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ENGI EN GINE NES S - SY SYST STEM EMS S - SA SALE LES S - SE SER RVI VICE CE
ALL FROM ONE SOURCE. Bad Bentheim, 03.07.2013
- Zeppelin Group is part of Zeppelin Foundation - The Count's pioneering achievements in 1900 laid the cornerstone for today's worldwide active Zeppelin Group - Zeppelin Foundation was originally founded in 1908 in order to continue with the airship activities of Ferdinand Count Zeppelin - After World War II the foundation started with various business areas in trading and industry
FUEL FILTER/WATER SEPARATOR A single valve on all of the double manifold filters isolates one filter/separator for service while the other keeps operating. This way, you keep running while draining contaminants from the collection bowl or while changing filter elements. Meshsize 30µm
• Secondary Fuel Filter Options • Three capabilities − Standard (10 microns and up) − Advanced (4 to 10 microns) − Ultra High (less than 4 microns)* • Advanced is shipped with new engines
Caterpillar takes safety seriously • Electronically controlled with manual backup air inlet shut off systems available on all engines • Updated design for 2006 • Hydra / Mechanical shut offs available on mechanical engines only • Setting of shutoff valves marked to ensure proper resets before restarting
New switch location. Contacts only on gate closure to prevent wear
•
Overspeed 18 % abo above ve fu full ll lo load ad sp spee eed d
Overspeed Overspe ed condition is the result of a fuel system that fails to operate correctly correctly. For an overspeed overspeed condition the the fuel control linkage linkage is moved to the "SHUTOFF" position and and the engine combustion air supply is stopped.
•
Low Engine Oil Pressure
Idle Idl e spe speed ed mi min. n. 1,4 ba barr Max spee speed d min. 2.1 bar bar For a low oil pressure condition, the protective system activates an alarm or moves the fuel control linkage, through the governor, to the "SHUTOFF" position. The combustion air supply is not shutoff for this condition.
•
For furhter maintenace recommandation see
KATO
•
Air Shutoff - Test
•
Cooling System Coolant Sample (Level 1) Obtain
•
Engine Oil and Filter - Change
•
Bearing (Spherical Roller) - Lubricate
•
Cooling System Coolant Sample (Level 2) – Obtain
•
Engine - Clean
•
Engine Crankcase Breather - Clean
•
Engine Protective Devices - Check
•
Fuel System Primary Filter
•
Clean/Inspect/Replace
•
Fuel System Secondary Filter - Replace
•
Insulation - Test
•
Rotating Rectifier - Check
The Zeppelin diagnosis of oil and coolants provides valuable information on the condition of engine, axles, gears, hydraulic and coolant system of each construction machine. Thus you can prevent failures and may even extend the intervals of oil changes. Your machines work better, live longer and are thus as a total more economic.
www.zeppelin-cat.zod.de
(A) Inlet valves (B) Exhaust valves (C) Flywheel
• Longer for increased cylinder spacing • High Cam Position • Cross-Flow Design • Single-Piece Design
• Two-Step Honing Process: • Deep cut grooves improve oil retention on the liner surface • Smoothed groove tops reduce wear of cylinder liner and piston rings
• Provides Better Liner Contact with Piston Rings and Skirt • Reduces Combustion Blow-by • Improves Control of Oil Consumption
Poor coolant treatment 5,300 h
ELC - 10,103 h
(1) Cylinder head (2) Water temperature regulators (3) Outlet hose (4) Vent line (5) Vent tube (6) Shunt line (7) Elbow (8) Water pump (9) Cylinder block (10) Oil cooler (11) Inlet hose (12) Radiator
1.
Coolant water outlet
2.
Plug
3.
Thermostat housing
4.
Water pump
5.
