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SULZER

TABLE OF CONTENTS

 
 

WmJp

0000

: ZA40

Of the Maintenance Manual

SHEET

1

PREFACE

0001

GENERAL GUIDE LINES FOR MAINTENANCE

 

000211

Precautionary measures for maintenance uork Recoacendations for uork procadure Criteria for the reneual of bearing shells

0002/2

NHMBERTNG OF BEARINGS AN0 CYLINOERS AN0 DEFINITION OF ENGINE SIOES

.

0022/1

MAINTENANCE SCHEOULE

Inspection/service intervals and service life of engine components

 

0030/0

Schedule table

0030/1 6 f.

Cross-section of engine

0030/7.

TABLES OF CLEARANCE AN0 WEAR

 

Remark on tables of clearance and uear

 

0352/0

Crankshaft main bearing, crankshaft locating bearing

0352/1

Cylinder Dinar,

valve rocker arm

035212

Inlet- b Exhaust valve guides, crank pin bearing

 

035213

Working piston

0352/4

Piston compression rings and oil scraper rings

035215

Camshaft bearings, camshaft locating bearing, camshaft drive, gear tooth backlash (non reversible engines)

035216

Canshaft bearings, camshaft drive, gear tooth backlash (reversible engines)

0352/6

Starting

air distributor (non reversible engines)

035217

Starting

air distributor (reversible engines)

035217

Reversible servo motor

IreversibTe engines)

 

035218

Inlet/exhaust valve actuating gear

035219

Governor drive

0352/10

Mechanical overspeed safety tut-out

0352/11

Fuel injection pump

0352/12

Lubricating oil pump, fuel.booster pump (for engines uith built-on pumps)

0352113

Cylinder cooling water pump (for engines with built-on pumps)

0352114

Raw water pump

(for engines with built-on puaps)

0352/15

Fuel nozzle cooling water pump (for engines with built-oil pumps)

 

0355116

TIGHTENING INSTRUCTIONS

035511

WORK SHEETS

       

Checking of lubricating oil by spot test

0356/1

 

Taking samples for laboratory analysis

035612

 

Engine block

-

Replacing cylinder head studs

lOOl/l

 

Crankshaft main bearings - Loosening and tightening the cross ties and main bearing studs

1201/1

 
 

-

Replacing main bearing shells standard bearings)

1201/2

 
         
     

1487

OOOO/la

ZA40

Crankshaft locating bearing

- Replacing

bearing shells and locating ring

     
   

halves

   

120211

   

Cylinder liners

- Reasuring uear and renoving uear ridge

2105/1

   
 

-

Renoving and fitting a cylinder liner

2105/2

   

Cylinder head

- Renoving and fitting a cylinder head

2701/.1

   
 

-

Replacing valve seats

 

27Olf.2

   
 

-

Regrinding of inlet and exhaust valve seats

2701/3

   
 

-

Replacing insert bush for fuel injection valve and lapping the contact faces

270114

   
 

-

Replacing guide bushes of inlet and exhaust valves

270115

   
 

-

Pressure test of water space

 

270116

   
 

-

Overhauling relief valves

 

270117

   

Rocker ares

- Replacing

rocker arms of inlet and exhaust

     
   

valves

   

270511

   

H.P. Fuel pipe and fuel delivery valves

- Reeoving, overhauling refitting

 

2716/1

   

Inlet and exhaust valves

- Replacing valve Springs and renoving and fitting valve spindles

272011

   
 

-

Regrinding the sealing faces

 

272012

   

Fuel injection valve

- Removing, dissantling and asseœbling

2722il

   
 

-

Testing spray pattern and

spray-off pressure

272212

   
 

-

Cleaning reconditioaing

 

272213

   

Starting air valve in cylinder head

- Removal, dismantling, lapping assembling and fitting

272811

   

Crankshaft

- Checking

crank deflection

 

310111

   
 

-

Loosening and tightening the coupling

     
 

bolt nuts

3101/2

   
 

; Fitting the counter weights

3101/3

   

Torsional vibration danper (HOLSET)

- Taking a sasple of Silicone fluid ...

313011

   

Barring engine

- Maintenance

 

3212/1

   

Connecting rod

- Inspection and replacing crank pin bearing shells

3302/1

   

Crank pin bearing

- Loosening and tightening the studs nuts of the crank pin bearing

330212

   
                 
           

10Q7

Piston

 

- Removal and fitting a piston

 

340111

   
 

-

Dismantling and asseabli

 

340112

   

Piston compression and ail scraper rings

-

Removing and fitting

 

3402/1

   

Canshaft

Camshaft

 

-

Checking gear tooth back ash, bearing clearances and adjusting the camshaft drive wheels

4101/1

   
 

-

Checking, cams, Removing and fitting camshaft

420111

   

Cams on caiashaft

Starting.air distributor

-

Replacing original (non split) cams by Z-piece-cams (only for non reversible engines)

4211/1

   

-

Disaantling and assenbling (non reversible engines

 

430111

   
   

-

Dismantling and assetnbling (reversible engines)

 

4301/1

   

Stop valve for starting air

Inlet/exhaust valve actuating

Reversible serve motor

Regulating linkage

Cut-out serve motor

Speed governor

Governor drive

Mechanical overspeed safety

Fuel injection pump

-

Disnantling and asseabling

 

430411

   

-

Adjusting valve clearances

 

440111

   

gear

-

Dismantling and assembl-ing

 

440112

   

(only revarsible engines)

-

Dismatling, checking and assembling

45DO/l

   

-

Removal and fitting the Springs in the spring linkage rod

4501/1

   

-

Diswantling and assenbli

ng

461211

   

-

Oil change

 

5101/1,2,3

   

-

Dismantling and assembli

ng

510511

   

tut-out

-

Removal and fitting spring

 

5303/1

   

-

Disaantling

and asserbling

 

550111

   

Exhaust

 

-

Adjusting pump on engine

.

550112

   

gas turbo charger

- Water rinsing in service

 

650111

   

Charge air cooler

Flap to charge-air by-pass

-

Renoval, cleaning fitting

 

6601/1

   

-

Dismantle and assemble

 

673Oil

   

Waste gate

 

-

Dismantle and assemble

 

6735il

   

Lubricating oil punp (For engines uith built-on pumps)

-

Dismantling and asserpbling

 

710111

   
                 
           

1987

0000/1c

ZA4CS

Fuel booster pump (For engines vith built-on pumps)

Cylinder cooling puap and rav

Fuel nozzle cooling vater punp

SCAIATIC fine filter for cylinder

Cylinder lubricators

Starting air pipes

-

Disaantiing and assenbling

710211

 

vater pump (For engines vith built-on pumps)

-

Disnantling and assernbling

7103ll

 

(for engines vith built-on pumps)

-

Oisaantling and assenbling

710511

 

lubricating oil

-

Operation check-out

720311

 

-

Rinsing the casing

722011

 

-

Overhauling flaae arresters and safety

860011

 
     

valves

   
 

TO0l.S

       
 

Explanations

   

9400/0

 

-m Hydraulic tensioning jacks

-

Storing, servicing, spares stock-keeping, seal rings

9400/0a

 
 

Tools list

   

9400/1

 
       

and f.

 
         

SULZER

 
 

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z

ZA40

Checking of Lubricating Oil by Suot Test

GROUP

SHEET

0356

1

I

Even the best lubricating oil ages and becomes dirty in service. It

must, therefore, be replaced at certain intervals by new oil. A simpl

method

for checking the condition of the oil is the so-called

Such a test should be carried out approxiaately every 500 service

hours by proceeding as follows:

When the oil has its normal service temperature and the oil pump

some oil should be drained froa a cock in the oil pip-

ing system in order to clean the cock froc dirt collected possibly

in it.

