MAK M43C Operating Instructions Manual Download Page 457 | Manualshive

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Stop Piston

Inspection / Checking

10.03.01.00

en / 31.07.2008

IB020372

1/2

10

See also:

07.03.01.nn

Spare parts list:

B1.05.05.434210, B1.05.07.433597

Time requirement:

1 Pers./ 0,20 h

Personnel qualification:

skilled engine hand

-------------------------------------------------------------------------------------------------------------------------------

Operating medium:

Heavy fuel and distillate fuel

Inspection:

Check the emergency stop function of the stop piston

every

750 h

Note:

The functional check may only be completed when the engine is stopped for other maintenance
or repair work!

Procedure:

1.

Actuate emergency stop.

2.

Check the position of the control rods.

Attention:

The control rods must be in the "Zero
Filling“ position.

3.

Check the stop piston (3) in the injection
pump, press the control rod (2) into the in-
jection pump by applying pressure to the
jointed lever (1) on the control rod.

Note:

Check all injection pumps.

If individual or one control rod can be forced into the injection pump against the pressure of the
stop piston, check the stop piston in the respective injection pump and overhaul if necessary
(

07.03.01.nn

).

If all control rods can be pushed into the injection pump, check the control air lines for leaks or da-
mage.

4.

Actuate the "

Reset

“ button on the safety system.

Note:

The stop piston is reset and the emergency stop system depressurized.

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Summary of Contents for M43C

Page 1: ...Engine Operating Instructions Type M43C 68 280 68 281 Engine Operating Instructions A0 M43C en 26 05 2009 AA000643 1 2 281717 Engine No Record No...

Page 2: ...to the agreed purpose and must not be used for any other purpose Copies or other reproductions including storage processing or distribution by using electronic systems may only be made to the agreed p...

Page 3: ...perating Instructions A3 Table of Contents A3 01 Introduction A3 02 Safety Instructions A3 03 Instructions for Heavy Fuel Operation A3 04 Initial Operation Engine A3 05 Operational Supervision Engine...

Page 4: ...Catalogue B0 Total Index Book A B and C B0 01 Introduction B0 02 Spare Parts B1 Table of contents B1 01 Safety instructions B1 03 Stand by parts B2 External Documentation C0 Total Index Book A B and...

Page 5: ...chapters the technical personnel is able to maintain the engine in such a manner that regarding its output reliability economy and service life opti mum operating results can be achieved If you need f...

Page 6: ...ird parties all safety regulations which are marked with the symbol have to be observed in all cases Technical instructions and or operations to be strictly observed are marked in the documents with a...

Page 7: ...ed and explained by our commissioning personnel Participants in this acceptance procedure are the authorized personnel of CATERPILLAR Motoren Kiel the managing and operating personnel of the operator...

Page 8: ...f an alarm occurs or engine power is reduced and the causes have to be eliminated Actions that must be performed after a safety emergency stop occurred Identify the reason for emergency stop based on...

Page 9: ...every single regulator rack of fuel pumps in both directions for proper operation by pulling and pressing Checking governor drive Verification of possible out of calibration of actuator if fitted 1 3...

Page 10: ...igated 2 4 Contact the Caterpillar MaK Service 3 Engine room monitoring Emergency Stop due to excessive oil mist concentration refer to A3 11 18 01 nn Checks Check engine room monitoring device operat...

Page 11: ...fer to A5 05 06 04 02 nn Fuel pumps and fill level scale on each fuel pump Injection valves refer to A5 05 07 08 01 nn Turbocharger 5 1 Contact your Caterpillar MaK Service 6 Check pneumatic emergency...

Page 12: ...may only be operated for a short time and under permanent observation At any rate the cause of the fault message must be remedied immediately 7 1 General fault messages Fault message Description Measu...

Page 13: ...Technical Engine Data A1 M20 M601C en 26 05 2009 AA000103 1 1 Technical Engine Data...

Page 14: ...Governor Data A1 04 en 20 02 2008 AA000097 1 1 Governor Data...

Page 15: ...Governor data A1 04 30 71 M43 en 26 05 2009 AA045578 1 1...

Page 16: ...are considerably changed in the main district of operation e g change from polar sea navigation to tropical regions eventually causing failures Caterpillar Motoren GmbH Co KG should be asked with res...

Page 17: ...are considerably changed in the main district of operation e g change from polar sea navigation to tropical regions eventually causing failures Caterpillar Motoren GmbH Co KG should be asked with res...

Page 18: ...peed 4 0 5 0 bar Cooling water min feed head at pump inlet 4 m water gauge 2 5 5 0 bar Fuel at injection pump inlet Distillate fuel 3 0 5 0 bar Heavy fuel 4 0 5 0 bar Injection nozzle opening pressure...

Page 19: ...50 C Fuel before injection pumps see diagram Permissible injection viscosity must be set on the viscothermic device to enable a kinematic vis cosity of 10 12 mm2 s cSt to be reached before the injecti...

Page 20: ...Torsional Vibration Calculation A1 09 en 20 02 2008 AA020354 1 1 Torsional Vibration Calculation...

Page 21: ...Torsional vibration calculation A1 09 12 13 M43 en 10 11 2008 AA043720 1 26...

Page 22: ...Shipping UK Ldt Odense Lindoe Steel Shipyard Ltd Middelesex HA4 8 ES P O Box 176 DK 5100 Odense C 2 Pacific Basin Shipping Ltd Denmark Central Hong Kong Abnahme Tested by Abnahme Tested by Abnahme Tes...

Page 23: ...ei Extreme 1 2 Irregular running This generally means the operation with unbalanced cylinder loads There are two extreme cases 1 2 1 Z ndaussetzer Keine Einspritzung aber Kompression voll vorhanden be...

Page 24: ...ine Kompression ausgebautes Triebwerk Allgemeine Hinweise Siehe Betriebsanleitung Notbetrieb Blatt A3 12 02 01 Spezielle Hinweise F r einen havarierten Motor muss die m gliche Drehzahl und Leistung er...

Page 25: ...o cylinders 5 00 Abschnitt Zylinder 1 Schwungrad section cylinder 1 flywheel 5 30 18 Gegengewichte 18 counter weights 74 80 Je 2 St ck an den Zylindern 2 pcs each on cylinders 1 2 3 4 5 6 7 8 9 Schwun...

Page 26: ...Steigung water addition 0 pitch 12 damping frahm 0 57 1053 65 Wellengenerator am Hauptgetriebe shaft generator at main gear P 1760 kW 2200 kVA n 1804 rpm ipto 3 6087 Abschnitt zw Ritzel und Pto Getri...

Page 27: ...0 38 00 1 0000 07 Triebwerk Zyl 5 running gear Cyl 5 282 20 5 00 38 00 1 0000 08 Triebwerk Zyl 4 running gear Cyl 4 282 20 5 00 38 00 1 0000 09 Triebwerk Zyl 3 running gear Cyl 3 282 20 5 00 38 00 1 0...

Page 28: ...38 00 1 0000 07 Triebwerk Zyl 5 running gear Cyl 5 282 20 5 00 38 00 1 0000 08 Triebwerk Zyl 4 running gear Cyl 4 282 20 5 00 38 00 1 0000 09 Triebwerk Zyl 3 running gear Cyl 3 282 20 5 00 38 00 1 00...

Page 29: ...er max pitch 8100 kW Belastung nach Propellerkurve Load acc To Propeller Law Gsl D mpfer Systemstelle 1 2 Gsl D mpfer Systemstelle 1 2 Gsl damper location 1 2 Gsl Damper Location 1 2 Moment torque kNm...

Page 30: ...l engine speed 1 min i 1 0 Wechselspannung Systemstelle 9 10 Alternating Stress Location 9 10 Spannung Stress N mm2 zul ssig admissible Total Ordnungen 1 5 _____ 3 0 4 5 300 320 340 360 380 400 420 44...

Page 31: ...Propeller _____ 1 5 0 5 zul ssig admissible 300 320 340 360 380 400 420 440 460 480 500 520 540 560 0 5 1 1 5 2 2 5 3 3 5 4 4 5 5 Motordrehzahl engine speed 1 min i 3 6087 Wechselspannung Systemstell...

Page 32: ...1 0 Wechselsp Systemstelle 7 8 Aussetzer Zyl 9 Alternating Stress Location 7 8 Misfiring Cyl 9 Spannung Stress N mm2 zul ssig admissible Total Ordnungen 1 5 _____ 3 0 1 0 300 320 340 360 380 400 420...

Page 33: ...____ 0 5 Propeller zul ssig admissible 300 320 340 360 380 400 420 440 460 480 500 520 540 560 0 1 2 3 4 5 6 7 8 9 10 Motordrehzahl engine speed 1 min i 3 6087 Wechselsp Systemstelle 18 19 Aussetzer Z...

Page 34: ...tordrehzahl engine speed 1 min i 1 0 Wechselspannung Systemstelle 7 8 Alternating Stress Location 7 8 Spannung Stress N mm2 zul ssig admissible Total Ordnungen 3 0 _____ 1 5 2 0 300 320 340 360 380 40...

Page 35: ...n Propeller _____ 1 5 0 5 zul ssig admissible 300 320 340 360 380 400 420 440 460 480 500 520 540 560 0 2 4 6 8 1 1 2 1 4 1 6 1 8 2 Motordrehzahl engine speed 1 min i 3 6087 Wechselspannung Systemstel...

Page 36: ...0 Wechselsp Systemstelle 7 8 Aussetzer Zyl 9 Alternating Stress Location 7 8 Misfiring Cyl 9 Spannung Stress N mm2 zul ssig admissible Total Ordnungen 3 0 _____ 1 5 2 0 300 320 340 360 380 400 420 44...

Page 37: ..._____ 1 0 Propeller zul ssig admissible 300 320 340 360 380 400 420 440 460 480 500 520 540 560 0 1 2 3 4 5 6 7 8 9 10 Motordrehzahl engine speed 1 min i 3 6087 Wechselsp Systemstelle 18 19 Aussetzer...

Page 38: ...ad Node 0 5 0 0214 6 5 0 0072 0 5 0 0397 6 5 0 0132 0 5 0 2528 6 5 0 0805 1 0 0 0028 7 0 0 0072 1 0 0 0051 7 0 0 0132 1 0 0 0307 7 0 0 0805 1 5 0 0343 7 5 0 0343 1 5 0 0637 7 5 0 0637 1 5 0 4054 7 5 0...

Page 39: ...Grad Node 0 5 0 9073 6 5 0 2426 0 5 1 9790 6 5 0 3874 0 5 1 2536 6 5 1 1931 1 0 0 0883 7 0 0 2426 1 0 0 1429 7 0 0 3874 1 0 0 5693 7 0 1 1931 1 5 1 4567 7 5 1 4567 1 5 3 1852 7 5 3 1852 1 5 2 1555 7 5...

Page 40: ...Grad Node 0 5 1 3414 6 5 1 1580 0 5 1 5098 6 5 1 0918 0 5 1 8582 6 5 0 9498 1 0 0 5581 7 0 1 1580 1 0 0 5406 7 0 1 0918 1 0 0 5276 7 0 0 9498 1 5 2 2861 7 5 2 2861 1 5 2 5424 7 5 2 5424 1 5 3 0915 7 5...

Page 41: ...12 Grad Node 0 5 1 8894 6 5 1 7357 0 5 1 6948 6 5 2 0337 0 5 1 2572 6 5 3 3087 1 0 1 3871 7 0 1 7357 1 0 1 4832 7 0 2 0337 1 0 2 6462 7 0 3 3087 1 5 3 4812 7 5 3 4812 1 5 3 2508 7 5 3 2508 1 5 2 0038...

Page 42: ...d Node 0 5 0 0245 6 5 0 0082 0 5 0 0431 6 5 0 0144 0 5 0 2554 6 5 0 0813 1 0 0 0032 7 0 0 0082 1 0 0 0056 7 0 0 0144 1 0 0 0310 7 0 0 0813 1 5 0 0392 7 5 0 0392 1 5 0 0692 7 5 0 0692 1 5 0 4096 7 5 0...

Page 43: ...rad Node 0 5 0 9076 6 5 0 2427 0 5 1 9790 6 5 0 3874 0 5 1 2536 6 5 1 1931 1 0 0 0883 7 0 0 2427 1 0 0 1429 7 0 0 3874 1 0 0 5693 7 0 1 1931 1 5 1 4572 7 5 1 4572 1 5 3 1852 7 5 3 1852 1 5 2 1555 7 5...

Page 44: ...rad Node 0 5 1 3415 6 5 1 1579 0 5 1 5098 6 5 1 0918 0 5 1 8602 6 5 0 9489 1 0 0 5580 7 0 1 1579 1 0 0 5406 7 0 1 0918 1 0 0 5277 7 0 0 9489 1 5 2 2864 7 5 2 2864 1 5 2 5424 7 5 2 5424 1 5 3 0948 7 5...

Page 45: ...2 Grad Node 0 5 1 8894 6 5 1 7357 0 5 1 6948 6 5 2 0337 0 5 1 2572 6 5 3 3087 1 0 1 3871 7 0 1 7357 1 0 1 4832 7 0 2 0337 1 0 2 6462 7 0 3 3087 1 5 3 4812 7 5 3 4812 1 5 3 2508 7 5 3 2508 1 5 2 0038 7...

Page 46: ...ie vorliegende Drehschwingungsberechnung wurde entsprechend den Regeln der Schwingungstechnik nach bestem Wissen und unter Zuhilfenahme modernster Rechenhilfsmittel durchgef hrt Important note This to...

Page 47: ...Acceptance Test Records A1 10 en 20 02 2008 AA000095 1 1 Acceptance Test Records...

Page 48: ...Technical Data Acceptance test records A1 10 20 32 33 M43 en 22 05 2009 AA045559 1 5...

Page 49: ......

Page 50: ......

Page 51: ......

Page 52: ......

Page 53: ...Operating Instructions A3 M20 M601C en 26 05 2009 AA000108 1 1 Operating Instructions...

Page 54: ...system A3 05 07 01 Initial operation Lubricating oil system A3 05 08 00 Initial operation Cooling water system A3 05 09 00 Initial operation Starting air system A3 05 11 00 Commissioning Putting into...

Page 55: ...Preservation Short term preservation A3 09 01 00 Preservation Long term preservation A3 09 02 00 Preservation Depreservation A3 09 03 00 Running in Engine A3 10 00 Running in Engine A3 10 01 00 Fault...

Page 56: ...Table of Contents A3 01 en 26 05 2009 AA020023 3 3 Emergency operation Operational misfire A3 12 02 01...

Page 57: ...a restrictor on the injection pump racks Unless otherwise indicated our information always refers to the maximum continuous power and if this is unknown to the operator he should make inquiries to th...

Page 58: ...e from the operating instructions and explanations should be noted down in the instructions After commissioning the engine all important data and work should be recorded in either the engine log book...

Page 59: ...ndards do not provide any information about the combustion properties of fuels Suppliers of fuels are cur rently working to define properties and limits more accurately Therefore it is becoming increa...

Page 60: ...ges Percentages of individual chemical elements Especially important is the vanadium content De pending on the measuring method the vanadium content can indicate a rising percentage of hea vy fuel in...

Page 61: ...al cylinders are supplied with a sufficient amount of air Consequences of a poorly performing turbocharger can be Drop in power produced by the engine Rising fuel consumption High temperatures of the...

Page 62: ...evention of accident regulations of the particular employee s liability insurance association or equivalent institution are to be observed for example Observe all fire warning and fire fighting proced...

Page 63: ...tection guards must be in operation position and operative Hearing protection must be worn Before putting the engine into operation ensure that there is no danger to persons by the starting engine pla...

Page 64: ...stated below are to be stringently observed as the readiness for service and operational reliability of the engine system during high extremes of use requires perfect fuel and depends upon optimal con...

Page 65: ...er increased The distinguishing properties of such residual oils are their high viscosity and their density as well as the increased portion of chemical compounds with sulphur vanadium sodium and cat...

Page 66: ...scometer HF1 Fuel fine filter duplex filter HF2 Fuel primary filter duplex filter HS1 HS2 Heavy fuel separator HF3 Fuel coarse filter HF4 Self cleaning fuel filter HT1 Heavy fuel day tank HT2 Mixing t...

Page 67: ...tling tank and a part of the water and heavy contaminations are separated from the heavy fuel as sludge Two setting tanks are to be provided for HFO operation and each one is to be designed for a full...

Page 68: ...m pressure must not rise when increasing the valve spring load 6 Fuel pressure regulating valve HR1 The valve is installed in the excess return line and must be set so that the pressure at the engine...

Page 69: ...team type a condensation trap should be installed at the steam outlet to ensure sufficient heating if possible Attention Fuel temperature before engine intake 150 C 11 Viscosity measurement and contro...

Page 70: ...selection of the suitable lube oil and the limit values are observed according to the operating media A4 05 08 nn The lube oil has important functions in engine operation as e g Replace metallic fric...

Page 71: ...re must be between 90 95 C 2 Oil level control Check the oil level daily see A3 05 08 nn Top up with fresh oil if 20 of the specified quantum has been consumed This will replace parts of the additives...

Page 72: ...ubeoil thermostat valve LF2 Lubeoil automatic filter LR2 Oil pressure regulaging valve LF4 Suction strainer LS1 Lubeoil separator LH1 Lubeoil cooler LH2 Lubeoil preheater LT1 Lubeoil sump tank LP1 Lub...

Page 73: ...y of the automatic filter too large 3 3 Lube oil automatic filter LF2 An automatic filter with oil or compressed air flushing or an automatic filter with oil flushing is em ployed as automatic lube fi...

Page 74: ...the elements Carefully check the filter elements for damage If the filter has various cartridges one damaged cartridge means a malfunction of the entire filter Renew damaged cartridges See servicing...

Page 75: ...Initial Operation Engine A3 05 00 en 20 02 2008 BA000022 1 1 Initial Operation...

Page 76: ...ilary fuel pump In case the day tank is at a higher level and the pump has a bypass line open the stop valve at the pump Check for smooth operation of the control rack linkages Each individual control...

Page 77: ...the standby or pre lubricating pump and Vent the entire lubricating oil system Check all flanges and threaded connections in the system for tight connection Check the lubrication of the following poi...

Page 78: ...be cooled Unless connected to a permanent venting arrangement all components and pipes belonging to the system must be consecutively vented The vent pipe from the engine to the header tank generally h...

Page 79: ...crankcase oil mist detector When the shut off valve is closed the air supply of the emergency stop cylinders at the injection pumps and at the crankcase oil mist detector are shut off in addition to...

Page 80: ...nality of the total system If alarm and safety devices as well as the switch device for the speed are disconnected all functions which are normally recorded automatically must be checked or performed...

Page 81: ...18 00 M20 M32 M43 en 30 01 2001 BA000636 2 3 H11 Wrong start H12 Start locking H13 Run from remote control R1 Speed adjustment S11 H9 Start S12 H10 Stop S13 Change over switch 1 Engine 2 Remote contr...

Page 82: ...fore starting the engine For operating pressure see A1 05 Adjust speed slightly higher than nmin at the speed switch R1 Start engine manually at the start solenoid or main start up valve 20 Keep the s...

Page 83: ...ns for starting the cold engine with heavy fuel are very restricted A more viscous fuel will make ignition more difficult in addition to the above thermal influences Incomplete combustion heavy deposi...

Page 84: ...Operational Supervision Engine A3 06 00 en 20 02 2008 BA000058 1 1 Operational Supervision...

Page 85: ...low 10 C as otherwise the permissible nominal ignition pressure is exceeded It can be run at full power if the intake air is pre warmed or mixed with machine air so that the temperature at the compres...

Page 86: ...ween the pump foot and the control edge of the pump element so that every pump can be used on every cylinder As the camshaft is assembled from individual sections per cylinder there are very small dif...

Page 87: ...rmal despite balanced individual cylinder performance Attention Under no circumstances is it permitted to change charges or even delivery data at the in jection pumps to achieve identical temperature...

Page 88: ...se e g deviating ambi ent conditions fuel type soiled charger etc see A3 11 18 nn Reduce engine performance if max permissible temperatures are exceeded in operation Additional check of combustion by...

Page 89: ...e gas temperatures points to changes in individual cylinders Even if no irregularities are detected when monitoring waste gas temperatures it is advisable to observe the engine at regular intervals th...

Page 90: ...re must not be corrected by changing a properly adjusted delivery start This will cause cylinder performance to deteriorate further 4 Turbocharger compressor turbine cleaning During operation a sticky...

Page 91: ...order to clean the compressor stage during operation a built in injection tube is used to spray water into the filter muffler or the intake port in front of the compressor impeller Note Cleaning is mo...

Page 92: ...irectly to city water to a different or larger metering device or a larger water container The only authorized configuration is the original configuration provided by Caterpillar Note The time between...

Page 93: ...if it is performed consistently and regularly after commissioning or rebuilding The frequency of cleanings depends on the extent of contamination of the turbine over a certain operating time see A5 0...

Page 94: ...NOZZLE RING AT LOW EXHAUST GAS TEMPERATURE OR AT LOW ENGINE LOAD may be used Definition of low engine load Low engine load means that the engine is running either at zero pitch and rated rpm s or on...

Page 95: ...turbine housings are equipped with a device for turbine cleaning The turbine cleaning device comprises injection nozzles and internal connecting lines On V type engines the connecting lines are combin...

Page 96: ...e exhaust turbocharger For higher engine loads the medium flowing through the lines is automatically switched to intake air from the engine Check valves in each air line prevent outside air from enter...

Page 97: ...hree way selector cock for heavy fuel distillate fuel The three way cock in the return line from the engine to the heavy fuel day tank and or to the mixing tank has to remain in its position so that t...

Page 98: ...en 16 12 1997 BA000078 1 1 Lubricating oil system Check daily the levels in the Lube oil sump tank Base frame Oil sump Monitor the lubricating oil pressure temperature For Pressure Temperature indicat...

Page 99: ...pressure temperature indications see A1 05 of the operation media for Temperatures of the Operating Media A1 06 as well as Acceptance Test Records A1 10 If for any reason whatsoever temperatures are t...

Page 100: ...ne inlet Alarm 2102 2 1 bar Low HT freshwater pressure at engine inlet Emergency stop 2103 1 9 bar If the cooling water pressure in the cooling water system is 0 2 bar below the minimum cooling water...

Page 101: ...f The pressure indicator for HT freshwater on the engine control stand displays the static pressure This static pressure is to be added to the operating pressure Example Static pressure at engine cont...

Page 102: ...instructions please refer to the manual Under full load operation the cooling water will be heated up by 7 to 10 K to a max outlet temper ature of 90 C 3 Example Fixed pitch propeller plant with atta...

Page 103: ...trol stand displays an operating pressure of min 2 0 bar At 70 nominal speed the attached cooling water pump must generate an operating differen tial pressure of 1 5 bar Below 70 nominal speed the coo...

Page 104: ...ing system Check the pressure in the air bottles Drain the water daily from the air bottles compressed air filter water traps and fittings Secure the compressed air supply for the emergency stop facil...

Page 105: ...piston and cylinder liner Restrictions for partial load operation on heavy fuel cannot be avoided for some special ships such as supply vessels diver base vessels etc and for generators if the low lo...

Page 106: ...entire operating range including partial load Differing rules may be applicable at partial load to protect the entire engine during for instance turbocharger failures See A3 12 00 If a new engine is f...

Page 107: ...Removal from operation Engine A3 07 00 en 21 02 2008 BA000094 1 1 Removal from Operation...

Page 108: ...rcooling Direct operation at the main engine Disconnect engine from the mains Switch main power switch to Off Engine stop control panel in manometer board Switch change over switch S13 to 1 Engine Adj...

Page 109: ...2 M20 M25 M32 M43 en 11 05 2000 BA000630 2 4 H11 Wrong start H12 Start locking H13 Run from remote control R1 Speed adjustment S11 H9 Start S12 H10 Stop S13 Change over switch 1 Engine 2 Remote contro...

Page 110: ...circulations and keep the engine at operating temperature or preheating temperature see A3 05 18 nn according to the interruption period and type of fuel In heavy oil operation a change over to disti...

Page 111: ...ventilation for engine room only if required to make cooling off of the engine more difficult Before a long term operation stop e g down time up to 4 weeks heavy oil engines must be changed over to d...

Page 112: ...Danger of Frost Engine A3 08 00 en 20 02 2008 BA000106 1 1 Danger of Frost...

Page 113: ...solution with protection against corrosion see A4 05 09 nn Attention The concentration level of the antifreeze solution is to be choosen in such a way that a sufficient degree of protection is ensured...

Page 114: ...mble work is always to be carried out or monitored by by skilled mashine personnel Short term preservation A short tern preservation A3 09 01 nn is to be carried out for a shut down of the engine with...

Page 115: ...Ensure sufficient ventilation below the covering In Central Europe check tarpaulin and preservation regulary every 4 weeks In case of bad climate conditions the measures of a long term preservation A...

Page 116: ...ndividual engine components are to be carried out according to the following sequence of operations 2 1 Fuel system In case of heavy fuel driven engine switch over to destilled fuel see A3 06 07 nn Cl...

Page 117: ...C and drain the cooling water Note The cooling water tracts are protected by the corrosion inhibiter in the cooling water see A4 05 09 02 Engines with caged exhaust valves fill the water spaces of th...

Page 118: ...Attention The engine finish may not be etched by cleaning and or washing agent Use only suitable washing agents Keep to the operation safety and sanitation instructions of the manufacturer Dry the cle...

Page 119: ...engine finish may not be etched by cleaning and or washing agent Use only suitable washing agents Keep to the operation safety and sanitation instructions of the manufacturer 2 Preservation measures e...

Page 120: ...out banjo plug of the starting air distributor Spray in preservation oil see 1 2 and refit banjo plug 2 3 Mechanic hydraulic governor Change the oil in case of due interval Fill governor according to...

Page 121: ...ufficient thickness 3 Preservation measures fittings and tools Thoroughly clean the small parts If necessary cover threads bores grooves and similar parts with self adhesive aluminium foil Then seal s...

Page 122: ...y measures were taken remove the protective plugs covers blanking flanges or other sealant parts and any locking devices Reconnect the engine to the plant if it has been necessary to seperate it 2 2 F...

Page 123: ...endent lubrication If necessary clean the preserved parts according to instructions of the manufacturer Drain protective oil Assemble new bearings and fill up oil 2 7 External depreservation Remove co...

Page 124: ...Running in Engine A3 10 00 en 16 02 2001 BA000242 1 1 Running in...

Page 125: ...t at 20 rated power and then go to full power within the time provided for each type of engine M 20 M 282 M 332 C 6 h M 25 M 32 M 453 C 8 h M 552 C M 601 M 601 C 8 10 h M 43 10 h If a heavy fuel engin...

Page 126: ...Fault Tracing Engine A3 11 00 en 20 02 2008 BA000130 1 1 Fault Tracing...

Page 127: ...nature of the trouble will be the determining factor as to whether the power or speed have to be reduced for the duration it lasts If there is a failure in the measuring instruments or monitors that c...

Page 128: ...o severe personal injuries and engine damages When an alarm is triggered the cause of it must be identified as quickly as possible In case of doubt stop the engine immediately by hand Attention Do not...

Page 129: ...for metallic material 3 Check of the timing gear train Remove all inspection doors from both sides Visually inspect the timing gear train for discoloration traces of seizing and chips Visually inspec...

Page 130: ...and blown through with open indicator valves for a sufficient period of time by means of starting air While doing so check the indicator valves for emerging oil fuel or water The engine may then only...

Page 131: ...p see manufacturer s instructions in book C control shaft is defective Governor failures Faulty connection between governor Control shaft is jamming fuel feed pressure is terminal shaft and injection...

Page 132: ...ystem is defective Air in the fuel system Water in the fuel Fuel feed pump is defective Repair or replace pump see A5 05 07 13 01 nn Fuel filter is clogged Clean filter see A5 05 07 12 01 nn Pressure...

Page 133: ...___________________________ Opaque exhaust gas engine is emitting soot Possible cause Remedy Pressure of injection valve is too low Nozzles are fouled by carbon deposits Nozzle needle is jammed or noz...

Page 134: ...de clearance see A5 05 01 05 01 nn ____________________________________________________________________________________ Exhaust gases are white Possible cause Remedy Exhaust gas condensation due to lo...

Page 135: ...Emergency Operation Engine A3 12 00 en 20 02 2008 BA000142 1 1 Emergency Operation...

Page 136: ...missing charge air pressure only permit a reduced bmep to protect the engine against thermal overload The fuel injection pump delivery must be reduced according to the bmep recommended below Determina...

Page 137: ...t casing of the turbocharger taken out of service with a blanking cover Start the engine and reduce the output If the installation is for heavy fuel we recommend the change to distillate fuel in emerg...

Page 138: ...efective Note If the charge air cooler has two stages the charge air temperature is raised at part load by isolating the low temperature circuit of the cooler which is controlled by charge air pressur...

Page 139: ...duced according to the mean effective pres sure recommended below Emergency operation of the main engine Switch over to distillate fuel otherwise if you continue on heavy fuel for more than 24 hrs ins...

Page 140: ...d conditions as for a fixed pitch propeller plant should be reached by reducing propeller pitch and engine speed Operation at rated speed is practically impossible because the engine output that can b...

Page 141: ...til the exhaust gas temperature after turbine is max 530 C Carefully monitor the exhaust gas temperatures during emergency operation especially if exhaust gas alarms have been cut out Charge air tempe...

Page 142: ...res A cylinder head valve or piston and connecting rod should only be removed if unavoidable If misfiring operation cannot be avoided it may be necessary to limit the power output of the whole plant i...

Page 143: ...occasionally check the flexible coupling visually and its temperature The defect should be repaired immediately Before returning to normal operation again the flexible coupling should be checked for d...

Page 144: ...njection at any cylinder The compression pressure of the troubled cylinder however is applied At engine operation the following has to be observed Attention Operation with closed valves is only permis...

Page 145: ...engine speed must not exceed 80 of the rated speed A1 10 This limit value applies to engines arranged rigidly as well as flexible The exhaust gas temperatures upstream turbocharger must not exceed the...

Page 146: ...Operating Media A4 en 26 05 2009 AA020105 1 1 Operating Media...

Page 147: ...mit curves A4 05 07 03 01 Regulations and care Limit specification A4 05 07 04 Regulations and care Heavy fuel specification A4 05 07 05 Regulations and care Viscosity temperature sheet A4 05 07 06 Re...

Page 148: ...stem For that the following notes and instructions must be observed Warranty When unsuitable operating media are used or are maintained insufficiently no warranty for trouble free operation can be gua...

Page 149: ...process materials During all work or contact with lube oil hydraulic fluid grease fuel distillate heavy oil water with anticorrosive antifreeze detergent solvent coolant CO2 N2 the safety instruction...

Page 150: ...Regulations and Recommendations Engine A4 05 00 en 20 02 2008 BA000158 1 1 Regulations and Recommendations...

Page 151: ...5 07 00 M20 M601C en 28 06 1996 BA000162 1 1 For the Caterpillar MaK engines used in shore based and ship based operation according to their equip ment condition two product groups of fuels are allowe...

Page 152: ...l Oil BFO Marine Fuel Oil MFO Bunker C Fuel Intermediate Fuel IF Light Fuel Oil LFO Thin Fuel Oil TFO Various organizations such as BSI British Standards Institution CIMAC Conseil International des Ma...

Page 153: ...AC provides fewer density limits for the A10 D15 classes Introduction of minimum viscosity with CIMAC The CIMAC specification is the basis for the Caterpillar MaK heavy fuel specification A4 05 07 05...

Page 154: ...e type of engine and the condition of the fittings and included in A4 05 07 03 00 an A4 05 07 03 01 The three sub ranges which develop in this manner mean the following The diagrams permit the determi...

Page 155: ...ve high temperature corrosion The ash content determines the mechanical wear So preference should be given to heavy fuel with a low ash content Mixing of fuel components to obtain the desired viscosit...

Page 156: ...hich could not be separated in a simple separating process mixing proportions 1 3000 to 1 6000 Proven additives can be obtained from most oil or additive suppliers b Additives against high termperatur...

Page 157: ...Regulations and care CCAI limit curves A4 05 07 03 01 M20 M601C en 28 05 1998 BA000178 1 1 CCAI limit curves Density kg l 15 C to be avoided limited approved permissible Viscosity cSt 50 C...

Page 158: ...ble X admissible in connection with suitable treatment system only increased density limit Caution Observe CCAI limit curves A4 05 07 03 nn Limit M 20 M25 M32 M43 specification CIMAC A10 X X X X CIMAC...

Page 159: ...m m max 0 10 0 10 0 10 0 15 0 15 0 15 7 0 15 7 0 15 7 Total sedim after ageing Totaler Sedimentanfall nach Alterung m m max 0 10 0 10 0 10 0 10 0 10 0 10 Water Wasser V V max 0 5 0 5 0 5 0 5 0 5 0 5...

Page 160: ...Regulations and care Viscosity temperature sheet A4 05 07 06 M20 M601C en 28 06 1996 BA000190 1 1...

Page 161: ...uboil con sumption also indicated a special oiltype should be used after consultation with MaK 1 1 Base Oil The base oil should be a high quality solvent refined product from a source suitable for eng...

Page 162: ...oil when operating on heavy fuel the installation of an Automatic back flush filter in conjunction with a following indicator filter as double filter is necessary See the details in the Instructions f...

Page 163: ...M X ESSOLUBE X 301 X MOBIL MOBILGARD 412 X MOBILGARD ADL X MOBILGARD M430 1 X MOBILGARD 1 SHC 2 X DELVAC 1640 X SHELL GADINIA X GADINIA AL X SIRIUS FB X ARGINA S X ARGINA T 1 X TEXACO TARO 12 XD X TAR...

Page 164: ...PLUS 404 X CHEVRON DELO 3000 MARINE OIL X DELO 3400 MARINE OIL X ESSO EXXMAR 30 TP X EXXMAR 40 TP X EXXMAR 30 TP PLUS X EXXMAR 40 TP PLUS X MOBIL MOBILGARD M430 X MOBILGARD M440 X MOBILGARD M50 X SHE...

Page 165: ...ating oil consumption rates of 1 g kWh which in individual cases may even be significantly below this value Under such conditions and due to the low refilling requirement the usability limit can alrea...

Page 166: ...engine is running on gas oil or MDO the total base number must not fall below 50 of the value of the new oil If only the base number has reached the lower limit and the other analysis values show a sa...

Page 167: ...itted with a normal 15W40 multipurpose oil Lubricating oil firm Lubricating oil brand AGIP OSO 68 OTE 68 DICREA SX 68 1 BP ENERGOL SHF HV 68 ENERGOL THB 68 ENERSYN TC S 68 1 CALTEX RANDO HD 68 REGAL R...

Page 168: ...onified consistency number 2 also suitable for pneu matic control instruments Lubricating oil firm Brand name AGIP GR MU 2 BP ENERGREASE MP MG 2 CALTEX MULTIFAK EP 2 CASTROL SPHEEROL SX 2 CHEVRON DURA...

Page 169: ...If the the preperation monitoring and maintenance work are not carried out properly even a short period of operation may result in damages due to corrosion Three decisive facts are to be considerd fo...

Page 170: ...his purpose if corrosion inhibiting oils are used Dosing For 1 dPH 21 4 g Mg SO4 per ton of water are required German total Permanent hardness Carbonate hardness dGH dPH dKH Comparison with other valu...

Page 171: ...of systems heating living quarters by engine cooling water or in case of shell cooling In this cases use only chemicals 1 1 Anti corrosion oil The fresh water is mixed outside the engine with anti co...

Page 172: ...pite of their good properties due to their poisonous nature Using and checking procedures must be obtained from the manufacturers taking particular care not to use any poisonous substance it fresh wat...

Page 173: ...order 1 Concentration too high possibly incorrect measurement In case the measured values are higher than 1 5 test again with fresh sample water If the result is confirmed a correction of the emulsio...

Page 174: ...he entire system Remove water inlets on the crankcase and flush out any sludge which may have formed Fill engine with an alkali solution e g P3T 308 from Messrs Henkel 0 5 solution and run it for appr...

Page 175: ...ater with anti freeze in it and replace it with cooling water with chemical corrosion protection in order to guarantee adequate radiator performance at higher ambient temperatures 3 Cleaning the cooli...

Page 176: ...r 19 dGH To determine the fresh water mixture proceed from the abscissa Cooling system capacity 2300 l via the intersection of the 19 dGH line to the ordinate Amount used and read off the amount of wa...

Page 177: ...gram III Emulsion freshening for excessive concentration amount of oil to be added in litres to obtain a 0 7 oil concentration measured oil concentration in vol amount of cooling water in circuit m 3...

Page 178: ...Maintenance A5 en 26 05 2009 AA000026 1 1 Maintenance...

Page 179: ...alve Rotor A5 05 01 03 01 00 Valve guide Oil scraper ring A5 05 01 05 01 01 Media guiding system A5 05 01 05 50 01 Cylinder Head A5 05 01 06 01 30 Nozzle sleeve A5 05 01 06 50 03 Relief Valve A5 05 01...

Page 180: ...02 06 02 04 Piston Rings and Grooves A5 05 02 07 01 01 Piston Pin A5 05 02 08 01 00 Small End Bearing A5 05 02 09 01 01 Piston A5 05 02 10 01 30 Engine housing A5 05 03 Explosion relief valve A5 05 0...

Page 181: ...r A5 05 06 14 01 00 Engine fuel system A5 05 07 Injection Pump A5 05 07 02 01 00 Injection Pump A5 05 07 03 01 03 Deflector Bolts A5 05 07 03 02 00 Pressure Valve A5 05 07 03 03 00 Injection Pump A5 0...

Page 182: ...ches A5 05 11 01 02 01 RPM Switch A5 05 11 05 01 02 Lubricating Oil Cooling Water Thermostat A5 05 11 06 01 01 Pressure Switch A5 05 11 06 05 02 Pressure Switch A5 05 11 06 06 02 Crankcase Monitoring...

Page 183: ...nance It is the purpose of the maintenance to replace parts subject to wear and tear or to repair these parts before they are damaged The Scheduled maintenance is thereby supported by inspections acco...

Page 184: ...erval schedule is subdivided into the following four areas Daily inspection and control work Initial inspection and maintenance work Work which has to be carried out after first commissioning or commi...

Page 185: ...Title of the job card Activity Maintenance work en 30 09 91 IB000003 1 1 Language Date of issue Registration number Page number of pages See also 01 01 01 nn 01 02 01 nn 01 08 01 nn Spare parts list B...

Page 186: ...is required The fourth pair of digits indicates the type of variant See job card Reference is made to other job cards required for maintenance work At this point the types of variants fourth pair of d...

Page 187: ...nance schedule Periodic maintenance work A large scale plan showing all maintenance work up to the largest maintenance interval clearly indicating all occurrences and the future work expenditure for t...

Page 188: ...uld be disposed of immediately and above all it should be taken care that this material is not overheated even by accident e g during combustion and welding operations If this should however has happe...

Page 189: ...or stand under suspended loads When carrying out overhead assembly work the specially designed or safety oriented climbing aids are to be used only Do not use engine plant parts for climbing on Keep a...

Page 190: ...maintenance work is being carried out have to be if prescribed shut off at the power supply and provided with the notice Do not switch on or the corresponding warning sign 1 4 Working with hydraulic d...

Page 191: ...5 C Observe instructions for use in accordance with DIN safety data sheet of the regulati ons for dangerous substances Observe the specialist disposal of all cleansing agents and chemicals in accordan...

Page 192: ...oler Temperature Charge air A1 10 Upstream charge air cooler downstream charge air cooler Temperature Exhaust gas A1 10 After cylinder downstream turbocharger Pressure Lubricating oil A1 05 At the mai...

Page 193: ...M43 VM43 en 26 05 2009 AA000649 2 10 Intervall Designation Doc Nr Work to be carried out Remarks Fuel system Fuel duplex filter A5 05 07 12 01 08 Maintenance Cleaning at 50 differential pressure Pres...

