External MAK

External Documentation C0
VM43
External Documentation
Type
VM43
Engine No.: Record No.:
67 018 282027
67 019
67 020
67 010
en / 16.12.2008 AA027305 1/2

VM43
Please note the copyright notice pursuant to ISO 16016
"All documents such as drawings, data and programmes, etc. and models, templates etc. shall remain our
exclusive property. They are only handed over 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 purpose. Neither originals nor copies may be handed over to third
parties or be made available in any other form.
All rights (in case of registration of patent, utility patent, design patent) reserved.
Offenders will be liable for damages."
Caterpillar Motoren GmbH & Co. KG
en / 16.12.2008 AA027305 2/2

Total Index C0.01
Book A, B and C
Engine Operating Instructions A0

Total Index Book A, B and C A0.01
Introduction A0.02
Safety instructions A0.03
Emergency Stop Safety System A0.04
Technical Engine Data A1

Governor Data A1.04
Working pressures of auxiliary equipment A1.05
Temperatures of operating media A1.06
Torsional Vibration Calculation A1.09
Acceptance Test Records A1.10
Operating 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 A3.06
Removal from operation Engine A3.07
Danger of Frost Engine A3.08
Running-in Engine A3.10
Fault Tracing Engine A3.11
Emergency Operation Engine A3.12
Operating Media A4
Introduction A4.02
Regulations and Recommendations Engine A4.05
Maintenance A5
Introduction A5.02
Tools A6
Table of contents A6.01
Spare Parts 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
en / 16.12.2008 AA020077 1/2

Total Index C0.01
Book A, B and C
Total Index Book A, B and C C0.01
Introduction Electrical Equipment C0.02
Table of contents C5.01
en / 16.12.2008 AA020077 2/2

Introduction C0.02
Electrical Equipment
M20-M601C
The structure of the contents ensures that you will find the required spares very quickly
Example: Electrical Equipment
Electrical engine equipment
C5.05.05 10.17.93
Book C Chapter Engine Regulation

External Documentation
- These documents reflect your actual engine equipment and are, therefore, not compatible with other or
similar engine plants.
- Possible modifications or additions to the catalogue due to conversions will be carried out on request by
our customer service.
Ordering Spare Parts:

Please observe the following when ordering spare parts:
1. All spare parts orders must be placed with your dealer.
2. In case of multi-engine plants please do not place a collective order.
3. Each engine must 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/Customer ref. No.

Order date
Forwarding address (telephone/fax number and person in charge)
Date of delivery
Required date of arrival (ETA)
Marks, special instructions, e.g. complete delivery
Ships name/plant
Engine type
Engine No.
Shipping instruction, unless otherwise specified we will choose the cheapest method of
shipment, not prepaid ex works
Drawing No. and sheet
Part No.
Catalogue sheet No.
Description and measuring point No.
Quantity
Address on invoice, i.e. the complete address to which the invoice is to be made out
en / 28.11.2006 AA035841 1/7

Introduction C0.02
M20-M601C
Procedure
Variant A
The damaged component with identification of measuring point must be identified on the engine or cable.
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-in connection.
Measuring point No. 8211.1
In the chapter Electrical Equipment Engine C5.05.05.10.nn the component with stock
No. 273 450 450 is easily found by means of the measuring point No. 8211.1 .
en / 28.11.2006 AA035841 2/7

Introduction C0.02
M20-M601C
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 B1
8211.1 Thermocouple type K 273 450 450

...
8211.6
en / 28.11.2006 AA035841 3/7

Introduction C0.02
M20-M601C
A relay 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 means of component identification K9.
Example B2
K9 Attaching type relay 213 480 770
en / 28.11.2006 AA035841 4/7

Introduction C0.02
M20-M601C
Variant C
With the electric 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. 213 483 072 is
easily found by means of the measuring point No.7301.
Example C
7301 Level probe 213 483 016
en / 28.11.2006 AA035841 5/7

Introduction C0.02
M20-M601C
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 the part "cable loom" can be ordered.
en / 28.11.2006 AA035841 6/7

cvb2 Caterpillar Motoren GmbH & Co. KG
Anfrage/Ersatzteilbestellschein / Spare Parts Inquiry or Order Sheet

Auftrags-Nr,/Kunden-Referenz-Nr. Auftragsdatum
P.O. Number/Customer Ref. No. Order date
Kufer/Buyer Empfnger/Consignee
(postalisch einwandfreie Anschrift) (genaue Warenempfnger-Anschrift) Liefertermin Erforderlicher Ankunftstermin
exact postal address exact addressee of consignee Date of Delivery (voraussichtliche Ankunftszeit)
Date of required arrival (eta)
Markierung, spezielle Anweisungen, z. B. vollstndige Lieferung

Marks, special instructions, e. g. complete delivery
Schiffsname/Anlage/Ship's name/Plant Motor-Typ/Engine Type Motor-Nr./Engine No. *) Versandart/Shipping Instructions
Bitte stets angeben Nur von Caterpillar auszufllen

Pl i d O l b l db C ill
Pos. Sach-Nr. Zeichnungs-/Teile-Nr. Sach-Nr. Zeichnungs-/Teile-Nr. Benennung und Messstellennummer Menge
Item Stock No. Drawing/Part No. Stock No. Drawing/Part No. Description and Measuring Point No. Quantity
Beispiel fr Bestellung Beispiel fr Bestellung
As an illustration for ordering As an illustration for ordering
213 480 770 9-A-1081-83, Page 5 Attaching type relay 4
1
2
3
4
5
6
7
8
9
10
*) Pro Einzelbestellschein nur eine Motor-Nr. angeben!
Please state only one engine no. on each spare parts order sheet! Rechtsverbindliche Unterschrift und Stempeldruck des Bestellers
Stamp and signed by buyer
Fordern Sie bitte rechtzeitig kostenlos neue Vordrucke zur Bestellung von Ersatzteilen an
44.17/11.06 Please forward your requirement of free-of-charge new order sheets in due time to us ..................................................................................................................................
Engine, measuring points C5.05.02

List of Measuring Points Engine
Sensors and Actuators C5.05.02.01.50.46
Engine, control C5.05.04

Governor- 2223-1G -
Regulateurs Europa C5.05.04.20.21.10
Adjustment "MaK-Prop 723+"
(Woodward) C5.05.04.20.29.34
Engine, regulation C5.05.05

Circuit diagram Motor
- C5.05.05.10.30.40
Description
Engine Monitoring Devices C5.05.05.10.50.05
Equipment List Engine
- C5.05.05.10.60.44
Turning Equipment
- C5.05.05.10.70.03
Maintenance Unit
- C5.05.05.45.23.01
Maintenance Unit
- C5.05.05.45.23.03
RPM Switch Unit C5.05.05.70.06.45
RPM Switch Unit
Description C5.05.05.75.11.45
Engine, exhaust gas system/supercharging C5.05.06

Turbocharger C5.05.06.10.21.39
Charge Air Cooler
- C5.05.06.30.17.22
Engine, lubricating oil system C5.05.08

Lub.-Oil Pump
- C5.05.08.07.22.93
Engine control equipment C5.05.11

Oil Mist Detector
- C5.05.11.02.03.00
en / 16.12.2008 AA020086 1/1

List of Measuring Points Engine C5.05.02.01.50.46
Sensors and Actuators
VM43
List of Measuring Points Engine
en / 15.03.2004 FD027294 1/4

List of Measuring Points Engine 12M43
c Unit Description
Sensor range Trigger Remarks
Signal range Normal
1104 Pressure switch 20 400 kPa 350 kPa

Lub. oil pressure low start stdby pump binary 500 kPa
1105 Pressure transmitter 0 1000 kPa 320 kPa * 350 kPa for GENO
Lub. oil pressure low pre alarm 4-20mA 500 kPa
shutdown
1106 Pressure switch 20 400 kPa 290 kPa
Lub. oil pressure low shutdown binary 500 kPa
1202 Resistance thermometer -40-160 C 70 C
Lub. oil temp. at engine inlet high alarm PT 100 60-65 C
1203 NTC/switch unit -40-120 C 75 C * shut down for GENO
Lub. oil temp. at engine inlet high binary 60-65 C
load reduction / shut down*
1251/1253 Oil mist detector VN116/93 1 evaluation unit for
9631 1251 Oil mist concentration in crankcase high 1251 : 0,5...25% 1251 2% 1251 , 1253 , 9631
alarm binary < 2%
1253 Oil mist concentration in crankcase high 1253 : 0,5...25% 1253 2%
load reduction / shut down* binary <2% * shut down for GENO
9631 Oil mist detector failure alarm 9631 -
binary
2102 Pressure transmitter 0 600 kPa * * 40 kPa below
Cooling water pressure HT at engine inlet low 4-20mA > 250 kPa operating pressure
alarm
2103 Pressure switch 20 400 kPa * * 60 kPa below
Cooling water pressure HT at engine inlet low binary > 250 kPa operating pressure
shutdown stop delay : 20s
2112 Pressure transmitter 0 600 kPa * * 40 kPa below
Cooling water pressure LT at engine inlet low 4-20mA > 200 kPa operating pressure
alarm
2201 Resistance thermometer -40-160 C -
Cooling water temp. HT at engine inlet - Dicare PT 100 > 75 C
Cooling water temp. HT at engine outlet high- PT 100 80-90 C
alarm
2212 NTC/switch unit -40-120 C 98 C * shut down by GENO
Cooling water temp. HT at engine outlet high- binary 80-90 C
load reduction / shut down*
2229 Resistance thermometer -40-160 C -
Cooling water temp. LT at engine inlet PT 100 < 40 C
indication
5102 Pressure transmitter 0 1000 kPa 100 kPa
Fuel oil pressure at engine inlet low - alarm 4-20mA 400 kPa
5111 Differential pressure indicater 0 80 kPa 80 kPa
Differential pressure fuel oil filter high alarm binary < 60 kPa
CD6_Mischke Page: 1
Status: 14.05.2003 ML 4312.7-46.92.00-01_en
c Unit Description
Signal range Normal
5201/5202* Resistance thermometer

5201 Fuel oil temp. at engine inlet low alarm / -40-160 C 5201 : 35 C
Dicare PT 100 40-50 C 1 sensor for 5201 + 5202*
5202 : 60 C * not in use with HFO
5202 Fuel oil temp. at engine inlet high alarm 40-50 C
5301A Level probe -
Leakage oil niveau at engine high - alarm binary
5301B Level probe -
Leakage oil niveau at engine high - alarm binary
6101 Pressure transmitter 0 6000 kPa 1250 kPa
Starting air at engine inlet low - alarm 4-20mA 1200-3000 kPa
6105 Pressure switch 100-1600 kPa 600 kPa Alarm delay : 2s
Stopping air pressure at engine low - alarm binary 750 kPa
6181 Absolute pressure transmitter 80 120 kPa
Intake air pressure in engine room - Dicare 4-20mA
7109 Pressure transmitter 0 400 kPa
Charge air pressure at engine inlet - Dicare 4-20mA
Charge air temp. at engine inlet high - alarm PT 100 45-60 C
7206 Resistance thermometer -40-160 C
Intake air temp. at turbocharger inlet - Dicare PT 100
7301 Level probe/switch unit -
Condense water in charge air canal binary
7307 Differential pressure transmitter 0 10 kPa
Charge air diff. pressure at charge air cooler - 4-20mA
Dicare
7309A Thermocouple type K -200-1300 C -
Charge air temp. at charge air cooler inlet A - NiCr-Ni < 200 C
Dicare (mV)
7309B Thermocouple type K -200-1300 C -
Charge air temp. at charge air cooler inlet B NiCr-Ni < 200 C
Dicare (mV)
8211.1A Thermocouple type K -200-1300 C * * Load dependend with
. Exhaust gas temp. after cylinder 1A.....6A NiCr-Ni < 440 C alarm delay : 16s
8211.6A load reduction / shut down* (mV) * shut down by GENO
8211.1B Thermocouple type K -200-1300 C * * Load dependend with
. Exhaust gas temp. after cylinder 1B.....6B NiCr-Ni < 440 C alarm delay : 16s
8211.6B load reduction / shut down* (mV) * shut down by GENO
8221A Thermocouple type K -200-1300 C * 350 C * Load dependend with
Exhaust gas temp. at turbocharger outlet A - NiCr-Ni < 400 C alarm delay : 16s
load reduction / shut down* (mV) * shut down by GENO
8221B Thermocouple type K -200-1300 C * 350 C * Load dependend with
Exhaust gas temp. at turbocharger outlet B - NiCr-Ni < 400 C alarm delay : 16s
load reduction / shut down* (mV) * shut down by GENO
8231A Thermocouple type K -200-1300 C -
Exhaust gas temp. at turbocharger inlet A - NiCr-Ni < 580 C
Dicare (mV)
CD6_Mischke Page: 2
Status: 14.05.2003 ML 4312.7-46.92.00-01_en
c Unit Description
Signal range Normal
8231B Thermocouple type K -200-1300 C -

Exhaust gas temp. at turbocharger inlet B - NiCr-Ni < 580 C
Dicare (mV)
R1 Resistance thermometer -40-160 C
Temperature compensation thermocouples PT 100
R16 Resistance thermometer -40-160 C
Electr. charge air temp. control PT 100
9419.1 Pick up 0-1200 upm -
RPM switching equipment 0-15 KHz < 1 KHz
9419.2 Pick up 0-1200 upm -
RPM switching equipment 0-15 KHz < 1 KHz
9419.3 Pick up 0-1200 upm -
Electronic governor 0-15 KHz < 1 KHz
9419.4 Pick up 0-1200 upm -
Electronic governor 0-15 KHz < 1 KHz
9429A Pick up /transmitter 0-30000 upm -
Turbine speed A Dicare 4-20mA < 31000 upm
Turbine speed A Indication 0-10V
9429B Pick up /transmitter 0-30000 upm -
Turbine speed A Dicare 4-20mA < 31000 upm
Turbine speed A Indication 0-10V
9503 Limit switch - *by GENO
Control lever at control stand engine stop binary
position / full fuel*
9509 Distance sensor / switching device 125% Load -
Fuel setting 0-20mA < 100% Load
9561 Limit switch -
Turning gear engaged - starting interlock binary
S2 Pressure switch 1-1600 kPa 600 kPa Stop cancellation
Starting air pressure after main starting valve binary > 1200 kPa
Y1.1 Solenoid valve -
Safety shutdown 24V DC / 6W
Start 24V DC / 6W
Starting interlock for manual emergency start 24V DC / 18,5W
M1 Actuator -
0 - 200mA
CD6_Mischke Page: 3
Status: 14.05.2003 ML 4312.7-46.92.00-01_en
Governor- 2223-1G - C5.05.04.20.21.10
Regulateurs Europa
VM43
Governor- 2223-1G -
Regulateurs Europa
en / 13.09.2007 FD035270 1/36

OPERATORS HANDBOOK
FOR SERIES 2223 - 1G ACTUATOR

Regulateurs Europa 2006
The contents of this document are the exclusive property of

Regulateurs Europa
They must not be copied or reproduced without the written
authorisation of the Company
INDEX
Foreword 1
Installation note 2
Safety 3
Service 5
Technical Data 7
Model Identification 8
General Description 9
Operating Principles 10
Operational Schematic Drawing & Index 12
Installation 14
Initial Starting Procedure 17
Actuator Calibration 18
Routine Maintenance 20
Fault Finding 21
Dismantling / Assembly 23
Drawings 24
FOREWORD
These instructions have been compiled to assist personnel responsible for the
operation and maintenance of equipment manufactured by Regulateurs Europa
Care has been taken to ensure that the equipment has been accurately
represented, but it should be appreciated that, with the continued progress of design
and the diversity of application, certain items may differ in detail.
It should be noted that these instructions are issued for general information and do
not constitute a specification of the equipment.
Whilst reserving the right to make any alteration in design which they may consider
advisable the manufacturers absolve themselves from making any such alteration
retrospective.
In addition to the information given herein, practical advice and assistance are
always available from our Service Department.
1
INSTALLATION NOTE
WARNING
The prime mover should be equipped with a separate overspeed shutdown device,
to protect against runaway or damage to the prime mover, with possible personal
injury or loss of life, should the governor/actuator fail.
2
SAFETY OF PERSONNEL OPERATING & MAINTAINING
EQUIPMENT MANUFACTURED BY REGULATEURS EUROPA
LIMITED
Before carrying out any repairs, adjustments or maintenance to any equipment by

Regulateurs Europa, it is essential the following safety precautions be observed:
1. The equipment may contain one or more of the following:
x High voltages
x Rotating parts
x High pressure oil
x Compressed air
x Preloaded springs
x PCBs
x Microprocessors
2. All of the above items represent a potential danger or hazard to operating

personnel and the operator should take care to make himself thoroughly familiar
with the operating principles, methods of adjustment and the dismantling and
assembly procedures (where applicable) concerning the equipment in his care.
3. Before carrying out any repairs, adjustments or maintenance to the equipment or

unit, the operator should ensure that any such unit or equipment cannot be
activated from a remote position. To achieve this condition, he should ensure that
all electrical/pneumatic supplies to the prime mover starter system are isolated at
their incoming source and that all electrical supplies to control systems are isolated
by the withdrawal of the relevant fuses or by disconnecting the incoming electrical
supply at the control board. In addition to these precautions, visual-warning notices
should be prominently displayed by the equipment or unit and also at any remote
control positions. Where control cabinets and consoles are secured with keys, all
such keys should be in the possession of the operator carrying out the work.
Information regarding position, level and type of work to be carried out should also
be made available to the Engineer in Charge of the installation to prevent
attempted use of the equipment or unit during breakdown.
4. In the case of electrical/electronic control systems, the operator should make

careful reference to the Instruction manual to ensure that he is aware of any special
safety precautions which are peculiar to that particular equipment or unit.
5. Before the equipment or unit is finally released for operation, operating personnel
should ensure that all tools and repair equipment has been removed and that all
safety guards are securely replaced (where applicable). All fuses should be
replaced and operating mediums (electrical and pneumatic supplies) should be
opened or reconnected.
3
ELECTROSTATIC PRECAUTIONS
WARNING
This equipment contains components that are electrostatic sensitive. Electrostatic

damage can cause immediate failure or shortening of useful life.
Servicing PCBs at component level should be done at an electrostatic free workstation.

