
nl
1 Spray testing device

(complete)
assorted spanners
nt
e
9427.44
9427.42
9427.45
Fo
rI
95.7225
9427.41
The fuel injection valves must be checked periodically as per maintenance schedule, or earlier if indications of faulty
combustion demands it, also after fitting a new fuel injection nozzle. The spray check has to be made with the spray te
sting device 9427.40 and its components.
For this test use only absolutely clean gas oil, which may not be poured back into the fuel tank 8 after the test.
Prior to checking a fuel injection valve, clean the same carefully externally and remove any existing combustion residue
on the injection nozzle with a brass wire brush.
The fuel injection valve to be tested is placed on the spray testing device 9427.40 and connected to the pressure connec
tion 9427.44 (without joint).
1995
27222/A1
Maintenance
ZA40S
Judging a fuel injection valve

To correctly judge a fuel injection valve, the following checks must be carried out:
D Loosen lock nut 2 and then spring tensioner 1, to relieve the nozzle needle of the fuel injection valve completely of
tension.
Check by a few short pump strokes of spray testing device 9427.40 whether the fuel is equally distributed from all spray
holes of the fuel nozzle.
D Using spring tensioner 1, adjust the opening pressure of the fuel injection valve to the value mentioned in the setting
table (normally 400 10 bar).
nl
Never hold fingers or hands directly against the spray holes of the injection nozzles due to the risk of
accidents.
Attention
D To check sealing between nozzle needle and nozzle needle seat of the fuel injection valve, keep a pressure of 200 20
bar constant, over a period of 5 seconds. During this time no dripping should be noticeable at the tip of the injection
nozzle.
lU
se
Fuel injection valves checked according to the above mentioned criteria and proven flawless can be further used.
Deficient fuel injection valves must be dismantled (see group 2722-1 and 2722-3) and their injection nozzles replaced
by new or overhauled injection nozzles.
Fuel injection valves which leak and drip have to be overhauled by the manufacturers or a specialized company.
Improper repair work on fuel injection valves can cause scrapping of the same.
Adjusting the opening pressure
rn
a
- Loosen the lock nut 2, move the pump lever up and down and at the same time tighten the spring tensioner 1 until the
opening pressure is read on the pressure gauge 20 (please note the required value, normally 400 10 bar, in the set
ting table).
nt
e
- Shut the pressure damping valve 3 and check with short fast pump strokes whether the fuel nozzle sprays equally.
When this condition is reached, tighten the lock nut 2 firmly, while holding the spring tensioner 1 steady with a span
ner.
Fo
rI
- After tightening the lock nut 2 check the opening spray pressure once more.
1995
2 z
27223/A1
Maintenance
ZA40S

Cleaning and Reconditioning
Tools:
1 Tool case
consisting of:
1 Checking disc
1 Copper mandrel
1 Wire brush
1 Tube
containing cleaning drills
and plug gauge
9427.48
1 Nozzle holder
2 Bush (hard)
9427.50
9427.51
9427.52
9427.53
Fuel injection valves in which the fuel nozzles no longer function satisfactorily must be dismantled and cleaned tho
roughly.
nl
Blocked nozzle holes have to be freed on the dismantled nozzle with the nozzle needle removed using the drill contained
in the tube 9427.53 of tool case 9427.48. After deblocking wash the nozzle body 10 out with gas oil or petroleum and blow
it through with compressed air. Dip the nozzle needle in clean gas oil or petroleum and insert it in the nozzle body. The
nozzle needle must slide onto its seat under its own weight.
For the cleaning of the nozzle interior do not use any pointed metallic utensils or tools, a wooden rod with a clean piece of
material is suited for this purpose.
se
The sealing face of the nozzle body must be checked.
Hold the bare nozzle body (without needle) with soft clamp jaws in the vice, sealing face upwards.
lU
Check the sealing face for flatness with the checking disc 9427.50 (Fig. 'A') whereby it is pressed against the sealing face
of the nozzle body and at the same time apply a circular movement. The checking disc being of bronze will leave a yello
wish mark on the high spots.
rn
a
During the check with the checking disc, the sealing face must be true or very slightly concave (higher on the edge than in
the centre). Damaged or uneven sealing surfaces must be overhauled by a specialized firm.
Finally wash the nozzle body thoroughly in gas oil or petroleum and blow it through with compressed air.
nt
e
Assemble the fuel injection valve and adjust the spray pressure and check the spray condition (see group 2722-2).
Should the function still not be satisfactory, replace the fuel nozzle by a new one or a reconditioned one. As a matter of
principle do not 'tinker' with the fuel nozzle as this may render a later repair impossible.
Fo
rI
We recommend sending fuel nozzles which do not function satisfactorily to a specialist firm or to New Sulzer Diesel
Winterthur for possible repair.
9427.50
1 z
1
2
95.7111
1995
27281/A1
Maintenance
ZA40S
Starting Valve in the Cylinder Head

Removing from the Cylinder Head, Dismantling, Lappingin, Assembling and Fitting
1
*2
3
4
5
6
7, 7a
8
9
10
* 11
12
9408.17
9427.15
9427.37
9427.47
Stud
Nut
Flange
Control air pipe
Oring
Snap ring
Cup spring (spring packet)
Valve casing
Screw
Pilot control valve
Nut
Valve spindle
lU
rn
a
18
20
rI
Piston
Oring
Spring
Casing
Soft iron joint
Rod seal
Piston seal ring
Spring
Disc
to instructions
9427.15
7a
8
9
10
11*
13
12
Fo
16
nt
e
19
18
14
19
18
15
se
1
2*
3 4
13
14
15
16
17
18
19
20
21
nl
1 Torque wrench
(140-560 Nm)
1 Extracting device
1 Centering sleeve
1 Overhaul device
1 Socket spanner top
(" / AF 24)
1 Socket spanner top
(" / AF 30)
1 Short extension
(" / 8")
Tools:
95.7227
17
95.7400
On the occasion of a general overhaul or if functional difficulties occur, remove the starting valves and recondition them.
Removal
- Loosen the nuts 2 and lift flange 3 off.
- Extract the starting valve complete with the spring packets 7 and 7a using the extracting device 9427.15 (Fig. 'B').
- Remove the soft iron joint 17.
3.00
27281/A1
Maintenance
ZA40S
- Should the removal be undertaken with the cylinder head fitted on the engine, close the opening in the cylinder head,
to avoid any foreign bodies falling into the combustion chamber.
- For further dismantling the starting valve loosen the screws 9 and remove them, after which the valve casing 8 can be
lifted off and the pilot control valve 10 removed with its spring 20.
- For turther dismantling clamp the valve spindle 12 at the milled face below the valve disc in the vice and loosen the nut
11.
- After removing the nut 11 the valve spindle can be slid out downwards
and the other inner parts removed upwards.
- After removing the parts check their condition.

- Faulty piston seal rings 19, rod seals 18, Orings 5 or 14 have to be re
placed by new ones of the correct specification. When replacing the pis
ton seal rings and the rod seals proceed with utmost care. Particularly do
not stretch or deform the slide ring of this twopart seal, as otherwise its
fitting becomes extremely difficult.
nl
7a
se
- Do not dismantle the spring packets 7 and 7a. Should it be necessary for
important reasons, pay careful attention to the arrangement of the cup
springs (note the figure on the right).
Lappingin
lU
- If the seat of the valve spindle has to be lappedin, fit the centring sleeve
9427.37 as shown in Fig. 'C' into the casing 16.
95.7228
- Using some lapping paste lapin the valve spindle onto the seat.
rn
a
- Badly damaged seat surfaces should first be ground by machine

(( = 45_) and only afterwards lappedin with grinding paste.
nt
e
Assembly
16
- The assembly of the valve is effected in reverse sequence analogous to the

dismantling.
rI
- Smear all the parts carefully with engine oil prior to fitting them in the
valve.
Fo
- Apply MOLYKOTE Gn to the thread; tighten the nut 11 with a torque

wrench to 180-190 Nm.
- Fit a new Oring 14 of correct specification smeared with oil into the
outer groove of the casing.
9427.37
3.00
95.7229
27281/A1
Maintenance
ZA40S
Fitting in the cylinder head
9427.47
- Before fitting the starting valve the sealing face in the

cylinder head must be checked for damages. If neces
sary recondition the sealing face with the overhaul de
vice 9427.47. For the application of the mentioned tool
refer to Fig. 'D'.
A fine lapping paste must be applied for reconditioning,
whereby the disc 21 is used as a guide. A thorough clean
ing of the sealing face and the bore in the cylinder head
after completion is absolutely essential.
21
- Insert a new soft iron joint 17 into the bore in the cylin
der head.
nl
- Smear the bore in the cylinder head with clean engine

oil and insert the complete starting valve onto the joint
17.
- Smear the threads of the studs well with MOLYKOTE

paste Gn.
se
- Mount the flange 3 and tighten the nuts 2 with a torque

wrench, with a socket spanner top " and extension
"/8" in small equal steps to a total of 250 Nm.
00.7290
Fo
rI
nt
e
rn
a
lU
- Check: Flange 3 must rest flush without clearance.
3 z
3.00
Group3
Betrieb
ZA40S
Fo
rI
nt
e
rn
a
lU
se
nl
Group 3
31011/A1
Maintenance
ZA40S
Crankshaft
Measuring Crank Deflections
Tools:
1 Checking device
9431.01
We recommend that the crank deflections be measured whenever:

- A general overhaul is being carried out.
- Main bearing shells have been replaced.
- There are indications of engine foundation deformation.
The following points have to be noted when taking crank deflections:

- All the running gear (pistons, connecting rods) should be in place.
- Measuring should always only be made on an engine which has cooled down.
nl
- A breakdown has occurred or for other reasons where a check on the support of the crankshaft is required.
se
- The dial gauge must always be fitted in the same position (see illustration on following page).
lU
- When dealing with a marine installation, it must be remembered that the loaded condition of the vessel should be as
nearly as possible the same at the time readings are taken.
Measuring procedure
rn
a
- The crankshaft is to be turned by the turning gear into such a position that the dial gauge (with about 1 mm of preten
sion) can be placed between two counterweights at measuring point 1, as shown in the illustration on the following
page, and set to '0'.
nt
e
- Then, with the aid of the turning gear, the crankshaft is turned in the normal running direction and stopped again so
that the value shown on the dial gauge at measuring points 2, 3, 4 and 5 can be read off and noted down.
- The noted values have to be recorded so that they can be compared with earlier or later measurements.
rI
- Where values are measured which lie outside those shown on the graphics 'A' and 'B', the cause has to be investigated,
whereby the crankshaft has to be uncoupled from driven equipment.
Fo
- In addition to this, the engine holdingdown bolts have to be slackened off to determine if a permanent deformation
of the engine foundation has occurred.
1995
31011/A1
Maintenance
ZA40S
Positions of the dial gauge during measuring

Position of dial gauge
at begining of measuring
Position of dial gauge

at end of measuring
~30
Positioning the dial gauge

End
Counterweight
Measuring positions
Beginning
Drawn for 8 cyl. engine
nl
(Tool 9431.01)
A
+0,10
+0,05
+0,05
0,10
+0,05
1 2 3 4 5
0,05
Fo
rI
+0,10
nt
e
mm
0,05
0,10
lU
rn
a
95.7231
2 z
95.7230
A NORMAL CRANKS and end crank No.

8 at the free end when neither torsional
vibration damper nor shaft is coupled up.
When the measured values still remain

outside the permissible limits, a closer in
vestigation has to be carried out and any
necessary corrections made. In such
cases contact should be made with the
engine builder.
0,20
1995 / L-Mot.
EXHAUST SIDE
Should the measured values exceed the

limit values, readings should be taken
again under various conditions (e.g. dif
ferent machinery room temperatures,
slackenedoff holdingdown bolts or un
der different loading conditions with ma
rine installations).
2 LIMIT VALUES for engines in opera

tion (engine cooled down).
0,15
0,25
1 LIMIT VALUES during engine erection

(strive for small negative values with Die
selalternator sets).
0,24
B END CRANKS (exception: crank at free

end, see Fig. 'A').
1 2 3 4 5
0,18
FREE END
se
DRIVING END
FUEL PUMP SIDE
Attention
The crank limit values refer to the
coupled condition!
31012/A1
Maintenance
ZA40S
Crankshaft
Loosening and Tightening the Coupling Bolts
Tools:
1
1
1
1
Hydr. hand pump

High pressure hose
Hydraulic cylinder
Special spanner
9408.01
9408.09
9408.36
9431.02
1
2
*3
*4
5
6
Crankshaft
Crankshaft end piece
Coupling bolt to shaft end piece
Coupling bolt to flywheel
Flywheel
Camshaft driving gear wheel
* Tightening according to instructions
To obtain a sufficiently firm connection, the coupling bolts for the flywheel and for the shaft end piece (locating bearing
shaft) must be very firmly tightened.
nl
Due to space reasons the tightening of the above mentioned bolts by impact wrench and hammer is only conditionally
possible. For this reason all bolts shall be tightened with the aid of a hydraulic cylinder 9408.36 and special spanner
9431.02. The utilization of these tools is shown in the illustrations overleaf.
se
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 final tighte
ning. The bolt elongation from tightening shall amount to 0.36 0.02 mm.
lU
Threads and nut seating surfaces must be smeared with MOLYKOTE paste Gn before tightening.
Working Procedure:
rn
a
First tighten all the nuts with the spanner - diagonally across - by hand as firmly as possible. Then tighten each bolt with
the aid of the hydraulic cylinder, the HPpump and the special spanner.
The tightening torque for the coupling bolts of the shaft end piece is 2300 Nm, or the pretensioning pressure on the
pressure gauge is 100 bar for the HPpump.
nt
e
The above tightening values are only valid if special spanner tool No. 9431.02 and hydraulic cylinder 9408.36 having a
piston area of 6.41 cm are utilized..
Should a hydraulic cylinder be used with a differing piston area then the correct pretensioning pressure can be calcula
ted according to the formula:
rI
P (bar) =
641
new piston area in cm 2
Fo
Loosening of the bolts is done in reverse sequence analogous to the tightening by using the same tools.
L-Mot. / 1995
31012/A1
Maintenance
ZA40S
II
I
5
2
6
1
3
9431.02
9408.36
lU
se
nl
II - II
nt
e
rn
a
II
9431.02
rI
Fo
9408.36
95.7232
9408.01
1995 / L-Mot.
9408.09
2 z
31013/A1
Maintenance
ZA40S
Crankshaft
Fitting the Counterweights
Tools:
1
1
1
2
1
2
1
Hydr. hand pump

Branch piece
Pressure gauge
HP hoses
Special spanner
Hydraulic jacks
Round bar 8 mm
1
*2
3
3a
4
5
6
7
9408.02
9408.03
9408.04
9408.09
9431.03
9433.07
9433.07a
Crankshaft
Waisted stud
Counterweight
Counterweight
Round nut
Centering pin
Cylinder
Piston
* Pretensioning according to instructions
The engine may not be turned when the hydraulic jacks are mounted!
Attention
nl
The fitting of counterweights 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.
se
Working procedure:
lU
- The contact surfaces of crank web and counterweight must be clean, dry and undamaged. The same applies to the
centring pin 5, except it has to be smeared with oil.
- Fit the two waisted studs 2 and tighten them to 50-100 Nm.
rn
a
- After mounting the counterweight screw the round nuts 4 on to the studs until fully landed.
P r e t e n s i o n i n g of the waisted studs
- Mount the hydraulic jacks 9433.07 on the waisted studs 2 till the cylinder 6 is landed on the counterweight.
nt
e
- Connect the hydraulic jacks to the hydr. hand pump 9408.02 by the HP hose 9408.09.
- With open relief valve of the hydr. hand pump, tighten the pistons 7, (using the special spanner 9431.03), onto the
waisted stud 2, until the piston 7 and the cylinder 6 are flush with the outer front side (Fig. 'B').
rI
- Close the relief valve on the hydr. hand 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 with a feeler gauge).
Fo
- Release the pressure to 40 bar 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 40 bar and measure the protrusion 'X1' on the jack and note it down (Fig. 'A').
When the waisted studs are correctly pretensioned the elongation amounts to: X1 - X = 0.75 0.05 mm.
If the stretch deviates considerably from this value, repeat the whole pretensioning procedure.
1995
31013/A1
Maintenance
ZA40S
L o o s e n i n g the waisted studs

- Mount both hydraulic jacks 9433.07 on the waisted studs 2 until the cylinders 6 are landed on the counterweight.
- Connect the hydraulic jacks to the hydr. hand pump 9408.02 by the HP hose 9408.09.
- Open relief valve on the hydr. hand pump and screw pistons 7 with special spanner 9431.03 onto the waisted studs,
until piston 7 and cylinder 6 are flush with the outer face.
- Now screw both jacks back until a gap of about 2 mm appears between cylinder 6 and the counterweight at 'S' (Fig.
'B').
If the gap is too small it may not be possible to loosen the pretensioning jack after the release. If the space is too large
the stroke of the jack may not suffice for a full pretension of the waisted studs.
- Actuate the hydr. hand pump and build up a pressure of about 600 bar (possibly a few bar more) and loosen the round
nuts 4 by about one full turn.
nl
- Release the pressure to 'Zero' and remove the jacks.
lU
rn
a
X1
se
nt
e
Fo
rI
95.7063
1995
9431.03
ZAL
9408.09
3 z
se
lU
3a
9431.03
y
ZAV
nl
9433.07
95.7233
9408.03
9408.04
9408.02
9408.09
Maintenance
DRAWN FOR ZA
Gezeichnet fr ZA
rn
a
2*
nt
e
rI
9433.07
Fo
B
ZA40S
31013/A1
1995
31301/A1
Maintenance
ZA40S
Torsional Vibration Damper

Taking a Silicon Fluid Sample
Tools:
1
1
1
1
1
2
3
4
C
K
Large screw driver

Flat punch
Hand hammer
Centre punch
Various spanners
Torsional vibration damper

Screw plugs
End cover of torsional vibration damper housing
Sealing ring
Silicon sampling tube
Lock by centre punching
Special 'sampling tubes' can be obtained from the manufacturer (see Fig. 'B').
nl
The service of a torsional vibration damper depends largely on the speed range in which the engine works. Friction on
the inner parts as well as changes in the characteristics of the silicon fluid can lead to a reduction in effect of the torsional
vibration damper. By periodically investigating the silicon fluid, the manufacturer of the damper can determine the ge
neral condition of same.
We therefore recommend that the silicon fluid should be investigated for the first time after about 12'000 running
hours. The results of the first investigation will determine at what intervals further checks should be carried out.
se
Before fluid samples are taken or any work is carried out on the vibration damper, the relevant service instructions of the
damper manufacturer must be observed.
lU
Taking a fluid sample

Preparation:
rn
a
Depending on the number of cylinders a torsional vibration damper may be fitted to the free end of the crankshaft as well
as to the free end of each camshaft.
nt
e
- On engines which are equipped with a crankshaft having a torsional vibration damper fitted on the free end, the clos
ing plate on the end casing at the free end or the corresponding pumps on engines having enginedriven pumps have to
be removed, before access can be gained to the screw plugs of the torsional vibration damper.
For the same reason the lateral camshaft closing plates have to be first removed for torsional vibration dampers fitted
to the camshaft.
- Rotate the crankshaft or camshaft respectively until one of the screw plugs 2 is in the best accessible position (Fig. 'A').
rI
- Using a flat punch, knock back the squeezed material in the slot, which serves as locking means.
- Loosen the screw plug, but do not unscrew it yet, it must still seal.
Fo
- Rotate the crankshaft or camshaft respectively until the two screw plugs 2 lie approximately horizontally (see Fig. 'A').
- Leave the damper in this position for at least three hours. (If the fluid sample is to be withdrawn from a removed
vibration damper the same conditions apply as regards the positions and the waiting time). In both cases the vibration
damper must have cooled down to about room temperature.
- Prepare the sample container, i.e. remove the screw cap and examine the bore which must be meticulously clean.
Attention
The threads on the two ends are unequal on the Holset Damper (see Fig. 'B').
1995
31301/A1
Maintenance
ZA40S
Drawing a sample (see Fig. 'A' and 'B')

- Unscrew the prepared screw plug 2 and in its place screw in immediately the sampling tube 'C' which is held ready.
- Wait till the silicon fluid flows out of the open sampling tube end. Depending on the viscosity of the silicon fluid this
may take some time. The process can be accelerated by the following:
1) Rotate the damper so that the sampling tube is as low as possible.
2) Remove the second screw plug 2 for a short period.
- As soon as the silicon fluid begins to flow out, close the sampling tube with the one screw cap.
- Unscrew the sampling tube from the damper casing (hold vertical) and fit immediately the screw plug 2 with a new
sealing ring 4. Avoid unnecessary leakage of silicon fluid.
- Fit the second screw cap on the sampling tube and finally tighten both moderately.
The special sampling tube permits drawing a specific quantity of silicon fluid from the damper. The
total numbers of samples should be limited to 10 times.
Attention
nl
- Tighten the screw plugs 2 with a torque of about 2,5 mkp and lock it by caulking metal into the slot with a powerful
blow of a centre punch at 'K'.
lU
Carl Hasse & Wrede GmbH

Mohriner Allee 30-42
D-12347 Berlin 47
Germany
se
The filled sample tube has to be labelled and sent to the following address for examination:
Holset Engineering Co. Ltd.
131 Parkinson Lane
Halifax HX1 3RD
England
rI
nt
e
rn
a
The label must contain the following information:

Engine type,
Engine No.
Number of operating hours of the vibration damper, also
its manufacturing serial number (this number is stamped into the cover in the vicinity of the warning
plate).
Fo
95.7234
1995
31301/A1
Maintenance
ZA40S
Proben Behlter / SAMPLE CONTAINER
Holset
nl
3/8BSF
Hasse & Wrede
se
M10x1
lU
nt
e
rn
a
M10x1
rI
Fo
5/16BSF
K
F
93.7153
3 z
1995
32121/A1
Maintenance
ZA40S
Turning Gear
Maintenance
1
2
3
4
5
6
7
8
8a
9
10
11
Assorted open end and ring spanners
Operating lever
Locking pin
Thrust ring
Spacer ring
Spacer ring
Oil drain plug
Cover for oil filling
Pinion
Pinion shaft
Oil level glass
Compression springs
Ball thrust bearings
Tools:
nl
AS Axial clearance
F Grease lubricated shaft
se
- Before starting the turning gear check the oil level. The level in the oil level glass 9 must be at least at the mark 'Min'.
For topping up use Hypoid gear oil class SAE 90, (no thinner oil may be used under any circumstances).
The oil should have good high pressure, corrosion protecting and antifoaming properties.
For filling oil remove the cover 7.
lU
- The shaft 8a, on which the pinion 8 is shifted for engagement and disengagement with the flywheel gear rim, must
always be well greased. (Serves also as rust protection).
rn
a
- About every 5 years drain the oil through the drain plugs 6 and replace it with 18 litres of fresh oil (for oil type see
above).
- If a lengthy duty is foreseen for the turning gear (for example an engine overhaul) grease the pinion teeth 8 with MO
LYKOTE grease.
Fo
rI
nt
e
- When replacing the ball bearings, make sure during fitting that the spacer ring 5, opposite the ball bearing housing
protrudes by 0.15 -00.05 mm, when it is pressed against the shaft shoulder.
1995
1995
2 z
8a
95.7235
max.
min.
AS=
0.3 0.6
rn
a
nt
e
rI
Fo
se
lU
4 11
95.7236
10
Maintenance
3 11
nl
32121/A1
ZA40S
33021/A1
Maintenance
ZA40S
Connecting Rod
Inspection and Replacement of Crankpin Bearing Shells
1
2
3
4
5
6
7
8
9
10
11
12
13
9408.02
9408.35
9433.02
9433.02a
9433.02b
9433.03
9433.03a
Stud (long)
Stud (Short)
Crankpin bearing upper part
Crankpin bearing lower part
Main bearing cover
Yoke
Engine housing
Adjusting nuts
Retaining device
Securing screw
Screw
Screw
Connecting rod
nl
1 Hydr. hand pump

with ancillaries
1 Hydr. cylinder (jack)
1 Removal device
2 Pin to removal device
1 Underlay to the
removal device
2 Lowering devices
2 Roller for the lowering
devices
Tools:
Bearing shells of the crankpin bearing can be removed and fitted without pulling out the working piston.
se
Procedure for the removal
- Loosen all the nuts of studs 1 and 2 as described in group 3302-2. Do not yet remove the nuts but leave them hand
tight.
lU
- 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 the crankpin bearing upper part has to be
inspected.
rn
a
- On both sides of the crankpin bearing upper part 3 screw in one ring screw each together with the steel rope of lower
ing device 9433.03. At the same time mount also the two rollers 9433.03a needed to lower crankpin bearing lower part
4.
nt
e
- Remove now all nuts of studs 1, then lower crankpin bearing lower part 4 with the aid of two lifting tackles, mounted
on the engine exterior. Lower with care, so as not to damage the threads of studs 1.
rI
- Mount removal device 9433.02 as shown in the illustration. For this screw in the two pins 9433.02a fully into the corre
sponding threaded holes in the main bearing cover 5. Fasten joke 6 of removal device 9433.02 with two screws 11 to
engine housing 7. Adjust retaining device 9 with adjusting nuts 8 in such a way that the removal device comes to lie
lightly against crankpin bearing upper part 3.
Fo
- 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 crankpin bearing upper part 3 together with connecting rod 13.
Attention
Lift the connecting rod with crankpin bearing upper part only just sufficiently that the bearing
shell can be removed.
In this position secure the connecting rod and crankpin bearing upper part by tightening securing
screw 10 firmly.
Before refitting used bearing shells check their condition carefully (see group 0002-2, 'Criteria for the replacement of
bearing shells'). Unduly worn or defective bearing shells must on no account be refitted, but must be replaced by new
ones. Any machining, scraping or filing of the bearing shells must absolutely be avoided!
Should it become necessary to regrind a worn roughened crankpin, then thicker bearing shells must be fitted, to suit the
reduced pin diameter. The following table advises on standard undersize bearing shells, the regrinding diameter for the
crankpin as well as the article denomination of the respective bearing shell undersize (dimensions are in mm).
L-Mot. / 12.96
33021/A1
Maintenance
Reduction of
crankpin
diameter
Crankpin
diameter
Shell thickness
ZA40S
Vertical bearing
clearance
Bore diameter
vertical
(shells fitted)
Article
denomination
349.6
0
-0.06
7.6
0
- 0.02
349.6 + 0.29
+ 0.22
200
1.2
348.8
0
-0.06
0
- 0.02
348.8 + 0.29
+ 0.22
202
3.0
347
0
- 0.06
8.9
0
- 0.02
+ 0.29
+ 0.22
204
5.0
345
0
- 0.06
9.9
0
- 0.02
+ 0.29
+ 0.22
205
8.0
342
0
- 0.06
11.4
0
- 0.02
+ 0.29
+ 0.22
206 *
347
nl
0.22 - 0.35
0.4
se
345
lU
342
* Undersized bearing shells with article denomination 206 may only be fitted after consulting New Sulzer Diesel Ltd.
rn
a
Working procedure for fitting
For fitting the bearing shells the shell rear side and the bore in the crankpin bearing body must be free from any damage.
Smear the running surface of the bearing shells lavishly with clean engine lubricating oil.
nt
e
- Fit the upper bearing shell equally spaced axially and radially into crankpin bearing upper part 3. Make sure that the
small tongue of the shell fits into the recess in the crankpin bearing upper part.
- Actuate hydr. hand pump 9408.02 to slightly raise connecting rod 13 together with crankpin bearing upper part 3, then
loosen securing screw 10.
rI
- Slowly lower the oil pressure by the relief valve of hydr. hand pump, till the bearing shell together with crankpin bear
ing upper part and connecting rod rests on the crankpin.
Fo
- 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 crankpin lower part 4 in the same manner as in upper part 3 described above.
- Using lowering device 9433.03 and rollers 9433.03a, lift crankpin bearing lower part with its bearing shell till it rest
against the crankpin.
- Fit the four nuts to studs 1.
- Tighten nuts of studs 1 as described in group 3302-2.
- Tighten nuts of studs 2 as described in group 3302-2.
Remark
The nuts of studs 1 should always be tightened before the ones of studs 2.
After completion of work remove all tools from the crankcase.