  • - Only then should the oil necessary for the test be filled in a clean container (preferably glass).

  • - Shake the container with oil sample well.

  • - Oip a clean glass or metal rod (diam. = 3 to 5 ma)

into the oil and

let a drop fa11 in the middle of a filter paper.

  • - Allow the filter paper to reaain in a horizontal position at normal room temperature for some hours (if possible on a hollow pad to ensure that the filter paper with the spot moistened with oil does not corne into contact uith any other natter).

  • - In order to enable comparisons, the same filter paper quality should always be used (obtainable fror oil fircs).

Froa the five spot tests shown at left, the gradua1 increase of oil

contamination cari be seen

clearly.

.

lests 1 and 2: The drap is froa an oil having only very few running

hours. The dark spot is not very sharply outlined showing the oil is

still in good condition.

Test 3: The drop is froa an oil which was already in service for a

relatively long time. A sharply outlined black spot is clearly visi-

ble, compared to the normal, bright colour of the oil. This oil cari,,

houever, still be left in service.

Test 4: This test already shows a clearly linited black zone in the

centre. Oil which produces such a picture should be analysed. A cer-

tain irprovement could be obtained by replacing a part of the used

oil by new oil.

Test 5: Oil which produces such a picture nust be analysed at once bl

a laboratory. The analysis Will show too high a degree of contanina-

tion. Such oil aust be replaced as soon as possible. (See sheet

0356/2).

We recommend gluing the spot tests on a sheet of paper in the sequen.

ce of the samples taken in order that the progress of contamination

cari be clearly seen. For each spot test, indications regarding date

of taking, running heurs, etc. should be recorded. The more experien.

ce one gets with such spot tests, the better the capability of jud-

gaent

Nota: The oil spot test examples show

on this sheet are only valid

for evaluating the degree of contamination. The alkalinity of the

oil cannot be seen on these pictures.

SUUER

; ZA4Q

TAKING LUBRICATING OIL SAMPLES FOR LABORATORY ANALYSIS

croup

0356

SHEET

2

After every 3000 operatinq heurs a sarple should be taken fror the engine lubricating oil and sent

to a laboratory for analysis. The saaple eust be taken froc the oil in circulation and at noria1 ser-

vice terperature fror a cock specially fitted for this purpose, and vhich is situated at the inlet of

the main lub. oil pipe into the engine.

Before taking the sample, drain about 2 litres into a container to reaove any possible dirt accueula-

tion in the drain cock.

Nov reaove the saeple oil (about 1 Litre) fror the engine into an absolutely clean container (61as is

best).

Hark the container uith the oil sarple with the follouing data:

Naae of Vesse1 or Plant

Engine Type

Engine No. or Cylinder No.

Date of sarpling

Running hours since last oil change

Type of lubricating oil (Brand nase)

Honitorina the Lubricatina Oil

Concerning the acceptable liott values for the oil, please refer to the recoerendat

ions in section

0356 (Lubricating Oil) of the 'Instruction eanual and description'.

1987

SULZER

.ZA40

1001s:

Spanner

Cleaning materials

ENGINE BLOCK

Replacement of Cylinder Head Stud Bolts

GROUP 1001

SHEET

1

KW

to Fiq.

  • 1 Upper edge of engine block

  • 2 Cylinder head stud bolt

  • 3 Sealing conpound

DF Sealing surface

RR Annular space

The cylinder head stud bolts 2, stud bolts for short, aust be protected against corrosion at the louer

end . The annular space 'RR' and the stud bolt shank nust be fully sealed off with a suitable sealing

corpound, uithout cavities up to about the leva1 of the Upper edge of the engine block 1 (sec illustra-

tion).

Note: - No filling aaterial may be added to the sealing conpound.

- Only use a corpound vhich Will allow the stud bolts to he unscreued again uithout difficulty.

Work Procedure durina Fittina and Sealinq:

  • - Other than the corrosion protection oil already supplied, no lubricant or Toçking agent the stud bolt 2.

may be applied to the threads of

  • - Thoroughly clean and de-grease the sealing surfaces 'DF' befcrs fitting, e.g. uith white spirit, perchlor, acetone, etc.

  • - Prime the sealing surfaces 'DF' with primer according to the ranufacturer's instructions.

  • - Screw in the stud bolts 2 and tighten uith a torque of 50 -'.

, 200 Nm.

  • - As a sealant ue recomrend the following two component silicon compounts.

  • - Fil1 the annular space 'RR' completely. In order to allow the sealing compound to be poured above the level of the top of the engine block 1, a ring of cardboard, putty or sirilar hav- ing an interna1 diareter of about 60 na has to be laid around the stud bolt shank until the sealing corpound has fully set. This is particularly important for 'V' engines.

  • - The ring has to be removed after hardening.

Riconrended Sealina Cowounds and Priners:

Type description

of sealant

No. of

rardener

coaponents

RTV-HE 622A

2

NE 6228

Primer

G 790,

Supplier

Wacker Cherie AG

Sonnenhalde 15

CH-4410 Liestal

Polastosil Y56

Silcoset 105

2

2

01-l

A or

D

P-3

no type de -

scription

or DP

Polish

product

Wochendorf AG

Auf dem Wolf 10

CH-4002 Base1

Similar products from other supplters lay be used.

*

lOOl/la

~ealinn Conoound Reauirements:

Requit-ad properties:

  • - non- acidic, e.g. acetic acid;

  • - resistant to oil, diesel oil, heavy fuel oil, water at a continuous temperature of about 1OO'C;

  • - short hardening time (approx. 24 heurs);

  • - flous easily SO that the annular space Will be corpletely filled without cavities;

  • - binds val1 to prired aetal surfaces;

  • - simple preparation and rixing;

  • - no to minimum shrinkage;

  • - the external surface ray not harden uith porosity;

  • - the sealing compound must remain sufficiently elastic that the stud bolts may be unscrewed at any tims

SULZER

:ZA40

Tools:

CRANlWUiFT MAIN BEARING

QROUP1201

Loosening and Pre-Tensioning of the

Tie Rods and Main Bearing Studs SHEET

Transverse

1

Kev to Illustrations

  • 1 Hydraulic handpump

9408.02

1

Nain bearing caver

10

O-Ring

uith accessories

2

Engine Housing

11

Disc

HP Hoses

  • 2 9408.09

3* Transverse Tie Rod

12

Round nut to iter 3

Feeler gauge

  • 1 9408.15

4* Rain bearing studs

13

Cylinder for Hydr. Jack

  • 1 Oepth

gauge

9408.16

5

Round nut to item 4

14

Shaft seal ring

  • 2 Hydr. jacks

9410.01

6 Cylinder for Hydr.Jack

15

Piston seal ring

  • 1 Round bar

941O.Ola

7

Piston for hydr. jack

16

Piston for hydr. jack

  • 1 Lifting device for hydr. 9412.10

8

Shaft seal ring

17

O-Ring

pre-tensioning jacks

9

Piston seal ring

18

Protection cap

  • 2 Hydr. Jacks

9427.01

 

*

Tighten acc. Instructions

 
  • 1 Round bar

9427.01a

  • 1 Special spanner

9431.03

.