If site work cannot be avoided, the following precautions must be taken:
x All tool tips must be earthed.

x Personal wrist or ankle earth straps must be worn. To protect against personal
hazard, the resistance of the earth strap should be approximately 250k ohms.
x PCBs or components should be transported in static free packaging and when
removed from packaging laid on static free surface after or prior to assembly.
Electrical Interference
To avoid possible malfunction of the equipment or infringement of Electrical
Interference Regulations, the following precautions must be taken:
x All cable screens to be terminated and earthed at the entry to the equipment
x The equipment to have a low impedance earth
x All doors and covers etc to be firmly secured.
4
SERVICE FACILITIES
To ensure prompt and satisfactory attention to customers enquiries, all

communications should refer to the UNIT TYPE and SERIAL NUMBER, as stamped
on the nameplate.
In order to obtain the most efficient service it is recommended that all enquiries for
service or spare parts to be addressed to the manufacturer of the equipment to which
the unit is fitted.
Customer training can be provided either in Roden, in Colchester or on site. Contact

below for further details.
Regulateurs Europa b v
1e Energieweg 8
9301 LK
RODEN NETHERLANDS
Tel: +31 (0)5050 19888 Fax: +31 (0)5050 13618
Regulateurs Europa Ltd

Port Lane
COLCHESTER ESSEX C01 2NX
ENGLAND
Tel: +44 (0)1206 799556 Fax: +44 (0)1206 792685
5
2223 Actuator
6
TECHNICAL DATA
Weight 108 Kg.
Output Shaft Dimensions 1 1/8 in. nominal diameter, 48 SAE serrations,
standard both sides of actuator.
Drive Shaft Dimensions Standard, 1.1/8 inch, Nominal diameter,
48 SAE serrations.
Alternative, 5/8 in. nominal diameter with 3/16
in. x 3/16 in. key.
Base Dimensions Square flat base, 250 mm x 250 mm with four
fixing holes 14.0 mm diameter at 220mm
centres.
Mounting Angle Nominally Vertical
Operating Angle Up to 30 degrees from the vertical.
Work Capacity (Stalled) 160J (120 ft. lbf.), 270J (200 ft. lbf. or
337J (250 ft. lbf.)
Output Torque 237 Nm., 397 Nm. or 495 Nm.
Oil Pressure
120 ft. lbf. work output 12.4 bar.
Input Speed and Direction of Rotation

Input Speed Range230 1150 rev/min. rotation in either direction
Output Movement
Rotary movement of the output shaft is 40 degrees from stop to stop, of which at
least 24 degrees (60%) is to be used from No Load to Full Load.
Input Power
120 ft. lbf. work output 0.75 kW @ 1000 rpm. approx.
Actuator Control Current (0 1A)

250 mA Actuator Output Position 2 is position No Load
750 mA Actuator Output Position 8 is position Full Load
7
MODEL IDENTIFICATION
Each actuator is allocated a serial and a type number. The serial number is stamped
on the nameplate attached to the main casing
It is essential to quote the type number and serial number when making
enquiries regarding service or spares.
8
GENERAL DESCRIPTION
These actuators have been designed for use with Regulateurs Europa Series 2200
Electronic Control Units, but can also be used with other equipment. They are
suitable for governing all types of industrial, marine and traction diesel engines and
also water and steam turbines.
They are proportional actuators in which the output shaft position is proportional to
the electric input signal. The essential part of the 2222 actuator is the solenoid to
which the pilot valve controlling the flow of oil to and from the first stage power
piston is attached.
The operating oil is contained within the body and an internal pump, driven directly
by the drive shaft, provides the necessary oil pressure. The hydraulic system is self
bleeding, and maintains its oil pressure at a preset rate by means of two spring
loaded accumulators one of which also acts as a relief valve to control the oil
pressure. Two pairs of non-return valves are fitted to the oil pump. Depending on the
direction of rotation of the actuator drive shaft one pair will be open and the other
pair closed.
A set of driving gears rotates the rotor sleeve to eliminate any stiction in the
movement of the pilot valve.
The first stage power piston operates a valve which controls the flow of oil to and
from the second stage power piston. The second stage power piston is connected
by linkage to the output shaft. Also connected to the output shaft is the second stage
return piston. This arrangement provides an output free of backlash, which gives the
best possible results on engines having a fuel control system with large friction
forces.
9
OPERATING PRINCIPLES (See Schematic Drawing)
Steady State Condition

When the actuator is in a steady state the electromagnetic force exerted by coil (28)
on magnets (27) is balanced by feedback spring (23). In this situation 1st stage pilot
valve (30) laps (seals off) the control ports in rotor (9) to 1st stage power piston (11)
which is thus held in position. The 2nd stage pilot valve (4) laps its control ports
holding power piston (10) in position and hence output shaft (24) is stationary.
Load Increase
When the engine is subjected to an increase in load there will be a reduction in
engine speed. This is sensed by the electronic control unit which changes the
control current signal to the actuator. This change in control current increases the
electromagnetic force exerted by the coil. The electro magnetic force in the coil, the
force of the magnets (27) and the force of the feedback spring (23) are no longer in
balance, therefore moving the 1st stage pilot valve (30) down allowing high-pressure
oil to the underside of 1st stage power piston (11). This piston rises and through
linkage moves 2nd stage pilot valve (4) downwards directing high pressure oil to
increase fuel output piston (10). This causes the piston to rise against the return
force of piston (2), because of the 2:1 ratio of 2nd stage output lever (15), and rotate
output shaft (24) increasing fuel to the engine. Movement of 1st stage power piston
(11) upwards is transmitted through linkage (14) (17) and (19) to bridge piece (22) to
reduce the force exerted by feedback spring (23). The reduction in spring force
causes 1st stage pilot valve (30) to move up towards the lapped position. At the
same time movement of increase fuel output piston (10) upwards is transmitted to
2nd stage pilot valve (4) which moves upwards towards the lapped position.
The above actions continue until the engine returns to the set speed, the
electromagnetic and feedback spring forces are in balance, the 1st and 2nd stage
pilot valves lap the control ports and a new steady state is reached at a higher
fuelling rate to match the increase in load.
Load Decrease
When the load applied to the power unit is reduced engine speed will rise
accordingly. This increase in speed is sensed by the electronic control unit, which
changes the control current to the actuator to decrease the electromagnetic force
exerted by the coil. Magnets (27) and 1st stage pilot valve (30) move up draining oil
from the underside of 1st stage power piston (11). This piston moves down under the
action of high pressure oil acting under 2nd stage pilot valve (4) which moves
upwards draining oil from increase fuel output position (10). High-pressure oil acting
under decrease fuel output piston (2) moves piston (10) down and rotates output
shaft (24) to reduce fuel to the engine. Movement of 1st stage power piston (11)
downward is transmitted through linkage to increase the force exerted by feedback
spring (23). The increase in spring force causes 1st stage pilot valve (30) to move
down towards the lapped position.
10
At the same time movement of increase fuel output piston (10) downwards is
transmitted to 2nd stage pilot valve (4) which moves downwards towards the lapped
position. The above actions continue until the engine returns to nominal speed, the
electromagnetic and feedback spring forces are in balance, the 1st and 2nd stage
pilot valves lap the control ports and a new steady state is reached at a lower
fuelling rate to match the increase in load.
Shut Down
If the stop solenoid (37) is energised stop valve (35) is pressed down draining the oil
behind shutdown valve (34)
With the solenoid de-energised, high pressure oil from the oil pump passes through
the stop valve (35) and holds the shut-down valve (34) in the open position against
the action of its return spring (33).
In this position, the shut-down valve (15) permits oil (blue line) to follow freely
between the rotor assembly and the 1st stage power piston (11).
When solenoid (37) is energised, the stop valve (35) is moved from the run position
where it was held by spring (36) to the shut-down position. This movement of the
pilot valve cuts off the supply of high pressure oil to the shut-down valve (34) and
releases oil above the valve to drain.
With the sudden loss of oil pressure on the shut down valve (34), its return spring
(33) moves the valve, to open the control line (blue) from the 1st stage power piston
to drain (green) and shuts of the line (bleu) from the rotor pilot valve (9 - 30). The
1st stage power piston then moves downwards and with it the 2nd stage power piston
(10) and thus the output shaft (24) will move to stop position and shuts down the
prime mover.
11
2223 SCHEMATIC IDENTIFICATION
1. Accumulator piston
2. Decrease fuel output piston 2nd stage
3. Drive shaft
4. Pilot valve 2nd stage
5. Driven pump gear
6. Check valve
7. Idler pump gear
8. Check valve
9. Rotor
10. Increase fuel output piston 2nd stage
11. Power piston 1st stage
12. Pushrod 1st stage power piston
13. Cross lever 1st stage
14. Rod
15. Output lever 2nd stage
16. Link
17. Intermediate lever
18. Pin
19. Lever feedback
20. Pin
21. Adjusting screw
22. Bridge piece
23. Feedback spring
24. Output shaft
25. Lever spring carrier
26. Bias spring
27. Magnet
28. Coil
29. Spring
30. Pilot valve 1st stage
31. Cross lever 2nd stage
32. Drive gears rotor
33. Return spring shutdown valve
34. Shut down valve
35. Stop valve
36. Return stop shutdown valve
37. Stop sollenoid
12
INSTALLATION
The drive gear ratio should be chosen so that the actuator runs at or near its
maximum speed when the prime mover is at full speed.
Actuator Installation (Serrated or Splined Drive Shafts)

a. Firstly, ensure that all mating surfaces are square, clean and free of burrs or
imperfections.
b. Check that the drive shaft diameter and number of serrations/splines correspond
with those of the driving member.
c. Check that the drive shaft length is not excessive for the driving member;
compensate if necessary by using shim plates.
d. Fit a gasket or liquid sealing. (Note: The use of a thick gasket under the actuator
is NOT recommended).
Lower the actuator onto the mounting flange whilst ensuring the alignment
between the drive shaft and driving member is correct. It is also important that
no side loading or bending movement is applied to the actuator drive.
e. With the two mating surfaces now in full contact, the securing nuts/bolts can be
tightened.
Actuator Installation (Bevel Drive Gears using Keyed Shafts)
a. Inspect both the drive shaft and driving member gears to make sure they are in
good working order; free from chipped or cracked teeth, and with run-out
between the engine builders limits.
b. Ensure that all mating surfaces are clean and free of imperfections before fitting
any gaskets or sealing rings provided.
c. Lower the actuator into position ensuring that the gears mesh correctly and have
the specified clearance; (0.05mm 0.15mm) this clearance is of utmost
importance and is adjustable by inserting shims under the base. A clearance
which is too small can result in premature gear or drive shaft failure, whilst an
excessive clearance causes gear wear.
Control Linkage
The linkage between the actuator output shaft and the fuel injection pump/control
valve should be designed to the following criteria:
x Correct ratio
x No backlash
x Low frictional losses
x Linearity
14
Correct Ratio
The geometry of the linkage should be designed so that at least 60% (i.e. 30
degrees) 2 to 8 on the Output Scale of the output shaft rotation is used for
moving the fuel injection pump/control valve between the No Load full speed and
the Full Load at Rated speed.
Backlash
Backlash should be kept to a minimum, as it will create a dead band in which speed
changes may take place without correction. In addition, backlash may cause
instability. Backlash may be minimised by using linkages having comparatively long
travels. A given amount of backlash, expressed as a percentage of the total travel
will then be much smaller.
Friction
Friction in the actuator linkage is undesirable and should be kept to a minimum. The
smaller the amount of work to be done by the governor the more rapid will be its
response.
Linearity
The geometry of the fuel injection pump/control valve linkage is normally arranged
so the increase in power from No Load to Full Load is as nearly as possible
proportional to the movement of the actuator output, throughout its range. Should
there be a non-linear relationship of fuel injection pump delivery to rack position, it
may be possible to make use of a non-linear linkage to correct the problem. The
object in all cases should be to obtain a linear relationship between actuator output
shaft position and prime mover torque.
15
Filling with Oil
After installation the casing must be filled to the indicated oil level mark on the
sightglass located in the side of the casing. To prevent any unwanted substances
from entering the actuator it is essential to clean the area surrounding the filler plug
prior to adding oil. The actuators should always be filled through a mesh filter. DO
NOT OVERFILL or UNDERFILL as this will result in poor actuator performance.
An actuator that is being filled for the first time or one which has just undergone
repairs may require to have the level rechecked soon after it has been started up.
This is due to the oil passages being filled, hence lowering the level.
Type and Grade of Oil

The actuator has been designed to operate using a standard SAE30 mineral oil for
most applications. However, should the ambient temperature be constantly below
10qC then it is advisable to use oil with a SAE20 value. Likewise if the ambient
temperature is constantly above 40qC then SAE40 oil is recommended.
As a general guide the oil used in the governor should be a good quality mineral oil.
It should have good oxidation stability, not deteriorate in service to produce deposits
and should have anti-foaming properties.
Viscosity range at 40qC (104qF) :-
a. Cold Conditions SAE20 68cS

b. Temperatel Conditions SAE30 100cS
c. Hot Conditions SAE40 150cS
As the oil used in the governor directly affects the operation, it is important to
remember the following rules:-
a. Only use the grade of oil suitable for the application.

b. DO NOT use hydraulic oils or those with a high alkaline value, TBN less than 15.
c. Ensure the correct level is maintained DO NOT overfill or underfill.
Oil Cooler
In some cases the actuator may be fitted with an oil cooler which is mounted onto
the casing. These units are installed where the actuator is constantly operating at
high work output and speed in high ambient temperatures, thus giving rise to an
excessive operating oil temperature.
16
INITIAL STARTING PROCEDURE
Ensure the actuator to fuel pump linkage is set up in accordance with the engine
builders instructions. If a new actuator is being fitted, as a general guide, the initial
connection of the linkage must be made with the actuator output and fuel pump
input in their respective zero positions. This ensures the actuator will have total
control of the fuel input.
Ensure that the actuator contains the correct level of oil.
Start and run the engine in accordance with the manufacturers instructions. When
the engine is being started for the first time since refitting the actuator, slight erratic
governing may be expected. This will be eliminated after a few seconds when the air
trapped in the hydraulic system has been automatically purged. Subsequent starting
operations should not experience this problem because of the unique Self
Bleeding action.
Before final adjustments of the external actuator linkages are made, it is necessary
to run the engine for 1 hour in order to achieve normal working temperature. When
this condition is reached the fuel pump link should be adjusted to obtain actuator
output position 2 at No Load while the engine is at Rated speed. If the engine is at
Full Load and Rated speed, the output position must be at 8. If the reading is less
than 8, the output lever length must be increased, and conversely if the reading is
higher than 8, the lever length must be decreased. These changes in length should
be made in small increments at No Load, making sure that the No Load position of 2
is maintained by adjusting the fuel pump linkage length accordingly. These
alterations should be repeated until the No Load to Full Load range falls between
positions 2 and 8.
17
ACTUATOR CALIBRATION
The Regulateurs Europa 2223 series actuator is a proportional actuator in which
the output position is proportional to the electric input signal.
Although these actuators have been set-up in the factory, they sometimes require
small adjustment on site. This is particularly the case if the actuator is fitted on the
prime mover on a non-horizontal face (at an angle).
Care should be taken when adjusting this with the running engine and as only slight
movement of this screw can cause the engine to overspeed.
Pre-Check
While the engine is running under a steady load observe the actuator position
according the electronic governor using the hand-held programmer or the p-c based
program Viking Vision.
Next, check the actual actuator position indicated by the dial on the side of the
actuator. If there is a difference this can be reduced by adjusting the setting of the
bias spring fitted on the servo within the actuator.
18
It must be noted that when the bias spring is adjusted the position of the output shaft
of the actuator will not change! The output shaft position of the actuator depends
upon the loading of the engine. If the bias spring setting is changed there will be an
initial change in actuator output position i.e. fuel rack which will result in a change of
engine speed. This is sensed by the electronic governor which will increase or
decrease the drive signal to the actuator. This in turn results in the actuator returning
to its original position (provided the load of the engine has not changed meanwhile)
but controlled from a different drive signal!
Finally, because of the fact that the drive signal has changed, the actuator position
displayed by the Viking has changed.
Adjustment
The build of the 2223 actuator is such that there is a direct control of the servo to the
1st stage power piston. Due to the fact that the sleeve of the control valve is rotating
and its compact design it is unlikely that the actuator needs adjusting on site.
However in the event that this is required it must be done according the following
procedure.
While the engine is stationary clean the cover and top part of the actuator. Remove
the top cover of the actuator, be careful that nothing can fall in.
The aluminium bridge over the bias spring is now visible. In the centre of this bridge
a setscrew with locknut is fitted. The end of the setscrew holds the spring carrier
fitted on top of the bias spring. If the compression of the bias spring is changed the
ratio of control current to position of the output shaft is changed.
In order to operate the actuator the oil pump must be driven i.e. the engine must be
in operation. The engine may be run while the cover of the actuator is removed,
however care must be taken that nothing can fall in.
Start the engine and run it under no-load or a very steady load condition. Release
the locknut and turn the adjusting screw NO MORE than a 1/4 turn in either
direction. Tighten the nut.
Check the indication of the actuator

position according the handheld
programmer or Viking Vision
indication. Compare this reading with
the actual actuator position. If both
positions are not equal repeat from
step 2. If the difference between both
readings has increased repeat from
step 2 but turn the setscrew in the
opposite direction.
If both readings are equal stop the
engine. Check if the lock nut is
tightened and fit the cover.
19
ROUTINE MAINTENANCE
Under normal working conditions RE actuators require the minimum of routine

maintenance, this consists of regular visual checks and replacement of oil.
Visual Examination
1. Check for correct level of oil.
An increase in oil level indicates engine oil is entering the actuator past the drive
seal; this can usually be confirmed by discolouration of the oil level sightglass.
A decrease in oil level indicates drive shaft seal failure. For both problems lift
actuator from the engine and fit a new drive shaft seal.
2. Check for excessive external oil leakage from joints, plugs etc.
3. Check security of governor mounting, clamp bolt on output lever, nuts etc.
Oil Change
The actuator oil should be changed yearly or after every 5000 hours of usage,
whichever occurs first. If the oil becomes contaminated or appears to be excessively
dirty it is recommended that it is replaced immediately.
1. The procedure for draining and refilling is as follows:-

2. If possible, run the actuator for a short period in order to warm up the oil.
3. Drain the oil from the actuator by removing the drain plug located in the base.
4. Should the oil show signs of contamination, it is advisable to flush out the
actuator with a small amount of fresh oil.
5. Refill to the specified level using the correct grade of oil for the application.
External Linkages
In order to minimise friction all linkage pivot points must be suitably lubricated. This
is especially the case where fork, blade and pin type pivots are used as opposed to
Unibal Joints, which require less maintenance.
It is important that the oil or grease to be used for these purposes will meet the
operating requirements of the actuator with regard to working temperatures, location
etc.
Finally, it is recommended that only qualified service personnel should be permitted

to carry out repair work other than routine maintenance. Assistance and advice
regarding this matter can be obtained by contacting Regulateurs Europa.
20
FAULT FINDING
The following section deals with a few of the major operating faults, which may arise
during a period of time and their possible solutions.
As previously mentioned, the manufacturers strongly recommend that only qualified

service personnel should be permitted to undertake repairs and maintenance of the
actuator unit.
Actuator Fails to Operate Fuel Racks to Start Engine

a. Check if the electric shutdown in the actuator is de-energised.
b. Check if the control signal electronic control module is present. Connect an amp
meter in series with it and start the engine again. The signal must reach at least
500 mA. When the engine is started, this must result in actuator position 5.
c. If the control signal is present check the input resistance of the electric servo unit
in the actuator. This must be +/- 13 . If not contact Regulateurs Europa.
Before starting manually pull the actuator to position 2. Next run the engine on start
air only. If in this instance the actuator output moves to 0 either the control signal is
missing or the electric shutdown is in operation.
d. Check actuator drive is intact.

e. Check actuator oil pressure by connecting a pressure gauge to port marked
inlet conn. from booster (see drawing 2223.1G.090). This pressure should be
at least 7.0 bar at 100 rev/min.
f. If booster fitted, check that the connections from and to the booster are
connected correct. If reversed there will be no oil pressure in the actuator.
Check if the air pressure signal is reaching booster and that the booster is filling
with oil and ejecting it.
Hunting
Hunting is best described as a rhythmic change in speed above and below that of
the set speed. The frequency of these changes rarely exceeds 2Hz.
a. In a new installation or after actuator overhaul, hunting may be due to air trapped
in the actuator oilways. This should purge itself after a few minutes of running.
b. Check that the actuator is filled to the correct level with the correct grade of oil.
c. Check the fuel rack linkage for backlash (lost motion) or excessive stick/slip.
d. Check linkage adjustment is correct and that 60% of output travel, 2 to 8 on
output scale, is used for No Load to Full Load change at full speed.
e. Check if the control signal to the actuator hunts with the same frequency and
amplitude as the output shaft of the actuator does. If this is case the hunting is
generated within the electronic control unit and not within the actuator itself.
21
Jiggle
Jiggle is the term used for rapid oscillation of the actuator output lever at a
frequency too high for the engine speed to follow. These movements are relatively
small and have little noticeable effect on speed.
Jiggle may be due to:-

a. Fault in the electronic control unit.
b. Incorrect setting of control parameters.
c. A fault in the wiring to or in the actuator.
d. Inadequate screening of the cable from the speed pickup to the control unit.
e. Inaccuracy of the flywheel marker holes or teeth for the speed pick up.
Loss of Oil
Loss of oil is most likely to be due to leakage past the drive shaft oil seal. If this is
the cause a new oil seal and, if worn, a new drive shaft should be fitted. Leakage
may also occur past the output shaft oil seals and from the various joints and these
should be checked.
22
Dismantling / Assembly
First remove actuator from engine.
1. Drive shaft Oil Seal Change

x The drive shaft oil seal (106) is fitted into housing (105) with a silicone rubber
component (RTV).
x To change the seal remove gear / splined adaptor (as fitted) from drive shaft.
x Remove old seal, clear and check drive shaft is not damaged.
x Pack oil seal with grease and fit into housing with RTV or similar.
x Re-fit gear / splined adaptor (as fitted) ensuring locking washer securing screw or
nut is tight.
2. Electrical Wiring
Access to the terminal block for the wiring from the coil to the cannon plug fitted on
the outside of the actuator can be accessed if necessary by removal of the top
cover. (See Wiring Diagram)
NOTE:
CAUTION
It is not recommended that any further dismantling of actuators is undertaken except

by those with knowledge of these units and with the appropriate test equipment.
The magnets in the coil assembly are electrically charged to the required level to set
the calibration of the unit. (i.e. 250 mA / output 2 and 750 mA / output 8).
If the magnets are removed from the centre of the coil this calibration will be lost!
The actuator should not give any problems and should not need any overhaul/re-
calibration until after 25000 hours in service.
23
DRAWINGS
2223 1G 090 Installation 2223/1G Actuator
2223 1G 100 Assembly 2223/1G Actuator
ES6018 Wiring Diagram
24
Adjustment "MaK-Prop 723+" C5.05.04.20.29.34
(Woodward)
M43
Adjustment "MaK-Prop 723+"
(Woodward)
en / 26.11.2008 FD039053 1/7

Kostentrger-Nr./Record No.
Programmierung "MaK-Genset 723+"
Adjustment "MaK-Genset 723+"
Software ABLS Version 4.00 / P/N 9926-660 rev. J
282027
Motortype/Engine Type
12CM43
Einstellwerte/Adjustment
Menu - Alarmlog Voreinstellung/Preadjust Betrieb/Service
1. First Alarm 1 -
2. 1/Spd Probe #1 Fault 2 -
3. 2/Spd Probe #2 Fault 3 -
4. 3/Both Probes Fault 4 -
5. 4/Torsional Alarm 5 -
6. 5/Rem Spd Inp Flt 6 -
7. 6/Rem Bsld Inp Flt 7 -
8. 7/Load Sensor Fault 8 -
9. 8/Synch Fault 9 -
10. 9/No Baseload 10 -
11. 10/Overspeed 11 -
12. 11/Act Wirebreak ? 12 -
13. Reset First Alarm ? 13 -
Datum/Date Abteilung/Departm. Name/Name Zeichnungs-Nr./Drawing No.