For a final check measure the bearing clearance on the fully fitted bearing and compare it with the values in Clearance
and Wear Table 0352-1.
12.96 / L-Mot.
13
10 9433.02b
9433.02
33021/A1
Maintenance
ZA40S
II - II
2
3
7
6
11
9433.03
8
1
nl
lU
se
II
9433.03a
9433.02b
9408.35
rI
3
10
11
6
7
9433.02
9408.35
nt
e
9408.02
rn
a
12 4
Fo
12
12
9433.02a
95.7237a
II
3 z
L-Mot. / 12.96
33022/A1
Maintenance
ZA40S
Connecting Rod
Loosening and PreTensioning the Studs of the Lower Connecting Rod Head
Tools:
Hydr. hand pump
Branch piece
Pressure gauge
HPhoses
Hydr. jacks
Round bar
9408.02
9408.03
9408.04
9408.09
9433.01
9433.01a
1 Connecting rod
2 Crankpin bearing
upper part
2a Crankpin bearing
lower part
3 Piston of jack
4 Cylinder of jack
* 5 Stud
6 Round nut
7 Compression shim
C Arrangement of the hydr.

jacks for pretensioning
the studs to the connecting
rod.
D Arrangement of the hydr.
jacks for pretensioning
the studs of the bearing.
T Bearing body separation
to instructions
To prevent damage to the components, the crankshaft may not be rotated after the pretensioning
jacks are mounted!
Lubrication of the stud threads in addition to the oil which is already present is not necessary.
Remark
nl
1
1
1
2
2
1
If the long studs have to be slackened (inspection or removal of lower crankpin bearing shell), the
short studs must always be slackened as well.
lU
Attention
se
Loosening
rn
a
In case the short studs have to be slackened (withdrawal of a piston), the long studs must not be
slackened.
The procedure for slackening the studs to the connecting rod (short studs) is the same as for the studs of the crankpin
bearing (long studs).
nt
e
Turn the crankshaft to a position corresponding to the one in Fig. 'C' or Fig. 'D'.
Working procedure:
- Clean the contact faces of the pretensioning jacks.
Fo
rI
- Screw the pretensioning jacks 9433.01 crosswise onto two diagonally opposite studs 5, till their cylinders 4 rest against
the foot of the connecting rod or the bottom end connecting rod head.
- Connect the pretensioning jacks by HPhoses 9408.09 with the hydr. hand pump 9408.02.
- Open relief valve on hydr. hand pump, and screw the pistons 3 of the pretensioning jacks in, till they land on the cylin
ders of the pretensioning jacks (see Fig. 'A').
- Now turn the pretensioning jacks back a little until a gap of about 2 3 mm appears between the pretensioning jack
and the connecting rod foot or the crankpin bearing body. If the clearance is too small, there may be difficulty un
screwing the pretensioning jacks. If it is too large, the jack stroke may not suffice to stretch the studs by the required
amount.
- Build up a pressure of 600 bar (or a little more) with the hydr. hand pump and unscrew the two nuts of the studs by
about 4 5 hole intervals.
- Release the pressure to 'zero', remove the pretensioning jacks and repeat the same procedure on the other two studs.
12.96
33022/A1
Maintenance
ZA40S
Pretensioning
Attention
In case the long and short studs were slackened (see under loosening), the long studs must always be
tightened before the short ones.
1. Studs to the connecting rod (short studs)
nl
se
Clean the contact faces of the nuts 6, screw them on and tighten them with the round bar 9433.01a until landed.
Screw pretensioning jacks 9433.01 crosswise onto two diagonally opposite studs till their cylinders 4 are landed.
Connect the jacks with the hydr. hand pump 9408.02 by the HPhoses 9408.09.
Open the relief valve of the hydr. hand pump and screw the pistons 3 completely into the jacks until they rest on the
cylinder of the jacks (see Fig. 'A').
Build up a pressure of about 100 bar with the hydr. hand pump and keep this pressure constant.
Tighten the round nuts 6 with the round bar until they are firmly seated (check seating with feeler gauge).
Release the pressure to 40 bar.
Measure protrusion 'X' of piston and make a note of it (see Fig. 'B').
Raise tensioning pressure to 600 bar. Keep this pressure constant and tighten the nuts 6 with the round bar until they
are firmly seated (check seating).
Release pressure to 40 bar and measure protrusion 'X1' of piston on both pretensioning jacks and make a note of it
(see Fig. 'B'). When the waisted studs are correctly pretensioned the elongation amounts to: X1 - X = 0.50 0.1
mm.
If the measured elongation deviates considerably from the above figure, repeat the whole procedure.
Release the pressure to 'zero' and finally pretension the other two studs in the same way.
lU
rn
a
2. Studs to bottom end connecting rod bearing body (long ones)
Fo
rI
nt
e
Preparations and work sequence are similar to the studs for top end bearing body (short ones) as described under 1).
- In order to ensure a correct seating of all bearing components, mount the pretensioning jacks crosswise on two oppo
site studs and connect them to the hydraulic hand pump. Raise first a pressure of 600 bar and keep this pressure for a
short period of time. Following this lower the pressure to 200 bar and keep this pressure constant, till nuts 6 have been
tightened to their seatings.
- Release pressure to 'zero' then mount the jacks onto the two studs not yet pretensioned. Tighten these equally in
accordance with the above described process, whereby these studs also have to be pretightened first to 600 bar and
this pressure kept for a short period. Following this lower the pressure again to 200 bar and tighten nuts 6 till seated.
- In this condition, i.e. all four studs pretensioned with 200 bar, no gap may remain between the two bearing body
halves at 'T' (see Fig. 'D').
- Release pressure to 40 bar and measure protrusion 'X' of piston on both pretensioning jacks and make a note of it
(see Fig. 'B').
- Raise a pressure of 600 bar on both jacks, keep this pressure constant and tighten the nuts 6 until they are fully seated
(check nut seating by feeler gauge).
- Release pressure to 40 bar and measure protrusion 'X1' (Fig. 'B') and record it.
- The difference 'X1' - 'X' is the elongation which should amount to 0.8 0.05 mm.
- Release the pressure to 'zero' and remount both jacks on the studs previously pretensioned to 200 bar. Raise again
the pressure to 200 bar and tighten nuts 6 till fully seated.
- Release pressure to 40 bar and measure protrusion 'X' of piston on both pretensioning jacks and make a note of it
(see Fig. 'B').
- Raise pressure to 600 bar tighten nuts 6 till fully seated (check seating by feeler gauge).
- Release pressure to 40 bar and measure protrusion 'X1' on both jacks (Fig. 'B').
- The difference 'X1' - 'X' is the elongation which should amount to about 0.8 0.05 mm. In case of substantial devi
ation the pretensioning procedure must be repeated on all four studs.
- After completion of the pretensioning, release pressure to zero and remove the pretensioning jacks (see respective
instructions). Close open connections by dust caps, then store pretensioning jacks and hydr. hand pump with hoses in
a clean dry space.
12.96
33022/A1
Maintenance
ZA40S
nl
9433.01
95.7238
X1
Fo
rI
nt
e
rn
a
lU
se
5*
3
4
6
95.7063
1995
33022/A1
Maintenance
ZA40S
C
9433.01
9433.01a
nl
lU
se
Fo
rI
9433.01a
9408.03
nt
e
2a
9408.04
9408.02
rn
a
9408.09
9433.01
9408.09
95.7239
9408.02
1995 / L-Mot.
4 z
34011/A1
Maintenance
ZA40S
Rotating Piston
Removal and Fitting a Piston
Tools:
1 Wear ridge milling tool

1 Carbon removing machine
(for carbon removal in upper
part of cylinder liner)
1 Guide rod
1 Eye screw
1 Insertion funnel
9421.09
9421.10
9434.05
9434.08
9434.10
1
2
3
4
5
Piston
Connecting rod
Studs
Connecting rod head
Screw
- Drain cylinder cooling water from

the engine.
nt
e
rn
a
lU
nl
se
- Possibly developed wear ridge in

the cylinder liner, to be removed
with the wear ridge milling tool
9421.09. For this follow the
instructions on group 2105-1.
- On cylinder liners, the uppermost
portion is provided with a fine
thread. The combustion residues
must first be removed by the car
bon removing machine 9421.10
(see group 2105-1) before the
piston may be pulled.
- Slacken pretension of connecting
rod studs 3 hydraulically, remove
their nuts
(please refer to group 3302-2).
3
4
- Ensure that the cylinder liner 8 is

fastened by the screw 5.
- Turn the crankshaft till the piston
is in T.D.C., screw eye screw
9434.08 into the piston top. (if
necessary clean the threaded hole
of carbon with a threading tap,
(M20).).
Fo
9434.05
rI
- Remove the cylinder head of the

cylinder concerned
9434.08
Piston ring
Oil scraper ring
Cylinder liner
Compression shim
Piston removal (Fig. 'A')
As the compression shim 9 is subject to wear, it is

necessary to check them for fretting and cracks dur
ing every piston overhaul. Damaged compression
shims must be replaced, however as a rule, shims 0.5
mm thick must be replaced by new ones during every
piston overhaul.
Remark
6
7
8
9
95.7240
- Fasten the guide rod 9434.05 onto the connecting rod head 4.
- Connect the piston to the crane with a shackle and a rope (weight of piston about 450 kg).
- Pull the piston slowly out of the engine with the crane, while holding the connecting rod head steady with the rod
9434.05 until the connecting rod 2 has been lifted out of the studs.
- Clean the removed piston carefully and measure the ring grooves (please refer to Clearance and Wear Table group
0352-1). For the cleaning of the piston use only tools which cannot damage the piston.
Attention
After pulling the piston the four studs 3 must be immediately removed!
The crankshaft may not be barred while studs 3 are fitted, as there is the risk of damage to the cylin
der liner 8, as well as to the studs.
L-Mot. / 3.00
34011/A1
Maintenance
ZA40S
Fitting the piston (Fig. 'B')

- Clean the cylinder liner bore carefully and liberally apply engine oil all over its bore.
- Turn the crank to T.D.C. and fasten the guide rod 9434.05 onto the connecting rod head 4.
- Clean the piston 1 carefully and attach it to the crane hook with eye screw 9434.08, shackle 9421.10 and a rope.
- Fit new piston and oil scraper rings to the piston (please refer to group 3402-1) and turn the rings so that their ends
are offset by 180_ degrees.
- Smear piston and rings with clean engine oil.
- Check the insertion funnel 9434.10 carefully for ridges or scratches, apply engine oil liberally on its taper bore and
place it on the cylinder liner. (Ridges in the insertion funnel would damage the piston and (sealing) surfaces of the
rings).
nl
- Lower 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 connecting rod is on the same side as the one on the
connecting rod head.
- Check the contact surfaces of connecting rod foot and connecting rod head, they must be clean and free from oil.
se
- Place the connecting rod head 4 with the aid of guide rod 9434.05 so that its top surface is parallel to the bottom sur
face of the connecting rod foot.
- Now lower the piston fully, while taking care that the foot of the connecting rod slides over the studs 3 in the connect
ing rod head without jamming.
lU
- Remove the guide bar 9434.05.
- Unscrew the eye screw 9434.08

from the piston crown and re
move the insertion funnel
9434.10.
9434.08
1
rn
a
9434.10
9434.10
- Fit the connecting rod nuts by

hand onto the studs 3 until they
are seated (do not grease the
thread).
rI
nt
e
- Turn the crankshaft until the pis

ton is in B.D.C.
- Pretension the connecting rod

waisted studs according to
instructions
Fo
- Fit the cylinder head (please refer

to group 2701-1) and connect
the various pipes.
3
9434.05
- Fill the cylinder cooling water

into the engine and ready the en
gine for operation.
95.7241
1995 / L-Mot.
2 z
3401--1/A2
Maintenance
ZA40S
5RWDWLQJ 3LVWRQ
5HPRYDO DQG )LWWLQJ D 3LVWRQ
IRU F\OLQGHU OLQHU ZLWK DQWLSROLVKLQJ ULQJ
7RROV
.H\ WR ,OOXVWUDWLRQV
:HDU ULGJH PLOOLQJ WRRO

&DUERQ UHPRYLQJ PDFKLQH
IRU FDUERQ UHPRYDO LQ XSSHU
SDUW RI F\OLQGHU OLQHU
*XLGH URG

(\H VFUHZ

,QVHUWLRQ IXQQHO

$QWLSROLVKLQJ ULQJ WRRO

IRU FRPSU VKLPV w PP
$QWLSROLVKLQJ ULQJ WRRO

IRU FRPSU VKLP PP
6FUHZV
0

3LVWRQ
&RQQHFWLQJ URG
6WXGV
&RQQHFWLQJ URG KHDG
6FUHZ
3LVWRQ ULQJ
2LO VFUDSHU ULQJ
&\OLQGHU OLQHU
&RPSUHVVLRQ VKLP
$QWLSROLVKLQJ ULQJ
nl

3LVWRQ UHPRYDO )LJ

$
DQG
%

r 'UDLQ F\OLQGHU FRROLQJ ZDWHU IURP WKH HQJLQH
r 5HPRYH WKH F\OLQGHU KHDG RI WKH F\OLQGHU FRQFHUQHG SOHDVH UHIHU WR JURXS r
$V WKH FRPSUHVVLRQ VKLP LV VXEMHFW WR ZHDU LW LV

QHFHVVDU\ WR FKHFN WKHP IRU IUHWWLQJ DQG FUDFNV GXU
LQJ HYHU\ SLVWRQ RYHUKDXO 'DPDJHG FRPSUHVVLRQ
VKLPV PXVW EH UHSODFHG KRZHYHU DV D UXOH VKLPV
PP WKLFN PXVW EH UHSODFHG E\ QHZ RQHV GXULQJ HYHU\
SLVWRQ RYHUKDXO
9434.08
1
10
Fo
rI
M12
nt
e
rn
a
5HPDUN
lU
se
r 5HPRYH WKH DQWLSROLVKLQJ ULQJ E\ XVLQJ WZR VFUHZV RI 0 VFUHZHG LQWR WKH UHVSHFWLYH WKUHDGV LQVLGH RI DQWLSROLVK
LQJ ULQJ VHH )LJ
$

2
9
9434.05
3
4
L-Mot. / 06.02
3401--1/A2
Maintenance
ZA40S
r 3RVVLEO\ GHYHORSHG ZHDU ULGJH LQ WKH F\OLQGHU OLQHU WR EH UHPRYHG ZLWK WKH ZHDU ULGJH PLOOLQJ WRRO )RU WKLV
IROORZ WKH LQVWUXFWLRQV RQ JURXS r
r 2Q F\OLQGHU OLQHUV WKH XSSHUPRVW SRUWLRQ LV SURYLGHG ZLWK D ILQH WKUHDG 7KH FRPEXVWLRQ UHVLGXHV PXVW ILUVW EH UH
PRYHG E\ WKH FDUERQ UHPRYLQJ PDFKLQH VHH JURXS r EHIRUH WKH SLVWRQ PD\ EH SXOOHG
r 6ODFNHQ SUHWHQVLRQ RI FRQQHFWLQJ URG VWXGV K\GUDXOLFDOO\ UHPRYH WKHLU QXWV SOHDVH UHIHU WR JURXS r
r (QVXUH WKDW WKH F\OLQGHU OLQHU LV IDVWHQHG E\ WKH VFUHZ
r 7XUQ WKH FUDQNVKDIW WLOO WKH SLVWRQ LV LQ 7'& VFUHZ H\H VFUHZ LQWR WKH SLVWRQ WRS LI QHFHVVDU\ FOHDQ WKH
WKUHDGHG KROH RI FDUERQ ZLWK D WKUHDGLQJ WDS 0
r )DVWHQ WKH JXLGH URG RQWR WKH FRQQHFWLQJ URG KHDG
r &RQQHFW WKH SLVWRQ WR WKH FUDQH ZLWK D VKDFNOH DQG D URSH ZHLJKW RI SLVWRQ DERXW NJ
nl
r 3XOO WKH SLVWRQ VORZO\ RXW RI WKH HQJLQH ZLWK WKH FUDQH ZKLOH KROGLQJ WKH FRQQHFWLQJ URG KHDG VWHDG\ ZLWK WKH URG
XQWLO WKH FRQQHFWLQJ URG KDV EHHQ OLIWHG RXW RI WKH VWXGV
$IWHU SXOOLQJ WKH SLVWRQ WKH IRXU VWXGV PXVW EH LPPHGLDWHO\ UHPRYHG
7KH FUDQNVKDIW PD\ QRW EH EDUUHG ZKLOH VWXGV DUH ILWWHG DV WKHUH LV WKH ULVN RI GDPDJH WR WKH F\OLQ
GHU OLQHU DV ZHOO DV WR WKH VWXGV
se
$WWHQWLRQ
r &OHDQ WKH UHPRYHG SLVWRQ FDUHIXOO\ DQG PHDVXUH WKH ULQJ JURRYHV SOHDVH UHIHU WR &OHDUDQFH DQG :HDU 7DEOH JURXS
r )RU WKH FOHDQLQJ RI WKH SLVWRQ XVH RQO\ WRROV ZKLFK FDQQRW GDPDJH WKH SLVWRQ
lU
)LWWLQJ WKH SLVWRQ )LJ

&

r &OHDQ WKH F\OLQGHU OLQHU ERUH FDUHIXOO\ DQG OLEHUDOO\ DSSO\ HQJLQH RLO DOO RYHU LWV ERUH
rn
a
r 7XUQ WKH FUDQN WR 7'& DQG IDVWHQ WKH JXLGH URG RQWR WKH FRQQHFWLQJ URG KHDG
r &OHDQ WKH SLVWRQ FDUHIXOO\ DQG DWWDFK LW WR WKH FUDQH KRRN ZLWK H\H VFUHZ VKDFNOH DQG D URSH
nt
e
r )LW QHZ SLVWRQ DQG RLO VFUDSHU ULQJV WR WKH SLVWRQ SOHDVH UHIHU WR JURXS r DQG WXUQ WKH ULQJV VR WKDW WKHLU HQGV DUH
RIIVHW E\ E GHJUHHV
r 6PHDU SLVWRQ DQG ULQJV ZLWK FOHDQ HQJLQH RLO
rI
r 3ODFH DQWLSROLVKLQJ ULQJ WRRO RU DQG LQVHUWLRQ IXQQHO RQ WKH F\OLQGHU OLQHU DQG OXEULFDWH ODY
LVKO\ ZLWK HQJLQH RLO &KHFN ZKHWKHU WKH IXQQHO LV IUHH RI ULGJHV DQG EXUUV ZKLFK PLJKW GDPDJH SLVWRQ DQG ULQJV
Fo
r /RZHU WKH SLVWRQ FDUHIXOO\ LQWR WKH F\OLQGHU OLQHU XQWLO WKH IRRW RI WKH FRQQHFWLQJ URG LV MXVW DERYH WKH VWXGV 7XUQ WKH
SLVWRQ ZLWK WKH FRQQHFWLQJ URG XQWLO WKH PDUNLQJ RQ WKH IRRW RI WKH FRQQHFWLQJ URG LV RQ WKH VDPH VLGH DV WKH RQH RQ WKH
FRQQHFWLQJ URG KHDG
r &KHFN WKH FRQWDFW VXUIDFHV RI FRQQHFWLQJ URG IRRW DQG FRQQHFWLQJ URG KHDG WKH\ PXVW EH FOHDQ DQG IUHH IURP RLO
r 3ODFH WKH FRQQHFWLQJ URG KHDG ZLWK WKH DLG RI JXLGH URG VR WKDW LWV WRS VXUIDFH LV SDUDOOHO WR WKH ERWWRP VXU
IDFH RI WKH FRQQHFWLQJ URG IRRW
r 1RZ ORZHU WKH SLVWRQ IXOO\ ZKLOH WDNLQJ FDUH WKDW WKH IRRW RI WKH FRQQHFWLQJ URG VOLGHV RYHU WKH VWXGV LQ WKH FRQQHFW
LQJ URG KHDG ZLWKRXW MDPPLQJ
r 5HPRYH WKH JXLGH EDU
r 8QVFUHZ WKH H\H VFUHZ IURP WKH SLVWRQ FURZQ DQG UHPRYH WKH LQVHUWLRQ IXQQHO DQG WKH DQWLSROLVKLQJ
ULQJ WRRO RU
r ,QVWDOO WKH DQWLSROLVKLQJ ULQJ LQWR WKH F\OLQGHU OLQHU ZLWKRXW FRROLQJ GRZQ RU KHDWLQJ XS E\ XVLQJ WZR VFUHZV RI
0 VFUHZHG LQWR WKH UHVSHFWLYH WKUHDGV LQVLGH RI DQWLSROLVKLQJ ULQJ EXW QRW SURWXQGLQJ WKH RXWHU DQWLSROLVKLQJ ULQJ
GLDPHWHU
r )LW WKH FRQQHFWLQJ URG QXWV E\ KDQG RQWR WKH VWXGV XQWLO WKH\ DUH VHDWHG GR QRW JUHDVH WKH WKUHDG
r 7XUQ WKH FUDQNVKDIW XQWLO WKH SLVWRQ LV LQ %'&
06.02 / L--Mot
&
3401--1/A2
Maintenance
ZA40S
9434.08
1
9434.10
9435.01
9435.02
nl
rn
a
lU
se
3
9434.05
10
M12
nt
e
r 3UHWHQVLRQ WKH FRQQHFWLQJ URG ZDLVWHG VWXGV DFFRUGLQJ WR LQVWUXFWLRQV

SOHDVH UHIHU WR JURXS r
rI
r &KHFN FDUHIXOO\ 7XUQ WKH SLVWRQ LQWR WKH 7'& SRVLWLRQ WKH DQWLSROLVKLQJ ULQJ PXVW QRW EH PRYHG XSZDUGV E\ WKH
SLVWRQ FURZQ
r )LW WKH F\OLQGHU KHDG SOHDVH UHIHU WR JURXS r DQG FRQQHFW WKH YDULRXV SLSHV
Fo
r )LOO WKH F\OLQGHU FRROLQJ ZDWHU LQWR WKH HQJLQH DQG UHDG\ WKH HQJLQH IRU RSHUDWLRQ
L-Mot. / 06.02
34012/A1
Maintenance
ZA40S
Rotating Piston
16 Screw with
locking plate
17 Retaining plate
18 Spherical head
19 Oil scraper ring
20 Centring pin (long)
21 Pin
22 Centring dowel
23 Stop piece
24 Cyl. pin
25 Ring screw
26 Wooden underlay
27 Nozzles
Piston crown
Piston ring
Piston rings
Orings
Oring
Upper spherical shell
Guide bush
Ratchet pawl
Ratchet ring
Ring spring
Ring
Piston skirt
Lower spherical shell
Supporting ring
Waisted screw
Spring guide piece
Spring
OB Bore for inner

cylinder lubrication
to instructions
se
9434.08
9434.09
9434.11
9434.12
9434.13
9434.14
1
2
2a
3
3a
4
5
6
7
8
9
10
11
12
*13
14
15
Depending on the output and design execution of the engine, variations in the design of the piston
may be fitted see Fig. 'A', whereby on a given engine, only pistons of the same design execution may
be fitted.
Variant 1: For engines with an output of 600 kW/Cyl. and 660 kW/Cyl.
Variant 2: For engines with an output of 720 kW/Cyl.
Variant 3: Piston with inner cylinder lubrication for the complete power range.
The following description is valid for the dismantling of a piston of all three variants.
When assembling a piston, be sure to pay attention to utmost cleanliness.
rn
a
lU
Remark
9408.17
nl
1 Torque wrench
(480 940 Nm / ")
1 Ring screw M20
1 Piston clamping device
2 Clamping bolts
2 Ring screw
2 Jacking screws
2 Centring rings (wood)
2 Ring screws M12
2 Jacking screws M20
1 Socket spanner AF 24
assorted open end and
ring spanners
Tools:
nt
e
1. Replacing a piston crown (Fig. A, B, C, D and E)