TO loosen and pre-tension transverse tie rods and main bearing studs (short called R.Brg. Studs) for

the reeoval and fitting of the main bearings proceed as follous:

Reaoval

  • 1. Loosen both transverse tie rods siaultaneously

  • 2. Loosen both M.Brg. stud nuts simultaneously

Fittinq

1. Press bearing caver upuards (Sheet 120112)

and hand fit round nuts

2. Screw-in transverse tic rods

3. Pre-tension both f4.Brg. stud nuts sinul-

  • 3. Unscrew transverse tie rods

taneously

  • 4. Lower bearing caver (Sheet 1201/2)

4. Pre-tension both transverse tie rods simul-

taneously

NOTES:

  • - If a11 the crankshaft main bearings eust be reuoved, loosen first fi

the transverse tic rods. If

only one of the rain bearings nust be reuoved, loosen the transverse tie rods of the specific boari.

ino ami also the transverse tie rods in the tueediate vicinitL

and later lift back the bearing caver,

otherwise it is difficult to lower

  • - When screwing-on the piston 16 or 7 respectively of the Cylinder 13 or 6 respectively of the pre- tension jack (Fig. "Al' and 'A2'), the oil is being pushed back to the puup. TO permit the oil to flow back m

the bleeder valve of the hand purp 9408.02 and connect the jacks uith the pum.p by hp

hoses. (If.you want to screw the pSston-on wtthout draining the oil to the pu~p, opon the non re-

turn valve on the hose socket of the jack by pressing it inwards. The oil Will then flou out).

  • - Before actuating the pump aake sure that the hose couplings are a11 coepletely tightened othrrvise the non return valve may not open, prevent the oil to reach the facks, and pro-tensioning is not achieved.

LOOSENIN6 THE TRANSVERSE TIE ROOS

Werkinq procedure: (Fig. "An and 'Al')

  • - Renove protective cap from transverse tie rod.

  • - Clean connecting surface of the disc 11 and screu one pre tensioning jacks 9427.01 on each opposing transverse tie rod 3, till the cylinders 13 land on the discs 11.

  • - Using special spanner 9431.03 screw the pistons 13 into the cylinders until thry land.

  • - Screv both pre tensioning jacks back aaain unttl a aap of 2 ut appears between the cylinder 13 and the discs 11.

1987

:VII

ld

&A

_ 9uiJd up a pressure of 500 to

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

until

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

the nuts circumference.

  • - Relieve the pressure, by opening thi bleeder valve on the PU~P,

  • - Remove pre-tensioning jacks and also the round nuts.

until the pressure gauge shous

'zero'

LOOSENING THE CRANKSHAFT MAIN BEARING STUCS

Please refer to notes on the obverse page!

Working procedure: (Fig.

"A" and "AZ")

  • - Use lifting device 9412.10 (fig. '6') to screu one pre-tensioning jack each onto the tua studs 4

unti

the jack cylinders 6 are restcng against the bearing caver 1.

  • - Screu-in the pistons 7 uith the round bar 9410.01a until they land.

  • - Screu back both complete pre-tensioning jacks until a gap of 2 mm appears betueen the cylinder 6 and the bearing caver 1.

  • - Build-up a pressure of 600 to 620 bar with the pump 9406.02 and keep pressure constant until you bave unscrewed both round nuts 5 by 4-5 hole spacings (on nut circumference) by using the round bar 9410.01a.

  • - Relieve the pressure by opening the bleeder valve on the pump, until the pressure gauge shows 'zero'.

  • - Remove the pre-tensioning jacks uith the aid of the lifting device 9412.10 and screw the two round nuts 5 by about 130 ta 140 mm dounuards ! (For the further procedure to louer the bearing caver pleass refer to sheet 1201/2). Attention!

It is important to unscrew jacks (by 2 mm) as described for both the transverse tie rods and the bea-

ring caver studs: If they are unscreved too much, the jacks cannot be removed as they jam against thé

nuts. If tha gap is too little the nuts cannot be loosened as they are still under pre-tension.

PRE-TENSIONING MAIN BEARING STUOS

Conditions at start of pre-tensioning:

e The bearing covers are fitted according to the instructions on sheet 120112 and are held by two rounc

nuts 5.

  • - The transverse tie rods of the neighbouring bearings are not vet pre-tensioned.

  • - The threads of the studs may net be lubricated uith MOLYKOTE-Paste.

Workina Procedure of Pre-Tensioninq:

  • - After the bearing caver is pressed upwards till fully seated against the engine hcusing (sec sheet 1207/2) and held in place by both nuts 5 screw the tuo pre-tensioning jacks 9410.01 onto the tuo stud with the aid of the lifting device 9412.10 (fig. '6') till their cylinders 6 are resting against the bearing caver.

  • - Cannect the pre-tensioning jacks to the handpump 9408.02 with the HP hoses 9408.09, open bleeder val Ve and SCreu the Pistons 7, using

round

bar

9410,01a,

into

the

cylinders 6 until they land.

-

Close

the

bleeder

valve

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

Ho7d this pressure constant until you have tightened the nuts 5 uith round bar 94lO.Ola until they ar

fu77y seated. (Check uith feeler gauge).

1967

  • - Release pressure ta 'Zero" and aeasure the protrusion "X' on the

jacks and note carefully. (Please refer to adjacent sketch).

  • - R.aise the pump pressure to 600 bar and hold constant until the nuts have been tightened uith the round bar for full seating.

(Check seating uith the feeler gauge).

  • - Release pressure to 'Zero" and seasure the protrusion "XI

" and

note carefully.

The difference between protrusions "X" and "Xl" should theoreti-

cally be 1,31

mm. These check neasures are an additional safe-

l4

guard to the pressure check of the pre-tensioning.

  • - Vhen the measured elongation is closely enough correct, re-

. move the pre-tensioning jacks with the lifting device 9412.10

  • - For extra safety establish the vertical bearing clearance.

PRE TENSIONING THE TRANSVERSE TIE ROTIS

Conditions at start of Pre-Tensioninq

  • - M.Brg.Studs must be tightened according to instructions.

  • - The thread of the transverse tie rods mav not be lubricated with HOLYKOTE-Paste.

.

N

  • - O-Ring 17 and disc 11 are fitted and the round nuts 12 are screwed onto the two opposing transverse tie rods requiring pre-tensioning. (Please refer to adjacent sketch).

  • - The contact face of the disc 11 is clean.

Note: The adjacent sketch shows a transverse tie rod with moun-

ted protection cap 18.

Workino procedure of Pre-Tensioninq:

  • - Screw one pre-tensioning jack 9427.01 onto each of the two transverse tie rods until their cylinders 13 are fully seated on the discs 11.

  • - Open bleeder valve of the hand pump and screu the piston 16 of the pre-tensioning jack, with the aid of special spanner 9431.03, into the cylinders 13 until they are fulle seated.

  • - Close the bleeder valve of the puep and pre.tension the transverse tie rods preliainarily with 100 bar. Hold thfs pressure until you have tightened the nuts 12 uith the round bar until they are fully seated. (Check seating with the feeler gauge).

  • - Release pressure to "Zero" and neasure the protrusfon "X" on both pre-tensioning jacks and note it carefully (please re- fer to adjacent sketch).

12

13

16

  • - Raise the puap pressure to 600 bar and hold it constant until the nuts 12 are tfghtened till fully seated. (Check seating with feeler gauge).

  • - Release tho pressure to 'Zero' and note it carefully.

and aeasure the protrusion 'Xl"

The difference between the measured values

"Xl - X' should be

theoretically 0,66 II uhen the pre-tensions is correct. These

eeasures serve as additional safety check of the hydraulic pre-

tensioning rethod.

) - If the established difference "X1 - X' is practically correct,

reœove the pre-tensioning jacks.

  • - Grease the thread lightly to prevent corrosion and fit protective cap 18.

1987

0 B

.