Page 194: ...first commissioning or after major repairs 24 h Duplex fuel filter A5 05 07 12 01 08 Maintenance Cleaning Strainer 24 h Lubricating oil duplex filter A5 05 08 04 01 01 Maintenance Cleaning Cartridges...

Page 195: ...ng see book C 150 h Prelubricating pump Prelubrication A5 05 08 10 00 00 Maintenance Checking 750 h Control shaft bearings A5 05 05 01 02 00 Maintenance Checking 750 h Cooling water system A4 05 09 01...

Page 196: ...d reassembly 7 500 h Anti corrosion oil emulsion A4 05 09 02 Change 7 500 h Inlet and exhaust valve cone A5 05 01 07 01 03 Inspection Disassembly and reassembly of one cylinder unit 7 500 h Piston rin...

Page 197: ...pection Replace 15 000 h Nozzle sleeve A5 05 01 06 50 03 Maintenance Disassembly and reassembly 15 000 h Inlet and exhaust valve cones A5 05 01 07 01 03 Inspection Disassembly and reassembly of all va...

Page 198: ...g device A5 05 12 08 01 01 Maintenance Disassembly and reassembly 22 500 h Pressure switch A5 05 11 06 05 02 Inspection Replace 24 000 h Exhaust gas turbocharger A5 05 06 14 01 00 Maintenance Disassem...

Page 199: ...00 Inspection Checking at all bearings 30 000 h Camshaft bearings A5 05 04 01 02 00 Inspection Disassembly and reassembly 30 000 h Vibration damper on camshaft A5 05 04 09 02 30 Repair Disassembly and...

Page 200: ...05 01 08 02 00 Repair Checking Valve seat ring inlet outlet A5 05 01 08 03 00 Repair Replace Cylinder head A5 05 01 11 01 30 Repair Reassembly Crank web deflection A5 05 02 02 01 00 Inspection Checkin...

Page 201: ...reassembly Injection pump A5 05 07 02 01 00 Repair Disassembly and reassembly Pressure valve A5 05 07 03 03 00 Maintenance Disassembly and reassembly Injection pump A5 05 07 04 01 00 Maintenance Repla...

Page 202: ...2 1 9075 003 no picture Note Valve clearance may only be checked with the engine at operating temperature i e 15 minutes after the engine has been stopped Valve clearance Fig 1 S Intake 0 4 mm Exhaust...

Page 203: ...4 and tighten lock nut 3 with M 250 Nm 1 9 Check absence of clearance at X and Y with feeler gauge of 0 02 mm W2 Afterwards adjust valve clearance S as per instruction 2 Set valve clearance 2 1 Measur...

Page 204: ...33420 A high pressure hose W1 3 433420 E Auxiliary materials Molykote Paste G Rapid Plus or equivalent product Attention High pressure lines may not be bent below minimum bending radius r 250 mm Unit...

Page 205: ...pressure pump by means of the high pressure lines W1 2 W1 3 1 5 3 Pull the hydraulic piston completely down via the threaded sleeve and with the hydraulic valve of the high pressure pump open 4 5 turn...

Page 206: ...ote paste G Rapid Plus to the threads and contact surface for the nuts and tighten by hand 2 5 Tighten the four rocker arm bracket bolts with the hydraulic clamping unit 2 5 1 Place the hydraulic clam...

Page 207: ...rly Reduce pressure by 50 bar The round nuts must be tight enough that they cannot be loosened with the pin 2 5 7 Depressurize the clamping elements dismantle the clamping unit 2 5 8 Repeat installati...

Page 208: ...k bearing clearance every 30 000 h Note The liners may only be lubricated with oil Molykote paste may not be used for installing the bushings Procedure 1 Disassembly 1 1 Remove securing rings Fig 1 4...

Page 209: ...4 Measure the rocker arm bush Fig 2 13 and shaft Fig 1 3 and replace the bush when the clearance meets or exceeds the wear limit 01 02 03 nn New clearance Wear limit mm mm 0 056 0 208 0 30 5 Assembly...

Page 210: ...liners may only be lubricated with oil Molykote paste may not be used for installing the liners Procedure 1 Measure the rocker arm bush 1 and 01 02 02 nn 2 Replace 2 1 Drive out the bush 1 with the p...

Page 211: ...ve rotor and the free wheels every 150 h Note The valve rotational speed in relation to the engine speed must be measured and documented when the new or overhauled cylinder cover is taken into service...

Page 212: ...mixture mixture ratio 1 1 if the rotational speed is noticeably slower than the speed indicated for new valves 2 1 If the valve rotational speed slows to n 1 min 1 at the rated engine speed the valve...

Page 213: ...ement 1 Pers 0 20 h Personnel qualification skilled engine hand Operating medium Heavy fuel Inspection of the valve guide clearance of the intake and exhaust valves after 15 000 h Auxiliary materials...

Page 214: ...be twisted during instal lation 2 Measuring the valve guide clearance 2 1 Measure the outer diameter of the valve shaft in the guide area of the bush 2 2 Measure the inner diameter of the guide across...

Page 215: ...equirement 1 Pers 0 25 h Personnel qualification skilled engine hand Operating medium Heavy fuel and distillate fuel Auxiliary material Vaseline or a product of equal standard Sequence of operations 1...

Page 216: ...cting flanges 1 2 1 3 Check the O rings 14 Replace faulty O rings 14 Insert the O rings in the grooves using vaseline and making sure that they are not twisted 1 4 Remove hexagon screws Fig 1 21 and e...

Page 217: ...B024333 3 4 01 1 6 Remove the cheese head screws Fig 3 22 with connecting flange 8 1 7 Pull the sleeves 10 out of the media block 6 1 8 Check the O rings 15 Replace faulty O rings 15 1 9 Remove lubric...

Page 218: ...probe refit the connector and submerge the tip of the alarm probe in a medi um Acknowledge the alarm if an alarm is triggered If an alarm is not triggered replace the alarm pro be and repeat the test...

Page 219: ...gon screw W5 431011 A Attention Do not fall short of minimum bending radius r 250 mm for high pressure hoses Only use hydraulic oil as operating medium Store devices protected against corrosion Safety...

Page 220: ...arm bracket 01 02 01 nn Note To prevent damage and ensure trouble free assembly and disassembly the complete rocker arm bracket must be removed 5 Remove injection pressure pipe 07 05 01 nn 6 Remove i...

Page 221: ...Secure the coupling that is not connected by means of plug 8 10 3 Close valve on high pressure pump and extend all 6 cylinder head screws simultaneously and continuously using a hydraulic pressure of...

Page 222: ...nto cylinder head Fit cylinder head lifting device W2 Lift cylin der head with hoist Watch for push rod bushing Attention Risk of damage for conduit connection cylinder head screws push rods fuel pres...

Page 223: ...t of O rings every 15 000 h Tools wrench for nozzle sleeve W1 432119 A torque wrench 200 500 Nm W2 1 9454 500 brass mandrel W3 no illustration Auxiliary material Vaseline Adhesive and sealant Loctite...

Page 224: ...ove the O rings 4 and 5 2 Install nozzle sleeve 1 2 1 Insert new O ring 71 x 3 55 with Vaseline in the lower groove 5 without twisting 2 2 Insert new O ring 72 69 x 2 62 with Vaseline in the upper gro...

Page 225: ...Pers 0 20 h Personnel qualification skilled engine hand Operating medium Heavy fuel and distillate fuel Maintenance Replacement of relief valve every 30 000 h Tools Torque wrench 20 200 Nm W1 1 9454 2...

Page 226: ...ief valve 3 by means of a wrench and remove it 4 Lubricate the thread of the new relief valve with high temperature thread paste Dag 5420 A 5 Mount new relief valve 3 with new joint ring 4 6 Firmly ti...

Page 227: ...l intake and exhaust valve cones every 15 000 h Tools Valve spring compressor unit W1 439222 D Pliers for circlips W2 1 9067 440 no picture Auxiliary materials Molykote Paste G Rapid Plus or equivalen...

Page 228: ...valve cone stem so as to engage 1 3 4 Press sleeve 12 above split spindle end and mount pin 10 1 4 Remove circlip 5 by means of pliers W2 Compress valve spring 3 by turning the stem of device 13 and...

Page 229: ...ed from such val ve cones before disassembly Valve cone valve seat repair 01 08 01 nn 01 08 02 nn 2 Assembly 2 1 Check valve guide clearance replace O ring 01 05 01 nn 2 2 Oil the de burred valve cone...

Page 230: ...ating time the inspection reveals damaged sealing surfaces deep graining uneven wear pattern on the valve cone seat Sequence of operations 1 Cleaning 1 Clean the valve stem Experience has shown that a...

Page 231: ...is HT corrosion as shown below i e no deep craters over the entire area of the bottom side of the valve heads the straightness deviation does not exceed the following values Fig 1 Span s 495 6 mm Cont...

Page 232: ...aged cracks blow by there is burnout s caused by high temperature corrosion on the underside of the valve head 2 5 mm Fig 2 there is coarse graining on the undesi de of the valve head so called co bbl...

Page 233: ...tive grinding machine manufacturer 3 3 After grinding measure the distance between the visible edge of the plating X and outer edge of the seat surface The valve cone must be replaced when the di stan...

Page 234: ...dure should not amount to more than 30 50 of the seat width b starting from the outside diameter 4 3 If the contact surface does not appear to be in good order do not regrind any more but rework both...

Page 235: ...24 B no picture Auxiliary materials Illuminated magnifying glass 8x magnification Diamond paste Dp 30 10 15 m Thinner DIAPLASTOL or equivalent product Note If the sealing surface of the valve seat val...

Page 236: ...en 18 05 2006 IB004816 2 5 01 Procedure 1 Inspection The grade hardness of the valve seat is designed to allow the seat to adapt to the valve cone to a certain extent Carbon deposits are therefore nor...

Page 237: ...surface the seat surface is burned through the reworking limit has been exceeded 2 Cleaning Clean all deposits and soil from the seat surface 3 Repair reworking the valve seat rings Note The seat rin...

Page 238: ...stance 3 1 4 Mill the valve seat in a single motion by turning to the right turn the rig as far as possible The bla des must cut noticeably Adjust the cutting pressure depending on how the cut feels A...

Page 239: ...ith moderate pressure The contact surface a which is visible after the grinding procedure should not amount to more than 30 50 of the seat width b around the entire edge of the entire circumference 01...

Page 240: ...cones which can no longer be used at the shaft end Fig 1 1 and be zel the resulting gap 2 to prevent defor mation Turn the valve head to ca 116 mm inner diameter of seat ring 2 Place the valve cone i...

Page 241: ...cone strike lightly Apply a light coating of Mo lykote paste G Rapid to the threading and contact surface of the nut Fig 2 1 Tighten nut 1 to M 150 Nm Next hold the seat ring in this position with a...

Page 242: ...cking Check starting valve of one cylinder for easy movement all 3 750 h For V engines only on cyl bank A Attention When working on the starter system close the main valves on the pressure tanks bleed...

Page 243: ...ition quickly and easily Note Do not move spindle 9 by turning locknut 3 5 If the parts do not move freely lubricate the piston 5 and guide in the cylinder head with engine oil 6 Fit cover 1 with new...

Page 244: ...r equivalent product Attention When working on the starter system close the main valves on the pressure tanks bleed the line and block the starting valve Procedure 1 Disassembly 1 1 Remove the rocker...

Page 245: ...ghten adjusting screw 20 until a slight resistance is felt Then tighten adjusting screw another 1 4 turn to set cutting pressure 1 9 4 Turn reseating tool evenly and slowly without additional pressure...

Page 246: ...eri phery Insert piston using insertion ring W1 2 2 Installation is completed in the reverse order as disassembly Replace O ring 2 Make sure that the clamping ring 4 is installed correctly Tighten the...

Page 247: ...ngine hand Operating medium Heavy fuel and distillate fuel Inspection inspect the cylinder head every 150 h Procedure 1 Check gasket between cylinder head cylinder liner and coolant distributor housin...

Page 248: ...If leaks are found at the media supply connecting flanges check all bolts to ensure that they are tight Replace gaskets as needed 3 Remove valve cover Inspect the top of the cylinder head 3 1 Check t...

Page 249: ...starter valve and rocker arm bracket 1 Clean cylinder block with cold cleaning solution 2 Clean intake and outlet ports underside of cylinder head not the valve seats with a wire brush and scraper al...

Page 250: ...illed engine hand Operating medium Heavy fuel and distillate fuel Tools See maintenance sheet 01 06 01 nn Ancillary materials High temperature threading paste Dag S 5080 Molykote paste G Rapid Plus Va...

Page 251: ...ylinder bushing and check for damage Insert new sealing ring Fig 1 1 into cylinder bushing collar Check and clean sealing surface at exhaust pipe 06 01 01 nn 3 Replace the following O rings Top O ring...

Page 252: ...ter manifold housing Ensure horizontal position of cylinder head on supporting surface 5 Align cylinder head Fit clamp for exhaust pipe and hook in chain links 06 01 01 nn Grease screw with high tempe...

Page 253: ...not activated otherwise the tightening is wrong 6 4 Tighten round nuts with pin firmly Ensure smooth movement 6 5 Check the firm contact of the round nut Reduce pressure by 50 bar It should no longer...

Page 254: ...ase cover approx 10 min after shutting down the engine 3 Check crankshaft bearings and big end bearings for even and normal temperatures 4 Visually check screws and nuts 5 Check extent of soiling of t...

Page 255: ...a web pair during one rotation of the crankshaft Fig 1 Depending on the location of the engine the rigidness of the foundation and the ship different values are given in comparison with loaded and unl...

Page 256: ...nt initial position 3 Turn the crankshaft so that the journal turns in the direction of the exhaust side and the dial gauge moves towards the control side 4 Watch the dial gauge and read the values fo...

Page 257: ...nes which are subject to higher load allow less deflection as engines which are subject to lo wer loads The values indicated here may not be exceeded if permissible web deflection tolerance for the re...

Page 258: ...Crank Web Deflection Inspection Measuring A5 05 02 02 01 00 M43 en 24 04 2006 IB020114 4 4 02...

Page 259: ...er to avoid unnecessarily shortening bearing life note the following Oil temperature and pressure requirements see A1 05 and A1 06 Oil brand recommendations viscosity class see A4 05 08 nn Information...

Page 260: ...nt flash on the bearing ca 3 m is worn through after a short operating period The bearing need only be replaced after heavy scoring a clearance limit has been exceeded or in accordance with the applic...

Page 261: ...engine oil do not tend to have a significant influence on the operating safety of a sliding bearing This bearing shell can be reused Fig 2 The wear pattern is even across the entire width of the bear...

Page 262: ...ar pattern includes a large area of damage with varying degrees of fretting This bearing shell can not be used again both bearing shells must be replaced Find and correct the cause of this damage Chec...

Page 263: ...Bearing Shells Inspection Evaluate A5 05 02 03 07 01 M43 VM43 en 05 06 2003 IB020121 3 4 02...

Page 264: ...Bearing Shells Inspection Evaluate A5 05 02 03 07 01 M43 VM43 en 05 06 2003 IB020121 4 4 02...

Page 265: ...Hydraulic set consisting of High pressure pump W1 High pressure line W2 433420 A High pressure line W3 433420 E Hydraulic clamping elements W4 1 9213 N Pin W5 Big end bearing installation and disasse...

Page 266: ...g 3 1 Place and tighten the hydraulic clamping elements W4 over the round nuts 2 Ensure that the slits are easily accessible Loosen hydraulic clamping elements by 1 turn 3 2 Connect the hydraulic clam...

Page 267: ...ay stretch which can cau se the round nuts to lock into place 6 Open valve of the high pressure pump W1 hydraulic jacks are relieved of tension 7 Wait until no pressure is left dismount hydraulic devi...

Page 268: ...rings Inspection Disassembly A5 05 02 04 01 30 30000 15000 M43 en 03 05 2004 IB024444 4 6 02 9 3 Tighten hexagon nuts 12 9 4 Mount guide rail extension 13 with carriage 14 on camshaft side 11 10 12 3...

Page 269: ...suspension 18 with carriage 14 12 Unscrew round nuts 2 13 Drive big end bearing cap 15 to the camshaft side out of the crankcase Remove bearing shell 19 14 Fix big end bearing cap 15 at the crane and...

Page 270: ...8 Dismount connecting rod holder at the counterweight 02 06 01 nn 19 Drive connecting rod 17 to the camshaft side out of the crankcase Remove bearing shell 20 20 Sling suspension 16 with suspended con...

Page 271: ...aps bearing shells connecting rod eyes and connecting rods are labeled according to the cylinder to which they belong and may not be switched around New parts must be labeled accordingly Procedure 1 B...

Page 272: ...crane and lift Mount connec tion to the carriage 14 1 5 Remove sling 1 6 Push connecting rod 17 towards the crank pin up to approx 20 mm 1 7 Put upper bearing shell without holes on the crank pin and...

Page 273: ...d holder at counterweight n 02 06 01 nn Secure connecting additionally with screw 20 at connecting rod holder 1 10 Dismount suspension 16 1 11 Turn connecting rod 17 downward by 180 so that the connec...

Page 274: ...end bearing cap 15 at crane and connect suspension 18 with carriage 14 at guide rail extension 13 1 14 Remove sling 1 15 Push big end bearing cap 15 towards the crank pin up to approx 160 mm Attention...

Page 275: ...the big end bearing bore 1 17 Push big end bearing cap 15 carefully against bearing shell 19 and bottom end of connecting rod The lug of the bearing shell must be exactly positioned in the notch of th...

Page 276: ...nd bolts 3 with washer 4 Assemble washer 4 with chamfer pointing towards bottom end of connecting rod 1 19 Install round nuts 5 and tighten by hand 1 20 Remove installation disassembly unit W6 1 21 Ch...

Page 277: ...big end bearing bolt at camshaft side steplessly hydraulic pressure p 85 bar 2 5 Firmly tighten the round nut 5 at cams haft side with a pin W5 2 6 Open the valve of the high pressure pump W1 the clam...

Page 278: ...Visual check of angle of rotation 180 22 2 12 Check to ensure that the round nut is seated properly Reduce pressure by 50 bar The round nuts must be tight enough so that they cannot be loosened with...

Page 279: ...e fuel Maintenance Exchange of all seals Tools Fork wrench W1 436500 C Torque wrench 20 200 Nm W2 1 9454 202 no illustration Auxiliary means Molykote paste G Rapid Plus or equivalent Sequence of opera...

Page 280: ...int rings in too much 2 3 Press piston 3 into the cylinder Attention Do not tilt the piston 3 2 4 Mount cup spring pack 2 2 5 Screw cover 1 on using fork wrench W1 and tighten Note Please note that th...

Page 281: ...ngs every 30 000 h Tools Hydraulic set consisting of High pressure pump W1 High pressure line 3 x 1m W2 433420 A Pin W3 Hydraulic tightening element lateral uniform strength bolts W4 1 9213 F Hydrauli...

Page 282: ...rocedure 1 Remove crankshaft bearings 1 1 Open the corresponding crankcase cover on the control and exhaust side 1 2 Turn the crankshaft to the position which removal can be completed most easily 1 2...

Page 283: ...into place 1 3 6 Open the valve on the high pressure pump the hydraulic clamping element is depressurized 1 3 7 Wait until the pressure drops completely Remove the hydraulic clamping element 1 3 8 Rep...

Page 284: ...en 04 05 2004 IB024452 4 9 02 1 4 2 Connect the hydraulic cylinder of the rig W10 to the high pressure pump W1 by means of the high pressure line W2 1 4 3 Bring the carrying arm into position and pla...

Page 285: ...ping element on the round nut 12 and tighten Make sure that the slits 13 are easily accessible Loosen hydraulic clamping elements by 1 turn 1 4 7 Repeat the installation procedure on the opposite side...

Page 286: ...can cause the round nuts to lock into place 1 5 Open the valve on the high pressure pump the hydraulic clamping elements W5 are depressu rized 1 5 1 Wait until the pressure reduces completely Remove...

Page 287: ...er to the plate Remove the round nuts 1 8 Lower the carrying arm carefully to the lower stop with the main bearing cover and lower bearing shell 1 9 Remove the lower bearing shell 1 10 Place the carri...

Page 288: ...Wear Nominal size current size 1 14 The bearing shells must be changed when the wear reaches 0 05 mm Nominal size 8 820 0 025 mm Attention If measurements indicate that the bea ring shells need to be...

Page 289: ...B024452 9 9 02 2 1 2 Raise the bearing cap with the rig Tighten the round nuts until the bearing shells barely touch 2 1 3 Measure the gap K between the crankcase and the bearing cover on the exhaust...

Page 290: ...ykote Paste G Rapid Plus or equivalent product Attention High pressure lines may not be bent below minimum bending radius r 250 mm The high pressure pump may only be operated with hydraulic oil Protec...

Page 291: ...d turn the bearing shell into the bearing as far as possible Place the carri er W11 into the oil bore until it stops Attention Bearing shell designation on the opposite control side 1 2 Insert turning...

Page 292: ...cover to the upper stop Be careful not to damage the main bearing bolts 2 2 Screw round nuts onto main bearing bolts evenly and tighten by hand with pin 2 3 Remove bearing cap mounts on plate Note Me...

Page 293: ...iform strength bolts with a pressure of p 2250 bar Attention The pressure must remain constant when the hydraulic pump is not being actuated to pre vent the bolts from being tightened incorrectly 3 11...

Page 294: ...9 5 6 02 4 2 Place the hydraulic clamping element W5 level on the plate above the chute Remove the chute 4 3 Raise the carrying arm Place the hydraulic clamping element on the round nut 12 and tighten...

Page 295: ...2 with a pin Check to ensure good action no stiffness 4 8 Check to ensure that the round nut is seated properly Reduce pressure by 50 bar The round nuts must be tight enough that they cannot be loosen...

Page 296: ...Rig W10 439214 A Carrier W11 439225 B Lashing eye M20 W12 no picture Attention High pressure lines may not be bent below minimum bending radius r 250 mm The high pressure pump may only be operated wi...

Page 297: ...iner and place against crankcase 1 3 Slide the crankshaft with a suitable hydraulic unit until it rests firmly against the thrust washer seg ments Set the dial gauge to zero and slide the crankshaft i...

Page 298: ...W1 by means of the high pressure line W2 Secure the coupling that is not connected by means of plug 2 2 4 Close the valve on the high pressure pump W1 and apply force to uniform strength bolt with a p...

Page 299: ...4 IB024463 4 9 02 2 3 Insert rig 2 3 1 Lift the rig W10 into the crankcase collapsed and place in the guide rails of the oil pan Insert carrier arm 2 3 2 Connect the hydraulic cylinder in the rig W10...

Page 300: ...ankcase and carrying arm 2 3 4 Loosen the round nuts on the crankshaft bearing bolts with the hydraulic rig 2 3 5 Place the hydraulic clamping element W5 level on the plate above the chute 10 Remove t...

Page 301: ...ed with the pin the pressure on the uniform strength bolts can be increased to p 50 bar more If the pressure is increased further the threading may stretch which can cause the round nuts to lock into...

Page 302: ...8 Run the carrying arm of the rig W10 to the crankshaft bearing cover Bolt the bearing cover to the plate Remove the round nuts 2 9 Lower the carrying arm with main bearing cover and bottom bearing sh...

Page 303: ...xial clearance see step 1 Only remove the upper thrust washer seg ments if they need to be replaced 2 16 Remove the lower bearing shell 2 17 Place the carrier W11 into the oil bore in the crankshaft u...

Page 304: ...nd nuts 12 hydraulically Lower the rig see step 2 3 3 2 Raise the bearing cap with the rig Tighten the round nuts until the bearing shells barely touch 3 3 Measure the gap K between the crankcase and...

Page 305: ...roduct Attention High pressure lines may not be bent below minimum bending radius r 250 mm The high pressure pump may only be operated with hydraulic oil Protect hydraulic equipment from corrosion dur...

Page 306: ...the back of the bearing and turn the bearing shell into the bearing as far as possible Place the carri er W11 into the oil bore until it stops Attention Bearing shell designation on the opposite cont...

Page 307: ...12 1 5 Oil the running surface of the lower bearing shell dry the back of the bearing and insert in main bearing cover Raise the rig again Attention The positioning nose on the lower shell is on the c...

Page 308: ...n the operating side to the high pressure pump W1 by means of the high pressure line W2 Secure the coupling that is not connected by means of plug 3 4 Close the valve on the high pressure pump and ext...

Page 309: ...ce pressure by 50 bar The round nut must be tight enough that it cannot be loosened with a pin 3 12 Open the valve on the high pressure pump W1 the clamping elements W4 are depressurized 3 13 Wait unt...

Page 310: ...lace the hydraulic clamping element on the round nut 12 and tighten Make sure that the slits 13 are easily accessible 4 4 Repeat the installation procedure on the opposite side 4 5 Connect the hydraul...

Page 311: ...round nuts must be tight enough that they cannot be loosened with the pin 4 9 Open the valve on the high pressure pump W1 the clamping elements are depressurized 4 10 Wait until the pressure reduces...

Page 312: ...ools Piston lifting unit W1 432134 A Hydraulic set consisting of High pressure pump W3 High pressure line W4 433420 A Hydraulic wrench consisting of Hydraulic wrench W5 435100 A Sockets W6 435102 A Sp...

Page 313: ...om the area above TDC for 1st piston ring up to gauging ring Do not damage the cylinder liner surface 6 Turn the upper piston edge up to just below the gauging ring Fig 2 4 7 Insert disassembly unit W...

Page 314: ...embly A5 05 02 06 01 30 M43 en 05 05 2004 IB024471 3 5 02 14 Split the connecting rod shank 14 1 Insert a socket wrench with a square head Fig 3 W6 in the hydraulic wrench W5 Mount the support Fig 4 W...

Page 315: ...is connected Safety note During pressure build up no parts of the body between support of the hydraulic wrench and connecting rod or balance weight 14 4 Close the valve on the high pressure pump W3 a...

Page 316: ...en 05 05 2004 IB024471 5 5 02 Attention Remove the big end if the piston will be stored for a longer period of time to prevent vibra tion damage in the cylinder liner area 19 Seal off the oil bore in...

Page 317: ...orque wrench 200 500 Nm W4 1 9454 500 no picture Auxiliary materials Molykote Paste G n plus or equivalent product Procedure 1 Turn the piston 1 1 Attach crane to piston lifting unit Fig 1 W1 lift pis...

Page 318: ...xagon nuts Fig 3 5 and remove with piston skirt 12 2 4 Clean piston crown 8 and piston skirt 12 Make sure that the contact surfaces of piston parts and spacer sleeves 6 are clean Attention Check the c...

Page 319: ...2 6 Piston assembly 2 7 Clean the contact surfaces of piston skirt 12 and piston crown 8 and check for unevenness Carefully smooth out any raised spots with oil stone 2 8 Clean bores for piston screws...

Page 320: ...crosswise to a torque of M 170 Nm 2 14 Loosen hexagon nuts again 2 15 Retighten piston screws 7 in the piston crown torque M 40 Nm 2 16 Tighten hexagon nuts 5 crosswise to a torque of M 60 Nm and then...

Page 321: ...inspection of all pi stons can be postponed to a later point in time if the mechanic decides to do so the inspection cannot be postponed for more than 30 000 operating hours During the inspection spec...

Page 322: ...away entirely or in sections all rings for the respective pi ston must be replaced If the chrome layer is worn on one of the rings the rings on all pistons must be checked 1 7 Clean the pistons ring...

Page 323: ...th the piston ring pliers Fig 1 W1 Record the position of the ring joints relative to the installation position of the piston in the measurement report 2 4 Clean all rings and check the wear If the ch...

Page 324: ...Operating medium Heavy fuel and distillate fuel Tools Piston installation disassembly unit W1 439223 A Piston installation disassembly unit W2 439223 A Installation rig W3 439220 C Procedure 1 Turn t...

Page 325: ...ng When working with new parts the clearance may not be sufficient when the parts are cold Full clearan ce is reached when the parts are at operating temperature 2 5 Check the oil bores 6 in the conne...

Page 326: ...certified workshop The small end bearing in the offset connecting rod eye has an electroplated running surface see 02 03 03 nn The small end bearing is evaluated on the basis of the operating wear lim...

Page 327: ...43 en 29 07 2008 IB020357 2 3 02 Smallest Largest Operational clearance clearance clearance limit Connecting rod eye A 0 06 0 092 0 12 Piston pin C Small end bushing B 0 2 0 302 0 31 Piston pin C Eye...

Page 328: ...cracks corro sion damage or other damage Appropriate crack test material such as Magna Flux and a magnifying glass must be used for this Carefully remove any material deposits first Connecting rod eye...

Page 329: ...In order to prevent the cylinder liner from detaching during turning the cylinder liner must be lok ked securely with the cylinder liner retainer Fig 2 W9 After installing a new piston the engine must...

Page 330: ...iston installation ring W12 9 Attach piston to crane and lift Oil cylinder liner and piston base well 10 Place the piston into the cylinder liner ca refully the piston must be inserted exactly in line...

Page 331: ...rm strength bolts Fig 3 20 13 2 Place segments 21 on the connecting rod split and tighten uniform strength bolts hand tight with ring wrench 13 3 Remove connecting rod holder W8 02 06 01 nn 13 4 Tight...

Page 332: ...A6 05 90 10 nn Note the direction of rotation relocate the socket wrench with square head if necessary and turn the hydraulic wrench 13 6 Connect the hydraulic wrench W5 with the high pressure pump W...

Page 333: ...Attention Hold the hydraulic wrench securely when reducing pressure The wrench may slip from the head of the bolt 13 9 Note the position of the uniform strength bolts chalk mark it must be at an angl...

Page 334: ...specified spring tension is not pro vided any more in the event of abnormal oil contamination or if any leaks should be identified du ring operation Procedure 1 Check the relief valve from the inside...

Page 335: ...2 2 03 3 4 Tighten screws 8 to a torque of M 25 Nm 3 5 After assembly check the explosion relief valve for proper operation by actuating it by hand 3 6 When mounting the explosion relief valve on the...

Page 336: ...ts list B1 05 03 431110 Time requirement 1 Pers 0 50 h Personnel qualification skilled engine hand Operating medium Heavy fuel and distillate fuel Maintenance Replace O rings Tools Eye bolts M16 W1 Cy...

Page 337: ...stributor housing mounting bolts 3 Screw the eye bolts Fig 3 W1 into the coolant distributor housing 6 and lift housing with crane Attention The lower cylinder liner retainer must be installed 01 06 0...

Page 338: ...the crankcase with a crane Replace coolant block gasket Fig 2 7 2 2 Tighten coolant distributor housing moun ting bolts 3 2 3 Slide sleeves 2 for starting air channel into place and secure 2 4 Apply...

Page 339: ...ine gauge inside micrometer W2 1 9419 G no picture or equivalent measuring instrument Procedure 1 Check cylinder liner Note Unusual forms of wear may be found in cylinder liners de pending on the resp...

Page 340: ...der liners can only be reworked by Caterpillar MaK Cylinder liner wear chart Evaluation criteria Wear limit Explanation mm Nominal new Limit value for conically honed cylinder liners 430 0 0 063 Radiu...

Page 341: ...9217 A Attention The cylinder liner sealing surface must be protected from damage Procedure 1 Remove cylinder liner 1 1 Remove piston 02 06 01 nn Remove cylinder liner retainer W2 1 2 Measure wear 03...

Page 342: ...3 en 28 07 1999 IB020188 2 2 03 1 7 Clean the sealing surface and O ring groove thoroughly and check for damage 1 8 Clean coolant area on the cylinder liner collar thoroughly 1 9 Clean cylinder liner...

Page 343: ...Liquid beef suet or green potassium soap Note Take complete measurements after instal ling a new cylinder liner After installing a new cylinder liner the en gine must be broken in in accordance with t...

Page 344: ...steps 1 3 and 1 4 of the disas sembly instructions 03 04 01 nn Note Insert the cylinder liner so that the mark 5 Fig 2 X top view cylinder liner collar faces the cou pling side in the direction of the...

Page 345: ...leaks Procedure 1 Check the tightness and seal of the engine connecting flange filter control unit and the line con nections of the following systems Coolant Engine oil Fuel Starting air exhaust gas...

Page 346: ...ft bearings are subject to no load alternation The bearings are only loaded at the lower bearing area the load here is relatively high Light edging is not unusual Procedure 1 Check camshaft bearing cl...

Page 347: ...earings are only loaded at the lower bearing area the load here is relatively high Light edging is not unusual Procedure Attention The camshaft bearing between the camshaft gear and the 1st cylinder m...

Page 348: ...020282 2 5 04 1 4 Loosen the hex head bolts Fig 1 1 on the left flange of the camshaft section 3 Turn the cams haft to access and remove all bolts which are inaccessible Remove all hex head bolts Re p...

Page 349: ...led out far enough that the straight pin 5 and the recess are no longer engaged 1 5 Remove retaining bolt Fig 2 11 1 6 Drive the camshaft bearing 4 out to the right with a suitable wood block and rubb...

Page 350: ...th positioning bore 1 16 Install retaining bolt Fig 2 11 Tighten bolt to M 130 Nm Note Install the oscillation damper after checking the last camshaft bearing 04 09 01 nn 2 Check the running surface o...

Page 351: ...ation damper and the camshaft section above the 1st cylinder 2 7 Check the running surfaces of the bearing journals of all camshaft sections for scoring 2 8 Replace defective camshaft sections 04 04 0...

Page 352: ...1 2 Bracket with hexagon bolt W1 3 Carriage W1 4 Arm compl 3x W1 5 Support only on cyl 1 W1 6 Screw W1 7 Tubular hexagon box wrench W1 8 Torque wrench 200 500 Nm W2 1 9454 500 no picture Auxiliary mat...

Page 353: ...024513 2 7 04 1 8 Remove oil pipes 9 1 9 Remove clamping screw 10 and both lower fastening screws 11 1 10 Bring into position support W1 1 and firmly mount to cam follower bracket 1 11 Bring into posi...

Page 354: ...4 1 12 In case of disassembly and assembly at cylinder 1 mount support W1 6 Here the camshaft cov er is bigger 1 13 Mount guide rail W1 2 Firmly tighten the nuts only after having aligned all parts of...

Page 355: ...he cam follower bracket 1 17 Bring into position bracket with hoist W1 3 Attention Before that roll out valve drive a bit on carriage W1 4 Pay attention to spacer sheets 13 Spacer sheets 13 are adjust...

Page 356: ...ut valve drive completely on the carriage Attention Rope of the hoist must be evenly coiled otherwise there is a risk of injury 1 20 Separate support W1 1 from carriage W1 4 by removing screws W1 7 1...

Page 357: ...Screw together carriage W1 4 and support W1 1 Use screws W1 7 2 9 Carefully roll valve drive into camshaft casing 2 10 Make sure there is sufficient clearance for inlet and exhaust cam followers Possi...

Page 358: ...f screws 10 11 12 with Molykote Paste G Rapid Plus and tighten screws in two steps as follows Step 1 Preload screws to M 270 Nm Step 2 Mark screws and continue turning by a torque angle of 30 by means...

Page 359: ...Paste G Rapid Plus or equivalent product Procedure Attention The camshaft may only be turned after the bolted connection is loosened when the rocker arms of the camshaft section to be replaced and al...

Page 360: ...t of the cylinder being checked 07 03 01 nn 1 4 Remove the lifters and the camshaft section for the corresponding cylinder and all camshaft sec tions to the right of the camshaft section being removed...

Page 361: ...amper Fig 2 10 04 09 01 nn and slide to the right as far as possible 1 5 2 Remove the intermediate piece 12 1 6 Place the sling Fig 3 W1 around the camshaft section 3 between the exhaust cam and injec...

Page 362: ...th camshaft section 3 flanges Turn the engine to make access any inaccessible hex head bolts and remove all bolts from the left flange Replace two opposing hex head bolts with longer bolts W2 Set meas...

Page 363: ...ardboard or a similar material 1 15 Pull the camshaft section Fig 4 3 out of the bearing block to the left while lowering the lifting unit Swing the camshaft section 90 and lift from the camshaft trou...

Page 364: ...ore in the bearing journal or in the bearing flange built into the left end of the camshaft section 2 7 Attach the camshaft section to the right camshaft section flange by tightening two opposing hex...

Page 365: ...to M 420 Nm 2 16 After installing the last camshaft section 2 16 1 Place the intermediate piece Fig 2 12 on the camshaft section 3 securely The recess must be placed into the camshaft section complet...

Page 366: ...10 04 09 01 nn 2 17 Install valve actuators and the injection pump drives 2 18 Install the lifters 2 19 Install the rocker arms and check valve clearance 01 01 01 nn 2 20 Install injection pump 07 02...

Page 367: ...ine hand Operating medium Heavy fuel and distillate fuel Inspection of the tooth profiles and oil nozzle every 3 750 h the axial clearance of the step gear every 15 000 h Tools Dial gauge with bracket...

Page 368: ...camshaft gear Fig 1 2 step gear 1 and crankshaft gear 3 for pitting misaligned running loose metal etc 1 3 Measure the tooth clearance between the step gear and the camshaft gear 2 and between the ste...

Page 369: ...ce of the step gear Fig 2 s with a feeler gauge or dial gauge Nominal value s 0 6 1 1 mm If damage is found on the teeth or if one of the permissible nominal values tooth or axial clearance is exceede...

Page 370: ...parts list B1 05 04 435140 Time requirement 1 Pers 0 50 h Personnel qualification skilled engine hand Operating medium Heavy fuel and distillate fuel Tools Torque wrench 20 200 Nm W1 1 9454 202 Rever...

Page 371: ...ed Procedure 1 Replace the O ring Fig 2 6 on the step gear shaft 2 1 1 Loosen the hex head bolts 7 and 8 and remove with sleeves 5 and locking plates 3 and 4 1 2 Remove the crankcase cover for the 1st...

Page 372: ...024305 3 3 04 Attention Do not damage the O ring 6 1 5 Apply Molykote to the contact surfaces and threads of the hex head bolts 7 and 8 1 6 Mount hex head bolts 7 and hex head bolts 8 with sleeves 5 a...

Page 373: ...mediate wheel channel toothing of governor drive shaft end play of cam shaft toothed wheel Tools Torque wrench 20 200 Nm W1 1 9454 202 Reversible ratchet 1 2 W2 1 9459 033 not shown Ancillary material...

Page 374: ...screws Fig 2 20 with resilient sleeves 21 1 4 Lightly attach governor drive housing 23 with sling to hoist and carefully lift out of cylinder crank housing Attention Risk of damage to lubricating oil...

Page 375: ...profiles of hypoid gears Fig 3 40 41 for pitting off track running or blow outs Check intermediate wheel 42 1 8 Check channel toothing of governor drive shaft 43 and governor Fig 1 10 for wear clean...

Page 376: ...0 and dowel pins Fig 3 32 2 3 Insert screws Fig 2 20 with resilient sleeves 21 2 4 Tighten screws 20 crosswise 2 5 Brush bearing surface of governor with Dirko 610 020 Put governor Fig 1 10 onto beari...

Page 377: ...own Ancillary materials Molykote Paste G Rapid or equivalent product Note After 30 000 operating hours the vibration damper must be exchanged against a new one Procedure 1 Disassembly 1 1 Remove later...

Page 378: ...d reassembly A5 05 04 09 02 30 30000 M43 en 31 01 2008 IB025919 2 2 04 2 3 Slide new dampers 1 onto intermediate piece 4 and fit screws 2 with extension sleeves 3 2 4 Tighten connecting bolts 2 using...

Page 379: ...lever in the operating console and oil lightly at the bearing surfaces Attention After cleaning with solvents a light coat of oil must be applied to all glossy metal parts to protect them from rust a...

Page 380: ...00 h Tools Fork wrench W1 0 9105 A not available as figure Auxiliary material Molykote paste G Rapid or a product of equal standard Safety note Danger of accident Be careful during disassembly Positio...

Page 381: ...020586 2 4 05 Sequence of operations 1 Close the main shut off valve on the air receiver 1 1 Vent the air pipes on the engine 1 2 Disassemble all pipework and cable connections from the starting valve...