Procedure for dismantling
- Screw ring screw 9434.08 into the top of piston crown and suspend the piston with rope on crane (Fig. 'B').
rI
- Fix the two centring ring halves 9434.14 with two clamping bolts 9434.11 (Fig. 'B' and 'C').
Fo
- Turn piston and place it into the piston clamping device 9434.09, tighten its bolts moderately, so that later the piston
cannot turn (Fig. 'D').
- Loosen all eight waisted screws 13 and remove them. Clamping bolts 9434.11 can remain in place (Fig. 'D').
- Fit a jack screw 9434.13 through each of the two holes 'b' (Fig. 'C') into the upper spherical shell 4 and tighten alter
nately until the piston skirt 10 is separated from piston crown 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 firmly, so that the piston skirt can be lifted off the piston
crown 1 with all inner parts.
Procedure for assembling
Before assembling a piston upper part check nozzles 27 of variants 2 and 3 (see Fig. 'A') for free passage.
- Place new piston crown 1 into the piston clamping device 9434.09 and tighten its bolts moderately (Fig. 'E').
- Fit new Orings 3 and 3a into the grooves of the piston crown and the upper spherical shell (use only original Orings)
and grease or oil them liberally.
1995
34012/A1
Maintenance
ZA40S
- Place the complete piston skirt 10 onto the piston crown 1, match the holes for the waisted screws 13 with the threaded
holes in the piston crown.
- Smear the head landings and the thread of the eight waisted screws 13 with oil and screw them in by hand.
- Unscrew both jacking screws 9434.13, remove them and tighten the eight waisted screws 13 alternately and diagonally
until the upper spherical shell 4 rests against the piston crown 1.
Attention
A gap of 1.0-1.4 mm always remains between piston crown 1 and piston skirt 10, i.e. also after fully
tightening the waisted screws 13.
- Tighten the eight waisted screws 13 with a torque wrench 9408.17 and suitable socket spanner insert (AF 24) first of all
20
Nm (pretightening).
to 120 +
-0
nl
- Mark the position of each screw head to the piston skirt with a marking pen. Pay attention to the marks on the screw
collar (4 x 90_), then finally tighten the screws by an angle of 90_.
The total torque is about 620 Nm, but the tightening must be carried out as described above.
- After having thus fully tightened the screws 13, turn the piston back to its original position and suspend it on the crane
with ring screw 9434.08 and rope (Fig. 'B').
se
- Remove the two clamping bolts 9434.11 as well as the centring ring halves 9434.14, and prepare the piston for fitting
into the engine (please refer to group 3401-1).
2. Dismantling and assembling a piston
lU
Working procedure for dismantling
- Screw in the ring screw 9434.08 into the piston crown 1 and suspend the piston by a rope on the crane (Fig. 'B').
rn
a
- Mount the two halves of the wooden centring device 9434.14 with the clamping bolts 9434.11 (Fig. 'B' and 'C').
- Turn piston and place it into the clamping device 9434.09, tighten its bolts moderately, so that later the piston cannot
turn (Fig. 'D').
- Loosen all eight waisted screws 13 and remove them. Clamping bolts 9434.11 can remain in place (Fig. 'D').
nt
e
- Attach the connecting rod with a rope to the crane and lift it vertically out of the piston, the lower spherical shell 11
and the supporting ring 12 are lifted along with it (Fig. 'F').
- Remove the ring 9 and the ring spring 8 and place them aside.
rI
- To prevent its getting lost later on, remove stop piece 23 off ratchet ring 7 and keep in a safe place (Fig. 'F')
Fo
- To lay the connecting rod down without difficulty, we recommend to replace the two clamping bolts 9434.11 (Fig. 'F')
by the two ring screws 9434.12 (Fig. 'H').
Attention
Take the greatest care not to damage the spherical head of the connecting rod and the lower spheri
cal shell 11.
- Fit two jacking screws 9434.13 through two threaded holes (M24) in the piston skirt and screw them in by hand until
they rest against the shoulder of the upper spherical shell 4 (Fig. 'G'). Fit ring screw M12 into the top ends of the
jacking screws and attach them by a rope to the crane.
- Tighten both jacking screws simultaneously, whereby the piston skirt 10 is separated from the piston crown 1 (Fig.
'G').
After the two parts are separated lift the piston skirt 10 off the piston crown (Fig. 'J' and 'K').
Attention
The ratchet ring 7 must remain lying on the upper spherical shell 4. If necessary tap it out with a piece
of wood.
- If the ratchet mechanism has to be dismantled, remove the screws 16 after bending the locking plates up. Remove the
retaining plate 17 and push out the ratchet pawls 6 with their springs 15 and the spring guide piece 14. The same ap
plies to the guide bush 5.
- Assemble the ratchet mechanism in reverse sequence, clean all parts with great care before fitting and smear with oil
moderately. For locking the screws 16 use new locking plates.
1995
34012/A1
Maintenance
ZA40S
- 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 lower spherical shell 11, which consists of two halves, has to be removed, fit two screws M20 for each half shell
into the supporting ring 12. From the opposite side drive in two clamping bolts 9434.11. By tightening the clamping
bolts against the M20 screws, you will press the respective spherical shell half 11 off the supporting ring 12 (please
refer to Fig. 'M').
This dismantling is best achieved by fixing the connecting rod to the floor and using two wooden blocks 26 as a working
base (Fig. 'M').
Attention
The two spherical shell halves 11 are marked together. They may only be used as a unit. Single shell
halves may not be replaced, also not interchanged with another piston!
Replacement of spherical shell
nl
The spherical shells need not be replaced if the running surface is worn and the lead bronze becomes visible.
They must however be replaced, when bits break out of the lead bronze or when it is badly scratched by foreign par
ticles.
3. Assembling a piston
se
Assembling the lower spherical shell
- Raise the connecting rod to vertical and fix it in this position (Fig. 'M').
lU
- Place two wooden blocks 26 of equal height on either side of the connecting rod.
- Heat the supporting ring 12 in an oil bath or in a furnace to 120 150_C and place it on the wooden blocks. Clean the
bore and the landing with a clean cloth.
rn
a
- Fit the two spherical shell halves 11 into the supporting ring 12, paying attention to the correct position of the dowel
pin 22 (Fig. 'M' and 'C', 'A', III-III).
Assembling the piston
nt
e
- From below immediately screw in four clamping bolts 9434.11 through the supporting ring 12 into the spherical shell
halves to ensure their correct position. Do not remove the clamping bolts nor the jacking screw M20 until the support
ing ring has cooled down.
rI
- Place the piston crown into the clamping device 9434.09 and tighten its bolts moderately (Fig. 'O').
Fo
- Fit new Orings 3 and 3a into the grooves in the piston crown and the upper spherical shell and smear them with grease
or oil (Fig. 'A' and 'O').
- Place upper spherical shell 4 onto the piston crown 1. Pay attention to the centring pin position (Fig. 'O').
- Place the ratchet ring 7, with cylindrical pin 24 pointing upwards, on the upper spherical shell (Fig. 'O').
- Check oil bore 'OB' for inner cylinder lubrication (see Fig. 'A' variant 3) for free passage.
- Fit two jacking screws 9434.13 into the piston skirt and lower it, hanging on the crane, over the parts fitted before (Fig.
'N' and 'O').
- As soon as the centring pin 20 mates the corresponding hole, reach with the hand into the piston skirt from 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. 'P'.
- Only now lower the piston skirt 10 completely, which possibly requires some strokes with a lead hammer (Fig. 'Q').
Attention
A gap of 1.0-1.4 mm will always remain between piston skirt and piston crown 1.
- 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. 'P'
and 'O').
- Attach the connecting rod, spherical head 18 downwards with the lower spherical shell 11 and supporting ring 12, on
two ring screws 9434.12 and a rope on the crane (Fig. 'R').
1995
34012/A1
Maintenance
ZA40S
- 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 its leading edges stand vertically (Fig. 'R').
- Now insert connecting rod into the piston, guide the ratchet pawl 6 to match with ratchet ring 7 (Fig. 'S' and 'T').
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 will be possible in one direction, whereby a well audible 'Chatter' is caused.
The connecting rod should not turn in the other direction.
- Remove the ring screws on the ends of special ring screws 9434.12 and fit the 'assembly' consisting of spherical shell 11
and supporting ring 12 into the piston, paying attention to the position of centring dowel 22 (Fig. 'A', III-III), please
refer to Fig. 'R' and 'A', III-III.
- Remove special ring screws 9434.12.
- Smear the head landing surface and the thread of waisted screws 13 with oil then screw them in by hand.
nl
20
Nm
- Tighten all eight waisted screws 13 with a torque wrench 9408.17 and socket insert (AF 24) first of all to 120 +
-0
(pretightening).
se
Mark the position of each screw with reference to the piston skirt with a marking pen. For this take the four markings
on the cylindrical heads of the screws into consideration (4 x 90_). Now tighten the screws fully by the angle of 90_
(Fig. 'U').
Checking clearances
rn
a
Checking the ratchet (rotating) mechanism
lU
After completed assembly, check with the feeler gauge, whether sufficient clearance exists between the spherical
connecting rod head and the lower spherical shell 11 (min. 0.07, max. 0.23 mm). The wooden centring ring must not
be fitted yet for this checking (Fig. 'U)'
Fo
rI
nt
e
Test the rotating mechanism to ensure the proper working of same as follows: The connecting rod should be turned
against the normal direction of rotation of the piston until the pawl fully engages in a tooth, then the connecting rod
must be pushed in the opposite direction of rotation to check if the ratchet mechanism is truly engaged.
This action must be repeated tooth by tooth until a full turn of the connecting rod is completed.
After this check fit wooden centring ring 9434.14 and fasten it by two clamping screws 9434.11 (Fig. 'U').
Now the piston can be turned and attached to the crane by a rope and prepared for fitting into the engine (Fig. 'B').
Piston fitting see group 3401-1.
1995
34012/A1
Maintenance
ZA40S
Variant 1
Variant 2
27
2
2a
3
nl
3a
I-I
nt
e
1
2
3
4
5
7
6
8
27
I
II
III
23
III - III
II
I
III
Fo
3a
Variant 3
rI
2a
19
rn
a
lU
se
19
21
II - II
14
20
16
9
11
10
17
18
12
*13
OB
21
22
95.7073
15
1995
1995
13
9434.11
11
12
9434.14
10
9434.08
13
13
se
lU
Gezeichnet fr ZA40
DRAWN FOR ZA40
rn
a
y
1
9434.09
12
11
9434.13
nl
13
95.7242
Maintenance
13
9434.09
10
9434.11
13
nt
e
rI
Fo
1 1,4 mm
34012/A1
ZA40S
34012/A1
Maintenance
ZA40S
9434.12
9434.14
12
11
nl
9434.11
9434.14
se
12
lU
11
rn
a
13
nt
e
Gezeichnet fr ZA40
DRAWN FOR ZA40
rI
25
Fo
9434.13
23
10
24
10
7
4
1
4
3
1
9434.09
95.7243
1995
34012/A1
Maintenance
ZA40S
L
18
14
5
6
se
nl
16
17
15
rn
a
lU
9434.13
rI
nt
e
10
Fo
Gezeichnet fr ZA40
DRAWN FOR ZA40
9434.11
J
7
11
12
M 20
20
4
3
M 20
26
1
9434.09
95.7244
1995
34012/A1
Maintenance
ZA40S
P
8
7
AF
se
24
23
nl
21
9434.13
rn
a
lU
nt
e
10
rI
Fo
Gezeichnet fr ZA40
DRAWN FOR ZA40
7
24
10
20
4
3
1
21
10
11.4 mm
AF
9434.09
95.7245
1995
34012/A1
Maintenance
ZA40S
9434.12
nl
9434.14
12
11
rn
a
lU
se
Gezeichnet fr ZA40
DRAWN FOR ZA40
nt
e
18
Fo
rI
6
9
8
9434.14
7
9434.11
9434.11
12
13
9
21
10
11
18
10
13
1
1
9434.09
95.7246
1995
10z
34021/A1
Maintenance
ZA40S

Removing and Fitting
Tools:
1 Piston ring expander
9434.18
1
2
2
3
1 Piston ring
2 Piston rings
3 Oil scraper ring
A
Cr
962 or 059 Top
4 Garter spring
Cr Chrome layer
1
2
2
Cr
nl
Special layer
Piston with
inner lubrication
Piston with
external lubrication
lU
se
231 Top
Cr
rn
a
nt
e
579 Top
96.7225
Cr
96.7233
Fo
rI
Remark
Piston rings of various design can be fitted into the uppermost groove of the piston crown (see Fig.
'A').
Should new piston rings and oil scraper rings be fitted, the running surface of the cylinder liner must
be honed first with the honing machine 9421.11 (see sheet 2105/1).
Use the piston ring expander 9434.18 (Fig. 'C') for removing and fitting piston rings. This tool contained in the engine
tool kit prevents overexpanding the rings, which would make them lose their shape.
Oil scraper rings have less tension and can be easily expanded by hand. However here also the ring must be expanded just
sufficiently as is absolutely necessary.
Jammed piston rings should first be eased with a suitable solvent instead of trying to force them out, with the result that
ring 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. All carbon deposits in the bottom of the grooves
must be removed carefully. A piece from an old piston ring sharpened at one end is an excellent tool for this.
1995
34021/A1
Maintenance
ZA40S
Although the flanks of the piston ring grooves are hard chrome plated, they must be checked for wear by measurement
(please refer to the Clearance Table 0325-1). It may be necessary to rechrome the flanks to restore them to their origi
nal dimension.
In principle new piston rings and oil scraper rings must be fitted to the pistons at every overhaul of the engine, please
consider to use only original spare parts!
The piston rings and oil scraper rings are usually fitted to the thoroughly cleaned piston when it is hanging on the crane.
To fit piston rings always use piston ring expander 9434.18. This avoids overstressing the piston rings.
The marking TOP stamped on one of the ring ends has to be facing upwards! The number next to the marking TOP is the
last three digits of the corresponding drawing number (identification number). Only such piston rings and oil scraper
rings may be fitted which bear the appropriate identification numbers as listed in Fig. 'A'.
Newly fitted piston rings must not stick in their grooves.
se
nl
Before fitting the oil scraper ring, first remove the garter spring from the ring. Open the garter spring by pulling apart the
junction and introduce it into the lowest ring groove for the oil scraper ring. There push the ends together i.e. the garter
spring is closed (please refer to Fig. 'B where the garter spring is shown in the open position).
Now expand the oil scraper ring slightly and carefully by hand and slide it into its ring groove. The ends of the scraper ring
and garter spring should be offset from each other.
Oil scraper ring and garter spring are one unit, as the garter spring is matched to the corresponding
scraper ring. The two parts may therefore not be replaced individually.
Regarding clearances between ring and ring groove please refer to the Clearance and Wear Table,
group 0352-1.
Fo
rI
nt
e
rn
a
Remark
lU
Note that the marking on the oil scraper ring end must also be facing upwards.
gespannt
STRETCHED
ungespannt
NOT STRETCHED
9434.18
95.7083
1995
2 z
Group4
Betrieb
ZA40S
Fo
rI
nt
e
rn
a
lU
se
nl
Group 4
41011/A1
Maintenance
ZA40S
Camshaft Drive
Checking Gear Tooth Backlash, Bearing Clearances and Adjusting Camshaft Driving Wheels
1 Drive gear wheel on
crankshaft
2 Large intermediate gear
wheel
3 Small intermediate gear
wheel
4 Camshaft gear
* 5, 5a Screws
6 End plate (driving end)
7 Spacer ring
8 Stop ring (only installed in
nonreversible engines)
9 Oil jet nozzle
Fig. A View on camshaft

drive gear wheel
Fig. B Longitudinal section
of gear train of
nonreversible engine
Fig. C Longitudinal section
of gear train of
reversible engine
M M3 Marks for correct
position of gear wheels
to instructions
nl
1 Feeler gauge
9408.15
1 Torque wrench
9408.17
(140 560 Nm / ")
1 Short extension " / 8"
" / AF17
1 Straight edge
(about 500 mm long)
1 Depth gauge
(measuring range about 450 mm)
Assorted double end spanners
Tools:
Whenever an opportunity 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 and Wear Table group 0352-1).
se
Early detection of any tooth damage can, by prompt replacement of the gear wheels, prevent serious damage.
lU
Use this opportunity to also check whether the spray nozzles in the gear train space spray oil onto the gear wheels when
the lubricating oil and the prelubricating pump is running. Oil must also flow from the journals of the intermediate gear
wheels.
The radial clearance of the intermediate gear wheel can be measured with the feeler gauge after removing the end plate
6 and the spacer 7.
rn
a
Should it have been necessary to loosen the screws 5 or 5a, retighten them with a torque wrench at 350 Nm and secure the
screws with locking wire. The threads of both screws and their landing faces are to be smeared with oil.
nt
e
Adjusting the camshaft drive gear wheels (see Fig. 'A')
rI
Bar the crankshaft until the mark 'M' on the driving gear wheel 1 is in the topmost vertical position, which means that the
crank web next to the flywheel points vertically upwards.
The two marks 'M2' on the large intermediate gear wheel 2 must be situated to the left and right of the mark 'M1' on the
drive gear wheel on the crankshaft.
Fo
The camshaft gear 4 has to be so positioned that the distance 'K' from the mark 'M3' on the toothed rim to the upper edge
of the engine housing measures 432 mm. For checking this distance place a straight edge onto the engine casing.
Remark for replacing a large intermediate gear wheel
Should a large intermediate gear wheel 2 have to be replaced, heat it to about 80 100_ C and quickly fit it in the correct
position on the small gear wheel 3 to line up the cylindrical dowel pin. Provisionally tighten some of the screws 5 before
the gear wheel has cooled.
L-Mot. / 1995
41011/A1
Maintenance
ZA40S
M3
lU
se
rn
a
3
2
M O.T.P.
T.D.C.
Fo
rI
nt
e
M2
M1
1
nl
K = 432 mm
95.7247
Gezeichnet fr ZAL40
DRAWN FOR ZAL40
1995 / L-Mot.
41011/A1
Maintenance
ZA40S
B
nicht umsteuerbar
NON-REVERSIBLE
I-I
nl
se
4
2
I-I
lU
umsteuerbar
REVERSIBLE
rn
a
5*
6
5a*
nt
e
4
2
5*
Fo
rI
5a*
7
95.7248
Gezeichnet fr ZAL40
DRAWN FOR ZAL40
95.7249
3 z
L-Mot. / 1995
42011/A1
Maintenance
ZA40S
Camshaft
Checking the Cams, Removing and Fitting the Camshaft
Tools:
9408.02
9408.03
9408.04a
9408.09
9408.17
9408.19
1
*2
3
4
5
6
9408.35
9442.20
9442.21
9442.22
Camshaft
Screw
Cover of camshaft bearing
Dowel pin
Underlay (copper, hard wood, aluminium)
Stopper ring for locating bearing
(only for nonreversible engines)
H Wooden underlay about 30 mm thick

* Tightening according to instructions
nl
2
2
2
2
1
Hydr. hand pump

Branch piece
Pressure gauge
HPhoses
Torque wrench
Force multiplier
Socket spanner insert
1" / AF 46
Hydr. jacks
Rollout rails
Supports with screws
Wooden spacer pieces
Eye screw M16
1
1
1
2
1
1
1
lU
se
Whenever the casing cover to the camshaft is removed, take the opportunity to visually inspect the condition of the run
ning surface of the cams as well as the tooth profiles of the camshaft drive gear wheels. If cams are found damaged inve
stigate whether possibly springs or other parts in the housing for valve actuation or in the fuel injection pumps are defec
tive.
In the course of an overhaul check in addition the radial and axial clearance in the camshaft bearings (consult Clearance
and Wear Table group 0352-1). If clearances are excessive remove the bearing shells and if necessary replace them.
Concerning inspection of a vibration damper on the camshaft please refer to group 3130-1.
Removing the camshaft
rn
a
- Remove all the valve push rods.
- Remove the fuel injection pumps and the valve actuating gear housing or lift them and support them on a wooden
underlay of about 30 mm thickness 'H'.
- Remove the camshaft casing covers and their frames.
nt
e
- Separate all the equipment driven by the camshaft from the end of the camshaft.
rI
- Remove those two bearing covers 3 where afterwards the rollout rails 9442.20 are fitted (use eye screw M16). It de
pends on the number of cylinders the engine has, on which bearings the rollout rails are mounted. The rails must be so
arranged that the camshaft is evenly supported.
(Fig. 'C' shows the arrangement for a nonreversible 8 cylinder engine).
Fo
- Loosen the bearing screws of all the other bearings by about one turn.
- Remove the bearing shells of the two bearings where the covers have already been removed to fit the rollout rails. To
do this, ease the camshaft off its bearings slightly, by two hydraulic jacks 9408.35 placed in the immediate vicinity of
these bearings with underlays 5 to protect the shaft, and applying pressure with the hand pump 9408.02. When placing
the jacks and underlays make provision that the shaft is pressed slightly away from the engine.
- Mount the two rollout rails 9442.20 and supports 9442.21 at the two bearings where covers and bearing shells were
removed, and press the rails against the shaft while tightening the fastening screws 7.
- Should the engine tilt towards the camshaft side (because of the ship listing during unloading etc.) use the hand cranks
of the rollout rails until their holding jaws are about 1 mm away from the camshaft to prevent its rolling out unexpect
edly, while still permitting removal of the other bearing shells.
- Remove all the remaining bearings shells.
- Check again that the camshaft is not held anywhere. Turn the crank counterclockwise, thus easing back the jaws of the
rollout rails and pull the camshaft out on the rails.
L-Mot. / 1995
42011/A1
Maintenance
ZA40S
- To move the shaft away attach it with two ropes in such a way that it hangs horizontally and does not bend.
F i t t i n g the camshaft
Conditions for fitting:
- All the valve push rods are removed, the valve actuating gear casings and fuel injection pumps either removed or
raised and placed on wooden 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
group 4101-1).
Fitting
nl
- Mount two rollout rails 9442.20 and supports 9442.21 on the engine casing (it depends on the number of cylinders the
engine has, at which of the camshaft bearing the rails are mounted).
- Place the camshaft 1 onto the rollout rails 9442.20.
- Clean the bearing areas on the camshaft and the bore of the camshaft bearing shells with a clean cloth.
se
- By rotating the cranks of the rollout rails clockwise 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, so that it can be rolled in unhindered.
lU
- Roll the camshaft into its bearings, making sure that the camshaft gear wheel engages the intermediate gear in the
right position. (Observe the check dimension 'K' as per group 4101-1).
rn
a
- Fit the bearing shells with clean dry outer surface and running surface of shell and shaft well oiled, leaving out the two
where the rollout rails are mounted. The bearing shells must be so placed that the dowels 4 of the bearing covers can
fit into the corresponding milled holes at the joining faces.
Axially the bearing shells should be approximately flush with each other.
nt
e
- To fit the bearing shells it is necessary to slightly raise the camshaft with the aid of the hydraulic jack 9408.35 placed in
the immediate vicinity of 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.
Take care that the dowel 4 in the cover fits correctly into the machined holes.
Fo
Attention
rI
- Mount the bearing covers 3 and fit the screws (with locking plates) by hand. Coat thread and head landing surfaces
with MOLYKOTE paste Gn.
- Dismantle the two rollout rails 9442.20 and supports 9442.21 and fit the two remaining bearings.
- Remove all the tools used for fitting.
1995
42011/A1
Maintenance
ZA40S
T i g h t e n i n g the bearing cover screws

- First tighten all screws in several steps with a torque wrench and a socket spanner 1" with 150 10 Nm followed by
final tightening with an angle of 60 65_ using a force multiplier.
- Check the radial clearance of all bearings with feeler gauge 9408.15 with greatest care. The axial clearance is checked
by pushing the camshaft axially from one stop to the other.
Remark
For reversible engines the reversing servomotor must first be fitted before the axial clearance can be
measured!
- If all clearances radially and axially are within the tolerances given in the clearance table, secure the screws of the
bearing covers with the locking plates.
- Refit the starting air distributor, the fuel injection pumps and the valve actuating gear.
nl
- Bar the crankshaft with the turning gear and check that with lubricating and prelubricating pump running the oil
flows out from all the camshaft bearings.
Fo
rI
nt
e
rn
a
lU
se
- To seal the frame of the engine casing, onto which the camshaft casing covers will later be fitted, clean them with a
degreasing agent (benzine, acetone etc.) and smear them with a sealing compound.
1995
1995 / L-Mot.
9408.02
9408.03
2*
3
4
5
9408.35
9408.09
9408.04a
9442.22
III - III
IV
9442.20
4 z
se
9442.20
9442.21
III
III
nl
5 9408.35 9442.22 1
lU
IV
Gezeichnet fr 8ZAL40
DRAWN FOR 8ZAL40
IV - IV
9442.21
rn
a
nt
e
rI
9442.21
II
II
95.7250
Maintenance
9442.20
9442.21
Fo
II - II
42011/A1
ZA40S
42111/A1
Maintenance
ZA40S
Cams on Camshaft
Replacing Original Cams by TwoPart Cams
14
9408.17
1, 1a
2
3
4
5
6
7
8
9
10
11
Supports
Stops
Carriage
Air stop valve
Grinding disc
Feeding crank
Pneumatic grinder
Camshaft
Clamping screws
Guide rods
Grip for side to side
movement of carriage 3
12 Clamping screws
13 Original cams
Upper cam half

Identification mark
Lower cam half
Dowel pin
Fuel cam
Valve cam
Arrangement of
grinder on free end
Fig. 'D' Arrangement of
grinder on driving end
se
O
U
Z
rn
a
lU
- Remove the fuel pump or the valve actuating

gear of the respective cam.
- Bar the crankshaft until the centre of the cam
profile of the defective cam faces upwards so
that the parting cut will be made at the thin
nest section (see Fig. 'C' and 'D').
nt
e
- Mount the device for cutting the cams as

shown in Fig. 'C' and 'D', whereby the two
supports 1 and 1a must be clamped onto the
camshaft.
- Connect the pneumatic grinder 7 to an air

supply system of 6 to 7 bar.
rI
Fo
O
P
U
Z
Fig. 'A'
Fig. 'B'
Fig. 'C'
Should it become necessary to replace a cam ei

ther for the fuel pump or for the valve actuation,
this can be done for nonreversible engines, by
fitting in place of the defective one a new split
(twopart) cam. This is done as described below:
14
14 Waisted screws
15 Brace
1 Torque wrench
(AF17 or AF30)
1 Pneumatic grinder
for cutting cams
nl
Tools:
O
U
Z
- Locate the two stops 2 in such a way that the

carriage 3 when moved back and forth cannot
touch any neighbouring parts.
- Mark the position of the cam to be replaced
on the camshaft with a felt tip pen. Use the
identification mark on the respective cam face
as a basis:
EX = Exhaust, IN = Inlet, B = Fuel.
95.7251
Mark for Exhaust cams

Mark for Inlet cams
- The working area and the adjacent space must be carefully covered with a suitable material so that no grinding dust
can find its way into the engine. The covering material must be noncombustible to trap the stream of sparks.
- Immediately adjacent to the defective cam the camshaft should be protected from possible damage by a steel sheeting
of about 0.2 mm.
1995
42111/A1
Maintenance
ZA40S
- 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 cut in the cam until the remaining thickness of the cam is about 0.2 mm.
- Bar the crankshaft until the cam to be replaced is so positioned that a second groove can be cut exactly opposite the
first.
- The cam cutting device can now be removed entirely. Drive a steel wedge gently into the groove with a hammer to
break the cam apart.
- Before fitting the split (twopart) cam the camshaft must be thoroughly cleaned and degreased. Take exceptional care
not to wipe out the marking previously made on the camshaft.
If the mark has been inadvertently wiped off, the cam must be positioned so that it corresponds to the information in
the setting table.
nl
- The split (twopart) cam 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 cam. The arrow 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 screws 14 with MOLYKOTE paste Gn and tighten the screws in
by hand, only to the extent that the cam cannot shift any more. Axially the cam must be located in such a way that the
rollers actuating push rods or fuel pumps protrude equally on either side.
- Prior to tightening the screws, their exact length must be measured and noted.
Screw elongation [mm]
Tightening torque [Nm]
lU
Figure
se
- Arrange the gaps between the two cam halves evenly, then firmly tighten the screws alternately in several steps ac
cording to values in the following table:
Fuel cam
l = 0.33 0.01
about 950
'B'
Valve cam
l = 0.27 0.01
about 610
rn
a
'A'
The deciding factor for correct tightening is the specified screw elongation and it may never be ex
ceeded!
Remark
The device for cutting original cams is not part of the standard engine tool kit. It must be specially
ordered from Wrtsile NSD Ltd.
The cam replacement must only be carried out by experienced personnel which has been specially
trained for this work.
Fo
rI
nt
e
Attention
3.00
42111/A1
Maintenance
ZA40S
5
2
6
11
9
1
9
10
lU
rn
a
9
Freies Ende
FREE END
3 z
15
8 9
13
1, 1a
12
1a
rI
Fo
11
nt
e
se
13
nl
9 1a
95.7252
Antriebseite
DRIVING END
1995
43011/A1
Maintenance
ZA40S

9408.17
1
2
3
4
5
5a
5b
5c
*6
7
8
8a
8b
Oil slinger
Cam
Flange
Oring
Control slide valve
Spring
Roller
Roller pin
Screw
Shaft
Cover
Joint
Screw
9
10
11
12
13
14
15
Casing
Oring
Camshaft
Dowel pin
Screw
Screw
Dowel pin
M
K
P
*
Adjusting mark
Check drilling
Locating mark (drill point)
Tightening according
to instructions.
nl
1 Torque wrench
(140 560 Nm)
1 Grip screw M5
Various spanners
Tools:
se
The starting air distributor generally requires no maintenance. However, approximately every fourth year during a ge
neral overhaul it is recommended to remove the control air slide valves 5 and to clean and check them. The clearances
should checked and compared with the Clearance and Wear Table group 0352-1. Also verify whether any parts require
replacement.
Removing the control slide valves
lU
The control slide valves 5 can only be removed after the roller pins 5c have been taken out.
Working procedure:
- Shut off the control air supply.
rn
a
Remark
- Loosen the screw 8b and remove cover 8.
nt
e
- Loosen the screw 6 and lift cam 2 off its shaft.

- Loosen screw 14 and remove the covers 3.
rI
- Press each control slide valve 5 lightly inwards against the force of spring 5a and at the same time pull the roller pin 5c
out with a grip screw (M5) and remove the roller 5b.
- The control slide valves can now be removed.
Take great care not to drop either the roller or the control slide valve on the floor!
Fo
Attention
Fitting the control slide valves

- Smear all components lightly with oil.
- Fit each control slide valve 5 with its spring 5a into its bore and press it inwards until the roller pin 5c can be fitted
through roller and valve body.
- When all the control slide valves are fitted, place the cam 2 onto the shaft 7 and initially tighten the screw 6 slightly by
hand. (The screw thread should be smeared with oil).
- Turn the cam around till the check drilling 'K' coincides with the locating mark 'P' (drill point).
- Tighten screw 6 with a torque wrench 9408.17 to 250 Nm. In this position the mark 'M' on the face of the cam must be
in line with the axis of control slide valve cylinder No. 1 of the engine, when the piston of cylinder No. 1 is in ignition
T.D.C.
- Make sure the control slide valves are sliding easily in their bores, by pushing them inwards several times against the
force of the springs 5a. The control slide valve must return immediately to the original position.
1995
43011/A1
Maintenance
ZA40S
- Fit the covers 3 equipped with new Orings 4 and tighten the screws 14.
- Fit cover 8 and tighten the screws 8b firmly.
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.
Fo
rI
nt
e
rn
a
lU
se
nl
Remark
1995
3 z
12
14
II
S
Gezeichnet fr 8ZA40
DRAWN FOR 8ZA40
12
rn
a
nt
e
rI
Fo
nl
2
K
95.7253
14
13
8b
8a
9
10
6*
7
8
5b
K
5c
4
5
5a
II
Maintenance
15
O
11
se
lU
I-I
ZA40S
43011/A1
1995
43011/A2
Maintenance
ZA40S

with Control Disc

9408.17
1
*2
3
4
5
6
7
8
9
10
*11
12
13
Camshaft
Screw
Cover
Control disc
Shaft
Washer
Housing
Cross intermediate piece
Ball
Ring
Nut M16
Oring
Spray disc
14 Screw
15 Slotted countersunk
head screw
16 Oring
17 Washer
18 Check disc
19 DU bush
20 End casing
21 Intermediate shaft
22 Screw
to instructions
nl
1 Torque wrench
(25-135 Nm)
Tools:
The starting air distributor generally requires no maintenance. However, during a overhaul or yearly, it is recommended
to remove the control disc and to clean and check them. The clearances should checked and compared with the Clear
ance and Wear Table group 0352-1. Also verify whether any parts require replacement.
se
Dismantling for checking clearances and surfaces
If only the rotating parts, i.e. their surfaces, are to be checked, proceed as follows:
lU
- Turn the crankshaft by means of the turning gear, so that the piston of cylinder 1 is 5 ( before ignition T.D.C..
- Shut off the control air supply.
rn
a
- Remove the inspection cover 1 for the starting air distributor.
20
Fo
rI
nt
e
20
96.8567
96.8576
12
18 17
2*
- Loosen the screws 2 and remove them together with the washers 17 (Fig. 'A').
- Remove cover 3 and check if the washer 6 is still tight.
- Mark the position of the control disc 4 with regard to the housing 7.
2000
43011/A2
Maintenance
ZA40S
- Draw the shaft 5 and the control disc 4 completely out of the housing 7, avoiding that the DU bushes 19 be damaged by
the cross intermediate piece 8. A spring dowel pin connects the cross intermediate piece to the shaft 5 (Fig. 'B').
- Check if the ball 9 is still in the shaft.
- Check whether the surfaces of the check disc 18 and the control disc 4 are worn.
I-I
nl
22
rn
a
4
18
10
11*
6
9
5
12
12 3
15
rI
18
97.7597
14
Fo
20
16
2*
17
nt
e
II - II
7
se
II
lU
II
8 7 19
1 13 20 21
Assembling after checking without replacing parts

- If during checking the crankshaft has not been turned, the nut 11 has not been loosened, and no parts have been re
placed, then lubricate the shaft 5 as well as the cross intermediate piece 8 and the control disc 4, and reassemble them
carefully.
- After assembling check the position of the control disc with the mark made beforehand.
- Install Oring 16 and fit the cover 3 with the lubricated screws 2 and washers 17.
- Tighten the screws 2 crosswise and evenly with a torque of 80-85 Nm.
Should it be necessary to replace also the DU bushes 19 or the Oring 12, then loosen first the control air pipes 13 from
the housing 7.
Afterwards, loosen the screws 14 and remove them together with the housing 7.
2000
43011/A2
Maintenance
ZA40S
If the friction surfaces of the check disc 18 or of the control disc are badly scratched, or if the running layer of the check
disc is worn, the parts must be replaced.
Proceed as follows:
- Loosen the nut 11, the shaft 5 being fitted, and remove the nut together with the ring 10.
Attention
For a clockwise rotation engine the nut 11 has a lefthand thread. For a counterclockwise rotation
engine the nut 11 has a righthand thread.
- The cone of the control disc is loosened by a light blow with a lead hammer on the end of the shaft 5.
- Dismantle the control disc together with the shaft.
- Loosen the slotted countersunk head screws 15 of the check disc 18 and remove them.
nl
- Remove the check disc.