.?-lOj! 185.361

SULZER

CRANj(SHAF"l' MAIN BEARINGS

 

Replacement of Crankshaft

Main

CROUP 1201

ZA40

Bearings Shells (Standard Shell Bearings)

SHEET

2

Tools:

Kev to Illustrations

 
  • 1 Hydr. Handpump with acessories 9408.02

1

Main bearing caver

19 Counterweight

 

HP Hoses

  • 2 9408.09

2

Engine casing

20

Upper shell

  • 2 Hydraulic jacks .

9408.36

3

Transverse tie rod

21

Louer shell

Hydraulic jacks

  • 1 9408.38

4

Main bearing studs

22 Crankshaft

 

Supports

  • 2 9410.02

5

Round nut

23

Oil trough

  • 1 and ZAV40S

Segment ZAV40

  • 1 Segment ZAL40 and ZAL40S

9412.01

9412.08

Condition at the start of Rork:

  • - Transverse tie rods and main bearing studs of the bearing to be repaired as well as the transverse tie rods of the two adjacent main bearings have been slackened. (refer to sheet 1.201/1).

  • - The transverse' tie rods of the bearing to be repaired have been unscrewed and reaoved.

Workino procedure:

  • - Screv the tuo round nuts 5 downwards, until a space of about 130 mm has been provided between the louer edge of the bearing caver and the connecting face of the nut. (see Fig. 'A').

  • - Fasten the two supports 9410.02 to the bearing caver 1 with tuo screus.

  • - Place two hydraulic jacks 9408.36 between the supports and the counterweight 19, and connect them to the handpunp 9408.02 by high pressure hoses.

  • - Actuate the purp to push the bearing cove'r from its guided position. (After pressing'it for abt. 110 ml the bearing caver Will slide down onto the round nuts 5 by its oun weight).

  • - Remove the tvo hydraulic jacks and' the two supports 9410.02 froa the engine. The support must on no account be left fitted to the bearina caver as the counte?weiahts 19 would knock aaainst them Gina

daeaae. uhen barrino the enoiner. (Fig. '8' and 'C')

  • - Place a hydraulic jack 9408.38 under the bearing caver and connect it to the hand puap. (THe bearinc caver and the bottom of the oil trough have been provided uith drilled recesses into which the hy- draulic jacks fit).

  • - Actuate the pump to lift the bearing caver sufficiently off the round nuts to permit unscreuing ther froc the studs.

  • - Open the bleeder valve 'EV' of the hand pump allowing the bearing caver to descend as much as the

jack permits.

Removino The Bearine Shells (Fig. 'Cl)

  • - In this position the lover bering shell, descending with the bearing caver cari be checked and if ne.

cessary be removed.

- The Upper bearing shell 20 cari be pushed out using the segment 9212.01 or 9412.06. Clean the segment

well

Press

tt agafnst the journal and at the saee tiae upwards against the bearing sheT1.

Attention! Safeguard the Upper shell with the hand froc falling out when pressing it out with the

segment.

Judgina The Bearina Shells For possibilitv of Re-use

The possibility of re-using a bearing shell depends in principle on the condition of its running sur-

face. Please refer on this matter to the recoenendations on sheet 0002/2.

1987

Crankshaft Main bearinq She'ls for Undersize Journals

In case the surface of the journal becomes rough and requires regrinding thicker bearing shells uith un-

dersize bores are required. The table below indicates the diameters to uhich the journals must be ground

to fit stocked undersize bearing shells: (Al1 dimensions are in mm).

/

0

Shaft-0

/

n

Sheli-

Thickness

1

n

0,4

349,6

-

8,06

10,lZ

-

Vertical

Bearing

Clearance

Bearing

Bore 0

[[:::II;jil,,,

I0esign

Key No.

I

349,6

-

>LJ

l

0,21

I

200

1

1

I 1,2

2,o

3,O

4,O

I 348,8 - ;,06 I '0,52 - ;,02 Il

348

- 00

136 ‘oBg2

>

_

0 02

,2' 4

I 348,8

- U,fY

l 0,21

5

0,3

348

+

0,29

+ 0,21

I

202

203

347

346

- 00,06

-

0

0

I

06

"842

- (02

‘lSg2 0

0,02

346

+

0,?9

+ 0,2'

204

205

580

0,4

182

3,O

5,0

.

345

- ii 06

>

'2,42

369,6

-

00

>

06

"*12

-

0 > 02

368,8

367

_

;

06

n'

_ ;,06

lO,52

_

oo

n'

'1s42 - 8,02

365

_ iso6

'2,42

_ i:,,

.,J

0,

,2' z

.

T

36

986

l

0,31

+ 0,2'

36

888

+

0,31

* 0,2'

17

36

+

0,31

+ 0,21

3l

i5

+

* n 91

0,31

0, 37

Fittinq the. Bearino Shells (Fig. "Ca)

206

200

202

204

205

'

ui

d

N

t

m

lz

1

Note! Do not ever reduce the clearance by filing the nating faces of the bearing shells. The ends of the

beariw

shells protrude somewhat over the faces of the bearing caver or the bearing saddle. 'bis is aean

to be and is necessary!

  • - Push the Upper bearing shell with uel' lubricated running surface but dry back, by hand between journa and bearing saddle bore, until its mating surfaces are equally spaced on both sides. If the shell can- not be easily pushed in, assist the fitting tion using a hydraulic jack.

by pressing the crankshaft slightly in the required direc-

  • - Place the louer bearing shell with dry back and well lubricated running surface into the bearing caver

  • - Using the hydraulic jack 9408.38 press the bearing caver opuards into its guide space in the engine casing, until it seats.

  • - two round nuts 5 onto the studs 4 till they are landed on the bearing caver. Remove the hydrau

fit the

lit jack.

  • - Fit the tuo transversal tie rods 3 into the bearing caver 1.

- Proceed with pre-tensioning the H.Brg. Studs and the transversal tie rods in accordance uith the in-

structions on sheet 1201/1.

1987

M

*O-R---

23-

.:.:y.:. \
.:.:y.:.
\

.:r:1:r:rt:t!t:1:;:t:ll

:.;.;.;<.:.

N7ï-l

9408.02<

EV

L-1OZ 185.399

9408. oz

SUMER

'ZA40

CRANKSHAFT LOCATING BEARING

Replacing Bearing Shells and

Locating Ring Halves

GROUP 1202

SHEET

1

Tools:

Kev to Illustrations

  • 1 Eye boit MT6

1

Bearing housing

  • 1 Dia1 gauge with

louer part

aounting pedestal

2

Upper locating ring half

  • 1 2a Louer locating ring half

Hydraulic jack

9421.06

  • 1 Hydr. Hand Purp

9408.02

3

Bearing shell

.

  • 1 HP Hose

9408.09

4

Locating Bearing shaft End

  • 1 Segment

9412.08

5

Positioning pins

  • 1 Mandrel

9412.09

6

Oil catcher Upper part

Force amplifier

  • 1 6a Oil catcher louer part

9408.19

  • 1 7 .Bearing housing Upper part

Torque urench

9408.17

Assorted spanners

8

End caver

and Socket spanners

9

Crankshaft main bearing

caver

  • 10 drive gear uheel

Caashaft

"11 Screws

llZ Locating Bearing Screw

  • 13 Positioning pin (long)

  • 14 Positioning pin (short)

15

Screws

16

17

Fitted bolts

23

Dia1 gauge

24 Flywheel

25

D

K

P

S Clearance

*

18 Through bolts

Oil containing piece

 

Fig. 'A'

and 'Dl

1

 

Fig. 'B'

Hydr. Jack 9421.06 and 'C'

1

Apply sealing corpound

Head piece of steel rope

Hydr. Hand Punp

Tighten to specific values in

instructions belou

GL Threaded hole

.

O-W?