Page 382: ...the spring 10 3 4 Disassemble screw connection 11 and nut 12 3 5 Disassemble piston 13 by means of the fork wrench W1 Note When disassembling nut 12 and piston 13 secure the spindle 14 against being...

Page 383: ...all valve parts in inverse disassembly order 5 3 Assemble the emergency actuation knob 9 with a new spring 10 and a new O ring 20 Note Daub the threads of all fixing screws slightly with Molykote past...

Page 384: ...1 1 Disassemble the connection between the injection pump control rod Fig 1 7 and jointed lever 8 on the control shaft 1 2 Remove the bracket 6 from the jointed lever 1 3 Remove the bushings Fig 2 1...

Page 385: ...injection pump control rod by installing the pin 3 the washers 4 and 5 and a new nut 2 2 5 Tighten the nut 2 with a torque of M 40 Nm Attention Check the linkage for ease of movement by pressing agai...

Page 386: ...ce cleaning Drain compressed air filter every 24 h Disassemble and clean compressed air filter initially 150 h Disassemble and clean compressed air filter every 7 500 h Auxiliary material Nitro Solven...

Page 387: ...etely 2 2 Close compressed air feed line and secure 2 3 Relieve compressed air filter via drain plug 2 4 Loosen housing cap 5 and remove check O ring 1 and replace if necessary 2 5 Loosen Phillips scr...

Page 388: ...23 Time requirement 1 Pers 0 20 h Personnel qualification skilled engine hand Operating medium Heavy fuel and distillate fuel Maintenance cleaning Drain compressed air filter every 24 h Disassemble an...

Page 389: ...exhaust line after the turbine must be loosened and the pipe checked for distortion In order to prevent damage to the compensators they may not be subjected to bending or radial force during removal o...

Page 390: ...ompensators may not be subjected to bending or radial forces 4 2 Loosen the hex head bolts 1 far enough that the upper sections of the clamps 3 are still con nected but can be slid easily 4 3 Slide th...

Page 391: ...ieces install compensator s and bolt securely into place Note the indicated direction of flow when installing the compensators 4 see arrow on the flange Compensators may not be subjected to bending or...

Page 392: ...exhaust line after the turbine must be loosened and the pipe checked for distortion In order to prevent damage to the compensators they may not be subjected to bending or radial force during removal o...

Page 393: ...ompensators may not be subjected to bending or radial forces 4 2 Loosen the hex head bolts 1 far enough that the upper sections of the clamps 3 are still con nected but can be slid easily 4 3 Slide th...

Page 394: ...ieces install compensator s and bolt securely into place Note the indicated direction of flow when installing the compensators 4 see arrow on the flange Compensators may not be subjected to bending or...

Page 395: ...pressure before after the cooler exceeds 1 5 times the test bench value see acceptance brake certificate A1 10 Auxiliary materials Cleaning agent as recommended by the manufacturer such as Vecom GmbH...

Page 396: ...and lower into suitable container for cleaning 1 5 Clean the charge air cooler in accordance with the manufacturer s instructions see Book C 1 6 Inspect the housing drain all condensation by opening...

Page 397: ...2 into the housing 3 carefully Note Apply a light coat of Molykote paste G Rapid Plus to the contact surfaces and threads of all bolts 2 4 Insert hexagon screws 28 with washers 37 2 5 Tighten hexagon...

Page 398: ...ating temperature and under full load at least 85 load if possible i e at high turbocharger rpm Clean pipes from the intake air system and downstream from each turbocharger Note Deposits and dirt part...

Page 399: ...r cleaning the air side the engine should be run under load for at least 5 minutes When the compressor impeller was contaminated the success of a cleaning can be told by the charge air pressure after...

Page 400: ...be must never be connected directly to city water to a different or larger metering device or a larger water container than those provided by Caterpillar Engines Attention Avoid getting uncontrolled a...

Page 401: ...res and low engine load Note The cleaning effect during turbine washing is caused by the mechanical impact of the water drop lets as well as by the water solubility of the deposits Attention Please no...

Page 402: ...ements for water for washing turbine and nozzle ring Clear freshwater drinking water without cleaners or solvents is to be used The wash water used should have minimal mineral and salt content Notes o...

Page 403: ...ilized and is below 430 C 2 Control valve 1 on the control panel is locked in the Operation air position 3 Shut off valve 4 is closed 4 Connecting the water supply to shut off valve 4 before pressure...

Page 404: ...valve 1 11 After approx 5 minutes close drain valve 3 completing this cleaning procedure 12 Disconnect the water supply completely including shut off valve 4 and pressure meter 5 from the fitting on c...

Page 405: ...ange the axial and radial bearing after 36 000 h Note Caterpillar points out that this maintenance sheet has only been configurated for the pur pose of maintenance planning As to any other information...

Page 406: ...0 A Socket width across flats 41 W3 435102 B Socket wrench for indicator valve W5 1 9100 060 not available as figure Auxiliary material Molykote paste G Rapid Plus or a product of equal standard Seque...

Page 407: ...eakage line Fig 2 10 fuel leakage line Fig 3 20 21 and control air pipes Fig 4 30 31 of the corresponding injection pump Note To remove the two outer injection pumps cylinder 1 and last cylinder leave...

Page 408: ...Injection Pump Repair Disassembly and reassembly A5 05 07 02 01 00 M43 en 16 02 2009 IB020380 3 6 07 1 10 Disassemble the connection Fig 5 40 between injection pump control rack 41 and control shaft...

Page 409: ...of the injection pump drive must be on the base circle of the fuel cam 1 if necessary turn the engine Attention In order to avoid damages to the hydraulic wrench W2 adjust a maximum pressure of p 500...

Page 410: ...ump over the fastening screws Insert pushrod 8 and pressure spring 3 into the receptacle provided on the injection pump Safety note Attention The spring tension of the injection pump drive acts agains...

Page 411: ...for leakage by means of compressed air 2 13 Check stop piston emergency stop device for correct function 10 03 01 nn 2 14 Mount the camshaft casing cover on camshaft side 2 15 Open the shut off valve...

Page 412: ...njection pump are manufactured to high tolerances in special workshops This is the only way to ensure proper function When overhauling a pump it is important to make sure that the individual pump comp...

Page 413: ...esting unit W2 with the help of a crane 1 2 Mount adapter W6 on valve support Fig 1 20 and connect to testing unit W2 via pressure pipe W1 The cap screws 33 must be tight 1 3 Pump to raise pressure to...

Page 414: ...support 20 down Attention Caution The spring tension of the pump spring 9 presses against the lo wer pump housing section 4 2 5 Release and dismantle two opposite screws Fig 3 36 2 6 Replace by longer...

Page 415: ...port 20 carefully Be careful with the pressure valve 22 2 16 Drive the pump element 1 out of the housing with a suitable wooden dowel 2 17 Clean all parts with gas oil and a stiff brush and blow out w...

Page 416: ...oned exactly in relation to the control sleeve and that the markings on the control sleeve and pump piston match up A tooth is milled into the control sleeve in order to allow the control sleeve to be...

Page 417: ...3 1 3 Tighten cheese head screws Fig 4 36 according to the sequence 19 21 22 20 in three steps 1 Step according to the sequence by applying M 40 Nm 2 Step according to the sequence by applying M 80 N...

Page 418: ...Operating medium Heavy fuel and distillate fuel Inspection Alternate inspection of the deflector bolts of two injection pumps every 3 750 h Replacement of all deflector bolts after 7 500 h Tools Calip...

Page 419: ...gauge of the caliper gauge 1 4 When the above wear value is reached replace deflector bolts 6 with new ones 2 Mount deflector bolts 2 1 Lightly lubricate thread and contact faces of the deflector bolt...

Page 420: ...hours on distillate fuel to thorou ghly flush the entire injection system In case of overhaul work care has to be taken to ensure that the individual components of an in jection pump remain assigned t...

Page 421: ...valve 4 into valve support 3 2 2 Replace O ring 6 2 3 Put valve support 3 onto injection pump Pay attention to dowel pins 5 2 4 Lubricate threads and contact faces of cheese head screws 1 und 2 with e...

Page 422: ...distillate fuel Attention After mounting a new injection pump it has to be made sure that the pump is preheated with circulating heavy fuel for at least 20 minutes After start the engine has to be ope...

Page 423: ...stillate fuel Tools Torque wrench 20 200 Nm W1 1 9454 202 Torque wrench 200 500 Nm W2 1 9454 500 Open jawed spanner for torque wrench W3 1 9106 A not available as figure Auxiliary material Molykote Pa...

Page 424: ...6 and disassemble it 1 5 Take the transverse thrust piece 15 out of the receptacle 14 1 6 Screw the cap screw 8 out of the cylinder head injection nozzle holder 20 1 7 Take the complete radial thrust...

Page 425: ...r head screws 16 by hand 2 7 Introduce the complete radial thrust piece 13 with cap screw 8 through the receptacle 14 into the cylinder head Dimension X must be at least 25 mm Attention During subsequ...

Page 426: ...clamping screw 4 alternately and step by step starting with a torque of M 100 Nm each until the prescribed torque of M 250 Nm is reached for pressure screw 6 and clamping screw 4 2 12 Tighten the fil...

Page 427: ...d High temperature thread paste Dag S 5420 A or equivalent product Note When operating the engine with heavy fuel oil the engine must be operated for at least 0 5 hours with distillate fuel before wor...

Page 428: ...gh pressure injection pipe 07 05 01 nn 1 6 Loosen the injector valve by turning the threaded sleeve 24 by means of wrench 25 and screw out until the bottom O ring Fig 1 7 is exposed 1 7 Remove hexagon...

Page 429: ...to be squeezed off in the locking groove of the cylinder head Attention No seal between the injector valve and sleeve in area Fig 1 X 2 4 Place injector valve in sleeve note the position of the locki...

Page 430: ...e fuel injector should only be checked in case of a significant deviation of the exhaust gas temperature from the respective cylinder value For this purpose the nozzle tester is provided which can als...

Page 431: ...aking or if the nozzle holes are clogged and the nozzle already opens below the minimum nozzle opening pressure of 390 bar repair or replace the injector according to 07 09 01 nn 5 1 For adjusting the...

Page 432: ...or equivalent product not available as figure Note The fuel injector must be removed reassembled every 7 500 operating hours or when an inspec tion 07 08 01 nn reveals faults All parts of the injectio...

Page 433: ...2 Position of the positioning pin Fig 2 17 1 3 Slacken nut 3 and relieve nozzle spring 4 by unscrewing the setting screw 11 Attention To slacken the nozzle nut 6 only use hexagon spanner W4 do not us...

Page 434: ...ts seat of its own weight If the needle hangs or is stuck the entire injector element 8 12 must be replaced 1 13 All parts especially injector needle and sealing surfaces must be inspected Replace any...

Page 435: ...to avoid damages to the hydraulic wrench W2 adjust a maximum pressure of p 465 bar on the high pressure pump Adjustment instructions see A6 05 90 10 nn 2 9 Put torque wrench Fig 3 W2 on nozzle nut Fig...

Page 436: ...erval for the filter will depend mainly on the engine operating conditions fuel qua lity and the quality of the fuel separation and will thus differ from unit to unit After commissioning a new system...

Page 437: ...essed air supply and load 6 max 10 bar 2 2 4 Shift the spouting guard 13 to the stop on the pistol nozzle put it into the cartridge opening and hold it tight Pull the trigger of the pistol and introdu...

Page 438: ...r damage operation sequence 2 4 2 3 8 Place filter insert in filter chamber mount cover replace seals if necessary 2 3 9 Fill filter chamber and vent see plate on filter cover 2 4 Cleaning of cartridg...

Page 439: ...ssure cleaner do not hold the nozzle too close to the gauze in order to prevent damage or displacement of the gauze wires 2 4 8 Rinse the cartridges in clean cleaning fluid blow them out and let them...

Page 440: ...Time requirement 1 Pers 0 50 h Personnel qualification skilled engine hand Operating medium Heavy fuel and distillate fuel Auxiliary materials Molykote Paste G Rapid Procedure 1 Disassembly 1 1 Remov...

Page 441: ...wards the middle of the line Note When loosening and sliding the locking rings be careful not to damage the pipe sealing surfaces 1 7 Slide the fuel line Fig 1 5 to the side with a 55mm open jawed wre...

Page 442: ...into the injection pump flange 2 3 Apply Molykote to hex head bolts 10 2 4 Install flange 2 with hex head bolts 2 5 Tighten bolts to M 130 Nm 2 6 Insert bushings 3 with O rings 7 and 8 and support ri...

Page 443: ...distillate fuel Maintenance Replacement of the fuel pulsation dampers every 7 500 h Auxiliary materials Molykote Paste G Rapid or equivalent product Procedure 1 Disassembly 1 1 Close the fuel shut off...

Page 444: ...new fuel pulsation dampers 1 in reverse order Attention When mounting the leakage monitoring pipe the valve body 3 of the fuel pulsation dam per must not be twisted Hold in place the valve body by mea...

Page 445: ...454 202 Torque wrench 200 500 Nm W2 1 9454 500 not shown Also needed G Rapid Plus Molykote paste Dirco Grau silicone sealant or comparable product Note If necessary the lube oil pump should be removed...

Page 446: ...using puller 1 5 Check tooth faces for wear pitting unevenness spalling 1 6 Loosen bolts 16 18 Remove cover 21 und cover 17 from pump housing 20 1 7 Remove drive gear 10 and impeller shaft 19 1 8 Che...

Page 447: ...percentage 80 2 5 Clean degrease and dry gear cone and drive gear cone shaft Attention Gear should always be mounted with the drive gear shaft in the vertical position cone pointing up 2 6 Place gear...

Page 448: ...ump 3 with gear 6 into the cylinder crankcase tooth faces of drive gears need to engage and install 2 13 Install resilient sleeves Coat hex nuts 1 and bolt threads with G Rapid Plus Molykote paste and...

Page 449: ...fluenced by part load operation with heavy fuel poor combustion poor centrifugal purifying or a defective automatic backflashing filter When starting up a new plant after major repairs or work on the...

Page 450: ...compressed air supply and load 6 max 10 bar 2 2 4 Shift the spouting guard 13 to the stop on the pistol nozzle put it into the cartridge opening and hold it tight Pull the trigger of the pistol and in...

Page 451: ...ges for damage operation sequence 2 4 2 3 8 Place filter insert in filter chamber mount cover replace seals if necessary 2 3 9 Fill filter chamber and vent see plate on filter cover 2 4 Cleaning of ca...

Page 452: ...gh pressure cleaner do not hold the nozzle too close to the gauze in order to prevent damage or displacement of the gauze wires 2 4 8 Rinse the cartridges in clean cleaning fluid blow them out and let...

Page 453: ...d A1 10 and at the specified lubricating oil temperature see A1 06 Sequence of operations 1 Disassembly Safety note Pay attention to the tension of the pressure spring Fig 1 3 on the control valve 1 1...

Page 454: ...8 IB022593 2 3 08 1 3 Clean all parts with gas oil and check them 1 4 Check the free passage of the control oil bore 12 in the pressure control valve and in the set screw 5 and remove any deposits 1 5...

Page 455: ...e sequence of disassembly Pay attention to the free movement of the pistons 4 and 11 2 3 Check the lubricating oil pressure at the pressure gauge on the control panel and adjust it if ne cessary 3 Adj...

Page 456: ...ays Prelubrication alone is no guarantee that damage caused by vibration is prevented since the components which run on sliding bearings are not able to float in the bearing because of the pre lubrica...

Page 457: ...e position of the control rods Attention The control rods must be in the Zero Filling position 3 Check the stop piston 3 in the injection pump press the control rod 2 into the in jection pump by apply...

Page 458: ...ment on the engine is to be checked for proper function Please refer to C5 05 05 10 50 nn 5 Fig 2 T3 Measuring point 6105 function of the safety system in the maintenance unit C5 05 05 45 23 01 5 1 Ve...

Page 459: ...adjustment instruction is valid for the following types Pressure range 0 2 2 5 bar mechanical switching differential 0 15 bar Pressure range 0 6 bar mechanical switching differential 0 2 bar Pressure...

Page 460: ...ch via the adjustment device Attention For setting the differential pressure switch the adjusting device must be equipped with two text connections pressure difference refer to view X 2 2 Inspect the...

Page 461: ...ice 3 3 Loosen the stop screw A 3 4 Remove the cover aside by loosening the locking screw B 3 5 Set the upper or lower switching point dif ferential pressure switch by means of the range spindle C The...

Page 462: ...relay on the plug in card must switch and the luminous diode 3 on the dial will go out Fig 1 2 Turn the pointer carefully to the left towards 0 rpm When reaching the engine speed the output relay wil...

Page 463: ...2 11 5 2 PICK UP IMPULSE dependent upon engine speed up to 1500 Hz at contact b14 and d14 If nothing could be detected whilst checking points 4 6 renew the plug in card Attention Carry out the rpm adj...

Page 464: ...tatic elements in case of failure is enabled by a manual control facility Hereto slacken counter nut 3 and turn set screw 4 clockwisely in order to get a lower tempera ture After setting counter again...

Page 465: ...static element Fig 1 5 into a water bath of temperature of approx 15 K above the temperature specified on the strap XX specification in degree C 2 2 The thermostatic element 5 must open steadiliy 3 As...

Page 466: ...rd tools Set of replacement parts Pressure switch M2103 emergency stop cooling water pressure Pressure switch M1106 emergency stop lubricating oil pressure Depending on the equipment status all other...

Page 467: ...essure switch When doing so slightly grease the O ring Fig 1 1 at the foot of the new pressu re switch before inserting it 2 3 Replacement of the plug 3 Testing of the completed work 3 1 Cooling water...

Page 468: ...tch Inspection Replace A5 05 11 06 05 02 22500 M32 M43 en 06 10 2008 IB025581 3 3 11 4 Put the engine and the safety system into normal operating condition again Notify the engine to be ready for oper...

Page 469: ...ch and connect the pressure calibrating device W1 to the test connection The adjustment value is to be inferred from the list of measuring points in Book C 2 2 In pressureless state the pressure switc...

Page 470: ...ig 2 4 3 2 By turning the hexagon socket screw 5 the switching point can be adjusted correspondingly 4 Assembly 4 1 Mount cover 4 4 2 Remove pressure calibrating device W1 4 3 Clip on plug to the pres...

Page 471: ...nd distillate fuel Maintenance a Check the underpressure in the measuring chamber every 750 h b Clean the infrared filter and replace the sintered bronze filter in the measuring attachment every 1 500...

Page 472: ...fter maintenance work operation sequence 5 1 At every lubrication oil change the system must be completely drained of oil operation se quence 1 3 even in the case of self bleeding dampers and the oil...

Page 473: ...per through 180 m several times 1 4 Mark the position of the damper to the crankshaft 1 5 Remove the antifatigue screws and faste ning screws 1 12 1 6 Dismantle the pump wheel carrier 15 and pump gear...

Page 474: ...e Maximum permitted value for gap s between spring ends and groove flanks 1 13 Apply an adequate quantity of Loctite 275 to both sides of the cup spring Fig 1 22 Tighten he xagonal screw 23 until cup...

Page 475: ...e the marking of the damper position to the crankshaft 5 1 Check the run out tolerances of the vibration damper Fig 1 5 2 Bleed the air from the oscillation damper Turn an oil flow bore hole 30 to the...

Page 476: ...onnel qualification Cat MaK specialist Operating medium Heavy fuel and distillate fuel Maintenance replace Vibration damper Replacement on an exchange basis after 45 000 h Note We have to point out th...

Page 477: ...iary material Bearing grease Kl ber Altemp QNB 50 Gear oil Shell Omala Oil 460 or a product of equal standard 1 Operating the turning device Safety note Protect engine against unintentional start up 1...

Page 478: ...inglever 1 to position V and hold 1 2 2 Move lever 2 to position Y so that the gearwheel of the turning device is disengaged from the flywheel toothing 1 2 3 Let off blockinglever and make sure that t...

Page 479: ...l only if the turning device is engaged 2 2 1 Grease the notch on the output shaft 9 and the gearwheel 3 with bearing grease by means of the grease nipple 4 Attention Grease the gearwheel toothing onl...

Page 480: ...Tools A6 en 26 05 2009 AA000112 1 1 Tools...

Page 481: ...tents A6 01 en 26 05 2009 AA020050 1 1 Tools A6 Table of contents A6 01 Tools A6 05 22 69 Hydraulic tensioning equipment A6 05 90 10 00 Hydraulic wrench A6 05 90 10 01 High Pressure Coupling Nipple A6...

Page 482: ...Tools A6 05 22 69 M43 en 02 04 2009 AA045052 1 28...

Page 483: ...utils Lista de las herramientas Lista de ferramentas Verkt y oversikt M 43 281717 68 280 281 S N Normalwerkzeug Standard tools Outillagenormal Herramientasnormales Ferramentasnormals Normal verkt y No...

Page 484: ...Cylinder head Description Figure Benennung Bild Werkzeug Nr Tool No St ck Qty N N N N Steckschl ssel 1 1 9100 060 Socket wrench Hochdruckschlauch 1 433420A High pressurehose Aufbewahrungskasten 1 1 91...

Page 485: ...N Spannzylinder f r Grundlager 2 1 9213 K Hydraulic jack for main bearings Spannzylinder f r Zylinderkopf und 6 1 9213 P Gegengewicht Hydraulik jack for cylinder head and balance weight Spannzylinder...

Page 486: ...Werkzeug Nr Tool No St ck Qty N N N N Spannzylinder f r Kipphebelbock 2 1 9213H Hydraulic jack for rocker arm bracket Innensechskantschl ssel 2 436500A Hexagon socket screw key Spannzylinder f r Pleu...

Page 487: ...inderkopf Cylinder head Description Figure Benennung Bild Werkzeug Nr Tool No St ck Qty N N N N Druckschlauch 1 433420C Delivery hose Einsatz SW 32 1 435102A Socket SW 32 Reaktionsarm 1 435100B Reacti...

Page 488: ...ng Bild Werkzeug Nr Tool No St ck Qty N N N N Einsatz SW 55 1 439208 001 Socket SW 55 Sonderabst tzung 1 435100C Special support Dichtung Spannzyl M25x3 2 433311 054 Seal for Hydraulic jack m Dichtung...

Page 489: ...Cylinder head Description Figure Benennung Bild Werkzeug Nr Tool No St ck Qty N N N N Gabelschl ssel 1 436500D Fork wrench Gabelschl ssel 1 436500E Fork wrench Hochdruckschlauch 1 0 m 5 433420E High...

Page 490: ...Figure Benennung Bild Werkzeug Nr Tool No St ck Qty N N N N Dichtung Spannzyl 1 433311 061 Seal for Hydraulic jack Dichtung Spannzyl 1 433311 052 Seal for Hydraulc jack Dichtung Spannyzl 1 433311 059...

Page 491: ...head Description Figure Benennung Bild Werkzeug Nr Tool No St ck Qty N N N N Spannvorrichtung 1 439222D Clamping device Zange f r Sicherungsringe 1 1 9067 440 Circlip pliers C 40 Ventileinschleifvorri...

Page 492: ...Figure Benennung Bild Werkzeug Nr Tool No St ck Qty N Z S N Sicherungsringzange 1 431020A Cirlip pliers Ventilsitzfr svorrichtung 1 439224B Valve reseating tool Spitzendruckindikator 1 1 9410 K Peak p...

Page 493: ...f Cylinder head Description Figure Benennung Bild Werkzeug Nr Tool No St ck Qty m N S N Zapfenschl ssel 1 0 9105A Pin wrench Ventilsitzfr ser 1 439224C Valve reseating tool 10 11 Zylinderdeckeldrehvor...

Page 494: ...6 05 01 Zylinderkopf Cylinder head Description Figure Benennung Bild Werkzeug Nr Tool No St ck Qty N m N Einf hrring Anlassventilkolben 1 439227A Guide Ring starting valve piston Andr ckvorrichtung 1...

Page 495: ...erkzeug Nr Tool No St ck Qty N N N Triebwerk Running gear Manschette 1 439220A collar Kolben Montagering 1 439220B Piston mounting sleeve Montagezangef r Kolbenring 1 431001A Piston ring expander N Si...

Page 496: ...Kurbelwangen Me ger t 1 1 9425A Crank web deflection dial gauge Ein und Ausbauvorrichtung 1 439228A f r Pleuelstange Mounting and removing device for connecting rod N Montagehilfe Kolbenbolzen 1 43922...

Page 497: ...3 3 A6 05 02 Description Figure Benennung Bild Werkzeug Nr Tool No St ck Qty Triebwerk Running gear Pleuelstangenhalter 1 439228B Connecting rod holder N 2x 1x m Drehmomentschl ssel 20 200Nm 1 1 9454...

Page 498: ...use Motor casing Eint rnvorrichtung 1 439225 001 Main bearing shell mounting device Mitnehmer f r Lagerschale 1 439225B Dog for main bearing shell Ein und Ausbauvorrichtung 1 439216A f r Zylinderlaufb...

Page 499: ...eh use Motor casing Halter f r Zylinderbuchse 1 439217A Cylinder liner hold down Ausdr ckvorrichtung Kalibrierring 1 439216B Ejector for anti polishing ring Ein und Ausbauvorrichtung 1 439214A f r Gru...

Page 500: ...03 M 43 en 03 04 2 WB000001 3 3 A6 05 03 Description Figure Benennung Bild Werkzeug Nr Tool No St ck Qty S Motorgeh use Motor casing Me lehref r Laufbuchse 1 439218 001 Ruler for cylinder liner m...

Page 501: ...No St ck Qty N N N Steuerung Timing gear Griff f r Deckeldemontage 2 432058A Handle Ein und Ausbauvorrichtung 1 439230A f r Nockenwelle Mounting and removing device for camshaft Ein u Ausbauvorrichtu...

Page 502: ...e Benennung Bild Werkzeug Nr Tool No St ck Qty N Steuerung Timing gear Steckschl ssel Einsatz SW 30 1 1 9424 030 Socket wrench insert SW 30 Umschaltknarre 1 2 1 1 9459 033 Ratchet 1 2 Drehmomentschl s...

Page 503: ...6 M 43 en 03 04 2 WB000001 1 1 A6 05 06 Description Figure Benennung Bild Werkzeug Nr Tool No St ck Qty N Abgasanlage Aufladung Exhaust system supercharging Sechskantschraube 9 431011A Hexagon screw m...

Page 504: ...aftstoffsystem Fuel System Einspannvorrichtung f r D senhalter 1 439208A Clamping device for nozzle holder Ringschl ssel 1 0 9100 055 spanner Ziehvorrichtung f r Einspritzd se 1 439111A Removing devic...

Page 505: ...Benennung Bild Werkzeug Nr Tool No St ck Qty N N N N Kraftstoffsystem Fuel System Reinigungspistole 1 1 9100 114 Cleaning gun Reinigungsrohr 1 1 9100 115 Cleaning pipe Einstellschl ssel 1 432101A Adju...

Page 506: ...raftstoffsystem Fuel System Abspritzdruckpr fvorrichtung 1 1 9470H Nozzletester Adapter f r D senhalter 1 439206A Union for nozzle holders Maulschl ssel 1 1 9106A Single end wrench N N 1 9470 030 1 94...

Page 507: ...07 M 43 en 07 02 1 WB000001 4 4 A6 05 07 Description Figure Benennung Bild Werkzeug Nr Tool No St ck Qty N Kraftstoffsystem Fuel System m Reinigungswerkzeug 1 432120A Cleaning tool...

Page 508: ...03 04 2 WB000001 1 1 A6 05 08 Description Figure Benennung Bild Werkzeug Nr Tool No St ck Qty N Schmier lsystem Lubricating oil system Ausdr ckwerkzeug f r Siebkerzen 1 1 9100 120 Ejector for filter c...

Page 509: ...075 003 Set of feeler gauges Diamantpaste 5 g 1 1 9493 002 Grinding paste 5 g Dicht u F llmasse Silicon 1 1 9492 002 Siicon sealing compound Schild 2 0 9570A Designation plate Achtung Bei Schweissarbe...

Page 510: ...Hydraulic tensioning equipment A6 05 90 10 00 M43 VM43 en 30 03 2005 AA022953 1 32...

Page 511: ...Anlage arbeitet zug nglich zu machen Foreword Dear User before using the bolt tensioning equipment you are advised to study these instructions carefully Bolt tensioning tools by ITH GmbH are designed...

Page 512: ...ichtungswechsel Austausch von Wechselbuchse 3 5 Kurz Bedienungsanleitung 4 0 Datenbl tter zum Schraubenspannzylinder 4 1 St ckliste 33 4 2 Ersatzteilzeichnung 33 4 3 Ma zeichnung 33 4 4 Technische Dat...

Page 513: ...ment of change bushing 3 5 Operating instructions in brief 4 0 Data sheets for bolt tensioning cylinder 4 1 Parts list 4 2 Spare parts drawing 4 3 Dimensional drawing 4 4 Technical data 4 1 Parts list...

Page 514: ...Daten Technical Data Auf m Brinke 18 49 0 291 9962 0 D 59872 Meschede Fax 49 0 291 9962 11 Druckschrift Print 09 80095d Seite Page 1 von of 6 Betriebsanleitung Kap 1 0 Technische Daten Operating Inst...

Page 515: ...mm Gewicht Weight in kg Gewindegr e Thread size Bestell Nr Order no Maschinen Nr Manufact no Baujahr Year of manufacture Betriebsspannkraft max Max tensioning force in kN Betriebsdruck max Max operat...

Page 516: ...hl der stromf hren den Phasen Number of conducting phases Stromaufnahme Current consumption in A Leistung Power in kW Schutzart Protective system Drehzahl R p m U min Bauform Construction Antrieb Pneu...

Page 517: ...uns nicht abgestimmten nderung der Maschine verliert diese Erkl rung ihre G ltigkeit This declaration will become invalid if the machine is modified or altered in any way without our previous agree me...

Page 518: ...d Damage to Equipment Auf m Brinke 18 49 0 291 9962 0 D 59872 Meschede Fax 49 0 291 9962 11 Druckschrift Print 09 80095d Seite Page 1 von of7 Betriebsanleitung Kap 2 0 Hinweise auf Unfall und Schadens...

Page 519: ...he joint If required ITH GmbH is avail able for consultation Bild 1 Bedienungsanletiung Fig 1 Operating instructions 2 1 2 Gewinde berstand Thread projection Vor dem Aufschrauben des Schraubenspannzyl...

Page 520: ...the change bushing of the bolt tensioning cylinder Compliance with the specified pressure maximum operating pressure see Tech nical Data Sheet is essential for achieving the guaranteed number of cycl...

Page 521: ...ed to bending stresses however small Fig 8 Bild 8 Schlauchleitung keiner Biegbelastung aussetzen Fig 8 Do not apply bending stress to hose Bild 9 Kupplungswinkel Fig 9 Coupling Elbow Eventuell ITH Hoc...

Page 522: ...satzbedingungen festge legt werden The user has to take care that the hose lines will be ex changed in adequate time in tervals also when no defects concerning safety regulations are visible at the ho...

Page 523: ...nce of 3 5 metres from the bolt tensioning cylinder Never stand in front of the unit in the direction in which the tensioning force is being ap plied The rise in the hydraulic pressure must be careful...

Page 524: ...ausgesetzt werden und da ein Biegeradius von 250 mm nicht unterschritten wird Dry climatized storage is essential for the perfect functioning of the unit After using the bolt tensioning cylin der all...

Page 525: ...Operating Instruction Auf m Brinke 18 49 0 291 9962 0 D 59872 Meschede Fax 49 0 291 9962 11 Druckschrift Print 09 80095d Seite Page 1 von of 15 Betriebsanleitung Kap 3 0 Bedienungsanleitung Operating...

Page 526: ...bstand beim Druckaufbau 3 5 m Always position the unit in such a way that the pressure gauge and bolt can be observed dur ing operation Safety distance during pres sure generation 3 5 metres Bild 17 S...

Page 527: ...ild 21 ITH Schraubenspannzylinder Fig 21 ITH bolt tensioning cylinder Hochbelastete Bauteile m ssen nach einer bestimmten Anzahl von absol vierten Zyklen ausgetauscht werden Dies gilt auch f r die Wec...

Page 528: ...dert Once the correct thread projec tion has been set turn the nut down to the surface This pre vents the bolt from screwing inwards when the bolt tensioning cylinder is being screwed into position Bi...

Page 529: ...ting Valve Druckbegrenzungsventil Absperrventil Pressure limiting valve Shut off valve Bild 26 Handhebel Hochdruckpumpen Aggregat Fig 26 Manual high pressure pump unit Schraubenspannzylinder darf noch...

Page 530: ...lieren ob Mutter an Auflagefl che anliegt Diesen Vorgang so lange wiederholen bis Mutter sich nicht mehr nachstellen l t Once the desired hydraulic pressure has been reached see section 3 1 5 switch t...

Page 531: ...tellung Pressure setting 3 3 3a Druckeinstellung bei Motor Aggregaten Pressure Setting for Pneumatic Pumps Bi ld 33 Pneumatik Hochdruckpumpen Aggregat Fig 33 Pneumatic high pressure pump unit Pneum un...

Page 532: ...tand von 3 5 m ein halten Connect the bolt tensioning cylinder and the pump with the high pressure hose Generate the previously de termined pressure see section 4 4 Important Do not stand in the tensi...

Page 533: ...chge f hrt werden wenn der Schraubenspannzylinder mit maximalem Druck siehe Technisches Datenblatt beauf schlagt ist In spite of the application of maximum pressure see tech nical data sheet if it is...

Page 534: ...e con nection or cylinder I Remove the cover with the two hole spanner provided Remove the spring package Important the first spring in the cylinder is hollow thereafter they are ar ranged alternately...

Page 535: ...dienungsanleitung Operating Instruction Section 3 0 Bedienungsanleitung Auf m Brinke 18 49 0 291 9962 0 D 59872 Meschede Fax 49 0 291 9962 11 Betriebsanleitung Kap 3 0 Bedienungsanleitung Operating In...

Page 536: ...pressure is indicated in bar by the pressure gauge on the pump unit The tensioning force can be determined using the table on the next page or cal culated by means of the follow ing equations 1 bar 0...

Page 537: ...beobachten e Absperrventil am Hochdruckpumpen Aggregat ffnen damit der Schraubenspannzylinder entlastet wird f Absperrventil erst dann wieder schlie en wenn Kolben im Schraubenspannzylinder zur ckged...

Page 538: ...ble approx 60 100 Nm Observe the turning of the nut in the observation groove e Open the stop valve on the high pressure pump unit and depressurize the cylinder f Do not close the stop valve until the...

Page 539: ...ding Endwert Finish reading Zyklenverbrauch Cycles used Gesamtverbrauc h Total usage Unterschrift Signature Auf m Brinke 18 49 0 291 9962 0 D 59872 Meschede Fax 49 0 291 9962 11 Druckschrift Print 09...

Page 540: ...ories and Spare Parts Auf m Brinke 18 49 0 291 9962 0 D 59872 Meschede Fax 49 0 291 9962 11 Druckschrift Print 09 80095d Seite Page 1 von of 3 Betriebsanleitung Kap 6 0 Zubeh r und Ersatzteile Operati...

Page 541: ......

Page 542: ...Hydraulic wrench A6 05 90 10 01 M43 VM43 en 21 04 2005 AA030963 1 13...

Page 543: ...ge arbeitet zug nglich zu machen Foreword Dear User before using the torque wrench equipment you are advised to study these instructions care fully torque wrench tools by ITH GmbH are designed and man...

Page 544: ...ach VDMA Unterlagen aufgebaut Sollten sich diese Unterlagen f r Ihren Anwendungsbereich als erg nzungsbed rftig erweisen so bitten wir um Ihre sofortige Information Im besonderen Ma e gilt dieses f r...

Page 545: ...Nr Manufacturing no Betriebsdruck max Pressure max in bar Gewicht Weight in kg 1 2 3 Schlauchleitung Hose line Bestell Nr Order no L nge length in m 1 2 4 Verbindungsst cke Jointing fittings Bezeichnu...

Page 546: ...e 1 0 m 50 kg 277 d e Testmoment test moment 1 0 m x 50 x 9 80665 490 33 Nm Umrechnungsfaktor f r Anzeigewert zum IST Drehmoment conversion factor for the indicated value to the is torque 490 33 277 1...

Page 547: ...nderung der Maschine verliert diese Erkl rung ihre G ltigkeit This declaration will become invalid if the machine is modified or altered in any way without our previous agree ment Bezeichnung der Mas...

Page 548: ...n Den mehrpoligen Stecker der Fern bedienung in die Steckkupplung am Geh use einschrauben und mit der Sicherungsmutter fixieren Screw the multiple pole plug for the remote control into the socket in t...

Page 549: ...the torque tables must also be used see 10 0 After setting the torque the pump is switched off again by pressing the black switch 5 5 Adapter Adapters F r den jeweiligen Anwendungsfall k nnen entspre...

Page 550: ...hand turning loosening The correct adapter should be pushed into the opposite side 5 8 Adaptereinsatz Adapter Nach Auswahl des entsprechenden Spezial Kraftsteckschl sseleinsatzes wird dieser in den D...

Page 551: ...Important The torque wrench must not be used before the locking button has clicked into position The direction of the support arm is determined by the existing support possibilities F Achtung Abst tzp...

Page 552: ...z im Drehmomentschrauber Je nach Drehmomentschraubertyp dreht sich der Einsatz zwischen 25 und 36 Die Drehung erfolgt nur wenn der wei e Taster der Hand Fernbedienung gedr ckt bleibt Hat der Drehmomen...

Page 553: ...sed again the hydraulic cylinder is again pressurised and the current torque is indicated on the pressure gauge Following this the unit must be switched off as described in section 5 14 5 14 Ausschalt...

Page 554: ...f gleichm ige Schmierung der Muttern achten Adjusting and installation according to 5 4 5 15 2 The bolt with the lowest friction will be tightened first Press the white button at the hand control as l...

Page 555: ...High Pressure Coupling Nipple A6 05 90 10 02 M43 VM43 en 01 07 2004 AA028654 1 4...

Page 556: ...Sicherheitsabstand von 3 0 bis 4 0 m einzu halten ist 1 0 Description The high pressure coupling nipples are sealed by a metallic sealing taper on the bolt tensioning cylinder and at the high pressur...

Page 557: ...ten the high pressure coupling nipple to max 50 Nm with a calibrated torque wrench Normal verformter Dichtkonus am Gewindeadap ter Montagedrehmoment 50 Nm Normally deformed sealing taper on the thread...

Page 558: ...high pressure coupling nipple to max 50 Nm with a calibrated torque wrench Normal verformter Dichtkonus am Gewindeadap ter Montagedrehmoment 50 Nm Normally deformed sealing taper on thread adapter In...

Page 559: ...Spare Parts Catalogue Typ M43C 68 280 68 281 Spare Parts Catalogue B0 M43C en 26 05 2009 AA000620 1 2 281717 Engine No Record No...

Page 560: ...he agreed purpose and must not be used for any other purpose Copies or other reproductions including storage processing or distribution by using electronic systems may only be made to the agreed purpo...

Page 561: ...uctions A3 03 Instructions for Heavy Fuel Operation A3 04 Initial Operation Engine A3 05 Operational Supervision Engine A3 06 Removal from operation Engine A3 07 Danger of Frost Engine A3 08 Running i...

Page 562: ...Total Index Book A B and C B0 01 en 26 05 2009 AA020059 2 2 External Documentation C0 Total Index Book A B and C C0 01 Introduction Electrical Equipment C0 02 Table of contents C5 01...

Page 563: ...do not place a collective order 3 Each engine must be treated separately stating its respective engine No Please find attached the required order sheets 4 For reasons of order handling each order must...

Page 564: ...troduction B0 02 M20 M601C en 26 11 2008 AA000036 2 3 Example of a spare parts sheet For further information please refer to http www marine cat com Catalogue Sheet No Part No Description Quantity Ite...