Seite/Sheet: 1
26.11.2008 CA 24 Steiner 4-SK-16608-2820270 von/of: 6
282027
12CM43
Menu - Monitor Analog Voreinstellung/Preadjust Betrieb/Service
1. Engine Speed 1 -
2. Speed Reference 2 -
3. Spd Ref Before Bias 3 -
4. Generator Load KW 4 -
5. Load Reference KW 5 -
6. PID % 6 -
7. Actuator LSS (%) 7 -
8. Actuator output (%) 8 -
9. Torsionals Rpm 9 -
10. Gain 10 -
11. Stop Mode 11 -
12. Failsafe Mode 12 -
13. Isoch Mode 13 -
14. Baseload Mode 14 -
15. Droop Mode 15 -
16. Unload Mode 16 -
17. Fuel Lim Mode 17 -
18. Shutdown Mode 18 -
Menu - Monitor Inputs

1. Speed #1 (rpm) 1 -
2. Speed #2 (rpm) 2 -
3. Syn Inp (+/- V DC) 3 -
4. Bs Ld Ref Inp (mA) 4 -
5. Rmt Ref Input (mA) 5 -
6. Loadsensor Inp (mA) 6 -
7. LS Input 7 -
8. 29/Run Stop 8 -
9. 30/Reset 9 -
10. 31/Lower 10 -
11. 32/Raise 11 -
12. 33/Droop Isoch 12 -
13. 34/Unload 13 -
14. 35/Base Load 14 -
15. 36/Gen Breaker 15 -
Menu - Monitor Outputs

1. Alarm RLY 1 -
2. Jet/Mjr Alm RLY 2 -
3. CB Open RLY 3 -
5. Analog Out #1 5 -
8. LS Output 8 -

Seite/Sheet: 2
282027
12CM43
Menu - Speed Setting Voreinstellung/Preadjust Betrieb/Service
1. Idle Speed 1 300 -
2. Rated Speed 2 500 -
3. Raise Speed Limit 3 540 -
4. Wait Min Spd Time 4 1 -
5. Accel Rate (rpm/sec) 5 3 -
6. Decel Rate (rpm/sec) 6 3 -
7. Synchroniser Rate 7 1 -
8. Speed Raise Rate 8 1 -
9. Speed Lower Rate 9 1 -
10. 4 mA Remote Ref 10 350 -
11. 20 mA Remote Ref 11 540 -
12. Spd Flt Ovrd Time 12 5 -
13. Hunt Alarm RPM 13 100 -
14. Hunt Alm Delay (sec) 14 1 -
15. Spd Fil MPU #1 (Hz) 15 6 -
16. Spd Fil MPU #2 (Hz) 16 6 -
17. Lower Pulse (RPM) 17 1 -
18. Raise Pulse (RPM) 18 1 -
Menu - kW Load
1. Maximum Load (kW) 1 6900 -
2. Unload Offset (kW) 2 50 -
3. Minimum Load (kW) 3 150 -
4. Raise Rate (kW/sec) 4 100 -
5. Lower Rate (kW/sec) 5 100 -
6. Load Ref at 4 mA 6 0 -
7. Load Ref at 20 mA 7 6900 -
8. Load Sens at 4 mA 8 0 -
9. Load Sens at 20 mA 9 * Depending on load sensor signal *
10. Load Input Filter 10 0,2 -
Menu - Droop
1. No Load Act (%) 1 20 -
2. Full Load Act (%) 2 80 -
3. Droop (%) 3 5 -
Menu - Fuel Limits

1. Start Lmt Dis Time 1 3 -
2. Maximum Limit 2 101 -
3. Start Lmt P1 (%/LSS) 3 44 -
4. Start Lmt P2 (%/LSS) 4 44 -
5. Start Lmt Rte units/s 5 2,5 -
Menu - Dynamics 1
1. Gain 1 1 0.3 -
2. Integrator Rate 1 2 0.7 -
3. Derivative Ratio 1 3 40 -
4. Fast Gain 1 4 0.6 -
5. Fast Gain Window 1 5 5 -
Seite/Sheet: 3
282027
12CM43
Menu - Dynamics 2 Voreinstellung/Preadjust Betrieb/Service
1. Gain 2 1 0,3 -
2. Integrator Rate 2 2 0,7 -
3. Derivative Ratio 2 3 40 -
4. Fast Gain 2 4 1 -
5. Fast Gain Window 2 5 5 -
Menu - Tune Aux Output

1. 1/PID% at 4 mA 1 not used 0
2. 1/PID% at 20 mA 2 - 100
3. 2/MPU #1 rpm at 4 mA 3 - 0
4. 2/MPU #1 rpm at 20 mA 4 - 100
5. 3/MPU #2 rpm at 4 mA 5 - 0
6. 3/MPU #2 rpm at 20 mA 6 - 100
7. 4/Load% at 4 mA 7 - 0
8. 4/Load% at 20 mA 8 - 100
9. 5/Act% at 4 mA 9 - 0
10. 5/Act% at 20 mA 10 - 100
11. 6/Tors RPM at 4 mA 11 - 0
12. 6/Tors RPM at 20 mA 12 - 100
13. 7/Jmp Lim% at 4 mA 13 - 0
14. 7/Jmp Lim% at 20 mA 14 - 100
Menu - Torsionals
1. No Tors above % Load 1 not used 20
2. Max Hunt RPM 2 - 2,5
3. Min Hunt RPM 3 - 0,5
4. Gain Factor 4 - 0,5
5. Integrator Factor 5 - 2,5
6. Change Rate 6 - 0,05
Menu - JMP Rate Limit

1. Jump 1 %/Act 1 not used 35
2. Rate Jump 1 %/sec 2 - 0,5
3. Enbl Jmp 2 at % Load 3 - 60
4. Jump 2 %/Act 4 - 40
5. Rate Jump 2 %/sec 5 - 2
Menu - Jet Assist

1. Loadstep 1 % Load 1 not used 25
2. Breakpoint % Load 2 - 50
3. Loadstep 2 % Load 3 - 30
4. Relay Pulse (sec) 4 - 50
Menu - Auto Isoch

1. Allowed Spd Error 1 not uesd 15
2. Spd Error Delay 2 - 1

Seite/Sheet: 4
282027
12CM43
Menu - Calibration Voreinstellung/Preadjust Betrieb/Service
1. Bs Ld Ref Inp Offs 1 not used 0
2. Bs Ld Ref Inp Gain 2 - 1
3. Rmt Ref Input Offs 3 - 0
4. Rmt Ref Input Gain 4 - 1
5. Loadsensor Inp Offs 5 - 0
6. Loadsensor Inp Gain 6 - 1
7. Offset Aux #1 7 - 0
8. Gain Aux #1 8 - 1
9. Offset Aux #2 9 - 0
10. Gain Aux #2 10 - 1
11. Offset Aux #3 11 - 0
12. Gain Aux #3 12 - 1
Menu - BSLD Fine Tune

1. Base Fine Max Spd 1 not used 525
2. Base Fine Min Spd 2 - 500
Menu Load Sharing

1. Load Share Offset 1 0 -
2. Load Share Gain 2 1 -
Menu CB Open Pulse

1. Pulse Used ? 1 FALSE -
2. Active above KW (%) 2 60 -
3. Active above ACT (%) 3 60 -
4. Pulse Time (sec) 4 0,2 -
5. Deactivate Delay (sec) 5 0,2 -
Menu - Port Setting

1. Set Download Mode 1 2 -

Seite/Sheet: 5
282027
12CM43
Menu - Configuration Voreinstellung/Preadjust Betrieb/Service
1. Gear #1 Teeth 1 30
2. Gear #2 Teeth 2 30
3. Act Forward Act 3 TRUE
4. Enable Synchronizer 4 FALSE
5. Cont Open Stop 5 TRUE
6. Overspeed 6 575
7. Use Torsionals ? 7 FALSE
8. Use Jmp Rte Lim ? 8 FALSE
9. Use Jet Assist ? 9 FALSE
10. Use Auto Iso ? 10 TRUE
11. Use Rs/Lo in Iso ? 11 FALSE
12. Block Rs/Lo in Iso ? 12 FALSE
13. CB Open on Stop ? 13 FALSE
14. BSLD Fine Tune Enbl ? 14 FALSE
15. Use Act Wirebreak ? 15 FALSE
16. Act mA_0 16 10
17. Act mA_100 17 180
Menu - Set Alarms

1. Loadsensor Used ? 1 TRUE
2. Loadsens Alarm ? ( 2 2
3. MPU #1 Failed Alarm ? ( 3 2
4. MPU #2 Failed Alarm ? ( 4 2
5. Torsional Alarm ? * ( 5 1
6. Bs Ld input Alarm ? ( 6 1
7. Rem Spd input Alarm ? ( 7 1
8. Spm input Alarm ? ( 8 1
9. Stop on Major Alm ? 9 TRUE
10. Brkr Open Rly NC ? 10 FALSE
11. Jet (F) / Mjr (T) Alm Rly ? 11 FALSE
12. Jet/Mjr Alm Rly NC ? 12 FALSE
13. Alarm Relay NC ? 13 FALSE
14. Act WB Major ALM ? 14 FALSE
Menu - Set Outputs

1. Select Aux 1 ( 1 not used 6
2. Select Aux 2 ** ( 2 - 2
3. Select Aux 3 ( 3 - 3
Menu - LON COM

1. LON Adres 1 -
*) 1 = No Alarm **) 1 = PID %

2 = Minor Alarm 2 = Speed MPU #1 RPM
3 = Major Alarm 3 = Speed MPU #2 RPM
4 = Load %
5 = Limit %
6 = Torsional Level RPM
7 = Jump Rate Limit %
Seite/Sheet: 6
Circuit diagram Motor C5.05.05.10.30.40
-
VM43
Circuit diagram Motor
en / 13.03.2004 FD027070 1/49

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Description C5.05.05.10.50.05
Engine Monitoring Devices
VM43
Description
Engine Monitoring Devices
en / 15.03.2004 FD027290 1/18

Description of the Engine Monitoring Devices
c 12M43
1. Engine Speed Pick-up Page 2

FA2-H-3C-XX
2. Temperature Measurement Unit

TS 31000
CD6_Mischke Page 1 of 2
Status: 22.04.02 BG 4312.7-46.92.00-01_en
Description of the Engine Monitoring Devices
c 12M43
Adjustment Instructions for Engine Speed Pick-up FA2H-3C-XX
1. Alignment of the speed pick-up for axial mounting position
Red mark, parallel to the direction of movement (counterboring)
2. Alignment of the speed pick-up for radial mounting position

Permissible deviation
Red mark, at right angle to the angle of skew

(counterboring)
Status: 22.04.02 BG 4312.7-46.92.00-01_en
Temperature-Measurement Unit
with Manual
Test Point Switch
Series TS 31000
Commissioning and Adjustment Manual
CYLINDER1
C
PROG
Issue: April 2002 (Software Version 1.22)

SIKA TS 31000 Operating Manual
Table of Contents
1 About this Manual ...................................................................................................3
2 Safety Instructions ..................................................................................................4
3 Description of TS 31000 .........................................................................................5
3.1 Assemblies and operating elements......................................................................... 5
3.2 Design and Function of TS 31000 ............................................................................. 6
4 Storage and Set-up .................................................................................................7
4.1 Storage........................................................................................................................ 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 selection ............................................................................................. 10
5.2.2 Select physical measurement unit ....................................................................... 10
5.2.3 Select motor type ................................................................................................ 11
5.2.4 Select sensor type............................................................................................... 11
5.2.5 Programming the access code ............................................................................ 12
6 Care, Maintenance and Disposal .........................................................................13
6.1 Care and maintenance ............................................................................................. 13
6.2 Disposal .................................................................................................................... 13
7 Troubleshooting....................................................................................................13
8 Technical Data.......................................................................................................14
3228005-E.doc April 2002 2

1 About this Manual

This operating manual is for the benefit of skilled and semi-skilled
workers.
Read the relevant notes carefully before every move and keep the pre-
set sequence.
Read the section "Safety Instructions" with special attention. Remember
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 Configuration of TS 31000
6. Care and Maintenance
7. Troubleshooting
8. Technical Data
In the case of problems or questions, please contact your local supplier
or SIKA directly:
Dr. Siebert & Khn GmbH & Co KG
Struthweg 7-9
D-34260 Kaufungen
Germany
Phone +49 56 05 8 03-0
Fax +49 56 05 8 03-54 or 60
Email: electronic@sika.net
3228005-E.doc April 2002 3

2 Safety Instructions
The TS 31000 is technically up to date. This applies to measurement
accuracy, function principle, and save operation of the instrument. To
ensure a safe operation 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 at the related
chapters of this operating manual. Warnings are marked by special
signs.
Attention: Material damage!

This sign draws attention to an action which can cause instruments
damage.
+ Note: This sign draws attention to important remarks.
3228005-E.doc April 2002 4

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
1
CYLINDER1
C
PROG
3 4
Figure 1: Front side of TS 31000
3228005-E.doc April 2002 5

3.2 Design and Function of TS 31000

The instruments of the TS 31000 type are 32 channel temperature
measurement units for thermo couples with a manual test point switch.
The selected channel is displayed in plain text on a LCD matrix display
. The related temperature is shown at the 4 digit LED display .
Programming of the instrument is carried out via the keys and 4 .
The keys are designed as light reflex buttons. Using 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 rear side of the
instrument, serving as connectors for thermo couples and cold
junctions. A power supply is connected through the 3 pole screwed
clamp connection.
The instrument is equipped with a microprocessor. It takes over the
entire control and linearizes the characters of the temperature sensors
and the cold junction sensors.
A build-in Watchdog-Timer supervises continuously the microprocessor
system and switches it into a defined initial condition if an error occurs.
3228005-E.doc April 2002 6

4 Storage and Set-up

4.1 Storage
TS 31000 must be stored dust-protected and dry. The ambient
temperature for storage must be between -10 C and +80 C.
4.2 Set-up
The instrument is installed in a casing for switchboard front mounting.
The 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
clamping device.
4.3 Connection
4.3.1 Power supply
The required power supply of TS 31000 is 24 VDC 15% which can be
connected to the 3 pole clamp connection at the rear side of the unit.
Observe the correct polarity.
c hannel 1-16
2 20
1 19
c hannel 17-32
2 20
1 19
Figure 2: Rear side of TS 31000
3228005-E.doc April 2002 7

4.3.2 Sensor inputs

TS 31000 has 32 thermo couple inputs and two PT100 cold junction
inputs. The PT100 inputs are 3 lead inputs.
The connections are distributed to two 20 pole strip connectors (DIN
41651) and Pin 17 is the common negative connector for all thermo
couples.
X1 X2
20 19 20 19
Pt100 1 - Pt100 1 - Pt100 2 - Pt100 2 -
18 17 18 17
Pt100 1 + thermo couple - Pt100 2 + thermo couple -
16 15 16 15
thermo couple 16 + thermo couple 15 + thermo couple 32 + thermo couple 31 +
14 13 14 13
12 11 12 11
10 9 10 9
8 7 8 7
6 5 6 5
4 3 4 3
2 1 2 1
Figure 3: Connector assignment of sensor inputs
Note: If connection and/or calibration leads can be affected by outer
+ influences like electro-magnetic fields, electrical switching processes

by thyristor controls etc., the leads should be screened and the
screening should be connected to earth. The thermo couples used
must have a jacket which is electrically insulated from the element.
3228005-E.doc April 2002 8

5 Commissioning and Configuration of TS 31000

5.1 Commissioning
After the power supply is connected, the instrument displays name and
version number. Then the measurement process starts by switching on
channel 1. The LCD display shows the name of the first measurement
channel in the first line in plain text, the second line shows the unit. The
corresponding LED display shows the related measurement value. With
the up s and the down key, the display can be switched through the
channels.
5.2 Configuration of TS 31000

To set up the TS 31000 to perform a requested measurement function,
it must be programmed via a configuration menu.
To call up the configuration menus proceed in the following way:
Press simultaneously key s and key for about 2 seconds.

The display switches to: CONFIG-MENU and the second line
displays 0000. A cursor appears on the 0 at the very left.
By pressing the s key, set 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 entry of the last digit the
instrument is in the configuration menu, provided that the entered
number is equal to the stored number. If the entered number is
wrong, the TS 31000 switches back to measuring operation.
Note: No customer specific access code is stored by maker. In this
+ case switch into the configuration menu by confirming numerically

the default number 0000 with the key.
Note: If you do not press a key in the configuration menu within a
+ period of 30 seconds, the instrument will switch back to the last

menu item QUIT CONFIG NO and after further 30 seconds back
to measuring operation without any key stroke.
Note: Press simultaneously the s und - key to quit the configuration

menu or go back to the first menu item (SET LANGUAGE) at any
+ place in the menu.
If you confirm with YES, the instrument will return to measurement
operation of channel 1.
If you confirm with NO, the instrument will return to the beginning of
the configuration menu.
3228005-E.doc April 2002 9

5.2.1 Language selection

To select the language for all displayed messages, proceed as follows:
Switch to the configuration menu. The following message appears:

SET LANGUAGE NO.
Switch with the s key to YES and confirm with the key.
The following messages appears for text messages in German:

DEU/GER/ALL JA.
If you want to change the language, switch with the s-key to NO

and confirm with the -key. Now the message ENGLISCH/ANGLAIS
NEIN appears for text messages in English and after another click
with the -key FRAN/FREN NEIN for text messages in French
and SPAN/ESPAN NEIN for the Spanish language.
The next menu item appears: SET UNIT NO.
5.2.2 Select physical measurement unit

To select the measurement unit, proceed as follows:
Switch to the configuration menu.
Press the -key until the message

SET DIMENSION NO appears.
The message appears TEMPERATURE C YES for the

measurement unit Celsius degree.
If you want to change the measurement unit, switch with the s-key to
NO and confirm with the -key. Now TEMPERATURE F NO is
displayed for the measurement unit Fahrenheit degree and after a
repeated click on the -Taste TEMPERATURE K NO for the
measurement unit Kelvin.
Now the next menu item SET MOTOR NO is displayed.
3228005-E.doc April 2002 10

5.2.3 Select motor type

To select the type of motor, proceed as follows:

SET MOTOR NEIN appears.
Switch with thes-key to YES" and confirm with the -key.
The message appears Motor Nr.: 1 JA for motor type 1.
If you want to change the motor type, switch with the s-key to NO
and confirm with the -key. Now the other motor types 2 to 9 are
displayed.
Note: A list of the motor types defined by you can be found in the
+ delivered appendix.
If you found the correct 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 follows:

SET SENSORTYP NO appears.
Switch with the s-key to YES" and confirm with the -key.
The message appears Sensor: TypK YES for a thermo couple of

the K (NiCr-Ni) type.
If you want to change the sensor type, switch with the s-key to NO
and confirm with the -key. Now the other sensor types are
displayed:
Type E = NiCr-CuNi
Type J = Fe-CuNi
Type T = Cu-CuNi
Type S = Pt10Rh-Pt
Type B = Pt30Rh-Pt6Rh
Type R = Pt13Rh-Pt
As soon as you have found the correct sensor type, switch with the
s-key to YES" and confirm with the -key.
3228005-E.doc April 2002 11

The next menu item appears SET ACCESS-CODE NO.
5.2.5 Programming the access code

To program a customer-specific access code, proceed as follows:

SET ACCESS-CODE NO appears.
Switch with thes-key to YES" and confirm with the -key.
Set each digit of the new access code with the s key and confirm
with the key.
To confirm the entry, you must enter the access code a second 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 only be called-up by entering this code.