122.839

m-m

1007

Check the condition of the bearing shells and locating ring halves in accordance with the instructions

in the maintenance schedule or according to the prescribed intervals of the classification society.

Within a oeriod of 5 vears a11 the bearinqs must have been inspected at least once.

Whether a bearing shell may be re-installed, depends mainly fron the condition of its running surface.

Please refer to sheet 0002/2 for respective information.

Locatinq Rihq Halves

For these parts the same reconnendations apply as for the bearing shells, i.e. only such locating ring

halves may be re-used, uhich are in good condition. It is also of the greatest importance that the ring

halves are refitted in the same location from where they uere renoved.

When removing the locating ring halves the shaft shoulders must also be inspected; They must be smooth

and clean.

Oversize Locatinq Rina Halves

In case the shoulder of the locating bearing shaft,uhich was subjected to the load during operation,

has become rough and has therefore to be re-machined, then oversize locating ring halves have to be fit-

ted.

.

When re-machining the Shorlder as little material as possible should be tut off, but the distance betwee

shaft shoulders susf,after machining correspond to one of fhe ('steps') dimensions 'L' in the table

below.

In accordance with the dimension 'L' oversize locating ,ring halves have to be selected and they have

without fail to be fitted on that side where the shoulder had been re-machined! Shaft shoulder and locat

ing ring half must be marked accordingly.

Index

Oversite

Length 'L'

Axial clea-

rance

mm

mm

mm

  • 200 0,20

OS8

150,8'y4

- '0,44

  • 201 2,o

152

*OgO

0,20 - 0,44

,202

4,O

154

+;,04

0,20 - 0,44

l Rerachined shaft shoulder

  • I Locating Bearing Shaft

-0.1

Thickness: 15 -o.,5

1987

LLVL/

IV

Removjnp

the Searinp Shells and the Locatino Rina yalves

York sequence: (Follou

Fig. 'A' on preceding

Rage)

LA4U

  • - Loosen the screws 15 of the oil catcher Upper part 6 and remove. Separate oil catcher Upper part 6 from the bearing housing upper part 7, use jack screus if necessary.

  • - Remove a11 the screus 11 of the bearing housing Upper part 7 and loosen the two locating bearing screus 12 in two or three equal steps and remove.

  • - Fit an eye bolt (H16) into the threaded hole ‘GL’ in the bearing housing Upper part 7 and lift the housing Upper part off. (about 80 kg).

  • - Remove

both Upper locating

ring halves 2 as uell as the Upper bearing shell.

  • - Adjust a (micrometer)-dia1 gauge 23 on the top of the locating bearing shaft (Fig. 'B' place a hydrau- lit jack 25 under the flyuheel and uith it lift the shaft by about 0.15

mm.

that the shaft remains radially in the tenter!).

.(Fig. 'Cl). (Take tare

  • - Use segment 9412.08 - pressing it against the shaft - to push the lower bearing shell out (Fig. 'B') and remove it.

  • - Use mandrel 9412.09 to press both locating bearing ring halves 2a out till you carilift them out. Attention! Before you attempt pulling the louer bearing shell or the louer locating ring haltes 2a out

check and ensure that the shaft does net push axially against one of the locating rings. If

necessary shift the crankshaft axially in the appropriate direction. The shaft must also be

equally spaced in the tenter radially, as otherwise the bearing shell is jammed and carion-

ly be removed with difficulty.

-

9472.08\

It.

r,

r

24

94-12.08

9412. 08/(--

1987

1202/lc

 

F

i

t

t

i

n

q

the Bearinq Shells and the Locatinq Rinq Halves

(Fig. 'A', 'B' and

'C')

ZA40

1

  • - Clean locating bearing shaft 4 and the bore of bearing housing louer part 1 carefully, lubricate the shaft journal 1ightTy.

  • - Check whether the bearing shells and the locating ring halves are undamaged.

  • - Check uhether the crankshaft is in such a position that axially sufficient space is available to f it the locating ring halves. If necessary shift the crankshaft slightly axially.

  • - Using hydraulic jack 25 under the flyuheel lift it and the shaft until the (micrometer)-dia1 gauge 23 mounted above the shaft journal shous 0.15 mm. (Fig. 'B'). Take great tare that the journal is radially in the tenter.

  • - Push the louer bearing shell as uell as the two louer locating ring halves by

h a n d

as far as

possible betueen shaft journal and housing bore, note that the bearinq surface of the locating ring

halves lie against the corresponding shaft shoulder.

  • - Press segment 9412.08 against the shaft journal and slip in the lover bearing shell until the divid- ing faces protrude by,the same amount on both sides.

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

  • - Release the pressure in the jack 25

under the flyuheel and remove the tools.

  • - Apply oil lavishly on the shaft journal, use neu engine oil.

  • - Apply sealing compound to the engines side of the bearing housing Upper part. (also a very thin coat of sealing compound on the horizontal separating faces).

  • - Place the Upper bearing shell 3 and the Upper locating ring halves 2 into the bearing housing Upper part and secure them uith the locating pins 5. (Fitting condition: Bearing shell on its rear side dry, on the running surface coated with oil, bore of the locating bearing housing Upper part dry).

Important! Before fittina them apolv molvcote-Daste G-n to the threads and landing faces of the

screws 11 and 12, as the tightening torque values are only valid, if this lubricant is

used.

w Fit bearing housing Upper part 7 and fasten to the engine end plate uith the screus 11 uniformly, at

first onlv liqhtly with about 100 Nm.

  • - Fit and tighten uniformly the tuo screus 12 in several equal steps uith a torque urench to 780 No.

If you use the force multiplier contained in the engine tools the tightening value is 220 Nn.

  • - Check that no clearance exists betueen the bearing housing Upper and louer part.

  • - Tighten the screus 12 with a torque urench to the final value of 1230 Nm or uhen using the force mu tiplier to 350 Nm.

  • - Finallly tighten the screws 11 also in several equal steps to the

final value of 740 #m.

1 I

  • - Measure the axial clearance of the crankshaft with the locating r

'ing ha1 ves fitted, by pressing the

crankshaft with a hydraulic jacks alternately onto both end posit

ions. 1 ha axial movenent is seasured

with a dia1 gauge (Please refer to clearance table 0352/1a).

  • - Finally lock the screws 11 in pairs with locking wire (Fig. ‘A’).

.

1987

F

i

t

t

i

n

a

the oil catcher (Fig. '0')

-

Clean and degrease

carefully front and horizontal separating faces of oil catcher Upper and louer

part (6 and 6a) and aoolv sealina coeoound to these surfaces.

-

Fit oil catcher louer part 6a first, locate uith taper pins 14 and tighten uith the screus.

-

Place oil catcher Upper part 6 into position, fit locating bolts 17 and through bolt 18,

-

Apply LDCTITE to the threads of screws 15 and bolts 18. (Refer to DDD2/la).

-

Alternately tighten tho nuts of bolts 17 and 18, then of screus 15, again nuts of bolts 17 and

18 in verv SDall

SteDS,

-

The clearance 'S' betueen shaft and oil catcher should be about 1 BD a11 round,

1987

SU=ER

ZA40

CYLINDER LINERS

Measuring the Wear and Removing

the Wear Ridge

Neasuring rail

Inside microaeter

Nilling tool for reiaoving the uear

ridge

KW to Illustration$

9421.02

9421.03

1

Cylinder liner

9421.09

2 Inside microneter

3 Keasuring rail

(Supplied only against specific order)

Nanual grinding machine

The uear of the cylinder liners should be

checked during every overhaul or uhenever

a piston is removed. Neasure aluays cvlinder

liners in fitted position and uhen enaine

is cooled doun.