Assembling and adjusting after replacing parts
- Apply a nonhardening sealing compound on the bearing area between the end casing 20 and the housing 7, and
install Oring 12.
se
- Fit the housing with the dowel pins and tighten the screws 14.
- Screw down the check disc 18 on the housing 7 with the slotted countersunk head screws 15.
The slotted countersunk head screws 15 must be secured with LOCTITE No. 0243.
lU
Attention
rn
a
- Lubricate the shaft 5 including the cross intermediate piece 8 and carefully install it in the housing 7 without damaging
the DU bushes. The cross intermediate piece and the intermediate shaft 21 must mesh.
- Push the control disc 4 onto the cone of shaft 5, lubricate the thread M16 of the shaft, and screw on the nut 11, taking
into account the lefthand or the righthand thread.
nt
e
- Fit ring 10 and nut 11. Tighten the nut slightly by hand, so that the control disc can still be moved on the cone.
Adjusting of the control disc
rI
- Turn the crankshaft by means of the turning gear, so that the piston of Cyl. 1 (or Cyl. 1R for VMot.) is 5 ( before
ignition T.D.C..
Fo
- Press the control disc slightly against the check disc 18, and turn it in the rotation direction of the camshaft until the
opening of the control disc just begins to release the slot on the check disc belonging to Cyl. 1 (Fig. 'C').
rechtsdrehend
RIGHT TURNING
linksdrehend
LEFT TURNING
97.7595
2000
43011/A2
Maintenance
ZA40S
- Tighten the nut 11 with a torque of 90-100 Nm.

- Check again the position of the control disc.
Checking the clearances and final assembly (Fig. 'D')
- Press the control disc 4 against the check disc until it stops.
- Measure the axial clearance between cross intermediate piece 8 and intermediate shaft 21, x1+x2=0.8-3.0 mm (see
also clearance table, group 0352-1).
- Check whether the shaft 5 not seizes up. For this, move the shaft slightly back and forth while making one revolution
with the crankshaft.
- Fit the cover 3 temporarily and press the control disc against the check disc.
nl
- Remove the cover 3 and install Oring 16 in the groove of the housing 7.
- Check the clearance x = 0.7-1.7 mm between the ball 9 and the washer 6.
- Lubricate the thread of the screws 2.
- Fit the cover 3 together with the screws 2 and the washers and tighten them with a torque of 80-85 Nm.
16
rI
nt
e
rn
a
lU
se
- Fit the inspection cover for the starting air distributor with a nonhardening sealing compound, and reconnect the
control air pipes (Fig. 'A').
9 6
Fo
x1
x2
97.7598
2*
2000
4 z
21
43041/A1
Maintenance
ZA40S
ShutOff Valve for Starting Air

2 Threaded spindles M10 9443.02

(complete)
1 Pliers type 'J'
for inside circlip
1 Lead drift
2 Wooden underlays
(about 60x60x250 mm)
Various d.e. spanners and
socket spanners
Sealing compound
1
2
3
3a
3b
4
5
Shutoff valve casing

Spring
Threaded plug
Circlip
Cujoint
Piston sealing ring complete
Shutoff valve piston
6
7
8
9
10
Nonreturn valve piston

Threaded plug
Screw
Nonreturn valve casing
Valve seat
D Use sealing compound
nl
10
Tools:
se
lU
2
3
95.7255
Fo
rI
nt
e
rn
a
3a
3b
Provided the starting air is clean, that no foreign particles can enter the valve and that no defects become evident, dis
mantling the valve every fourth year is sufficient.
Before you start with dismantling the valve, the shutoff valves on the starting air vessels must be closed. The pressure
gauge for the starting air may not show any pressure. The main starting air pipe and the control pipe must be disconnec
ted from the shutoff valve for starting air.
1995
43041/A1
Maintenance
ZA40S
Dismantling
- Place the complete valve with the screws 8 facing upwards on a work bench. (The weight is about 56 kg).
- Mark the position of the three parts 1, 9 and 10 on the circumference.
- Loosen all the screws 8 equally by about five turns and observe whether 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 can happen that these parts stick together on account of the sealing compound used for the previous
mounting.
- Loosen the four screws 8 fully and remove them.
- Remove all inner parts, clean and check them.
- Traces of former sealing compound must be thoroughly removed from the faces of casings 1 and 9 as well as from the
valve seat 10.
nl
- Should the complete piston sealing ring 4 no longer be in perfect condition, it must be replaced together with its O
ring.
Assembling (see Fig. 'B')
se
Smear all parts with the exception of the faces marked by 'D' on the illustration with oil immediately before assembling
the valve.
lU
The piston sealing ring 4, consisting of an Oring and a sliding ring, has to be fitted with great care (without overstret
ching it) into the shutoff valve piston 5, after which the other components are assembled as described below.
- Remove the circlip 3a and the threaded plug 3 from the shutoff valve casing 1.
rn
a
- Fit the spring 2 and the shutoff valve piston 5 into the shutoff valve casing 1.
- Insert a threaded spindle 9443.02a into the shutoff valve piston 5 and tighten the nut 9443.02c thereby pulling the
piston into the casing 1, paying special attention to slidingin the piston sealing ring 4 into its bore.
nt
e
- Place the air shutoff valve 1 on two wooden underlays 'H' and apply a thin coat of sealing compound onto the sealing
faces marked 'D'.
- Seat the valve seat 10 onto the shutoff valve casing 1 (note the correct position with respect to the screw holes and the
marks made prior to dismantling the valve).
rI
- Insert the nonreturn valve piston 6 with its spring 2 into the nonreturn valve casing 9 and prestress with the second
threaded spindle 9443.02.
Fo
- Apply a light coat of sealing compound on the sealing faces marked 'D' of the nonreturn valve casing 9, and place this
onto the vale seat 10 (note the correct positioning).
- Insert screws 8 and tighten equally and firmly with a socket spanner (AF 17), then remove the two threaded spindles
9443.02.
- Fit the threaded plug 3 with a cujoint 3b, tighten firmly and secure with a circlip 3a.
- Refit the fully assembled air shutoff valve onto the engine.
1995
43041/A1
Maintenance
ZA40S
9443.02a
9443.02c
9443.02b
rn
a
lU
se
nl
10
nt
e
45_
rI
45_
Fo
H
3
3a
3b
95.7256
9443.02c
9443.02b
9443.02a
3 z
1995
44011/A1
Maintenance
ZA40S
Inlet and Exhaust Valve Drive

Adjusting the Valve Clearance
Tools:
2
1
1
1
1
Feeler gauges
Allen key
Allen key
Ring spanner
Ring spanner
9408.15
AF 10
AF 14
AF 32
AF 50
5 9
Valve spindle
Valve spindle
Special screw M33
Lock nut AF 50
Ball socket
Special screw M20
Lock nut AF 32
6 7
10
8
9
10
11
12
Ball socket
Main rocker arm
Roller
Cam
G Cam base circle
se
nl
3 4
1
2
3
4
5
6
7
11
G
12
95.7257
9408.15
95.7258
lU
rn
a
The valve clearance has to be checked and readjusted every time the cylinder head or the rocker arms are removed.
Should loud clicking noises be heard which appear to come from the rocker arm housing while 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 down engine.
For checking the clearance bar the crankshaft until the roller 11 of the valve actuating gear for the cylinder concerned sits
on the base circle of the cam.
nt
e
The following clearances are normal for a cooled down engine:

INLET VALVE = 0.6 + 00.1 mm
EXHAUST VALVE = 1.2 + 0.1

0 mm
rI
The valve clearance is adjusted as described below
Fo
- Loosen the lock nuts 4 and 7 and turn the special screws 3 and 6 right back.
- Push feeler gauge (0.6 mm for inlet valves or 1.2 mm for exhaust valves) fully between the ball socket 5 and the valve
spindle 1 or 2 respectively.
- Tighten special screw 3 lightly with Allen key AF 14, until the feeler gauge is slightly gripped, but can still be moved by
pulling. (The spring pressure is clearly felt).
- Leave the feeler gauge clamped in this way, hold the special screw 3 with the Allen key and tighten at the same time the
lock nut 4 firmly.
- Leave the feeler gauge clamped in valve 1. Push the second feeler gauge (of the same thickness) fully under the ball
socket 8 of valve 2.
- Tighten special screw 6 until the feeler gauge is gripped lightly.
- Hold special screw 6 with Allen key AF 10 and tighten the lock nut 7 with ring spanner AF 32 firmly.
- Pull out both feeler gauges.
Remark
After tightening the lock nut the feeler gauges should be a good fit and should be movable back and
forth.
1 z
1995
44012/A1
Maintenance
ZA40S
Inlet and Exhaust Valve Drive

9444.01
9444.02
Guide housing
Guide piston
Spherical end pin
Spring
Oring
Circlip
Spring plate
Dowel pin
Casing for push rod
Orings
Connecting piece
Cylinder head
Push rod
Main rocker arm
13
nt
e
11
24
24a
15
rn
a
10
12
Retaining pin
Roller pin
Circlip
Thrust disc
Roller
Bush
Engine casing
Special (ball head) screw
Lock nut
Special (ball head) screw
Lock nut
Screw
Cam
to instructions
lU
se
23
23a
14
11
16
17
18
19
20
21
22
23
23a
24
24a
* 25
N
*
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
9408.17
1 Torque wrench "

(140 560 Nm / ")
1 Dismantling tool
1 Special jack screw
2 Jack screws M 12
1 Grip screw M 6
1 Socket head insert
(" / AF 30)
Various spanners
nl
Tools:
rI
6 7
25*
8
22
Fo
22
4
3
2
1
N
16
95.7259
4
1
2
17
18
19
M 16
18
21
19
20
1
During a general overhaul or if it becomes nec

essary, the valve actuating gear has to be dis
mantled, checked and cleaned, as described
overleaf:
1995
44012/A1
Maintenance
ZA40S
Dismantling
- Turn the crankshaft until the roller lies on the base circle of the cam.
- Slacken the lock nuts 23a and 24a and screw the special (ball head) screws 23 and 24 right back.
- Sway the push rod 13 sideways and remove it.
- Remove the shroud for push rod 9.
- Loosen the screws 25, fastening the valve actuating gear to the engine casing and remove them.
- Withdraw the complete valve actuating gear and place on the work bench. (If necessary use two jack screws M12 to
jack the (valve actuating gear) guide housing 1 off the engine casing. The required threaded holes have been provided
in the flange.
M 16
M6
lU
se
16
1
rn
a
- Should it be necessary to remove the spherical end

pin 3, screw the special jack screw 9444.02 from be
low into the guide piston 2 and push the spherical
end pin 3 out.
- Unscrew the spindle of the dismantling tool until

the spring pressure has slackened and remove the
tool.
- Remove all the internal parts and check on their
condition.
nl
- Screw in the spindle of the dismantling tool until the

retaining pin 16 is relieved and withdraw the pin us
ing a grip screw (M6).
- Mount the dismantling tool 9444.01 as shown on

Fig. 'B'.
9444.01
nt
e
- The roller 20 can be removed by taking the circlip 18

off on one side and pushing the roller pin out. (Take
care that the roller bush 21 does not fall out of the
roller!).
95.7260
Fo
Assembling
rI
- Clean all the removed parts well and check them for
reuse (please also refer to the Clearance Table
group 0352-1).
- Liberally oil all the parts before assembling and fit them in reverse order to the dismantling sequence.
- To fit the retaining pin 16, press the guide piston into the guide housing 1, with dismantling tool 9444.01, as far as
necessary.
- Replace the Oring 5 each time the valve actuating gear is dismantled.
- Before fitting the complete valve actuating gear, the landing surfaces of housing 1 and engine casing must be cleaned
well.
- Coat the threads and landing faces of screws 25 (fastening the guide housing) with oil and tighten to 290 Nm.
- After the parts have all been assembled, adjust the valve clearance as described on group 4401-1.
1995
2 z
45001/A1
Maintenance
ZA40S
Dismantling, Checking and Assembling
1
2
3
4
*5
6
7
8
9
10
11
12
** 13
14
15
16
17
18
19
Engine casing
Casing
Oring
Cylinder
Flywheel disc
Piston
Guide ring
Screw
Locating bearing ring
Stop collar
Control ring
Cover
Waisted stud
Round nut
Connecting piece
Dowel pin
Oring
Bearing rings
Dowel pin
20
21
22
23
24
25
26
27
28
Bearing bush
Camshaft
Circlip
Compression spring
Slide valve
Taper dowel pin
Screw
Screws
Dowel pin
AG Jacking thread
D Apply sealing compound
for assembling
* Shape and weight vary
according to number of
cylinders
** Tightening according
to instructions
9408.02
9408.03
9408.04
9408.09
9408.15
9408.16
9431.03
9433.07
9445.01
nl
Hydr. hand pump

Branch piece
Pressure gauge
HPhose
Feeler gauge
Depth gauge
Special spanner
Hydr. jack
Support plate
Eye screws M12
Jack screws M12
1
1
1
1
1
1
1
1
1
2
2
se
Tools:
Reversible Engine
The camshaft must be in the end position towards the 'free end', when dismantling the reversing ser
vomotor. If this is not the case, start the engine for a short time in the corresponding sense of rota
tion. If this is no longer possible, remove all the actuating casings of the fuel pumps, inlet and exhaust
valves, then push the camshaft by hand axially till the stop at the 'free end'.
Under no circumstance may the camshaft be shifted by a chain puller or a hydr. jack or similar de
vice while the engine is at standstill.
nt
e
rn
a
Attention
lU
The reversing servomotor needs no maintenance during operation. It should, however, be dismantled, cleaned and
checked during a general overhaul. Worn or damaged parts must be replaced.
Working procedure:
rI
1. Dismantling
- Separate all the pipework from the reversing servomotor (place a container underneath).
Fo
- Loosen and remove the screws 26 and press off and remove cover 12 with the aid of jack screw M12.
- Slacken the waisted stud 13 with the aid of hydr. jack 9433.07 and unscrew and remove round nut 14 (please refer to
section 3.1).
- Screwin eye screw M12 into the cylinder 4 and attach it to the crane with a rope (Fig. 'C').
- Fasten support plate 9445.01 to the connecting piece 15 with the screws 27 and to the cylinder with two screws 26 (Fig.
'C' and 'D').
- Loosen and remove all the screws 8 and, using two of these screws (M20), press off the cylinder 4 including the parts
fastened by support plate 9445.01 from casing 2.
- If it is necessary to remove also the flywheel disc 5 from the camshaft, fit an eye screw M12 into the flywheel disc and
attach it to the crane by a rope (weight max. 65 kg).
- With the aid of two grip screws M12 and suitable spacers remove the two taper dowels 25, then apply two jack screws
M12 and press the disc off the camshaft.
- To remove the casing 2 from the engine casing use two of the screws (M20) 8 as jack screws in the threaded holes
provided in the casing for this purpose and press off the casing 2 until it is free of the dowel pins 28.
- Use an eye screw M12 and rope to attach the casing to the crane (about 120 kg) and remove it.
1995
45001/A1
Maintenance
ZA40S
- To dismantle the parts which were pulled off together with the cylinder 4, remove circlip 22, then slide them off con
necting piece 15 for cleaning and checking (Fig. 'A' and 'C').
Pay particular attention to the running surfaces of locating bearing rings 9 and 18. Heavy wear of the locating bearing
rings increases the axial clearance of the camshaft (please refer to Clearance Table group 0352-1).
2. Assembling
2.1 Preparations:
- Clean all the components carefully and, just prior to fitting them, smear them lightly with oil.
- Blow through all the oil bores with compressed air.
- Replace the Orings 2 and 17 by new genuine original Orings.
- Screw in the waisted screw 13 until its stop in the camshaft.
- Apply sealing compound to the sealing surface on the engine casing.
2.2 Working procedure:
nl
- The camshaft must be pushed to its end position at the 'free end'.
se
- Push the casing 2 over the camshaft making sure that the dowel pins 28 fit their holes (Fig. 'B').
- Fit Oring 3 (Fig. 'B').
lU
- Mount the flywheel disc 5 with fitted rings 9 and 18 onto the camshaft, fit the two taper dowels 25 and tap in moder
ately. Remove the eye screw.
- Fit screws 8 and tighten equally.
rn
a
- Fit the cylinder 4 with all the parts shown in Fig. 'C', which are held by the support plate 9445.01.
- Remove the support plate 9445.01 and screw in the round nut 14 onto the waisted stud 13, until it is seated.
nt
e
- Using the hydraulic jack 9433.07, pretension the waisted stud 13 to 600 bar (please follow exactly the instructions
in section 3.2 and on Fig. 'E').
- After tensioning check the axial clearance (please refer to Clearance Table group 0356-1).
- Fit the cover 12 with a new Oring 17 and tighten the screws 26.
rI
- Reconnect all the pipes to the reversing servomotor, and to check tightness start the lubricating oil pump.
Fo
3. Loosening and pretensioning the waisted stud (Fig. 'E')

3.1 Loosening:
- Mount the pretensioning hydraulic jack 9433.07 onto the stud 13 until its cylinder 'Z' is seated.
- Connect the piston 'K' by HPhose 9408.09 with the hydr. hand pump 9408.02.
- Open the relief valve on the hydr. hand pump screw in the piston 'K' with the aid of special spanner 9431.03 until it
is seated in the cylinder 'Z'.
- Unscrew the complete pretensioning jack until a clearance of about 2 mm exists between cylinder and connecting
piece 15 at 'X'.
- Close the relief valve on the hydr. hand pump and pretension the waisted stud 13 to about 600 bar (or a little
more).
- Unscrew the round nut 14 with a round bar by about turns and release the pressure by opening the relief valve on
the hydr. hand pump.
- The round nut should now be loose, the pretensioning jack and the round nut can be removed.
1995
45001/A1
Maintenance
ZA40S
3.2 Pretensioning (Fig. 'E')

- After fitting the various parts according to section 2, fit the round nut 14 onto the waisted stud 13 ensuring that the
landing faces are clean and the thread not specially lubricated.
- Fit the pretensioning jack 9433.07 onto the waisted stud till the cylinder 'Z' is seated on the connecting piece 15
(check seating with the feeler gauge).
- Connect the piston 'K' by HPhose 9408.09 with the hydr. hand pump.
- Open the relief valve on the hydr. hand pump and screw 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 relief valve on the hydr. hand pump and raise a pressure of 100 bar.
- Hold this pressure constant while the round nut 14 is tightened

until seated (check the seating with the feeler gauge).
14
- Raise the pressure to 600 bar, hold it constant while the round
nut is tightened until it is seated (check the seating with feeler
gauge).
nl
- Release the pressure to 40 bar and measure protrusion 'X' and

note it down (please refer to the adjacent Fig.).
X1
X
se
- Lower the pressure to 40 bar and measure the protrusion 'X1'

and note it down.
95.7063
Fo
rI
nt
e
rn
a
lU
- Calculate check measurement nL (X1 - X).

When the pretensioning has been correctly carried out this dif
ference should be 0.7 0.1 mm. The establishment of the check
measurement (nL) serves solely as an additional, but important
check on the tensioning.
1995
1995
20
21
25
22
AG
M 12
AG
M 12
26
10
11
19
18
16
17
15 14
13*
12
se
lU
95.7261
rn
a
nt
e
4 5 6 7 R
rI
Fo
nl
24
23
45001/A1
Maintenance
ZA40S
AG
28
19
16
13
18
10
22
15
18
rn
a
nt
e
rI
Fo
AG
27
se
lU
26
9445.01
nl
95.7262
26
AG
27
ZA40S
Maintenance
45001/A1
1995
45001/A1
Maintenance
ZA40S
nl
13
Y
Z
Fo
rI
nt
e
rn
a
lU
15
se
14
9433.07 9431.03
9408.02
9408.09
9408.04
95.7263
9408.03
1995
6 z
45011/A1
Maintenance
ZA40S
Regulating Linkage
Removal and Fitting of the Spring Linkage Rod Springs
Tools:
1 Depth gauge
9408.16
1 Special tool
9446.01 B
Various open end spanner
1, 1a
2
3
4
5, 6
7
Linkage joint
Circlip
Connecting piece
Springs
Spring plate
Ring (2piece)
Spring removal
Should it be necessary to dismantle the spring linkage rod which 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.
nl
Before unbolting the linkage joint 1, dimension 'X' has to be determined and noted down. After removing the linkage
joints, the tool has to be fitted as shown in Fig. 'A' and the springs 4 put under tension until the circlip 2 can be removed.
The connecting piece 3 can now be removed and the springs 4 unloaded (see Fig. 'B').
Spring fitting
lU
se
The reverse procedure to that of removal is used when fitting the connecting piece 3.
The bores of the spring plates 5 and 6 are to be smeared with MOLYKOTE paste Gn before fitting.
The linkage joint 1 has to be screwed back in until the previously determined dimension 'X' is reached exactly and then
secured with the lock nut.
rn
a
6 3
1a
rI
nt
e
9446.01 B
Fo
MOLYKOTE paste G-n
95.7267
1 z
1995
46121/A1
Maintenance
ZA40S
CutOut Servomotor
2 Threaded bars M16 x 500

with nuts
9446.03
Various spanners
1
1a
2
3
3a
4
5
6
7
8
9
10
Casing (onepart)
Casing (twopart)
Spring
Slide valve
Valve body
Spring
Spring plate
Piston
Piston seal
Flange
Rod seal
Snap ring
11
12
13
14
15
16
17
18
19
20
21
22
Oring
Valve guide
Piston
Cylinder
Piston seal
Oring
Flange
Fuel pump control shaft
Lever
Screw
Oring
Clamp screw
Tools:
nl
If the control air is well filtered and dewatered, the cutout servomotor requires practically no maintenance. During a
more important engine overhaul or when functional defects have been noticed, it is recommended to dismantle the cut
out servomotor and to clean it.
se
Prior to dismantling, the clamp screw 22 has to be loosened and the lever 19 pushed sideways. After this proceed as
described below.
- Loosen and remove two diagonally opposed screws 20 (Fig. 'B').
lU
- Fit in their place the two threaded bars 9446.03 and screw their nuts until landed on flange 17 (Fig. 'C').
- Loosen the two remaining screws 20 and remove them.
rn
a
- Loosen alternately the two nuts of the threaded bars 9446.03, paying attention that the bars themselves do not rotate,
instead the flange 8 and the piston 6 are lifted off the casing 1.
- After the spring 2 is completely released, 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 can be withdrawn.
nt
e
Assembling is done in the reverse sequence to dismantling.

- All the parts have to be clean and lightly smeared with oil prior to fitting them. The Orings must all be replaced by new
genuine original ones.
rI
- Use the two threaded bars 9446.03 for compressing the spring and fitting the piston 6 and the flange 8 (Fig. 'C').
Fo
- Pay particular attention and care when inserting the piston 6 and the flange 8 into the casing 1, to prevent any damage
to the seal rings 7.
- When the spring is sufficiently compressed, fit two screws 20 and tighten them.
- Remove the threaded bars and fit and tighten also the other two screws 20.
- Finally fit the lever 19 in its original position and fasten it with the clamp screw 22.
Remark
In cases where the cutout servomotor is equipped with a staring fuel limiter as shown in Fig. 'A1' the same instructions
apply. In addition, however, the piston 13 has to be equipped with a new Oring and before assembling the Oring 16
must be fitted.
If the casing is in two parts as shown in Fig. 'A2', the Oring 21 must also be replaced.
1995
46121/A1
Maintenance
ZA40S
8
9
11
10
20 18
3a
A1
22
13 14 15 16 17 20
se
A2
1a
nl
19
lU
12
nt
e
rn
a
21
19
20
18
22
Fo
rI
95.7265
20
7 9
9446.03
95.7266
8
1995
2 z
Group5
Betrieb
ZA40S
Fo
rI
nt
e
rn
a
lU
se
nl
Group 5
51011/A1
Maintenance
ZA40S
Speed Governor
Oil Change
WOODWARD EGB58P
Access to needle valve of mechanical governor
Oil level indication
Cooling oil inlet
Oil drain cock
Connection for oil to booster inlet
Serrated drive shaft
Connection for oil from booster outlet
Feedback needle
9
10
11
12
13
14
15
16
Serrated governor output shaft

Cooling oil outlet
Oil filler neck
Setting knob for SPEED DROOP
Speed setting motor
Setting knob for power limitation
Setting knob for speed (r.p.m.)
Access to feedback
EGB-58P
nl
1
2
3
4
5
6
7
8
13
rn
a
16
11
14
lU
12
se
15
8
5
nt
e
Fo
rI
10
9
95.7268
Fitting and removal of the governor on the engine

When lifting off or replacing the governor, care has to be taken to ensure that the splines at the lower end of the governor
shaft do not get damaged.
Furthermore, when the governor is being replaced, the shaft must slide into the drive without binding.
Pipework and rods must be connected up stressfree.
1995
51011/A1
Maintenance
ZA40S
Maintenance
Information concerning maintenance work, maintenance intervals and repairs is to be taken from the WOODWARD
publications which are supplied with the governor and engine.
In principle, repairs should only be made to the governor by experts from a WOODWARD service station (or specially
trained personnel). At the same time it is essential that the governor test records to be found in the engine acceptance
trial documentation be made available according to which the governor must be correctly adjusted.
We highly recommend that a complete governor, already exactly set up for the engine, be held as a spare ready to be
exchanged when necessary.
Oil change
Under good running conditions the oil can remain in the governor for up to 6 months (approx. 3000 h) or more. Should,
however, blackening or ageing of the oil be determined, it has to be renewed immediately.
nl
The old governor oil is to be drained off when the engine is hot and at a standstill by opening the oil drain cock 4.
se
After this, fill the governor up to the upper mark on the oil level sight glass with lightweight flushing oil or clean Diesel oil
(gas oil) and run the engine at reduced speed for about one min. In order to prevent the flushing fluid from entering the
booster and then remaining in the oil, the air pipe connection to the booster has to be removed before starting the flus
hing process and reconnected afterwards.
During this short run of the engine the speed should be altered frequently so that the governor oscillates. This can be
done by pulling the emergency stop lever (on the regulating linkage) towards the zero position and then immediately
releasing it.
lU
The flushing or gas oil is to be drained from the governor afterwards.
rn
a
After a flushing process has been completed successfully, fill the governor with new, clean oil (for oil specification see
WOODWARD bulletin).
When the engine is running, the oil level should lie between the two marks on the oil level sight glass.
Fo
rI
nt
e
After putting the governor back into service, the system has to be vented as described in the section 'Adjusting the droop
feedback' in the WOODWARD bulletin.
1995
2 z
51011/A2
Maintenance
ZA40S
Speed Governor
Oil Change
WOODWARD PGA58
Charge air connection for fuel limitation
Oil level indicator
Governor output position indicator
Splined drive shaft
Splined governor output shaft
Oil filter
Oil connection for booster outlet No. 1
Oil drain cock
Oil connection for booster inlet
Feedback needle valve
11
12
13
14
15
16
17
18
19
Governor hood
Oil filling connection
Overspeed checking device
Electrical connection
Connection for pneumatic speed setting
Oil inlet connection
Oil drain connection
Knob for manual speed setting
nl
1
2
3
4
5
6
7
8
9
10
PGA58
rn
a
lU
se
13
1
2
nt
e
rI
19
15
18
16
17
10
9
3
Fo
12
11 14
5
4
95.7269