Unauthorized persons can no longer change the set parameters.
+ Note: If the code was wrongly entered, the message CODE

ERROR appears.
Then the message QUIT CONFIG NO appears.
If you want to quit the configuration menu, switch with the s-key to
YES and confirm the message with the -key. Otherwise, the
instruments goes back to the menu item SET LANGUAGE.
After quitting the configuration menu, the instrument goes back to

measurement operation channel 1.
3228005-E.doc April 2002 12

6 Care, Maintenance and Disposal

6.1 Care and maintenance
Attention: Keep TS 31000 clean. This is especially important for the
reading surface to ensure both, a good legibility of the LC-display
and a proper operation of the light reflection buttons.
No special maintenance is required for TS 31000.
6.2 Disposal
SIKA will take care of proper disposal.
Return the TS 31000 freight prepaid.
7 Troubleshooting
Attention:
The following table contains remedy actions.
Malfunction Cause Remedy

Instead of temperature values, Connection between Check thermo couple and
the instrument displays ---- thermo couple and connections
instrument interrupted.
Instrument displays: Value of cold junction is Check cold junction and
REFJUNC. OVERFLOW out of permissible range. connections
TS 31000 does not work Outer influences, e.g. Screen the instrument
properly. magnetic fields. from magnetic fields
Wrong supply voltage Check actual voltage
Faulty installation Check installation
Faulty programming. Check programming
Display of silly characters or Switch off and on the
measurement values. instrument
Note: If the instrument does not work properly after checking of the
+ above mentioned points, contact your supplier or SIKA. Possibly TS

31000 must be checked in the factory.
3228005-E.doc April 2002 13

8 Technical Data
Voltage supply
nominal 24 VDC (18...32 VDC) protected against polarity mix-up,
galvanically insulated
Power consumption
2 Watts
Inputs
Thermo couple K, E, J, T, S, B or R. A thermo couple linearization was
firmly set in the factory.
Measurement range and accuracy

-90 to 1300 C thermo couple type K 0,15% of r.r. 1 digit
-90 to 750 C thermo couple type E 0,15% of r.r. 1 digit
-90 to 1000 C thermo couple type J 0,15% of r.r. 1 digit
-90 to 350 C thermo couples type T 0,50% of r.r. 1 digit
100 to 1650 C thermo couples type S 0,15% 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 inputs with over/under voltage protection
Resolution
1K
Measurement rate
120 measurements per minute
Cold junction
twice Pt100, 3 lead technique, measurement range -10 to +100 C
Display of measurement values

2-line alphanumerical LCD display for text comments
16 digits/line 5,5 mm digit height
4-digit LED display, 15 mm digit height
Selection of measurement channel

via two light reflex buttons s and
Connections
two 20-pole strip connectors to DIN 41651 for thermo couples and cold
junctions
3-pole screwed clamp connection for power supply
Dimensions
Front size: 96 x 96 mm,
Depth: 75 mm
3228005-E.doc April 2002 14

Protection class
Front: IP54
Storage and service temperature

-10 to +80 C / 0 to +55 C
3228005-E.doc April 2002 15

Equipment List Engine C5.05.05.10.60.44
-
VM43
Equipment List Engine
en / 15.03.2004 FD027292 1/7

Equipment List Engine 12M43
c Unit
Devices, Sensors and Actuators
Description Sensor range Stock No. Drawing No.
Signal range
1104 Pressure switch 20 400 kPa 283 480 205 MBC5100-1211-DB04

Lub. oil pressure low start stdby pump binary 061B000466
1105 Pressure transmitter
1105 Lub. oil pressure low 0 1000 kPa 283 480 197 MBS3150-2011-6BB04
prealarm shutdown 4-20mA 060G1475
Lub. oil pressure low shutdown binary 061B000466
1202 Resistance thermometer -40-160 C 263 481 017 0.00.6-93.17.00-32
Lub. oil pressare at engine inlet high alarm PT 100
1203 NTC -40-120 C 213 464 022 0.00.6-93.17.00-20
Lub. Oil pressare at engine inlet high load NTC
load reduction/engine stop
X1/A1 Attaching type switching device 233 463 034 0.00.6-93.17.02-11
1251/1253 Oil mist detector VN116/87
9631 1251 Oil mist concentration in crankcase high 1251 : 0,5...25% 283 450 407 0.00.6-71.30.00-41
alarm binary
1253 Oil mist concentration in crankcase high 1253 : 0,5...25%
load reduction binary
9631 Oil mist detector failure alarm 9631 -
binary
2102 Pressure transmitter 0 600 kPa 283 480 198 MBS3100-1811-6BB04
Cooling water pressure HT at engine inlet low 4-20mA 060G1464
alarm
Cooling water pressure HT at engine inlet low binary 061B000466
shutdown
Cooling water pressure LT at engine inlet low - 4-20mA 060B1464
alarm
Cooling water temp. HT at engine inlet - Dicare PT 100
Cooling water temp. HT at engine outlet high - PT 100
alarm
2212 NTC -40-120 C 213 464 023 0.00.6-93.17.00-21
Cooling water temp. HT at engine outlet high NTC
load reduction/engine stop
X1/A2 Attaching type switching device 233 463 034 0.00.6-93.17.02-11
Cooling water temp. LT at engine inlet - PT 100
indication
Fuel oil pressure at engine inlet low - alarm 4-20mA 060G1475
5111 Differential pressure switch 0 80 kPa 193 094 468 0.00.6-71.35.00-41

Differential pressure fuel oil filter high alarm binary
CD6_Mischke Page: 1
Status: 14.05.2003 EG 4312.7-46.92.00-01_en
c Unit
Signal range
5201/5202 Resistance thermometer 263 481 016 0.00.6-93.17.00-31

5201 Fuel oil temp. at engine inlet low alarm -40-160 C
5202 Fuel oil temp. at engine inlet high Alarm PT 100
(not in use with HFO)
5301A Level probe - 213 483 074 0.00.6-91.31.00-24
Leakage oil niveau at engine high - alarm ground switching
Plug 977 032 805 VG95234-E-10SL-3SN
5301B Level probe - 213 483 074 0.00.6-91.31.00-24

Leakage oil niveau at engine high - alarm ground switching
Plug 977 032 805 VG95234-E-10SL-3SN

Starting air pressure low - alarm 4-20mA 060G1945
6105 Pressure switch 100-1600 kPa 283 460 020 0.00.6-71.35.00-51
Stopping air pressure low - alarm binary
6181 Absolute Pressure transmitter 80 120 kPa 283 460 011 0.00.6-93.25.00-28
Intake air pressure in engine room Dicare 4-20mA
Charge air pressure at engine inlet Dicare 4-20mA 060G1463
Charge air temp. at engine inlet high alarm PT 100
Intake air temp. at turbocharger inlet Dicare PT 100
7301 Level probe - 213 483 072 0.00.6-91.31.00-22
Condense water in charge air canal alarm ground switching
Plug 977 032 805 VG95234-E-10SL-3SN
7307 Differential pressure transmitter 0 10 kPa 263 460 006 0.00.6-93.25.00-27

Charge air diff. pressure at charge air cooler 4-20mA
Dicare
7309A Thermocouple type K -200-1300 C 223 482 350 1.00.7-48.99.00-51
Charge air temp. at charge air cooler inlet A NiCr-Ni
Dicare (mV)
7309B Thermocouple type K -200-1300 C 223 482 350 1.00.7-48.99.00-51
Charge air temp. at charge air cooler inlet B NiCr-Ni
Dicare (mV)
8211.1A Thermocouple type K -200-1300 C 223 482 350 1.00.7-48.99.00-51
..... Exhaust gas temp. after cylinder 1A.....6A NiCr-Ni
8211.6A load reduction/engine stop (mV)
8211.1B Thermocouple type K -200-1300 C 223 482 350 1.00.7-48.99.00-51
..... Exhaust gas temp. after cylinder 1B....6B NiCr-Ni
8211.6B load reduction/engine stop (mV)
Exhaust gas temp. at turbocharger outlet A NiCr-Ni
load reduction/engine stop (mV)
CD6_Mischke Page: 2
Status: 14.05.2003 EG 4312.7-46.92.00-01_en
c Unit
Signal range

Exhaust gas temp. at turbocharger outlet B NiCr-Ni
load reduction/engine stop (mV)
Exhaust gas temp. at turbocharger inlet A NiCr-Ni
Dicare (mV)
Exhaust gas temp. at turbocharger inlet B NiCr-Ni
Dicare (mV)
R16 Resistance thermometer -40-160 C 263 481 017 0.00.6-93.17.00-32
Electr. charge air temp. control PT 100
9419.1 Pick up 0-1200 upm 283 450 603 0.00.6-93.21.00-76
9419.2 RPM switching equipment 0-15 KHz
Plug 213 480 101 CA06EW-14S-5S-B-03A34
9419.3 Pick up 0-1200 upm 283 450 603 0.00.6-93.21.00-76
9419.4 Electronic governor 0-15 KHz
Plug 213 480 101 CA06EW-14S-5S-B-03A34
9429A Pick up 0-40000 upm NA297 (DSH1840.01)

Turbine speed A 0-1 KHz
Plug 263 450 019 0.00.6-94.63.00-07
9429B Pick up 0-40000 upm NA 297 (DSH1840.01)

Turbine speed B 0-1 KHz
Plug 263 450 019 0.00.6-94.63.00-07
9503 Limit switch - 213 483 430 1.00.7-48.99.00-87

Control lever at control stand engine stop / full binary
fuel
9509 Distance sensor 125% load 260 480 070 1.00.7-48.99.00-53
Fuel setting 0-20mA
Plug 213 480 101 CA06EW-14S-5S-B-03A
9561 Limit switch - DTE7-2RN-PG

Turning gear engaged starting interlock binary
S1 Limit switch - BZE7-2RN-PG

Turning gear engaged contactor reverser ON binary
S2 Pressure switch 1 1600 kPa 283 460 020 0.00.6-71.35.00-51
Starting air pressure at main starting valve binary
CD6_Mischke Page: 3
Status: 14.05.2003 EG 4312.7-46.92.00-01_en
c Unit
Signal range
Y1.1 Solenoid valve - 213 413 018 0.00.6-41.26.00-32

Shutdown 24V DC / 6W
Plug 253 460 054 49020200(GDM3011)
Y1.2 Solenoid valve - 283 410 065 0.00.6-41.21.00-91
Start 24V DC / 6W
Plug 253 460 054 49020200(GDM3011)
Starting interlock for manual emergency start 24V DC / 18,5W
Plug 253 460 054 49020200(GDM3011)
M1 Actuator -
0 - 200mA
With back up 0.00.6-72.13..00-08
Without back up 0.00.6-72.13.00-09
Plug connector (14) 253 460 058 CA3106E-20-27S-F80-DN
S11/H9 Start push button
Luminous key 977 037 060
Frame 977 037 062
Push button cap 977 037 066
Bulb 223 480 054
S12/H10 Stopp push button
Frame 977 037 062
Bulb 223 480 054
S13 Change over switch engine/remote
Locking key 223 460 037
Key base 977 037 068
S14 Lamp-test push button
Frame 977 037 062
S15 Lower push button
Frame 977 037 062
S16 raise push button
Frame 977 037 062
H11 Lamp false start
Frame 977 037 062
Bulb 223 480 054
CD6_Mischke Page: 4
Status: 14.05.2003 EG 4312.7-46.92.00-01_en
c Unit
Signal range
H12 Lamp starting interlock

Frame 977 037 062
Bulb 223 480 054
H13 Lamp remote control
Frame 977 037 062
Bulb 223 480 054
P4 Engine speed indication 0-10V 263 480 305 NQ96-10/0-10V
Scale 0-600 233 481 038 SS82-06
P2 Turbocharger speed indication 0-10V 263 480 305 NQ96-10/0-10V
Scale 0-30000 263 480 309 SS87-17
P3 Turbocharger speed indication 0-10V 263 480 305 NQ96-10/0-10V
Scale 0-30000 263 480 309 SS87-18
P1 Exhaust gas temp. measuring instrument NiCr-Ni 283 450 220 0.00.6-93.40.00-47
Busboard (XC1A/XC1B) 283 360 070 9.01.7-91.11.00-14
X1.1 Plug connector (40)
X1.2 Housing (Female) 977 062 817
X1.3 Housing insert 977 062 818
X2.1 Contact socket 977 062 812
X2.2 Washer 977 062 822
X2.3 , X2.4 Plug box (Male) 977 062 819
X3.3 , X3.4 Housing insert 977 062 815
X3.5 Contact pin 977 062 814
X3.1 Plug connector (19)
X3.2 Male 263 480 303 CA3102E-20A-48P-B-04
XC1 , XC2 Female 977 032 812 VG95234-G-20A-48SN
XA1/1-35 Terminal 977 062 506 047826(AST)
XA2/1-30 Terminal 977 062 506 047826(AST)
XA3/1-50 Terminal 977 062 506 047826(AST)
XA4/19-25 Terminal 977 062 506 047826(AST)
XA5/1-20 Terminal 977 062 506 047826(AST)
XA6/1-40 Terminal 977 062 506 047826(AST)
XA7/1-10 Terminal 977 062 506 047826(AST)
XA8/1-30 Terminal 977 062 506 047826(AST)
XA9/1-10 Terminal 977 062 506 047826(AST)
XA1/R1 Terminal / PT100 213 481 075 801473(DK4/32PT100)
Manometer charge air 0.00.6-71.33.00-93
Manometer cooling water HT 0.00.6-71.33.00-97
Manometer cooling water LT 0.00.6-71.33.00-97
Manometer fuel oil 0.00.6-71.33.00-96
Manometer lub. oil 0.00.6-71.33.00-95
Manometer starting air 0.00.6-71.33.00-94
CD6_Mischke Page: 5
Status: 14.05.2003 EG 4312.7-46.92.00-01_en
c Unit
Signal range
Manometer stop air 0.00.6-71.33.00-92

Service unit 263 410 060 0.00.6-41.25.00-37
Compressed air filter 223 860 024 0.00.6-41.54.00-11
Safety valve 3200 kPa 213 660 044 UFPNZUB008002
Safety valve 850 kPa 223 860 023 0.00.6-41.20.00-96
3/2 way valve NW40 283 410 065 0.00.6-41.21.00-91
Non return valve 963 090 121 RHZ10-PLM-ED
CD6_Mischke Page: 6
Status: 14.05.2003 EG 4312.7-46.92.00-01_en
Turning Equipment C5.05.05.10.70.03
-
Turning Equipment
en / 07.04.2008 FD036815 1/6

Maintenance Unit C5.05.05.45.23.01
-
M20/M25/M32/M43
Maintenance Unit
en / 15.03.2006 FD022856 1/25

Pressure reducing station R417000844
R417000845
R417000888
Operating instructions
Imprint:
The copyright of this users manual remains the property of Bosch-Rexroth AG.
Included are instructions and technical drawings, which may not be reproduced or copied
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
the actual design.
This edition supersedes all previous ones.

No part of this edition may be reproduced whithout our prior permission.
Order Number: 883 890 035 3 BDL 001 AC

Table of contents
Safety information 28
Explanation of symbols 28
GB Occupational safety 29
Design and mode of operation 30

General 30
Block diagram 32
Versions 33
Startup 34
Ports and Installation, Assembly position, 34
Maintenance and care 35

General 35
Replacing the sealing elements, dismantling 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
Replacing the sealing elements, assembly 42
Setup and Tests 43
Spare parts package 44
Storage and transportation 45

General 45
Technical specifications 46
General 46
Circuit diagram 46
Dimensional drawing 47
After sales service and adresses 48

Any questions? 48
883 890 035 3 BDL 001 AC (10/06) 27

Safety information
Danger!
This symbol is to be found with all
information and warnings in these
Explanation operating instructions regarding work
of symbols safety, where there is potential danger
to humans.
Take notice of such warnings and act
with particular caution in these cases.
Warning!
This symbol is to be found in these
operating conditions wherever it is
Warning! 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!