Page 565: ...e No Versandart Shipping Instructions Bitte stets angeben Pl i d Nur von Caterpillar auszuf llen O l b l d b C ill Pos Item Bestell Nr Part No Katalog Blatt Nr Catalogue Sheet No Sach Nr Stock No Zeic...

Page 566: ...Spare Parts B1 M20 M601C en 26 05 2009 AA000047 1 1 Spare Parts...

Page 567: ...20 DD Piston and Connecting rod B1 05 02 432601 DD Piston Rings B1 05 02 432617 AA Cover Mounting B1 05 02 436345 EE Engine housing B1 05 03 Engine Housing B1 05 03 431110 YY Engine Housing Cover B1 0...

Page 568: ...Control Shaft B1 05 05 434210 RR Control Linkage Mounting B1 05 05 434217 DD Air Pipe for Engine Stop Mounting B1 05 05 434241 ZH Filling Transmitter Mounting B1 05 05 434243 DD Control Stand Mountin...

Page 569: ...Piping B1 05 07 438540 MM Leak Fuel Piping B1 05 07 438540 PP Engine lubricating oil system B1 05 08 Gearwheel for Lubricating Oil Pump B1 05 08 1 6422 XX Lubricating Oil Pump Mounting B1 05 08 43641...

Page 570: ...ir Piping B1 05 10 438617 QQ Engine control equipment B1 05 11 Pressure Regulator B1 05 11 1 4817 AA Additional Measuring Points B1 05 11 430926 FF Gauge Panel B1 05 11 434630 GG Media Pipe B1 05 11 4...

Page 571: ...mpletely harmless however it should not be exposed to temperatures above 300 C since above 325 C a thermal decomposition and the formation of hydrofluoric acid can occur Replaced seals should be dispo...

Page 572: ...KEGEL AUSLASS 2 432107 007 EXHAUST VALVE STEM 8 VENTILFEDERSCHEIBE 2 432107 008 VALVE SPRING CAP 9 DREHVORRICHTUNG VOLLST 2 SIEHE B1 05 01 432225 VALVE ROTATOR COMPL SEE B1 05 01 432225 10 VENTILFEDER...

Page 573: ...DUZIERSTUTZEN 1 432107 044 REDUCER 45 SICHERHEITSVENTIL VOLLST 1 1 2250 005 RELIEF VALVE COMPL 46 INDIZIERVENTIL VOLLST 1 9 2107 025 INDICATOR VALVE COMPL 47 ABDECKUNG 1 432107 047 COVERING 48 TELLERF...

Page 574: ...STANDSST CK 1 1 0520 180 DISTANCE PIECE 86 ABSTANDSST CK 1 1 0520 181 DISTANCE PIECE 87 ABSTANDSST CK 1 1 0520 182 DISTANCE PIECE 88 ABSTANDSST CK 1 1 5520 193 DISTANCE PIECE 89 ABSTANDSST CK 1 1 5520...

Page 575: ...1 1 7082 623 O RING 128 O RING 1 1 7084 660 O RING 200 VENTILBR CKE AUSLASS VOLLST 1 433515 100 EXHAUST VALVE CROSS BAR COMPL 202 DRUCKST CK 1 433515 102 RAM 203 DRUCKST CK 1 433515 103 RAM 204 EINST...

Page 576: ...433510 103 BALL HEAD PIN 504 EINSTELLSCHRAUBE 1 433510 104 ADJUSTING SCREW 506 SECHSKANTMUTTER 1 1 2017 283 HEXAGON THIN NUT 600 KIPPHEBEL AUSLASS 1 433520 100 EXHAUST VALVE ROCKER 502 BUCHSE 1 433510...

Page 577: ...Zylinderkopf Cylinder Head B1 05 01 432107 HH M43 VM43 en 10 03 2009 EB030459 6 13 01...

Page 578: ...Zylinderkopf Cylinder Head B1 05 01 432107 HH M43 VM43 en 10 03 2009 EB030459 7 13 01...

Page 579: ...Zylinderkopf Cylinder Head B1 05 01 432107 HH M43 VM43 en 10 03 2009 EB030459 8 13 01...

Page 580: ...Zylinderkopf Cylinder Head B1 05 01 432107 HH M43 VM43 en 10 03 2009 EB030459 9 13 01...

Page 581: ...Zylinderkopf Cylinder Head B1 05 01 432107 HH M43 VM43 en 10 03 2009 EB030459 10 13 01...

Page 582: ...Zylinderkopf Cylinder Head B1 05 01 432107 HH M43 VM43 en 10 03 2009 EB030459 11 13 01...

Page 583: ...Zylinderkopf Cylinder Head B1 05 01 432107 HH M43 VM43 en 10 03 2009 EB030459 12 13 01...

Page 584: ...Zylinderkopf Cylinder Head B1 05 01 432107 HH M43 VM43 en 10 03 2009 EB030459 13 13 01...

Page 585: ...TUNG VOLLST 1 432144 104 LUBE OIL PIPE COMPL 6 MEDIENKLOTZ 1 432144 106 DISTRIBUTOR PLATE 7 ABSCHLUSSFLANSCH 1 432144 007 CONNECTING FLANGE 8 ANSCHLUSSFLANSCH 1 432144 108 CONNECTING FLANGE 9 H LSE 24...

Page 586: ...halten Motor Nr Ersatzteilblatt Nr Bestell Nr Each order must include the following Engine No Spare parts sheet No Part No 25 VERSCHLUSSSCHRAUBE 8 1 1040 356 SCREW PLUG 26 VERSCHLUSSSCHRAUBE 3 1 1056...

Page 587: ...Medienf hrung Mediums Guide B1 05 01 432144 FF M43 en 30 08 2004 EB027190 3 6 01...

Page 588: ...Medienf hrung Mediums Guide B1 05 01 432144 FF M43 en 30 08 2004 EB027190 4 6 01...

Page 589: ...Medienf hrung Mediums Guide B1 05 01 432144 FF M43 en 30 08 2004 EB027190 5 6 01...

Page 590: ...Medienf hrung Mediums Guide B1 05 01 432144 FF M43 en 30 08 2004 EB027190 6 6 01...

Page 591: ...wing Engine No Spare parts sheet No Part No ZYLINDERKOPFHAUBE VOLLST 1 432190 BB CYLINDER HEAD CAP ASSEMBLY 1 HAUBE 1 432190 051 COVER 2 GEWINDEBOLZEN 1 432190 052 STUD 3 KREUZGRIFF 2 432190 003 PALM...

Page 592: ...Zylinderkopfhaube Cylinder Head Cap B1 05 01 432190 BB M43 VM43 en 10 12 2003 EB020906 2 2 01...

Page 593: ...u folgende Angaben enthalten Motor Nr Ersatzteilblatt Nr Bestell Nr Each order must include the following Engine No Spare parts sheet No Part No VENTILDREHVORRICHTUNG VOLLST 1 432225 AA VALVE ROTATOR...

Page 594: ...Ventildrehvorrichtung Valve Rotator B1 05 01 432225 AA M43 VM43 en 10 12 2003 EB011939 2 2 01...

Page 595: ...Motor Nr Ersatzteilblatt Nr Bestell Nr Each order must include the following Engine No Spare parts sheet No Part No FREILAUF VOLLST 1 432227 CC FREEWHEEL ASSEMBLY 1 FREILAUF OBERTEIL 1 432227 001 FREE...

Page 596: ...Freilauf Freewheel B1 05 01 432227 CC M43 VM43 en 04 07 2003 EB025765 2 2 01...

Page 597: ...001 GEAR WHEEL 4 SCHWINGUNGSD MPFER VOLLST 1 SIEHE B1 05 12 436347 VIBRATION DAMPER COMPL SEE B1 05 12 436347 5 PUMPENRADTR GER 1 432520 005 PUMP GEAR SUPPORT 6 ZAHNRAD 1 432520 056 GEAR WHEEL 7 DEHNS...

Page 598: ...Kurbelwelle mit Gegengewichten Crankshaft with Balance Weights B1 05 02 432520 DD M43 en 19 03 2004 EB022677 2 3 02...

Page 599: ...Kurbelwelle mit Gegengewichten Crankshaft with Balance Weights B1 05 02 432520 DD M43 en 19 03 2004 EB022677 3 3 02...

Page 600: ...Y 3 LAGERSCHALE VOLLST 1 432601 003 NORMAL BEARING COMPL 4 KOLBENBOLZEN VOLLST 1 432601 004 PISTON PIN COMPL 5 SICHERUNGSRING 2 1 0061 303 CIRCLIP 100 PLEUELSTANGE VOLLST 1 432810 100 CONNECTING ROD C...

Page 601: ...lude the following Engine No Spare parts sheet No Part No 200 KOLBEN VOLLST 1 432670 400 PISTON COMPL 201 KOLBENUNTERTEIL 1 432670 201 PISTON SKIRT 202 KOLBENOBERTEIL 1 432670 202 PISTON CROWN 203 O R...

Page 602: ...Kolben mit Pleuelstange Piston and Connecting rod B1 05 02 432601 DD M43 VM43 en 29 07 2008 EB029119 3 4 02...

Page 603: ...Kolben mit Pleuelstange Piston and Connecting rod B1 05 02 432601 DD M43 VM43 en 29 07 2008 EB029119 4 4 02...

Page 604: ...thalten Motor Nr Ersatzteilblatt Nr Bestell Nr Each order must include the following Engine No Spare part sheet No Part No KOLBENRINGAUSR ST VOLLST 1 432617 AA SET OF PISTON RINGS COMPL NUT 1 FEUERSTE...

Page 605: ...otor Nr Ersatzteilblatt Nr Bestell Nr Each order must include the following Engine No Spare parts sheet No Part No DECKEL ANBAU VOLLST 1 436345 EE COVER MOUNTING ASSEMBLY 1 DECKEL 1 436345 251 COVER 2...

Page 606: ...Deckel Anbau Cover Mounting B1 05 02 436345 EE M43 en 14 04 2004 EB027334 2 2 02...

Page 607: ...COMPL 4 NOCKENWELLENLAGER 9 431110 004 CAMSHAFT BEARING 5 ANLAUFSCHEIBE 2 431110 005 THRUST WASHER 6 ZYLINDERBUCHSE 9 SIEHE B1 05 03 431611 CYLINDER LINER SEE B1 05 03 431611 7 KALIBRIERRING 9 431110...

Page 608: ...SCH 9 9 1165 009 FLANGE 30 ZYLINDERSCHRAUBE 11 1 1152 715 HEXAGON SOCKET HEAD CAP SCREW 31 GEWINDEBOLZEN 27 1 0017 402 THREADED HEAD 32 ZYLINDERSCHRAUBE 45 1 1158 218 HEXAGON SOCKET HEAD CAP SCREW 33...

Page 609: ...ER 53 DICHTRING 16 1 7010 302 JOINT RING 54 DICHTRING 14 1 7010 252 JOINT RING 57 DICHTUNG 9 1 7073 737 GASKET 59 O RING 9 1 7084 655 O RING 60 O RING 9 1 7084 656 O RING 61 O RING 9 1 7082 523 O RING...

Page 610: ...latt Nr Bestell Nr Each order must include the following Engine No Spare parts sheet No Part No 108 MUTTER 20 251110 011 NUT 109 LAGER 2 431110 004 BEARING 110 AUFNAHMEBOLZEN 2 9 1111 209 BOLT 111 BUC...

Page 611: ...Zylinderkurbelgeh use Engine Housing B1 05 03 431110 YY M43 en 17 09 2008 EB027068 5 10 03...

Page 612: ...Zylinderkurbelgeh use Engine Housing B1 05 03 431110 YY M43 en 17 09 2008 EB027068 6 10 03...

Page 613: ...Zylinderkurbelgeh use Engine Housing B1 05 03 431110 YY M43 en 17 09 2008 EB027068 7 10 03...

Page 614: ...Zylinderkurbelgeh use Engine Housing B1 05 03 431110 YY M43 en 17 09 2008 EB027068 8 10 03...

Page 615: ...Zylinderkurbelgeh use Engine Housing B1 05 03 431110 YY M43 en 17 09 2008 EB027068 9 10 03...

Page 616: ...Zylinderkurbelgeh use Engine Housing B1 05 03 431110 YY M43 en 17 09 2008 EB027068 10 10 03...

Page 617: ...LST 8 SIEHE B1 05 03 431636 CAMSHAFT COVER COMPL SEE B1 05 03 431636 3 KURBELRAUMDECKEL VOLLST 18 SIEHE B1 05 03 431633 CRANKCASE COVER COMPL SEE B1 05 03 431633 4 DECKEL 1 431112 009 COVER 5 DECKEL 1...

Page 618: ...latt Nr Bestell Nr Each order must include the following Engine No Spare parts sheet No Part No 19 DEHNH LSE 4 1 0502 138 EXTENSION BUSH 20 VERSCHLUSSSCHRAUBE 4 1 1041 609 SCREW PLUG 21 DICHTRING 4 1...

Page 619: ...Verkleidung f r Zylinderkurbelgeh use Engine Housing Cover M43 en 27 08 2007 EB031427 3 4 03 B1 05 03 431112 ZP...

Page 620: ...Verkleidung f r Zylinderkurbelgeh use Engine Housing Cover M43 en 27 08 2007 EB031427 4 4 03 B1 05 03 431112 ZP...

Page 621: ...ollowing Engine No Spare parts sheet No Part No KURBELRAUMENTL FTG ANBAU VOLLST 1 431165 CC CRANKCASE BREATHER MOUNTING ASS 1 FLANSCH 1 1 5340 314 FLANGE 2 FLANSCH 1 1 5340 131 FLANGE 3 VERSCHLUSSSCHE...

Page 622: ...Kurbelraumentl ftung Anbau Crankcase Breather Mounting B1 05 03 431165 DD M43 en 11 02 2002 EB025025 2 2 03...

Page 623: ...KK OIL PAN MOUNTING ASSEMBLY 1 LWANNE VOLLST 1 431220 001 OIL PAN COMPL 2 DICHTUNG 1 431220 002 GASKET 3 FLANSCH 1 1 1200 110 FLANGE 4 DICHTUNG 1 1 1250 052 GASKET 7 FLANSCH 1 251220 005 FLANGE 8 DIC...

Page 624: ...Anbau der lwanne Oil Pan Mounting B1 05 03 431220 KK M43 en 16 09 2004 EB027536 2 2 03...

Page 625: ...1 ABDECKBLECH 1 431360 051 COVER PLATE 2 ABDECKBLECH 7 431360 052 COVER PLATE 3 ABDECKBLECH 1 431360 053 COVER PLATE 4 ABDECKBLECH 1 431360 054 COVER PLATE 5 HALTER 2 431360 055 BRACKET 8 SECHSKANTSC...

Page 626: ...Abdeckblech Anbau Cover Plate Mounting B1 05 03 431360 UU M43 en 10 01 2006 EB029067 2 2 03...

Page 627: ...1 1 2 03 POS BENENNUNG STCK BEST NR ITEM DESCRIPTION NUMBER PART NO Jede Bestellung mu folgende Angaben enthalten Motor Nr Ersatzteilblatt Nr Bestell Nr Each order must include the following Engine No...

Page 628: ...Zylinderbuchse Cylinder Liner B1 05 03 431611 AA M43 en 18 03 1999 EB012031 2 2 03...

Page 629: ...Nr Ersatzteilblatt Nr Bestell Nr Each order must include the following Engine No Spare part No Order No TRIEBRAUMDECKEL VOLLST 1 431633 HH CRANKCASE COVER ASSEMBLY 1 TRIEBRAUMDECKEL 1 431633 201 CRANK...

Page 630: ...Triebraumdeckel mit Entlastungsventil Crankcase Cover With Relief Valve B1 05 03 431633 HH M43 en 17 11 2008 EB033488 2 2 03...

Page 631: ...RT NO Jede Bestellung mu folgende Angaben enthalten Motor Nr Ersatzteilblatt Nr Bestell Nr Each order must include the following Engine No Spare part No Order No DECKEL F R NOCKENWELLENTROG VOLLST 1 4...

Page 632: ...Deckel f r Nockenwellentrog Cover for Camshaft Case B1 05 03 431636 BB M43 en 24 02 2004 EB026976 2 2 03...

Page 633: ...RT NO Jede Bestellung mu folgende Angaben enthalten Motor Nr Ersatzteilblatt Nr Bestell Nr Each order must include the following Engine No Spare part No Order No DECKEL F R NOCKENWELLENTROG VOLLST 1 4...

Page 634: ...Deckel f r Nockenwellentrog Cover for Camshaft Case B1 05 03 431636 CC M43 en 24 02 2004 EB026978 2 2 03...

Page 635: ...SPANNSCHEIBE 3 1 0068 222 CONICAL SPRING WASHER 11 SPANNSCHEIBE 1 1 0068 240 CONICAL SPRING WASHER 100 VERKLEIDUNG VOLLST 7 431714 100 COVER COMPL 107 BUNDBOLZEN 2 431714 107 BOLT 108 STERNGRIFF 2 1 3...

Page 636: ...1714 300 COVER COMPL 110 SPANNSCHEIBE 4 1 0068 225 CONICAL SPRING WASHER 111 B GELGRIFF 2 1 3060 104 HANDLE 112 SECHSKANTSCHRAUBE 4 1 1387 338 HEXAGON SCREW 400 VERKLEIDUNG VOLLST 1 431714 400 COVER C...

Page 637: ...Pumpenraumverkleidung Pump Covers B1 05 03 431710 PP M43 en 21 04 2004 EB027365 3 5 03...

Page 638: ...Pumpenraumverkleidung Pump Covers B1 05 03 431710 PP M43 en 21 04 2004 EB027365 4 5 03...

Page 639: ...Pumpenraumverkleidung Pump Covers B1 05 03 431710 PP M43 en 21 04 2004 EB027365 5 5 03...

Page 640: ...wing Engine No Spare parts sheet No Part No KURBELWELLENABDICHTUNG VOLLST 1 437340 AA CRANKSHAFT SEAL ASSEMBLY 1 SCHWUNGRADNABE 1 437340 001 FLYWHEEL HUB 2 ABSCHLUSSDECKEL 1 437340 002 COVER 3 SPRITZR...

Page 641: ...Kurbelwellenabdichtung Crankshaft Seal B1 05 03 437340 AA M43 en 13 01 1998 EB011764 2 2 03...

Page 642: ...ARING JOURNAL 3 DECKEL 1 433120 053 COVER 4 ANLAUFSCHEIBE 1 433120 004 THRUST WASHER 5 ZAHNRAD 1 433120 005 GEARWHEEL 8 SECHSKANTSCHRAUBE 162 1 1374 461 HEXAGON BOLT 9 SECHSKANTSCHRAUBE 4 1 1372 469 H...

Page 643: ...Nockenwelle Camshaft B1 05 04 433120 NN M43 en 17 04 2002 EB025205 2 2 04...

Page 644: ...Nr Ersatzteilblatt Nr Bestell Nr Each order must include the following Engine No Spare parts sheet No Part No SCHWINGUNGSD MPFER ANBAU VOLLST 1 433140 PP VIBRATION DAMPER MOUNTING ASSEMBLY 1 SCHWINGU...

Page 645: ...Schwingungsd mpfer Anbau f r Nockenwelle Vibration Damper Mounting for Camshaft B1 05 04 433140 PP M43 en 10 12 2007 EB032037 2 2 04...

Page 646: ...2 ZB BOTTOM PART FOR VALVE MECHANISM ASS 2 LROHR 8 433502 052 OIL PIPE 3 LROHR 1 433502 053 OIL PIPE 4 LROHR 1 433502 105 OIL PIPE 5 BLECH 1 433502 055 PLATE 6 BLECH 6 433502 110 PLATE 7 BLECH 4 43350...

Page 647: ...OCKING LEVER AXLE 12 DEHNH LSE 1 1 0502 186 EXTENSION SLEEVE 107 SECHSKANTSCHRAUBE 1 1 1367 553 HEXAGON BOLT 108 SPANNSTIFT 1 1 0039 311 SPRING DOWEL PIN 109 SICHERUNGSRING 2 1 0060 240 CIRCLIP 110 PA...

Page 648: ...M DESCRIPTION NUMBER PART NO Jede Bestellung mu folgende Angaben enthalten Motor Nr Ersatzteilblatt Nr Bestell Nr Each order must include the following Engine No Spare part sheet No Part No 305 BUCHSE...

Page 649: ...Unterer Ventilantrieb Bottom Part for Valve Mechanism B1 05 04 433502 ZB M43 en 20 03 2004 EB027094 4 7 04...

Page 650: ...Unterer Ventilantrieb Bottom Part for Valve Mechanism B1 05 04 433502 ZB M43 en 20 03 2004 EB027094 5 7 04...

Page 651: ...Unterer Ventilantrieb Bottom Part for Valve Mechanism B1 05 04 433502 ZB M43 en 20 03 2004 EB027094 6 7 04...

Page 652: ...Unterer Ventilantrieb Bottom Part for Valve Mechanism B1 05 04 433502 ZB M43 en 20 03 2004 EB027094 7 7 04...

Page 653: ...433580 008 COMPRESSION SPRING 10 DISTANZPLATTE 4 2 1 433580 010 DISTANCE PLATE 4 2 10 DISTANZPLATTE 4 3 1 433580 019 DISTANCE PLATE 4 3 10 DISTANZPLATTE 4 4 1 433580 018 DISTANCE PLATE 4 4 10 DISTANZP...

Page 654: ...UMBER PART NO Jede Bestellung mu folgende Angaben enthalten Motor Nr Ersatzteilblatt Nr Bestell Nr Each order must include the following Engine No Spare parts sheet No Part No 27 SECHSKANTMUTTER 3 1 2...

Page 655: ...Einspritzpumpenantrieb Injection Pump Drive B1 05 04 433580 AA M43 en 23 10 2000 EB011779 3 3 04...

Page 656: ...LASTIC CONNECTING ROD COMPL 3 HEBEL 1 434110 003 LEVER 4 HEBEL 1 434110 004 LEVER 5 BOLZEN 2 9 4110 111 BOLT 6 DISTANZBUCHSE 2 9 4110 009 SPACER 7 VERBINDUNGSLEITUNG VOLLST 1 434110 207 CONNECTING PIP...

Page 657: ...Angaben enthalten Motor Nr Ersatzteilblatt Nr Bestell Nr Each order must include the following Engine No Spare parts sheet No Part No 22 GELENKKOPF 1 9 4110 026 LINK HEAD 23 GELENKKOPF 1 9 4110 027 L...

Page 658: ...Regleranordnung Governor Mounting B1 05 04 434110 FF M43 en 08 04 2008 EB029076 3 4 04...

Page 659: ...Regleranordnung Governor Mounting B1 05 04 434110 FF M43 en 08 04 2008 EB029076 4 4 04...

Page 660: ...Part No REGLERANTRIEB ANBAU VOLLST 1 434111 DD GOVERNOR DRIVE MOUNTING ASSEMBLY 1 REGLERANTRIEB VOLLST 1 SIEHE B1 05 04 434118 GOVERNOR DRIVE COMPL SEE B1 05 04 434118 2 H LSE 1 251110 014 SLEEVE 3 DI...

Page 661: ...Reglerantrieb Governor Drive B1 05 04 434111 DD M43 en 08 05 2002 EB025333 2 2 04...

Page 662: ...No Spare parts sheet No Part No REGLERANTRIEB VOLLST 1 434118 AA GOVERNOR DRIVE ASSEMBLY 1 REGLERANTRIEBSWELLE 1 434118 001 GOVERNOR DRIVE SHAFT 2 ZWISCHENWELLE 1 434118 002 INTERMEDIATE SHAFT 3 SCHRA...

Page 663: ...Reglerantrieb Governor Drive B1 05 04 434118 AA M43 VM43 en 25 03 2004 EB025128 2 2 04...

Page 664: ...Engine No Spare parts sheet No Part No ZWISCHENRAD ANBAU VOLLST 1 435140 GG IDLE WHEEL MOUNTING ASSEMBLY 1 STUFENRAD VOLLST 1 435140 301 IDLE WHEEL COMPL 2 ACHSE VOLLST 1 435140 302 AXLE COMPL 3 SICHE...

Page 665: ...Zwischenrad Anbau Idle Wheel Mounting B1 05 04 435140 GG M43 en 13 03 2004 EB027110 2 2 04...

Page 666: ...e No Spare parts sheet No Part No BEDIENSTAND VOLLST 1 1 4523 AA CONTROL STAND ASSEMBLY 1 ZEIGER VOLLST 1 1 4523 001 POINTER COMPL 2 RASTE VOLLST 1 1 4523 002 DETEND COMPL 3 WARTUNGSEINHEIT VOLLST 1 S...

Page 667: ...Bedienstand Control Stand B1 05 05 1 4523 AA M20 M25 M32 M43 en 24 03 2009 EB032120 2 2 05...

Page 668: ...PTION NUMBER PART NO STANDARD NO 10 0 DRUCKLUFTFILTER VOLLST 1 1 4900 HH COMPRESSED AIR FILTER ASSEMBLY 10 0 1 O RING 1 O RING 10 0 2 FILTERELEMENT 1 FILTER ELEMENT 10 0 3 O RING 1 O RING E P CKCHEN N...

Page 669: ...Druckluftfilter Compressed Air Filter B1 05 05 1 4900 HH M20 M601C en 28 10 1996 EB000413 2 2 05...

Page 670: ...E ASSEMBLY 3 VENTILTELLER VOLLST 1 VALVE DISK COMPL 6 KOLBEN 1 PISTON 7 O RING 1 O RING 8 O RING 1 O RING 9 O RING 1 O RING 10 O RING 1 O RING 11 FEDER 1 SPRING 12 KOLBENF HRUNGSBAND 1 PISTON GUIDE RI...

Page 671: ...3 2 Wegeventil 3 2 Way Valve B1 05 05 1 4906 ZM M25 M32 M43 en 26 04 2001 EB010999 2 3 05...

Page 672: ...3 2 Wegeventil 3 2 Way Valve B1 05 05 1 4906 ZM M25 M32 M43 en 26 04 2001 EB010999 3 3 05...

Page 673: ...301 CONTROL SHAFT 2 LAGERBOCK VOLLST 10 434210 103 BEARING BRACKET COMPL 3 LAGERBOCK VOLLST 1 434210 003 BEARING BRACKET COMPL 5 STELLRING 2 1 0090 047 SET COLLAR 6 DEHNH LSE 11 1 0502 152 EXTENSION...

Page 674: ...DESCRIPTION NUMBER PART NO Jede Bestellung mu folgende Angaben enthalten Motor Nr Ersatzteilblatt Nr Bestell Nr Each order must include the following Engine No Spare parts sheet No Part No 110 SCHEIBE...

Page 675: ...Reguliergest nge Injection Pump Control Shaft B1 05 05 434210 RR M43 en 09 06 2008 EB027119 3 4 05...

Page 676: ...Reguliergest nge Injection Pump Control Shaft B1 05 05 434210 RR M43 en 09 06 2008 EB027119 4 4 05...

Page 677: ...REGULIERGEST NGE VOLLST 1 434217 DD CONTROL LINKAGE MOUNTING ASSEMBLY 1 STANGE 1 434217 201 ROD 2 HEBEL 1 434110 004 LEVER 4 BOLZEN 2 9 4110 111 BOLT 5 DISTANZBUCHSE 2 9 4110 009 SPACER 8 SECHSKANTSCH...

Page 678: ...Reguliergest nge Anbau Control Linkage Mounting B1 05 05 434217 DD M43 en 06 03 2004 EB027130 2 2 05...

Page 679: ...PIPE COMPL 2 STOPPLEITUNG VOLLST 1 434241 302 AIR PIPE COMPL 3 VERBINDUNGSLEITUNG VOLLST 9 434241 203 CONNECTING PIPE COMPL 4 STOPPLEITUNG VOLLST 1 434241 004 AIR PIPE COMPL 5 STOPPLEITUNG VOLLST 1 43...

Page 680: ...Stoppleitung Anbau Air Pipe for Engine Stop Mounting B1 05 05 434241 ZH M43 en 20 04 2006 EB029691 2 2 05...

Page 681: ...tellung mu folgende Angaben enthalten Motor Nr Ersatzteilblatt Nr Bestell Nr Each order must include the following Engine No Spare parts sheet No Part No F LLUNGSGEBER ANBAU VOLLST 1 434243 DD FILLING...

Page 682: ...F llungsgeber Anbau Filling Transmitter Mounting B1 05 05 434243 DD M32 M43 en 17 11 2006 EB026182 2 2 05...

Page 683: ...7 BRACKET 8 HALTER 1 434520 108 BRACKET 9 HALTER VOLLST 1 434520 309 BRACKET COMPL 12 ELASTISCHE VERBINDUNG 3 2 4639 003 FLEXIBLE CONNECTION 13 ELASTISCHE VERBINDUNG 4 9 4520 040 FLEXIBLE CONNECTION 1...

Page 684: ...40 ADJUSTABLE MALE RUN TEE 41 GEWINDWREDUZIERUNG 6 1 5036 052 REDUCER 42 T VERBINDUNGSSTUTZEN 7 1 5095 442 UNION TEE 43 T VERBINDUNGSSTUTZEN 2 1 5095 512 UNION TEE 45 VERSCHLUSSBUTZEN 2 1 3088 543 PLU...

Page 685: ...220 WASHER 73 SCHEIBE 2 1 0040 223 WASHER 75 SPANNSTIFT 1 1 0039 293 SPRING DOWEL PIN 79 DEHNH LSE 7 1 0502 134 EXTENSION BUSH 82 ROHRKLEMME 16 1 5011 002 PIPE CLAMP 83 ROHRKLEMME 4 1 5011 042 PIPE CL...

Page 686: ...OS BENENNUNG STCK BEST NR ITEM DESCRIPTION NUMBER PART NO Jede Bestellung mu folgende Angaben enthalten Motor Nr Ersatzteilblatt Nr Bestell Nr Each order must include the following Engine No Spare par...

Page 687: ...Bedienstand Anbau Control Stand Mounting B1 05 05 434520 PP M43 en 21 04 2009 EB030515 5 8 05...

Page 688: ...Bedienstand Anbau Control Stand Mounting B1 05 05 434520 PP M43 en 21 04 2009 EB030515 6 8 05...

Page 689: ...Bedienstand Anbau Control Stand Mounting B1 05 05 434520 PP M43 en 21 04 2009 EB030515 7 8 05...

Page 690: ...Bedienstand Anbau Control Stand Mounting B1 05 05 434520 PP M43 en 21 04 2009 EB030515 8 8 05...

Page 691: ...heet No Part No ANSCHLUSSARMATUREN VOLLST 1 1 7259 NN SET OF CONNECTING FITTINGS COMPL 1 SCHLAUCHLEITUNG 1 1 7259 201 HOSE PIPE 4 ROHR 1 9050 095 TUBE 5 SCHNEIDRING 3 1 5059 217 CUTTING RING 6 BERWURF...

Page 692: ...Anschlu armaturen f r Turbolader Reinigungsanlage Connection Fittings for Turbocharger Cleaning Device B1 05 06 1 7259 NN M43 VM43 en 04 06 2008 EB031716 2 2 06...

Page 693: ...enthalten Motor Nr Ersatzteilblatt Nr Bestell Nr Each order must include the following Engine No Spare parts sheet No Part No DECKEL ANBAU VOLLST 1 431775 AA COVER MOUNTING ASSEMBLY 1 DECKEL 1 437240...

Page 694: ...Deckel Anbau Cover Mounting B1 05 06 431775 AA M43 en 14 04 2004 EB027367 2 2 06...

Page 695: ...ABGASSTUTZEN 1 437208 001 EXHAUST NOZZLE 3 DICHTUNG 1 437208 003 GASKET 5 FLANSCH 1 1 5383 205 WELDING FLANGE 6 DICHTUNG 1 1 7073 568 GASKET 7 BLINDFLANSCH 2 1 5340 314 BLANK FLANGE 8 DICHTRING 2 1 70...

Page 696: ...Abgasstutzen Exhaust Nozzle B1 05 06 437208 AA M43 VM43 en 12 03 2008 EB032384 2 2 06...

Page 697: ...9 437210 002 CLAMP COMPL 4 ABGASROHR 1 437210 154 EXHAUST PIPE 5 KOMPENSATOR VOLLST 8 437210 055 EXPANSION JOINT COMPL 6 KOMPENSATOR VOLLST 1 437210 056 EXPANSION JOINT COMPL 9 VERBINDUNGSLASCHE 3 43...

Page 698: ...IPTION NUMBER PART NO Jede Bestellung mu folgende Angaben enthalten Motor Nr Ersatzteilblatt Nr Bestell Nr Each order must include the following Engine No Spare parts sheet No Part No 35 DICHTRING 2 1...

Page 699: ...Abgasleitung Anbau Exhaust Manifold Mounting B1 05 06 437210 ZA M43 en 23 03 2005 EB028123 3 4 06...

Page 700: ...Abgasleitung Anbau Exhaust Manifold Mounting B1 05 06 437210 ZA M43 en 23 03 2005 EB028123 4 4 06...

Page 701: ...9 437210 002 CLAMP COMPL 4 ABGASROHR 1 437210 104 EXHAUST PIPE 5 KOMPENSATOR VOLLST 8 437210 055 EXPANSION JOINT COMPL 6 KOMPENSATOR VOLLST 1 437210 056 EXPANSION JOINT COMPL 9 VERBINDUNGSLASCHE 3 43...

Page 702: ...IPTION NUMBER PART NO Jede Bestellung mu folgende Angaben enthalten Motor Nr Ersatzteilblatt Nr Bestell Nr Each order must include the following Engine No Spare parts sheet No Part No 35 DICHTRING 2 1...

Page 703: ...Abgasleitung Anbau Exhaust Manifold Mounting B1 05 06 437210 ZZ M43 en 23 03 2005 EB028121 3 4 06...

Page 704: ...Abgasleitung Anbau Exhaust Manifold Mounting B1 05 06 437210 ZZ M43 en 23 03 2005 EB028121 4 4 06...

Page 705: ...4 COVERING COMPL 5 VERKLEIDUNG VOLLST 1 437220 305 COVERING COMPL 6 VERKLEIDUNG VOLLST 1 437220 306 COVERING COMPL 7 VERKLEIDUNG VOLLST 1 437220 307 COVERING COMPL 8 VERKLEIDUNG VOLLST 1 437220 308 CO...

Page 706: ...HALTER VOLLST 1 437220 510 BRACKET COMPL 30 ABDECKBLECH VOLLST 8 437220 330 COVERING PLATE COMPL 31 ABDECKBLECH VOLLST 8 437220 331 COVERING PLATE COMPL 32 ABDECKBLECH VOLLST 1 437220 332 COVERING PL...

Page 707: ...37220 852 COVER 53 SPRITZBLECH 1 437220 853 COVER 54 SPRITZBLECH 1 437220 354 COVER 56 HALTER 1 437220 756 BRACKET 61 ISOLIERUNG VOLLST 1 437220 361 INSULATION COMPL 63 ISOLIERUNG VOLLST 1 437220 363...

Page 708: ...2 SPANNSCHEIBE 49 1 0068 222 CONICAL SPRING WASHER 83 SPANNSCHEIBE 101 1 0068 225 CONICAL SPRING WASHER 84 SPANNSCHEIBE 68 1 0068 209 CONICAL SPRING WASHER 85 DEHNH LSE 5 1 0502 188 EXTENSION BUSH 86...

Page 709: ...Verkleidung f r Abgasleitung Exhaust Line Covering B1 05 06 437220 VV M43 en 04 01 2008 EB032082 5 9 06...

Page 710: ...Verkleidung f r Abgasleitung Exhaust Line Covering B1 05 06 437220 VV M43 en 04 01 2008 EB032082 6 9 06...

Page 711: ...Verkleidung f r Abgasleitung Exhaust Line Covering B1 05 06 437220 VV M43 en 04 01 2008 EB032082 7 9 06...

Page 712: ...Verkleidung f r Abgasleitung Exhaust Line Covering B1 05 06 437220 VV M43 en 04 01 2008 EB032082 8 9 06...

Page 713: ...Verkleidung f r Abgasleitung Exhaust Line Covering B1 05 06 437220 VV M43 en 04 01 2008 EB032082 9 9 06...

Page 714: ...ZEN VOLLST 1 437250 205 AIR INLET UNION COMPL 6 DICHTUNG 1 437250 206 GASKET 8 SCHMIER LLEITUNG 1 437250 208 LUBRICATING OIL PIPE 9 FLANSCH 1 437250 209 FLANGE 10 DICHTUNG 1 437250 210 GASKET 11 SICHE...

Page 715: ...EW 30 SECHSKANTSCHRAUBE 8 1 1387 239 HEXAGON SCREW 31 SECHSKANTSCHRAUBE 4 1 1387 372 HEXAGON SCREW 32 SECHSKANTMUTTER 24 1 2007 040 HEXAGON NUT 33 BOLZEN 2 1 0252 214 PARALLEL PIN 35 DEHNH LSE 14 1 05...

Page 716: ...HLER VOLLST 1 437287 100 HOUSING FOR CHARGE AIR COOLER COMPL 102 ABDECKBLECH VOLLST 1 437287 102 COVER PLATE COMPL 105 VERSCHLUSSDECKEL 2 1 9027 054 PLUG 106 VERSCHLUSSSCHRAUBE 5 1 1041 609 SCREW PLUG...

Page 717: ...Turbolader Anbau Turbocharger Mounting B1 05 06 437250 KK M43 en 21 04 2009 EB027141 4 8 06...

Page 718: ...Turbolader Anbau Turbocharger Mounting B1 05 06 437250 KK M43 en 21 04 2009 EB027141 5 8 06...

Page 719: ...Turbolader Anbau Turbocharger Mounting B1 05 06 437250 KK M43 en 21 04 2009 EB027141 6 8 06...

Page 720: ...Turbolader Anbau Turbocharger Mounting B1 05 06 437250 KK M43 en 21 04 2009 EB027141 7 8 06...

Page 721: ...Turbolader Anbau Turbocharger Mounting B1 05 06 437250 KK M43 en 21 04 2009 EB027141 8 8 06...

Page 722: ...LEICHSBLOCK 1 437254 105 DISTANCE BLOCK 6 DRUCKREGLER VOLLST 1 437254 206 PRESSURE REGULATOR COMPL 7 MANOMETER VOLLST 1 437254 003 PRESSURE GAUGE COMPL 8 DOPPELNIPPEL 1 437254 108 DOUBLE NIPPLE 9 REDU...

Page 723: ...gende Angaben enthalten Motor Nr Ersatzteilblatt Nr Bestell Nr Each order must include the following Engine No Spare parts sheet No Part No 28 ROHRLEITUNG VOLLST 1 437259 653 PIPE COMPL 29 STUTZEN 2 1...

Page 724: ...Armaturenplatte Control Board B1 05 06 437254 HH M43 en 04 03 2009 EB032903 3 4 06...

Page 725: ...Armaturenplatte Control Board B1 05 06 437254 HH M43 en 04 03 2009 EB032903 4 4 06...

Page 726: ...PIPE COMPL 6 ROHRLEITUNG VOLLST 1 437259 556 PIPE COMPL 7 ROHRLEITUNG VOLLST 1 437259 557 PIPE COMPL 8 ROHRLEITUNG VOLLST 1 437259 558 PIPE COMPL 9 ROHRLEITUNG VOLLST 1 437259 559 PIPE COMPL 10 ROHRL...

Page 727: ...CHSKANTSCHRAUBE 2 1 1367 239 HEXAGON SCREW 31 SECHSKANTSCHRAUBE 6 1 1387 311 HEXAGON SCREW 34 SECHSKANTMUTTER 7 1 2007 034 HEXAGON NUT 35 SECHSKANTMUTTER 2 1 7260 026 HEXAGON NUT 39 DEHNH LSE 4 1 0502...

Page 728: ...INT RING 63 DICHTRING 1 1 7010 083 JOINT RING 64 DICHTRING 1 1 7010 133 JOINT RING 65 DICHTRING 2 1 7033 110 JOINT RING 70 GERADER ZWISCHENSTUTZEN 1 1 5070 505 STRAIGHT ADAPTER 71 GEWINDEREDUZIERUNG 1...