Plug
A: Thermostat housing B. Thermostat 98 C
(1) Oil manifold (2) Oil supply line (3) Oil return line (4) Oil filter (5) Bypass valve for the oil filter (6) Oil pan (7) Oil pump (8) Bypass valve for the oil cooler (9) Suction lines (10) Bypass valve for the oil pump (11) Oil cooler
(12) Camshaft bearing journals (13) Rocker arm shaft (14) Oil passage to adjustable idler gear (15) Oil passage to air compressor (16) Oil passage to the fixed idler stub shaft (17) Piston cooling jet (18) Oil passage to cluster idler gear (19) Crankshaft main bearings (20) Oil passage from filter (21) Oil manifold
• Revolutionary Filter Design • Reduces Oil Contaminant Particle Size and Quantity • Increased contamination control • Double the efficiency without decreasing the filter change interval • Reduces wear on all oil lubricated surfaces • Captures the Most Harmful Particles: 5 – 10 Microns in Size • Series Filtration • Fuel Filter Efficiency Options • Standard (10 microns and up) • Advanced (4 to 10 microns) − Shipped with new engines • Ultra high (less than 4 microns)*
*currently not measurable
(1) Fuel supply line (2) Electronic unit injectors (3) Fuel gallery (4) Electronic Control Module (ECM) (5) Fuel pressure sensor (6) Fuel temperature sensor
• Captures the Most Harmful Particles: 5 – 10 Microns in Size • Series Filtration • Fuel Filter Efficiency Options • Standard (10 (10 microns and up) • Advanced (4 (4 to 10 microns) − Shipped with new engines • Ultra high (less ( less than 4 microns)* microns) *
*currently not measurable
• Secondary Fuel Filter Options • Three capabilities − Standard (10 microns and up) − Advanced (4 to 10 microns) − Ultra High (less than 4 microns)* • Advanced is shipped with new engines
*currently not measurable
Solenoid cont contro role led d from from EC ECM M~1 110 10 Volt olt DC
•
By changi changing ng the fue fuell rate rate (contr (controll olling ing the inject injectors ors), ), ECM Controls and Regulates the speed and engine power.
1. Coolant air to engine 2. Charge air cooler 3. Air befor cooler 4. Turbo outlet 5. Xxx 6. Xxx 7. Air filter
Electro-Mechanical
1970
1975
EMCP II
1980
1985
EMCP I
1990
EMCP II+P
1995
EMCP II+
2000
EMCP 4.x
2005
EMCP 3.x
2010
New Event Reset Button
New Event Log Navigation Button
Button Text Added
New Navigation Button Layout & Style New Engine Overview Button Symbol
New Main Menu Navigation Button
Daily
Initial 20 to 40 Service Hours
- Coolant Level - Check
- Belts - Inspect/Adjust/Replace
- Electrical Connections – Check
Every Week
- Engine Air Cleaner Service Indicator - Inspect
- Generator - Inspect
- Engine Oil Level - Check
- Generator Bearing Temperature - Test/Record
- Fuel System Primary Filter/Water Separator -Drain
- Generator Lead (Flat Braided Cable) - Check
- Generator Load - Check
Initial 250 Service Hours
- Jacket Water Heater - Check
-Engine Valve Rotators – Inspect
- Power Factor - Check
Every 250 Service Hours
- Voltage and Frequency - Check - Walk-Around Inspection
- Coolant Sample (Level 1) - Obtain
Every 250 Service Hours or 6 Months - Battery Electrolyte Level - Check - Engine Oil Sample - Obtain - Fuel Tank Water and Sediment - Drain - Hoses and Clamps - Inspect/Replace
Every 500 Service Hours or 1 Year
Every Year
- Belts - Inspect/Adjust/Replace
- Coolant Sample (Level 2) - Obtain
- Cooling System Supplemental Coolant Additive (SCA) -
- Rotating Rectifier - Check
Test/Add
- Varistor - Check
- Engine Oil and Filter - Change
Every 3 Years
- Engine Protective Devices - Check
- Coolant Temperature Regulator - Replace(FFJ1-Up)
- Fuel System Primary Filter (Water Separator) Element -
Every 3000 Service Hours or 3 Years
Replace - Fuel System Secondary Filter - Replace
- Alternator - Inspect - Coolant Temperature Regulator - Replace
Every 2000 Service Hours or 1 Year
- Crankshaft Vibration Damper - Inspect
- Engine Crankcase Breather - Clean
- Engine Mounts - Inspect
- Generator Lead (Round Cable) - Check
- Engine Valve Rotators - Inspect
- Generator Set Vibration - Inspect
- Starting Motor - Inspect
- Radiator - Clean
- Turbocharger - Inspect
- Stator Lead - Check
- Water Pump - Inspect
Every 4000 Service Hours or 2 Years
When Required
- Coolant (DEAC) - Change(FFJ1-Up)
- Batteries - Replace - Battery - Recycle
Every 4500 Service Hours
- Battery or Battery Cable - Disconnect
- Generator Bearing – Lubricate
-Engine Air Cleaner Element (Dual Element) Clean/Replace
Every 6 Years
-Engine Air Cleaner Element (Single Element) -
- Coolant (ELC) - Change(FFJ1-Up)
Clean/Replace - Fuel System - Prime
Every 12 000 Service Hours or 6 Years - Coolant (ELC) - Change
- Generator - Dry - Generator Set - Test - Rotating Rectifier - Test - Varistor - Test - Winding - Test