This symbol is found wherever
components have to be transported,
stored or mounted in a particular
position. (to DIN 30 600)
Grease!
This symbol is to be found wherever
components, areas etc. need to be
Fett lubricated.
Grease
Secure by glue!
This symbol is marking parts which
must be secured by means of a liquid
adhesive (according to DIN 30 600).
883 890 035 3 BDL 001 AC (10/06) 28

Safety information
Warning
Do only pressurise the pressure-reducing station, if it has been
Occupational mounted properly.
safety Do not handle the pressure-reducing station, if it is pressurised.
Always cut off the air supply before starting work.
Technical State
The pressure-reducing station has been designed according to the
latest state of the technology and safety standards for operation.
Proper Use
The pressure-reducing station has the following purpose:
Reduction of a high inlet pressure to a low outlet pressure.
The ambient conditions as well as the operating pressure range

specified in the technical data have to be observed. The compressed
air supplied must be clean, dry and free of lubricant.
Air quality:
PNEUROP-
Quality class acc. to : recommendation ISO 8573-1
6611 / 1984
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 liable
for any resulting damage.
This device may cause danger if it is used improperly, under

inappropriate conditions or by unqualified personnel.
Using the device appropriately does, of course, also mean observing

the assembly, dismantling and maintenance instructions.
Guarantee
The pressure-reducing station must by maintained and repaired by
authorised, skilled personnel only.
The user must only operate the pressure-reducing station in perfect

condition.
The user is obliged to report any changes of the device's condition that
might reduce its safety.
Unauthorised modifications and changes that might reduce the safety

of the pressure-reducing station are not permitted.
Before commissioning please read the operating instructions

carefully.
883 890 035 3 BDL 001 AC (10/06) 29

Design and mode of operation
Purpose
The pressure-reducing station has the following purposes:
General x Filtering the pressurized air and condensing
x Reduction of a high inlet pressure to a low outlet pressure
x Monitoring of the reduces outlet pressure via pressure gauge and
safety valve
x Ventilation of the compressed air tab A.
Design
The pressure-reducing station consists of a housing that contains the
following components (fig. 1) :
compressed air filter with drain valve (1), pressure control valves (2),
safety valve (3), pressure gauge (4), 3/2-way valve, operated electro-
magnetically (5) and pressure switch (6) with testing tab (7).
Mode of operation
The pressurized air entering at point P (pmax = 30 bar) flows through
the compressed air filter (1) and is cleaned from solid impurities. The
resulting condensate is collected in the lower part of the housing and
may be drained via the drain valve.
The cleaned, pressurized air then reaches the pressure control valve
(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
safety valve (3) has to limit the operating pressure in the pressure-
reducing station to a maximum of 8,5 bar in order to prevent damages
to the connected devices.
The compressed air continues to flow from the pressure control valve
(2) to the electro-magnetically operated 3/2-way valve (5). This valve
can supply the tab A with compressed air. In addition to tab A tab
P1 also furnishes a constant compressed air supply.
The pressure switch (6) is used for monitoring of the reduced outlet
pressure. In case a lower threshold limit of the pressure value has
been exceeded, an electrical contact is closed.
The compressed air tab 14 can be used to supply compressed air to
the testing tab (7) for the pressure switch, thus ensuring that the
function of the pressure switch (6) can be continuously monitored
during operations. In order to enable this feature, the adjusting screw
of the testing tab has to be turned into the housing until it stops.
883 890 035 3 BDL 001 AC (10/06) 30

If the compressed air supply at tab P is interrupted, the pressure-

reducing station is vented by force; thus ensuring that no pressure is
present at any of the subsequent devices.
General
(cf. block diagram on page 32 and circuit diagram on page 46)
Versions
Fig. 2a - 2c show three versions of the pressure reducing station,
which basically differ in the arrangement of the pressure switch and
the pressure gauge.
883 890 035 3 BDL 001 AC (10/06) 31

Block-
4
diagram
fig. 1
5
A
P1
6
7
14
2
3
P
883 890 035 3 BDL 001 AC (10/06) 32

fig. 2a : R417000888 (replacement for 335 320 200 0)

Versions
pressure gauge
drain valve
3/2-way-valve
safety valve pressure switch
fig. 2b : R417000845 (replacement for 335 320 201 0)
pressure gauge
drain valve
3/2-way-valve
883 890 035 3 BDL 001 AC (10/06) 33

Startup
fig. 2c : R417000844 (replacement for 335 320 202 0)

Versions
drain valve
3/2-way-valve
Ports and Ports and Installation

Installation The pressure-reducing station is fixed with 3 screws M10. The boring
pattern can be taken from the dimensional drawing.
Pneumatic connections are materialised by traded ports M14x1.5.
Assembly
position
Assembly position
For assembly purposes it has to be taken into account that the drain
valve points downwards.
Warning! 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 of suitable transportation protecting plugs.
The disassembled pressure-reducing station must be protected from
environmental influences. Before assembly the transportation
protecting plugs must be removed. In addition the device must be
visually inspected for damages of any kind.
883 890 035 3 BDL 001 AC (10/06) 34

Maintenance and care
Maintenance intervals
In order to guarantee a safe operation of the pressure-reducing
General station, all sealing elements must be replaced after 3 years at the
latest provided that the required compressed-air quality and the
permissible ambient conditions are observed. We recommend to
return the pressure reducing station to Bosch Rexroth AG for
repairs. For the replacement of sealing elements at own
responsibility a spare part kit 335 320 003 2 is available.
The following maintenance and care instructions have to be adhered

to:
Drain valve
The filters should be drained daily using the drain valve. In order to do
so, the handles of the drain valve should be slightly moved sideways.
Warning!
Warning! If the valves are under pressure, the condensate is very powerfully
ejected. Do not move the handles with your hands but use suitable
tools to move the handles 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 or dissolvents can be used. Dry the filter cartridge
before returning it to its position.
Follow fig.3 for the removal and reinsertion of the cartridges.
Danger!
Conduct all works on the pressure-reducing station only in an un-
pressurized state.
Warning! Warning!
Check the seals at the fastening screw.
Ensure that the cartridge is not installed at an angle.
Replacing the filter cartridges

Extremely dirty filter cartridges should be replaced by new ones.
The required parts are contained in the spare parts package
335 320 003 2.
Fett Greasing the sealing elements

Grease The sealing elements of the pressure-reducing station have to be
greased lightly using the lubricant contained in the repair set before
assembly, except if they are subject to special maintenance and care
instructions.
Before assembly, all sealing seats, faces etc. have to be cleaned.
883 890 035 3 BDL 001 AC (10/06) 35

Replacing the sealing elements, dismantling

Dismantling
The following section describes the dismantling and assembly of a
pressure-reducing station for the replacement of the sealing elements.
All elements necessary for a complete scheduled overhaul are

contained in the spare parts package 335 320 003 2.
In 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 and vent the device !
Interrupt the electric power supply.
Dismantling the filters and the drain valves (fig. 3)

x Loosen fastening screw T1 and remove sealing ring 1, filter 2 and
O-ring 3
x Remove valve screw T2 and sealing ring 4
x Remove circlip 7 and spring 6 as well as valve 5 from the valve
screw T2.
883 890 035 3 BDL 001 AC (10/06) 36

fig.3 B A
1
2
3
T1
MA = 150Nm
Y
X
C B A
T26 T25
T11
7 26
5
4
view Y
T2
MA = 60Nm
view X
883 890 035 3 BDL 001 AC (10/06) 37

Dismantling the pressure switch (fig. 4a)

(Version R417000888 , R417000844 , 3353202000 and
Dismantling 3353202020)
x Disassemble pressure switch T3. Loosen screw T4 (2x)

x Remove O-ring 36
Dismantling the pressure switch (fig. 4b)

(Version R417000845 and 3353202010)

x Disassemble adapter T12 and screw T24 (2x)
x Remove O-ring 11 and 36
Dismantling the pressure 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, bushing 18, valve ring 19, O-ring 21 and O-ring 34 from the
drill hole. Remove spring 20
x Dismantle circlips 22, 24 and filters 23, 25
x Remove banjo bolt T11 from the housing and remove piston cup
26
(cf. fig. 3).
Dismantling the adjusting screw (fig. 4a)
x Disassemble circlip 12 and remove washer T5

x Remove adjusting screw T6 from the housing. Remove O-rings 8,
9 and 10
x Remove ventilation 13.
883 890 035 3 BDL 001 AC (10/06) 38

fig.4a
13
fig.4b
T5
8
12 9
T6
10
36
T3
T4
11
T12
T24
fig.5 T3 T4 36
T8
T7
T9 24 9.8
35 37
14 25 17
13.6 +0.2
X
16
23 15
18
22 34
B-B Y
20
21
19
Take care of view X
mounting position !
view Y
883 890 035 3 BDL 001 AC (10/06) 39

Dismantling the 3/2-way valve (fig. 6)

Dismantling
x Loosen screw T25 and remove holding plate T26 (fig. 3)
x Dismantle servo valve 33. In order to do so, remove ventilation
T13, the coil T14 and 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 spring T18,

bushing T19, piston T20, sleeve T21, ram T22, washer T23 (6x),
washers 32, spacer T24 (2x), sealing ring 28 (4x) as well as
grooved ring 29
x Disassemble circlips 24, 30 and filters 25, 31.
883 890 035 3 BDL 001 AC (10/06) 40

fig.6
C-C T16
T17
X 25
24
Y 30
31
D D
T15
33
T14
T13 MA = 1.2 +0.2 Nm
T18
T19
32
28
T23 D-D
T24 27
28
X
T22
28
T24
T23
28
32
T21
T20
29
Y
883 890 035 3 BDL 001 AC (10/06) 41
Replacing the sealing elements, assembly

Assembly Reassemble the device in reverse sequence.
Take care not to damage the sealing elements during assembling.
Fett All sealing elements must prior to assembling be slightly lubricated

Grease with the grease from the spare parts kit. Before this all sealing
surfaces are to be cleaned.
Assembly of the filter and the drain valve (fig. 3)

x Replace sealing ring1, filter 2 and O-ring 3. Tightening torque for
fastening screw T1: MA = 150 Nm
x Replace 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-rings 8, 9, 10, 11, 36, circlip 12 and ventilation 13.
Assembly of pressure control valve (fig. 5)

x Replace circlip 15, valve 16, valve nut 17, bushing 18, valve ring
19, spring 20, O-rings 14, 21, 34 and piston 35.
Warning! Warning!
Keep clearance 13.6 +- 0.2 mm for valve nut 17. For checking use
adjusting sleeve 37.
Secure valve nut 17 with substance for locking screws (e. g. Loctite
241).
Warning! Warning!
Ensure correct assembly position of valve ring 19!
x Replace circlips 22, 24 and filters 23, 25.
883 890 035 3 BDL 001 AC (10/06) 42

Assembly of the 3/2-way valve (fig. 6)

Assembly x Replace gasket 27, sealing ring 28 (4x) and grooved ring 29
Warning! Warning!
Bushing T19 and sleeve T21 must overhang the upper housing edge
by 0.4 r0.1mm. Attach washers 32 accordingly.
x Replace servo valve 33
Warning! Warning!
In case of pressure reducing stations with holding plate T26 (new
version) during assembly the srew T25 must be fixed by a screw
securing means (e.g. Loctite 241).
In case of pressure reducing stations without holding plate T26 (old

version) the exhaust T13 must be tightened with a torque of MA =
1.2+0.2 Nm and a screw 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
Test Setup and Tests of the pressure-reducing station
After the dismantling/mounting of the pressure-reducing station, it is
required to set up the operating pressure of the pressure control
valves again. In order to do so, the grub screw T7 has to be loosened
and the cap T8 has to be screwed from the housing with the exception
of the last five turns.
Set tab P to a pressure of 30 bar. By turning the cap T8 the operating
pressure at the pressure control valve can be adjusted, then tighten
the grub screw T7.
Warning! Warning!
Turn cap T8 only in pressureless state.
Check the 3/2-way valve for correct performance by working it.

Finally the complete pressure-reducing station has to be tested for
tightness.
883 890 035 3 BDL 001 AC (10/06) 43

Spare parts package:

Order number 335 320 003 2
Spare parts
package
Item Description Dimension Qty.
335 320 003 2 1 sealing ring 36 x 42 x 2 1
2 filter 1
3 O-ring 23,3 x 2,4 1
4 sealing ring 22 x 27 x 1,5 1
5 valve 1
6 conical spring 0,8 x 12,7 x 26,5 1
7 circlip 15 x 1 1
8 O-ring 6 x 1,5 1
9 O-ring 5 x 1,2 1
10 O-ring 4 x 1,2 1
11 O-ring 6,75 x 1,78 1
12 circlip 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 8x9x4 1
19 valve ring 1
20 conical spring 1 x 11,2 x 18,1 1
21 O-ring 5,28 x 1,78 1
22 circlip 20 x 1,5 1
23 filter 20 x 2,3 1
24 circlip 8,3 x 0,5 2
25 filter 8x2 2
26 piston cup 3x8x4 1
27 gasket 18 x 3 1
28 sealing ring 4
29 grooved ring 12,8 x 21,2 x 4 1
30 circlip 30 x 1,2 1
31 filter 30 x 2 1
32 washer 13 x 0,2 6
33 servo valve 1
34 O-ring 10 x 1,3 1
35 piston 1
36 O-ring 6x2 1
37 adjusting sleeve 1
38 lubricant 20g
883 890 035 3 BDL 001 AC (10/06) 44

Storage and transportation
During storage and transportation the pressure-reducing station must

in principle be protected against mechanical damage and weather
influences.
General
Contacts with aggressive media must be avoided.
Compressed air ports must be closed in a way to prevent entry of dirt,

humidity and foreign matter.
The ambient 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 storage period must be taken into account for deter-
mining the replacement intervals appropriately.
Transportation
Danger!
In principle the provisions for the prevention of accidents must be
observed. Above all the device must during transportation be secured
against getting out of place resp. falling down.
883 890 035 3 BDL 001 AC (10/06) 45

Technical specifications
General
Technical Data
Permissible medium compressed air
inlet pressure max. 30 bar
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 application range 273 K 343 K
Circuit diagram
fig. 7
A
4
2
P P1
14
883 890 035 3 BDL 001 AC (10/06) 46

Dimensional drawing / Version R417000888

fig. 8
threaded tabs: M14 x 1.5; 12 deep
883 890 035 3 BDL 001 AC (10/06) 47

After sales service and adresses
Are there any questions left?

If anything is still not clear after reading these operating instructions,
any please let us know. Your suggestions for improvements are always
welcome.
Questions?
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 Drive & Control Company
Marine Technique
Ulmerstrae 4
D 30880 Laatzen
Tel.: +49 (0) 511 2136 251

Fax.: +49 (0) 511 2136 165
e-mail: marinesales@boschrexroth.de
Internet: http://www.boschrexroth.de
48
Maintenance Unit C5.05.05.45.23.03
-
M20/M25/M32/M43
Maintenance Unit
en / 23.03.2007 FD034174 1/25

Pressure reducing station R417000844
R417000845
R417000888
Operating instructions
Imprint:
The copyright of this users manual remains the property of Bosch-Rexroth AG.
Included are instructions and technical drawings, which may not be reproduced or copied
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
the actual design.
This edition supersedes all previous ones.

No part of this edition may be reproduced whithout our prior permission.
Order Number: 883 890 035 3 BDL 001 AC

Table of contents
Safety information 28
Explanation of symbols 28
GB Occupational safety 29
Design and mode of operation 30

General 30
Block diagram 32
Versions 33
Startup 34
Ports and Installation, Assembly position, 34
Maintenance and care 35

General 35
Replacing the sealing elements, dismantling 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
Replacing the sealing elements, assembly 42
Setup and Tests 43
Spare parts package 44
Storage and transportation 45

General 45
Technical specifications 46
General 46
Circuit diagram 46
Dimensional drawing 47
After sales service and adresses 48

Any questions? 48
883 890 035 3 BDL 001 AC (10/06) 27

Safety information
Danger!
This symbol is to be found with all
information and warnings in these
Explanation operating instructions regarding work
of symbols safety, where there is potential danger
to humans.
Take notice of such warnings and act
with particular caution in these cases.
Warning!
This symbol is to be found in these
operating conditions wherever it is
Warning! 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!

This symbol is found wherever
components have to be transported,
stored or mounted in a particular
position. (to DIN 30 600)
Grease!
This symbol is to be found wherever
components, areas etc. need to be
Fett lubricated.
Grease
Secure by glue!
This symbol is marking parts which
must be secured by means of a liquid
adhesive (according to DIN 30 600).
883 890 035 3 BDL 001 AC (10/06) 28

Safety information
Warning
Do only pressurise the pressure-reducing station, if it has been
Occupational mounted properly.
safety Do not handle the pressure-reducing station, if it is pressurised.
Always cut off the air supply before starting work.
Technical State
The pressure-reducing station has been designed according to the
latest state of the technology and safety standards for operation.
Proper Use
The pressure-reducing station has the following purpose:
Reduction of a high inlet pressure to a low outlet pressure.
The ambient conditions as well as the operating pressure range

specified in the technical data have to be observed. The compressed
air supplied must be clean, dry and free of lubricant.
Air quality:
PNEUROP-
Quality class acc. to : recommendation ISO 8573-1
6611 / 1984
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 liable
for any resulting damage.
This device may cause danger if it is used improperly, under

inappropriate conditions or by unqualified personnel.
Using the device appropriately does, of course, also mean observing

the assembly, dismantling and maintenance instructions.
Guarantee
The pressure-reducing station must by maintained and repaired by
authorised, skilled personnel only.
The user must only operate the pressure-reducing station in perfect

condition.
The user is obliged to report any changes of the device's condition that
might reduce its safety.
Unauthorised modifications and changes that might reduce the safety

of the pressure-reducing station are not permitted.
Before commissioning please read the operating instructions

carefully.
883 890 035 3 BDL 001 AC (10/06) 29

Purpose
The pressure-reducing station has the following purposes:
General x Filtering the pressurized air and condensing
x Reduction of a high inlet pressure to a low outlet pressure
x Monitoring of the reduces outlet pressure via pressure gauge and
safety valve
x Ventilation of the compressed air tab A.
Design
The pressure-reducing station consists of a housing that contains the
following components (fig. 1) :
compressed air filter with drain valve (1), pressure control valves (2),
safety valve (3), pressure gauge (4), 3/2-way valve, operated electro-
magnetically (5) and pressure switch (6) with testing tab (7).
Mode of operation
The pressurized air entering at point P (pmax = 30 bar) flows through
the compressed air filter (1) and is cleaned from solid impurities. The
resulting condensate is collected in the lower part of the housing and
may be drained via the drain valve.
The cleaned, pressurized air then reaches the pressure control valve
(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
safety valve (3) has to limit the operating pressure in the pressure-
reducing station to a maximum of 8,5 bar in order to prevent damages
to the connected devices.
The compressed air continues to flow from the pressure control valve
(2) to the electro-magnetically operated 3/2-way valve (5). This valve
can supply the tab A with compressed air. In addition to tab A tab
P1 also furnishes a constant compressed air supply.
The pressure switch (6) is used for monitoring of the reduced outlet
pressure. In case a lower threshold limit of the pressure value has
been exceeded, an electrical contact is closed.
The compressed air tab 14 can be used to supply compressed air to
the testing tab (7) for the pressure switch, thus ensuring that the
function of the pressure switch (6) can be continuously monitored
during operations. In order to enable this feature, the adjusting screw
of the testing tab has to be turned into the housing until it stops.
883 890 035 3 BDL 001 AC (10/06) 30

If the compressed air supply at tab P is interrupted, the pressure-

reducing station is vented by force; thus ensuring that no pressure is
present at any of the subsequent devices.
General
(cf. block diagram on page 32 and circuit diagram on page 46)
Versions
Fig. 2a - 2c show three versions of the pressure reducing station,
which basically differ in the arrangement of the pressure switch and
the pressure gauge.
883 890 035 3 BDL 001 AC (10/06) 31

Block-
4
diagram
fig. 1
5
A
P1
6
7
14
2
3
P
883 890 035 3 BDL 001 AC (10/06) 32

fig. 2a : R417000888 (replacement for 335 320 200 0)

Versions
pressure gauge
drain valve
3/2-way-valve
fig. 2b : R417000845 (replacement for 335 320 201 0)
pressure gauge
drain valve
3/2-way-valve
883 890 035 3 BDL 001 AC (10/06) 33

Startup
fig. 2c : R417000844 (replacement for 335 320 202 0)

Versions
drain valve
3/2-way-valve
Ports and Ports and Installation

Installation The pressure-reducing station is fixed with 3 screws M10. The boring
pattern can be taken from the dimensional drawing.
Pneumatic connections are materialised by traded ports M14x1.5.
Assembly
position
Assembly position
For assembly purposes it has to be taken into account that the drain
valve points downwards.
Warning! 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 of suitable transportation protecting plugs.
The disassembled pressure-reducing station must be protected from
environmental influences. Before assembly the transportation
protecting plugs must be removed. In addition the device must be
visually inspected for damages of any kind.
883 890 035 3 BDL 001 AC (10/06) 34

Maintenance intervals
In order to guarantee a safe operation of the pressure-reducing
General station, all sealing elements must be replaced after 3 years at the
latest provided that the required compressed-air quality and the
permissible ambient conditions are observed. We recommend to
return the pressure reducing station to Bosch Rexroth AG for
repairs. For the replacement of sealing elements at own
responsibility a spare part kit 335 320 003 2 is available.
The following maintenance and care instructions have to be adhered

to:
Drain valve
The filters should be drained daily using the drain valve. In order to do
so, the handles of the drain valve should be slightly moved sideways.
Warning!
Warning! If the valves are under pressure, the condensate is very powerfully
ejected. Do not move the handles with your hands but use suitable
tools to move the handles 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 or dissolvents can be used. Dry the filter cartridge
before returning it to its position.
Follow fig.3 for the removal and reinsertion of the cartridges.
Danger!
Conduct all works on the pressure-reducing station only in an un-
pressurized state.
Warning! Warning!
Check the seals at the fastening screw.
Ensure that the cartridge is not installed at an angle.
Replacing the filter cartridges

Extremely dirty filter cartridges should be replaced by new ones.
The required parts are contained in the spare parts package
335 320 003 2.
Fett Greasing the sealing elements

Grease The sealing elements of the pressure-reducing station have to be
greased lightly using the lubricant contained in the repair set before
assembly, except if they are subject to special maintenance and care
instructions.
Before assembly, all sealing seats, faces etc. have to be cleaned.
883 890 035 3 BDL 001 AC (10/06) 35