Page 729: ...Reinigungsanlage f Turbolader Cleaning Dev for Turbocharger B1 05 06 437259 ZY M43 en 04 03 2009 EB032877 4 7 06...

Page 730: ...Reinigungsanlage f Turbolader Cleaning Dev for Turbocharger B1 05 06 437259 ZY M43 en 04 03 2009 EB032877 5 7 06...

Page 731: ...Reinigungsanlage f Turbolader Cleaning Dev for Turbocharger B1 05 06 437259 ZY M43 en 04 03 2009 EB032877 6 7 06...

Page 732: ...Reinigungsanlage f Turbolader Cleaning Dev for Turbocharger B1 05 06 437259 ZY M43 en 04 03 2009 EB032877 7 7 06...

Page 733: ...LLST 1 438629 GG PRESSURE SWITCH MOUNTING ASSEMBLY 1 ROHR VOLLST 1 438629 101 PIPE COMPL 2 ROHR VOLLST 1 438629 102 PIPE COMPL 7 SCHELLE 1 438629 107 CLAMP 11 STUTZEN 2 1 5094 188 MALE CONNECTOR 12 DI...

Page 734: ...Druckw chter Anbau Differenzdruck Ladeluft Pressure Switch Mounting Differential Pressure for Charge Air B1 05 06 438629 GG M43 en 23 09 2004 EB027511 2 2 06...

Page 735: ...de Angaben enthalten Motor Nr Ersatzteilblatt Nr Bestell Nr Each order must include the following Engine No Spare parts sheet No Part No EINSPRITZVENTIL VOLLST 1 432260 CC FUEL INJECTOR ASSEMBLY 1 D S...

Page 736: ...Einspritzventil Fuel Injector B1 05 07 432260 CC M43 VM43 en 29 02 2008 EB029122 2 2 07...

Page 737: ...ASSEMBLY 2 D SENMUTTER 1 432267 102 NOZZLE NUT 3 DRUCKBOLZEN 1 432267 103 PRESSURE BOLT 4 EINSTELLSPINDEL 1 432267 104 ADJUSTING SPINDLE 5 EINSTELLSCHRAUBE 1 432267 005 ADJUSTING SCREW 7 DRUCKFEDER 1...

Page 738: ...D senhalter Nozzle Holder B1 05 07 432267 CC M43 VM43 en 29 02 2008 EB029125 2 2 07...

Page 739: ...206 BAFFLE BODY 7 OBERER FEDERTELLER 1 433597 207 UPPER SPRING PLATE 8 DROSSEL 1 433597 208 THROTTLE 9 PUMPENFEDER 1 433597 009 PUMP SPRING 10 REGELSTANGE 1 433597 210 CONTROL ROD 12 UNTERER FEDERTELL...

Page 740: ...NG 27 O RING 2 433597 028 O RING 28 O RING 4 433597 041 O RING 29 DICHTRING 3 433597 042 JOINT RING 30 DICHTRING 1 433597 043 JOINT RING 31 SCHRAUBE 4 433597 231 SCREW 32 DICHTRING 2 433597 045 JOINT...

Page 741: ...433597 308 O RING 106 O RING 1 433597 054 O RING 107 O RING 1 433597 055 O RING 108 PRALLK RPER VOLLST 2 433597 206 BAFFLE BODY COMPL 109 X RING 1 433597 108 X RING 110 O RING 1 433597 038 O RING 111...

Page 742: ...ngaben enthalten Motor Nr Ersatzteilblatt Nr Bestell Nr Each order must include the following Engine No Spare parts sheet No Part No 122 SCHLITZSCHEIBE 1 433597 026 SLOTTED DISC 123 SCHRAUBE F R SCHLI...

Page 743: ...Einspritzpumpe Fuel Injection Pump B1 05 07 433597 KK M43 VM43 en 03 07 2007 EB031154 5 8 07...

Page 744: ...Einspritzpumpe Fuel Injection Pump B1 05 07 433597 KK M43 VM43 en 03 07 2007 EB031154 6 8 07...

Page 745: ...Einspritzpumpe Fuel Injection Pump B1 05 07 433597 KK M43 VM43 en 03 07 2007 EB031154 7 8 07...

Page 746: ...Einspritzpumpe Fuel Injection Pump B1 05 07 433597 KK M43 VM43 en 03 07 2007 EB031154 8 8 07...

Page 747: ...he following Engine No Spare part sheet No Part No DICHTUNGSSATZ VOLLST 1 433599 AA SET OF GASKETS ASSEMBLY O RING 3 433597 028 B1 05 07 433597 O RING O RING 4 433597 041 B1 05 07 433597 O RING O RING...

Page 748: ...05 07 437667 FUEL FILTER COMPL SEE B1 05 07 437667 3 ZWISCHENT CK 1 437660 103 INTERMEDIATE PIECE 5 DICHTUNG 2 1 7073 733 GASKET 6 DICHTRING 4 1 7073 102 JOINT RING 7 SECHSKANTSCHRAUBE 8 1 1372 388 H...

Page 749: ...Kraftstoffilter Anbau Fuel Filter Mounting B1 05 07 437660 DD M43 en 05 09 2007 EB031472 2 2 07...

Page 750: ...2 1 7010 133 JOINT RING 5 O RING 2 1 7667 005 O RING 6 DECKELSICHERUNG 2 2 7657 006 COVER SECURING 8 STIFTSCHRAUBE 8 1 1234 357 STUD 9 SECHSKANTMUTTER 8 1 2007 038 HEXAGON NUT 10 DECKEL 2 1 7667 110 C...

Page 751: ...G 2 1 7010 064 JOINT RING 39 K KENANSCHLAG 1 1 7667 039 STOP PIECE 50 WINKELKUGELHAHN 2 1 7667 014 ANGLE BALL COCK 51 L SBARER DOPPELNIPPEL 2 1 7667 013 SPACER BLOCK 55 LWANNE 1 1 7667 555 OIL PAN 58...

Page 752: ...Kraftstoff Doppel Feinfilter Duplex Fuel Fine Filter B1 05 07 437667 CC M43 en 19 02 2008 EB031478 3 4 07...

Page 753: ...Kraftstoff Doppel Feinfilter Duplex Fuel Fine Filter B1 05 07 437667 CC M43 en 19 02 2008 EB031478 4 4 07...

Page 754: ...lowing Engine No Spare parts sheet No Part No VERKLEIDUNG F R KRAFTSTOFFLEITG VOLLST 1 437669 BB FUEL PIPE COVERING ASSEMBLY 1 VERKLEIDUNG VOLLST 1 437669 101 COVERING PLATE COMPL 2 VERKLEIDUNG VOLLST...

Page 755: ...Verkleidung f r Kraftstoffleitung Fuel Pipe Covering B1 05 07 437669 BB M43 en 06 05 2004 EB027431 2 2 07...

Page 756: ...EVE 4 VERBINDUNGSST CK 1 438510 104 CONNECTING PIECE 5 ZYLINDERSCHRAUBE 1 258510 103 CYLINDER HEAD SCREW 6 SICHERUNGSRING 32 438510 006 CIRCLIP 7 O RING 2 1 7084 625 O RING 8 O RING 4 1 7084 671 O RIN...

Page 757: ...Kraftstoffverteiler Sammelleitung Fuel Distributing Collecting Pipe B1 05 07 438510 NN M43 en 20 03 2004 EB027218 2 3 07...

Page 758: ...Kraftstoffverteiler Sammelleitung Fuel Distributing Collecting Pipe B1 05 07 438510 NN M43 en 20 03 2004 EB027218 3 3 07...

Page 759: ...LIVERY PIPE ASSEMBLY 1 RADIALDRUCKST CK 1 438526 101 RADIAL THRUST PIECE 2 AUFNAHMEK RPER 1 438526 002 RECEIVING CASING 3 QUERDRUCKST CK 1 438526 103 TRANSVERSE THRUST PIECE 4 DRUCKSCHRAUBE 1 438526 0...

Page 760: ...Einspritzdruckleitung Anbau Fuel Injector Delivery Pipe Mounting B1 05 07 438526 BB M43 VM43 en 22 01 2008 EB026233 2 2 07...

Page 761: ...8533 CC FUEL PRESSURE DAMPER MOUNTING ASSEMBLY 1 BLASENSPEICHER VOLLST 2 438533 001 FUEL PRESSURE DAMPER COMPL 2 HALTER VOLLST 1 438533 052 BRACKET COMPL 3 HALTERUNGSSCHELLE 2 1 5028 758 CLAMP 4 REDUZ...

Page 762: ...Kraftstoffdruckd mpfer Anbau Fuel Pressure Damper Mounting B1 05 07 438533 CC M43 en 30 04 2004 EB027440 2 2 07...

Page 763: ...NG ANBAU VOLLST 1 438535 CC FUEL FILTER PIPE MOUNTING ASSEMBLY 1 KRAFTSTOFFILTERLEITUNG VOLLST 1 438535 101 FUEL FILTER PIPE COMPL 2 KRAFTSTOFFILTERLEITUNG VOLLST 1 438535 102 FUEL FILTER PIPE COMPL 5...

Page 764: ...Kraftstoffilterleitung Anbau Fuel Filter Pipe Mounting B1 05 07 438535 CC M43 en 06 05 2004 EB027436 2 2 07...

Page 765: ...CKLEITUNG VOLLST 1 438540 006 LEAK FUEL PIPE COMPL 10 HALTER 1 438540 510 BRACKET 13 ROHR VOLLST 1 438540 513 PIPE COMPL 14 ROHR VOLLST 2 438540 514 PIPE COMPL 18 SCHEIBE 1 438540 518 WASHER 20 O RING...

Page 766: ...Kraftstoffleckleitung Leak Fuel Piping B1 05 07 438540 MM M43 en 20 03 2004 EB027179 2 3 07...

Page 767: ...Kraftstoffleckleitung Leak Fuel Piping B1 05 07 438540 MM M43 en 20 03 2004 EB027179 3 3 07...

Page 768: ...1 438540 153 LEAK FUEL PIPE COMPL 4 KAFTSTOFFLECKLEITUNG VOLLST 1 438540 154 LEAK FUEL PIPE COMPL 5 KAFTSTOFFLECKLEITUNG VOLLST 1 438540 155 LEAK FUEL PIPE COMPL 6 KAFTSTOFFLECKLEITUNG VOLLST 1 43854...

Page 769: ...ende Angaben enthalten Motor Nr Ersatzteilblatt Nr Bestell Nr Each order must include the following Engine No Spare parts sheet No Part No 40 ROHRKLEMME 16 1 5011 001 PIPE CLAMP 41 ROHRKLEMME 10 1 501...

Page 770: ...Kraftstoffleckleitung Leak Fuel Piping B1 05 07 438540 PP M43 en 03 05 2004 EB027434 3 3 07...

Page 771: ...31 1 1 6422 31 Z 32 1 1 6422 32 Z 33 1 1 6422 33 Z 34 1 1 6422 34 Z 35 1 1 6422 35 Z 36 1 1 6422 36 Z 37 1 1 6422 37 Z 38 1 1 6422 38 Z 39 1 1 6422 39 Z 40 1 1 6422 40 Z 41 1 1 6422 41 Z 42 1 1 6422...

Page 772: ...P MOUNTING ASS 1 ZAHNRADPUMPE VOLLST 1 SIEHE B1 05 08 436417 GEAR PUMP COMPL SEE B1 05 08 436417 2 ZAHNRAD 1 1 6422 033 GEARWHEEL 6 ROHRKR MMER 1 436410 006 BEND 8 SCHEIBE 1 436440 005 WASHER 9 FLANSC...

Page 773: ...Schmier lpumpen Anbau Lubricating Oil Pump Mounting B1 05 08 436410 DD M43 en 12 11 2003 EB026393 2 2 08...

Page 774: ...ATING OIL PUMP ASSEMBLY 4 ANTRIEBSRADWELLE LAUFRADACHSE 1 436417 304 POWER ROTOR SHAFT IMPELLER AXLE 8 BUCHSE 8 436417 108 BUSH 9 ZYLINDERSCHRAUBE 8 436417 109 HEXAGON SOCKET HEAD CAP SCREW 10 ZYLINDE...

Page 775: ...Schmier lpumpe linksdrehend Lubricating Oil Pump anti clockwise B1 05 08 436417 MM M43 en 28 09 2006 EB030364 2 3 08...

Page 776: ...Schmier lpumpe linksdrehend Lubricating Oil Pump anti clockwise B1 05 08 436417 MM M43 en 28 09 2006 EB030364 3 3 08...

Page 777: ...ING OIL PUMP ASSEMBLY 4 ANTRIEBSRADWELLE LAUFRADACHSE 1 436417 304 POWER ROTOR SHAFT IMPELLER AXLE 8 BUCHSE 8 436417 108 BUSH 9 ZYLINDERSCHRAUBE 8 436417 109 HEXAGON SOCKET HEAD CAP SCREW 10 ZYLINDERS...

Page 778: ...Schmier lpumpe rechtsdrehend Lubricating Oil Pump clockwise B1 05 08 436417 NN M43 en 28 09 2006 EB030367 2 3 08...

Page 779: ...Schmier lpumpe rechtsdrehend Lubricating Oil Pump clockwise B1 05 08 436417 NN M43 en 28 09 2006 EB030367 3 3 08...

Page 780: ...heet No Part No SCHMIER LFILTER ANBAU VOLLST 1 437650 BB LUBRICATING OIL FILTER MOUNTING ASSEMBLY 1 SCHMIER LFILTER VOLLST 1 SIEHE B1 05 08 437657 LUBRICATING OIL FILTER COMPL SEE B1 05 08 437657 3 O...

Page 781: ...Schmier lfilter Anbau Lubricating Oil Filter Mounting B1 05 08 437650 BB M43 en 30 08 2007 EB031475 2 2 08...

Page 782: ...D PLUG 3 VERSCHLUSSSCHRAUBE 2 1 1041 609 HEXAGON HEAD SCREW PLUG 4 DICHTRING 2 1 7010 133 JOINT RING 5 O RING 2 1 7657 406 O RING 8 STIFTSCHRAUBE 12 437657 008 STUD 9 SECHSKANTMUTTER 16 1 2007 040 HEX...

Page 783: ...6 SECHSKANTMUTTER 2 1 2007 032 HEXAGON NUT 27 SPANNH LSE 1 1 0039 881 SPRING DOWEL PIN 28 O RING 1 437657 028 O RING 29 DICHTRING 1 437657 029 JOINT RING 45 VERSCHRAUBUNG 2 257657 045 SCREWED CONNECTI...

Page 784: ...et No Part No 100 KUGELHAHN 1 437657 100 BALL COCK 101 EINSCHRAUBSTUTZEN 4 437657 101 PIPE UNION 102 VERSCHRAUBUNG 2 437657 102 SCREWED CONNECTION 200 SIEBEINSATZ VOLLST 2 1 7657 450 SIEVE ELEMENT COM...

Page 785: ...Schmier l Doppelfilter Duplex Lubricating Oil Filter B1 05 08 437657 AA M43 en 24 05 2000 EB012187 4 5 08...

Page 786: ...Schmier l Doppelfilter Duplex Lubricating Oil Filter B1 05 08 437657 AA M43 en 24 05 2000 EB012187 5 5 08...

Page 787: ...7810 004 SET SCREW 6 DRUCKFEDER 1 256417 206 COMPRESSION SPRING 10 ZYLINDERSCHRAUBE 4 1 1152 111 CHEESE HEAD SCREW 11 VERSCHLUSSSCHRAUBE 1 1 1040 607 SCREW PLUG 12 O RING 1 437810 012 O RING 13 O RING...

Page 788: ...OLBEN 1 9 6417 502 PISTON 204 SPINDEL 1 9 7810 204 SPINDLE 206 KUGEL 1 1 8090 128 BALL 207 DRUCKFEDER 1 9 6417 507 COMPRESSION SPRING 208 SPRENGRING 1 1 0063 516 SPRING RING 209 SICHERUNGSRING 1 1 006...

Page 789: ...Druckbegrenzungsventil Pressure Limitation Valve B1 05 08 437810 AA M32 M43 en 28 10 2008 EB030362 3 5 08...

Page 790: ...Druckbegrenzungsventil Pressure Limitation Valve B1 05 08 437810 AA M32 M43 en 28 10 2008 EB030362 4 5 08...

Page 791: ...Druckbegrenzungsventil Pressure Limitation Valve B1 05 08 437810 AA M32 M43 en 28 10 2008 EB030362 5 5 08...

Page 792: ...N VALVE COMPL SEE B1 05 08 437810 8 DICHTUNG 2 9 8420 007 GASKET 9 DICHTUNG 1 438420 010 GASKET 10 DICHTUNG 1 1 7073 303 GASKET 11 DICHTUNG 1 1 7073 305 GASKET 12 SCHWEISSFLANSCH 1 1 5340 131 WELDING...

Page 793: ...Schmier lleitung Lube Oil Pipes B1 05 08 438420 FF M43 en 05 09 2007 EB031469 2 2 08...

Page 794: ...CONTROL PIPE MOUNTING ASSEMBLY 1 SCHMIER LLEITUNG VOLLST 1 438445 301 LUBE OIL PIPE COMPL 2 SCHMIER LLEITUNG VOLLST 1 438445 302 LUBE OIL PIPE COMPL 6 ROHRKLEMME 4 1 5011 002 PIPE CLAMP 9 SECHSKANTSCH...

Page 795: ...Steuerleitung f r ldruck Oil Pressure control Pipe B1 05 08 438445 EE M43 en 05 09 2007 EB031466 2 2 08...

Page 796: ...Nr Ersatzteilblatt Nr Bestell Nr Each order must include the following Engine No Spare parts sheet No Part No SCMIER LD SEN F R ZAHNR DER VOLLST 438450 DD LUBE OIL NOZZLE FOR GEARWHEEL ASS 1 LD SE VOL...

Page 797: ...Schmier ld sen f r Zahnr der Lube Oil Nozzle for Gearwheel B1 05 08 438450 DD M43 en 25 04 2002 EB025286 2 2 08...

Page 798: ...o Spare parts sheet No Part No SCHMIER LLECKLEITUNG ANBAU VOLLST 1 438480 KK LEAK OIL PIPE MOUNTING ASSEMBLY 1 LECKAGEROHR 8 438480 001 LEAK OIL PIPE 2 STECKROHR 1 438480 002 TUBE 3 SICHERUNGSRING 16...

Page 799: ...Schmier lleckleitung Anbau Leak Oil Pipe Mounting B1 05 08 438480 KK M43 en 13 03 2004 EB027204 2 2 08...

Page 800: ...COMPL 3 HALTER 1 438494 253 BRACKET 4 HALTER 2 438494 254 BRACKET 6 DICHTUNG 1 438494 002 GASKET 7 BLENDE 1 438494 257 ORIFICE PLATE 10 DICHTUNG 2 1 7073 723 GASKET 11 DICHTUNG 2 1 7073 353 GASKET 12...

Page 801: ...T NO Jede Bestellung mu folgende Angaben enthalten Motor Nr Ersatzteilblatt Nr Bestell Nr Each order must include the following Engine No Spare parts sheet No Part No 27 VERSCHLUSSSCHRAUBE 1 1 1041 60...

Page 802: ...Schmier lleitung f r Turbolader Lubricating Oil Pipe for Turbocharger B1 05 08 438494 PP M43 en 11 10 2004 EB027611 3 3 08...

Page 803: ...ST NR ITEM DESCRIPTION NUMBER PART NO Jede Bestellung mu folgende Angaben enthalten Motor Nr Ersatzteilblatt Nr Bestell Nr Each order must include the following Engine No Spare parts sheet No Part No...

Page 804: ...Abdeckbleche f r Schmier lfilter Cover plates for lube oil filter B1 05 08 438815 FF M43 en 12 05 2006 EB029875 2 2 08...

Page 805: ...Nr Bestell Nr Each order must include the following Engine No Spare parts sheet No Part No ABDECKBLECHE F SCHMIER LLEITUNG VOLLST 1 438815 GG COVER PLATES FOR LUBE OIL PIPES COMPL 1 ABDECKBLECH VOLLST...

Page 806: ...Abdeckbleche f r Schmier lleitung Cover plates for lube oil pipes B1 05 08 438815 GG M43 en 16 01 2008 EB032079 2 2 08...

Page 807: ...Motor Nr Ersatzteilblatt Nr Bestell Nr Each order must include the following Engine No Spare parts sheet No Part No DECKEL ANBAU VOLLST 1 436475 CC COVER MOUNTING ASSEMBLY 1 DECKEL 1 436475 201 COVER...

Page 808: ...Deckel Anbau Cover Mounting B1 05 09 436475 CC M43 en 09 05 2006 EB029727 2 2 09...

Page 809: ...heet No Part No K HLWASSERLEITUNG VOLLST 1 438320 SS COOLING WATER PIPE ASSEMBLY 1 K HLWASSERKLOTZ 9 438320 101 COOLING WATER CONNECTION 2 FLANSCH 16 438320 002 FLANGE 3 K HLWASSERROHR 16 438320 003 C...

Page 810: ...K hlwasserverteiler Sammelleitung Cool Water Distrib Collecting Pipe B1 05 09 438320 SS M43 en 13 03 2004 EB027163 2 3 09...

Page 811: ...K hlwasserverteiler Sammelleitung Cool Water Distrib Collecting Pipe B1 05 09 438320 SS M43 en 13 03 2004 EB027163 3 3 09...

Page 812: ...ATER PIPE 4 K HLWASSERANSCHLUSS 1 438330 404 COOLING WATER PIPE 5 K HLWASSERLEITUNG 1 438330 104 COOLING WATER PIPE 7 DICHTUNG 4 1 7073 302 GASKET 8 DICHTUNG 6 1 7073 737 GASKET 9 O RING 2 1 7084 681...

Page 813: ...10 133 JOINT RING 24 DICHTRING 1 1 7010 252 JOINT RING 25 VERSCHLUSSSCHRAUBE 1 1 1041 613 HEXAGON HEAD SCREW PLUG 26 VERSCHLUSSSCHRAUBE 12 1 1041 609 HEXAGON HEAD SCREW PLUG 27 VERSCHLUSSSCHRAUBE 1 1...

Page 814: ...K hlwasserleitung Cooling Water Pipe B1 05 09 438330 MM M43 en 20 03 2004 EB027177 3 4 09...

Page 815: ...K hlwasserleitung Cooling Water Pipe B1 05 09 438330 MM M43 en 20 03 2004 EB027177 4 4 09...

Page 816: ...ASSEMBLY 1 ENTW SSERUNGSLEITUNG VOLLST 1 438392 251 DRAIN PIPE COMPL 2 ENTW SSERUNGSLEITUNG VOLLST 1 438392 252 DRAIN PIPE COMPL 3 ENTW SSERUNGSLEITUNG VOLLST 1 438392 253 DRAIN PIPE COMPL 5 HALTER 1...

Page 817: ...Entw sserungsleitung Anbau Drain Pipe Mounting B1 05 09 438392 HH M43 en 15 01 2009 EB027402 2 2 09...

Page 818: ...AINING ASSEMBLY 2 KLOTZ 1 438395 502 BLOCK 3 HALTER 2 438395 203 BRACKET 4 DICHTUNG 1 438494 002 GASKET 5 ROHRKLEMME 4 1 5011 063 PIPE CLAMP 6 ROHRKLEMME 6 1 5011 035 PIPE CLAMP 7 SECHSKANTSCHRAUBE 6...

Page 819: ...HRLEITUNG 1 9131 218 STEEL PIPE 103 ROHRLEITUNG 1 9131 218 STEEL PIPE 104 FLANSCH 1 438396 103 FLANGE 105 BERWURFMUTTER 5 1 5040 143 UNION NUT 106 DICHTRING 2 1 7033 113 JOINT RING 107 MUFFENDURCHGANG...

Page 820: ...Entw sserung f r Turbolader Draining for Turbocharger B1 05 09 438395 RR M43 en 20 04 2009 EB032943 3 5 09...

Page 821: ...Entw sserung f r Turbolader Draining for Turbocharger B1 05 09 438395 RR M43 en 20 04 2009 EB032943 4 5 09...

Page 822: ...38395 RR M43 en 20 04 2009 EB032943 5 5 09 POS BENENNUNG STCK BEST NR ITEM DESCRIPTION NUMBER PART NO Jede Bestellung mu folgende Angaben enthalten Motor Nr Ersatzteilblatt Nr Bestell Nr Each order mu...

Page 823: ...ZUF HRLEITUNG VOLLST 1 437299 LL AIR ADMISSION PIPE ASSEMBLY 1 LUFTLEITUNG VOLLST 9 437299 051 AIR PIPE COMPL 2 LUFTLEITUNG VOLLST 1 437299 052 AIR PIPE COMPL 5 HALTER 1 437299 055 BRACKET 6 HALTER 1...

Page 824: ...Luftzuf hrleitung Air Admission Pipe B1 05 10 437299 LL M43 en 20 04 2004 EB027387 2 2 10...

Page 825: ...38610 003 SLEEVE 4 H LSE VOLLST 1 438610 004 SLEEVE COMPL 7 ANFAHRVENTIL VOLLST 1 SIEHE B1 05 05 1 4906 MASTER STARTING VALVE COMPL SEE B1 05 05 1 4906 8 SICHERHEITSVENTIL VOLLST 1 1 8660 106 RELIEF V...

Page 826: ...Luftleitung f r Grundmotor Air Pipe on Engine B1 05 10 438610 CC M43 en 07 04 2004 EB027292 2 2 10...

Page 827: ...14 DD AIR ADMISSION PIPE ASSEMBLY 1 LUFTLEITUNG VOLLST 1 438614 101 AIR PIPING COMPL 2 LUFTLEITUNG VOLLST 1 438614 102 AIR PIPING COMPL 4 STUTZEN 1 1 5093 222 MALE CONNECTOR 5 STUTZEN 1 1 5098 014 MAL...

Page 828: ...Luftzuf hrleitung Air Admission Pipe B1 05 10 438614 DD M43 en 05 07 2004 EB027513 2 2 10...

Page 829: ...ST 1 438617 004 CONTROL AIR PIPE COMPL 6 HALTER 10 438540 012 BRACKET 7 WINKELSTUTZEN 1 1 5093 242 UNION ELBOW 8 KONUS REDUZIERANSCHLUSS 12 7 8810 042 UNION REDUCING 9 T VERBINDUNGSSTUTZEN 10 1 5095 5...

Page 830: ...tzteilblatt Nr Bestell Nr Each order must include the following Engine No Spare parts sheet No Part No 27 SECHSKANTSCHRAUBE 2 1 1372 184 HEXAGON BOLT 29 SECHSKANTMUTTER 2 1 2007 032 HEXAGON NUT 30 STE...

Page 831: ...Steuerluftleitung Anbau Control Air Piping B1 05 10 438617 QQ M43 en 06 12 2007 EB029883 3 3 10...

Page 832: ...T B1 05 05 1 4902 PRESSURE REDUCER SEE LIST B1 05 05 1 4902 10 0 3 MONTAGEWINKEL 1 1 4817 3 MOUNTING ANGLE 10 0 4 STELLSCHRAUBE 1 1 4817 4 ADJUSTING SCREW 10 0 5 O RING 1 1 4817 5 O RING 10 0 6 DOPPEL...

Page 833: ...Druckregeleinheit Pressure Regulator B1 05 11 1 4817 AA M25 M601C en 20 03 1997 EB000196 2 2 11...

Page 834: ...ngaben enthalten Motor Nr Ersatzteilblatt Nr Bestell Nr Each order must include the following Engine No Spare part No Order No ZUS TZLICHE MESSSTELLEN VOLLST 1 430926 FF ADDITIONAL MEASURING POINTS AS...

Page 835: ...Zus tzliche Messstellen Additional Measuring Points B1 05 11 430926 FF M43 en 06 05 2004 EB027428 2 3 11...

Page 836: ...Zus tzliche Messstellen Additional Measuring Points B1 05 11 430926 FF M43 en 06 05 2004 EB027428 3 3 11...

Page 837: ...R 2 9 4630 006 PRESSURE GAUGE 0 10 BAR 7 MANOMETER 0 4 BAR 1 9 4630 007 PRESSURE GAUGE 0 4 BAR 8 MANOMETER 0 10 BAR 1 9 4630 008 PRESURE GAUGE 0 10 BAR 9 MANOMETER 0 40 BAR 1 9 4630 009 PRESSURE GAUGE...

Page 838: ...1 434630 037 SWITCH 38 BEFESTIGUNGSFLANSCH 1 434630 038 FASTENING FLANGE 39 HILFSSCHALTER 1 434630 039 SWITCH 40 SCHILDTR GER 1 434630 040 PLATE SUPPORT 45 STECKVERBINDER 2 0 9963 042 CONNECTOR 46 ST...

Page 839: ...Manometertafel Gauge Panel B1 05 11 434630 GG M43 en 08 08 2008 EB027341 3 3 11...

Page 840: ...205 PIPE COMPL 6 VERBINDUNGSLEITUNG VOLLST 1 434639 206 PIPE COMPL 7 VERBINDUNGSLEITUNG VOLLST 2 434639 207 PIPE COMPL 8 VERBINDUNGSLEITUNG VOLLST 1 434639 208 PIPE COMPL 9 VERBINDUNGSLEITUNG VOLLST...

Page 841: ...RBINDUNGSSTUTZEN 17 1 5095 042 PIPE UNION 45 WINKELSTUTZEN 2 1 5093 222 ADJUSTABLE ELBOW 46 VERBINDUNGSSTUTZEN 4 1 5095 242 UNION ELBOW 48 SCHWENKVERSCHRAUBUNG 2 1 5093 627 BANJO 50 GEWINDEREDUZIERUNG...

Page 842: ...ilblatt Nr Bestell Nr Each order must include the following Engine No Spare parts sheet No Part No 81 SECHSKANTSCHRAUBE 1 1 1387 449 HEXAGON SCREW 84 SECHSKANTMUTTER 28 1 2007 034 HEXAGON NUT 87 SCHEI...

Page 843: ...Medienleitung Media Pipe B1 05 11 434639 ZC M43 en 20 04 2004 EB027332 4 6 11...

Page 844: ...Medienleitung Media Pipe B1 05 11 434639 ZC M43 en 20 04 2004 EB027332 5 6 11...

Page 845: ...Medienleitung Media Pipe B1 05 11 434639 ZC M43 en 20 04 2004 EB027332 6 6 11...

Page 846: ...PIPE COMPL 3 ROHR VOLLST 1 434810 103 PIPE COMPL 4 ROHR VOLLST 7 434810 054 PIPE COMPL 9 ABSTANDSHALTER 2 9 4810 009 DISTANCE PIECE 10 SIPHONBLOCK 9 434810 110 SIPHON BLOCK 11 ANSCHLUSSPLATTE 9 434810...

Page 847: ...Triebraum berwachung Crankcase Oil Mist Detector B1 05 11 434810 ZF M43 en 07 08 2008 EB032964 2 3 11...

Page 848: ...Triebraum berwachung Crankcase Oil Mist Detector B1 05 11 434810 ZF M43 en 07 08 2008 EB032964 3 3 11...

Page 849: ...ng Engine No Spare parts sheet No Part No WASSERERKENNUNG VOLLST 1 434818 CC WATER DETECTION ASSEMBLY COMPL 1 LEITUNG VOLLST 1 434818 051 PIPE COMPL 2 LEITUNG VOLLST 1 434818 052 PIPE COMPL 3 STUTZEN...

Page 850: ...Wassererkennung Water Detection B1 05 11 434818 CC M43 en 11 02 2002 EB025036 2 2 11...

Page 851: ...438845 FF BRACKET MOUNTING ASSEMBLY 1 HALTER VOLLST 2 438845 201 BRACKET COMPL 2 KONSOLE VOLLST 1 438845 202 CONSOLE COMPL 3 BLECH 2 438845 203 PLATE 4 SCHWINGUNGSD MPFER 6 438845 204 VIBRATION DAMPER...

Page 852: ...Halter Anbau Bracket Mounting B1 05 11 438845 FF M43 en 22 05 2006 EB029899 2 2 11...

Page 853: ...teilblatt Nr Bestell Nr Jedere bestelling moet de volgende gegevens beinhouden Motor nr nr van het onderdelenblad bestel nr DRUCKW CHTER VOLLST 0 9 1 5 1 4843 044 PRESSURE SWITCH COMPL DRUCKW CHTER VO...

Page 854: ...Druckw chter Pressure Switch B1 05 11 9 4843 AA M20 M601C en 16 12 2008 EB009411 2 2 11...

Page 855: ...CH 1 436347 105 FLANGE 7 SEITENPLATTE 1 436347 107 SIDE PLATE 9 INNENSTERN 1 436347 109 STAR 10 BEILAGE 30 436347 110 SHIM 11 BEILAGE 436347 111 SHIM 12 SECHSKANTSCHRAUBE 30 436347 112 HEXAGON BOLT 13...

Page 856: ...Schwingungsd mpfer Vibration Damper B1 05 12 436347 CC M43 en 10 10 2000 EB023328 2 2 12...

Page 857: ...ng mu folgende Angaben enthalten Motor Nr Ersatzteilblatt Nr Bestell Nr Each order must include the following Engine No Spare parts sheet No Part No SCHWUNGRAD ANBAU VOLLST 1 437310 AA FLYWHEEL MOUNTI...

Page 858: ...Schwungrad Anbau Flywheel Mounting B1 05 12 437310 AA M43 en 20 01 1998 EB011818 2 2 12...

Page 859: ...Nr Bestell Nr Each order must include the following Engine No Spare parts sheet No Part No T RNVORRICHTUNG VOLLST 1 437330 EE BARRING GEAR ASSEMBLY 1 T RNMASCHINE VOLLST 1 SIEHE B1 05 12 437332 TURNIN...

Page 860: ...T rnvorrichtung Barring Gear B1 05 12 437330 EE M43 en 06 09 2002 EB025586 2 2 12...

Page 861: ...HEEL 7 ZWISCHENWELLE 1 437332 007 INTERMEDIATE SHAFT 8 ZAHNRAD 1 437332 008 GEAR 9 ABTRIEBSWELLE 1 437332 009 OUTPUT SHAFT 10 VERSCHIEBEZAHNRAD 1 437332 010 TRANSFER GEAR 11 VERSCHIEBEGABEL 1 437332 0...

Page 862: ...CH 1 9 7332 027 FLANGE 28 H LSE 4 9 7332 028 SLEEVE 29 RILLENKUGELLAGER 1 9 7332 043 BALL BEARING 30 RILLENKUGELLAGER 1 1 8014 491 BALL BEARING 31 KEGELROLLENLAGER 2 437332 031 TAPERED ROLLER BEARING...

Page 863: ...CREW 48 SECHSKANTSCHRAUBE 2 1 1372 146 HEXAGON SCREW 49 GEWINDESTIFT 1 1 1102 052 SET SCREW 50 GEWINDESTIFT 1 1 1102 046 SET SCREW 51 GEWINDESTIFT 2 1 1100 035 SET SCREW 52 STIFTSCHRAUBE 4 1 1253 164...

Page 864: ...tor Nr Ersatzteilblatt Nr Bestell Nr Each order must include the following Engine No Spare parts sheet No Part No 65 GRENZWERTSCHALTER 1 9 7332 084 MICROSWITCH 66 VERSCHLUSSSCHRAUBE 3 1 1040 613 PLUG...

Page 865: ...T rnmaschine Turning Device B1 05 12 437332 AA M43 en 26 09 2002 EB025609 5 7 12...

Page 866: ...T rnmaschine Turning Device B1 05 12 437332 AA M43 en 26 09 2002 EB025609 6 7 12...

Page 867: ...T rnmaschine Turning Device B1 05 12 437332 AA M43 en 26 09 2002 EB025609 7 7 12...

Page 868: ...or Nr Ersatzteilblatt Nr Bestell Nr Each order must include the following Engine No Spare parts sheet No Part No TOTPUNKTANZEIGER ANBAU VOLLST 1 437350 AA DEAD CENTRE INDICATOR MOUNTING ASSEMBLY 1 TOT...

Page 869: ...Totpunktanzeiger Anbau Dead Centre Indicator Mounting B1 05 12 437350 AA M43 en 11 10 1999 EB021984 2 2 12...

Page 870: ...2 HALTER 1 434691 202 BRACKET 3 HALTER 2 344692 022 BRACKET 6 HALTER 1 434691 006 BRACKET 9 HALTER 4 434639 016 BRACKET 18 PROFIL 1 7010 223 PROFILE 19 PROFIL 1 7010 216 PROFILE 21 PROFIL 344692 070...

Page 871: ...ten Motor Nr Ersatzteilblatt Nr Bestell Nr Each order must include the following Engine No Spare parts sheet No Part No 48 SECHSKANTSCHRAUBE 4 1 1387 447 HEXAGON SCREW 51 SCHEIBE 10 1 0040 222 WASHER...

Page 872: ...Kabelf hrung Anbau Cable Guide Mounting B1 05 14 434691 MM M43 en 03 03 2009 EB030001 3 4 14...

Page 873: ...Kabelf hrung Anbau Cable Guide Mounting B1 05 14 434691 MM M43 en 03 03 2009 EB030001 4 4 14...

Page 874: ...Stand by parts B2 en 26 05 2009 AA000114 1 1 Stand by parts...

Page 875: ...Stand by parts Stand by parts B2 05 20 14 M43 en 22 05 2009 AA045561 1 21...

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Page 896: ...External Documentation Type M43C 68 280 68 281 External Documentation C0 M43C en 26 05 2009 AA020128 1 2 281717 Engine No Record No...

Page 897: ...the agreed purpose and must not be used for any other purpose Copies or other reproductions including storage processing or distribution by using electronic systems may only be made to the agreed purp...

Page 898: ...uctions A3 03 Instructions for Heavy Fuel Operation A3 04 Initial Operation Engine A3 05 Operational Supervision Engine A3 06 Removal from operation Engine A3 07 Danger of Frost Engine A3 08 Running i...

Page 899: ...Total Index Book A B and C C0 01 en 26 05 2009 AA020077 2 2 External Documentation C0 Total Index Book A B and C C0 01 Introduction Electrical Equipment C0 02 Table of contents C5 01...

Page 900: ...be treated separately stating its respective engine No Please find attached the required enquiry order sheets 4 For reasons of order handling each order must contain the following data P O number Cust...

Page 901: ...ble Exhaust thermocouple cylinder 1 Next to the plug a metal plate with identification of the measuring point is fitted Additionally the measu ring point number is identified on the cable of the plug...

Page 902: ...C en 28 11 2006 AA035841 3 7 Variant B By means of the drawings Sensor Actuators Arrangement Engine General View Here as well measuring point 8211 1 can be found Procedure as described above Example B...

Page 903: ...can be clearly identified by means of the drawing Junction Box 1 In this example K9 In the chapter Electrical Equipment Engine C5 05 05 10 nn the component with stock No 213 480 770 is easily found by...

Page 904: ...documents Sensoric Level Sensor Junction Box 1 Alarm System Level probe B7301 Water min Measuring point No 7301 In the chapter Electrical Equipment Engine C5 05 05 10 nn the component with stock No 21...

Page 905: ...02 M20 M601C en 28 11 2006 AA035841 6 7 Variant D Ordering a cable If a cable has to be replaced at least a measuring point or plug designation is to be safely identified By stating the engine number...

Page 906: ...structions Bitte stets angeben Pl i d Nur von Caterpillar auszuf llen O l b l d b C ill Pos Item Sach Nr Stock No Zeichnungs Teile Nr Drawing Part No Sach Nr Stock No Zeichnungs Teile Nr Drawing Part...

Page 907: ...05 04 20 26 02 Oil Regulations Woodward C5 05 04 20 27 01 Engine regulation C5 05 05 Three position Controller Console Mounting C5 05 05 09 16 01 Electrical Equipment C5 05 05 10 25 71 Circuit diagram...

