Service Bulletin ZAS–11.

1
31.03.98
Technical Information to all Owners / Operators (Supersedes Bulletin
of Sulzer ZA40S Engines ZAS–11 of 01.03.95)

Cylinder Liner with Thread

Contents: Page

1. Introduction 1
2. Cylinder Liner with a
Thread in the Upper Part 1
3. Modification of Existing
Cylinder Liners 3
4. Carbon Removal before
Withdrawing of the Piston 5
5. Spare Cylinder Liners 5
6. Conclusion 5
28.57.07.40 – Printed in Switzerland

Wärtsilä NSD Switzerland Ltd PO Box 414 Tel. +41 52 262 49 22

Wärtsilä NSD Schweiz AG CH-8401 Winterthur Fax +41 52 212 49 17
Wärtsilä NSD Suisse SA Switzerland Tlx 896 659 NSDL CH
1. INTRODUCTION
This Service Bulletin informs you about the current cylinder liner design with a thread in the
upper part and the possibilities for adaptation of the original cylinder liners installed in
engines already in service.

2. CYLINDER LINER WITH A THREAD IN THE UPPER PART

On the conventional cylinder liner design (without thread), the products of combustion in the
annular gap between the piston crown and cylinder liner are deposited on the component
which exhibits the higher surface temperature (phenomenon of the stiction temperature of
HFO), which in the case of the original cylinder liner design is the piston crown. This
phenomenon led the designer to create an area at the cylinder liner where the temperature is
slightly higher than that of the piston crown for a counter formation of deposit as well.
In the case of the cylinder liner with a thread in the upper part, the deposit will form on the
threaded part of the cylinder liner first, because the thread peaks exhibit a higher
temperature than the piston crown, thus assisting the carbon deposits, due to the higher
stiction temperature, to form on the upper part of the cylinder liner before deposition on the
piston crown will take place (please refer to the following sketches).
The deposit on the cylinder liner has a scraping effect on the deposits forming on the piston
crown, thus limiting the carbon buildup. This will ensure that the necessary oil film on the
cylinder liner running surface remains undisturbed and prevents the transportation of
lubricating oil by the piston crown into the combustion space where it would be burned,
creating unwanted hard carbon deposits.
Field tests have confirmed that with a thread in the upper area of the cylinder liner, a constant
lubricating oil film on the cylinder liner running surface with correspondingly lower oil
consumption over a longer operating period can be reached.

Original Design of Cylinder Liner

TDC Mid Stroke

Build up of carbon
deposit on the
piston crown
Lube oil film
Contact area

Lube oil transport by

the piston crown

Reduced amount of
lube oil available
for the piston rings

1/6 Service Bulletin ZAS-11.1

 Current Design of Cylinder Liner
TDC Mid Stroke
Build up of carbon deposits on
the cylinder liner top part (due
to higher stiction temperature of
the threaded area)
Gap
Lube oil film

Lube oil transport

by the piston rings
Contact area

Result: Lower lube oil

consumption

Thus, the thread in the top part of the cylinder liner will not only influence the cylinder liner
and piston ring wear in a positive manner, it will also help to reduce the lubricating oil
consumption.

Original Liner Design Current Liner Design with Thread in Top Part
(for new engines and spare cylinder liners)

2/6 Service Bulletin ZAS-11.1

3. MODIFICATION OF ORIGINAL CYLINDER LINERS

Existing cylinder liners can be modified by machining a thread into the upper part of the
cylinder liner (please refer to the sketch below).

( ) Existing Dimension
M 401.5 x 1.5 )

M 401.5 x 1.5
( 3 + 0.1

According to wear ridge

0

C
400 H7

Wear Ridge
Groove
Ø TDC

Top piston ring

C 401.5 (max. wear limit)

0.3 + 0.1

Pos. A
0

1.5

The modification of existing cylinder liners can best be carried out on a lathe whilst the
cylinder liner is withdrawn. However, under n o circumstance should adjustments to the
running surface of the cylinder liner be carried out by machining.