Replacing the sealing elements, dismantling

Dismantling
The following section describes the dismantling and assembly of a
pressure-reducing station for the replacement of the sealing elements.
All elements necessary for a complete scheduled overhaul are

contained in the spare parts package 335 320 003 2.
In 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 and vent the device !
Interrupt the electric power supply.
Dismantling the filters and the drain valves (fig. 3)

x Loosen fastening screw T1 and remove sealing ring 1, filter 2 and
O-ring 3
x Remove valve screw T2 and sealing ring 4
x Remove circlip 7 and spring 6 as well as valve 5 from the valve
screw T2.
883 890 035 3 BDL 001 AC (10/06) 36

fig.3 B A
1
2
3
T1
MA = 150Nm
Y
X
C B A
T26 T25
T11
7 26
5
4
view Y
T2
MA = 60Nm
view X
883 890 035 3 BDL 001 AC (10/06) 37

Dismantling the pressure switch (fig. 4a)

(Version R417000888 , R417000844 , 3353202000 and
Dismantling 3353202020)

x Remove O-ring 36
Dismantling the pressure switch (fig. 4b)

(Version R417000845 and 3353202010)

x Disassemble adapter T12 and screw T24 (2x)
x Remove O-ring 11 and 36
Dismantling the pressure 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, bushing 18, valve ring 19, O-ring 21 and O-ring 34 from the
drill hole. Remove spring 20
x Dismantle circlips 22, 24 and filters 23, 25
x Remove banjo bolt T11 from the housing and remove piston cup
26
(cf. fig. 3).
Dismantling the adjusting screw (fig. 4a)
x Disassemble circlip 12 and remove washer T5

x Remove adjusting screw T6 from the housing. Remove O-rings 8,
9 and 10
x Remove ventilation 13.
883 890 035 3 BDL 001 AC (10/06) 38

fig.4a
13
fig.4b
T5
8
12 9
T6
10
36
T3
T4
11
T12
T24
fig.5 T3 T4 36
T8
T7
T9 24 9.8
35 37
14 25 17
13.6 +0.2
X
16
23 15
18
22 34
B-B Y
20
21
19
Take care of view X
mounting position !
view Y
883 890 035 3 BDL 001 AC (10/06) 39

Dismantling the 3/2-way valve (fig. 6)

Dismantling
x Loosen screw T25 and remove holding plate T26 (fig. 3)
x Dismantle servo valve 33. In order to do so, remove ventilation
T13, the coil T14 and 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 spring T18,

bushing T19, piston T20, sleeve T21, ram T22, washer T23 (6x),
washers 32, spacer T24 (2x), sealing ring 28 (4x) as well as
grooved ring 29
x Disassemble circlips 24, 30 and filters 25, 31.
883 890 035 3 BDL 001 AC (10/06) 40

fig.6
C-C T16
T17
X 25
24
Y 30
31
D D
T15
33
T14
T13 MA = 1.2 +0.2 Nm
T18
T19
32
28
T23 D-D
T24 27
28
X
T22
28
T24
T23
28
32
T21
T20
29
Y
883 890 035 3 BDL 001 AC (10/06) 41
Replacing the sealing elements, assembly

Assembly Reassemble the device in reverse sequence.
Take care not to damage the sealing elements during assembling.
Fett All sealing elements must prior to assembling be slightly lubricated

Grease with the grease from the spare parts kit. Before this all sealing
surfaces are to be cleaned.
Assembly of the filter and the drain valve (fig. 3)

x Replace sealing ring1, filter 2 and O-ring 3. Tightening torque for
fastening screw T1: MA = 150 Nm
x Replace 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-rings 8, 9, 10, 11, 36, circlip 12 and ventilation 13.
Assembly of pressure control valve (fig. 5)

x Replace circlip 15, valve 16, valve nut 17, bushing 18, valve ring
19, spring 20, O-rings 14, 21, 34 and piston 35.
Warning! Warning!
Keep clearance 13.6 +- 0.2 mm for valve nut 17. For checking use
adjusting sleeve 37.
Secure valve nut 17 with substance for locking screws (e. g. Loctite
241).
Warning! Warning!
Ensure correct assembly position of valve ring 19!
883 890 035 3 BDL 001 AC (10/06) 42

Assembly of the 3/2-way valve (fig. 6)

Assembly x Replace gasket 27, sealing ring 28 (4x) and grooved ring 29
Warning! Warning!
Bushing T19 and sleeve T21 must overhang the upper housing edge
by 0.4 r0.1mm. Attach washers 32 accordingly.
x Replace servo valve 33
Warning! Warning!
In case of pressure reducing stations with holding plate T26 (new
version) during assembly the srew T25 must be fixed by a screw
securing means (e.g. Loctite 241).
In case of pressure reducing stations without holding plate T26 (old

version) the exhaust T13 must be tightened with a torque of MA =
1.2+0.2 Nm and a screw 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
Test Setup and Tests of the pressure-reducing station
After the dismantling/mounting of the pressure-reducing station, it is
required to set up the operating pressure of the pressure control
valves again. In order to do so, the grub screw T7 has to be loosened
and the cap T8 has to be screwed from the housing with the exception
of the last five turns.
Set tab P to a pressure of 30 bar. By turning the cap T8 the operating
pressure at the pressure control valve can be adjusted, then tighten
the grub screw T7.
Warning! Warning!
Turn cap T8 only in pressureless state.
Check the 3/2-way valve for correct performance by working it.

Finally the complete pressure-reducing station has to be tested for
tightness.
883 890 035 3 BDL 001 AC (10/06) 43

Spare parts package:

Order number 335 320 003 2
Spare parts
package
Item Description Dimension Qty.
335 320 003 2 1 sealing ring 36 x 42 x 2 1
2 filter 1
3 O-ring 23,3 x 2,4 1
4 sealing ring 22 x 27 x 1,5 1
5 valve 1
6 conical spring 0,8 x 12,7 x 26,5 1
7 circlip 15 x 1 1
8 O-ring 6 x 1,5 1
9 O-ring 5 x 1,2 1
10 O-ring 4 x 1,2 1
11 O-ring 6,75 x 1,78 1
12 circlip 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 8x9x4 1
19 valve ring 1
20 conical spring 1 x 11,2 x 18,1 1
21 O-ring 5,28 x 1,78 1
22 circlip 20 x 1,5 1
23 filter 20 x 2,3 1
24 circlip 8,3 x 0,5 2
25 filter 8x2 2
26 piston cup 3x8x4 1
27 gasket 18 x 3 1
28 sealing ring 4
29 grooved ring 12,8 x 21,2 x 4 1
30 circlip 30 x 1,2 1
31 filter 30 x 2 1
32 washer 13 x 0,2 6
33 servo valve 1
34 O-ring 10 x 1,3 1
35 piston 1
36 O-ring 6x2 1
37 adjusting sleeve 1
38 lubricant 20g
883 890 035 3 BDL 001 AC (10/06) 44

Storage and transportation
During storage and transportation the pressure-reducing station must

in principle be protected against mechanical damage and weather
influences.
General
Contacts with aggressive media must be avoided.
Compressed air ports must be closed in a way to prevent entry of dirt,

humidity and foreign matter.
The ambient 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 storage period must be taken into account for deter-
mining the replacement intervals appropriately.
Transportation
Danger!
In principle the provisions for the prevention of accidents must be
observed. Above all the device must during transportation be secured
against getting out of place resp. falling down.
883 890 035 3 BDL 001 AC (10/06) 45

General
Technical Data
Permissible medium compressed air
inlet pressure max. 30 bar
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 application range 273 K 343 K
Circuit diagram
fig. 7
A
4
2
P P1
14
883 890 035 3 BDL 001 AC (10/06) 46

Dimensional drawing / Version R417000888

fig. 8
threaded tabs: M14 x 1.5; 12 deep
883 890 035 3 BDL 001 AC (10/06) 47

After sales service and adresses
Are there any questions left?

If anything is still not clear after reading these operating instructions,
any please let us know. Your suggestions for improvements are always
welcome.
Questions?
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 Drive & Control Company
Marine Technique
Ulmerstrae 4
D 30880 Laatzen
Tel.: +49 (0) 511 2136 251

Fax.: +49 (0) 511 2136 165
e-mail: marinesales@boschrexroth.de
Internet: http://www.boschrexroth.de
48
Electrical Equipment C5.05.05.70.06.45
RPM Switch Unit
RPM Switch Unit
en / 03.03.2008 FD021336 1/2

c RPMSWITCHUNIT
Equipment list
Unit Description CAT- No. Stock- No. Drawing - No.
A1 Plug in card (without presetting) 263 360 140 9.01.7-91.21.00-16
Plug in card (presetting for engine M20) 193 300 029 9.01.7-91.21.00-16
Plug in card (presetting for engine VM32) 193 466 037 9.01.7-91.21.00-16
A2 Plug in card 263 360 150 9.01.7-91.21.00-17
CD6 / Mischke Seite: 1

Status: 28.10.2004 EG 1.00.7-36.29.00-45_en
Caterpillar : Confidential Green
RPM Switch Unit C5.05.05.75.11.45
Description
RPM Switch Unit
Description
en / 07.04.2008 FD020042 1/10

Description of the RPM Switch Unit
c
1. Technical Data
Operating voltage: 24V DC+30% / -25%
Power draw: 20W
Type of protection: switchboard housing with enclosure from

the front IP54 acc. to DIN 40050
Protection against false polarity: provided
Transient protection: provided
Ambient temperature: 0 ... 70 C
Contact load of output relays:
Plug-in cards A1 and A2 breaking capacity: 50W / 24V DC

continous current: 1A
Plug-in card A2 relay K3 breaking capacity: 50W / 24V DC

100VA / 220V AC
continous current: 1A
Analog outputs for engine

speed range: 0 ... *** rpm
Current output: 4 ... 20mA
Load resistor: - 500V

Voltage output: 0 ... 10V / max. 10mA
Setting range for the speed

switching points: 0 ... 1300rpm
Hysteresis: 20rpm 10%
Input for engine start signal
from the START-stop system 24V DC 20%
*** adjusted in dependence on the engine type
Status: 21.06.02 BG 1.00.7-36.29.00-45_en
c
2. Function of the RPM Swich Unit
The RPM switch unit consists of electronic and electro-mechanical control units which control the
monitoring of the speed limit values depending on sensors with frequency output. Furthermore the
control of the engine speed indicators is carried out via this unit and the engine start stop device
is suppressed until the engine is at a complete standstill.
2.1 Overspeed Protection System
The task of the electric MaK overspeed protection system is to monitor the diesel engine with
regard to its permissible technical maximum speed and to stop the engine immediately if this
speed is exceeded. The complete system for each engine consists of the following input devices:
sensor with frequency output, RPM switch, safety system, alarm system and shutdown solenoid
with pneumatic miniature cylinders on the fuel pumps. Of this equipment the two sensors, the
shutdown solenoid and the miniature cylinders are fitted to the engine.
2.2 Principle
An RPM switch monitors both sensors and if the set speed value is exceeded emits an immedi-
ate shutdown signal to the safety system via a potential-free contact. The safety system stores
the shutdown signal and immediately actuates the shutdown device on the engine. Furthermore
a closed current loop is formed via a potential-free contact which serves for triggering the alarm
system. Both circuits are externally monitored for wire break. The system is self- monitoring and
automatically indicates possible faults to the alarm system. The following faults are recorded
and indicated autonomously.
Failure of 24V DCoperating voltage

Failure of sensor *
Sensor cable broken
* In case of failure of one sensor the overspeed protection system continues to be

operative via the second sensor.
2.3 Functional Check
A functional check of the electronic can be carried out via the test pushbutton of the RPM switch
both with engine stopped or running. There will be no automatic engine shutdown.
A functional check of the mechanical shutdown devices can be carried out by actuating the emer-
gency stop pushbuttons. There will be an automatic engine shutdown.
Status: 21.06.02 BG 1.00.7-36.29.00-45_en
c
3. Plug-in Cards
All of the plug-in cards of the RPM switch unit are of Euro-format 100 x 160mm. The use of code
strips ensures that the individual plug-in cards types cannot be mixed up.
3.1 Plug-in Card A1: 9.01.7-91.21.00-16
Two speed switching points to be set at option.
1. switching point n = 1.15 nominal speed OVERSPEED with 2 potential-free contacts for trig-
gering of the safety and alarm systems.
2. switching point n = nznd (firing speed) in connection with plug-in card A2, relay K3 (2 change-
over contacts) for switching off the electric motor driven prelubrication pump and the cooling
water preheating unit.
2. switching point n = nznd (firing speed) in connection with plug-in card A2, relay K4 (1 change-
over contact) for triggering of the externally installed service hour counter.
3.2 Plug-in Card A2: 9.01.7-91.21.00-17
One speed switching point to be set at nmin (1 change-over contact) for alarm suppression at en-
gine stop.
RPM Switch Setting of Switching Point
Via the potentiometer RPM the speed switching point can be set
to any desired value
RPM
Let the engine run at switching speed and then set the switching
point.
Engine Stand Still Monitoring (M20 only)
In order to avoid mechanical damages to the engine starting unit, the engine start signal from the
start-stop unit is released only after the engine has come to a complete standstill. A starting inter-
lock is indicated via LED on plug-in card A2.
Status: 21.06.02 BG 1.00.7-36.29.00-45_en
c
4. Balancing of RPM Switch and Adjustment of Switching Point
Via potentiometer R28 and R39 the speed switching points can be adjusted V20
R28
to any desired value
R23
- SCALERANGE0 1300rpm CHANNEL I

CHANNEL II
R34
After the adjustment has been carried out, the indicating dials are to be ar- V24
rested via lock. The RPM switch is already balanced at MaKs works. How-
R39
ever, if a readjustment should become necessary nevertheless, balancing is
to be carried out as follows.
4.1 Balancing of Switching Point Range
Adjust the speed potentiometers R28 an 39 precisely to a current engine speed as high as possi-
ble. Then adjust the trimming potentiometers R23 and R34 in clockwise direction until both light
emitting diodes V20 and V24 cease to light. Balance CHANNALS I and II by carefully turning left
on R23 or R34 respectively. In doing so, the light emitting diodes V20 or V24 resp. will light up.
Check the switching point adjustment by changing the engine speed and in case of deviations
repeat the procedure.
Attention:
The switching hysteresis is to be taken into account for adjustment.
4.2 Balancing of the Analogue Outputs 4-20mA and 0-10V
Adjust the output current to 12mA via R63 at engine speed ** or the
output voltage to 5V via R67 respectively.
R67
R63
Attention:
When rebalancing, the scale ranges of the indicators for engine

speed are to be taken into acount.
Scale range of
Engine type engine speed indication Engine speed **
M20 / VM32 0 ... 1200rpm 600rpm

M32 / M453 0 ... 800rpm 400rpm
M43 / VM43 0 ... 600rpm 300rpm
M25 0 ... 1000rpm 500rpm
Status: 21.06.02 BG 1.00.7-36.29.00-45_en
c RPMSWITCHUNIT
Equipment list
Unit Description CAT- No. Stock- No. Drawing - No.
A1 Plug in card (without presetting) 263 360 140 9.01.7-91.21.00-16
A2 Plug in card 263 360 150 9.01.7-91.21.00-17
CD6 / Mischke Seite: 1

Status: 28.10.2004 EG 1.00.7-36.29.00-45_en
Caterpillar : Confidential Green
Turbocharger C5.05.06.10.21.39
VM43
Turbocharger
en / 19.10.2006 FD032686 1/133

Turbocharging
Operation Manual
TPL73-A30
ABB Turbo Systems Ltd

Turbocharger
Type TPL73-A30
n Mmax Mmax
1/s C
n Bmax Bmax
kg
Application according to
the Operation Manual
made in Switzerland
HZTL2481 German

Operating condition and replacement intervals
The operational limits for the turbocharger nBmax, tBmax, nMmax, tMmax, inspection- and replacement intervals for the compon-
ents concerned on the rating plate are valid for the operational mode and compressor inlet condition, which has been agreed upon
between the engine builder and ABB.
Note: Replacement intervals of components depends on the load profile, turbine inlet temperature, suction air temperature and
turbocharger speed. In case the operation conditions differs significantly from what is considered to be normal for the cur-
rent application, it is recommended to contact ABB for a re-calculation of replacement intervals. Frequent load alterations,
high temperatures and high speed lower the life of components.
Unless otherwise agreed, the application limits nMmax, tMmax are valid for the test operation for a limited time.
We herewith confirm that this Operation Manual has been drawn up orientated towards the Product Liability Law 1/1/90 as well as to
the European Machinery Directives.
We reserve all rights in this document and in the information contained herein.
Reproduction, use or disclosure to third parties without express authority by ABB Turbo Systems Ltd is strictly forbidden.
Copyright by ABB TURBO SYSTEMS Ltd 2004

Design and specifications are subject to change without notice.
Printed on naturally white paper, bleached free from chlorine and environmentally acceptable.
The CD is made of polycarbonate and contains in addition aluminium, lacquer, dye stuffs and materials of the adhesive label. The CD-cover is made of
recycled cardboard.
These materials may be disposed with the domestic wastes or at a specialised collecting centre.

ABB Turbo Systems AG
Bruggerstrasse 71a
CH-5401 Baden
Switzerland
!
"#$ Seite 3
Vorbemerkungen 0

Sicherheits- und Gefahrenhinweise 1

Inbetriebnehmen 2

Betrieb und Unterhalt 3

Beheben von Strungen 4

Demontage und Montage 5

Ausserbetriebnehmen 6

Service - Stellen Verzeichnis 7
ABB Turbo Systems Ltd %

&'&
ABB
0
Turbolader Betriebshandbuch TPL Kapitel 0
Vorbemerkungen Seite 1
0
Vorbemerkungen
Inhalt Seite
1
Vorwort ........................................................................................................................................ 3
2
Funktionsbeschreibung ............................................................................................................ 5
3
Bestimmungsgemsse Verwendung ....................................................................................... 6
4
Organisatorische Massnahmen .............................................................................................. 7
5
Originalteile und Sicherheit ..................................................................................................... 7
6
Befhigung des Personals ....................................................................................................... 8
7
Kundendienst ............................................................................................................................. 8
8
Ausfhrungsvarianten ............................................................................................................... 8
9
Lagern neuer Turbolader ......................................................................................................... 9
10
Abkrzungen .............................................................................................................................. 9
11
Leistungsschild Turbolader ................................................................................................... 10
Volume: 11 Seiten
Edition: 03 / 2002
HZTL 10457_DE
-.- ABB
Kapitel 0 Turbolader Betriebshandbuch TPL
Seite 2 Vorbemerkungen
10457_DE
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1
Vorwort
Dieses Betriebshandbuch hilft Ihnen, den von ABB Turbo Systems AG gelieferten Turbolader
besser kennenzulernen und seine bestimmungsgemsse Einsatzmglichkeit wirkungsvoll zu
nutzen.
Dieses Betriebshandbuch gibt Ihnen wichtige Hinweise, damit Sie diesen Turbolader sicher,
sachgerecht und wirtschaftlich betreiben knnen. Sie finden hilfreiche Informationen, mit denen
Sie Gefahren frhzeitig erkennen und vermeiden knnen, Reparaturkosten und Ausfallzeiten
vermindern sowie Zuverlssigkeit und Lebensdauer des Turboladers erhhen knnen.
Dieses Betriebshandbuch ergnzt und erweitert bereits bestehende nationale Vorschriften zum
Unfallschutz und zur Unfallverhtung.
Dieses Betriebshandbuch muss stndig am Einsatzort des Turboladers verfgbar sein.
Dieses Betriebshandbuch ist unbedingt vor Arbeitsbeginn von allen Personen zu lesen, die mit
dem oder am Turbolader arbeiten.
Auch Personal, das nur gelegentlich (z.B. bei Montage und Wartung) an der Maschine ttig ist,
muss das Betriebshandbuch gelesen und verstanden haben.
Die Anweisungen sind unbedingt zu befolgen.
Das gilt besonders fr die allgemeinen und speziellen Sicherheitshinweise vor und in den
entsprechenden Kapiteln.
Fragen Sie in Zweifelsfllen den fr Ihren Bereich zustndigen Beauftragten fr Sicherheit und
Unfallschutz.
10457_DE
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1 2 3 4 5 6
10
11
12
13
Fig. 0-1
Schnittdarstellung Turbolader
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2
Funktionsbeschreibung
Der Turbolader besteht aus zwei Strmungsmaschinen, einer Turbine und einem Verdichter,
die auf einer gemeinsamen Welle angebracht sind.
Die Abgase des Diesel- oder Gasmotores strmen durch das Gaseintrittsgehuse (7) und den
Dsenring (8) auf das Turbinenrad.
Das Turbinenrad (9) nutzt die im Abgas enthaltene Energie zum Antrieb des Verdichterrades
(12), wobei durch den Verdichter Frischluft angesaugt und vorverdichtete Luft in die Zylinder
gedrckt wird.
Die Abgase gelangen durch die am Gasaustrittsgehuse (6) angeschlossene Abgasleitung ins
Freie.
Der Turbolader ist gasdicht.
Die Luft, die fr den Betrieb des Diesel- oder Gasmotors bentigt und im Turbolader verdichtet
wird, gelangt durch den Saugstutzen oder den Schalldmpfer (1) in das Verdichterrad (12). Sie
durchstrmt den Diffusor (11) und verlsst den Turbolader durch den Druckstutzen am
Luftaustrittsgehuse (13).
Der Rotor luft in zwei radialen Gleitlagern (2/5) welche sich in der Lagerbchse (4) zwischen
Verdichter und Turbine befinden. Das axiale Schublager (3) befindet sich auf der Verdichter-
seite.
Die Gleitlager sind an einem zentralen Schmierlkanal angeschlossen, der vom Schmierl-
kreislauf des Motors gespeist wird. Der laustritt liegt immer an der tiefsten Stelle des Lager-
gehuses (10).
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3
Bestimmungsgemsse
Verwendung
Dieser von ABB Turbo Systems gelieferte Turbolader ist ausschliesslich fr den Einsatz an
Dieselmotoren entwickelt worden, um die fr den Betrieb des Dieselmotors bentigte Luft-
menge und den notwendigen Ladedruck zu erzeugen.
Jeder darber hinausgehende Gebrauch gilt als Sonderanwendung, die ABB Turbo Systems
abklren muss. Fr weitergehende Anwendungen haftet der Hersteller nicht.
Dieser Turbolader ist nach dem Stand der Technik und nach den anerkannten sicher-
heitstechnischen Regeln gebaut und betriebssicher.
Vom Turbolader knnen dennoch Gefahren fr Leib und Leben des Benutzers oder Dritter
ausgehen oder der Turbolader und andere Sachwerte beschdigt werden, wenn er nicht von
geschultem Personal oder nicht sach- und bestimmungsgemss eingesetzt wird.
Bestimmungsgemsses Verwenden des Turboladers schliesst auch das Einhalten der Be-
triebs-, Wartungs- und Instandhaltungsbedingungen ein, die vom Hersteller vorgeschrieben sind.
Der Turbolader darf nur in technisch einwandfreiem Zustand, seiner Bestimmung entsprechend
und unter Beachtung des Betriebshandbuches bedient und benutzt werden.
Strungen, die die Sicherheit beeintrchtigen knnen, sind umgehend zu beseitigen.
Eigenmchtige Vernderungen am Turbolader schliessen eine Haftung des Herstellers fr dar-