Page 908: ...Cooling Pump Unit HT C5 05 09 01 11 56 E Engine C5 05 09 01 40 05 Cooling Water Preheating Set C5 05 09 09 08 05 Engine Adjusting Valve C5 05 09 09 15 00 Engine control equipment C5 05 11 Oil Mist Det...

Page 909: ...List of Measuring Points C5 05 02 01 09 89 M43 en 04 02 2009 FD039517 1 14 List of Measuring Points...

Page 910: ...atum Name Norm DIN IEC Caterpillar Motoren GmbH Co KG VT3 cvb Urspr Ers f Ers d Me stellenliste List of Measuring Points 1 00 1 09 61 00 35 281716 721 Caterpillar Confidential Green Blatt page 1 von o...

Page 911: ...This measuring point has the function Load Reduction and acts as a TAHH Temperature Alarm High High It has to be suppressed when the engine load is below 40 and has to be delayed for 16s The sensor s...

Page 912: ...te deviation of m ean average value reduct alarm cyl alarm of turbocharger outlet reduction alarm of turbocharger outlet alarm of turbocharger inlet 480 C 380 C 470 C 500 C 400 C 490 C 490 C 290 C 490...

Page 913: ...d Main engine unidirectional The clutch must be disengaged automatically The CP propeller pitch must be automatically set to zero For multi engine installation with a combining gear and one propeller...

Page 914: ...belkonzentration im Kurbelraum 2 0 5 25 Shutdown oil mist concentration in crankcase 2 binary 2103 PALL Frischwasserdruck HT vor Motor h 0 400 kPa Shutdown cooling water pressure HT at engine inlet 16...

Page 915: ...tern Start Pump cooling water pressure HT at engine inlet 250 kPa binary h 20 kPa below operating value 2111 PLL Frischwasserdruck NT vor K hler 0 600 kPa NO contact extern Start Pump cooling water pr...

Page 916: ...ff 500 min 1 binary 9532 1 S Motorlastsignal 0 110 signal for CPP load control Function engine load signal 4 20 mA 9532 2 S Motorlastsignal 0 110 signal for exhaust gas supervision Function engine loa...

Page 917: ...icator filter 90kPa binary CM 1202 TAH Schmier ltemperatur vor Motor 70 C 40 160 C analog Alarm lub oil temp at engine inlet 60 65 C Pt100 1251 QAH lnebelkonzentration im Kurbelraum 2 0 5 25 NC contac...

Page 918: ...L Kraftstoffdifferenzdruck an Kreislaufpumpe 50 kPa 60 340 kPa NC contact Alarm fuel oil diff pressure at circulating pump 30s 100 kPa yard supply 5251 VAH Kraftstoffviskosit t vor Motor 12 4 cSt 0 50...

Page 919: ...stemperatur nach Zylinder 4 n min 0 600 C analog Alarm exhaust gas temp after cyl 4 16s see page 3 4 20mA CM8211 5 TAHH Abgastemperatur nach Zylinder 5 n min 0 600 C analog Alarm exhaust gas temp afte...

Page 920: ...nterdr ckung 7201 Alarm Alarm suppression 7201 binary 9601 SA Spannungsausfall an Klemmstelle X1 Alarmkreis NC contact Alarm voltage fail at terminal X1alarm circuit 1s binary 9616 SA St rung elektron...

Page 921: ...r 0 50 cSt analog extern yard supply DICARE Fuel viscosity at engine inlet 11 cSt 4 20mA CM6181 P Ansaugluftdruck im Maschinenraum 80 120 kPa analog DICARE intake air pressure in engine room 4 20mA CM...

Page 922: ...cvb Urspr Ers f Ers d Me stellenliste List of Measuring Points 1 00 1 09 61 00 35 281716 721 Caterpillar Confidential Green Blatt page 13 von of 13 CM9429 NI Turboladerdrehzahl 0 30000 min 1 analog DI...

Page 923: ...List of Measuring Points Engine Sensors and Actuators C5 05 02 01 50 88 M43 en 01 02 2005 FD029289 1 4 List of Measuring Points Engine Sensors and Actuators...

Page 924: ...arm 1251 0 5 25 binary 1253 0 5 25 binary 9631 binary 1251 2 2 1253 2 2 1 evaluation unit for 1251 1253 9631 2102 Pressure transmitter Cooling water pressure HT at engine inlet low alarm 0 600 kPa 4 2...

Page 925: ...at engine inlet high alarm 40 160 C PT 100 65 C 45 60 C 7206 Resistance thermometer Intake air temp at turbocharger inlet Dicare 40 160 C PT 100 50 C 7301 Level probe switch unit Condense water in ch...

Page 926: ...uel rack stop position binary 9509 Distance sensor switching device Fuel setting 125 Load 0 20mA 100 Load 9561 Limit switch Turning gear engaged starting interlock binary 9601 Relay contact Voltage fa...

Page 927: ...UG40 Actuator C5 05 04 20 20 34 en 18 02 2002 FD022663 1 27 UG40 Actuator...

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Page 953: ...O Box 1519 Fort Collins CO 80522 1519 USA 1000 East Drake Road Fort Collins CO 80525 USA Phone 1 970 482 5811 Fax 1 970 498 3058 E mail and World Wide Web Home Page http www woodward com Woodward has...

Page 954: ...Booster Servomotor C5 05 04 20 22 01 en 20 10 2003 FD022607 1 37 Booster Servomotor...

Page 955: ...36684M Booster Servomotor Single Cylinder 8901 037 043 051 Tandem 8901 065 067 Two Stage 8901 091 103 Installation and Operation Manual Manual 36684M...

Page 956: ...s or electric control s the actuator s fuel control s the driving mechanism s the linkage s or the controlled device s fail IMPORTANT DEFINITIONS WARNING indicates a potentially hazardous situation w...

Page 957: ...s 29 How to Contact Woodward 29 Engineering Services 30 Technical Assistance 31 Illustrations and Tables Figure 1 1 Schematic of Single Booster Connections to PG Type Governor 3 Figure 1 2 Schematic o...

Page 958: ...Booster Servomotor Manual 36684 ii Woodward...

Page 959: ...ide of the piston opposite this oil forces the piston against the oil which flows through ports at the other end of the cylinder to the governor When air is removed from the piston the spring returns...

Page 960: ...overnor s accumulator Outlet 2 is connected to the speed setting servo of PGA PGPL and PGG governors equipped with any shutdown feature Outlet 3 is connected to a point directly under the power piston...

Page 961: ...Manual 36684 Booster Servomotor Woodward 3 Figure 1 1 Schematic of Single Booster Connections to PG Type Governor Figure 1 2 Schematic of Tandem Booster Connections to PG Type Governor...

Page 962: ...Booster Servomotor Manual 36684 4 Woodward Figure 1 3 Outline Drawing of Single Booster...

Page 963: ...Manual 36684 Booster Servomotor Woodward 5 Figure 1 4 Outline Drawing of Tandem Booster...

Page 964: ...Booster Servomotor Manual 36684 6 Woodward Figure 1 5 Outline Drawing of Two Stage Booster...

Page 965: ...ngine and it must vent the air cylinder of the booster to atmosphere when starting air is removed from the engine Air pressure at the booster air inlet must not exceed 3500 kPa 500 psi CAUTION Purge a...

Page 966: ...he volume of oil supplied to the governor in one stroke of the booster servomotor Installing and Adjusting a Tandem Booster Models 8901 065 and 8901 067 Figures 1 4 and 2 3 On PGA governors decals ind...

Page 967: ...is usually best to adjust both of these screws the same distance and regulate the rate of oil flow through outlets 2 and 3 with their respective needle valves Installing and Adjusting a Two Stage Boo...

Page 968: ...of oil going to the governor through oil outlets 1 and 3 This controls the maximum amount of fuel output during a booster assisted start x If you use outlet 2 the shuttle piston adjusting screw limits...

Page 969: ...Manual 36684 Booster Servomotor Woodward 11 Figure 2 1 Governors Used with Single Cylinder Boosters...

Page 970: ...Booster Servomotor Manual 36684 12 Woodward Figure 2 2 Governors Used with Single Cylinder Boosters...

Page 971: ...Manual 36684 Booster Servomotor Woodward 13 Figure 2 3 Governors Used with Tandem Boosters...

Page 972: ...Booster Servomotor Manual 36684 14 Woodward Figure 2 4 Governors Used with Two Stage Boosters...

Page 973: ...prevents oil from flowing from the booster back to the sump in the governor Second Phase of Operation Figure 3 2 Single Booster Phase 2 Refer to Figure 3 2 which represents a single cylinder booster...

Page 974: ...tle piston reaches the end of its stroke it uncovers the passages to outlets 1 and 3 and oil flow through outlet 2 ceases Oil remaining in the booster flows through outlets 1 and 3 to the relay and po...

Page 975: ...the main piston is vented to atmosphere through the starting air valve Spring forces return the main booster piston and shuttle piston to their original positions Reduced pressure in the booster cause...

Page 976: ...Booster Servomotor Manual 36684 18 Woodward...

Page 977: ...ted on the cover of the manual this is manual 36684 3 The part reference number in the parts list and the description of the part or part name Figures 4 1 4 2 and 4 3 and their associated parts lists...

Page 978: ...ve Assembly 3 36684 31 Cylinder Head 1 36684 32 Booster Spring 1 36684 33 Accumulator Cylinder 1 36684 34 Piston 1 36684 35 End Cap 1 36684 36 5 16 24 Screw 4 36684 37 Flat Washer 8 36684 38 5 16 Shak...

Page 979: ...Manual 36684 Booster Servomotor Woodward 21 Figure 4 1 Exploded View of Single Boosters...

Page 980: ...84 32 Booster Spring 2 36684 34 Piston 2 36684 36 5 16 24 Screw 6 36684 37 Flat Washer 6 36684 38 5 16 Shakeproof Washer 6 36684 39 1 4 Threadseal 2 36684 40 Flat Washer 2 36684 41 1 4 28 Nut 2 36684...

Page 981: ...Manual 36684 Booster Servomotor Woodward 23 Figure 4 2 Exploded View of Tandem Boosters...

Page 982: ...36684 76 500 Flat Washer 1 36684 77 500 13 Hex Nut 1 36684 78 500 13 Stroke Limit Screw 1 36684 79 3 484 ID O ring 1 36684 80 Servo Head Assembly 1 36684 81 Steel Ball 1 36684 82 Ball Check Spring 1...

Page 983: ...Manual 36684 Booster Servomotor Woodward 25 Figure 4 3 Exploded View of Two Stage Boosters...

Page 984: ...Booster Servomotor Manual 36684 26 Woodward...

Page 985: ...tructured program and includes the full standard Woodward product warranty Woodward Product and Service Warranty 5 01 1205 This option allows you to call in the event of an unexpected outage or in adv...

Page 986: ...dward for repair please contact Woodward in advance to obtain a Return Authorization Number When shipping the item s attach a tag with the following information x name and location where the control i...

Page 987: ...ng information x the part number s XXXX XXX that is on the enclosure nameplate x the unit serial number which is also on the nameplate How to Contact Woodward In North America use the following addres...

Page 988: ...via telephone email us or use our website and reference Customer Services and then Technical Support Product Training is available at many of our worldwide locations standard classes We also offer cu...

Page 989: ...s steam etc Rating Application Control Governor Information Please list all Woodward governors actuators and electronic controls in your system Woodward Part Number and Revision Letter Control Descrip...

Page 990: ...1519 USA 1000 East Drake Road Fort Collins CO 80525 USA Phone 1 970 482 5811 x Fax 1 970 498 3058 Email and Website www woodward com FM 57982 BS EN ISO 9001 1994 6 March 2001 Woodward has company own...

Page 991: ...Digital Speed Control 723 C5 05 04 20 26 02 en 09 11 2004 FD021449 1 79 Digital Speed Control 723...

Page 992: ...MANUAL B36146V2 C APPLICATION NAME SINGLE ENGINE PROPULSION CUSTOMER NAME MaK MAIN CHASSIS 8262 974 723 PLUS DIGITAL CONTROL CABINET OPERATION AND MAINTENANCE MANUAL...

Page 993: ...prevent damage to a control system that uses an alternator or battery charging device make sure the charging device is turned off before disconnecting the battery from the system CAUTION Electronic c...

Page 994: ...4 2 1 Discrete Relay outputs 4 2 4 2 2 Analog inputs 4 2 4 2 3 Analog outputs 4 3 4 3 BASIC CONTROL 4 3 4 3 1 Speed sensing 4 3 4 3 2 Speed reference 4 4 4 3 3 Speed Control 4 5 4 4 GENERATOR MODE 4 5...

Page 995: ...5 12 5 3 9 INFO OTHER ENG 5 14 5 3 10 PORT SETTING 5 14 5 3 11 SPEED SETTING 5 14 5 3 12 LOAD SHARING 5 16 5 3 13 FUEL LIMITERS 5 17 5 3 14 DISPLAY 5 19 5 3 15 ANALOG I O 5 19 5 3 16 DISCRETE I O 5 2...

Page 996: ...ND HELD PROGRAMMER CONTROL WIRING DIAGRAM The manual describes the procedures necessary to take the system from a mechanically installed condition to the fully operational condition For installation i...

Page 997: ...personnel and or lifting equipment to move the cabinet 1 5 Notes Warnings and Cautions The following examples show how notes warnings and cautions are used in this manual Notes are used in the text t...

Page 998: ...store static electric charges as much as synthetics 3 Keep plastic vinyl and styrofoam materials such as plastic or styrofoam cups cup holders cigarette packages cellophane wrappers vinyl books or fo...

Page 999: ...ESD Protection and Handling Manual B36146V2 C 2 2 Woodward...

Page 1000: ...can also be expanded for future control needs The custom programmable version can be used for more unique engine functions such as Dual Fuel Engine monitoring and safety and air fuel ratio control Th...

Page 1001: ...s an error If the request was not received correctly for example there was a transmission error such as parity or a bad CRC checksum the slave will not respond and the master must resend the request a...

Page 1002: ...on Mode the speed is changed using a 4 20 mA signal or it can run in constant speed mode In Genset Mode the engine runs at rated speed and speed changes occur via the raise and lower discrete inputs 3...

Page 1003: ...control is switched off or is defective The speed changes are done from the backup module inside the cabinet or from the mechanical governor itself if there is double engine backup mode the droop kno...

Page 1004: ...elect I0 6 Synchronise Command NOT USED in Single Engine Operation I0 7 Gearbox Clutch Feedback I1 0 Stop Command NC Principle I1 1 Emergency Stop Command I1 2 Propulsion Mode Select I1 3 Genset Mode...

Page 1005: ...mum Speed Selected Lamp Q1 0 Constant Speed Mode Lamp Q1 1 Genset Propulsion Mode Lamp Q1 2 Local Control Mode Lamp Q1 3 Load Limitation Lamp Q1 4 Speed Setting Mode Active Lamp Q1 5 Governor Fault Re...

Page 1006: ...owing selections can be made 1 PID Output 2 Actual Speed Output 3 Actual Load Output kW 4 Actual Limit Output 5 Torsional Level Output 6 Jump Rate Limiter Output 7 Actual Speed Reference 4 3 Basic Con...

Page 1007: ...Rated Speed at the Accel Rate If a Lower or Raise contact is given the speed reference is stopped The reference can be adjusted again with the Lower or Raise contacts The rate depends on the Lower Ra...

Page 1008: ...in Integrator rate Derivative ratio Fast proportional gain and window The dynamic settings of the PID must be set for the engine type and type of application LSS Bus The Low Signal Select bus selects...

Page 1009: ...2 Slave offset until fuel index on fuel pump is the same on Master engine as on the Slave engine Load both the engines till full load Adjust the engine 2 Slave Gain until the fuel index on fuel pump...

Page 1010: ...load rate is adjusted with Load Rate act s As soon as the level of the master is reached the slave follows the actuator signal received from the master 4 5 3 Transfers between Master and Slave The fol...

Page 1011: ...hen the engine is started in propulsion mode the clutch fuel limit is activated just after the start fuel limit is disabled This clutch fuel limit limits the maximum fuel rack position until the clutc...

Page 1012: ...d the Ice breaking mode or Fuel Reference Mode When this mode is selected the engine will not be controlled by the 723plus control but by a 4 20 mA fuel reference signal input This fuel reference inpu...

Page 1013: ...e electronic governor fails the engine ramps up to the speed reference of the mechanical back up governor and that governor takes control of the engine When two engines are clutched in the one in whic...

Page 1014: ...is tuneable in service mode No symbol Entry that can only be monitored 5 2 Configure Mode To access the Configure menus the engine must be shutdown Refer to Chapter 6 HAND HELD PROGRAMMER On the Hand...

Page 1015: ...it can be configured which alarm will be generated 1 No Alarm 2 Minor Alarm 3 Major Alarm Boost Press In Fld In case the Boost pressure input signal is lower than 2 mA or above 22 mA it can be config...

Page 1016: ...No alarm will be given in case of lost of communication For Single engine operation this parameter must be set to False LON ADRESS Number The Address number of the unit In case of Master Slave commun...

Page 1017: ...smitted characters 1 1 stop bit 2 1 5 stop bits 3 2 stop bits Parity This field is the parity used for error checking 1 Off 2 Odd 3 Even Modbus Format This field determines which format this block use...

Page 1018: ...ly Open or Normally Close Status False The contact is configured as Normally Open NO True The contact is configured as Normally Closed NC Jet Assist Cnt NC To configure the Jet Assist Contact for the...

Page 1019: ...the PLC This parameter will be transferred by Modbus communication from 723plus to the PLC False Backup control is NOT present on other engine For Single engine operation this parameter must be set t...

Page 1020: ...dow Outside this window the Fast Prop Gain is activated Fast Gain Window 1 Fast Gain Window works in conjunction with Fast Prop Gain as described above Fast Gain Window is not absolute but an anticipa...

Page 1021: ...pendant gain curve Speed 1 3 rpm The third speed setpoint of the 4 point speed dependant gain curve Gain 1 3 The actual gain belonging to the third speed setpoint of the 4 point speed dependant gain c...

Page 1022: ...ctivated when the Enable P2 Curve parameter is set to True Description Range Nominal Actual Speed 2 1 rpm 0 2000 0 Gain 2 1 0 01 100 0 0 3 Speed 2 2 rpm 0 2000 400 Gain 2 2 0 01 100 0 0 3 Speed 2 3 rp...

Page 1023: ...ed will reach a value below the Min Spd Limit the 723plus will take over control again and the engine speed will be kept to this minimum speed when in fuel control mode until the 4 20 mA fuel referenc...

Page 1024: ...is the load in at which the second limiter becomes active Jump 2 LSS Jump 2 LSS is the allowed jump from the PID before the rate limiter becomes active Rate Jump 2 sec Rate Jump 2 sec is the rate at...

Page 1025: ...l Gain By changing this Gain Factor minimum Proportional Gain can be determined Integrator Factor This parameter sets the factor which determines the maximum Integrator Rate where the control automati...

Page 1026: ...Boost In Offset Offset calibration of the third analog Input Boost In Gain Gain calibration of the third analog Input Rmt Spd Offset Offset calibration of the fourth analog Input Rmt Spd Gain Gain ca...

Page 1027: ...to HandHeld mode 2 This means on J1 a Woodward Handheld programmer p n 9907 205 can be used to change or view parameters By means of changing the parameter from 2 into 1 the UPCI Servlink mode will be...

Page 1028: ...peed Lower Raise Rate Lower Raise rate is the rate rpm s at which the speed reference is ramped when using the Lower Raise Speed inputs This value is only activated when the control is switched in gen...

Page 1029: ...ved This is only for the second engine slave engine to be clutched to the gearbox The Load rate stays active until the same level as the master input signal level has been reached Unload Rate act s Un...

Page 1030: ...trt Lmt Rate units s 0 1 100 0 2 5 Clutch Fuel Limit 0 0 100 0 100 0 Max Fuel Limit 0 0 100 0 100 0 Load Limit Act 0 0 100 0 60 0 Load Limit Rate Act sec 0 1 10 0 1 0 Boost Lim in A mA 4 0 20 0 4 0 Bo...

Page 1031: ...int in case the actual actuator position is higher than the Load Limit setpoint Boost Lim in A mA Manifold air pressure input signal mA point A This field sets the first input signal for the manifold...

Page 1032: ...l I value DISPLAY VALUE Running as Slave DISPLAY VALUE Speed Speed displays the actual engine speed derived from the speed sensors The speed will be displayed in rpm Speed Reference Speed Reference di...

Page 1033: ...dresses have been set this value will stay at 0 rpm Fuel Demand Input mA Fuel Demand Input is the actual fuel demand input signal This value is displayed in mA and will be in between 4 20 mA This inpu...

Page 1034: ...p Contact DISPLAY VALUE Fuel Cntrl Mode DISPLAY VALUE Lower Contact DISPLAY VALUE Raise Contact DISPLAY VALUE Reset Contact DISPLAY VALUE Gen Prop Contact DISPLAY VALUE Limit Contact DISPLAY VALUE Clu...

Page 1035: ...made Clutch and Generator breaker is open Unload Clutch Relay Unload Clutch Relay displays the status of the Unload Clutch Relay output True Relay is in ON status False Relay is in OFF status Also tak...

Page 1036: ...will be stopped if this setpoint has been exceeded and Overspeed Alm will be TRUE Both Mpu fail Both Mpu fail will be activated if both speed sensors fail When in RUN mode and engine speed of sensor 1...

Page 1037: ...ignal This is the 4 mA point on a linear curve block Spd out at 20 mA Actual Speed value at 20 mA output signal This is the 20 mA point on a linear curve block kW out at 4 mA Actual kW load value at 4...

Page 1038: ...signal This is the 20 mA point on a linear curve block Spd ref out at 4 mA Actual speed reference value at a 4 mA output signal This is the 4 mA point on a linear curve block Spd ref out at 20 mA Act...

Page 1039: ...Tuneables Manual B36146V2 C 5 26 Woodward...

Page 1040: ...is running The Configure menus may only be entered if the I O is shutdown and hence the engine stopped The Debug menu allows access to the GAP software 6 2 Configure Menus To access the Configure men...

Page 1041: ...ey This transfers all new setpoint values into EEPROM memory The EEPROM retains all setpoints when power is removed from the control CAUTION To prevent possible damage to the engine resulting from imp...

Page 1042: ...Displays the In Pulse Woodward logo application name and software revision ESC To return to menu header or to main screen SAVE Saves entered values set points BKSP Deletes last figure when entering ex...

Page 1043: ...Hand held Programmer Manual B36146V2 C 6 4 Woodward...

Page 1044: ...NG DIAGRAM This chapter contains the Control Wiring Diagram 9951 047 Sheet one of the drawing contains notes and additional information The following sheets identify the system cables and show their i...

Page 1045: ...Control Wiring Diagram Manual B36146V2 C 7 2 Woodward...

Page 1046: ...I O N O R P R O C U R E M E N T W I T H O U T T H E E X P R E S S W R I T T E N P E R M I S S I O N O F T H E W O O D W A R D G O V E R N O R C O M P A N Y O R O N E O F I T S S U B S I D I A R I E S...

Page 1047: ...T E S P O W E R D I S T R I B U T I O N P O W E R D I S T R I B U T I O N O P T I O N A L 7 2 3 C O N T R O L 7 2 3 C O N T R O L 7 2 3 C O N T R O L S 7 2 1 6 P L C S 7 2 1 6 P L C S 7 2 1 6 P L C S...

Page 1048: ...V H 2 2 A P R 2 0 0 0 N O T E S 1 2 4 5 6 7 8 9 D I O D E 1 N 4 0 0 7 P N 1 6 8 3 0 1 5 R E S I S T O R 3 3 K O H M 3 W P N 1 6 4 4 5 9 3 B R E A K E R 6 A 2 P P N 1 7 3 3 5 8 7 R E S I S T O R 2 4 9...

Page 1049: ...B R I D G E B L K X 3 1 1 6 A W G B L K 1 6 A W G B L K 0 V M 1 6 A W G B L K 1 6 A W G R E D 1 F 3 2 1 1 6 A W G R E D 1 X 6 8 1 B R I D G E R E D 1 7 1 1 F 3 1 1 K 1 0 A 1 4 9 1 F 3 1 X 6 8 1 0 2 2...

Page 1050: ...5 6 D W G N O C A G E C O D E 7 9 9 5 1 0 4 7 S I Z E A 3 R E V S C A L E 8 B C H E C K E D D R A W N S H E E T D A T E 5 9 O F P O W E R D I S T R I B U T I O N O P T I O N A L H V H 2 2 A P R 2 0 0...

Page 1051: ...X 6 8 1 0 2 N 1 4 3 7 2 3 3 M E 1 M E 2 S Y N C H R O N I S E D U N L O A D E D 4 5 1 X 6 8 1 3 4 J E T A S S I S T 6 1 3 5 7 M A J O R A L A R M 8 9 1 3 2 L S L I N E S 1 0 1 3 3 S H 1 1 1 0 0 S P E...

Page 1052: ...3 R E V S C A L E 8 B C H E C K E D D R A W N S H E E T D A T E 7 9 O F 7 2 3 C O N T R O L H V H 2 2 A P R 2 0 0 0 N 1 4 3 7 2 3 2 3 1 X 6 8 1 3 6 L O N C O M M U N I C A T I O N 2 4 1 3 7 S H 2 5 2...

Page 1053: ...E E T D A T E 8 9 O F 7 2 3 C O N T R O L H V H 2 2 A P R 2 0 0 0 N 1 4 3 7 2 3 4 1 4 2 1 X 6 8 1 2 7 G E N E R A T O R L O A D I N P U T 4 3 1 2 6 C O M S H 4 4 4 5 1 0 8 N O T U S E D 4 6 1 0 9 C O...

Page 1054: ...N I 0 0 4 4 4 1 X 6 8 1 1 X 6 8 5 5 G O V E R N O R F A U L T R E S E T C O M M A N D I 0 1 6 1 5 5 S 1 3 1 X 6 8 6 7 M I N S P E E D C O M M A N D I 0 2 B R I D G E G R A 8 B R I D G E R E D 9 S P A...

Page 1055: ...1 X 6 8 3 1 I 2 M 9 1 N 3 I 1 M N 3 I 2 M 0 V L I N E 1 X 6 8 3 1 S P E E D C O M M A N D I 1 4 3 2 S P E E D C O M M A N D F A S T E R I 1 5 3 3 S P E E D C O M M A N D S L O W E R 3 4 C O N S T A N...

Page 1056: ...L C Q M 9 1 N 3 I 1 M N 3 Q M 0 V L I N E Q L Q 0 0 1 6 3 N 3 0 0 1 K 3 1 A 1 C O M B I N A T O R S P E E D S E L E C T O R Q 0 1 1 7 2 N 3 0 1 1 K 1 1 A A 1 G O V E R N O R M I N O R A L A R M Q 0 2...

Page 1057: ...A 1 C O N S T A N T S P E E D L A M P Q 1 1 1 8 1 N 3 1 1 1 K 1 9 A 1 G E N S E T L A M P P R O P U L S I O N L A M P Q 1 2 1 8 2 N 3 1 2 1 K 2 0 A 1 L O C A L C O N T R O L L A M P 1 6 2 N 3 1 2 1 K...

Page 1058: ...V S C A L E 8 B C H E C K E D D R A W N S H E E T D A T E 1 3 9 O F B A C K U P C O N T R O L O P T I O N A L H V H 2 2 A P R 2 0 0 0 U 9 5 3 B A C K U P C O N T R O L 1 1 X 6 8 1 1 8 M A X 2 4 V 4 1...

Page 1059: ...9 O h m 2 W H T B L U 1 1 1 5 G N D 8 5 N 1 5 1 1 K 2 1 1 1 1 K 2 1 1 6 2 1 1 1 2 W H T G N D 1 4 1 K 3 1 1 6 3 1 1 1 2 1 4 1 5 2 1 K 3 1 1 4 U 8 8 8 5 N 1 5 2 1 K 2 2 1 1 1 K 2 2 1 6 2 1 1 1 2 W H T...

Page 1060: ...6 D W G N O C A G E C O D E 7 9 9 5 1 0 4 7 S I Z E A 3 R E V S C A L E 8 B C H E C K E D D R A W N S H E E T D A T E 1 5 9 O F S I G N A L A M P L I F I E R H V H 2 2 A P R 2 0 0 0 U 8 S I G N A L A...

Page 1061: ...A G E C O D E 7 9 9 5 1 0 4 7 S I Z E A 3 R E V S C A L E 8 B C H E C K E D D R A W N S H E E T D A T E 1 6 9 O F R E L A Y S H V H 2 2 A P R 2 0 0 0 4 8 X 3 7 1 K 1 A 2 1 6 A W G B L K 4 8 X 3 8 1 K...

Page 1062: ...1 3 2 U 9 6 1 K 1 1 B A 2 S U P P L Y V O L T A G E F A I L U R E B A C K U P G O V E R N O R 1 1 2 N 3 0 2 1 K 1 2 A A 1 1 4 1 1 1 2 1 9 4 1 K 1 2 A A 1 A 2 G O V E R N O R M A J O R A L A R M T O S...

Page 1063: ...E T L A M P P R O P U L S I O N L A M P 1 2 2 N 3 1 2 1 K 2 0 A 1 1 4 1 1 1 2 2 0 7 1 K 2 0 A 1 A 2 L O C A L C O N T R O L L A M P 1 2 2 N 3 1 3 1 K 2 1 A 1 1 4 1 1 1 2 2 0 8 1 K 2 1 A 1 A 2 L O A D...

Page 1064: ...1 1 A 1 1 G O V E R N O R M I N O R A L A R M T O A L A R M S Y S T E M 1 4 1 4 1 2 1 K 1 1 B 1 7 2 1 2 1 1 1 1 B 1 1 S U P P L Y V O L T A G E F A I L U R E B A C K U P G O V E R N O R 1 4 1 4 1 2 1...

Page 1065: ...A Y O U T P U T H V H 2 2 A P R 2 0 0 0 1 K 1 5 1 7 6 1 2 1 1 1 5 1 1 N O T U S E D 1 4 1 4 1 2 1 K 1 6 1 7 7 1 2 1 1 1 6 1 1 N O T U S E D 1 4 1 4 1 2 1 K 1 7 1 7 7 1 2 1 1 1 7 1 1 4 4 1 X 6 8 1 9 9...

Page 1066: ...W N S H E E T D A T E 2 1 9 O F R E L A Y O U T P U T H V H 2 2 A P R 2 0 0 0 2 0 9 1 K 2 1 1 1 1 K 2 2 1 1 1 K 2 2 1 8 3 1 2 1 1 2 2 1 1 S P E E D S E T T I N G F R O M E C R A C T I V E L A M P 1 4...

Page 1067: ...A M C O N T R O L W I R I N G 7 2 3 S 7 P R O P U L S I O N B A S I C S I N G L E E N G I N E 5 6 D W G N O C A G E C O D E 7 9 9 5 1 0 4 7 S I Z E A 3 R E V S C A L E 8 B C H E C K E D D R A W N S H...

Page 1068: ......

Page 1069: ...nd United States Colorado 2 Illinois 3 Michigan 2 New York South Carolina Tennessee Canada Qu bec China Beijing Czech Republic Plzen Germany Tettnang Korea Pusan Mexico Mexico City New Zealand Christc...

Page 1070: ...Oil Regulations Woodward C5 05 04 20 27 01 en 06 06 2006 FD032293 1 25 Oil Regulations Woodward...

Page 1071: ...25071J Oils for Hydraulic Controls Manual 25071J...

Page 1072: ...NT DEFINITIONS WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION indicates a potentially hazardous situation which if not avoided...

Page 1073: ...formance x protect the lubricant Surface protective additives include anti wear agents corrosion and rust inhibitors and detergents and dispersants Performance additives include pour point depressants...

Page 1074: ...proved by the addition of a variety of chemical compounds such as anti wear agents corrosion and rust inhibitors and detergents and dispersants If information is needed about the additive contents of...

Page 1075: ...cannot agglomerate and form sludge Performance Additives Oil performance characteristics also can be greatly improved with additional compounds such as pour point depressants seal swell agents and Vis...

Page 1076: ...e this type of permanent shear has occurred the polymer contributes less to high temperature thickening Therefore high VI oils using polymeric VI improvers require a polymer that will continue to prov...

Page 1077: ...e of these compounds may be soluble in oil resulting in a viscosity increase others may be insoluble and form varnish or sludge Oxidation is affected by many factors temperature lubricated materials c...

Page 1078: ...Oils for Hydraulic Controls Manual 25071 6 Woodward...

Page 1079: ...uld be that with 150 SUS at operating temperature and a high VI WARNING A loss of stable governor control and possible prime mover overspeed may result if the viscosity exceeds the 50 to 3000 SUS rang...

Page 1080: ...idic products of combustion Sludge Dispersion Dispersants are especially useful in protecting engines that rarely reach normal operating temperature This type of service leads to the formation of slud...

Page 1081: ...an oil filled side plate may continue to use oils with a ZDP anti wear additive as the oil does not come into contact with the silver contacts Proper Oil Selection There are two essential factors that...

Page 1082: ...mperature range where oil gets progressively thicker to reach its pout point The approximate pour point is represented by the low temperature end of the hatched section left hand end If the oil is too...

Page 1083: ...Manual 25071 Oils for Hydraulic Controls Woodward 11 Figure 2 1 Oil Chart Figure 2 2 Viscosity Comparisons...

Page 1084: ...limited availability in some areas As with any oil it is not recommended that these be mixed with each other or with petroleum oils CAUTION Some classes of synthetic oils may not be compatible with d...

Page 1085: ...se oils do not deteriorate rapidly at high temperatures and do not congeal readily at low temperatures SHC base fluids are free of aromatics sulfur and wax normally present in conventional mineral oil...

Page 1086: ...d In addition to oils listed in the Oil Chart oils which meet the API American Petroleum Institute engine service classification in either the S group or the C group starting with SA and CA through th...

Page 1087: ...whether filling the governor for the first time or whether adding make up oil Clean oil cannot remain clean if the container or pouring spout is not clean Partially used cans of oil should not be use...

Page 1088: ...required It is also an indication that perhaps a different oil should be used especially if it has only been a short time since the last oil change A varnish buildup is an indication that governor ope...

Page 1089: ...different than when new NOTE some oil may smell burned and still be acceptable Check with oil company representatives If in doubt change oil x Any water antifreeze or other incompatible material cont...

Page 1090: ...though particles of dirt are always present good properly maintained filtration controls dirt particles effectively Proper use of filtration not only pays for itself but it also reduces the overall co...

Page 1091: ...r x size particles x 1 01 is 1 efficient x 1 1 is 9 efficient x 1 5 is 33 efficient x 2 0 is 50 efficient nominal x 5 0 is 80 efficient x 10 0 is 90 efficient x 20 0 is 95 efficient x 75 0 is 98 7 eff...

Page 1092: ...by x too high an oil temperature x too long an interval between oil changes x water condensing inside the governor during cooldown periods water in oil can cause hydrolysis which is a known failure mo...

Page 1093: ...side a governor is considered to be a misuse outside Woodward control Such misuse is not covered by Woodward warranty WARNING If a governor has become lacquered it is imperative that this situation be...

Page 1094: ...519 USA 1000 East Drake Road Fort Collins CO 80525 USA Phone 1 970 482 5811 x Fax 1 970 498 3058 E mail and Home Page www woodward com FM 57982 BS EN ISO 9001 1994 6 March 2001 Woodward has company ow...

Page 1095: ...Three position Controller Console Mounting C5 05 05 09 16 01 en 12 11 2008 FD024024 1 66 Three position Controller Console Mounting...

Page 1096: ...ephon 0 23 24 3 98 0 Telefax 0 23 24 3 98 3 89 Internet www pleiger de pe e mail info pe pleiger de PLEIGER ELECTRONICS 362MC Manual Operation Installation Connection Technical data Hardware extension...

Page 1097: ...atory note on controller output parameters 18 5 6 Input menu 19 5 6 1 Explanatory note on calibration 20 5 6 2 Explanatory note on scaling 20 5 7 Output menu 21 5 8 Display menu 22 5 8 1 Explanatory n...

Page 1098: ...ays and messages from A to Z 35 Appendix A5 Symbols employed in this manual 35 Appendix B Hardware extensions for the 362MC Appendix B1 Hardware extension 2nd relay set 36 Appendix B2 Hardware extensi...

Page 1099: ...ble connection of a terminal or a PC to the Pleiger service programme 362McDiag In addition to the user friendly operating and display functions the 362MC does of course also provide additional contro...

Page 1100: ...r removing the front frame and lifting the lower part of the foil the fuse for switching outputs and the connector for the service interface are also accessible after installation of the controller Th...

Page 1101: ...be used to branch to the desired menu and the parameter selection function The desired parameter is selected here in the same manner using the q and p buttons The 1st line of the display shows the nam...

Page 1102: ...alarm 5 3 1 This presentation of the setpoint entry procedure is based on the assumption that both controllers have been configured as fixed setpoint controllers with setpoint type fixed value The 1st...

Page 1103: ...controller Manual mode is activated via the Manual menu to enable adjustment of a continuous controller output of the 1st controller or to adjust a controller output of the 2nd controller This menu ca...

Page 1104: ...ently valid password To this end digits 1 to 4 have to be set to the stored value for the password in each case beginning from a value of 0 After input of the 4th digit shown in the example here as pa...

Page 1105: ...ord is selected and entered as already described in detail under Password entry Any number 0000 and 9999 is permissible as the value for the password 5 2 Commissioning menu After entering the password...

Page 1106: ...itching filter 5 3 2 1Alarm 99 0 C Alarm limit Setp amount 1Alarm Lower alarm limit ActVal Setp 0 0 C Alarm OFF See also Explanatory note on 220 0 C Alarm limit 1Alarm limit value alarm 5 3 3 1Alarm 9...

Page 1107: ...ated When an alarm is activated the alarm relay is de energised Alarm ON closed circuit principle and the current display is switched to the error display This display remains active until the alarm i...

Page 1108: ...essary to enter the profile no assigned to the controller under Prof No again for this purpose 5 4 2 Entering parameters for one controller only When the 362MC is used for one controller only DsplCtr...

Page 1109: ...natory note on PI PI action controller structure 5 5 2 PD PD action D component is always relative to PID PID action the system deviation and damped PD2 PD action D2 component is always relative to PI...

Page 1110: ...nd relay ON The 3 Point controller with feedback 3PntPW operates internally as a continuous controller with two down line pulse width modulators and two switching outputs Its output corresponds to the...

Page 1111: ...d The operational characteristics of Cont correspond to those of Pleiger controller 361 D Cascade step controller internal interconnection of 2 controllers to create the cascade controller CscStep Con...

Page 1112: ...ffects a change in the controller output of a magnitude corresponding to the P component PD controller proportional plus differential action controller In the case of the PD controller a D component c...

Page 1113: ...with the other PI and PID controllers the P I and D components are set via parameters Kr Tn and TV Vd Operating time T drive of the actuator controls the stepping function of the 3 Point output with f...

Page 1114: ...input assigned I Secondary actual value cascade ActValU PT100 1 1st PT100 input or 0 4 20mA see 1 Trend compensation Trend PT100 2 2nd PT100 input Disturbance compensation Disturb Lin 0 3rd linear in...

Page 1115: ...value Rmax the current value of the resistor feedback sensor will be stored as 100 end position Each entered value will be stored only when the following procedure is observed select R scale select pa...

Page 1116: ...on OutputX NC OutputY 1Lin 0 362MC output assignment for 361 D function OutputX NC in the Parameter Value min Meaning Comment profile each controller max OutputY NC No output assigned 1Relais 1st rela...

Page 1117: ...Meaning Comment general max Line 1 1Setp W Setpoint controller 1 Line 2 1Setp V Setpoint secondary controller 1 See also Explanatory note on 2nd L1 1ActV X Actual value controller 1 controller inputs...

Page 1118: ...troller programme cannot be started When this error applies the 362MC loads the factory presets as a precautionary measure Please check urgently in the following order the profiles of both controllers...

Page 1119: ...rror recur frequently the cause of the error is to be eradicated Errors at important inputs will lead to the controller programme being stopped and initiation of an alarm as safe and reliable operatio...