1995
51011/A2
Maintenance
ZA40S
Maintenance
Oil change
nl
The old governor oil is to be drained off when the engine is hot and at a standstill by opening the oil drain cock 8.
se
(gas oil) and run the engine at reduced speed for about one min. In order to prevent the flushing fluid from entering the
booster and then remaining in the oil, the air pipe connection to the booster has to be removed before starting the flus
hing process and reconnected afterwards.
During this short run of the engine the speed should be altered frequently so that the governor oscillates. This can be
done by pulling the emergency stop lever (on the regulating linkage) towards the zero position and then immediately
releasing it.
lU
The flushing or gas oil is to be drained from the governor afterwards.
rn
a
WOODWARD bulletin).
Fo
rI
nt
e
1995
2 z
51011/A3
Maintenance
ZA40S
Speed Governor
Oil Change
WOODWARD PGGEG58
Oil connection to oil cooler inlet
Oil level indicator
Governor output position indicator
Splined drive shaft
Splined governor output shaft
Oil filter
Oil drain cock
Oil connection for booster inlet
Feedback needle valve
11
12
13
14
15
16
17
18
19
Governor hood
Oil filling connection
Oil connection from oil cooler outlet
Electrical connection
Knob for manual speed setting
Knob for load limit
Knob for 'speed droop'
Oil drain plug
nl
1
2
3
4
5
6
7
8
9
10
PGG-EG 58
se
12
14
15
17
16
18
nt
e
rn
a
lU
11
10
rI
3
13
Fo
5
96.7781
19

1996
51011/A3
Maintenance
ZA40S
Maintenance
Oil change
nl
The old governor oil is to be drained off when the engine is hot and at a standstill by opening the oil drain cock 8 and by
unscrewing the oil drain plug 19.
The oil in the oil cooler and starting booster must also be drained. Remove and clean the oil filter 6. After cleaning fit the
filter straight away since it is essential that it be in place when carrying out the following procedure.
se
(gas oil) and run the engine at reduced speed for about one min.
During this short run of the engine the speed should be altered frequently so that the governor oscillates.
lU
Afterwards drain off the flushing or gas oil in the same way as the old oil from the governor, starting booster and oil
cooler.
rn
a
WOODWARD bulletin).
Fo
rI
nt
e
1996
2 z
51051/A1
Maintenance
ZA40S
Governor Drive
Tools:
*1 Screw (2piece execution)

2 Shaft upper part
(2piece execution)
2a Shaft lower part
(2piece execution)
3 Shaft (1piece execution)
4 Casing
5 Bearing bushes
6 Bearing bushes
7 Cylindrical pin
* 8 Screw
9 Spur gear wheel
10 Bevel gear
11 Bevel gear
* 12 Screw
D
OF
SP
OE
Apply sealing compound

Dry, oilfree for assembling
Spray hole
Oil inlet
to instructions
9408.17
nl
1 Torque wrench
(25 135 Nm / ")
(Driver ", AF 10)
D
3
rn
a
5
SP
6
OE
nt
e
OF
Fo
rI
12* 11
10
OF
For the replacement of the gear wheels

or the bearing bushes, the speed control
governor and the complete governor
drive must be removed.
Dismantling
- Remove the locking wires securing the
screws 8 and 12.
- Loosen the screws 8 and 12 and re
move them.
8*
SP
During a major overhaul the gear wheels

and the bearing bushes must be checked
for wear (please refer to Clearance and
Wear Table group 0352-1).
lU
1*
2
2a
se
An annual visual check of the gear

wheels is recommended. this necessitates
the removal of the corresponding hous
ing covers on the engine.
95.7270
- Withdraw shaft 3 (on the 1piece type)

or the parts 2 and 2a (on the 2piece
type) upwards and remove the bevel
gear 11.
- Pull off spur gear wheel 9, push in bevel gear 10 and remove it.
- The bearing bushes 5 and 6 are pressed in. To withdraw them use suitable tools. It is recommended 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.
L-Mot. / 1995
51051/A1
Maintenance
ZA40S
Assembling
- For assembling the governor drive proceed in the reverse sequence to dismantling. For this all the parts must be clean
and show no wear or damage.
- Shafts and gear wheels as well as the bearing bushes to be smeared with clean oil.
- The faces of shafts and gears, marked 'OF' in the illustration, must be dry and oilfree.
- Fit first the shaft 3 or 2 and 2a respectively and afterwards 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 oil, fit them and tighten to 70 Nm.
- Check the axial clearances of the two shafts (please refer to the Clearance Table group 0352-1) and if found in order
lock the screws with locking wire.
nl
- Use sealing compound to seal the casing 4 towards the engine casing and also the governor casing towards the gover
nor drive casing 4.
Tightening the screws 1
Fo
rI
nt
e
rn
a
lU
se
Where the shaft is in two parts 2 and 2a, tighten the screws 1 with a torque of 22 Nm using oil as lubricant on thread and
landing face.
1995 / L-Mot.
2 z
53031/A1
Maintenance
ZA40S

Removing and Fitting the Spring
9408.40
9446.01A
16
17
18
19
20
21
22
23
24
25
26
27
Cylinder for load limiter

Piston rings
Latch
Cutout piston
Cutout shaft
Adjusting screw
Bearing flange
Spring
Spring case
Steel balls
Springs
Shaft

for assembling
se
* in ZAL40S engines only

one spring is installed
1 Fuel control shaft

2 Clamp screw
3 Lever for safety cutout
device
4 Cover
* 5 Spring
6 Cutout push rod
7 Cover
8 Casing
9 Threaded plug
10 Intermediate gear wheel
11 Driving gear
12 Gear wheel on camshaft
13 Load limiter lever
14 Torsion spring
15 Piston for load limiter
1 Ring spanner with

extension arm
1 Spring compressing device
1 Screwdriver
various open end and
ring spanners
nl
Tools:
lU
rI
nt
e
rn
a
Fo
During an engine overhaul the condition of the

tooth profile of the drive gear wheels 10 and 11 of
the safety cutout device has to be checked, for
which the cover 7 must be removed (Fig. 'C').
Through the same aperture the condition of the
cutout push rod shoulder 6, on which the latch 18
catches, can be inspected. This shoulder may not
be either rounded nor damaged.
Use a screwdriver and unlatch the latch 18, by
pushing it off the cutout push rod 6. This must be
done while the safety cutout and the fuel injection
regulating linkage is still fully assembled.
To prevent a strong recoil of shaft 27 during the cut
out check of the mechanical overspeed safety cut
out device, hold against the front side of shaft 27
with a ring spanner and extension arm 9408.40.
For tensioning the mechanical overspeed safety
cutout device use the ring spanner with extension
arm 9408.20 as well.
Attention
Due to risk of accidents the

cover 4 may never be removed
as long as the spring 5 is under
tension and the cutout push
rod 6 is not secured by the
spring compression device
9446.01A (Fig. 'A' and 'C').
By unlatching the latch 18 the spring 5 is partly re

leased.
95.7271
9446.01A
1995
53031/A1
Maintenance
ZA40S
Removal of the spring

- Remove the threaded plug 9 (Fig. 'c') and screw in spring compressing device 9446.01A into the rear end of the cut
out push rod 6 (Fig. 'A').
- Turn the grip of the device 9446.01A in a clockwise direction until the spring 5 is compressed (Fig. 'A').
- Loosen the screw 2, which clamps the lever 3, and push the lever sideways away (Fig. 'C').
- Remove the cover 4 (Fig. 'A').
- Turn the grip of the device 9446.01A back in a counter clockwise direction, until the spring is decompressed (Fig. 'B').
- If it is necessary to remove the shaft 20, first decompress the spring 5, then remove the remote tachometer transmitter,
then the flange 22 (Fig. 'D').
Do not move the adjusting screw 21 unless absolutely necessary. If it cannot be avoided, mark its posi
tion accurately beforehand, so that it can be restored to its original position.
If necessary the complete shaft must be mounted into an infinitely variable lathe, to establish the
correct cutout point. (The correct cutout data can be obtained from the shop trial documents of the
engine). The cutout point can be adjusted by turning the adjusting screw 21 (please also refer to the
Operating Instructions group 5303-2).
Fo
rI
nt
e
rn
a
lU
se
Remark
nl
- The complete shaft 20 including driving gear 11 and cutout piston 19 etc. can now be withdrawn.
1995
VI
27
1
2
8 9
11
SH
10
SH
D 12
II - II
27
1 13
IV
III
3 14
II
II
IV
se
lU
III
rn
a
nt
e
rI
Fo
IV
20
nl
I-I
15 16
19 18 9
III - III
13
95.7272
17
ZA40S
Maintenance
53031/A1
L-Mot. / 1995
53031/A1
Maintenance
ZA40S
IV - IV
lU
se
nl
12
rn
a
10
V-V
11
20
Fo
rI
nt
e
24
21
VII - VII
VII
18
22
VII
26
25
26
95.7273
1995 / L-Mot.
4 z
24
23
55011/A1
Maintenance
ZA40S
Fuel Injection Pump

I-I
nt
e
III
7
17
6
5
J
Supply chamber
Return chamber
Carrier
Piston for pneumatic
safety shutdown
For M12 jack screws
Leakage fuel
Leakage fuel outlet
Alignment marks
Alignment marks
Relief groove
Oil inlet
Connecting bore for oil
Circumferential groove
for lub. and seal oil
to instructions
AS
LF
LO
M
M1
ON
SO
SO1
ZN
A
B
J
K
II - II
10*
11
12
LF
13
14
15
16
13
23
Fo
rI
Thrust disc
Bush
Circlip
Roller pin
Rod seal
Dowel pin
Backup ring
rn
a
17
18
19
20
21
* 22
23
24
25
26
27
28
29
30
31
nl
9444.01
9455.12
9455.13
Pump housing
Guide piston
Lower spring plate
Tappet
Oring
Upper spring plat
Regulating rack
Clamp ring
Regulating sleeve
Screw
Pump cover
Oring
Deflector screw
Pump cylinder
Pump plunger
Cover to pneumatic
shutdown device
Set screw
Return spring
Circlip
Guide pin
Roller
Screw
Set screw
Oring
9408.17
1
2
3
4
5
6
7
8
9
* 10
11
12
13
14
15
16
se
9408.17
III
1 Torque wrench
(140-560 Nm)
1 Torque wrench
(480-940 Nm)
1 Withdrawing device
1 Eye nut (ZALS)
1 Suspension device (ZAVS)
1 Grip screw M6
2 Jack screws M12
lU
Tools:
24
LO
ON
ZN
SO1
30
M1
18
19
4
3
20
2
1
SO
25
26
21
27
21
28
95.7278
3.00
55011/A1
Maintenance
ZA40S
Removing the fuel injection pump from the engine

(For simplicity sake the fuel injection pump will in this group be called pump for short)
- Bar the crankshaft, so that the roller 21 rests on the cam base circle.
- Close the shutoff valves for the fuel inlet and return
pipe of the relevant pump.
- Loosen all the screws 10, then tighten them again by
hand until seated.
ZAL40S
- Loosen and remove the four screws which fasten the

pump onto the engine.
ZAV40S
9455.12
9455.13
nl
- Use two jack screws (M12) to separate the pump casing

form the engine casing and lift it until the dowel pin 30
is no longer engaged.
(The pump can be pushed out of its guide by barring the
engine crankshaft, whereby the cam lifts the pump.
This has to be done carefully and only when all the con
nections to the pump are removed).
95.7279
lU
se
- Attach pump to crane with suspension device 9455.12

or 9455.13 and pull it out fully and move it away. Please
refer to Fig. 'B').
Dismantling the pump (Fig. 'A')
rn
a
It will seldom be necessary to dismantle a pump into all its component parts. Usually partial dismantling suffices to repla
ce some worn parts. However, the complete dismantling procedure is described below for information.
It would be of advantage to construct a device permitting the pump to be mounted vertically with the cover upwards or
downwards, fastening it with screws similarly to the manner it is fastened on the engine.
nt
e
Working procedure:
- Fix the pump to a work bench with the cover downwards.

- Mount the withdrawing device 9444.01 as shown in Fig.
'C' and, by turning its spindle, push the guide piston 2
in, until the pin 20 can be withdrawn with the grip screw
(M6).
20
rI
Fo
- Relieve the withdrawing device 9444.01 and remove it.
M6
- 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 shown in Fig. 'D'). This will cause
the spring plate 3 to be lifted slightly off the guide pis
ton 2. When the clearance is large enough, the pump
plunger 15 can be pushed out between the lower spring
plate 3 and the tappet 4.
9444.01
- For the removal of the lower spring plate 3, place an un

usable pump plunger in place of the one just removed,
clamp it in a vice, and pull hard on the guide piston.
1995
95.7280
55011/A1
Maintenance
ZA40S
- The roller 21 can be removed together with bush 26 and thrust discs 25, after removing the circlip 27 and pushing the
roller pin 28 out.
Attention
The bush 26 is loose in the roller 21 and it, as well as the thrust discs 25, can fall out.
- Should it become necessary to replace tappet 4, press it out with a round bar
from below.
- To remove the upper spring plate 6 and the regulating sleeve 9, loosen the locat
ing screw 17.
- If it is necessary to remove also the regulating rack 7, it is important to deter
mine its exact position beforehand either by measuring or by a mark, before the
clamp ring 8 is removed.
4
19
- Unscrew the locating screw 23 and push the pump cylinder 14 out with a piece of
hard wood or a lad punch.
3
2
nl
- Now remove the screws 10, which were slackened off at the beginning, and lift
off the pump cover 11 from the housing, by using the jacking screw (M12).
- After removing the cover 16, the regulating rack 7 can be pushed out of the
pump housing.
15
se
The pump cylinder 14 and the pump plunger 15 are a matched

pair and may not be interchanged. They are also not supplied
individually. The pump plunger must be protected from any
kind of damage. It should therefor be pushed back into its cor
responding cylinder as soon as it has been removed.
lU
Attention
95.7281
IV - IV
rn
a
The removed parts can now be cleaned and their condi

tion checked. (Please also refer to the Clearance and
Wear Table group 0352-1).
The various bores in the pump housing must be blown out
with compressed air.
22*
1
nt
e
Assembling the pump (see Fig. 'A')
rI
Preassembling conditions:
- All the parts must be absolutely clean and undamaged.
- Assemble the parts in a clean and dust free place.
- Replace all the Orings 5, 12 and 24 by new ones.
- The copper joint rings of the screws 13 and 23 must ei
ther be annealed or replaced by new ones.
Fo
II
Assembling:
- Place the pump housing 1 on a work bench with the
head facing upwards.
- Insert the pump cylinder 14, with Oring 24 fitted, into
the pump housing 1, line up the milled slot in the pump
cylinder with the hole for the locating screw 23, screw in
the locating screw and tighten it firmly.
Remark
III - III
AS K
16
8 7
10
Dip the pump cylinder in clean diesel

oil prior to inserting it into the hous
ing.
IV
29
IV
95.7282
AS II
1995
55011/A1
Maintenance
ZA40S
- Invert the pump housing and place it with head downwards on the work bench.
- Insert the fuel regulating rack 7 and fit the cover 16 with its joint. Push the clamping 8 exactly to its position prior to
dismantling and clamp it firmly with its clamp screw.
- Insert the regulating sleeve 9 (toothed end first) in such a way that the mark on one tooth of the regulating rack 7
comes to lie between the two marks of the regulating sleeve 9 (please refer to Fig. 'E').
- Fit the upper spring plate 6 and insert locating screw 17 (with a copper joint) and tighten it (please refer to Fig. 'A').
- Place the spring 18 onto the upper spring plate 6 and note where the mark is on the edge of the regulating sleeve 9 (see
mark 'M1').
- Fit roller 21 with bush 26 and thrust discs 25 into the guide piston 2 and push the roller pin 28 through. Insert both
circlips 27 into the grooves on the roller pin. All these parts must be well oiled before fitting.
nl
- Insert the pump plunger 15 between the lower spring plate 3 and the tappet 4, and tap it down with a lead punch or a
hard wood block,until the circlip 19 snaps into the groove. (A clearance of 0.01 to 005 mm must remain between pump
plunger and lower spring plate i.e. the pump plunger must be free to rotate without jamming).
se
- Grip the previously completed guide piston 2 from behind, dip the pump plunger 15 in clean Diesel oil, then insert the
guide piston with the plunger first. The mark 'M1' on the pump plunger carrier 'J' must line up with the corresponding
marks in the slot of the regulating sleeve 9 and the milled groove in the guide piston 2 must lie on that side of the pump
where the hole for the locating pin 20 (Fig. 'A') is located in the housing.
- Using device 9444.01 push the guide piston into the pump housing until the locating pin 20 can be inserted (Fig. 'C').
lU
Should it be felt that the guide piston meets with resistance before the locating pin 20 can be in
serted, this means that the carrier 'J' of the pump plunger has come up against the regulating sleeve.
The device 9444.01 must then be partially released and the pump plunger slightly turned by moving
the regulating rack 7. Now tighten the device, gently attempting to push the guide piston into its
housing until the pin 20 can be inserted.
Under no circumstances may simply more force be applied when solid resistance is suddenly felt
during this fitting.
rn
a
Attention
nt
e
- Release the device 9444.01 and remove it. Now invert

the pump again with its head facing upwards.
- Fit the pump cover 11 with inserted backup ring 31 and

Oring 12 (see Fig. 'F') onto the pump (note position of
the connecting hole for the leak fuel pipe and the back
up ring). Always use a new Oring for the assembly!
rI
11
31
On the fully assembled pump, the fuel regulating rack 7

must be free to be moved to and fro without sticking.
12
Fo
- Apply oil to the screws 10 on thread and head landing,

insert them and tighten equally in steps to a torque of
140 Nm.
LF
00.7300
3.00
55011/A1
Maintenance
ZA40S
Preservation
Should a pump have to be put into storage for any length of time, the spaces 'A' and 'B' (Fig. 'A' I-I) have to be filled with
a thin Vaseline oil and the pump has to be stored upright. All openings must be closed with plastic plugs.
Mounting the pump on the engine
- Bar the crankshaft until the cam profile of the respective pump faces downwards.
- Check to ensure that the landing surfaces and guide elements in the engine casing and the pump are in perfect condi
tion.
- Smear the guide elements with oil and carefully mount the pump, whilst ensuring that the dowel pin 30 as well as the
regulating rack engage properly (do not use any sealing compound).
nl
- Smear the threads and head landings of the screws 22 (Fig. 'E' IV-IV) with oil and tighten the screws diagonally, in
equal stages to a final torque of 600 Nm.
- By moving the connecting members between the regulating linkage and pump regulating rack to and fro, ensure that
nothing is sticking.
- Connect the pipes to the pump and open the shutoff valves of the fuel inlet and return pipes.
se
- 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 abnormal heating.
lU
Where new parts have been fitted during the pump overhaul (pump plunger and cylinder), the
clamp ring 8 on the fuel regulating rack of the pump fitted on the engine must be readjusted (please
refer to group 5501-2).
Fo
rI
nt
e
rn
a
Remark
5 z
1995
55012/A1
Maintenance
ZA40S
Fuel Injection Pump

Adjusting and Checking
Withdrawing device
Adjusting device (complete)
Intermediate piece
Gauge
Various spanners
9444.01
9455.02
9455.09
9455.10
1
7
8
9
13
35
36
37
38
39
40
41
42
43
Dial gauge (8455.06)

Tensioning nut
Clamping piece
Waisted bolt
Measuring cylinder
(9455.03)
Nozzle
Measuring pin (9455.05)
Pressure gauge 0-10 bar
(9455.07)
Pressure gauge 0-6 bar
(9455.08)
C Clamping device for

measuring pin (9455.05)
14
15
16
30
31
32
33
34
Pump housing
Regulating rack
Clamp ring
Regulating sleeve
Fig. 'A' group 5501-1
Deflector screws
Fig. 'A' group 5501-1
Pump cylinder
Pump plunger
Cover
Gasket
Locking plug (9455.04)
Spring piston
Nozzle
Air hose coupling
1
1
1
1
nl
Tools:
se
As a rule the manufacturer adjusts the fuel injection pumps (called injection pumps for short) in such a manner that they
deliver the same amount of fuel at a certain position of the regulating rack.
lU
An injection pump has to be adjusted if:
the pump cylinder 14 with pump plunger 15, the regulating rack 7, or
the regulating sleeve 9 have been exchanged;
the clamp ring 8 on the regulating rack 7 has been moved.
rn
a
Depending on the requirements on the engine, several design variants of pump plungers 15 may be built in the injection
pumps. However, only use one design variant of pump plungers in the same engine.
nt
e
Pump plungers with the designation
S CIT (Constant Injection Timing) or
rI
S VIT (Variable Injection Timing) are used.
They in turn are marked with an execution number.
Fo
The table below shows the pump plunger executions and the relevant adjusting values of the injection pumps.
Pump plunger
Execution No.
Delivery stroke
(mm)
Load indicator
(Pos.)
Correction factor
CIT
.019
15.88
8.65
.617
14.73
8.65
.958
11.77
8.65
.542
14.73
8.65
2.07
.466
12.32
8.65
1.78
.465
12.32
8.65
1.98
VIT
For the executions, as well as for the adjusting data of the injection pumps refer to the engine setting table. The data
listed in this table must be used for checking and adjusting a injection pump.
A check or an adjustment of the injection pump can be done either outside of the engine (section A), or with the injec
tion pump fitted on the engine (section B).
3.00
55012/A1
Remark
Maintenance
ZA40S
The injection pump covers 16 can have two different connection threads for the highpressure pipes:
- old execution M27x1.5
- new execution M39x3
If the cover 16 shows an M39x3 connection thread, mount an intermediate piece 9455.09 on
the cover 16 before fitting the adjusting device 9455.02. Check the correct length of the mea
suring pin 41! During the whole adjusting procedure the latter must protrude from the top
edge of the connection thread.
Alte Ausfhrung
OLD EXECUTION
Neue Ausfhrung
NEW EXECUTION
rn
a
lU
9455.02
se
nl
9455.09
30
30
16
Fo
rI
nt
e
41
3.00
55012/A1
Maintenance
ZA40S
A) Adjusting and checking of an injection pump outside the engine

S Injection pump with CIT plunger:
Example with execution No. .019:
Delivery stroke 15.88 mm (refer also to the table)
Adjusting procedure:
Plug the leakage oil connection with the locking plug 31 of the adjusting device 9455.02 (Fig. 'C'). The fuel inlet or
return connections must remain open.
2)
Place the measuring pin 41 on the pump plunger 15 and fit the adjusting device with the gasket 30 as shown in Fig.
'C'. The device is to be screwed down moderately with four waisted bolts 38.
3)
Connect the air hose to the adjusting device. The necessary air pressure at the pressure gauge 42 must be constantly
6-9 bar.
4)
Screw down the withdrawing device 9444.01 to the pump housing 1 as shown in Fig. 'B'.
5)
Bring the pump plunger 15 up with the spindle of the withdrawing device 9444.01, until the pressure gauge 43 shows
the maximum pressure (e.g. 4 bar), see 'a' in Fig. 'E'. Note down the pressure value!
6)
Bring the pump plunger down with the aid of the withdrawing device until the pressure gauge 43 does not indicate
pressure any more; see 'b' in Fig. 'E'.
7)
Run the pump plunger up until the pressure gauge 43 indicates exactly half of the maximum pressure measured
before (e.g. 2 bar). Set dial gauge 35 to '0' with weak pretension ('c' in Fig. 'E').
8)
Continue to run up the plump plunger until the dial gauge 35 indicates the specified delivery stroke (e.g. 15.88 mm),
see 'd' in Fig. 'E'.
9)
Loosen the clamp ring 8 (Fig. 'D') to the regulating rack 7, and move the latter until the pressure gauge 43 indicates
half of the maximum pressure (e.g. 2 bar), see 'e' in Fig. 'E'.
In this position the clamp ring 8 is to be fitted without any clearance between pump housing 1 and clamp ring 8 with
the aid of the gauge 9455.10 (Fig. 'D').
rI
Fo
nt
e
rn
a
lU
se
nl
1)
9444.01
3.00
55012/A1
Check:
Maintenance
ZA40S
- Return the pump plunger to the initial position until the pressure gauge 43 indicates zero pressure ('f'
in Fig. 'E').
- Bring the pump plunger up until the pressure gauge 43 indicates exactly half (e.g. 2 bar) of the max.
pressure (e.g. 4 bar). Set dial gauge 35 to '0' with weak pretension. Start of delivery ('g' in Fig. 'E').
- Continue to run up the plunger until the pressure gauge 43 again indicates only half of the maximum
pressure (e.g. 2 bar), end of delivery. Read the delivery stroke from the dial gauge 35 (e.g. 15.88 mm),
see 'h' in Fig. 'E'.
The measured delivery stroke must correspond to the value listed in the engine setting table.
Admissible difference 0.02 mm. If the difference is bigger repeat the adjusting procedure.
nl
- After checking mark the clamp ring 8 to the regulating rack 7 with an oilresistant paint drop (Fig. 'D').
S Injection pump with VIT plunger:
Delivery stroke 12.32 mm and correction factor 1.78

(refer also to the table)
se
The same preparations are to be made as described in above items 1 to 4.
Bring the pump plunger 15 up with the spindle of the withdrawing device 9444.01 (Fig. 'B'), until the pressure gauge
43 shows the maximum pressure (e.g. 4 bar), see 'a' in Fig. 'F'. Note down the pressure value.
6)
Bring the pump plunger down with the aid of the withdrawing device until the pressure gauge 43 does not indicate
pressure any more; see 'b' in Fig. 'F'.
7)
Run the pump plunger up until the pressure gauge 43 indicates exactly half of the maximum pressure measured
before (e.g. 2 bar). Set dial gauge 35 to '0' with weak pretension ('c' in Fig. 'F').
8)
Continue to run up the plunger until the pressure gauge 43 again indicates half of the maximum pressure (e.g. 2
bar). Read the measured delivery stroke from the dial gauge 35 (e.g. 11.62 mm), see 'd' in Fig. 'F'.
9)
The dimension difference is calculated from the delivery stroke in the setting table:
e.g. 12.32 mm
minus measured delivery stroke e.g. 11.62 mm
dimension difference
= 0.70 mm
rI
nt
e
rn
a
lU
5)
Fo
In case of a negative dimension difference the correction becomes negative.