TO permit corparisons uith previous measures

it is inevitable that neasurina is aluavs do-

ne in the sane olace and that the measured

values are noted in a log.

TO this end use aluays the reasuring

rail 3

(tool 9421.02) uhich is available in the en-

gine tools. lt is SO designed that is cari

siaply be hooked over the top face of the liner

as shown in the sketch to the right.

Neasure in the four points A,B,C and 0 in fi

enaine axis and at riaht anales to it.

Avoid measuring errors by preventing the in-

side micrometer being exposed to big terpe-

rature variations (froa hand heat, holding

it for a long tiRa).

Generally the most important uear occurs on

point 'A'. For raxirur periissible inside

dianeter please refer to clearance table

0352/2a.

After a long operiting tiirea so-called uear

ridge appears in the top part of the running

surface. This uear ridge must beground off

during overhaul uithout daraqing the running

surface

in any uay. SometiBe the uear ridge

must be reroved to permit uithdraual of the

piston.

If this is the case louer the pi'ston

1:

::

::

::

:-

:i

.i

.*

by barring the engine caver the piston and

 

-

GROUP

210:

SHEET

1

 

-

the liner surface above it carefully to'prevent any grinding dust froc penetrating betueen piston an d

cylinder liner. After the uear ridge is ground away the cylinder liner bore must bo cleaned very car e-

fully to prevent it being scratched uhen the piston is uithdraun.

Attention! Should a re-rachining of the running surface becoee necessary this aay not be done by

turning it on a lathe, as thir vould impair the correct guiding of the piston. The machin -

ing ray only be done by honing the bore of the cylinder liner.

For reioving the uear ridge as uell as for the honipg of the liner bore special devices aay be order *ed

frai the engin@ aaker or possibly be rented against a fee.

-

1987

SULZER

 

CYLINDER LINER

 

GROUP

2105

ZAL40

Removing and Fitting a Cylinder Liner

SHEET

2

1001s:

Kev to Illustrations

 
  • 1 Hydr. Hand pump

9408.02

1

Cylinder liner

7,7a O-Rings (same dimensions)

  • 1 Branch piece

9408.03

2

O-Rings

8

Cylinder lubrication

 
  • 1 Pressure gauge

9408.04

*3

Screw t!20

conduit

  • 2 HP Hoses

9408.09

4

Centering piece

9

Screws

  • 1 Torque wrench -

9408.17

5

Screws

10 Crank pin bearing asserbly

  • 1 Electr.Hand grinder

6

Engine Casing

11

Screus

(if necessary)

9421.01

* Tighten according to

 
  • 1 Pressure yoke

9421.04

instructions.

  • 1 Suspension device 9421.08

 
  • 1 Shackle

  • 1 Rope (capacity 1 t)

    • 52 r

INote Reaardina Runninq-in of New Cylinder

Liners

When one or several cylinder liners have

* been replaced it is necessary that they are

'run in', whereby the instructions section

0360 of the "Service instruction and Oescril

,tion Book" on 'Running-in The Engine After

An Overhaul' have to be folloued.

.

Preparatorv Work for the Kithdrawal of a

Cvlinder Liner

  • - Drain a11 the cooling water froa the en- gine. Remove the cylinder head and with- draw the piston of cylinder 1Sner con- cerned.

  • - Barr the crankshaft until the crank of the liner concerned stands in T.D.C.

  • - Shield the space below the liner concer- ned .with clean cardboard or sinflar to trap any falling dirt.

Removal

  • - Loosen pipe connections 8 and remove the banjo bolts (Fig. 'A' and 'A,')

  • - loosen screu 3 of the centering piece 4 and remove it (Fig. 'A' and 'A,').

  • - Turn the crack pin bearing to the position show

in Fig. 'E' (21G512b).

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

in Fig. '6'.

  • - Turn the crank pin tearing with fastened jacking yoke into the position as show

in Fig. 'C'.

  • - kctuate the hand pusp 9408.02 carefully paying attention that the yoke correctly mates the bottom of the cylinder linder.

  • - Check aaain uhether the screu 3 (M 20) has actually been renoved! (Fig. 'A')

  • - Continue puuping and jack the cylinder liner out of its guide (Ettention! the stroke of the jack in tt;e yoke is cnly 54 mm)

  • - nount tbe suspension device 9421.08 on ?he cylinder liner top and fasten it vi th the screus 9

(Fig. 'C' and 'El). (h'atch that the screws 9 tate with the holes in the cylinder lir;er collar).

  • - Fzsten are shackle vith the rope at 'Ah' on the scspecsion device and pull tt,e cylinder liner (abt. 430 kg; out

(illtistr. 'C').

  • - Remove the jacking yoke and

the hydr. hand pu~p from the engine.

  • - Place the ren;ovedcylinder liner on an even surface and reaove the suspension device.

  • - Clean tte landing surface on the engine casing and check uhether it is danaged.

  • - Clean the guiding bores in the engine casing and if necessary smooth out with ea.erycloth.

Fittinq

  • - Cbeck ubether tte landing surface for tte cylicder liaer ar;d tbe guiding bores in tte engjne cas- ing are clean acd srootb. Snear the landing surface on cylinder licer/engine casing vith sealing coapour,d Hylorar SC32/M or Golden Herretite.

  • - Equip ?he cylirder liner uith new heat resisting o-rings (pl.refer to operating rr.anLal section 0328) and srear t~ese as uell as the guiding surfaces 'F' in the engine frane with fresh engine lntricating oil.

  • - #ount the suspension device 9421.08, fasten it uith the screvs 9 in the liner collar and lift the cylinder liner uith the crane on shackle and rope at the suspension point 'AH'. (Keight abt. 400 K

  • - h'ith the cylfnder liner suspended at eye level tlow compressed air through the lubricating conduit bores at the tottor.

  • - Louer the cylinder liner slouly and carefully into ihe engine casing.

  • - Before ihe cylinder liner mates the guide bores turn it SO that the centering piece 4 when further louering uill fit into the provided bore on the cacshaft side. When guide bores are srcoothand uell tallow lubricated guides and O-Rings the cylinder liner ïill slide doun on its oun ueight into the engine casing. If necessary tap the liner collar lightly uith a lead hasser.

  • - Finally locate the liner with the screu 3 dipped in oil and join cylinder lutricating conduits on the Gottom end of tbe liner. Tighten the screu 3 uith50

Km.

  • - If necessary lap the sealing surface on the liner collar with lapping ring 9421.01 and lapping

paste.

  • - Actuare the tand crank of the cylinder lutricatcr and ckeck that tt,eoil issues from both lubricat- ing holes in the cylinder liner.

\hY

N

-7

I

-l Y------ l

SULZER

 

CYLINDER HEAD

~KW

2701

ZA40

Removing

and Fitting a Cylinder Head

SHEET

1

1001s:

Kev to Illustrations

 

Hand pump with

  • 1 1

Mut

18

HP fuel pipe

accessories

9408.01

2

Rocker arn Cowling

20

Cylinder liner

  • 1 3

Oepth gauge

9408.16

Thread protecting cap

21

Soft iron gasketv

 
  • 1 l4

Torque urench

9408.17

Cylinder head Studs

22

Insert bush

9427.01a

  • 1 5

Round bar

O-Ring

23 O-rings

 
  • 8 6

Hydraulic jacks

9427.01

Mut for item 4

24

Oil connecting piece

 
  • 7 7

HP Hoses

9427.02

O-Rings

25

Screw

  • 1 8

Lifting device

9427.03

Valve guides

26

Flange

  • 2 9

Special nuts

9427.04

Valve seat

27 Spacer

 
  • 2 10

Jacking screus

9427.09

O-Rings

28

Engine casing

  • 1 11

Mandrel

9427.10

Pushrod cladding

29 Screu

  • 1 12

Cleaning tool

9427.11

O-Rings

30 Centering pin

  • 1 13

Lifting device

9427.34

Connecting piece

31

Piston of hydr. jack

 
  • 1 14

Socket

spanner

9427.57

Screws

32

Cylinder of hydr. jack

Assorted spanners

15

Tubular rubber ring

33 Hose coupling

 
  • 16 * Tighten to specification

Push rod

 
  • 17 Cylinder head

A Major overhaul includes a thorough checking of the cylinder heads. This also covers an inspection

of the water cooling spaces. When treated cooling water is used these spaces generally remain clear.