Page 1120: ...nector is accessible on the installed controller after removing the front frame and raising the bottom labelling window 7 1 Sevice programme McDiag The service programme McDiag which has been develope...

Page 1121: ...890121 123456789012345678901234567890121 123456789012345678901234567890121 123456789012345678901234567890121 123456789012345678901234567890121 123456789012345678901234567890121 12345678901234567890123...

Page 1122: ...tandard configuration Terminal Signal name 1 L1 Voltage supply connection 2 N Standard 230V AC or 115V AC 3 SL Protective earth conductor or cabinet earth 4 N Output 1st relay set 5 Open Connection fo...

Page 1123: ...ler 362MC has one relay set consisting of relay and relay as its switching output A 2nd relay set is available as a hardware extension Two variants apply for connection of the switching voltage 9 3 1...

Page 1124: ...r a nominal voltage of 24V DC These inputs are to be connected to 24V and the reference potential 0 24 is to be connected to terminal 20 9 6 Connection of the resistor feedback sensor The remote resis...

Page 1125: ...ver external compensation is possible with a resistor between terminal 36 and 37 The resistance value for RL must correspond to the resistance of one connecting wire 9 9 Connection of a I value transm...

Page 1126: ...ut Measuring range 0 4 20mA 0 5V 0 10V Resolution 20 A 5 10mV Measuring accuracy 0 5 Internal resistance 250 Ohm 4th input resistance input Measuring range 0 200 Ohm Resolution 0 2 Ohm Measuring accur...

Page 1127: ...Line 2 2nd L1 2nd L2 Lang LCDcntr PW lock PW chng Output1 Output2 1Setp A 1Setp B 1Alarm 1Alarm 2Setp A 2Setp B 2Alarm 2Alarm PW inp alternate each second Operational display Manual mode Manual mode...

Page 1128: ...adband Dimension Disturbance compensation Display selection Controller no External setpoint Position feedback Hysteresis P gain Setpoint gain Language changeover Contrast setting LCD display Display l...

Page 1129: ...degrees Celsius Dimension degrees Fahrenheit Display controller 1 of 2 Actual value secondary controller 1 Actual value controller 1 Disturbance controller 1 Position feedback in controller 1 1st lin...

Page 1130: ...it Error 1st actual value above upper alarm limit Error 1st actual value below lower alarm limit Error 1st PT100 below measuring range Error 1st PT100 above measuring range Error 2nd actual value abov...

Page 1131: ...This again enables control with voltages other than the supply voltage e g for DC actuators The maximum permissible contact load as specified on the data sheet is to be observed The control switching...

Page 1132: ...0 20mA 4 20mA or with opposite effective direction 20 0mA 20 4mA is assigned by the user as required The same applies to the voltage outputs The outputs are defined as unipolar or bipolar outputs via...

Page 1133: ...ng with a min wire cross section of 0 22mm 120 ohm is recommended as the terminating impedance for the RS485 interface Parameterisation The transmission speed Baudr and the user address Slave no of th...

Page 1134: ...commissioning menu 5 6 When the value NC is assigned to the Trend parameter the special trend compensation function is passive D component without trend compensation The normal D component of the sta...

Page 1135: ...tion Here an inlet temperature sensor TIN has been added to the outlet temperature control TOUT of a main engine The effects of the dead time between the outlet temperature sensor and the mixing valve...

Page 1136: ...lly to include the entry options shown in the table below See also Controller parameters menu 5 5 Compensation The special disturbance compensation function is not equally applicable or expedient for...

Page 1137: ...l controller output Y setpoint Setp V of the secondary controller It thus has a direct effect on the control process of the secondary controller In the case of the cascade step controller the primary...

Page 1138: ...haracteristic The characteristic to weight the influence of the disturbance is defined via 5 interpolation points distributed evenly over the value range The values between the interpolation points ar...

Page 1139: ...y controller In this way the setpoint for the inlet temperature is adjusted before the disturbance is able to manifest itself in the form of an altered outlet temperature Setp W Y Setp V Cooler M PT10...

Page 1140: ...or the 1st controller for example the entire sequence of setpoint programme 1 will be started and the various time setpoints resulting from the programme will be controlled by the 1st controller Progr...

Page 1141: ...r the 1st controller a setpoint extern external input programme can also be assigned to StpPrg1 setpoint to the 2nd controller programme no 1 See 1SpTypA above StpPrg5 to programme no 5 I 2SpTypB fixe...

Page 1142: ...ns simultaneously the setpoint programme will be stopped at the last time setpoint It will subsequently be resumed on pressing the Auto button for Automatic mode Programme end When Time 0s is programm...

Page 1143: ...0 70 60 50 40 30 0s 40s 80s 0s 40s 80s 0s 40s 80s Time Parameter Value min Meaning Comment general max Line 1 1Setp W Setpoint controller 1 Line 2 1SpPrg Setpoint programme controller 1 2nd L1 1Setp V...

Page 1144: ...meters if appropriate Adjusting the parameters In most applications only minor adaptations of the factory set up is necessary The most important adaptations concern the controller parameters Kr and Tn...

Page 1145: ...ditional differential trend compensation of the 2nd PT100 measuring sensor e g control of the outlet temperature of a cooling circuit in a main engine with trend compensation for the inlet temperature...

Page 1146: ...ist kalibr E6 NC NC NC NC NC 200 0 0 C Changes Factory presets Rmin Rmax Profile 1st controller CtrlTyp ParSet Struct Kr Tn Tv Vd T drive Ts min T cycl Deadbd Hyst Ymin Ymax Kw Struct Kr Tn Tv Vd T dr...

Page 1147: ...br NC NC NC NC NC NC 200 0 0 C Changes Factory presets Rmin Rmax Profile 2nd controller OutputY OutputX 2Relais NC Changes Factory presets Profile 2nd controller CtrlTyp ParSet Struct Kr Tn Tv Vd T dr...

Page 1148: ...t kalibr E6 NC NC NC NC NC 200 0 0 C Changes Factory presets Rmin Rmax Profile 1st controller CtrlTyp ParSet Struct Kr Tn Tv Vd T drive Ts min T cycl Deadbd Hyst Ymin Ymax Kw Struct Kr Tn Tv Vd T driv...

Page 1149: ...nges Factory presets Rmin Rmax x Profile 1st controller OutputY OutputX 1Relais NC Changes Factory presets Profile 1st controller CtrlTyp ParSet Struct Kr Tn Tv Vd T drive Ts min T cycl Deadbd Hyst Ym...

Page 1150: ...s Factory presets Rmin Rmax Profile 1st controller OutputY OutputX 1Relais NC Changes Factory presets Profile 1st controller CtrlTyp ParSet Struct Kr Tn Tv Vd T drive Ts min T cycl Deadbd Hyst Ymin Ym...

Page 1151: ...es Factory presets Rmin Rmax Profile 1st controller OutputY OutputX 1Lin 4 NC Changes Factory presets Profile 1st controller CtrlTyp ParSet Struct Kr Tn Tv Vd T drive Ts min T cycl Deadbd Hyst Ymin Ym...

Page 1152: ...eset all values 0 Please use a copy of this sheet to document your settings and changes SpPrgNo Setp1 Time1 Setp2 Time2 Setp3 Time3 Setp4 Time4 Setp5 Time5 Setp6 Time6 Setp7 Time7 Setp8 Time8 Setp9 Ti...

Page 1153: ...Pleiger Elektronik GmbH Co KG Page 58 Manual for 362MC Nr 9360000120 Edition 2 00 Subject to modifications Note...

Page 1154: ...Pleiger Elektronik GmbH Co KG Manual for 362MC Nr 9360000120 Edition 2 00 Subject to modifications Page 59 Note...

Page 1155: ...A Measuring range 0 100 Special version 1st Linear input PT100 Measuring range 0 500 C 1st Linear input PT100 Measuring range 0 200 C without communication interface Hardware extension communication i...

Page 1156: ...NC Hyst 1 0 ExtSetp NC Ymin 0 FeedBk Resist Ymax 100 R scale kalibr Rmin Rmax Kw 1 2 Setp E6 Struct PID 2 Param E5 Kr 10 0 Rel On E4 Tn 150s Rel Off E3 Tv 0 1s Rel On E2 Vd 1 0 Rel Off E1 T drive 90 0...

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Page 1508: ...Description Engine Monitoring Devices C5 05 05 10 50 13 M43 en 01 02 2005 FD029195 1 24 Description Engine Monitoring Devices...

Page 1509: ...r Confidential Green c 1 Relay Page 2 9 01 7 91 08 00 02 06 2 Temperature Monitoring Page 3 Switching Device RH41M 3 Engine Speed Pick up Page 4 FA2 H 3C XX 4 Turbocharger Speed Acquisition Page 5 FTW...

Page 1510: ...o 48V The relay is protected against false polarity and over voltages such as may be expected on board Technical Data Rated voltage 24V DC 30 25 Power draw 200mW Relay contacts 1 change over contact 1...

Page 1511: ...ses via this closed contact contact II which is in its normal position when the temperature is not excessive and the resistor In the event of wire break in the probe line or voltage failure contact I...

Page 1512: ...dential Green c Adjustment Instructions for Engine Speed Pick up FA2H 3C XX 1 Alignment of the speed pick up for axial mounting position 2 Alignment of the speed pick up for radial mounting position R...

Page 1513: ...Caterpillar Technical Data Measurement range 1Hz 35kHz Input level 50mVeff 80Veff Sensor voltage 12V 25mA Sensor monitoring built in signalisation by LED and zero mA on the current output Output 0 4...

Page 1514: ...failure overload short circuit Stop Signal engine stop for speed governor 1x make contact Operating panel engine 1 contact each for operating the indicator lamps for start stop false start starting i...

Page 1515: ...e to fuel supply position The starting valve remains locked in electrically as long as either the firing speed is reached or the time tstart has expired False Start If the engine does not reach the fi...

Page 1516: ...d electrically and the emergency start button is blocked Automatic Stop In case of over speed or other criteria which might endanger the engine e g lubricating oil pressure below danger level or if an...

Page 1517: ...Temperature Measurement Unit with Manual Test Point Switch Series TS 31000 Commissioning and Adjustment Manual Issue April 2002 Software Version 1 22 PROG CYLINDER1 C...

Page 1518: ...ge 7 4 2 Set up 7 4 3 Connection 7 4 3 1 Power supply 7 4 3 2 Sensor inputs 8 5 Commissioning and Configuration of TS 31000 9 5 1 Commissioning 9 5 2 Configuration of TS 31000 9 5 2 1 Language selecti...

Page 1519: ...er well the signs pictograms and their importance The manual is divided in eight sections 1 General 2 Safety Instructions 3 Description of TS 31000 4 Storage and Set up 5 Commissioning and Configurati...

Page 1520: ...of the instrument a competent and safety observing personnel is required Related instructions can be found in this section Warnings which relate to individual function sequences or actions are found...

Page 1521: ...April 2002 5 3 Description of TS 31000 3 1 Assemblies and operating elements 1 LCD matrix display 2 4 digit LED display 3 light reflex button Selection key 4 light reflex button Enter key Figure 1 Fro...

Page 1522: ...ing these buttons the point to be measured is selected and the instrument is configured and adjusted to match the required measurement job 2 Plug in strip connectors with locking are located at the re...

Page 1523: ...front dimensions are 96x96 mm The cut out section in the switchboard must be 91x91 mm The instrument is inserted from the front into the switchboard and is fixed from the rear side by the delivered c...

Page 1524: ...thermo couple 12 thermo couple 14 thermo couple 16 Pt100 1 Pt100 1 20 18 16 14 12 10 8 6 4 2 19 17 15 13 11 9 7 5 3 1 X2 thermo couple 17 thermo couple 19 thermo couple 21 thermo couple 23 thermo cou...

Page 1525: ...the digit at the cursor position to the same value as with the stored access code Then confirm the digit with the key The cursor moves forward one position Set digit by digit in the same manner After...

Page 1526: ...PAN ESPAN NEIN for the Spanish language Switch with the s key to YES and confirm with the key The next menu item appears SET UNIT NO 5 2 2 Select physical measurement unit To select the measurement un...

Page 1527: ...rrect motor type switch with the s key to YES and confirm with the Taste The next menu item appears SET SENSORTYPE NO 5 2 4 Select sensor type To select the sensor type to DIN EN 60584 proceed as foll...

Page 1528: ...nd time Set again each digit of the new access code with the s key and confirm with the key The message appears CODE CHANGE Note Keep the new access code in mind From now on the configuration menu can...

Page 1529: ...f temperature values the instrument displays Connection between thermo couple and instrument interrupted Check thermo couple and connections Instrument displays REFJUNC OVERFLOW Value of cold junction...

Page 1530: ...of r r 1 digit 400 to 1700 C thermo couples type B 0 25 of r r 1 digit 100 to 1650 C thermo couples type R 0 15 of r r 1 digit Number of measurement channels maximum 32 inputs for thermo couples all...

Page 1531: ...SIKA TS 31000 Operating Manual 3228005 E doc April 2002 15 Protection class Front IP54 Storage and service temperature 10 to 80 C 0 to 55 C...

Page 1532: ...Equipment List Engine C5 05 05 10 60 85 M43 en 01 02 2005 FD029241 1 6 Equipment List Engine...

Page 1533: ...l mist detector failure alarm 1251 0 5 25 binary 1253 0 5 25 binary 9631 binary 263 450 185 0 00 6 71 30 00 40 2102 Pressure transmitter Cooling water pressure HT at engine inlet low alarm 0 600 kPa 4...

Page 1534: ...esistance thermometer Charge air temp at engine inlet high alarm 40 160 C PT 100 263 481 017 0 00 6 93 17 00 32 7206 Resistance thermometer Intake air temp at turbocharger inlet Dicare 40 160 C PT 100...

Page 1535: ...setting 125 load 0 20mA 260 480 070 1 00 7 48 98 00 53 9509 Plug 213 480 101 CA06EW 14S 5S B 03A 9561 Limit switch Turning gear engaged starting interlock binary DTE7 2RN PG S1 Limit switch Turning ge...

Page 1536: ...ame 977 037 062 Push button cap 977 037 065 S12 H10 Bulb 223 480 054 Change over switch engine remote Locking key 977 037 079 Key base 977 037 081 S13 Key base 977 037 081 Lamp test push button Lumino...

Page 1537: ...63 480 304 CA3102E 14S 5P B 04 XC2 Female 977 032 801 CA08EW 14S 5S B F80 X1 1 70 Terminal 977 062 506 047826 AST X6 1 50 Terminal 977 062 506 047826 AST X3 1 60 Terminal 977 062 506 047826 AST X8 23...

Page 1538: ...Turning Equipment C5 05 05 10 70 05 en 20 02 2009 FD039636 1 6 Turning Equipment...

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Page 1544: ...Maintenance Unit C5 05 05 45 23 03 M20 M25 M32 M43 en 23 03 2007 FD034174 1 25 Maintenance Unit...

Page 1545: ...Operating instructions Pressure reducing station R417000844 R417000845 R417000888...

Page 1546: ...d either in part of whole nor may they be used for evaluation or distributed for competition pur poses The diagrams and drawings used in this manual are for guidelines only and are not to be used for...

Page 1547: ...mantling 36 Dismantling the filters and the drain valves 36 Dismantling the pressure switch 38 and the adjusting screw Dismantling the pressure control valves 38 Dismantling the three two way valve 40...

Page 1548: ...is necessary to ensure that guidelines regulations and warnings are adhered to and that the work processes are carried out correctly without damage to or destruction of the servo actuator This way up...

Page 1549: ...4 ISO 8573 1 Solid matters 4 7 Oil rate 3 3 Pressure dew point 2 3 Applications other than those stated are regarded as not appropriate Improper use is at the customer s risk The manufacturer is not l...

Page 1550: ...e 2 Here the reduction from the inlet pressure to a lower outlet pressure 3 bar 8 5 bar takes place The outlet pressure set at the pressure control valve is indicated at the pressure gauge 4 The safet...

Page 1551: ...by force thus ensuring that no pressure is present at any of the subsequent devices cf block diagram on page 32 and circuit diagram on page 46 Versions Fig 2a 2c show three versions of the pressure re...

Page 1552: ...Design and mode of operation Block diagram P P1 A 14 1 2 3 4 5 6 7 fig 1 32 883 890 035 3 BDL 001 AC 10 06...

Page 1553: ...0888 replacement for 335 320 200 0 pressure gauge drain valve 3 2 way valve safety valve pressure switch fig 2b R417000845 replacement for 335 320 201 0 pressure gauge safety valve drain valve pressur...

Page 1554: ...into account that the drain valve points downwards Warning When disassembled dirt humidity or foreign matter must not enter the compressed air ports For this reason the ports must be closed by means...

Page 1555: ...ndles sideways Cleaning of the filter cartridge The filter cartridges have to be cleaned regularly according to the state of contamination of the compressed air For cleaning purposes cleaner s naphtha...

Page 1556: ...case of such an overhaul the following instructions for the dismantling mounting have to be adhered to Warning Warning Conduct all works in a de pressurized state Shut off the compressed air supply an...

Page 1557: ...Maintenance and care 37 fig 3 C B A 1 2 3 T1 MA 150Nm Y X C B A T25 T26 T11 26 7 view X view Y 5 T2 MA 60Nm 6 4 883 890 035 3 BDL 001 AC 10 06...

Page 1558: ...ure control valves fig 5 x Loosen grub screw T7 and remove cap T8 from the housing x Remove spring T9 and piston 35 with O ring 14 x Disassemble circlip 15 and pull valve 16 together with valve nut 17...

Page 1559: ...fig 4a 39 13 8 9 10 36 fig 4b T5 12 T6 T3 T4 11 T12 T24 36 T4 T3 fig 5 T8 T7 T9 35 14 24 25 X 23 22 9 8 37 17 16 15 18 34 20 21 13 6 0 2 Y B B 19 Take care of mounting position view X view Y 883 890 0...

Page 1560: ...loosen the screw T15 2x x Remove gasket 27 x Loosen screw T16 2x and remove the base plate T17 Warning Warning compression spring T18 is pre stressed x Disassemble the following parts compression spri...

Page 1561: ...Maintenance and care T18 T19 32 T23 T24 28 X 28 T20 T21 T22 32 T23 T24 28 29 Y 28 X Y 33 T15 T16 T17 25 24 30 31 C C D D T13 1 2 Nm M A 0 2 T14 D D 27 fig 6 41 883 890 035 3 BDL 001 AC 10 06...

Page 1562: ...place sealing ring 4 valve 5 spring 6 and circlip 7 Tightening torque for valve screw T2 MA 60 Nm x Replace piston cup 26 Assembly of the pressure switch and the adjusting screw fig 4 x Replace O ring...

Page 1563: ...securing means e g Loctite 241 must be applied Secure screw T15 2x and screw T16 2x with substance for locking screws e g Loctite 241 Setup and Tests of the pressure reducing station After the disman...

Page 1564: ...p 20 x 1 1 13 ventilation M14 x 1 5 1 14 O ring 32 9 x 3 5 1 15 circlip 14 x 1 1 16 valve 1 17 valve nut 1 18 bushing 8 x 9 x 4 1 19 valve ring 1 20 conical spring 1 x 11 2 x 18 1 1 21 O ring 5 28 x 1...

Page 1565: ...ient temperature during storage and transportation must neither drop below 35qC nor exceed 80qC Storage Warning Warning Consider that sealing elements are subjected to ageing also during storage The s...

Page 1566: ...r outlet pressure min 3 bar max 8 5 bar pressure reducing valve adjusted to 7 5 bar safety valve adjusted to 8 5 bar pressure switch adjusted to 6 0 bar decreasing threaded tabs M14 x 1 5 thermal appl...

Page 1567: ...Technical specifications Dimensional drawing Version R417000888 fig 8 threaded tabs M14 x 1 5 12 deep 47 883 890 035 3 BDL 001 AC 10 06...

Page 1568: ...gestions for improvements are always welcome If you require any further information please contact the sales staff in our Marine Technique Division directly or the address below Bosch Rexroth AG The D...

Page 1569: ...RPM Switch Unit C5 05 05 70 06 43 en 29 10 2004 FD020233 1 18 RPM Switch Unit...

Page 1570: ...1 2 6 Ambient temperature 0 70 C C ontact loadof output relays P lug incardsA2 A6 A9 breakingcapacity 50W 24VDC continouscurrent 1A P lug incardsA2 A8 breakingcapacity 50W 24VDC 100VA 220VAC continous...

Page 1571: ...oidandtheminiaturecylindersarefittedtotheengine 2 2 Principle An R P M switch monitorsbothsensorsandif theset speedvalueisexceededemitsanimmedi ate shutdown signal to the safety systemvia a potential...

Page 1572: ...nconnectionwithplug incardA6 relayK4for release of alarms 2changeover contacts 2 switchingpoint n nz nd firingspeed for releaseof of alarms 2change over contacts 3 3 Plug in Card 3 9 01 7 91 21 00 16...

Page 1573: ...gof ACsignalswithswitchingindication LE D equippedwith2relays for multiplicationof contacts 3 8 Plug in Card A8 9 01 7 94 01 00 02 R elaycardfor switchingof ACsignalswithswitchingindication LE D equip...

Page 1574: ...ndR 34inclockwisedirectionuntil both light emittingdiodesV20andV24ceasetolight BalanceC HANNALSI andII bycarefullyturning left on R 23 or R 34 respectively Indoingso thelight emittingdiodesV20or V24re...

Page 1575: ...l voltmeter toJ4or X15resp onterminal 31 32 measuringrange2V 3 Adjust the trimming potentiometers P 3 and P 4 in clockwise direction until limit Stop low click max 25revolutions andremember theindicat...

Page 1576: ...esetting for engine M25 193 375 001 9 01 7 91 21 00 16 Plug in card presetting for engine M32 193 466 036 9 01 7 91 21 00 16 Plug in card presetting for engine VM32 193 466 037 9 01 7 91 21 00 16 Plug...

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Page 1587: ...Safety System Description C5 05 05 70 15 62 en 17 03 2004 FD020236 1 25 Safety System Description...

Page 1588: ...nputs and Outputs The inputs and outputs of the syfety systemmentioned under items 2 2 to 2 5 are monitored for wirebreak O peratingconditionandwirebreakat theinputsandoutputsareindicatedbyindivid ual...

Page 1589: ...act with triggering if any limit value is exceeded by the signal transmitters Thefollowingpotential freerelaycontactsareprovidedadditionally 2 9 Starting Interlock Remote Indication P er input one cha...

Page 1590: ...rlock reduc tionor automaticstopisactuated 3 Function of the Safety System The safety systemconsists of electronic and electro mechanical subassemblies which carryout thefollowingcontrol commandsdepen...

Page 1591: ...s If anylimit valueisexceededbyasignal transmitter theengineisstoppedbytriggering of theshut downdevice Theshut downcommandisstoredandmust becancelledmanuallyvia theilluminatedbutton C ANC E LSTO P af...

Page 1592: ...nsmittersper plug incardispossible In the event of wire break in the connection line of a signal transmitter the summary alarm SAF E TY SYSTE M F AULT will be released F or a differentiated indication...

Page 1593: ...nal transmit ter exceeds a limit value the indicator lamp assigned to the respective signal transmitter will light upandanalarmwill bereleased A functional test can be carried out with the test button...

Page 1594: ...00 11 Bulb 223480054 MG5 7S 28VAC DC A6 P lug incard 243480610 9 01 7 93 01 00 08 A7 H1 H4 P lug incard 243480630 9 01 7 94 01 00 11 Bulb 223480054 MG5 7S 28VAC DC A8 P lug incard 243480610 9 01 7 93...

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Page 1612: ...Panel Instrument C5 05 05 70 17 00 en 18 03 2004 FD027397 1 6 Panel Instrument...

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Page 1617: ...37 065 S2 H2 Bulb 223 480 054 Dimmer Potentiometer drive D1 R1 S Potentiometer 4K7 P10 R1 V1 Dimmer 24V DC 35W 02 966 0 Lamp test push button Luminous key 22 213 011 Frame 977 037 062 S3 Push button c...

Page 1618: ...Machinery control room C5 05 05 70 17 50 en 19 10 2007 FD027401 1 6 Machinery control room...

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Page 1623: ...F rame 977037062 P ushbuttoncap 977037065 S2 H2 Bulb 223480054 R elay E C R Bridge R elay R A660024 K01 Lamp test pushbutton Luminouskey 977037060 F rame 977037062 S3 P ushbuttoncap 977037063 Lampfal...

Page 1624: ...Engine Adjusting Valve C5 05 06 09 15 00 en 25 02 2004 FD020148 1 10 Engine Adjusting Valve...

Page 1625: ...dependent and in according to Dimension sheet Dimension sheet Dimension sheet Electrically Operated Control Valves Electrical Motor Drive MOV 81 MOV S 81 MOV 3 81 Types Construction Materials Single s...

Page 1626: ...0 Hz single phase AC or 380 V 50 or 60 Hz three phase current other supply voltages on request Type of protection DIN 40050 IP 65 Allowable ambient temperature 20 to 60 C Limit switch torque dependent...

Page 1627: ...respective wiring diagrams Start up and Adjustment instructions Drive 1 2 kN and 4 5 kN Drive 12 kN and 24 kN For start up of the valve place the drive by means of the hand wheel e in the middle of th...

Page 1628: ...e sealings are settling a bit at the beginning The maintenance of the stuffing box is also important In case of leakage the stuffing box gland has to be fastened at once If this is no longer possible...

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Page 1634: ...Turbocharger C5 05 06 10 21 32 M43 en 13 01 2006 FD031327 1 114 Turbocharger...

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Page 1747: ...ABB Turbo Systems AG Bruggerstrasse 71a CH 5400 Baden Switzerland ABB...

Page 1748: ...Charge Air Cooler C5 05 06 30 17 36 M43 en 08 08 2008 FD037884 1 3 Charge Air Cooler...

Page 1749: ...612025 5 21 U profil U profile 70 176 875 2 22 Fjeder Spring 514224 7 8 23 Sp ndestift Spring straight pin 140813030050 8 24 Skinne Rail bracket 70 162 599 2 25 Skrue Screw 12160606010 10 26 Styreskru...

Page 1750: ...ing NOTE Only Vaseline or silicone paste can be used as lubricant for installation of O rings Fixation blocks insufficient adjusted Re adjust fixation blocks Furthermore it is recommended to change O...

Page 1751: ...Cooling Pump Unit HT C5 05 09 01 11 56 M43 en 26 02 2009 FD039765 1 12 Cooling Pump Unit HT...

Page 1752: ...INSTRUCTION MANUAL FOR PUMP TYPE DHBF DHBS Project DHBS125 315 Application Cooling water Tag no Purchase no 31533 257 IRON order no 3576351 IRON pump no DHB1091 NOTE Read this manual before mounting...

Page 1753: ...pter 1 DHBF S 1 Page 2 of 11 IRON Pump A S Generatorvej 10 DK 2730 Herlev Tel 45 4491 6788 Email iron ironpump dk Table of contents Generally 3 Part list Assembly drawing 3 Technical data 5 Installati...

Page 1754: ...or defects and faults on receipt The pump should be stored dry at temperatures between 0qC and 60qC af ter long time of storage the pump should be checked monthly See service page All lifting device m...

Page 1755: ...g 161 1 Casing cover 181 1 Pump stool 210 1 Shaft 230 1 Impeller 321 1 Radial ball bearing 341 1 1 Motor flange 341 2 1 Motor stool 360 1 Bearing cover 412 1 O Ring 433 1 Mech seal 502 1 Casing wear r...

Page 1756: ...installed on floor during the test The noise from motor has not been in cluded in this figure Max output pressure The output pressure must never exceed a rate of 65 of the test pressure stated on the...

Page 1757: ...hould be connected to a motor starter 8 Check that no tension and or moments are transferred from the piping The illustrated pump is with standard flange DIN 2501 PN10 For topical dimensions please se...

Page 1758: ...between impeller and casing wear ring Threaded hole for puller bolt Threaded hole for puller bolt Free hole in cover Mounting hole in cover Mounting hole in cover Dismantling of cover from Motor stoo...

Page 1759: ...aft bearing are fitted into the cover Mount plate and spacer and clamp the parts 4 Lubricate the shaft by a soap mix do NEVER use sili cone products 5 Place carefully and by hands the rotating part of...

Page 1760: ...e pump not filled by liquid Air in the pump or in the media 2 Foreign bodies blocking suction or pressure pipe 3 The pump being blocked by particles 4 Too high suction height the NPSHA has been ex cee...

Page 1761: ...e Pump no Pos no HVFULSWLRQ For optimal operation we recommend after 25 000 hours 3 years of operation to replace the mech seal pos 433 and casing wear ring pos 502 Furthermore the O ring pos 412 shou...

Page 1762: ...nd instruction manual For pump DHBS 125 125 315 Pump no DHB1091 Iron order no 3576351 Rev 06 Chapter 1 DHBF S 1 page 11 af 11 IRON Pumps A S Generatorvej 10 DK 2730 Herlev Tel 45 4491 6788 Email iron...

Page 1763: ...E Engine C5 05 09 01 40 05 M43 en 25 02 2009 FD039686 1 41 E Engine...

Page 1764: ...Drehstrom K figl ufermotor Kortsluten motor Elmotorer Induktie motor Moteu cage Motores de jaula de ardilla Machine Instructions GB 3 Betriebsanleitung D 6 Motorinstruktioner S 9 Motorinstruktioner DK...

Page 1765: ...ctive 89 336 EEC amended by 92 31 EEC and 93 68 EEC regarding the intrinsic characteristics to emission and immunity levels Low Voltage Directive 73 23 EEC amended by 93 68 EEC Design The design of th...

Page 1766: ...ed motors normally contains 6 winding terminals and at least one earth terminal Earthing shall be carried out according to local regu lations before the motor is connected to the supply voltage The vo...

Page 1767: ...ndstill heating elements bimetallic switches or PT 100 resistance elements WARNING Voltage may be connected at standstill inside the termi nal box for heating elements or direct winding heating Connec...

Page 1768: ...70 C the table values may be doubled WARNING The maximum operating temperature of the grease and bearings must not be exceeded Higher speed operation eg frequency converter appli cations or slower spe...

Page 1769: ...Temperatur von 105 C ber einen Zeitraum von 6 bis 8 Stunden durchgef hrt werden Eventuelle Verschl sse oder Pfropfen m ssen vor dem Trockenvorgang entfernt werden damit die Feuchtigkeit aus dem Motor...

Page 1770: ...n Lagersch den und evtl Bruch des Wellen ende von h chster Wichtigkeit Anschluss Der Anschlusskasten befindet ist bei der Standardaus f hrung auf der Oberseite des Motors und macht die Kabelzuf hrung...

Page 1771: ...lierte Motoren Bei wertikal installierten Motoren m ssen die angege benen Werte um 50 verringert werden Ist der Motor mit einem Schmierstoffauslassventil ver sehen besteht die M glichkeit frische Schm...

Page 1772: ...svatten m ste normalt omlindas Direktstart eller Y Uttagsl dan till en standard enhastighetsmotor inneh l ler normalt 6 lindningsuttag och minst ett jorduttag Motorn skall anslutas till jord enligt g...

Page 1773: ...ag trots att motorn st r still Montering och demontering Allm nt Detta arbete m ste utf ras av kunnig personal som anv nder ndam lsenliga verktyg och arbetsmetoder Lager Lager kr ver speciell omsorg L...

Page 1774: ...eraturen f r fett och lager f r inte verskridas Kortare sm rjintervaller kr vs vid h gvarvsdrifter eller l gre varvtal vid stor last Vid en f rdubbling av varvtalet kr vs en minskning av sm rjinterval...

Page 1775: ...trekant igangs tning Klemkassen p motorer med n hastighed indeholder normalt 6 viklingsklemmer og mindst n jordklemme Jordingen skal udf res i henhold til lokale forskrifter f r motoren tilsluttes for...

Page 1776: ...rende p tv rs af motorklemmer selvom moto ren er standset Montering og demontering Vigtigt Dette arbejde skal udf res af kvalificeret personale ved hj lp af egnet v rkt j og passende arbejdsmetoder L...

Page 1777: ...vensom formeranvendelse eller lavere hastigheder med st rre belastning I s danne tilf lde skal Svend H yer A S kontaktes for yderligere oplysninger Ved en fordobling af hastigheden skal man typisk red...

Page 1778: ...n deze gedemonteerd worden voor het verar mingsproces Als de motorwikkelingen zijn doordrenkt met zeewa ter dan zal de motoren hoogstwaarschijnlijk moeten worden herwikkeld Direct starten of ster drie...

Page 1779: ...c condenswater afloop pluggen worden geleverd in een open uitvoering In een stofrijke omgeving moeten de condenswater afloop pluggen gesloten worden Opstelling Een correcte opstelling van de elektromo...

Page 1780: ...Grootte Hoeveelheid 3600 3000 1800 1500 1000 500 900 vet g r min r min r min r min r min r min 112 132 15 4200 4800 7000 7800 10000 10500 160 180 20 3200 4200 6000 7000 9000 10000 200 225 25 1800 310...

Page 1781: ...atuur van 15K boven de lagertemperatuur heeft Als de omgevingstemperatuur onder de 25 C komt is het raadzaam om Svend Hoyer S A te raadplegen voor het eventuele gebruik van een laag temperatuur vet WA...

Page 1782: ...s bouchons pour orifice de vidange sont install s retirez les avant le s chage Au cas o les enroulements auraient t en contact avec de l eau de mer ceux ci devront tre r enroul s nouveau D marrage dir...

Page 1783: ...pr sence d une ambiance tr s poussi reuse Positionnement Un positionnement correct permet d viter toute d t rio ration des paliers et toute autre vibration pouvant entra ner une rupture d extr mit d a...

Page 1784: ...0 7000 7800 10000 10500 160 180 20 3200 4200 6000 7000 9000 10000 200 225 25 1800 3100 5500 6500 8500 9000 250 280 35 800 2000 5000 6000 8000 8500 315 50 800 2000 4600 5500 7500 8000 355 60 1000 4000...

Page 1785: ...tures de paliers sup rieures d environ 15 K Si la temp rature ambiante reste inf rieure 25 C n h sitez pas consulter Svend H yer A S afin d obtenir des renseignements concernant l utilisation des grai...

Page 1786: ...rmalmente deben devanarse de nuevo si son mojados por agua de mar Arranque directo o por estrella tri ngulo La caja de bornes de los motores de una sola velocidad normalmente contiene 6 bornes devanad...

Page 1787: ...adas 4 x 90 y otros con cajas de bornes montadas en el lado Si las entradas de cables no se usan deben cerrarse Adem s del devanado principal y el borne a tierra la caja de bornes tambi n puede conten...

Page 1788: ...80 C Los valores deben ser reducidos a la mitad por cada subida de 15 K de la temperatura del cojinete Si la temperatura m xima del cojinete es 70 C los valo res de la tabla pueden ser duplicados ADV...

Page 1789: ...arico condensa devono essere rimossi durante l essicamento Se gli avvolgimenti sono rimasti immersi in acqua di mare normalmente devono essere rifatti Avviamento diretto oppure avviamento stella trian...

Page 1790: ...asti ai cuscinetti vibrazioni e possibili rotture delle estremit dell albero Collegamento I motori in versione standard hanno la scatola morsetti situata sulla sommit del motore con ingresso cavi su e...

Page 1791: ...ella sono valide a condizione che vengano aggiunte piccole quantit di grasso nuovo ad intervalli regolari come indicato sopra I valori in tabella si riferiscono ad una temperatura dei cuscinetti di 80...

Page 1792: ...mber 2005 73 23 93 68 89 392 Svend H yer A S MS 56 132 Y2 80 400 25q Ri M t 20 U 1000 2 U V P kW 20q 90q 12 16 105q 6 8 6 660V 8 400V 8 Y2E2 80 400 690 motorinstruktioner A5 10 OUTL indd 29 26 10 05 1...

Page 1793: ...30 September 2005 L1 L2 L3 2 25q q 1000 x x x 1 2 motorinstruktioner A5 10 OUTL indd 30 26 10 05 11 25 35...

Page 1794: ...31 September 2005 90q 100 x x x x x SPM x 160 2RS 2RS 50 70 20000 40000 4 motorinstruktioner A5 10 OUTL indd 31 26 10 05 11 25 37...

Page 1795: ...0 5000 6000 8000 8500 315 50 800 2000 4600 5500 7500 8000 355 60 1000 4000 5000 7000 8000 80q 15 70q Svend H yer A S 40 x x 100 140 cST 40q x NLGI 2 3 x 30q 120q 200 225 25 900 1500 4300 5000 6500 700...

Page 1796: ...33 September 2005 80q 15 25q Svend H yer A S motorinstruktioner A5 10 OUTL indd 33 26 10 05 11 25 44...

Page 1797: ...enia Uzwojenie zamoczone w wodzie morskiej zwykle musi zosta przezwojone Rozruch bezpo redni b d przez prze cznik Y Skrzynka zaciskowa silnik w standardowych jednobiegowych zazwyczaj zawiera 6 zacisk...

Page 1798: ...Nieu ywane wej cia kablowe musz zosta zamkni te Opr cz zacisk w uzwojenia g wnego i uziemienia w skrzynkach zaciskowych znajduj si r wnie pod czenia termistor w grza ek postojowych roz cznik w bimeta...

Page 1799: ...go r wnie poda Silniki z o yskami typu 2RS trzeba smarowa ponownie najpierw otwieraj c silnik nast pnie wyczy ci o yska i nasmarowa je nowym smarem do poziomu na oko o 50 70 Wzorzec okresu przesmarowa...

Page 1800: ...utningdiagramm Forbindelsesdiagram Aansluitdiagram Connection Conexi n Collegamento Schemat polaczen W1 U R 1 2 S S R T T U1 V V1 W W1 Y U R 1 2 S S R T T U1 V V1 W L1 L2 L3 L2 L1 L3 L1 L2 L3 L2 L1 L3...

Page 1801: ...38 September 2005 Personal Notes motorinstruktioner A5 10 OUTL indd 38 26 10 05 11 26 01...

Page 1802: ...For yderligere tekniske informationer kontakt venligst vores salgsafdeling Important notice Texts and data of this catalogue are not binding and we reserve the right to change them without previous n...

Page 1803: ...S 331 42 V rnamo Tel 46 37 04 77 13 Fax 46 37 01 00 46 E mail svendhoyer svendhoyer se http www svendhoyer se Norge Svend H yer AS Torvet 1 N 3256 Larvik Tel 47 33 18 00 11 Faks 47 33 18 00 13 e mail...

Page 1804: ...Cooling Water Preheating Set C5 05 09 09 08 05 en 27 06 2002 FD020647 1 39 Small continous flow heater...

Page 1805: ...r 367 369 80687 M nchen P O Box 210466 80674 M nchen Tel Fax E mail 49 89 546779 0 49 89 546779 10 support elwa com Wasservorw rmaggregat Water Preheating Unit Type KVE hnliches Bild Similar picture D...

Page 1806: ...ain components 8 2 2 1 Druckbeh lter Pressure vessel 1 8 2 2 2 Heizbatterie Heating battery 2 8 2 2 3 Pumpe Pump 3 9 2 2 4 Schaltschrank Switch cabinet 4 10 2 2 5 R ckschlagklappe Non return flap 5 10...

Page 1807: ...hen Tel Fax E mail 49 89 546779 0 49 89 546779 10 support elwa com Anhang Appendix Anhang Appendix 1 Ma zeichnung Dimension drawing Anhang Appendix 2 Verdrahtungschema Heizbatterie Wiring diagram of h...

Page 1808: ...r preheating units As well as the general safety instructions con tained in the Notes on safety section also comply with the specific safety notes given in the other sections We cannot accept any liab...

Page 1809: ...d in these installation and operating instructions national regulations in place gov erning accident prevention any in house works and safety instructions issued by the owner 1 6 SICHERHEITSHINWEISE F...

Page 1810: ...SSIONING section when taking the unit back into operation 1 8 UNZUL SSIGE VERWENDUNG NON DESIGNATED USE Die Betriebssicherheit des gelieferten Ger ts oder Moduls ist nur bei bestimmungsgem sser Verwen...