The correction value is calculated from the dimension difference:
e.g. 0.70 mm x correction factor (see table)
e.g. 1.78 = 1.25 mm
The correspondent delivery stroke adjustment is calculated from the measured delivery stroke:
e.g. 11.62 mm
plus correction value
e.g. 1.25 mm
final value
= 12.87 mm
10) Depending on the calculated final value, bring the pump plunger up or down till the final value, e.g. 12.87 mm, has
been reached (see dial gauge 35, 'e' in Fig. 'F').
11) Loosen the clamp ring 8 (Fig. 'D') to the reglating rack 7, and move the latter until the pressure gauge 43 indicates
half of the maximum pressure (e.g. 2 bar), see 'f' in Fig. 'F'.
In this position fit the clamp ring 8 by means of the gauge 9455.10 without any clearance between pump housing 1
and clamp ring 8 (Fig. 'D').
3.00
Check:
55012/A1
Maintenance
ZA40S
- Return the pump plunger to the initial position until the pressure gauge 43 indicates zero pressure ('g'
in Fig. 'F').
- Bring the pump plunger up till the pressure gauge 43 indicates exactly half (e.g. 2 bar) of the maximum
pressure (e.g. 4 bar).
Set dial gauge 35 to '0' with weak pretension. Start of delivery ('h' in Fig. 'F').
- Continue to run up the pump plunger until the pressure gauge 43 again indicates only half of the max.
pressure (e.g. 2 bar), end of delivery.
Read the delivery stroke from the dial gauge 35 (e.g. 12.32 mm), see 'i' in Fig. 'F'.
The measured delivery stroke must correspond to the value listed in the setting table.
Admissible difference 0.02 mm. If the difference is bigger repeat the adjusting procedure.
- After checking mark the clamp ring 8 to the regulating rack 7 with an oilresistant paint drop (Fig. 'D').
nl
Fitting of an adjusted injection pump on the engine
The torsion springs of the regulating linkage must not be additionally pretensioned.
rn
a
Attention
lU
se
After the injection pump has been adjusted and fitted as described in Group 5501-1, the regulating rack is to be adju
sted.
Set the load indicator to position 8.65 and lock it (see also items 7 to 9 "Adjusting and checking of an injection pump on
the engine").
By means of the gauge 9455.10 adjust the position of the regulating rack 7 (Fig. 'D'). The gauge 9455.10 must be seated
without any clearance between pump housing 1 and clamp ring 8. The thickness 10 0.03 mm of the gauge corresponds
to the setting value. The clamp ring must not be moved.
Use the adjusting screws (Fig. 'D') to carry out and obtain the setting mentioned above. After that the screws must lie on
the stop levers without any clearance, as shown in Fig. 'D'. After setting the adjusting screws secure them with lock nuts.
nt
e
B) Adjusting and checking of an injection pump on the engine

S Injection pump with CIT plunger:
Delivery stroke 15.88 mm (refer also to the table)
rI
Close the shutoff cock for the fuel inlet and return piping.
2)
Disconnect the fuel pressure pipe from the injection pump.
3)
Remove one deflector screw 13 from the pump housing.
4)
Screw the fuel leakage pipe off the pump cover and plug the open connection with locking plug 31 of the adjusting
device 9455.02 (Fig. 'C').
5)
Turn the engine until the roller of the injection pump is on the cam base circle.
6)
Place the measuring pin 41 on the pump plunger 15 and fit the adjusting device with the gasket 30 as shown in Fig.
'C'. The device is to be screwed down moderately with four waisted bolts 38.
7)
Loosen the elastic rod between speed control and regulating linkage.
8)
Loosen the clamp screw of the lever to the shutdown servomotor and move the lever on the regulating shaft axially
until the latter can be turned freely (see group 4612-1).
9)
Set the load indicator to Pos. 8.65 by means of the emergency shutoff lever, and lock the regulating linkage in this
position.
Fo
1)
10) Connect the air hose to the adjusting device.

The necessary air pressure at the pressure gauge 42 must be constantly 6-9 bar.
3.00
55012/A1
Remark
Maintenance
ZA40S
For all measurements the camshaft is to be turned forward only (considering the clearances).
If it has been turned too far, turn it back and then forward again up to the relevant measuring point.
11) Turn the engine slowly forward until the pressure gauge 43 indicates the maximum pressure (e.g. 4 bar), see 'a' in
Fig. 'E'. Note down the pressure value!
12) Slowly turn the engine backward until the pressure gauge 43 does not indicate any pressure any more, see 'b' in Fig.
'E'.
13) Turn the engine forward until the pressure gauge 43 indicates exactly half of the maximum pressure measured be
fore (e.g. 2 bar).
Set dial gauge 35 to '0' with weak pretension ('c' in Fig. 'E'). This position means start of delivery.
nl
14) Continue to turn the engine forward until the dial gauge 35 indicates the specified delivery stroke (e.g. 15.88 mm),
see 'd' in Fig. 'E'.
15) Move the regulating rack 7 (Fig. 'D') by means of the two adjusting screws at the stop levers, till the pressure gauge
43 indicates half of the maximum pressure (e.g. 2 bar), see 'e in Fig. 'E'. Fasten the screws with lock nuts.
The torsion springs of the regulating linkage must not be additionally pretensioned. The adjusting
screws (Fig. 'D') must lie on the stop levers without any clearance.
lU
Attention
se
16) In this position fit the clamp ring 8 by means of the gauge 9455.10 without any clearance between pump housing 1
Check of CIT pump plungers:
Turn back the engine until the roller of the injection pump is on the cam base circle.
Set dial gauge 35 to '0' with weak pretension.
Turn the engine forward until the pressure gauge 43 indicates exactly half of the maximum pressure = start of deliv
ery. Note down the measured stroke = idle stroke.
From the scale of the flywheel read the angle with regard to the ignition T.D.C., and note it down too = start of
delivery in crank angle degrees.
Continue to turn the engine forward until the pressure gauge 43 again indicates half of the maximum pressure =
end of delivery. Read the measured stroke = total stroke from the dial gauge 35 and note it down.
Subtract the idle stroke from the measured total stroke. The result is the delivery stroke in mm.
The delivery stroke calculated in this way must correspond to the value mentioned in the setting table or to the
relevant value in the table above; tolerance 0.02 mm.
From the scale of the flywheel read the angle with regard to the ignition T.D.C., and note it down too = end of deliv
ery in crank angle degrees.
After checking mark the clamp ring 8 to the regulating rack with an oilresistant paint drop (Fig. 'D').
Fo
rI
nt
e
rn
a
After adjusting and checking an injection pump remove the gauge 9455.10 which has possibly been fitted.
The elastic rod between speed control and regulating linkage, as well as the lever for the shutdown servomotor are to be
refitted.
3.00
55012/A1
Maintenance
ZA40S
S Injection pump with VIT plunger:

Delivery stroke 12.32 mm and correction value 1.78

(refer also to the table)
The same preparations are to be made as described in above items 1 to 10 (see "Adjusting and checking of an injection
pump on the engine", paragraph "Injection pump with CIT plunger").
11) Turn the engine slowly forward until the pressure gauge 43 indicates the maximum pressure (e.g. 4 bar), see 'a' in
Fig. 'F'. Note down the pressure value!
nl
12) Slowly turn the engine backward until the pressure gauge 43 does not indicate any pressure any more, see 'b' in Fig.
'F'.
Set dial gauge 35 to '0' with weak pretension ('c' in Fig. 'F').
13) Turn the engine forward until the pressure gauge 43 indicates exactly half of the maximum pressure measured be
fore (e.g. 2 bar).
se
14) Continue to turn the engine forward until the pressure gauge 43 again indicates half of the maximum pressure (e.g.
2 bar). Read the measured delivery stroke from the dial gauge 35 and note down the value (e.g. 11.62 mm), see 'd' in
Fig. 'F'.
rn
a
lU
15) The dimension difference is calculated from the delivery stroke in the setting table:
e.g. 12.32 mm
minus measured delivery stroke e.g. 11.62 mm
dimension difference
= 0.70 mm
nt
e
In case of a negative difference the correction becomes negative.

The correction value is calculated from the dimension difference, e.g. 0.70 mm x correction factor:
e.g. 1.78 = 1.25 mm
rI
The correspondent delivery stroke adjustment is calculated from the measured delivery stroke:
e.g. 11.62 mm
plus correction value
e.g. 1.25 mm
final value
= 12.87 mm
Fo
16) Depending on the calculated final value, turn the engine forward or backward till the final value, e.g. 12.87 mm, has
been reached (see 'e' in Fig. 'F').
17) Move the regulating rack 7 (Fig. 'D') by means of the two adjusting screws at the stop levers, till the pressure gauge
43 indicates half of the maximum pressure (e.g. 2 bar), see 'f in Fig. 'F'.
Fasten the adjusting screws with lock nuts.
18) In this position fit the clamp ring 8 by means of the gauge 9455.10 without any clearance between pump housing 1
Attention
The torsion springs of the regulating linkage must not be additionally pretensioned. The adjusting
screws (Fig. 'D') must lie on the stop levers without any clearance.
Check of VIT pump plungers:

-
Checking of the above adjustment is to be carried out as described in "Adjusting and checking of an injection pump
on the engine", paragraph "Check of CIT pump plungers".
3.00
55012/A1
Maintenance
DRAWN FOR ZA40
ZA40S
C
35
(945506)
36
9455.02
43 (945508)
(945507) 42
37
39
(945503)
nl
II
40
33
41
(945505)
se
32
(945504) 31
30
lU
14
15
nt
e
rn
a
31
(945504)
Fo
II - II
rI
No clearance
38
II
34
1
Oil-resistant paint drop
8
7
7
Lock nut
9455.10
Adjusting screw
Stop lever
Torsion spring
Adjusting screw
Lock nut
3.00
55012/A1
Maintenance
ZA40S
Adjusting procedure for injection pump with CIT pump plunger

The adjustment takes place in alphabetical order
Pressure gauge 43
Pressure gauge 43
y
nl
Dial gauge 35
value not important
End position
Start position
CIT pump plunger
se
c
Pressure gauge 43
g
Pressure gauge 43
Dial gauge 35
nt
e
adjusted to 0
Dial gauge 35
adjusted to 0
e
Pressure gauge 43
Fo
rI
Pressure gauge 43
Delivery stroke
rn
a
lU
Control edge
Dial gauge 35
value not important
Dial gauge 35
Dial gauge 35
value not important
15.88 mm
Pressure gauge 43
Pressure gauge 43
Dial gauge 35
Dial gauge 35
value e.g. 15.88 mm
15.88 mm
3.00
55012/A1
Maintenance
ZA40S
Adjusting procedure for injection pump with VIT pump plunger
The adjustment takes place in alphabetical order
se
Dial gauge 35
adjusted to 0
Dial gauge 35
f
Pressure gauge 43
Fo
rI
Pressure gauge 43
Pressure gauge 43
lU
nt
e
adjusted to 0
Delivery stroke
Delivery stroke
rn
a
measured
Pressure gauge 43
Dial gauge 35
value not important
value not important
nl
Dial gauge 35
VIT pump plunger
End position
Pressure gauge 43
Start position
Pressure gauge 43
Dial gauge 35
Dial gauge 35
value not important
12.87 mm
Pressure gauge 43
Pressure gauge 43
Pressure gauge 43
Dial gauge 35
Dial gauge 35
Dial gauge 35
value e.g. 11.62 mm
12.87 mm
12.32 mm
3.00
10 z
Group6
Betrieb
ZA40S
Fo
rI
nt
e
rn
a
lU
se
nl
Group 6
6601--1/A1
Maintenance
ZA40S
Charge Air Cooler

Removal, Cleaning and Mounting
Tools:
12
13
14
15
16
Tubestack plate
Gasket
Sealing flange
Screws
Sealing ring
(Rubber 10 mm )
17 Tubestack
AP Suspension points
(for cooler removal)
DR Drainage
V Vent
nl
Expansion belows
Diffusor
Screws
Bracket
Air inlet housing
Air cooler
Water trap
Screws
Flow reversing chamber
Connection chamber
Casing of charge air cooler
Drain connection
Gasket
1
2
3
4
5
5a
5b
6
7
8
9
10
11
4 Shackles
Various spanners
Ropes
4 Eye screws
--- Check daily on the running engine whether the nozzle in the drain connection is unclogged, i.e. whether air is coming
out. A clogged nozzle must e freed immediately. Should water issue with the air, check whether it is condensate or
water from the cooling system (possibly leaking cooler tubes).
se
--- The cooler must be cleaned if:
lU
a) The pressure drop of the air through the cooler exceeds the value fixed in the Operating Data Sheet table (see
Operating Manual, group 0230---1/A2).
b) The temperature difference of the cooling water between cooler inlet and cooler outlet has risen to 12_C.
(These values refer to normal running load).
rn
a
It is not always necessary to remove the cooler for the cleaning operation.
Cleaning of the cooler
nt
e
Water side:
rI
The water side of the charge air coolers can be cleaned without dismantling the cooler. To this end the connection chamber 8 and the flow reversing chamber 7 (Fig. A) must be removed, whereupon the tubes can be pushed through with tube
brushes and a liberal application of water.
Fo
--- Sediments which cannot be removed from the tubes with the brushes, must be cleared by immersing the cooler in a
chemical solvent. Consult a specialist firm for this undertaking and follow its recommendations 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 all the details required).
Air side:
--- On engines equipped with a permanent charge air cooler washing device, the cooler can be washed periodically in
operation.
Where this installation does not exist it is best to remove the cooler form the engine and place it in a chemical cleaning
bath. After the cleaning the cooler must be rinsed, carefully neutralized and finally be blown through with compressed air.
As cleaning agent the product of a well known firm should be used like for example:
ALTREX,
HENKEL,
ACC, etc.
It goes without saying that the instructions for preparing the baths and the actual cleaning procedure of the various firms
must be followed carefully.
After re-assembly of the cooler it must be subjected to a pressure test at 4 bar.
09.04
66011/A1
Maintenance
ZA40S
Dismantling the charge air cooler

- Shut off the water flow to the cooler and drain the cooler. (Open the cock at 'DR', or remove the threaded plug respec
tively).
- Disconnect all the pipes from the cooler.
- Remove the expansion bellows 1, the diffusor 2 and the air inlet housing 5 (Fig. 'A' and 'B').
- Loosen the screw 3 of the bracket 4 and remove them.
- Remove all but a few of the screws 6.
- Attach a shackle at 'AP' on either end of the bracket 4. Fix the shackles with ropes to the crane.
- Remove the remaining screws 6 and pull the cooler horizontally sufficiently away from the charge air cooler casing 9,
that it can be rested on the floor.
nl
- For further dismantling remove the screws 15, which fasten the sealing flange 14 (Fig. 'C').
- Remove the sealing flange 14 and sealing ring 16, and place the cooler upright on the floor with the connection cham
ber 8 uppermost.
- Withdraw the tubestack 17 from the casing with the crane.
se
- Attach four eye screws, equally spaced into the threaded holes of the connections of connection chamber 8 and attach
them with ropes to the crane hook.
lU
- To clean the inside of the cooler tubes, remove the flow reversing chamber 7 and the connection chamber 8 from the
tubestack 17.
- Defective cooler tubes can be put out of action by soldering both ends or by blanking them off with tapered hardwood
plugs. The number of blankedoff tubes may not exceed 10% of all the tubes.
Assembling the charge air cooler
rn
a
- The cleaned cooler must be subjected to a pressure test at 4 bar.
nt
e
- Fit the flow reversing chamber 7 and the connection chamber 8 to the cleaned cooler tubestack (use only new joints!).
- Place the cooler casing vertically on two wooden underlays, and set the gasket 13 on the flange (connecting chamber
end). Attach the tube stack by ropes to the crane and lower it (flow reversing chamber first) into the casing, slowly so as
not to damage the gasket 13.
rI
- After fastening the tubestack to the casing with the screws, place the complete cooler into a horizontal position.
Fo
- Place gland ring 16 over the flow reversing chamber 7 protruding out of the casing over the gland frame 14, which is
fastened to the casing by screws 15.
- The complete cooler is attached with shackles and ropes to the crane and is mounted to the charge air cooler casing 9,
in reverse sequence to the dismantling, and fastened with the screws. For the sealing between the charge air cooler
and the casing use sealing compound.
- Tighten all the screws 3, so that the bracket 4 is again fastened to the support (Fig. 'A').
- Finally connect all the water pipes to the connection chamber 8.
1995
66011/A1
Maintenance
ZA40S
Remark on the use of chemical cleaning agents

If the degree of dirt deposit in the cooler necessitates a cleaning with chemical solvents, ensure firsts without any doubt
that the cooler materials are not attacked by them. For the air side cleaning, products of the following firms may for
example be used:
ALTREX . . . . by Wyandotte Chemical Corporation
ACC . . . . . . . . by Drew Chemical Corporation
Regarding the mixtures and the application follow strictly the instruction of the suppliers.
To remove sediments in the inside of the tubes chemically, we recommend to consult the cooler manufacturers. Before
using chemical agents the supplier should contact the cooler manufacturers. If difficulties are encountered regarding
the application, ask New Sulzer Diesel Ltd. indicating the cooler make and type.
nl
Remark
Detailed information concerning the operation, maintenance and repair of charge air coolers is provided in a separate
Instruction Manual issued by the cooler manufacturers.
Since in most cases GEA coolers are provided, it is advisable to obtain the Instruction Manuals directly from GEA at the
following address:
se
GEA Luftkhlergesellschaft Happel GmbH u. Co.

43-45 Knigsallee
D 44789 Bochum (Germany)
rn
a
lU
Should a cooler of other manufacture be fitted, the instruction material must be obtained from the respective manufac
turer.
It is also possible to order such Instruction Manuals from the engine builder or supplier. For this, the following informa
tion is to be provided:
Engine type and number
Engine supplier
nt
e
Cooler make and type
Fo
rI
Desired language
1995
66011/A1
Maintenance
ZA40S
II
AP
9
5b
lU
7
nt
e
rn
a
D 6
Khler am Freien Ende

COOLER ON FREE END
5a DR D
10
rI
Fo
11 12 13
se
II
3
4
nl
4
AP
C
17
14 15 16
95.7274
11 7
1995
66011/A1
Maintenance
ZA40S
II
2
4
II
nl
V
5
AP
3
AP
se
5b
nt
e
rn
a
D DR 5a
lU
Fo
rI
Khler auf Antriebseite

COOLER ON DRIVING END
16 15 14
10
C
17
13 12 11
95.7275
7 11
5 z
1995
67301/A1
Maintenance
ZA40S
Flap for Charge Air Bypass

1
2
3
4
5
6
7
8
9
10
11
12
Sleeve
Valve flap
Allen screw
Flange
Limit feeler
Shaft
Spur gear wheel
Cylinder
Spur rack
Piston seal ring
Piston seal ring
Solenoid valve
nl
4 Open end spanner AF 41
Tools:
se
A halfyearly functional check of the charge air bypass flap must be carried out.
For this check the control air piping to the flap controls has to be removed during an operating stop. In this condition the
flap can be checked for ease of movement. This can be done with the aid of an open end spanner which is applied on the
sleeve 1 (see illustration). With its help the flap can be moved from fully open to fully closed 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 bypass.
lU
- Loosen the screws to valve flap 2 and remove them. Remove the valve flap together with the two spring dowel pins.
- Loosen and remove Allen screw 3. Remove sleeve 1.
rn
a
- Take off limit feeler 5, loosen fastening of flange 4, remove flange. The shaft 6 can now be removed together with the
spur gear wheel 7.
- Loosen fastening to cylinder 8 and remove cylinder.
nt
e
- Remove spur rack.

Assembling
Fo
rI
The assembling of the bypass flap is done analogously to dismantling but in reverse sequence. Attention must 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 position.
Before assembly, all moving parts are to be smeared lightly with MOLYKOTE paste.
Remark
Leakages at the vent (see Fig.) indicate defective piston seal rings 11 and 12.
If only the piston seal rings 10 and 11 must be replaced, withdraw first the spur gear wheel 7 from the
shaft 6. For that the valve flap remains in situ.
Attention must be paid that during assembly the marks on the spur gear wheel mate with the mark on
the spur rack.
3.00
67301/A1
Maintenance
II - II
ZA40S
I
II
nl
10
III
III
se
lU
11
rn
a
12
VENT
III - III
Entlftung
Fo
rI
nt
e
II
3.00
2 z
00.7302
67351/A1
Maintenance
ZA40S
WasteGate
Variant 'A'
Tools:
1 Testing device
for pneumatic fittings
and wastegate
9408.26
1
2
3
4
5
6
7
Flange
Screw
Pressure piece
Piston
Valve
Grooved cone piece
Spring
8,8a
9
10
11
12
13
14
Test connection
Limit switch
Stop plate
Piston seal ring
Piston seal ring
O-ring
Pressure reducing valve
Should, in the course of the halfyearly function check of the wastegate, the valve be jammed in any position or does not
open properly, then the wastegate has to be dismantled in the following manner:
nl
- Remove wastegate as a complete unit.

- Loosen and remove screw 2 together with its bush.
- Loosen screwed connection to pressure piece 3 and remove the latter.
- Loosen screwed connection to flange 1 and remove flange.
se
- With the aid of a wooden piece press hard on piston 4, till it is metallically seated. Simultaneously press onto valve disc
5 with sufficient force to keep the valve closed. The two grooved cone pieces 6 can then be removed.
- Slowly relieve pressure on piston 4.
lU
- Piston 4, valve 5 and the spring 7 can now be removed.
rn
a
Assembling
Fo
rI
nt
e
The assembling of the wastegate is carried 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 correspondence with the turbocharger specification. The set values are entered in the setting
table.
Before assembly, all parts shall be lightly smeared with MOLYKOTE paste.
1995
67351/A1
Maintenance
ZA40S
nt
e
II
Fo
rI
14
8a
rn
a
lU
se
nl
12
13
10
10
4
11
II
1
8
95.7277
9
3
1995
2 z
67351/A2
Maintenance
ZA40S
WasteGate
Variant 'B'
Tools:
1 Testing device
for pneumatic fittings
and wastegate
9408.26
1
2
3
4
5
6
Housing
Cover
Piston
Pressure regulating valve
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
The wastegate must be subjected to a monthly function check on the running engine. Should any faults appear or should
the lamp WASTEGATE FAILURE light up in the control room then the wastegate has to be overhauled as described
below:
Attention
nl
- Loosen screws 8 to cover 2. Specially long screws are built in for detensioning springs 11 and 12.
Stroke limiting screw 5 must not be adjusted !
- Dismantle piston 3. Clean piston as well as housing 1.
- Check piston seal ring 10 and guide ring 9 and replace them if necessary.
se
- After reassembling smear piston lightly with oil and check its easy movement in the casing.
lU
Assembling
Assembling is carried out analogous to dismantling but in reverse sequence.

Should gasket 6 (1 mm thick) need to be replaced, ensure that a gasket of the same thickness is again
fitted.
rn
a
Attention
Before assembling smear all moving parts lightly with clean engine oil.
nt
e
The holding pressure of the wastegate is adjustable on pressure regulating valve 4. For this adjust
ment utilize the tools contained in testing device 9408.26. With the aid of these adjusting tools the
holding pressure can be correctly set. (Please refer to group 6735-1 of the Operating Manual). The
setting data is recorded in the setting table.
Fo
rI
Remark
1995
67351/A2
Maintenance
ZA40S
lU
se
nl
rn
a
nt
e
rI
Fo
95.7284
1995
10
11
2 z
12
Group7
Betrieb
ZA40S
Fo
rI
nt
e
rn
a
lU
se
nl
Group 7
71011/A1
Maintenance
ZA40S

Dismantling and Reassembly

1 Depth gauge
1 Torque wrench
(480 940 Nm)
1 Puller
4 Eye bolts M16
Various open end
and ring spanners
9408.16
9408.17
Pilot valve
Pump housing
Bolt M16 x 50
Bearing cover
Drive wheel
Thrust ring
Waisted bolt
Oring
Bearing bushes
Pump transport wheel
(driver)
11 Cover
12 Gasket, 1 mm thick
13 Pump transport wheel

(driven)
14 Gasket
15 Shim
16 Cover
17 Spring
18 Dowel pins
G Place for eye bolt M16
K Drilling for measuring the
wheel displacement on the
pump shaft
nl
9471.01
1
2
3
4
5
6
7
8
9
10
Tools:
With a new engine the gear teeth profiles of the pump drive wheel 5 have to be inspected after a few weeks in service.
se
During a general overhaul the pump has to be dismantled and inspected. Heavily worn parts must be renewed (see Clea
rance and Wear Table group 0352-1).
Dismantling
lU
- Drain pump.
rn
a
- 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 all the set bolts clamping the pump to the engine except one.
- Screw in four M16 eye bolts into the pump housing at 'G' (see Fig. 'B') and hang the pump (approx. 332 kg) on a lifting
hoist.
nt
e
- Now remove the remaining set bolt and press off the pump from the engine with two M16 jacking screws until it is no
longer centred by the dowel pins 18.
- Take away the pump and set it on a flat surface for further dismantling.
Do not lose the shim 15.
Fo
Attention
rI
- Remove cover 16 and withdraw the pilot valve 1 and spring 17.
- 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 shown in Fig. 'C' and evenly tighten its M16 bolts hard until the drive wheel 5 is released
from the shaft. If necessary, strike the rear face of the puller once or twice hard with a hammer in order to aid release.
After loosening the drive wheel 5, further dismantling is carried out as follows:
- Remove the drive wheel 5.
- Unscrew the bolts 3 and lift off the cover 4 (Fig. 'A').
- It is now possible to withdraw the pump transport wheels 10 and 13 and to inspect them (see also Clearance and Wear
Table group 0352-1).
- Should the bearing bushes 9 have to be removed, they have to be pressed out of the housing and bearing cover and the
new ones pressed in with a suitable tool.
L-Mot. / 1995
71011/A1
Maintenance
ZA40S
Reassembly
- Oil all bare parts immediately before assembly.
- Slide both the pump transport wheels 10 and 13 into the housing 2 as shown on Fig. 'A' and then put on the bearing
cover 4 which is then located by dowel pins.
- Evenly tighten the bolts 3 and secure them with locking wire (2 mm diameter).
- Set the drive wheel 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 Gn and screw it
home onto the thrust ring by hand. The initial tightening is done with the aid of a torque wrench to a torque of 50 Nm
(= starting position).
nl
- Using a depth gauge through one of the holes 'K', measure the distance 'X' (= Outside edge of thrust ring to face of
drive wheel) and note it down (Fig. 'D').
- Tighten the bolt 7 further until the axial displacement of the gear wheel along the shaft comes to 1.3 0.05 mm which
has to be determined by measuring the distance 'X' several times.
(Theoretically the final tightening torque would be about 700 Nm. However, the measurable displacement is the de
termining factor).
se
- The bolt 7 must not be secured.
- Before fitting the pump on the engine a new Oring 8 has to be inserted in the groove on the pump flange.
Fo
rI
nt
e
rn
a
lU
- When fitting the complete pump on the engine, its correct position is determined by the dowel pins 18 (Fig. 'B').
1995 / L-Mot.
71011/A1
Maintenance
ZA40S
I-I
II
A
10
7
K
6
11
12
13
nl
14
lU
se
II
17
nt
e
rI
9471.01
Fo
16
rn
a
II - II
18
15
3
2
95.7287
(AF 46)
7
6
10
D
X
3 z
L-Mot. / 1995
71021/A1
Maintenance
ZA40S
Fuel Booster Pump


1
2
3
9474.01
4
9474.02
5
6
7
8
9
10
11,11a
12
13
14
15,15a,15b
16
17
Valve body (relief valve)

Stop
Spring
Joint
Screw
Holes for dowel pins
Oring
Circlip
Oring
Sealing disc
Oring
Bearing housing
Oring
Pump casing
Bearing bushes
Pump cog wheel (driven)
Bearing cover
18
19
20, 20a
21
22
23
* 24
25, 25a
26
Pump cog wheel (driving)

Screw
Shaft seal
Backing ring
Driving gear wheel
Press ring
Screw
Dowel pin
Screw
G Threaded hole
for eye bolt M12
AG Threaded hole
for jack screw M16
9408.16
9408.17
nl
1 Depth gauge
1 Torque wrench
(140 560 Nm / ")
1 Puller
1 Round bar
1 Socket spanner " AF30
1 Eye screw M12
Various open end
and ring spanners
Tools:
to instructions
se
On a new engine the tooth profile of the pump driving gear wheel must be inspected after a few weeks of engine opera
tion.
lU
During a general overhaul the pump must be dismantled and checked for wear. Worn parts must be replaced (see Clea
rance and Wear Table group 0352-1).
Dismantling
rn
a
- Drain the pump.
- Disconnect the pipes from the pump casing and close its openings with blanks (for example wood) to prevent any
foreign bodies from entering.
nt
e
- Remove the screws fastening the pump to the engine with the exception of one screw.
- Fit an eye bolt M12 in the pump casing at 'G' (see Fig. 'C') and attach the pump (about 95 kg) to the crane.
- Now remove the last screw holding the pump to the engine. Fit two jack screws M16 at 'AG' and press the pump away
from the engine until it is no longer positioned by the dowel pins (Fig. 'A').
rI
- Move the pump for dismantling to a work bench.
Fo
- Loosen the screw 24 and remove it with press ring 23.

