Diesel After-Sales Service

Service Bulletin ZAS–16

Technical Information to all the Owners 10.08.95
of Sulzer ZA40S Type Diesel Engines

Flow Control Valve KS 72126

for Cylinder Lubrication

Contents: Page

– INTRODUCTION 1

– 1. SAFETY PRESSURE SETTING 1

OF FLOW CONTROL VALVES
SO 184

– 2. MODIFICATION OR 2
REPLACEMENT OF FLOW
CONTROL VALVES SO 184
OR SO 236

– 3. SERVICE BULLETINS 3
PUBLISHED FOR
ZA40S ENGINES
28.69.07.40 – Printed in Switzerland

New Sulzer Diesel Ltd Diesel After-Sales Service PO Box 414 CH-8401 Winterthur, Switzerland
Phone: (052) 262 80 10 (24hours) Telex: 896 659 NSDL CH Telefax: (052) 213 94 83
INTRODUCTION
This Service Bulletin deals with the flow control valve KS 72126 which is fitted between the
gear pump and the hydraulic motor of the cylinder lubricator drive of engines equipped with
load dependent cylinder lubrication.
Since the introduction of the ZA 40S  type engine there were in total three types of flow con
trol valves applied for the cylinder lubrication.
Original : 3 FRM 102x/50 LD SO 184
Intermediate : 3 FRM 102x/50 LD SO 236
Present : 3 FRM 102x/50 LD SO 247
The main differences between the valve types are as follows:
SO 184: Builtin safety valve adjusted to 50 bar (but the strong spring applied allows ad
justments of higher pressures and the protection of the gear pump KS 72106 could
be lost).
SO 236: Builtin safety valve adjusted to 50 bar at 30 l/min. The special spring used does
not allow the above setting to be exceeded.
SO 247: Safety valve adjustment and the spring used are as valve SO 236. However, the
valves are internally strengthened to improve on performance and lifetime.
Some recent reports have shown that there are still a number of the previous types SO 184 and
SO 236 fitted to engines in service and we therefore advise you to take the following steps in
case problems are experienced in your installation:
a) Upgrade the existing valves SO 184 and SO 236 according to paragraph 1. and 2.
b) Replace the existing valves with valve SO 247.
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.

1. SAFETY PRESSURE SETTING OF FLOW CONTROL VALVES SO 184

Flow control valves SO 184 in service of which the safety valve opening pressure is not known
or incorrect must be checked at the earliest opportunity.
The testing can be carried out according to the diagram below and is made statically with the
engine at standstill:
Temporary Arrangement for Setting and Testing the
Safety Valve Opening Pressure on the Flow Control Valve
Blankedoff tempo
rarily during testing
B
Gear A Flow Control Hydraulic
Pump Valve Motor

Temporary Pipe T
Adjusting Screw
Connection for Safety Valve
from Hydraulic with Lock Nut
Hand Pump to
Internal Drain
Inlet on Flow
Hydraulic Connection to
Valve
Hand Pump Engine Oil Sump

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1.1. Items used to Setup Temporary Setting / Testing Arrangement
(Please refer to diagram on page 1.)
 Hydraulic hand pump with hose. (Use pump and hose from the tool kit).
 Pressure gauge 0 - 160 bar. (Available in the tool kit).
 Suitable pipe connections for temporary pipe between hydraulic hand pump and connec
tion "A" on flow valve.
 Shutoff plug to blankoff pipe connection between flow control valve connection "B"
and hydraulic motor.
 Clean oil for hydraulic hand test pump.
Please note: Do not use a pneumatically driven test pump due to the high risk of overpres
surizing the flow control valve and oil pipes.

1.2. Procedure of Testing / Setting the Safety Valve of the Flow Control Valve

Testing and/or adjustments to be carried out according to diagram on page 1 and is to
be made statically with the engine at standstill.

Unscrew the oil pipe between connection "B" of the flow control valve and the hydraulic
motor at the most accessible point and blankoff the flow control valve side.

Remove oil pipe between the gear pump and connection "A" of the flow control valve.

Fit the temporary pipe connection between hydraulic hand pump hose and connection
"A" of the flow control valve.

Exchange the 1000 bar pressure gauge on the hand pump for the pressure gauge with a
range of 0 - 160 bar from the tool kit.

Adjust the safety valve to a static opening pressure of 30 - 40 bar, whereby some oil
should appear at the drain connection "T".

Secure the lock nut of the safety valve with "Loctite" and mark with oil resistant paint.
Any readjusted and checked flow control valve should be marked with SO 184 X.

2. MODIFICATION OR REPLACEMENT OF FLOW CONTROL VALVES SO 184

OR SO 236

Flow control valves SO 184 and SO 236 can be modified by the makers to type SO 247.
We leave it to you to decide whether you have the flow control valves type SO 236 and type
SO 184 modified or replaced by the present flow control valve type SO 247.
Modifications: Are carried out by the Makers directly. Please ask them for a quotation.
Replacement valves: Are available from the New Sulzer Diesel After Sales Organization or
through their Representatives.

New Sulzer Diesel Ltd has issued this Service Bulletin with their best knowledge and ability.
However, New Sulzer Diesel 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 New Sulzer Diesel Ltd, are not permitted.

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3. SERVICE BULLETINS PUBLISHED FOR ZA40S ENGINES

We have so far published the following Service Bulletins which are valid for ZA40S type
engines:
Z-6.2 dated 31.07.92 / Assessment of Main and Connecting Rod Bearings
Z-7 dated 19.07.85 / Flushing Instructions
Z-8.1 dated 13.12.91 / Undersized Bearings and Reconditioning of Crankshafts
Z-9.2 dated 28.09.93 / Lubricating Oil Treatment and Requirements
ZAS-1.1 dated 20.10.93 / Cylinder Liner Overhaul
ZAS-2 dated 06.11.92 / Grinding of Inlet / Exhaust Valves and Seats, New Valve Seat and
New Relief Valve Design
ZAS-3 dated 10.06.93 / Oil Scraper Rings
ZAS-4.2 dated 22.03.95 / Top Piston Ring
ZAS-5 dated 03.12.93 / Instruction for Testing of Fuel Injection Nozzles
ZAS-6 dated 01.04.94 / Ring for Rotating Piston for ZA40S Type Engines
ZAS-7 dated 05.04.94 / Adjustments and Maintenance Requirements
on Oil Mist Detector
ZAS-8 dated 05.04.94 / Turnomat for Exhaust Valves and Rotocap for Inlet Valves on
ZASType Engines
ZAS-9 dated 01.06.94 / Exhaust Pipe Expansion Bellows
ZAS-10 dated 01.08.94 / High Temperature Cooling Water System
ZAS-11 dated 01.03.95 / Cylinder Liner with a Thread in the Upper Part of the Bore
ZAS-12 dated 01.03.95 / New Spindle Design for Pressure Control Valve KS 87085
ZAS-13 dated 31.03.95 / New Inlet Valves
ZAS-14 dated 01.06.95 / New High Pressure Fuel Pipe Assembly
ZAS-15 dated 10.08.95 / New Fuel Injection Nozzle Specification
Should you not be in possession of the above mentioned documentation suitable for your
plant, kindly contact your local New Sulzer Diesel representative for your copy.

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