Untreated cooling uater however usually causes scale formation vhich impairs the cooling effect. For

the removal of this scale ue recommend consulting a specialist fira for chamical descaling.

The surfaces in contact with the combustion œust be inspected for cracks. If cracks are suspected,

and also after replacing valve seats and insert bushes, the water spaces have to be subjected to a

uater pressure test (7 bar). (Plaase refer to sheet 270116).

Valve seats uith water side leakage must be replaced. Damaged seat surfaces have to be reconditioned

(please refer to instruction on sheets 2701/2 and 2701/3 respectively).

The O-rings 7 of the valve guide bushes 8 must be replaced at each overhaul. The same applies to da-

maged or badly worn valve guide bushes 8 (Please refer to sheet 2701/5).

Leaking insert bushes 22, also badly damaged ones must be replaced (Please refer to sheet 2701/4).

Uneven or slightly damaged insert bushes 22 cari be reconditioned with the aid of too1'9427.10 and the

prescribed grinding /lapping paste. (Please refer to sheet 2701/4).

If the seating surface for the soft iron joint between cylinder head and cylinder liner is daaaged

it cari be reconditioned with the help of lapping ring tool No. 9421.01 and grinding/lapping paste.

The same tool cari be used for seating surfaces of cylinder head and ylinder liner.

REMOVING A CYLINDER HEAD

  • --------B--- Preparations

    • - Grain the cylinder cooling water froa the engine and shut the shut-off cocks for the fuel valve cooling water.

    • - Garr the crankshaft to bring the piston of the respective cyltnder to T.D.C. on the ftrfno stroke. This means the inlet and exhaust valves are closed.

    • - Loosen the nuts 1 of the rocker arm cowling 2 in even steps

and

lift

of lifting device 9427.34 (Pl.ref.to Fig. 'J').

the

couling

2

with

the

help

1987

ZP40

  • - Reaove both push rods 16 and the screus 14 holding the connecting piece 13.

  • - flnscrew and rerove HP fuel pipe 18 and plug the openings on the fuel valve as well as in the HP fuel pipe, using clean cloth. Separate a11 other pipe connections of (exhaust, Air, etc.) froc the

cylinder head.

  • - Remove the thread protecting caps 3 and clean the thread of the cylinder head studs 4 and the area

around

the stud nuts on the top of the cylinder head.

LOOSENING the Cvlinder Head Stud Nuts (Fig. C)

Notes

  • - When screuing the pistons 31 of the jacks 9427.01 onto the stud thread (Fig. '0') the oil is pressed out of the cylinder and cari return to the pump uhen the HP hoses are correctly connected to the jack whereby the non return valve on the jack is opened. connected jack the oil cari flou out.

If this valve is pressed in by hand on the un-

_ Do not start pumping before a11 the hose couplinos are correctly and firmlv ioined otherwise oil may

l

not enter the jacks as the non returnvalve

does not open.

Work

Procedure

Fit a jack 9427.01 on each of the 8 cylinder head studs, until the cylinders 32 touch the cylinder

-

the notes above).

-

the hand pump.

-

re constant.

-

on the purp.

.

-

-

Reœove a11 the nuts 6.

 

-

-

-

F

i

t

t

i

n

Q

a Cvlinder Head

Pieparations (Fig. 'A' and

-----BB-----

'8')

caver of the engine at 'S'. Continue screwing the pistons 31 in until they are at 'B' flush with the

jack cylinders 32. Then unscrew the coaplete iacks until at 'S' a oao of about 2 am exists. (Observe

Connect a11 the short HP hoses 9427.02 according to Fig. 'C' and connect the two long HP hoses to

Actuate the pusp and pre-tension the eight cylinder head studs vi'th 600-620 bar and hold this oressu.

.- Unscrev a11 the nuts 6 by 4-5 hole spaces.

When a11 the nuts are in this position release the pressure to 'Zero', by opening the bleeder valve

Disconnect the hose couplings between the eight jacks and rer'ove jacks and hoses. If they are not

iwaediately reused, close the connecting openings uith closing caps.

Apply the jack screus 9427.09 and jack the cylinder head off the cylinder liner (Fig. '6').

The cylinder head freed, fit the lifting device 9427.03 on the studs of the rocker arrs couling 2

and lift the cylinder head off by crane. (Please refer to Fig. 'RT' for ZV-and for ZAL engines).

Caver the open conbustion space with a wooden or cardboard lid to prevent foreign bodies to fa11 in.

The sane should be done with the openings of the push rod claddings.

  • - Clean the seating face on cylinder liner and cylinder head thoroughly. Any uneveness to be groung off with grinding device 9421.01 and grinding paste.

1987

27 Ol/lb

2640

A

_ Place a nev cylinder head (soft iron) gasket on the cylinder liner. (It should be a principle practi-

-

ce not ta re-use any jointings like gaskets, O-rings etc.) Check uhether the gasket lies flat.

  • - Place new o-rings 10 into the grooves at the collar of the cylinder liner. Smear these before with e n engine lub. oil. (U se aluays only original O-rings corresponding to SULZER specification, see sheet Q326-1 of the description and operating manual).

  • - Ascertain that a11 the cylinder head studs 4 are screwed in until fully seated.

  • - Smear the guide area on the cylinder liner collar and the inner side on the botton of th'e cylinder head lightly with engine lub. oil.

  • - Check combustion space for cleanliness and remove any foreign particles.

  • - Check the drilling in the cylinder head 17 for centrjng dowel 30 and the drilling in flange 26 for the oil connecting piece 24 for cleanliness. Smear the drilling in the flange and the O-rings on the oil connecting piece lightly with engine lub. oil.

'rlorkSeauence

  • - fit the lifting device 9427.03 on the cylinder head and attach it to the crane. (Position loop as per Fig.

'K ' for ZAV-S engines and 'K' for ZAL-S engines'.

,

of rope

  • - Louer the cylinder head slouly over the cylinder head studs until the centering pin 30 and the oil connecting piece 24 have mated. In case the cylinder head does not slip down on its own weight to rest on the cylinder head gasket on the cylinder liner apply the tuo special nuts 9427.04 on two opposite studs. Tighten these nuts alternately with the socket spanner 9427.57 and a ratchet or a spanner until the cylinder head is seated. (Please refer to Fig. 'H').

Pre

t

e

n

s

i

o

n

i

n

Q

the Cvlinder Head Studs

  • - Clean the seating surface of a11 the nuts 6. Lubricate the thread of the studs and the seating sur- faces with oil, do not use MOLYCOTE grease.

  • - Screw down, by hand, a11 the nuts 6 until they seat and only then apply the round bar 9427.01a to "Tighten'. Renark: It is isportant that a11 the nuts run freely on their threads and that they cari be down by hand until seated.

screwed

  • - Fit a11 the hydr. jacks 9427.01 on the cylinder head studs, 32 are seated on the cylinder head.

screw them down until their cylinders

  • - The pistons 31 of the hydraulic jacks aust be screwed into the cylinders 32 until they are flush wit~h

  • l their Upper edges at '8' ! If this point is not folloued the required stroke cannot be obtained by the jack. Use the special spanner 9431.03 to screw doan the pistons 31. (Fig. '0'). Please refer tp the note on the previous page.