- Fit the puller 9474.01 as shown on Fig. 'D' and tighten its two screws M16 equally and firmly, until the driving gear
wheel 22 has been pulled of the shaft. If necessary tap the centre of the puller hard once or twice with an iron hammer,
to aid the withdrawal.
After the removal of the driving gear wheel proceed with dismantling as follows:
- Remove the screws 26 (Fig. 'C') and pull the bearing housing 12 off the pump casing 14.
- Pull the Oring 7 off the shaft.
- Loosen and remove the screws 19 and lift the bearing cover 17 off the pump casing 14.
- Remove pump cog wheels 16 and 18.
- If the shaft seals 20 have to be replaced, remove circlip 8 and backing ring 21.
- The sequence of dismantling the remaining parts is obvious from the Figs. 'A' and 'D'.
- Should it be necessary to replace the bearing bushes 15, remove the old ones with a suitable tool and press in the new
bushes with great care.
1995
71021/A1
Maintenance
ZA40S
Assembling
- Clean all the parts carefully and, immediately before assembling the pump smear them with fresh oil.
The Orings 7, 9, 11, 11a and 13 as well as the shaft seal rings 20 and 20a must be replaced by new 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
backing ring 21 and the circlips 8 are in place!
- Fit pump cog wheels 16 and 18 into the pump casing, fit the bearing cover 17 and insert and tighten the screws 19 all
equally and firmly.
- Fit Oring 7 onto the driving shaft.
- Place Oring 11 in the groove, mount the bearing housing 12, insert and tighten the screws 26 equally and firmly and
lock the screws finally with locking wire.
- Fit the driving gear wheel 22 onto the driving shaft. (The tapered part of the shaft as well as the tapered bore in the
driving gear wheel must be specially clean and dry).
nl
- Fit press ring 23, smear the screw 24 on thread and head landing with oil and screw in by hand until seated and tighten
at first to about 20 Nm (= 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. 'E').
lU
- The screw 24 does not have to be locked.
se
- Tighten the screw 24 further, until the driving gear wheel 22 has been shifted on the shaft by 0.45 0.05 mm, which
must be checked by repeated measuring of the distance 'X'.
The tightening torque is theoretically 190 Nm but the measurable shifting is the decisive factor.
- Before fitting the pump to the engine, place the Oring 13 into the groove of the pump flange.
Fo
rI
nt
e
rn
a
- When fitting the pump on the engine the correct position is determined by the dowel pins (Fig. 'A') which must engage
with the holes 6 in the pump casing.
1995
3 z
2
III 1
4
3
IV
AG IV
25a
25
III - III
I-I
AG
III
26
II
9474.01
22
22
11
10
9
8
7
B
13
12
23
22
21
24*
(SW30)
20
IV - IV
nl
20a
15b
se
lU
24* 23
rn
a
nt
e
rI
Fo
II
15a
14 11a
19
15
16
17
18
ZA40S
Maintenance
71021/A1
95.7288
1995
71031/A1
Maintenance
ZA40S
Cylinder Cooling and Raw Water Pump

9408.01
9408.16
9431.03
9433.07
1
2
3
4
5
6
6a
7
8
9
10
11
12
Round nut
Drive wheel
Sleeve
Locking wire
Bolts M16 x 130
Bearing housing
Dowel pin
Oring
Shaft sealing ring (GACO)
Bush
Spacer ring
Rotary mechanical seal
Pump housing
M16
Gezeichnet fr ZV40/48
DRAWN FOR ZV40/48
13
14
15
16
17
18
19
20
21
22
23
Bolts M16 x 50
Oring
Cover
Shaft
Impeller
Oring
Bearing bushes
Piston sealing ring
Rod sealing ring
Piston
Cylinder
Hydr. hand pump

Depth gauge
Special spanner
Tensioning jack
Jacking screws M16
Eye bolt M16
L Leakage drain
nl
1
1
1
1
2
2
Tools:
8 9
10
11
13
14
rn
a
lU
se
12
nt
e
15
Fo
rI
16
17
0.34 0.48
19
18
6a
L
95.7292
The following instructions are valid for both the cylinder cooling water and the raw water pump.
The only difference between the two pumps lies in the choice of material, form and position of the pump housing and in
the size of the impeller 17.
1995
71031/A1
Maintenance
ZA40S
With a new engine the gear teeth profiles of the pump driving gear wheel 2 have to be inspected after a few weeks in
service.
During a general overhaul the pump has to be dismantled and the parts inspected. Heavily worn parts must be renewed
(see also Clearance Table 0352/14 and /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. Renewal 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 set bolts clamping the pump to the engine except one.
- Connect the pump to a lifting hoist with a rope (weight: cylinder cooling water pump 142 kg / raw water pump 184 kg).
- Now remove the remaining bolt.
nl
- Press off the pump from the engine, using two M16 jacking screws, take it away and place it on a work bench for further
dismantling.
Dismantling
se
- Screw the tensioning jack 9433.07 onto the thread of the shaft 16 and connect it up to the hydr. hand pump 9408.01.
Using the special spanner 9431.03, screw down the piston of the tensioning jack until the faces of the piston 22 and the
cylinder 23 are level. Unscrew the complete hydraulic jack by about a half to a full turn (Fig. 'B').
lU
- Tension the shaft 16 with a pressure of 620 bar and unscrew the round nut 1 by one turn.
- Fully release the pressure. Remove the tensioning jack, round nut 1 and drive wheel 2 from the shaft.
- Unscrew the bolts 13 and remove cover 15.
rn
a
- Withdraw the impeller 17, shaft 16, bushes 9 and rotary mechanical seal 11 from the pump.
- Slacken off and remove the bolts 5. Separate the bearing housing 6 from the pump housing and remove the sleeve 3
and the shaft sealing ring 8.
nt
e
- Clean all the parts and check them for wear (see also Clearance and Wear Table 0352/13a).
Reassembly
rI
Preparation:
Fo
All the individual parts must be clean and then oiled just before fitting.
The Orings 7 and 14 as well as the shaft sealing ring 8 have to be replaced by new ones before commencing reassembly.
This also applies to the spacer ring 10 and the rotary mechanical seal 11.
Attention
It is absolutely essential that during assembly the faces of the following parts are clean, dry and un
damaged:
Shaft 16, impeller 17, bush 9, sleeve 3, driving gear wheel 2 and round nut 1.
Working procedure:
- Slide the sleeve 3 into the bearing bushes 19 and fit the shaft sealing ring 8.
- Fit the bearing housing 6 to the pump housing 12; tighten the bolts 5 evenly and hard and secure them with locking
wire (ensure beforehand that also the Oring 7 has been laid into the bearing housing flange).
- Fit the spacer ring 10 into the pump housing.
- Slide the impeller 17 and bush 9 with the rotary mechanical seal onto the shaft 16 and assemble together.
- Smear the Oring 14 lightly with oil and insert it in the groove in the cover, fit the latter and tighten the bolts 13 evenly
and hard.
1995
71031/A1
Maintenance
ZA40S
- Screw the round nut 1 fully down without lubricating its thread.
- Screw down the hydr. tensioning jack 9433.07 with the special spanner 9431.03 so that the outer faces of the piston and
cylinder are level with each other and then connect it up to the hydr. hand pump 9408.01 (Fig. 'B').
- Tension the shaft with 100 bar, hold this pres
sure constant and screw the round nut 1 fully
down, then release the pressure to 40 bar.
20
21
- Measure the protrusion of piston 22 (dimension

'X') of the tensioning jack and note it down
(starting position).
- Release pressure to 40 bar and measure the pro

trusion of piston 22 (dimension 'X1') of the ten
sioning jack.
O
B
rn
a
When fitting the pump onto the engine, ensure

that the Oring 18 has first been inserted in the
flange of the bearing housing 6.
se
The axial clearance of the shaft will be, with a new

pump and after tensioning shaft, about 0.34 to 0.48
mm and this has to be checked.
9408.01
lU
When the bolt tensioning has been correctly car

ried out, the checking dimension amounts to:
'X1' - 'X' = 1.4 0.1 mm
22
nl
- Increase pressure to 600 bar and keep it

constant until the round nut has been tightened
and is firmly seated.
23
(9433.07)
95.7293
Fo
rI
nt
e
The pipes must be connected up to the pump

stressfree.
X
X1
3 z
1995
71051/A1
Maintenance
ZA40S
Fuel Valve Cooling Water Pump


3 4
Nut
Drive gearwheel
Sleeve
Locking wire
Bolts M12 x 110
Bearing housing
Oring
Shaft sealing ring (GACO)
Bush
Spacer ring
Rotary mechanical seal
(GULLIVER GV38C)
12 Pump housing
13 Bolts M12 x 40
14
15
16
17
18
19
20
21
Oring
Cover
Shaft
Impeller
Oring
Bearing bushes
Dowel pin
Split pin 3.2 x 22
LS
L
S
X
Bearing clearance
Leakage drain
Axial clearance
Checking dimension
9 10 11 12
se
1 2
1
2
3
4
5
6
7
8
9
10
11
nl
9408.16
9408.17
1 Depth gauge
1 Torque wrench
(140 560 Nm / ")
1 Socket head insert
" / 30 across flats
Various open end
and ring spanners
Tools:
13
lU
14
rn
a
15
16
nt
e
rI
LS
Fo
21
17
19
20
18
95.7296
With a new engine the gear teeth profiles of the pump drive wheel 2 have to be inspected after a few weeks in service.
During a general overhaul the pump has to be dismantled and inspected. Heavily worn parts must be renewed (see
Clearance and Wear Table group 0352-1).
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. Renewal 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.
1995
71051/A1
Maintenance
ZA40S
- Connect the pump to a lifting hoist with a rope (weight = 55 kg).

- Now remove the remaining mounting bolt.
- Press off the pump from the engine, using two M16 jacking screws, take it away and place it on a work bench for fur
ther dismantling.
Dismantling
- Remove the bolts 13 and the cover 15.
- Remove the split pin 21 and unscrew the nut 1, holding the hexagon at the impeller end of the shaft with a spanner.
- Remove the drive wheel 2 and withdraw the impeller 17 together with the shaft 16.
nl
- 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
Reasembly follows the dismantling procedure, only in the reverse order whereby the following points must be particular
ly noted:
se
- The bearing bushes 19 have to be lightly oiled. However, the parts 2, 3, 9, 16 and 17 must be dry before assembly.
- Ensure that the dowel pin 20 engages correctly.
lU
- The shaft sealing rings 8 and 11 as well as the Orings 7, 14 and 18 must be replaced by new ones.
- The bolts 5 have to be secured with locking wire (diameter 2 mm) after tightening.
The nut 1 has to be tightened as follows:
rn
a
- Lubricate the thread of the shaft 16 with oil.
- Screw the nut 1 fully down onto the shoulder of the drive wheel 2, which must be possible by hand.
nt
e
- Using the torque wrench, tighten the nut 1 to an initial torque of 30+ 50 _ Nm (= starting point) then determine and
note down the dimension 'X' by means of the depth gauge 9408.16
- The nut 1 has then to be tightened by a further ( 95+ 50 _ . Measure the distance 'x' again and note it down as 'X1'.
Fo
rI
- When the pump has been correctly assembled and the nuts has been tightened according to instructions:
1995
X1 - X
= 0.66 0.70 mm
Axial clearance 'S'
= 0.30 0.44 mm
Bearing clearance 'LS' = 0.045 0.091
2 z
72031/A1
Maintenance
ZA40S
SCAMATIC Fine Filter for Cylinder Lubricating Oil

Function Check and Maintenance
11
12
13
14
15
16
17
18
19
20
21
22
23
Securing screw
Lock washer
Joint
Screw with nut and lock nut
Sealing ring
Lock washer
Hexagonal head screw
Sealing ring
Cover
Special sealing ring
Filter insert
Filter housing
Sealing ring
24
25
26
27
28
29
Joint
Screw plug
Connection union
Protective sheathing
Corset
Screws
A
B
C
D
Oil inlet
Oil outlet
Sludge drain
Oil outlet from actuating
mechanism
E Sludge chamber
15
16 17 18 19
nt
e
rn
a
Function check
se
lU
14
nl
Various spanners
Tools:
rI
27
12
11
21
28
The sludge chamber 'E' of the filter housing is

connected to the engine casing by a pipe which al
lows periodic desludging. Should it be discov
ered, 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:
29
23
E
26 B
In installations where the filter is only necessary

when the oil level in the header tank sinks below a
certain level, an operational check has only to be
made quarterly. To do this, the level in the header
tank has to be appropriately lowered and the
shutoff cock before the filter opened since it can
only work when oil flows through it.
Servicing
22
Fo
13
20
When the filter is working properly, the noise

coming from the actuating mechanism can be
clearly heard in operation (about 20 times per
minute). In installations where oil flows continu
ously through the filter when it is in operation, a
check for correct working should be made every
week by listening to it.
24
25
- Drain the filter.
95.7297
- Separate the oil outlet pipe 'D' from the filter.
- Unscrew the screws 14 and lift off cover 19 ver

tically along with all its attached parts.
- 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.
1995
72031/A1
Maintenance
ZA40S
- Unscrew the screws 29 and carefully remove the corset 28 axially. It is now possible to wash the filter element in paraf
fin or Diesel oil and blow it out with compressed air.
Attention
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 clan cloth soaked in petrol or gas oil can be used to clean the outer surface of the filter by wiping it along the direc
tion 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.
Fo
rI
nt
e
rn
a
lU
se
nl
When guiding in the complete filter insert, ensure that the bottom of same with the rubber ring 23 slides over the guide
neck in the housing 22 without any undue force.
1995
2 z
72201/A1
Maintenance
ZA40S
Cylinder Lubricating Oil Pumps

Flushing out the Housing
1
2
3
4
5
6
7
8
9
10
11
11a
12
13
14
15
16
17
18
Gear shaft
Baseplate
Drive shaft
Shaft seal
Cylinder lubricating oil pump
shaft (coupling piece with helical
gear wheel 10)
19 Freewheel
20 Freewheel rollers
A
B
C
E
Suction pipe
Delivery pipe
Oil drain screw
Vent screw with builtin relief valve
Dust cover
Stroke adjustment screw
Housing cover
Stroke operating disc
Housing
Stroke control disc
Main piston
Pump element
Control plunger
Helical gear wheel on gear shaft
Hand crank
Compression spring
Oil outlet connection
Gasket
1 Screwdriver
nl
Tools:
11a
nt
e
rn
a
1
2
lU
se
The cylinder lubricator should be rinsed

through every 6 months.
13
rI
6
7
8
14
9
A
15
95.7298
C
10
20
19
18
17
- With the engine at a standstill, shut off the

oil supply and drain the housing 5 by remov
ing the oil drain screw 'C'.
- Remove the housing vent screw 'E' and
pour a few litres of paraffin or clean Diesel
oil through each housing.
- After flushing out the oil sludge in this way,
slowly open the supply shutoff cock in or
der to flush out any remaining flushing
fluid.
- On completion of this, screw the oil drain
screw 'C' back in and tighten it.
Fo
11
12
Working procedure
- Screw in the air vent screw 'E' as far as it will

go and then slacken it back by about two
turns.
- Open the supply shutoff cock slightly until
all the air has been purged from the pumps
and oil flows from the air vents 'E'. Tighten
the vents and fully open the supply shutoff
cocks.
Before starting up the engine, turn the hand
cranks 11 until the flow control check
glasses indicate that all the cylinder lubri
cating oil pump elements are working prop
erly. (Follow the instructions of the pump
supplier).
16
1
1995
Group8
Betrieb
ZA40S
Fo
rI
nt
e
rn
a
lU
se
nl
Group 8
8136--1/A2
Maintenance
=$6
([KDXVW :DVWH*DWH
'LVPDQWOLQJ DQG $VVHPEOLQJ
'HSWK JDXJH
7RUTXH ZUHQFK
ZLWK ER[ VSDQQHU $)
7HVWLQJ GHYLFH
IRU SQHXPDWLF ILWWLQJV
DQG ZDVWHJDWH

1XW
$GMXVWLQJ SODWH
6FUHZ
&RYHU
/RFN QXW
1XW
(ODVWLF VFUHZ
7HQVLRQ ZDVKHU
3LVWRQ
3LVWRQ ULQJ JDV WLJKW
&RPSUHVVLRQ VSULQJ
9DOYH VSLQGOH
%DODQFH SLVWRQ
9DOYH VHDW
1XW
&\OLQGHU EXVK
+RXVLQJ
' 6HDOLQJ IDFH

6 9DOYH VWURNH
9 9HQW
7LJKWHQLQJ DFFRUGLQJ
WR LQVWUXFWLRQV
nl

7RROV
se
7KH H[KDXVW ZDVWHJDWH PXVW EH FKHFNHG KDOI\HDUO\ IRU SHUIHFW IXQFWLRQ 6KRXOG SUREOHPV DULVH GXULQJ VXFK D IXQFWLRQDO
FKHFN RU VKRXOG GHIHFWV EH GHWHFWHG WKH FRPSOHWH H[KDXVW ZDVWHJDWH PXVW EH UHPRYHG IURP WKH HQJLQH
/RRVHQ QXW DQG UHPRYH WKH DGMXVWLQJ SODWH

/RRVHQ DQG UHPRYH IRXU VFUHZV
rn
a
5HPRYH WKH FRYHU
lU
'LVPDQWOLQJ
/RRVHQ ORFN QXW ZKLOH WKH QXW LV KHOG LQ SRVLWLRQ

5HPRYH WKH ORFN QXW
nt
e
/RRVHQ QXW ZKLOH WKH KH[DJRQ RI WKH HODVWLF VFUHZ LV KHOG LQ SRVLWLRQ
5HPRYH WKH QXW DQG WKH WHQVLRQ ZDVKHU
5HPRYH WKH SLVWRQ ZLWK WKH SLVWRQ ULQJ JDV WLJKW DQG WKH FRPSUHVVLRQ VSULQJ
7KH EDODQFH SLVWRQ LV VKULQN ILWWHG RQ WKH YDOYH VSLQGOH
Fo
5HPDUN
rI
5HPRYH WKH YDOYH VSLQGOH ZLWK WKH HODVWLF VFUHZ DQG WKH EDODQFH SLVWRQ
5HPRYH WKH YDOYH VHDW

/RRVHQ DQG UHPRYH QXWV
5HPRYH WKH F\OLQGHU EXVK
6PDOO GDPDJH RQ WKH VHDOLQJ IDFH ' RI WKH YDOYH VSLQGOH PD\ EH UHPHGLHG E\ D VOLJKW FXW RQ WKH ODWKH EXW FDUH PXVW EH
WDNHQ WKDW DV OLWWOH PDWHULDO DV SRVVLEOH LV FXW RII 7KH VHDOLQJ IDFH PXVW UHPDLQ VKDUS HGJHG
$Q\ GDPDJH RQ WKH VHDOLQJ IDFH ' RI WKH YDOYH VHDW PD\ EH UHPHGLHG E\ ODSSLQJ ZLWK D VXLWDEOH ODSSLQJ SODWH DQG ILQH
JULQGLQJ SDVWH +HUH WRR WKH VHDOLQJ IDFH ' PXVW UHPDLQ VKDUSHGJHG DQG XQGDPDJHG
05.03
8136--1/A2
Maintenance
=$6
$VVHPEOLQJ
$VVHPEOLQJ WKH H[KDXVW ZDVWHJDWH LV FDUULHG RXW DQDORJRXVO\ WR GLVPDQWOLQJ EXW LQ UHYHUVH VHTXHQFH ZKHUHE\ DWWHQWLRQ
PXVW EH SDLG WR WKH IROORZLQJ SRLQWV
- ,I GLVMRLQHG EHIRUH KHDW WKH EDODQFH SLVWRQ XS WR & EHIRUH VKULQNLQJ LW RQWR WKH YDOYH VSLQGOH
- )LW WKH HODVWLF VFUHZ ZLWK /2&7,7(
- $IWHU WLJKWHQLQJ WKH QXW VHFXUH LW ZLWK WKH ORFN QXW
,Q FDVH WKH YDOYH VHDW RU WKH YDOYH VSLQGOH VHDW KDYH EHHQ PDFKLQHG WKH YDOYH VWURNH 6 PXVW EH
FKHFNHG DQG DGMXVWHG
Fo
rI
nt
e
rn
a
lU
se
nl
5HPDUN
05.03
8136--1/A2
Maintenance
=$6
,,
,,
,,,
13
17 3
16
V
nl
,,
12
11 9 10
,,,
15*
11
3 `
CONTROL AIR
Steuerluft
CHARGE AIR
Ladeluft
Fo
rI
nt
e
Abgas
rn
a
EXHAUST GAS
lU
se
14
05.03
8136--1/A2
Maintenance
ZA40S
([KDXVW :DVWH*DWH
'LVPDQWOLQJ DQG $VVHPEOLQJ
0. YHUVLRQ
'HSWK JDXJH
7RUTXH ZUHQFK
ZLWK ER[ VSDQQHU $)
7HVWLQJ GHYLFH
IRU SQHXPDWLF ILWWLQJV
DQG ZDVWHJDWH

1XW
$GMXVWLQJ SODWH
6FUHZ
&RYHU
/RFN QXW
1XW
(ODVWLF VFUHZ
7HQVLRQ ZDVKHU
3LVWRQ
3LVWRQ ULQJ JDV WLJKW
&RPSUHVVLRQ VSULQJ
9DOYH VSLQGOH

%DODQFH SLVWRQ
9DOYH VHDW
1XW
&\OLQGHU EXVK
+RXVLQJ
' 6HDOLQJ IDFH

6 9DOYH VWURNH
9 9HQW
7LJKWHQLQJ DFFRUGLQJ
WR LQVWUXFWLRQV
nl

7RROV
se
7KH H[KDXVW ZDVWHJDWH PXVW EH FKHFNHG KDOI\HDUO\ IRU SHUIHFW IXQFWLRQ 6KRXOG SUREOHPV DULVH GXULQJ VXFK D IXQFWLRQDO
FKHFN RU VKRXOG GHIHFWV EH GHWHFWHG WKH FRPSOHWH H[KDXVW ZDVWHJDWH PXVW EH UHPRYHG IURP WKH HQJLQH
/RRVHQ QXW DQG UHPRYH WKH DGMXVWLQJ SODWH

/RRVHQ DQG UHPRYH IRXU VFUHZV
rn
a
5HPRYH WKH FRYHU
lU
'LVPDQWOLQJ
/RRVHQ ORFN QXW ZKLOH WKH QXW LV KHOG LQ SRVLWLRQ

5HPRYH WKH ORFN QXW
nt
e
/RRVHQ QXW ZKLOH WKH KH[DJRQ RI WKH HODVWLF VFUHZ LV KHOG LQ SRVLWLRQ
5HPRYH WKH QXW DQG WKH WHQVLRQ ZDVKHU
5HPRYH WKH SLVWRQ ZLWK WKH SLVWRQ ULQJ JDV WLJKW DQG WKH FRPSUHVVLRQ VSULQJ
7KH EDODQFH SLVWRQ LV VKULQN ILWWHG RQ WKH YDOYH VSLQGOH
Fo
5HPDUN
rI
5HPRYH WKH YDOYH VSLQGOH ZLWK WKH HODVWLF VFUHZ DQG WKH EDODQFH SLVWRQ
5HPRYH WKH YDOYH VHDW

/RRVHQ DQG UHPRYH QXWV
5HPRYH WKH F\OLQGHU EXVK
6PDOO GDPDJH RQ WKH VHDOLQJ IDFH
'
RI WKH YDOYH VSLQGOH PD\ EH UHPHGLHG E\ D VOLJKW FXW RQ WKH ODWKH EXW FDUH PXVW EH
WDNHQ WKDW DV OLWWOH PDWHULDO DV SRVVLEOH LV FXW RII 7KH VHDOLQJ IDFH PXVW UHPDLQ VKDUS HGJHG
$Q\ GDPDJH RQ WKH VHDOLQJ IDFH
'
RI WKH YDOYH VHDW PD\ EH UHPHGLHG E\ ODSSLQJ ZLWK D VXLWDEOH ODSSLQJ SODWH DQG ILQH
JULQGLQJ SDVWH +HUH WRR WKH VHDOLQJ IDFH
'
PXVW UHPDLQ VKDUSHGJHG DQG XQGDPDJHG
05.03
8136--1/A2
Maintenance
ZA40S
$VVHPEOLQJ
$VVHPEOLQJ WKH H[KDXVW ZDVWHJDWH LV FDUULHG RXW DQDORJRXVO\ WR GLVPDQWOLQJ EXW LQ UHYHUVH VHTXHQFH ZKHUHE\ DWWHQWLRQ
PXVW EH SDLG WR WKH IROORZLQJ SRLQWV
- ,I GLVMRLQHG EHIRUH KHDW WKH EDODQFH SLVWRQ XS WR q& EHIRUH VKULQNLQJ LW RQWR WKH YDOYH VSLQGOH
- )LW WKH HODVWLF VFUHZ ZLWK /2&7,7(
- $IWHU WLJKWHQLQJ WKH QXW VHFXUH LW ZLWK WKH ORFN QXW
,Q FDVH WKH YDOYH VHDW RU WKH YDOYH VSLQGOH VHDW KDYH EHHQ PDFKLQHG WKH YDOYH VWURNH
6
PXVW EH
FKHFNHG DQG DGMXVWHG
Fo
rI
nt
e
rn
a
lU
se
nl
5HPDUN
05.03
8136--1/A2
Maintenance
ZA40S
,,
,,
,,,
16
13
17 3
nl
,,
12
11 9 10
,,,
15*
11
CONTROL AIR
Steuerluft
CHARGE AIR
Ladeluft
Fo
rI
nt
e
Abgas
rn
a
EXHAUST GAS
lU
se
14
05.03
86001/A1
Maintenance
ZA40S
Starting Air Pipes

Overhauling the Flame Traps and Relief Valves
1
2
3
4
5
Casing upper part

Casing lower part
Flame trap insert
Copper joint
Screw plug
6
7
8
9
10
Cover
Spring
Socket screw
Valve body
Housing
Flame trap
nl
During a general overhaul the flame traps (Fig. 'A') which are fitted in the connections of the starting air pipes, must be
checked and if necessary cleaned.
To obtain access to the interior for cleaning, unscrew the plug 5. The holes in the insert 3 must be pushed through.
Replace the old copper joint 4 by a new one.