After machining a thread into the upper part of the liner, the
threaded part has to be smoothed by means of a wire brush.

Please note:
If chemical cleaning agents (electrical cleaner or similar) are used to clean the bore of the
cylinder liner after completion of work, then protective clothing must be worn. Precautions
must also be taken against fire risks if inflammable chemicals are used. Please adhere
strictly to the safety instructions given by the supplier or manufacturer of the chemical agent!

3/6 Service Bulletin ZAS-11.1

There are portable machines available from specialized firms like Chris-Marine AB
(Thread Turning Machine Type TTM as shown below) which can machine the thread into the
cylinder liner in situ. However, it is very important that, if any machining work on the cylinder
liner is carried out in situ, neither foreign particles nor cleaning agent which is used to clean
the cylinder liner after completion of work can enter the crankcase.

Chris-Marine Thread Turning Machine Type TTM

To avoid any kind of contamination of the crankcase a catching basin can be attached on the
bottom of the cylinder liner (please refer to sketch below) and the crankpin should be
protected with rags.

ÏÏÏÏÏÏÏÏÏÏ
Catching basin
ÏÏÏÏÏÏÏÏÏÏ Lower part of the cylinder liner

ÏÏÏÏÏÏÏÏÏÏ
For practical reason, for easier accessibility and also for the sake of cleanliness we
recommend, however, to cut the thread with the portable thread turning machine whilst the
cylinder liner is removed from the engine. After the modification is carried out it is important
to thoroughly clean the cylinder liner and wash off any foreign particles and dirt especially
from the bore of the liner before it is refitted in the engine.

4/6 Service Bulletin ZAS-11.1

4. CARBON REMOVAL BEFORE WITHDRAWING OF THE PISTON

Since the carbon deposition on cylinder liners with a thread in the upper part of the bore will
chiefly take place in the upper part of the cylinder liner, it is evident and of the utmost
importance that the carbon is removed before the piston is withdrawn during an overhaul.
For cases where the carbon deposit is too hard for manual removal, special machines
designed for this task are available.

Chris-Marine Carbon Removing Machine Type CTR

B
0
ø 400 - 0,1

The dimensions shown in section B must be strictly observed in order not to

damage the thread in the upper part of the cylinder liner. For the same reason it is
advisable to leave the carbon which remains in the thread untouched. Before the
carbon deposits are removed from the threaded area the piston must be covered
with a plastic sheet which is taped to the cylinder liner wall, to ensure that no
foreign particles can enter the crankcase.
A similar Carbon Removing Machine Type ECD is also available from HUNGER.

5. SPARE CYLINDER LINERS

Please find in the table below the code no. of the available types of cylinder liners:

Code No. Thread in Top Part Lubrication Type

KS 21402 NO cylinder lubricators
KS 21403 YES cylinder lubricators
KS 21404 YES inner piston lubrication

Cylinder liners as well as both thread turning and carbon removing machine are available
through Wärtsilä NSD France, Mantes or our Network Companies.

6. CONCLUSION

The piston running behaviour will be appreciably improved by the application of cylinder
liners with a fine thread in the top part, the lubricating oil film conditions on the running
surface of the cylinder liner optimized and the wear behaviour of piston rings and cylinder
liner, as well as the cylinder lubricating oil consumption positively influenced.

5/6 Service Bulletin ZAS-11.1

This Service Bulletin should be kept in a separate file in the control room. The respective pages or
tables of the Service Bulletin with modifications to the Operating Manual, Maintenance Manual or
Code Book should be copied and filed in the respective Manual or Book.

Wärtsilä NSD Switzerland Ltd has issued this Service Bulletin with their best knowledge and
ability. However, Wärtsilä NSD Switzerland Ltd can not take any liability for any or all information
contained in this or any other Service Bulletin.
Changes of any nature to the form and or to the content of this or any other Service Bulletin as
published by Wärtsilä NSD Switzerland Ltd, are not permitted.

6/6 Service Bulletin ZAS-11.1