    • - Connect the éand purp 9408.01 by the HP hoses with the hydr. jacks 9427.01.

    • - Shut the bleeder valve, actuate the pump and raise the pressure to 100 bar, Hold this pressure con- stant until a11 the nuts have been tightened with the round bar until fully seated.

    • - Qpen the bleeder valve on the puop and louer the pressure ta 'Zero'.

    • - Measure the projection

'X' of

jack piston over jack cylinder uith a

depth gauge and note them down. (Please refer to sketch on the side).

  • - Shut bleeder valve and actuate the punp raisin9 the pressure to 600 bar, hold the pressure constant until a11 the nuts 6 have been tightened down until seated.

  • - Release the oil pressure fully to 'Zero' and measure the projsc, tion jack piston over cylinder 'Xl' with the depth gauge and note thea down.

- Cylculate the tension value
I

'Xl' - 'Xl. For correctly pre-tensio-

ned cylinder head studs the difference betueen the tuo measures

should be about l ...

~III. These reasures serve as additional but

important check on the correctness of the pre-tension,

- If considerable differences are established in the measured values, then it is necessary to de- ten-

sion the cylinder head studs once more

sioning procedure.

(please refer to sheet 2701/Ta)

and to repeat

the pre-ten-

  • - When the stretching measure of a11 the studs corresponds approxiaately with the indicated value, re- move a11 jacks and the puap and close a11 open hose connections uith sealing caps.

Note: Leaking hydr. jacks do not permit correct pre-tensioning of the studs. In such a case the defec-

tive jack must be dismantled and equipped with neu sealing rings. The piston 31 cari be withdrawn

fron the cylinder, when the circlip is reaoved froa the cylinder. When reasseabling the jack par-

ticular tare nust be taken when fitting the face seal.

Replacinq the O-Rinos in the Oil Connectino Piece uithout removino the Cvlinder Head

(Please refer to Fig. 'E')

The O-rings 23 on the oil connecting piece 24 cari be replaced with-out removing the cylinder head, for

this proceed as follows:

  • - Loosen the screws 25 and remove flange 26 and spacer 27.

  • - Push connecting piece 26 downward and upward and replac'e first the louer then the Upper O-rings.

  • - Remove the old O-rings smear a neu set uith engine lub. oil and fit them.

  • - After replacing the O-rings 23 push the connecting piece 24 again into its central position then fit the spacer 27 and the flange 26 and tighten with the screus 25 moderately.

Fittinq the Rocker Arm Cowlina, Please refer to sheet 2705/1

Adjustinq the Valve clearances for Inlet and Exhaust Valves, Please refer to sheet 4401/1.

27O?/ld ZA 40
27O?/ld ZA 40
27O?/ld
ZA
40
27O?/ld ZA 40
27O?/ld ZA 40
27O?/ld ZA 40
  • 0- 1OZ LU.363

0 -

WZ IX.362

1982

701 /le

t--db

9427.01

1

il

Ij
II

Il

11

II

4 b
4
b

F--

w

9408.01

ZA

LO

942z34

_*

‘.

I

I

.

;’

:

\

--

,-

4

0 K

ZAL

2xL

40

40s

 

Cylinder

Head

 

Group:

2701

 

Replacing

Valve Seats

 

Sheet:

2

Tools:

Key to Illustration:

 
  • 1 Spindle M24 x 365

9427.26

*

1

Cylinder head

5

D.E. Ring spanner

AF 46/50

with two nuts

2

Rawl pin

6

Valve guide bush

  • 1 sleeve, compl. with

Upper

9427.27 *

3,3a

Nut M24

7

O-rings

bal1 bearing

and nut

4

O-rings

8

Valve Seat

  • 2 Cones

9427.30 *

 

9

Bush

  • 4 Clamping jaws with

9427.31 *

 

2 O-Rings

dimen. 66,04 x 5,33

  • 1 disc

Centering

9427.32

  • 1 Spindle M24 x 600

9427.26b

Assorted spanners

* built

up

tioning, replacement

condition). For the replacement

If the seat surface of valve seats is badly damaged or on which too much material was ground away during recondi-

of the valve seat is necessary.

(The valve may lie in the seat maximum 1.5 mm deeper

 

as in new

guide bush 6 must ti

toolwith

the four

of the valve seats it is best to stand the cylinder head on its side. Thevalve

until the extraction

be removed.

Removing a valve seat (Fig. ‘A’)

N

I

4 - 17.260.699

6

the nuts 3 and 3a and the cones 9427.30 respectively

  • - Unscrew and separate clamping jaws 9427.31 fitted cari be pushed through the valve Seat. (The O-Rings

jaws together).

4 are holding the clamping

  • - With the tool in place tighten

nut 3a by hand, until the clamping jaws 9427.31 grip the valve seat on its bottom

edge. While tightening

move the spindle 9427.26 simultaneously,

axially to and fio

until you feel

that the cane

grips with its shoulder the valve seat at ‘X’. Only when this is the case tighten the

nut 3a -with

a span-

ner.

  • - Mount the centering disc 9427.32 and the Upper sleeve with bal1 bearing

and special nut 9427.27 and tum the

special nut with a spanner

until the valve seat 8 bas been withdrawn,

from its bore.

2701/2a

zA40

Note:

Should avalve seat hold exceptionally tightly in the cylinder head, causingproblemswith thewithdrawal,

it is possible to loosen the valve seat with the following method:

With an arc-welding set apply a welding bead a11around the seat periphery on the sloping seat surface. When the valve seat has cooled it has shrunk due the weld bead, and cari be readily withdrawn. Of course thevalve seat is then unusable. (While welding take tare that noweld spatter set on the bore surface of the cylinder head).

Fitting

a valve

seat (Fig.

‘B’)

Place the cylinder head on its side, permitting

to fit the

valve seat in horizontal

direction.

Clean the bore,

and

the seating surface

in the

cylinder head with great tare.

Any unevenness

or damage

must be

polished out.

 

-

Clean the sealing surfaces of the valve seat 8 and coat them with Loctite 648.

 

-

Smear the O-rings ine O-rings!).

7 with lubricating oil, then place them into the grooves in the valve seat 8. (Utilize new genu-

-

Push the valve seat by hand as far as possible into the bore in the cylinder head, then install the seat fitting device

as shown

in Fig.

‘B’ and pull the seat

in until fully seated.

(The valve guide bush 6 must be fïtted

for this

proce-

dure). The valve seat rests on the shoulder

at

‘AS’ but must have a clearance

at the point

‘S’.

After the replacement

of the valve seat it is recommended

(Piease refer

to sheet 2701/6).

to subject the cylinder head to a water pressure

test.

Remark

Should

a bush

9 have

to be

replaced in the exhaust valve bore in the cylinder caver, then the bush outer

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

n

4-107.240.499

9427.27

9

8

9427.9

Cylinder Head

Grinding

the Valve Seats of Inlet

and Exhaust Valves

Tools:

Key to Fig.

‘A’

  • 1 Cylinder

head

tum-over device

9427.17

1 Cyhnder

head

(only supplied

against specific order)

2 Valve guide bush

 
  • 1 Valve seat grinding machine

9427.18

3 Grinder

spindle

  • 1 Hand grip

9427.35

4 Valve seat

Marking blue

5 Nut

 

6

Brake (wooden etc. for steadying)

staff, pipe

7

Centring device

For information

on the grinding

of valve spindle

seat please refer to sheet 272012