Smear the thread of the plug 5 for locking with LOCTITE No. 221.
Relief valve
se
The relief valve to starting air piping (Fig. 'B') can be dismantled after socket screw 8 has been removed. If necessary the
seat surface 45 in housing 10 can be re-machined. The seat surface of valve body 9 is spherically machined.
lU
Should re-machining be carried out or parts of the relief valve be replaced then the opening pressure of 33 bar must be
verified by a check.
The opening pressure can be reduced by machining the spring landing on cover 6 or increased by machining the cover
landing on housing 10, whereby 1 mm stroke difference amounts to about 1.8 bar difference in the opening pressure.
rn
a
Before assembling smear all internal parts lightly with MOLYKOTE paste.
nt
e
rI
Fo
2
3
95.7286
10
1
1995
Group9
Betrieb
ZA40S
Fo
rI
nt
e
rn
a
lU
se
nl
Group 9
9400--1/A1
Maintenance
ZA40S
Tools
Explanation
All the tools required for the normal maintenance of the engine are listed on the following group 9400---2/A1 onwards.
Listed are also such special tools which are only rarely used and which do not form part of the standard tool kit of the
engine. These tools can be obtained against a special order. A third type of tools are listed which are only made available
on a loan basis. Such tools are identified by a special note in the third column of the tools list.
The information in the third column indicates for what purpose the tool has to be used.
The code numbers in the first column are the same as the tools numbers given in the work sheets. When ordering a tool,
do not forget to give this identifying number and for general tools such as spanners etc. indicate the type and size.
The engine builder reserves to right to alter tools, to remove them from the tools list, or to add new ones to it and no
claims for reimbursement or supplementary delivery can be considered.
Fo
rI
nt
e
rn
a
lU
se
nl
The governing factor for the scope of tools delivered is the agreement made upon closing the contact.
06.04
94002/A1
Maintenance
ZA40S
Hydraulic PreTensioning Jacks

Storage, Care, Spares Stock and Sealing Rings
1 Cylinder
2 Piston
3 Circlip
4 Piston seal ring (complete)

5 Rod seal ring (complete)
D
2
NPT / 8
lU
se
nl
rn
a
95.7289
D
2
NPT / 8 3
Fo
rI
nt
e
95.7290
1995
94002/A1
Maintenance
ZA40S
The hydraulic pretensioning jacks forming part of the engine tool kit are to be stored, when not in use, in a clean dry
place, where they are protected from any sort of damage and from corrosion attack by a coating of lubricating grease.
(The connections are to be closed by dust caps). During prolonged storage or when used very frequently, the Orings of
the rod and piston seal rings can become hard, thus not sealing well any longer. We therefore recommend storing a quan
tity of these sealing elements (in plastic bags for protection) so that the hydraulic tools are always able to perform well.
When fitting new slide rings please proceed with utmost care, to avoid damaging them, stretching them or deforming
them. Below please find the sealing ring dimensions of the pretensioning jacks for ZALS and ZAVS engine .
Dimension
d
Studs of the crankshaft main

bearing
240
165
162
9427.01
Studs of the cylinder head and

transverse tie rods
158
110
142
9433.01
Studs of the crankpin bearing
128
69.6
9433.07
Studs for the counterweights

on the crankshaft
140
M90 x 6
220 x 214 x 5.8
120 x 125 x 3.8
M60
nl
90 x 94 x 3.8
M39 x 3
110 x 105 x 3.8
60 x 64 x 3.8
95
M42 x 3
120 x 115 x 3.8
60 x 64 x 3.8
140 x 135 x 3.8
145
96
rn
a
Central screw in the reversing

servomotor
(only for reversible engine)
Pos. 5
9410.01
Pos. 4
se
Application
lU
Tool No.
Fo
rI
nt
e
Cooling water pump, oil pump

(with enginedriven pumps)
1995
2 z
9400--3/A1
Maintenance
ZA40S
Tools
Tools List
General Application
Open end / ring spanners

2 pieces each of following AF in mm:
10, 13, 14, 17, 19, 22, 24, 27, 30, 32, 36,
41, 46, 50, 55 and 60
nl
93.7461
93.7462
rn
a
lU
se
Single open end spanner Type 100

2 Pieces
AF 65 mm
rI
nt
e
Cranked double end ring spanners

2 Pieces
AF 13/17 mm
2 Pieces
AF 19/22 mm
2 Pieces
AF 24/30 mm
2 Pieces
AF 27/32 mm
2 Pieces
AF 36/41 mm
2 Pieces
AF 46/50 mm
Fo
95.7291
Allen key (wrenches) Type 460

2 pieces each of following AF in mm:
4, 5, 6, 8, 10, 14, 17 and 22
93.7465
1995
9400--3/A1
Maintenance
ZA40S
Socket spanner Type 410

2 Pieces
AF 13/17 mm
2 Pieces
AF 19/22 mm
nl
95.7299
se
Jointed pin hole spanner

1 Piece X = 320 mm
(for setting the cams on the
camshaft)
rI
nt
e
rn
a
lU
95.7300
Fo
Socket tool set driver

1 Set of sockets with accessories
in case AF 12 to 32
95.7294
Socket tool set driver

1 Set of sockets with accessories
in case AF 22 to 50
95.7295
1995
9400--3/A1
Maintenance
ZA40S
V 1
Spanner socket
Driver 1
1 Pieces
1 Pieces
AF 46 mm
AF 60 mm
95.7301
Driver
1 Pieces
1 Pieces
1 Pieces
1 Pieces
1 Pieces
Spanner socket with insert
nl
AF 6 mm
AF 8 mm
AF 10 mm
AF 14 mm
AF 17 mm
95.7302
rn
a

1 Piece
AF 17 mm
lU
se
V 1/2
95.7303
nt
e
V 3/4
1 x
x 1
x
Fo
rI
Adapter piece
1 Piece
1 Piece
1 Piece
95.7304
V
3/4
Crow foot spanner 3/8 driver

1 Piece
AF
95.7305
3/8

Driver
1 Piece
AF 55 mm
95.7306
1995
9400--3/A1
Maintenance
ZA40S
Fitting tongs
for SEEGER circlip
1 Piece
Type J1
1 Piece
Type J2
1 Piece
Type J3
Type A1
Type A2
se
1 Piece
1 Piece
nl
95.7307
nt
e
rn
a
lU
95.7308
M
M
M
M
M
8
10
12
16
20
Fo
rI
Screws Type B4
5 Pieces
5 Pieces
5 Pieces
5 Pieces
5 Pieces
x
x
x
x
x
80
100
100
130
150
95.7309
Ring screws
5 Pieces each of
M10, M12, M16, M20, M24, M30
93.7472
1995
9400--3/A1
Maintenance
ZA40S
mm
mm
mm
mm
mm
95.7310
se
95.7311
lU
M 6 x 150 mm
M 8 x 150 mm
M 10 x 150 mm
nt
e
rn
a
Grip screws
2 Pieces
2 Pieces
2 Pieces
nl
Screwdrivers Type 110

2 Pieces
X= 4
2 Pieces
X = 5.5
2 Pieces
X = 6.5
2 Pieces
X= 8
2 Pieces
X = 10
Fo
rI
1 Combination pliers
95.7312
1995
9400--3/A1
Maintenance
ZA40S
Engine suspension device

(for fully assembled engines)
consisting of:
9405.01
Suspension pins for ZAL-S

X = 200 mm
se
Suspension pins for ZAV-S

X = 330 mm
95.7314
8
8
Special studs with
Fo
9405.02
rI
nt
e
rn
a
lU
nl
95.7313
Nuts M42 x 3 for ZAL-S

X = 674 mm
95.7315
16 Special studs with

16 Nuts M42 x 3 for ZAV-S
X = 314 mm
This pre-tensioning device is not part of
the engine tool kit
(it is supplied only against special order)
1995
9400--3/A1
Maintenance
ZA40S
Special Tools
9408.01
9408.09
Hydraulic hand pump

Make: ENERPAC Type P-39
complete with accessories comprising:
9408.04
9408.04a
Oil filling screw
95.7316
9408.10
Venting valve
9408.03
9408.02
1
Hydraulic hand pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Upon special order a pneumatically actuated hydraulic

pump type ENERPAC can
be supplied with accessories.
9408.03
Branch piece with two coupling sockets
9408.04
Pressure gauge
0---1000 bar
9408.04a 1
Pressure gauge
0---160 bar
9408.09
HP hoses
9408.10
Double nipple NPT 3/8 with

copper joints
9408.14
Peak pressure indicator

0---250 bar
Fo
rI
nt
e
rn
a
lU
se
nl
9408.02
9408.15
Feeler gauge
9408.16
Depth gauge
(measuring range 330 mm)
93.7485
93.7487
3.00
9400--3/A1
Maintenance
ZA40S
Torque wrenches
1 Piece
25 w 135 Nm
1 Piece
140 w 560 Nm
1 Piece
480 w 940 Nm
93.7477
Force multiplier x 1
9408.19
nl
9408.17
rn
a
Articulated grip 10
3/8 square
95.7319
Plug-in ratchet
X = 73 mm
rI
9408.25
nt
e
9408.20
lU
se
95.7318
Fo
95.7320
9408.26
Testing device
for pneumatic fittings and waste-gate
a) Air pump
b) Pressure gauge 0 w 4 bar
c) Pressure gauge 0 w 6 bar
d) Pressure gauge 0 w 15 bar
e) HP-hose
f) Setting tool
c
f
b
1995
91.7079
9408.35
9400--3/A1
Maintenance
ZA40S
Hydraulic jacks (ram)

16 mm stroke
Make ENERPAC type RC---50 or
RARIPRESS type BM---4---RG
X = 65 mm
95.7321
Hydraulic jacks
with spherical head pieces:
Make ENERPAC type RC 55
(133 mm stroke, 6.41 cm2 piston area) or
RARIPRESS type BS---46---RM
(150 mm stroke, 7.07 cm2 piston area)
95.7322
Hydraulic jack
with flat head pieces:
Make ENERPAC type RC 55
(133 mm stroke) or
(150 mm stroke)
nt
e
9408.37
rn
a
lU
9408.36
se
nl
9408.38
Fo
rI
95.7323
Hydraulic jacks
Make ENERPAC type RC---1010
(260 mm stroke) or
(260 stroke)
95.7324
9408.40
Ring spanner with extension arm for

engaging and releasing the mechanical
overspeed and safety cut-out device
AF 36 mm
X = 735 mm
95.7113
1995
9400--3/A1
9410.01
ZA40S
Hydraulic jacks for the

studs of the crankshaft main bearings
10
Round bar 10 x 150 mm

150
9410.01a 1
Maintenance
95.7325
240
Supports for propping up the hydraulic

jacks when removing the crankshaft
main bearing covers
(inclusive of 2 screws each)
nl
95.7326
230
9410.02
Segment for removing and fitting the

crankshaft main bearing shells
ZAV-S
se
rn
a
lU
9412.01
nt
e
Device for the removal and fitting of the

lower shell of the thrust bearing
rI
95.7327
Fo
as well as of the main bearing shells of:

ZAL-S
consisting of:
9412.08
Segment
9412.09
Mandrel
X = 300 mm
95.7329
Lifting device for hydraulic

pre-tensioning jack
X = 1500 mm
9412.10
95.7328
95.7330
1995
10
9421.01
9400--3/A1
Maintenance
ZA40S
Device for lapping the sealing faces on

cylinder liners and cylinder heads
(the hand grip may be fitted on either
side as required)
95.7340
558
Measuring rail
for measuring cylinder liner bore
95.7341
nl
9421.02
00.7305
nt
e
Pressure yoke
with 2 two hydr. jacks 9421.06
for withdrawing the cylinder liner
00.7304
450
9421.06
rI
9421.04
se
Setting gauge
for calibrating the measuring tool
X = 400 mm
rn
a
9421.03a 1
Measuring tool
for measuring the cylinder liner bore
X = 965 mm
X
lU
9421.03
870
Fo
95.7342
9421.08
Suspension strap
for removing and fitting of cylinder liner
95.7343
288
9421.09
Milling tool
for removal of the wear ridge
in the cylinder liner
95.7344
X = 400 mm
(Design execution Wrtsil
or Chris Marine)
11
3.00
9400--3/A1
9421.10
Maintenance
ZA40S
Carbon removing machine

for carbon removal in upper part of cylinder liner
(only for cylinder liner with fine thread,
it is supplied only upon special order)
X = 200 mm
95.7114
se
Honing machine
for honing of the running surface of the
cylinder liner
X = 1436 mm
(design execution Wrtsil
or Chris Marine, it is supplied only
upon special order)
Fo
rI
nt
e
rn
a
lU
nl
X
9421.11
9421.12
95.7119
Fitting tool
for spring dowel pin in cylinder liner
(non-standard tool)
X = 500 mm
95.7120
X
9421.13
9.97
Extraction tool
for spring dowel pin in cylinder liner
(non-standard tool)
X =726 mm
95.7115
12
Device for pre-tensioning

the studs of the cylinder head
Hydraulic jacks
Round bar
8 x 120 mm
HP-hoses
3/8 x 600 mm
se
9427.02
158
nl
9427.01a 1
600 mm
9427.01
9400--3/A1
Maintenance
ZA40S
95.7345
Lifting and suspension bracket

for cylinder heads
rI
nt
e
9427.03
rn
a
lU
120
Fo
95.7346
9427.04
145
SW65
Special nuts M60

for pressing the cylinder head down
while fitting it
95.7347
9427.05
Extraction device
for the sleeves of the cylinder head nuts
95.7348
66
13
1995
9400--3/A1
Maintenance
ZA40S
Device for pressure test

of the cylinder head
consisting of:
95.7349
Flange with hose coupling half and

gasket
9427.07
548
nl
Sealing ring with two O-rings
Jacking screws
for separating the cylinder head from
the cylinder liner
95.7350
700
lU
9427.09
se
105
9427.06
M24
Lapping mandrel
with centring disc for the reconditioning
of the seat surface of the fuel injection
valve in the cylinder head
95.7352
Fo
rI
9427.10
nt
e
rn
a
95.7351
9427.11
Cleaning tool
for the seat surface of the fuel valve in
the cylinder head
95.7353
365
9427.15
Stirrup with spindle

for the removal of fuel injection valve
and starting valves
95.7354
1995
14
9427.16
9400--3/A1
Maintenance
ZA40S
Valve seat grinding machine

for the seats of inlet and exhaust valve
spindles
(It is supplied only upon special order)
95.7355
1350
9427.17
nl
835
Turn-over device for cylinder heads
nt
e
rn
a
lU
se
This device is not supplied with the engine

(It is supplied only upon special order)
rI
ca. 415
Valve seat grinding machine

for the seats of inlet and exhaust valves
in the cylinder head
Fo
9427.18
95.7356
95.7357
15
1995
9400--3/A1
Maintenance
ZA40S
X
9427.19
Socket spanner
for nuts of rocker gear housing
X = 100 mm
95.7358
Fitting device
for fitting the fuel delivery valve
on the fuel stud
X = 150 mm
nl
9427.20
se
95.7124
rI
Fo
9427.22
Mandrel
for fitting the valve seats
X = 170 mm
9427.23
Special socket spanner

for relief valve in the cylinder head
X = 620 mm
3.00
95.7360
Socket spanner
for tightening the fuel stud AF 65 mm
X = 84 mm
nt
e
9427.21a 1
Spanner plate
for tightening cap nuts of the fuel HP
pipes with a torque wrench AF 50 mm
X = 120 mm
lU
rn
a
9427.21
00.7306
95.7451
95.7452
16
Device for the tensioning

of the valve springs during the removal
and fitting of inlet and exhaust valves
95.7458
80
Combination tool
for the removing and fitting of:
--- Insert bushes for the fuel injection
valve
--- Guide bushes for the inlet and exhaust valves
--- Valve seats of the inlet and exhaust
valves
consisting of:
80
rI
nt
e
9427.25
rn
a
lU
se
nl
9427.24
9400--3/A1
Maintenance
ZA40S
122
Fo
1
Spindle M24 x 365
9427.26a 1
Spindle M24 x 600
9427.26b 1
Spindle M24 x 760
9427.26c 1
Spindle M24 x 880
9427.27
Upper sleeve with ball bearing and nut

AF 46 mm
9427.28
Lower sleeve
9427.29
Nut M24
M24
9427.26
(a, b, c)
9427.28
225
9427.26
9427.27
9427.29
95.7459
110
17
1995
9400--3/A1
Maintenance
ZA40S
97
Accessories for the combination tool 9427.25:
9427.30
Cones
for the withdrawal of the inlet and exhaust valve seats
95.7460
Clamping jaws with two rubber rings

for the withdrawal of the inlet and exhaust valve seats
Centring disc for:

--- Fitting of fuel injection valve insert
bushes
--- Fitting of valve guide bushes
--- Withdrawal and fitting of inlet and
exhaust valve seats
rn
a
95.7461
170
nt
e
9427.32
lU
se
9427.31
nl
112
rI
95.7462
Fo
9427.33
52
Guide cone
for fitting the insert bushes for fuel injection valves into the cylinder heads
95.7463
452
9427.34
Lifting bracket
for dismantling and fitting of the complete rocker gear housing
95.7464
1995
18
9427.35
9400--3/A1
Maintenance
ZA40S
Hand grip
for turning inlet or exhaust valves when
checking the seating surface for correct
contact, or for the correct angle of the
seating surface
X = 120 mm
95.7465
Inlet valve 30_
Marking template
each for checking theseating surface of
inlet or exhaust valves
0
Exhaust valve 30_ ---2
se
9427.36
nl
+6
+4
lU
0
Exhaust valve 45_ ---2
Sleeve
for centring starting air valve during lapping-in
X = 110 mm
Fo
rI
9427.37
95.7466
nt
e
rn
a
(only for engines with:

MCR = 720 kW/Cyl. or ratings
ER I = 660 kW/Cyl.; ER II = 600 kW/Cyl.)
X = 140 mm
9427.38
9427.39
95.7467
Ring
for relapping the seating shoulder of the
fuel injection nozzles
X = 45 mm
95.7468
Handwheels for indicator valve

X = 112 mm
94.7076
19
1995
9400--3/A1
9427.40
Maintenance
ZA40S
Spray testing device

for fuel injection nozzles
consisting of:
9427.43
9427.41
Base plate with clamps
9427.42
BOSCH nozzle testing device

EFEP-67D with pressure gauge and
test oil container
9427.44
HP-delivery pipe
9427.42
9427.44
Connecting nipple
9427.45
9427.45
Collecting tray
se
nl
9427.43
lU
9427.41
Overhaul device
for reconditioning the starting valve seat
in the cylinder head
X = 561 mm
rn
a
00.7307
Fo
rI
nt
e
9427.47
95.7469
9427.48
9427.50
Checking disc 48x20 mm
9427.51
Copper mandrel 13x70 mm
9427.52
Wire brush
9427.52
Tool box
for servicing the fuel nozzles
consisting of:
9427.51
95.7470
9427.53
3.00
9427.53
Tube containing:
5 Cleaning drills
1 Plug gauge
for rejection check of the nozzle holes
9427.50
20
Socket spanner
for the cap nut of the fuel injection valve
90
9427.57
9400--3/A1
Maintenance
ZA40S
V 1
95.7471
Set of gauges
for checking the crankshaft deflection
(in a case)
se
93.7505
364
lU
9431.01
nl
225
rn
a
Special spanner
for the nuts of the coupling bolts of the
flywheel and of the torsional vibration
damper
nt
e
9431.02
SW 60
95.7472
Fo
rI
370
9431.03
Special spanner
for the hydraulic jacks for pretensioning
the studs of the cylinder heads, the
crankshaft counterweights and the transverse tie rods
95.7473
370
21
1995
9400--3/A1
9431.04
Maintenance
ZA40S
Mounting device
for fitting the damper
(This device is not supplied with the engine)
Hydraulic jacks
for pre-tensioning the studs of the
crankpin bearing assembly
(for pump and HP hoses please refer to
tool No. 9408.01)
se
95.7475
128
1995
Fo
95.7476
120
22
9433.01a 1
rI
nt
e
rn
a
lU
9433.01
nl
95.7474
9433.02a 2
Removal device
for the removal of the crankpin bearing
shells with fitted rotating piston
(only for ZAL-S)
493
9433.02
9400--3/A1
Maintenance
ZA40S
Pins to removal device

(only for ZAL-S)
95.7477
Underlay
to the removal device fitted between
hydraulic cylinder and crankpin bearing
upper part
95.7478
Lowering devices
consisting of a steel rope together with
eye bolt
Fo
9433.03
rI
nt
e
rn
a
lU
9433.02b 1
se
nl
145
9433.03a 2
95.7479
1980
Roller for the lowering devices

95.7480
75
23
1995
9400--3/A1
9433.04
Maintenance
ZA40S
Removal rail
for removal of crankpin bearing lower part
(only for ZAV-S)
X = 678 mm
Removal device
for removal of crankpin bearing shells
with fitted rotating piston
(only for ZAV-S)
X = 560 mm
nt
e
rn
a
9433.06
lU
se
nl
95.7481
9433.07
Fo
rI
95.7482
Hydraulic jacks for pre-tensioning:

--- Studs of crankshaft counterweights
--- Central bolt of reversing servomotor
(only for reversible engines)
--- Water and lubricating oil pump
(only with engine-driven pumps)
X = 140 mm
X
95.7483
9433.07a 1
1995
24
9433.08
9400--3/A1
Maintenance
ZA40S
Fixing plate
for connecting rod head during removal
of cylinder liner
(only for ZAL-S)
X = 208 mm
X
Fixing plate
for connecting rod head during removal
of cylinder liner
(only for ZAV-S)
X = 240 mm
rn
a
nt
e
9433.09
lU
se
nl
95.7121
rI
95.7122
Fo
25
1995
9400--3/A1
9434.01
Maintenance
ZA40S
Device for the removal

and fitting of a rotating piston
(only for ZAV-S)
c
a
consisting of:
a) 1 Attaching device
b) 1 Guide rod
c) 1 Anchor shackle
95.7484
Prop for the removal and fitting of a

rotating piston with (only for ZAV-S)
a) 1 Slide piece
X = 540 mm
Rod with two screws M12 x 40

for guiding the crankpin bearing assembly during removal and fitting of a rotating piston
95.7485
130
rn
a
nt
e
9434.05
lU
se
9434.02
nl
470
95.7486
9434.08
Fo
rI
25
Ring screw M20

for suspending the piston
M20
95.7487
9434.09
Piston clamping device

(for the dismantling and assembling of
the piston)
95.7488
9434.10
Insertion funnel
for fitting the rotating piston
95.7489
549
1995
26
9400--3/A1
Maintenance
ZA40S
Tooling for dismantling and assembling

a rotating piston
consisting of:
nl
Ring screws
for fixing lower spherical shell when fitting the connecting rod
X = 425 mm
Jacking screws
for separating piston skirt form its crown
(for two pistons)
X = 455 mm
95.7491
95.7492
rn
a
lU
9434.13
95.7490
9434.12
Locking screw
for fastening centring ring halves 9434.14
(quantity depends on the number of cylinders and installation)
X = 240 mm
se
9434.11
Centring ring
consisting of two halves each for the
fixation of the connecting rod
(quantity depends on the number of cylinders and installation)
X = 248 mm
rI
nt
e
9434.14
Fo
95.7493
X
9434.18
Piston ring expander

for removal and fitting of piston rings
and oil scraper rings
X = ca. 400 mm
27
95.7127
1995
9400--3/A1
9442.01
Maintenance
ZA40S
Device for removing and fitting cams,

pressure rings, camshaft drive gear
wheels and the piston of the reversing
servomotor
(This device is not supplied with the engine; it is only supplied upon special order)
95.7494
Tapered shaft
nl
9442.01
It consists of:
Displacement tube
with nut on ball bearing
95.7496
rI
nt
e
rn
a
9442.03
lU
se
95.7495
Fo
9442.07
M42
95.7497
Threaded spindle
M42
9442.08
Collar nut M42
95.7498
1995
28
9400--3/A1
Maintenance
ZA40S
Accessories for device 9442.01:

9442.09
Spanner for the nut 9442.08
95.7499
Brackets for removal of cams
nl
9442.10
95.7500
Threaded rods
with two nuts each and two washers
se
95.7501
M24
High pressure pump

with electric drive
(it is only supplied upon special order)
Fo
845
rI
9442.12
nt
e
rn
a
lU
9442.11
480
95.7502
9442.15
High pressure hose B---5000---A

connecting high pressure pump and
cams
95.7503
5285
29
06.03
9400--3/A1
ZA40S
Gauge
for checking the cam position
X = 315 mm
X
9442.17
Maintenance
nl
95.7504
Device for removing and fitting the camshaft
se
95.7505
Roll-out rails with cranks
nt
e
rn
a
lU
9442.20
consisting of:
rI
Supports
with two screws M20 x 130 each
Fo
9442.21
331
95.7506
Wooden underlays
for supporting the hydraulic jack
9408.35
further:
300
9442.22
ZAV-S
ZAL-S
Hydraulic jacks (see tool No. 9408.35)

95.7507
1995
30
35
9443.02
9400--3/A1
Maintenance
ZA40S
Threaded spindles M10

for dismantling and assembling the shutoff valve for starting air
a)
b)
c)
Spindle
Washer
Nut
M10
95.7510
Device
for fitting the housing of the starting air
distributor (with control disc)
se
9443.03
nl
160
Withdrawing device
for the guide piston of the exhaust valve
and fuel pump drives
X = 165 mm
rI
nt
e
rn
a
9444.01
lU
97.7566
95.7511
Fo
9444.02
260
Jacking screw
for the ball head of the valve drive
95.7512
M16
9445.01
Holding plate
for the dismantling and assembling of
the reversing servomotor
(only for reversible engines)
95.7513
290
31
3.00
9400--3/A1
9446.01
Maintenance
ZA40S
M16
Special device
(combination A) for tensioning spring
of the overspeed trip,
(combination B) tensioning spring of
the elastic rod between the governor
and the fuel regulating linkage
M12
A
95.7514
M16
Threaded rods M16x500

with nuts, for tensioning the spring of
the cut-out servomotor
95.7515
se
Adjusting device
for setting the fuel injection pumps
consisting of:
Holder
9455.04
Locking plug
9455.05
Measuring pin
9455.06
9455.07
Pressure gauge 0---10 bar
9455.08
Pressure gauge 0---6 bar
9455.09
Intermediate piece
for adjusting device 9455.02
(required for fuel injection pump, if the
cover shows an M39x3 connection
thread)
9455.08
9455.07
rI
9455.03
3.00
9455.06
Fo
9455.05
9455.03
9455.04
Dial gauge
95.7517
30
nt
e
9455.02
rn
a
lU
9446.03
nl
696
00.7308
32
9455.10
9400--3/A1
Maintenance
ZA40S
Gauge
for setting the fuel injection pumps
9455.12
Eye nut
for attaching the fuelinjection pump
when removing and fitting it
Spacers
for cutting out individual fuel injection
pumps
X = 71 mm
95.7519
se
rI
nt
e
rn
a
lU
9455.11
nl
95.7518
Fo
95.7520
b
9455.13
a)
b)
Removal device
for suspending the fuel injection pump
during fitting and removal
(only for ZAV-S)
2 Screws
1 Ring screw
X = 290 mm
33
95.7521
3.00
9400--3/A1
9465.16
Maintenance
ZA40S
Connecting piece
for measuring the exhaust gas back pressure
00.7309
1 Puller flange
nt
e
4 Screws M16
rn
a
consisting of:
23
Puller
for the driving gear wheel of the lubricating oil ump
se
lU
9471.01
nl
150
95.7522
ZAL-S = 150
Fo
rI
ZAV-S = 165
150
9474.01
Puller
for the driving gear wheel of the fuel
booster pump
consisting:
1 Puller flange
2 Screws M16
95.7523
2 Clamping segments
3.00
34 z

Maintenance Manual ZAL40S Int Use

Hochgeladen von

Dokumentinformationen

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Maintenance Manual ZAL40S Int Use

Hochgeladen von

Copyright:

Verfügbare Formate

y

Copyright 2004 by Wrtsil Corporation

THIS PUBLICATION IS DESIGNED TO PROVIDE AN ACCURATE AND AUTHORITATIVE INFORMATION

Wrtsil Italia S.p.A., Business Unit Service

+39 335 784 1217

DIRECT DIAL NUMBERS

Fax: +39 040 319 5767

North, Central and East Europe

Phone: +39 040 319 5071

Wrtsil 38B engines

Phone: +39 040 319 5072

Phone: +39 040 319 5081

Fax: +39 040 319 5216

Phone: +39 040 319 5080

Middle East and South Asia

Phone: +39 040 319 5073

Phone: +39 040 319 5082

Southern Europe and Africa

Phone: +39 040 319 5074

Phone: +39 040 319 5083

Phone: +39 040 319 5075

Phone: +39 040 319 5084

The list of Wrtsil Network companies is available at www.wartsila.com web site.

This page is intentionally left blank.

)RU 3DUWLFXODU $WWHQWLRQ

:UWVLO ,WDOLD 6S$

Wrtsil Italia S.p.A.

7KH 0DLQWHQDQFH 0DQXDO LV VXEGLYLGHG LQWR WKH IROORZLQJ PDLQ GLYLVLRQV

 *HQHUDO JXLGHOLQHV IRU PDLQWHQDQFH

 7RROV OLVW

Wrtsil Italia S.p.A.

Inspection / Service Intervals and Service Life of Engine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0030-0/A1

Maintenance Schedule (for Engines Operating on Heavy Fuel Oil) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0030-1/A1

Engine Cross Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0030-1/A1

Dimensions and Material Specifications of Piston and Rod Seal Rings

Clearance and Wear Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0352-1/A1

Clearance and Wear Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0352-1/A1

Clearance and Wear Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0352-1/A1

Clearance and Wear Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0352-1/A1

Wrtsil Switzerland Ltd

Tightening Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0355-1/A1

Taking Lubricating Oil Samples for Laboratory Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0356-1/A1

Engine Housing (Frame) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001-1/A1

Crankshaft Main Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1201-1/A1

Crankshaft Main Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1201-2/A1

Crankshaft Thrust Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1202-1/A1

Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2105-1/A1

Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2701-1/A1

Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2701-2/A1

Wrtsil Switzerland Ltd

Starting Valve in the Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2728-1/A1

Turning Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3212-1/A1

Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3302-2/A1

Rotating Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3401-2/A1

Piston Rings and Oil Scraper Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3402-1/A1

Camshaft Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4101-1/A1

Wrtsil Switzerland Ltd

Speed Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5101-1/A1

Speed Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5101-1/A2

Speed Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5101-1/A3

Mechanical Overspeed Trip and Safety CutOut Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5303-1/A1

Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5501-1/A1

Charge Air Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6601-1/A1

Flap for Charge Air Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6730-1/A1

:UWVLO ,WDOLD 6S$

7KH 0DLQWHQDQFH 0DQXDO LV VXEGLYLGHG LQWR WKH IROORZLQJ PDLQ GLYLVLRQV

*HQHUDO JXLGHOLQHV IRU PDLQWHQDQFH

7RROV OLVW

&KHFN ZDWHU OHYHO

&OHDQ FRROLQJ V\VWHP

&KHFN RLO OHYHO DQG ZKHQ QHFHVVDU\ WRS XS

&KHFN SUHVVXUH WHPSHUDWXUH IORZ UDWH DQG

&KHFN WKH SURSHU IXQFWLRQ RI OXEH RLO VHSDUD

7DNH RLO VDPSOH IRU ODERUDWRU\ DQDO\VLV

&KHFN FRQWDPLQDWLRQ DQG RLO OHYHO ZKHQ QHF

&OHDQ FRROLQJ V\VWHP

&KHFN SUHVVXUH WHPSHUDWXUH IORZ UDWH DQG

6HDZDWHU FRROLQJ V\VWHP

&KHFN SUHVVXUH WHPSHUDWXUH IORZ UDWH DQG

&KHFN WKH SURSHU IXQFWLRQ RI IXHO RLO VHSDUD

'UDLQ DLU UHFHLYHUV

&KHFN DLU FRPSUHVVRU

&KHFN DLU GULHU DQG ILOWHU