aus entstehende Schden aus.
Der Turbolader ist fr den Dieselmotor, einschliesslich Drehzahl und Leistung, spezifiziert. Wird
er anderweitig verwendet, lehnt ABB Turbo Systems alle Garantieansprche ab.
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4
Organisatorische
Massnahmen
Ergnzend zum Betriebshandbuch sind zustzlich die allgemeinen, gesetzlichen Vorschriften

zur Unfallverhtung und zum Umweltschutz im Verwenderland zu beachten.
Das gilt auch fr das Bereitstellen und Tragen von persnlichen Schutzausrstungen.
Unter Beachtung des Betriebshandbuches ist der sicherheits- und gefahrenbewusste Umgang
des Personals an und mit dem Turbolader regelmssig zu berprfen.
Der Turbolader ist bei sicherheitsrelevanten Vernderungen oder bei entsprechendem Betriebs-
verhalten sofort stillzusetzen. Die Strung ist der dafr zustndigen Person oder Stelle zu
melden.
Vernderungen und An- und Umbauten am Turbolader, die die Sicherheit beintrchtigen knn-
ten, mssen vorher von ABB Turbo Systems genehmigt werden.
5
Originalteile und Sicherheit
Originalteile und Zubehr sind speziell fr den von ABB Turbo Systems AG gelieferten Turbo-
lader konzipiert.
Wir machen ausdrcklich darauf aufmerksam, dass nicht von uns gelieferte Originalteile und
Zubehr auch nicht von uns geprft und freigegeben sind.
Der Einbau und / oder die Verwendung solcher Produkte kann daher die konstruktiv vorgegebe-
nen Eigenschaften des Turboladers negativ verndern.
Dadurch kann die aktive und / oder passive Sicherheit des Turboladers nachteilig beeinflusst
werden.
Fr Schden, die durch das Verwenden von Nicht-Originalteilen und entsprechendem Zubehr
entstehen, schliesst ABB Turbo Systems jede Haftung aus.
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6
Befhigung des Personals
Der Turbolader darf nur von ausgebildetem und autorisiertem Personal bedient und gewartet
werden.
Arbeiten an mechanischen Bauteilen, wie Lagern oder Rotoren drfen nur von ausgebildeten
Monteuren von einer offiziellen Service-Stelle der ABB Turbo Systems AG ausgefhrt werden!
Es ist sicherzustellen, dass nur dazu beauftragtes Personal am Turbolader ttig wird.
7
Kundendienst
Fr Ersatzteilbestellungen, technische Rckfragen und Wartungsarbeiten finden Sie am Ende

von diesem Handbuch (s. Kap. 7) eine Liste mit einer aktualisierten, weltweiten bersicht von
Service-Stationen der ABB Turbo Systems AG.
8
Ausfhrungsvarianten
Dieses Betriebshandbuch ist gltig fr unterschiedliche Ausfhrungsvarianten von Turboladern.
Deshalb kann es vorkommen, dass auch Teile aufgelistet sind, die beim gelieferten Turbolader
nicht vorhanden sind.
Unsere Vertretungen und Service-Stellen (siehe Service-Stellen Liste im Kap. 7) erteilen Aus-
kunft, falls in der vorliegenden allgemeinen Vorschrift besondere Flle nicht bercksichtigt sein
sollten.
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9
Lagern neuer Turbolader
Von ABB Turbo Systems neu gelieferte Turbolader sind ab Lieferdatum 6 Monate lang, ohne
zustzliche Konser-vierungsmassnahmen, an trockenen Orten mit einer durchschnittlichen Luft-
feuchtigkeit von 40 bis 70% lagerbar.
Nach Ablauf von 6 Monaten und dann alle 6 Monate, die Oberflche (Isolation entfernen) und alle
zugnglichen Rume mit Korrosionsschutzl einsprhen.
10
Abkrzungen
Folgende Abkrzungen werden verwendet:
Abschn. Abschnitt
bzw. beziehungsweise
Fig. Abbildung
Kap. Kapitel
kpl. komplett
Nr. Nummer
s. siehe
Tab. Tabelle
Temp. Temperatur
TL Turbolader
TS Turbinenseite
.d.M. ber dem Meer
VS Verdichterseite
zB. zum Beispiel
- Arbeitsschritte / Aufzhlungen
+ zus. Arbeitsschritte bei Optionen
Hinweise fr den Zusammenbau
Conformit Europenne
10457_DE
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11
Leistungsschild Turbolader

ABB Turbocharger
Type HT
n Mmax 1 1 t Mmax 1
HZTL 428 765 P.
s
n Bmax 2 t Bmax 2 C
6
7 8 kg 3 4 5
Application according to
the Operation Manual
made in Switzerland
Einsatzgrenzen:
1 n Mmax, t Mmax: Turbolader - Einsatzgrenzen
bei Motorberlast (110%).
Nur im Prfstandbetrieb, wenn nicht anders mit dem Motorenbauer ver-
einbart.
2 n Bmax, t Bmax: Turbolader - Einsatzgrenzen

im Betrieb.
n = Turbolader - Drehzahl
t = Abgastemperatur vor Turbine
Kontrollintervalle und Wechsel-zeiten von Turboladerkomponenten:

3 Kontroll-Intervalle der Gleitlager in 1000 h
4
Wechselzeit des Verdichters in 1000 h
Ohne Angaben: 100'000 h
5 Wechselzeit der Turbine in 1000 h

Ohne Angaben: 100'000 h
Weitere Angaben:
6 Kunden Part-Nummer
7 Feld fr die Sonderausfhrungsbezeichnung
8 Gewicht des Turboladers in kg
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Hinweis Fr die auf dem Leistungsschild angegebenen Werte bezglich Einsatzgrenzen,

Kontrollintervalle und Wechselzeiten gelten die mit dem Motorenbauer vereinbarten
Bedingungen.
Vorsicht ! Der Turbolader darf nur bis zu den auf dem Leistungsschild angegebenen Einsatz-
grenzen nBmax, tBmax betrieben werden. Diese sind mit dem Motorenbauer anwen-
dungsspezifisch festgelegt.
Einsatzgrenzen nMmax, tMmax sind, wenn nicht anders vereinbart, nur im Prfstand-
betrieb zulssig.
Die Kontrollintervalle und Wechselzeiten der angegebenen Turboladerkomponenten

sind unbedingt einzuhalten!
Turboladerkomponenten mit abgelaufener Betriebsdauer drfen unter keinen Um-
stnden weiter verwendet werden!
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1
Turbolader Betriebshandbuch Kapitel 1
Sicherheits- und Gefahrenhinweise Seite 1
1
Sicherheits- und
Gefahrenhinweise
Inhalt Seite
1
Grundlegende Sicherheitshinweise ......................................................................................... 3
2
Spezielle Sicherheitshinweise ..................................................................................................4
2.1
Sicherheit beim Anschliessen ............................................................................................. 4
2.2
Sicherheit beim Inbetriebnehmen und beim Betrieb ........................................................... 5
2.3
Sicherheit beim Reinigen ................................................................................................... 5
2.4
Sicherheit bei Demontage und Montage ........................................................................... 6
2.5
Sicherheit bei Ausserbetriebnahme .................................................................................... 6
3
Gefahrenhinweise und Gefahrenschutz ................................................................................. 7
3.1
Mechanische Einflsse ....................................................................................................... 7
3.2
Werk- und Arbeitsstoffe ..................................................................................................... 8
3.3
Lrm .................................................................................................................................. 10
Volume: 10 Seiten
Edition: 03 / 2002
HZTL 10451_DE
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Kapitel 1 Turbolader Betriebshandbuch
Seite 2 Sicherheits- und Gefahrenhinweise
Notizen
10451_DE
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1
Grundlegende Sicherheitshinweise
Folgende Symbole und Benennungen werden in diesem Betriebshandbuch fr Sicherheitshin-

weise verwendet:
Warnung ! Ernsthafte Personenschden oder tdliche Unflle knnen die Folge sein, wenn Arbeits-
und Bedienungsanweisungen mit diesem Symbol nicht oder ungenau befolgt werden.
Warnhinweise mssen strengstens eingehalten werden.
Vorsicht ! Folgenschwere Maschinen- oder Sachschden knnen die Folge sein, wenn Arbeits-
und Bedienungsanweisungen mit diesem Symbol nicht oder ungenau befolgt werden.
Vorsichtshinweise sind genauestens einzuhalten.
Hinweis Wirkungsvolleres und einfacheres Arbeiten ist die Folge, wenn Arbeits- und Bedienungs-
anweisungen mit diesem Symbol befolgt werden.
Hinweise erleichtern Ihre Arbeit.

10451_DE
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ABB
2
Spezielle Sicherheitshinweise
Die hier aufgefhrten Hinweise dienen Ihrer Sicherheit und verhelfen Ihnen zu einem sicheren
Umgang mit dem Turbolader und mit seinen Betriebsmitteln.
Befolgen Sie unbedingt diese Sicherheitshinweise beim Betrieb mit und bei Arbeiten am Turbo-
lader.
- Nur in physisch und psychisch stabiler Verfassung am Turbolader ttig werden.
- Schutzkleidung (Helm, Gehrschutz, Schutzbrille, Schutzanzug, Handschuhe, Sicherheits-

schuhe) tragen.
- Einzelteile und grssere Baugruppen sorgfltig an geeigneten und technisch einwandfreien

Hebezeugen/ Lastaufnahmemitteln mit ausreichender Tragkraft befestigen.
- Sich nicht unter schwebenden Lasten aufhalten.
- Bei Montagearbeiten ber Krperhhe die dafr vorgesehenen Aufstiegshilfen und Arbeits-
bhnen verwenden.
- Maschinenteile nicht als Aufstiegshilfen benutzen.
- Bei Schweissarbeiten oberhalb des Turboladers unbedingt den Luftfilter abdecken, damit die
Filtermatte nicht beschdigt wird.
2.1
Sicherheit beim Anschliessen
- Nur die Anschlsse fertigstellen, fr die Sie ausgebildet sind.
10451_DE
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2.2
Sicherheit beim Inbetriebnehmen
und beim Betrieb
- Vor Arbeitsbeginn Sichtprfung der Arbeitsumgebung machen.
- Hindernisse und herumliegende Gegenstnde der Arbeitsumgebung beseitigen.
- Vor dem Inbetriebnehmen den Turbolader auf Beschdigungen und Lecks kontrollieren.
- Jede Arbeitsweise unterlassen, die die Sicherheit am Turbolader beeintrchtigen knnte.
- Turbolader ca. alle 12 Betriebsstunden bzw. mindestens einmal pro Tag auf ussere er-
kennbare Schden und Mngel prfen.
- Schden und Vernderungen des Betriebsverhaltens sofort der zustndigen Person/ Stelle
melden.
- Im Schadensfall Turbolader sofort stillsetzen und gegen unbeabsichtigtes und unbefugtes

Benutzen sichern.
2.3
Sicherheit beim Reinigen
- Vor dem Reinigen den Boden gegen unbeabsichtigt eindringendes l und Betriebsmittel
abdichten.
- Schutzkleidung (l- und benzinfeste Handschuhe, Schutzanzug, Augenschutz, Knieschutz,

Fussschutz) tragen.
- Mit Betriebs- und Reinigungsmitteln usserst vorsichtig umgehen.
- Beim Umgang mit Lsungsmitteln unbedingt Schutzkleidung tragen. Hautkontakt, Einatmen

und Durchnssen der Kleidung vermeiden.
- Nach der Reinigung Elektrokabel auf Scheuerstellen und Beschdigungen berprfen.

10451_DE
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2.4
Sicherheit bei Demontage und Montage
- Vorgeschriebene Einstell-, Wartungs- und Inspektionsarbeiten und -intervalle einhalten.
- Bedienpersonal vor Beginn ber Sonder- und Instandsetzungsarbeiten informieren.
- Absorbentien bereitstellen zum Aufnehmen versehentlich auslaufender Betriebsmittel.
- Fr sicheres und umweltschonendes Ablassen, Auffangen und Entsorgen von Betriebs- und
Hilfsstoffen sorgen.
- Montage- Demontagearbeiten nur durch geschultes Personal durchfhren lassen.

Arbeiten an mechanischen Bauteilen, wie Lagern oder Rotoren drfen nur von ausgebilde-
ten Monteuren von einer offiziellen Service-Stelle der ABB Turbo Systems AG ausgefhrt
werden!
2.5
Sicherheit bei Ausserbetriebnahme
- Rotor gegen Drehen sichern.
- Turbolader vor dem Konservieren reinigen.
- Beim Konservieren des Turboladers Schutzkleidung tragen.
- Arbeitsumgebung sauber halten und von l und Betriebsmitteln reinigen.
- Am Boden liegende Hindernisse entfernen.
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3
Gefahrenhinweise und Gefahrenschutz
Beim Betrieb mit und bei Arbeiten am Turbolader knnen Gefahren ausgehen:
- vom Turbolader und seinem Zubehr
- von den dabei verwendeten Betriebsmitteln
- vom ungengenden Beachten von Sicherheitshinweisen
- vom ungengenden Ausfhren von Wartungs- und Prfarbeiten.
3.1
Mechanische Einflsse
Krperschden
Warnung ! Bewusstlosigkeit und Verletzungen durch:
Quetschen, Scheren, Schneiden, Wickeln, Zertrmmern
Einziehen, Stossen, Stechen, Reiben
Herausspritzen von Flssigkeiten unter Hochdruck und hoher Temperatur
Rutschen, Stolpern, Strzen.
Ursachen
- scharfe Kanten, spitze Teile

- Quetsch-, Scher- und Wickelbereiche
- Heraus- / Wegschleudern von Werkteilen
- Bruch oder Bersten von Teilen wegen berbeanspruchung.
- elastische Elemente (Federn), Flssigkeiten und Gase unter Druck oder im Vakuum
- rutschige, lverschmierte Arbeitsumgebung, Bodenhindernisse.

10451_DE
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ABB
Schutzmglichkeiten
- Leder-Schutzhandschuhe tragen.
- Eng anliegende Schutzkleidung tragen.
- Lngere Bart- und Kopfhaare zusammenbinden, Haarschutz tragen.
- Gesichts- und Augenschutz tragen.
- Sicherheitsschuhe tragen.
- Boden, Gerte und Turbolader sauberhalten.
- labsorbentien bereithalten und lauffangwannen bereitstellen oder aufstellen.
- Leckagen beseitigen.
3.2
Werk- und Arbeitsstoffe
Das sind chemische Substanzen wie le, Fette, Khlflssigkeit, Reinigungs- und Lsungsmit-
tel, Suren und andere Gefahrenstoffe.
Krper- und Sachschden
Warnung ! Allergien, Hautschden, Bewusstlosigkeit, Vergiftung oder Benommenheit nach Ein-

atmen.
Verletzungen durch Verbrhen und Verbrennen der Haut.
Vertzungen durch Dmpfe oder Sure- und Laugenkontakt.
Vorsicht ! Umweltverschmutzung und Schdigung durch Auslaufen und Eindringen von Werk-
und Arbeitsstoffen in Boden und Gewsser.
10451_DE
ABB -A-
Ursachen
- Einatmen von schdlichen Gasen, Nebeln und Dmpfen
- Hautkontakt mit schdlichen Flssigkeiten
- Mit Gefahrenstoffen benetzte oder durchtrnkte Arbeitskleidung
- Auslaufen und Umkippen von Behltern mit Arbeitsstoffen
- Auslaufen durch Leckagen
- Nicht gasdichte und nicht der Gefahrenstoffverordnung entsprechende Behlter und Sammel-
container
- Brennende Zigaretten oder offenes Feuer beim Umgang mit Arbeitsstoffen
Schutzmglichkeiten
- Hchste Vorsicht beim Umgang mit Arbeits- und Werkstoffen.
- Unbedingt Schutzkleidung tragen (lfeste, lsungsmittelfeste und surefeste Handschuhe,

dichte Schutzanzge, Atemschutz).
- Hautkontakt und Einatmen unbedingt vermeiden.
- Fr ausreichende Be- und Entlftung des Arbeitsraumes sorgen.
- Gefahrenhinweise auf den Behltern der Werks- und Arbeitsstoffe beachten.
- Gefahrenstoffbehlter nach Gebrauch sofort dicht verschliessen.
- Alt-Betriebsmittel entsprechend den gesetzlichen Vorschriften sicher auffangen, in geeigne-

ten, vorgeschriebenen Behltern getrennnt aufbewahren und als Sondermll umweltgerecht
entsorgen.
- Behlter mit Neu- / Alt-Betriebsmitteln sicher und dicht verschliessen.
- Bei Leckagen oder nach Verschtten sofort geeignete Absorbentien ausstreuen und diese
umweltgerecht als Sondermll entsorgen.