Page 1811: ...n pump forces the medium through the continuous flow heating battery while a non return flap on the unit s outlet prevents the me dium flowing through opposite to the pumping direction The pump and th...

Page 1812: ...vessel with inlet and outlet flange drainage connection legs and sleeve for the safety valve As standard the pressure vessel is manufac tured from sheet steel which has a protective coating on the sid...

Page 1813: ...her Nennweite Die Pumpenwelle ist zum Geh use mit einer nicht entlasteten Gleitringdichtung abgedichtet und mit dem Motor ber eine starre Kupplung verbunden Der Pumpenkopf Motor Laterne und Laufrad la...

Page 1814: ...eise ist dem Schaltplan im Anhang 3 zu entnehmen The switch cabinet contains the circuit breakers for protecting the heating elements and the pump as well as the controlgear for the breakers The entir...

Page 1815: ......

Page 1816: ...e range is shown on the scale below the adjusting knob Bild Regler Sonderausstattung Special equipment Elektronischer 2 Punktregler mit Tempera turanzeige 1 Elektronischer Mehrstufenregler mit Soll un...

Page 1817: ...rks guar antee Die f r die Montage n tigen Abmessungen s o wie Anschlu masse sind in der Zeichnung A n hang 1 zu entnehmen Refer to the drawing in Appendix 1 for the dimen sions and connection sizes r...

Page 1818: ...d h sie mu mit den Pfeilen auf der Haube der Pumpe verglichen werden Stimmt die Drehrichtung nicht mit den Pfeilen berein so mu durch Vertauschen von 2 Phasen die richtige Drehrichtung hergestellt wer...

Page 1819: ...sfl ssigkeit ber Zulauf und Entleermuffe ausgesp lt werden Feste Ablage rungen im Beh lter und zwischen den Heizta schen bzw Heizk rpern k nnen nur nach Aus bau des Heizeinsatzes entfernt werden Um Sc...

Page 1820: ...nfolge unter Verwen dung einer neuen Flanschdichtung Turn off power shut off inlet and outlet and drain pressure vessel Remove top of terminal box disconnect wiring from terminal strip withdraw cables...

Page 1821: ...lten einige Tropfen Silikon l auf die Welle zwischen Laterne und Kupplung gespritzt werden Dadurch wird ein Verkleben der Dichtungsfl chen verhindert Pump and motor do not require maintenance If the p...

Page 1822: ...penwelle mit einem Schraubenzieher in Richtung Motor heben so da die Pumpenwelle die Motorwelle ber hrt Innensechskantschrauben in der Kupplung mit 5 Nm 0 5 kpm anziehen Pr fen ob der Abstand zwischen...

Page 1823: ...imiter has tripped Motor protection switch on the pump has tripped 6 3 PUMPE PUMP Motor l uft nicht Motor does not run when started Keine Stromzufuhr am Motor Sicherung durchgebrannt oder Sicherungs a...

Page 1824: ...Suction pipe pump partly blocked Air in suction line Pumpe l uft keine F rderleistung Pump is running but does not deliver Saugleitung Pumpe verstopft R ckschlagventil blockiert Saugleitung undicht L...

Page 1825: ...er preheating unit siehe Typenschild Anschlu leistung Connected load siehe Typenschild Betriebsspannung Operating voltage siehe Typenschild Betriebsdruck max Operating pressure max 4 bar Betriebstempe...

Page 1826: ...emme einzeln Single terminal Erdungsklemme einzeln Single earth terminal Kabeleinf hrungen Cable gland Anschlu flansch Dichtung Coupling flange gasket 2 Schaltschrank Switch cabinet Stck Qty Die Bezei...

Page 1827: ...t 4 R ckschlagklappe Non return flap Stck Qty R ckschlagklappe Non return flap Gegenflansche Counter flange 5 Sonderausstattung Special equipment Stck Qty Sicherheitsventil Safety valve Thermometer Th...

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Page 1842: ...45 37 400 50 22 5 22 5 0 37...

Page 1843: ...Engine Adjusting Valve C5 05 09 09 15 00 en 25 02 2004 FD000518 1 10 Engine Adjusting Valve...

Page 1844: ...dependent and in according to Dimension sheet Dimension sheet Dimension sheet Electrically Operated Control Valves Electrical Motor Drive MOV 81 MOV S 81 MOV 3 81 Types Construction Materials Single s...

Page 1845: ...0 Hz single phase AC or 380 V 50 or 60 Hz three phase current other supply voltages on request Type of protection DIN 40050 IP 65 Allowable ambient temperature 20 to 60 C Limit switch torque dependent...

Page 1846: ...respective wiring diagrams Start up and Adjustment instructions Drive 1 2 kN and 4 5 kN Drive 12 kN and 24 kN For start up of the valve place the drive by means of the hand wheel e in the middle of th...

Page 1847: ...e sealings are settling a bit at the beginning The maintenance of the stuffing box is also important In case of leakage the stuffing box gland has to be fastened at once If this is no longer possible...

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Page 1853: ...Oil Mist Detector C5 05 11 02 03 05 M43 VM43 en 07 08 2008 FD037853 1 63 Oil Mist Detector...

Page 1854: ...Operation Manual Part No 11078 Version 1 7 07 2008 VISATRON Oil Mist Detectors VN115 87plus VN116 87plus VN215 87plus IACS UR M67 type approved...

Page 1855: ...manual carefully and take note of the given advice x Use the VISATRON series VN87plus devices only for the purpose described in the operation manual x Incorrect maintenance and handling errors may cau...

Page 1856: ...t for faster processing CAUTION Unplug the OMD during welding processes on the engine Use a monitoring device at a safe location to read off the current oil mist concentration SAB recommends to wait u...

Page 1857: ...ct Kind of equipment Oil Mist Detector Type designation VISATRON VN115 87plus VISATRON VN116 87plus VISATRON VN215 87plus is in compliance with following standards EN 61000 4 2 EN 61000 4 3 EN 61000 4...

Page 1858: ...3 Schematic electrical wiring diagram 28 3 Commissioning 29 3 1 Adjusting or checking the suction pressure 29 3 2 Filling of siphon blocks VN280 of VN215 87plus system with oil 30 3 3 Filling of siph...

Page 1859: ...nal test 48 7 1 On board test 48 7 2 Factory test with smoke generator on VN115 87plus VN116 87plus and VN215 87plus installations 50 7 3 Additional pressure measurement on VN115 87plus and VN116 87pl...

Page 1860: ...kcase compartments and other engine locations The system works actively and is not waiting for oil mist clouds This ensures proper reaction times from the beginning of oil mist generation to an oil mi...

Page 1861: ...rce inside the engine VN116 87plus The suction system is connected to the Valve Box 116 4 This type of oil mist detector is able to detect an oil mist alarm indicating in the valve box window the left...

Page 1862: ...ducer and a protection cover Figure 2 VISATRON VN116 87plus oil mist detector with protection cover and pressure regulator unit Protection cover Pressure regulator unit The suction system always requi...

Page 1863: ...essure it is recommended that the output of the air jet pump is blown back into the crankcase If the air is blown into the engine room SCHALLER AUTOMATION offers an optional oil separator which should...

Page 1864: ...rial interface for monitoring devices is integrated x Additional error codes x Switch for the adjustment of the main alarm level is placed on the rear side of the measuring head no disassembly of the...

Page 1865: ...tion sense of the engine x At least one suction point per chain drive or gear drive is necessary x Avoid the splash oil disk of the crankshaft bearings x Select points in the upper area of the crankca...

Page 1866: ...y engine builder determine an additional suction point at the camshaft bed SCHALLER AUTOMATION recommends a final test procedure per engine type called OMDEA Oil Mist Detection Efficiency Approval Acc...

Page 1867: ...ON VN116 87plus installation on a 6 cyl engine with engine wall connections oil draining through pipe siphons exhaust suction point engine wall connection engine wall connection pipe siphon engine wal...

Page 1868: ...Alternative installation of VN116 87plus OMD Figure 11 Recommendation for best VN215 87plus OMD installation D 66440 Blieskastel Saarland Germany Industriering 14 P O Box 1280 Industrielle Automation...

Page 1869: ...ll thickness or if 14 mm is not available o Seamless steel Pipes 13 71 mm known as1 4 inch pipes schedule no 40 0 540 inch outer diameter 0 088 inch wall thickness The length of the exhaust pipe outle...

Page 1870: ...to the G3 4 thread with 110 Nm torque x Put the pipe siphon in the hole x Fix the clamping nut x Fill the pipe siphon with oil see chapter commissioning x Fix the flexible tube on the top fitting D 66...

Page 1871: ...mage of pipe siphon Figure 16 Oil draining principle Crank case atmosphere Header pipe Flexible hose to suction point Oil Flexible hose to pipe siphon D 66440 Blieskastel Saarland Germany Industrierin...

Page 1872: ...per included with the connection units x Drill through x Seal all threads with Loctite 572 x Max torque 30 Nm OKAY Wrong alignment Wrong angles Wrong distance 1 2 3 Figure 18 Side view x Avoid wrong a...

Page 1873: ...the crankcase compartment The suction funnels have to be fitted in such a way that flooding by splashing bearing oil or returning piston cooling oil is avoided see Figure 19 CAUTION Make sure funnels...

Page 1874: ...e arrangement at valve box VN215 87plus system only Figure 20 Pipe arrangement for 4 to 8 suction points or or D 66440 Blieskastel Saarland Germany Industriering 14 P O Box 1280 Industrielle Automatio...

Page 1875: ...upplied rubber plugs 2 1 7 Compressed air connection If the SAB pressure regulator see Figure 22 is used connect the compressed air supply at the NTP BSP G1 4A fitting Use only dry and clean compresse...

Page 1876: ...he classification societies the Alarm relay must be connected either to the shutdown or to the slow down input During normal operation the alarm relay is switched off In case of an oil mist alarm the...

Page 1877: ...switched on when the OMD is in correct operation see Figure 26 Figure 25 Wire break resistors Wire break resistors The optional pre alarm output can be used to initiate either a pre warning signal or...

Page 1878: ...ed 6 14 Alarm 2 relay closed Alarm 1 relay open 7 15 Alarm 2 relay open Alarm 1 relay common 8 16 Alarm 2 relay common Figure 26 Pin assignment The relay outputs are potential free Power supply 18 31...

Page 1879: ...used communication cable must be twisted pair and shielded We recommend LAPPKABEL UNITRONIC FD CP TP plus UL CSA AWG20 The total bus length is limited to 400 m The VISATRON device cable entry see Figu...

Page 1880: ...monitoring device is the bus master and the OMD devices are the slaves It s necessary to adjust different bus addresses at each slave device Normally the first OMD device gets the address 1 and so on...

Page 1881: ...cator II Alarm monitoring system T Ready and alarm signals RS485 2 wire bus Engine safety system Engine control room Optional 4 20 mA VN87plus Engine room D 66440 Blieskastel Saarland Germany Industri...

Page 1882: ...may cause a change in detecting sensitivity x Connect U tube manometer at inspection cover see Figure 31 U tube manometer is included in the service box available as an option x Switch on compressed a...

Page 1883: ...of the filling pump see Figure 33 as many times until first oil drops are coming out x Unscrew the lower siphon block plug see Figure 32 x Insert filling pump nozzle Figure 32 Siphon block VN280plus...

Page 1884: ...s the rear plate CAUTION Do not fill with more than 12 strokes waste oil flow in the tubes and could suck out of the block internal siphons x Close the threaded hole with the plug a small amount of oi...

Page 1885: ...ng pump nozzle see Figure 37 Figure 35 Siphon block VN180 Oil input Figure 36 Filling pump Fitting Lock nut x Screw in the fitting of the filling pump x Press the nozzle to stop position x Tighten the...

Page 1886: ...with the next block 3 4 Filling of pipe siphons for VN115 87plus and VN116 87plus system with oil Figure 38 Pipe siphon Fitting to flexible hose and oil input x Remove flexible hose x Fill in 70ml lu...

Page 1887: ...3 0 3 7 6 5 0 5 5 Table 2 Sensitivity switch position and corresponding oil mist alarm level Inside the measuring head 2 5mg l oil mist concentration is approx 23 absolute opacity compared to the full...

Page 1888: ...WC yes no Adjusted negative pressure mmWC Electrical check Is the power supply connected to the terminal and is the voltage within the specified range yes no Measured supply voltage Volts Is the monit...

Page 1889: ...the Oil Mist Alarm LED switches on At 100 opacity compared to the alarm level the Oil Mist Alarm LED starts blinking If the opacity later goes down later the alarm condition will be stored Oil Mist A...

Page 1890: ...down relay is not switched on Blinking LED on display Series VN87plus device failures 14 Negative pressure airflow too low 13 Optical sensor dirty 12 Voltage of internal battery too low 11 Ambient tem...

Page 1891: ...ship owner Use a monitoring device at a safe location to read off the current oil mist concentration SAB recommends to wait until more than the half of the indication LED s are switched off VISATRON d...

Page 1892: ...ambient cooling components 8 Electronics temperature too high 75 C 1 Remove or turn away ambient heating components 2 Install metal heat shields against radiation 3 Install vortex coolers 7 Reset butt...

Page 1893: ...g when the device was switched off for a long period Figure 45 Cleaning of IR Filter glass in the left and the right chamber Fresh air bore of right chamber Needle IR filter glass Cleaning fluid Cott...

Page 1894: ...always new ones 5 4 Exchange air filter in pressure regulator unit Figure 47 The air filter is behind the lock screw of the throttle block Lock screw WARNING Switch off the compressed air supply durin...

Page 1895: ...ing air fitting Scavenging air fitting Figure 49 Step 2 is to unplug the connectors Measuring head main connector Optional on VN116 and VN215 units Valve box connector D 66440 Blieskastel Saarland Ger...

Page 1896: ...ws To mount the new measuring head execute the 3 steps in reverse order WARNING Check the values of the wire break resistors or in case of doubt use the old ones D 66440 Blieskastel Saarland Germany I...

Page 1897: ...to press out the 4 rubber gaskets with a blunt tool and finally to remove the carrier plate Rubber gasket Figure 52 Step 3 is to exchange the suspension system if necessary Upper spring insulation sy...

Page 1898: ...p 5 is to pull out the gaskets before the carrier plate is mounted Upper bellow of the suction channel Dismounted rubber sealing before start of assembly Fixing screws To finish the assembly execute t...

Page 1899: ...which protects the filter circuit in the connector To reset this fuse unplug the main connector and wait 5 minutes before you plug it again WARNING Unplug the main connector during the exchange of the...

Page 1900: ...5 Perform quarterly maintenance procedure 1 4 6 Exchange air filter in pressure regulator unit See chapter 5 4 page 41 Yearly 7 Perform half yearly maintenance procedure 5 6 8 Clean suction system wi...

Page 1901: ...11072 It consists of the following parts x Test plate A x Test glass B x Working instruction A B Attention You will stop or slow down the engine Test procedure step by step Step 1 Open the bolts of t...

Page 1902: ...4 is blinking and the Oil Mist Alarm RESET button is pressed the OMD device enters a test mode In this test mode the LED bar displays the measured opacity After pressing the Oil Mist Alarm RESET butto...

Page 1903: ...chapter 2 1 3 A complete test can be done only at standstill of the engine The crankcase service covers must be opened first Then fill in a small amount of smoke fluid see Chapter Accessories into the...

Page 1904: ...ctional and smoke test as shown in the previous chapters On board test and Factory test with smoke generator Figure 58 Manometer connected to siphon block VN180 Figure 59 Manometer connected to header...

Page 1905: ...diameter suction pipes which are delivered from SCHALLER AUTOMATION These pipes have also fittings for the manometer at the pipe end see Figure 59 Use only a digital manometer with a differential meas...

Page 1906: ...box VN215 87plus right 10408 Pipe connection for valve box VN215 87plus left 10411 Rubber insert for valve box pipe connection VN215 11652 Connection box VN115 87plus 10018 Suspension element top 1001...

Page 1907: ...block VN280 1connection with manometer fitting 10160 Mounting plate VN280 11062 Oil pump VN280 10013 Siphon block VN180 10612 Siphon block VN180 with manometer fitting 10089 Mounting plate VN180 1006...

Page 1908: ...lus 07 2008 Page 55 SCHALLER AUTOMATION Figure 60 Service box D 66440 Blieskastel Saarland Germany Industriering 14 P O Box 1280 Industrielle Automationstechnik GmbH Co KG Tel 49 0 6842 508 0 Fax 260...

Page 1909: ...ents top 2 16 10002 Air filter for pressure regulator unit 1 17 11078 Manual series VN87plus in English 1 18 10046 U pipe manometer 1 19 10354 Philips screwdriver 1 20 10157 Screwdriver 4 mm 1 21 1035...

Page 1910: ...Out NTP BSP G3 4A Pressure reducer connections In NTP BSP G1 4A Out NTP BSP G1 4A Air pressure Before pressure reducer 2 15 bar Before air jet pump max 500 mbar Negative pressure in measuring head 60...

Page 1911: ...00Hz Relative humidity up to 95 Protection class IP54 Approval of classes Type approved for closed areas designed for installation on combustion engines environmental category D GL IACS UR M67 conform...

Page 1912: ...62 Mechanical dimensions of VN115 87plus top view Figure 63 Mechanical dimensions of VN116 87plus side view D 66440 Blieskastel Saarland Germany Industriering 14 P O Box 1280 Industrielle Automationst...

Page 1913: ...64 Mechanical dimensions of VN116 87plus top view Figure 65 Mechanical dimensions of VN215 87plus side view D 66440 Blieskastel Saarland Germany Industriering 14 P O Box 1280 Industrielle Automationst...

Page 1914: ...ure 66 Mechanical dimensions of VN215 87plus top view Figure 67 Drilling template of the OMD base plate D 66440 Blieskastel Saarland Germany Industriering 14 P O Box 1280 Industrielle Automationstechn...

Page 1915: ...land Singapore Spain United Arabian Emirates United Kingdom United States of America As details in relevant addresses are supposed to change please find actual addresses of the relevant service partne...

Page 1916: ...Coupling RATO C5 05 12 13 03 12 M43 en 02 03 2009 FD039902 1 42 Coupling RATO...

Page 1917: ...Caterpillar Motoren Kiel 3107011045_11047_11049_11051_11053 G47KTR Special Exicution 1G47K0R005 1G47KTR005 VULKAN Kupplungs und Getriebebau B Hackforth GmbH Co KG Postfach 200462 44634 Herne Germany H...

Page 1918: ...wing EG4710003R Partlist EG471Z003R Delivery Condition AG47K0R005 InstallationandOperating Instructions E B RATO_R_1G47K0R005E Aliment Instructions for highli flexible VULKAN RATO S R Couplings S R A...

Page 1919: ...50 total kW 0 9 1 3 n K max min 1 K a mm K r mm F ax1 0 kN C rdyn kN mm nominal 1300 1200 C T dyn total kNm rad warm 910 840 nominal 0 9 1 13 rel Damping warm 0 63 0 79 2 9 6 0 50 700 12 15 200 233 90...

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Page 1921: ...QT 13 1 4G47970030 Cover FM 690 X 575 X 15 C45 N 14 16 7033624000 DISC 24 VERG 17200 15 16 7001124055 C HEXAGON BOLT M 24 X 55 10 9 933M 16 96 7033630000 DISC 30 42CRMO4 QT EN 10083 1 19 32 7000130125...

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Page 1923: ...us 11 Page 1 Drawing Printed by BUHRMEISTER Item Quant Part Number Description Dimensions Material Remark DM 1 4 2G450TA002 Rato S ST GUMMI 2 8 3G45D70000 LINK FM 0 X 0 X 0 42CrMo4V EN 10083 1 3 16 70...

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Page 1925: ...Z003R Date 12 11 2008 Elast Element Status 11 Page 1 Drawing Printed by BUHRMEISTER Item Quant Part Number Description Dimensions Material Remark DM 1 1 EG471Z002R Flex Element St Gummi 2 32 3G47K3000...

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Page 1927: ...Operating Instructions 1G47K0R005 VULKAN RATO R Couplings VULKAN Kupplungs und Getriebebau B Hackforth GmbH Co KG Postfach 200462 D 44634 Herne Germany Heerstrasse 66 D 44653 Herne Germany Phone 49 23...

Page 1928: ...ng 4 4 1 Assembly procedures 5 5 Commissioning 7 6 Maintenance 7 6 1 Operational behaviour with reference to certain mechanical characteristics of the elastomer material 7 6 2 Operational behaviour wi...

Page 1929: ...ure that no fragments of the broken coupling are propelled from the machine For couplings installed on dynamically supported crafts the safety regulations as published in document A373 of the IMO Inte...

Page 1930: ...so that no extensive disassembly is required for installation of the coupling In order to ensure proper functioning and utilisation of the full capacity of the highly flexible RATO R coupling certain...

Page 1931: ...ing bush item 9 Insert disk flange item 4 in the machine with the membrane item 12 and connect RATO R element item 1 using screws item 59 Now you can begin with the assembly of the flexible RATO S ele...

Page 1932: ...les are marked by notches on the element Cylinder pin item 55 Bush item 2 Plates Securing elements Insert securing elements items 16 19 and 28 with one bush from item 1 each and tighten slightly Tight...

Page 1933: ...inadvertent switching on or rotation The usability and durability of highly flexible couplings are primarily determined by their design and dimensioning Other important factors are the properties of...

Page 1934: ...nfluences they contain advanced ageing protection agents These substances are contained in the matrix of the rubber material but are used up over time 7 Replacement of the flexible elements The elemen...

Page 1935: ...l the flexible section item 1 follow the instructions in 0 The coupling is now ready for operation 8 Service and spare parts Address VULKAN Customer Service Department Heerstrasse 66 D 44653 HERNE Ger...

Page 1936: ...gular alignment must be measured using appropriate measuring instruments We recommend that both shafts are rotated by 90 deg before each measurement in order to eliminate any inbuilt errors due to ecc...

Page 1937: ...ieses relativ gro en Versatzes aber auch wegen der Schwierigkeit den gew nschten Versatz gezielt einstellen zu k nnen werden bei derartigen Anlagen die Ausrichttoleranzen entsprechend erh ht The align...

Page 1938: ...mm 06 1 75 0 75 0 R R R R mm 75 0 2 5 237 0 236 2 R R R mm 0 75 2 236 1 237 6 2 R R R 2 2 2 34 2 12 4 3 34 1 2 12 Dieser Wert ist gr er als die empfohlene Ausrichttoleranz in der Tabelle deshalb mu mi...

Page 1939: ...dinate the resulting loads in the connected surface planes with the builders of the system F r elastisch aufgestellte Anlagen und komplett montierte Kupplungen kann die axiale Ausrichtung nur ber die...

Page 1940: ...art mm 32 0 30 0 10 0 X X X X mm 30 0 2 6 90 0 90 2 X X X mm 10 0 2 2 90 4 90 2 X X X 2 2 w 2 4 3 w 2 2 1 w w 4 w 3 w 4 3 w 1 w 2 w 2 1 w Der Winkelversatz ist in Ordnung da er unter dem gem Tabelle 1...

Page 1941: ...nts with a long operational life to investigate the influence of AGEING on the operational safety of the coupling The results of these investigations can be summarized as follows Due to the constructi...

Page 1942: ...94 G 1710 32 G 4910 44 G 1910 34 G 5010 100 G 2110 37 G 5110 100 G 2310 39 G 5310 155 G 2510 43 G 5410 48 G 2710 43 G 5510 107 G 2910 46 G 5610 107 G 3010 53 G 5810 103 G 3110 53 G 6010 52 G 3210 56 G...

Page 1943: ...10R 35 G 2110R 39 G 2310R 41 G 2410R 22 G 2510R 46 G 2610R 50 G 2710R 49 G 2730R 32 G 2910R 52 G 2930R 34 G 3110R 59 G 3210R 69 G 3310R 68 G 3330R 41 G 3430R 44 G 3510R 44 G 3810R 53 G 3910R 88 G 4710...

Page 1944: ...cks with a depth up to 5 of the radial rubber thickness are to be considered acceptable if they occur around the whole surface figure 3 depth X If cracks are predominantly in the outer rubber surface...

Page 1945: ...20 5 52 G 3410 13 0 22 0 57 G 3510 13 0 22 0 57 G 3610 14 0 24 0 61 G 3710 14 0 24 0 61 G 3810 15 0 25 5 66 Dimension Group Depth X mm Depth Y mm Depth Z mm G 3910 15 0 25 5 66 G 4010 15 0 25 5 66 G 4...

Page 1946: ...0 G 1710R 6 4 10 8 G 1910R 6 8 11 6 G 2110R 7 4 12 6 G 2310R 8 0 13 6 G 2410R 8 9 15 1 G 2510R 8 6 14 6 G 2610R 9 3 15 8 G 2710R 9 3 15 8 G 2730R 9 6 16 3 G 2910R 10 1 17 2 G 2930R 10 4 17 7 G 3110R 1...

Page 1947: ...depth we recommend replacing the re levant row as soon as possible 2 2 Interval for checking RATO couplings x When after checking a RATO coupling surface cracks have been found which have a depth LESS...

Page 1948: ...terial rubber not hardened The moulding of the cracks should be if possible very accurately rounded and should not show sharp corners During and after grinding it is not allowed to use French chalk or...

Page 1949: ...R CRIT 9 1a Modificatio 3 15 11 2006 Photo 1 Grinding tools The rework of the cracks can be done with a suitable belt grinder The abrasive belts are available in three different grades of coarseness...

Page 1950: ...Criteria for inspection S R CRIT 10 1a Modificatio 3 15 11 2006 Photo 3 Segment corners reworked Photo 4 Additionally protection of the surfaces with Coating LP...

Page 1951: ...ved for the treatment of all element surfaces Instructions for application of VULKAN Coating LP For the treatment of surfaces of highly flexible elements which have been sanded crack free according to...

Page 1952: ...7 Vulkancoating Lipren_EN doc The waiting time before re commissioning the coupling is at least one hour after application of the last coat VULKAN Coating LP can be stored for 6 months in closed cans...

Page 1953: ...gency telefone number 0049 2365 49 2232 2 COMPOSITION INFORMATION ON INGREDIENTS Chemical characteristics Aqueous dispersion of a polymer consisting of polychlorbutadienes Concentration ca 32 58 Other...

Page 1954: ...recautions to prevent the product from entering the sewage system PROCEDURE FOR CLEANING Absorb with liquid binding material e g sand universal binder silica gel acid binder sawdust Place in a suitabl...

Page 1955: ...ation TRGS 900 Can be absorbed by the skin TECHNICAL PROTECTIVE MEASURES For latex processing e g drying Provide for adequate ventilation or exhaust PERSONAL PROTECTIVE GEAR RESPIRATORY PROTECTION In...

Page 1956: ...ite ODOUR Faint SAFETY RELATED DATA pH VALUE ca 13 20 C MELTING POINT MELTING RANGE ca 0 C BOILING POINT BOILING RANGE ca 100 C 1013 hPa FLASH POINT Not applicable IGNITION TEMPERATURE Not applicable...

Page 1957: ...gulations e g in a suitable incineration plant No waste code has been defined for this product in accordance with the European Waste Catalogue 14 TRANSPORT TRANSPORT ADDITIONAL INFORMATION Not a hazar...

Page 1958: ...Coupling RATO C5 05 12 14 01 35 M43 en 02 03 2009 FD039904 1 42 Coupling RATO...

Page 1959: ...056 Dimension Group Series Drawing No Partslist No Caterpillar G2137 2400 1G2130R013 1G2137R013 VULKAN Kupplungs und Getriebebau B Hackforth GmbH Co KG Postfach 200462 44634 Herne Germany Heerstrasse...

Page 1960: ...03R Delivery Condition AG2130R013 InstallationandOperating Instructions E B RATO_R_G1620_G3420_BR2200_2401e Aliment Instructions for highli flexible VULKAN RATO S R Couplings S R A 1 3 to 5 3 Criteria...

Page 1961: ...6 T K max 1 kNm 24 T K max 2 kNm 72 T max kNm 0 T KW kNm 4 8 PKV50 total kW 1 47 n K max min 1 2525 Ka mm 6 Kr mm 15 Fax1 0 kN 0 3 C rdyn kN mm 0 93 nominal 34 C T dyn total kNm rad warm 23 8 nominal...

Page 1962: ......

Page 1963: ...N10083 1 10 1 2G21K2002M C MEMBR ASSEMBLY 16 32 7033612000 Disc FM 20 X 12 1 X 4 5 42CrMo4 QT EN10083 1 19 32 7000112070 HEXAGON BOLT M 12 X 70 10 9 931M 20 32 7000112050 HEXAGON BOLT M 12 X 50 10 9 9...

Page 1964: ......

Page 1965: ...17200 10 30 7001112040 HEXAGON BOLT M 12 X 40 10 9 933M 11 30 7020112000 Hex Nut M 12 10 934 12 60 7033612000 Disc FM 20 X 12 1 X 4 5 42CrMo4 QT EN10083 1 13 2 7006112040 C HEX FITTEDBOLT M 12 X 40 1...

Page 1966: ......

Page 1967: ...8 04 04 Version 001 TB 10 Simonetta Marschall J rgen Kestermann Page 1 12 Installation and Operating Instruction E B G1620R G3430R BR2200 2401 VULKAN RATO R Couplings VULKAN Kupplungs und Getriebebau...

Page 1968: ...ation of the coupling 5 3 1 Delivery condition of the RATO R coupling 5 3 2 Procedure before the installation of the RATO R couplings 5 3 3 Assembly of the RATO R couplings 6 4 Design of the flexible...

Page 1969: ...o be ensured use of perforated plates If the possibility of exceeding the permissible speed of the coupling nkmax cannot be excluded com pletely e g in case of an incident or because of a failure of t...

Page 1970: ...as to be checked and approved by the classi fication society The expected and satisfactory behaviour is guaranteed only provided that all com ponents comply to the values the torsional vibration calcu...

Page 1971: ...ered according to the following drawing AG 3 2 Procedure before the installation of the RATO R couplings x Remove the fixation elements Pos 22 35 x Deposit the membrane dimension group 10 as a unit x...

Page 1972: ...rn engineering practice For series 2400 in addition the add hub 6 and the plate flange 4 have to be connected with the driving side machine Now both machines are to be mounted and aligned according to...

Page 1973: ...e tightening torque required for the chosen screw quality has to be kept When using 10 9 bolts hardened washers have to be provided Subsequently the assembly of the flexible part can be started 4 Desi...

Page 1974: ...g fixation elements 20 39 The pre scribed tightening torque 20 is to be kept hexagon bolt turn in Installation condition after having turned in the flexible part example of a double row RATO R coup li...

Page 1975: ...Kestermann Page 9 12 Now insert the split interm ring 60 and establish the connection hub 5 split interm ring 60 membrane dimension group 10 with the connecting elements 22 35 Please pay attention to...

Page 1976: ...but also by the elastomer material selected and its resistance against environmental influ ences 6 1 Operating performance considering the mechanical properties of the Elastomer material Basically th...

Page 1977: ...an additional sur face protection is used With respect to sizes G 34 up to G 73 a foil is vulcanized in the surface Once a year or after special incidents this protective coating has to be checked wit...

Page 1978: ...tem 46 please give us the following information of the RATO R coupling x 1 order No x 2 drawing No x 3 partslist No 7 2 Assembly of the flexible part Before starting the assembly it is recommended to...

Page 1979: ...ar alignment must be measured using appropriate measuring instruments We recommend that both shafts are rotated by 90 deg before each measurement in order to eliminate any inbuilt errors due to eccent...

Page 1980: ...ieses relativ gro en Versatzes aber auch wegen der Schwierigkeit den gew nschten Versatz gezielt einstellen zu k nnen werden bei derartigen Anlagen die Ausrichttoleranzen entsprechend erh ht The align...

Page 1981: ...mm 06 1 75 0 75 0 R R R R mm 75 0 2 5 237 0 236 2 R R R mm 0 75 2 236 1 237 6 2 R R R 2 2 2 34 2 12 4 3 34 1 2 12 Dieser Wert ist gr er als die empfohlene Ausrichttoleranz in der Tabelle deshalb mu mi...

Page 1982: ...dinate the resulting loads in the connected surface planes with the builders of the system F r elastisch aufgestellte Anlagen und komplett montierte Kupplungen kann die axiale Ausrichtung nur ber die...

Page 1983: ...art mm 32 0 30 0 10 0 X X X X mm 30 0 2 6 90 0 90 2 X X X mm 10 0 2 2 90 4 90 2 X X X 2 2 w 2 4 3 w 2 2 1 w w 4 w 3 w 4 3 w 1 w 2 w 2 1 w Der Winkelversatz ist in Ordnung da er unter dem gem Tabelle 1...

Page 1984: ...ong operational life to investigate the influence of AGEING on the operational safety of the coupling The results of these investigations can be summarized as follows Due to the constructional design...

Page 1985: ...0 33 0 59 0 58 0 58 0 54 0 53 0 081 X 75 0 82 0 361 X 62 0 36 0 64 0 62 0 381 X 90 0 95 0 391 X 67 0 38 0 67 0 67 0 431 X 73 0 42 0 76 0 73 0 451 X 105 0 112 0 461 X 34 0 20 0 41 0 34 0 36 0 481 X 67...

Page 1986: ...0 32 0 29 0 24 0 231 X 31 0 19 0 35 0 28 0 35 0 31 0 28 0 251 X 35 0 21 0 39 0 30 0 39 0 35 0 30 0 271 X 38 0 23 0 42 0 34 0 42 0 38 0 34 0 271 X 2 23 0 14 0 26 0 22 0 23 0 32 0 291 X 40 0 24 0 45 0...

Page 1987: ...e radial rubber thickness are to be considered acceptable if they occur around the whole surface figure 3 depth X If cracks are predominantly in the outer rubber surface including the radius area an e...

Page 1988: ...10 18 0 30 5 77 4510 18 0 30 5 77 4910 19 0 32 5 83 5110 19 0 32 5 83 5410 20 0 34 0 90 5610 20 0 34 0 90 5310 20 0 34 0 90 5810 22 0 37 5 97 6010 22 0 37 5 97 6210 23 0 39 0 103 6310 23 0 39 0 103 65...

Page 1989: ...mmend replacing the re levant row as soon as possible 2 2 Interval for checking RATO couplings x When after checking a RATO coupling surface cracks have been found which have a depth LESS than the max...

Page 1990: ...care that the temperature is not too high at the final end of the grinding procedure and the material rubber not hardened The moulding of the cracks should be if possible very accurately rounded and s...

Page 1991: ...inspection S R CRIT 8 1a Photo 1 Grinding tools The rework of the cracks can be done with a suitable belt grinder The abrasive belts are available in three different grades of coarseness fine medium r...

Page 1992: ...Criteria for inspection S R CRIT 9 1a Photo 3 Segment corners reworked Photo 4 Additionally protection of the surfaces with Coating LP...

Page 1993: ...ved for the treatment of all element surfaces Instructions for application of VULKAN Coating LP For the treatment of surfaces of highly flexible elements which have been sanded crack free according to...

Page 1994: ...7 Vulkancoating Lipren_EN doc The waiting time before re commissioning the coupling is at least one hour after application of the last coat VULKAN Coating LP can be stored for 6 months in closed cans...

Page 1995: ...gency telefone number 0049 2365 49 2232 2 COMPOSITION INFORMATION ON INGREDIENTS Chemical characteristics Aqueous dispersion of a polymer consisting of polychlorbutadienes Concentration ca 32 58 Other...

Page 1996: ...recautions to prevent the product from entering the sewage system PROCEDURE FOR CLEANING Absorb with liquid binding material e g sand universal binder silica gel acid binder sawdust Place in a suitabl...

Page 1997: ...ation TRGS 900 Can be absorbed by the skin TECHNICAL PROTECTIVE MEASURES For latex processing e g drying Provide for adequate ventilation or exhaust PERSONAL PROTECTIVE GEAR RESPIRATORY PROTECTION In...

Page 1998: ...ite ODOUR Faint SAFETY RELATED DATA pH VALUE ca 13 20 C MELTING POINT MELTING RANGE ca 0 C BOILING POINT BOILING RANGE ca 100 C 1013 hPa FLASH POINT Not applicable IGNITION TEMPERATURE Not applicable...

Page 1999: ...gulations e g in a suitable incineration plant No waste code has been defined for this product in accordance with the European Waste Catalogue 14 TRANSPORT TRANSPORT ADDITIONAL INFORMATION Not a hazar...

Page 2000: ...Engine Adjusting Valve C5 05 13 09 15 00 en 22 11 2000 FD020145 1 10 Engine Adjusting Valve...

Page 2001: ...dependent and in according to Dimension sheet Dimension sheet Dimension sheet Electrically Operated Control Valves Electrical Motor Drive MOV 81 MOV S 81 MOV 3 81 Types Construction Materials Single s...

Page 2002: ...0 Hz single phase AC or 380 V 50 or 60 Hz three phase current other supply voltages on request Type of protection DIN 40050 IP 65 Allowable ambient temperature 20 to 60 C Limit switch torque dependent...

Page 2003: ...respective wiring diagrams Start up and Adjustment instructions Drive 1 2 kN and 4 5 kN Drive 12 kN and 24 kN For start up of the valve place the drive by means of the hand wheel e in the middle of th...

Page 2004: ...e sealings are settling a bit at the beginning The maintenance of the stuffing box is also important In case of leakage the stuffing box gland has to be fastened at once If this is no longer possible...

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Page 2010: ...Engine Adjusting Valve C5 05 13 09 15 01 en 22 11 2000 FD020150 1 10 Engine Adjusting Valve...

Page 2011: ...dependent and in according to Dimension sheet Dimension sheet Dimension sheet Electrically Operated Control Valves Electrical Motor Drive MOV 81 MOV S 81 MOV 3 81 Types Construction Materials Single s...

Page 2012: ...0 Hz single phase AC or 380 V 50 or 60 Hz three phase current other supply voltages on request Type of protection DIN 40050 IP 65 Allowable ambient temperature 20 to 60 C Limit switch torque dependent...

Page 2013: ...respective wiring diagrams Start up and Adjustment instructions Drive 1 2 kN and 4 5 kN Drive 12 kN and 24 kN For start up of the valve place the drive by means of the hand wheel e in the middle of th...

Page 2014: ...e sealings are settling a bit at the beginning The maintenance of the stuffing box is also important In case of leakage the stuffing box gland has to be fastened at once If this is no longer possible...

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Page 2020: ...Ambiguous Document References X0 en 26 05 2009 QV020011 1 8...

Page 2021: ...Ambiguous Document References X0 en 26 05 2009 QV020011 2 8 Please select target document for A5 05 05 09 06 nn A5 05 05 09 06 00 A5 05 05 09 06 01...

Page 2022: ...Ambiguous Document References X0 en 26 05 2009 QV020011 3 8 Please select target document for A5 05 06 01 01 nn A5 05 06 01 01 17 A5 05 06 01 01 18...

Page 2023: ...Ambiguous Document References X0 en 26 05 2009 QV020011 4 8 Please select target document for B1 05 06 437210 B1 05 06 437210 ZA B1 05 06 437210 ZZ...

Page 2024: ...Ambiguous Document References X0 en 26 05 2009 QV020011 5 8 Please select target document for A3 06 06 nn A3 06 06 01 A3 06 06 04 A3 06 06 31...

Page 2025: ...Ambiguous Document References X0 en 26 05 2009 QV020011 6 8 Please select target document for B1 05 06 43725n B1 05 06 437250 KK B1 05 06 437254 HH B1 05 06 437259 ZY...

Page 2026: ...Ambiguous Document References X0 en 26 05 2009 QV020011 7 8 Please select target document for B1 05 07 438540 B1 05 07 438540 MM B1 05 07 438540 PP...

Page 2027: ...Ambiguous Document References X0 en 26 05 2009 QV020011 8 8 Please select target document for B1 05 08 436417 B1 05 08 436417 MM B1 05 08 436417 NN...

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