10451_DE
-A-
ABB
3.3
Lrm
Krperschden
Warnung ! Hrverlust, Taubheit, Schwerhrigkeit
Gesundheitsstrungen wie Verlust des Gleichgewichts, des Bewusstseins und

Herz- / Kreislaufstrungen.
Ursachen
- Maschinengeruschpegel ber 90 dB (A).
Schutzmglichkeiten
- Gehrschutz tragen.
10451_DE
ABB -A-
2
Inbetriebnehmen Seite 1
2
Inbetriebnehmen
Inhalt Seite
1
lversorgung...............................................................................................................................3
1.1
lfiltrierung ..........................................................................................................................3
1.2
ldruck / ltemperatur ........................................................................................................3
2
Prfarbeiten bei Inbetriebnahme ...............................................................................................5
2.1
bersicht Prfarbeiten .........................................................................................................5
2.2
Prfen vor Inbetriebnahme ..................................................................................................8
2.3
Prfen nach Inbetriebnahme ...............................................................................................8
2.4
Prfen nach 100 Betriebsstunden .......................................................................................9
3
Inbetriebnahme nach Stillegung ...............................................................................................9
Volume: 9 Seiten
Edition: 03 / 2002
HZTL 10458_DE
-.- ABB
Seite 2 Inbetriebnehmen
10458_DE
ABB -.-
1
lversorgung
Eine bei allen vorkommenden Betriebszustnden funktionierende und sorgfltig ausgefhrte
lversorgung ist eine wichtige Voraussetzung fr einen strungsfreien Betrieb der Turbolader.
Die Schmierung des TPL-Turboladers erfolgt in der Regel mit l aus dem Motorlkreislauf.
Hinweis Beachten Sie die Vorschriften des Motorenherstellers zur Schmierlauswahl und
lwechsel-Intervallen.
1.1
lfiltrierung
TPL 61 65
Fr TPL Turbolader der Grssen TPL 61 TPL 65 ist eine Schmierlfiltrierung mit einer
Filtermaschenweite 0.034 mm erforderlich.
TPL 69 85
Eine Schmierlfiltrierung mit einer Filtermaschenweite 0.050 mm ist fr TPL 69 TPL 85
Turbolader ausreichend. Bei einer feineren Filtrierung (Empfehlung: Partikel grsser 0.034 mm
abscheiden), kann mit einer Erhhung der Lagerlebensdauer gerechnet werden.
Diese Filtrierung kann durch den Einsatz eines zustzlichen, sich selbstreinigenden Feinfilters
erreicht werden.
Hinweis Beachten Sie die Vorschriften des Motorenherstellers.
1.2
ldruck / ltemperatur
Der ldruck vor den Lagern (Messstelle im Blindanschluss) muss fr einen strungsfreien
Betrieb genau eingehalten werden.
Hinweis Beachten Sie die Vorschriften des Motorenherstellers.
10458_DE
-.- ABB
Notizen
10458_DE
ABB -.-
2
Prfarbeiten bei Inbetriebnahme
Diese Prfarbeiten sind vorbeugende Sichtkontrollen, berwachungs- und Messarbeiten, die

die Funktionsfhigkeit des Turboladers sicherstellen. Sie helfen, Abweichungen vor und bei
Inbetriebnahme zu erkennen und dadurch Maschinenschden frhzeitig zu verhindern.
- In den unten angegebenen Zeitabstnden sind an den aufgelisteten Prfstellen Kontroll- und
Messarbeiten durchzufhren.
- Vor und bei allen Prfarbeiten sind die Sicherheitshinweise in Kap. 1 zu beachten.
2.1
bersicht Prfarbeiten
Prfsymbole und -zeiten
Prfort
Prfstelle
(in bersicht sichtbar)
Prfstelle
(in bersicht verdeckt)
Prfen
Messwerte erfassen
Kurzbezeichnung der Prfzeitpunkte
vor Inbetr. vor Inbetriebnahme
nach Inbetr. nach Inbetriebnahme
10458_DE
-.- ABB
vor Inbetr.
nach Inbetr.
Fig. 2-1
10458_DE
ABB -.-
Intervall Prf-, Mess-, Einstell-

Pos. Prfstelle siehe
Prfzeit arbeiten
Manometer Handbuch
- ldruck prfen
vor Inbetrieb- lleitung Motorenbauer
nahme
Luftfiltermatte - auf Beschdigung prfen Kap. 3
Gas-, Luft- und

- Dichtigkeit prfen Abschn. 2.3
lleitungen
Laderdrehzahl - messen Kap. 3

nach Inbetrieb-
nahme
Ladedruck - messen Kap. 3
- vor/nach Turbine, Verdichter und l-

Temperaturen zufuhr bei verschiedenen Motor- Kap. 3
leistungen messen
10458_DE
-.- ABB
2.2
Prfen vor
Inbetriebnahme
Vorsicht ! Vor der ersten Inbetriebnahme sowie nach jeder Revision des Schmiersystems wird
dringend empfohlen, mit Bypassleitung das komplette Schmiersystem mit warmem
l grndlich durchzusplen.
Beim Einfahren des Motors sowie nach jeder Revision des Schmiersystems emp-
fehlen wir dringend einen Einfahrfilter zu benutzen.
- Die lfilter mssen vor Inbetriebnahme auf Sauberkeit berprft werden.
- berprfen des ldruckes in den lzufuhrleitungen.
- Die berwachungseinrichtungen sind auf Funktion zu prfen.
2.3
Prfen nach
Inbetriebnahme
- Nach dem Anlassen des Motors alle Gas-, Luft- und lleitungen auf Dichtheit prfen.
- Drehzahl, ldruck, Ladedruck und Temperaturen vor und nach Turbine und Verdichter bei
verschiedenen Motorleistungen messen.
- Messwerte mit den Werten des Abnahmeprotokolls vergleichen und dabei unterschiedliche
Betriebsbedingungen bercksichtigen.
Vorsicht ! Vor dem Abstellen, Motor ca. 3 Minuten im Leerlauf weiterlaufen lassen, damit die
Wrme in den Lagern vom weiterzirkulierenden Schmierl abgefhrt werden kann.
10458_DE
ABB -.-
2.4
Prfen nach
100 Betriebsstunden
Nach den ersten 100 Betriebsstunden Schmierlfilter reinigen oder wechseln (s. Kap. 3).
3
Inbetriebnahme
nach Stillegung
- Falls vorhanden, Blindflansch zwischen Luftaustrittsgehuse und Ladeluftleitung entfernen.
- Motorenseitige lzirkulation in Betrieb nehmen.
10458_DE
-.- ABB
3
Betrieb und Unterhalt Seite 1
3
Betrieb und
Unterhalt
Inhalt Seite
1
Prfarbeiten .................................................................................................................................3
1.1
bersicht Prfarbeiten .........................................................................................................3
1.2
Prfen alle 25 bis 50 Stunden..............................................................................................6
1.3
Prfen nach Angaben des Motorenbauers ..........................................................................6
1.4
Prfen alle 8'000 - 12'000 Stunden......................................................................................6
1.5
Eintrge in das Maschinentagebuch....................................................................................7
2
berwachung ..............................................................................................................................9
2.1
Drehzahlmessung ................................................................................................................9
2.2
U - Manometer TPL 73 - 85 ..............................................................................................10
2.3
Pumpen des Turboladers ..................................................................................................11
2.4
Streifen der rotierenden Teile ............................................................................................11
Volume: 32 Seiten
Edition: 02 / 2003
HZTL 10459_DE
ABB Turbo Systems Ltd ABB
-B-
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4
Beheben von Strungen Seite 1
4
Beheben von Strungen
Inhalt Seite
1
Strungen, Ursachen, Abhilfe ....................................................................................................3
Volume: 4 Seiten
Edition: 06 / 2002
HZTL 10454_DE
-.- ABB
Seite 2 Beheben von Strungen
10454_DE
ABB -.-
Beheben von Strungen Seite 3
1
Strungen, Ursachen, Abhilfe
Strung Ort Ursachen Abhilfe siehe

- reparieren oder mit Motoren-
Motor - Strungen im Einspritzsystem
hersteller Kontakt aufnehmen
- Luftmangel, z.B. Luftfilter durch - reinigen Kap. 3
Schmutz verstopft
- Verdichter / Turbine verschmutzt - reinigen Kap. 3

Turbolader
- Abgasgegendruck zu hoch - Boiler oder Abgasschalldmpfer
Abgastemperatur
reinigen oder reparieren
zu hoch, dabei
Motorleistung und
- Turbine beschdigt oder erodiert - Service-Stelle anrufen Kap. 7
-drehzahl
unverndert
- Khler verschmutzt - reinigen
- Khlwassermenge zu gering - auffllen
Ladeluft-
- Khlwassereintrittstemperatur zu - Khlsystem kontrollieren/reinigen
khler
hoch
- Entlftung nicht ausreichend - besser entlften
- Luftreceiver undicht - reparieren
- Gasleitung zwischen Motor und - reparieren

Motor
Turbine undicht
- Einspritzung verstellt - richtig einstellen

- Manometeranzeige fehlerhaft - Manometer ersetzen
Ladeluftdruck zu
niedrig, dabei
- Zuleitung zum Manometer - Leck reparieren
Motorleistung und
undicht
-drehzahl
unverndert;
- Luftfilter verschmutzt, deshalb - reinigen Kap. 3
Ansaugbedingung
Druckabfall zu gross
normal Turbolader
- Verdichter / Turbine verschmutzt - reinigen Kap. 3
- Verdichter / Turbine beschdigt - Service-Stelle anrufen Kap. 7
- Abgasgegendruck zu gross - Boiler oder Abgasschalldmpfer

reinigen
10454_DE
-.- ABB
Seite 4 Beheben von Strungen
Strung Ort Ursachen Abhilfe siehe

- Strungen im Einspritzsystem - richtig einstellen
Ladeluftdruck zu hoch,
dabei Motorleistung und
Motor - Motorleistung hher als vermutet - Motorleistung
-Drehzahl unverndert;
kontrollieren
Ansaugbedingung
- Einspritzung verstellt - richtig einstellen
normal
Turbolader - Manometeranzeige fehlerhaft - Manometer ersetzen
- Rotorunwucht wegen starker - Service-Stelle anrufen Kap. 7
Verdichter/Turbinenverschmutzung
Vibrationen Turbolader - Turbine oder Verdichter beschdigt - Service-Stelle anrufen Kap. 7
- Lager defekt - Service-Stelle anrufen Kap. 7
- Lager beschdigt - Service-Stelle anrufen Kap. 7
Auslaufgerusche - Rotor streift - Service-Stelle anrufen Kap. 7

Auslaufzeit Turbolader
zu kurz - Turbolader verschmutzt - reinigen Kap. 3
Anlauf zgernd
- Fremdkrper im Turbolader - Service-Stelle anrufen Kap. 7
- lfilter stark verschmutzt - reinigen
- lpumpe im Schmiersystem defekt - kontrollieren

Schmierldruck
Turbolader
zu tief - Axialspiel des Rotors zu gross - Service-Stelle anrufen Kap. 7
- Manometer zeigt falsch an - Manometer ersetzen
- Notltank ausser Betrieb

Leckage Notltank 1) - Undichtheit Kap. 2
nehmen
- Durchfluwiderstand erhht, weil:
- Ladeluftkhler oder - reinigen Kap. 3

Schalldmpfer verschmutzt
Turbolader
- starke Schmutzablagerung in der - reinigen Kap. 3
Stndiges Pumpen des Turbine
Turboladers
- Abgasdruck nach Turbine erhht, - reinigen
weil Boiler oder Abgasschall-
Motor dmpfer verschmutzt
- Fanggitter verschmutzt - reinigen

Servicestelle anrufen, wenn die Ursache des Pumpens nicht gefunden wird
1) nur TPL 73-B.. 85-B..
10454_DE
ABB -.-
5
Demontage und Montage Seite 1
5
Demontage und Montage
Inhalt Seite
1
Gewichte ..................................................................................................................................... 3
2
Turbolader abbauen und anbauen ........................................................................................... 5
3
Turbolader demontieren und montieren .................................................................................. 7
3.1
Axialspiel ............................................................................................................................. 7
3.2
Rotorblock ausbauen .......................................................................................................... 9
3.3
Diffusor und Dsenring ausbauen .................................................................................... 13
3.4
Rotorblock einbauen ......................................................................................................... 15
3.5
Turbinenseitige Demontage /Montage des Dsenringes ................................................. 17
4
Tabelle der Anziehmomente ................................................................................................... 19
5
Ersatz- und Reserveteile ......................................................................................................... 20
6
Werkzeuge ................................................................................................................................ 23
6.1
TPL 69 -A.. ........................................................................................................................ 23
6.2
TPL 73 -A.. 85 -A.. Rotor mit Schraubverbindung ......................................................... 25
6.3
TPL 73 -A.. 85 -A.. Rotor mit Polygonverbindung ......................................................... 27
7
Verzeichnis der Teilenummern ............................................................................................... 31
Volume: Seiten 31
Edition: 02 / 2003
HZTL 10460_DE
-C-
ABB
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7XUERODGHUNRPSOHWW
(ohne Schalldmpfer/Luftsaugstutzen)
73/
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1'415
2'080
3'200
4'920
8'380
Baugruppen
Gewicht
3RV %H]HLFKQXQJ [kg]
73/ 73/ 73/ 73/ 73/
Luftsaugstutzen radial 80 140 155 242 290
Luftsaugstutzen axial -- -- -- -- --
Schalldmpfer 140 244 404 576 955
Verdichtergehuse Innenteil 83 148 260 355 550
Einsatzwand 85 134 276 431 850
Diffusor 36 57 80 125 225
Verdichtergehuse Aussenteil 180 290 475 680 1149
Rotorblock 356 546 950 1356 2118
Turbinendiffusor 46 72 150 250 460
Dsenring 17 25 44 63 95
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M16x1,5 M16x1,5 M16x1,5 M16x1,5 M16x1,5
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76002 M12 1) M14 1) M16 1) M18 1) M20 1)

2) 2) 2) 2) 2)
M16 M18 M20 M22 M24
61037

M16 M18 M20 M22 M24
61036

M16 M18 M20 M22 M24
61035

M16 M18 M20 M22 M24
61032

M16 M18 M20 M22 M24
61009

M16 M16 M20 M20 M24
42042

M16 M18 M20 M22 M24
74026

M16 M18 M20 M22 M24
74027

M18x1,5 M18x1,5 M18x1,5 M22x1,5 M22x1,5
86505

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2)
2 6kt-Schraube 42042 / 42046 /
2)
15 6kt-Schraube 61009 / 61032 /
61035
3 6kt-Mutter 61037
1 Dichtung 42041
1 Dichtung 42045
2 O-Ring 42012 / 76040
2 O-Ring 77005 / 77006
1 O-Ring 86506
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6
Ausserbetriebnehmen Seite 1
6
Ausserbetriebnehmen
Rotorblock mit Schraubenverbindung
Inhalt Seite
1
Kurzfristiges Stillsetzen des Turboladers ................................................................................3
1.1
Rotor blockieren TPL 69 85 ..............................................................................................5
1.2
Abschlussdeckel anbringen .................................................................................................9
2
Turbolader konservieren ..........................................................................................................11
2.1
Ausserbetriebnehmen bis zu 12 Monaten .........................................................................11
2.2
Ausserbetriebnehmen ber 12 Monate .............................................................................11
Volume: 11 Seiten
Edition: 03 / 2002
HZTL 10456_DE
-B- ABB
Seite 2 Ausserbetriebnehmen
10456_DE
ABB -B-
1
Kurzfristiges Stillsetzen des Turboladers
Muss der Dieselmotor im Fall eines Turboladerschadens mglichst rasch wieder betrieben wer-
den knnen (Notreparatur), dann kann der Turboladerrotor gemss Angaben in Abschnitt 1.1
blockiert werden.
Wenn mehr Zeit verfgbar steht, dann wird empfohlen, den Rotorblock auszubauen und ein
Abschlussdeckel gemss Abschnitt 1.2 anzubringen.
Vorsicht ! Es sind in beiden Fllen die Vorschriften des Motorenherstellers fr den Betrieb des
Motors mit blockiertem / abgeblendetem Turbolader genau zu beachten!
10456_DE
-B- ABB
25005
90020
90480
Fig. 6-1
Rotor blockieren
10456_DE
ABB -B-
1.1
Rotor blockieren
TPL 69 85
In Notfllen mit beschdigtem Turbolader kann es vorkommen, dass der Motor ohne, bzw. bei
Anwendungen mit mehreren Turboladern mit reduzierter, Aufladung weiter betrieben werden
muss. Wenn der Motor mglichst rasch wieder in Betrieb gebracht werden muss, dann kann
der Rotor des beschdigten Turboladers blockiert werden.
Steht mehr Zeit zur Verfgung, dann wird der Ausbau des Rotorblocks und Anbringen eines
Abschlussdeckels gemss Kapitel 1.2 empfohlen.
Vorsicht ! Die Vorschriften des Motorenherstellers sind zu beachten!
Zum Blockieren des Rotors ist wie folgt vorzugehen (siehe auch Fig. 6-1):
- Schalldmpfer oder Luftsaugstutzen und Verdichtergehuse-Innenteil mit Einsatzwand und

Diffusor entfernen (s. Kap. 5).
- Verschlusschraube (25005) entfernen (s. Fig 6-1).
- Montage-Demontage-Vorrichtung (90020) montieren.
- Rotor mit der Arretierung (90480) blockieren.
Hinweis Zur Sicherung der Arretierung ins bestehende Loch ein Gewinde (M12 oder 1/2")
schneiden und die Arretierung mit einer Schraube (A) sichern.
Vorsicht ! Ein blockierter Rotor muss auf jeden Fall ausgebaut werden.
Whrend dem Betrieb des Motors mit blockiertem Turbolader muss die Schmier-
lversorgung auch an diesem angeschlossen und eingeschaltet sein, sofern der
Gaseintritt nicht abgeblendet werden kann (siehe nchster Abschnitt). Ansonsten
knnen noch intakte Komponenten durch berhitzung beschdigt werden.
10456_DE
-B- ABB
Weitere Massnahmen und Hinweise fr den Betrieb mit einem blok-

kierten Turbolader:
Es mssen verschiedene Flle unterschieden werden:
1. 2-Takt Motor mit einem Turbolader:

Es sind keine weiteren Massnahmen erforderlich. Der Motor kann gemss den Angaben des
Motorenbauers betrieben werden.
2. 2-Takt Motor mit mehreren Turboladern:

- Der Kompensator am Verdichteraustritt muss ausgebaut und die Luftleitung auf der Motoren-
seite abgeblendet werden (unbeschdigte Turbolader bauen einen Receiverdruck auf!).
- Durch zustzliches Abblenden des Gaseintritts kann die Betriebsgrenze des Motors angeho-
ben werden. Zudem wird die Belastung und Temperatur des blockierten Rotors gesenkt.
- Kann der Gaseintritt nicht abgeblendet werden, dann sind folgende Betriebsgrenzen einzu-
halten:
1. Der Druck im Ladeluftreceiver darf 1 bar berdruck nicht berschreiten.
2. Max. zulssige Motorlast: 50%.
- Es ist in jedem Fall auf die Drehzahl der unbeschdigten Turbolader zu achten. Die Drehzahl-
grenze nBmax gemss Turbolader Rating Plate darf nicht berschritten werden.
3. 4-Takt Motor mit einem Turboladern:

Es sind keine weiteren Massnahmen erforderlich. Der Motor kann als Saugmotor gemss
den Angaben des Motorenbauers betrieben werden.
4. 4-Takt Motor mit zwei Turboladern:

a) Getrennte Receiver:
Bei Motoren mit getrennten Luft- und Abgasreceivern sind keine weiteren Massnahmen erfor-
derlich. Der Motor kann als Saugmotor gemss den Angaben des Motorenbauers betrieben
werden.
10456_DE
ABB -B-
b) Gemeinsamer Receiver:
- Wenn der Motor mit einem gemeinsamen Luftreceiver und getrennten Abgasreceivern aus-
gestattet ist, dann muss unbedingt der Kompensator am Verdichteraustritt des beschdigten
Turboladers ausgebaut und die Luftleitung auf der Motorenseite abgeblendet werden. An-
sonsten kann der unbeschdigte Turbolader leer durchdrehen und auf berdrehzahl lau-
fen.
- Abhngig vom Aufladesystem des Motors wird der blockierte Rotor mit mehr oder weniger
starken Pulsen des Abgassystems beaufschlagt. Insbesondere bei Stossaufladung (Turbinen-
gehuse mit mehr als einem Gaseintritt) wird die Blockiervorrichtung dabei stark belastet.
Daher sollten folgende Betriebsgrenzen nicht berschritten werden:
1. Bei gleichdruckhnlichen Systemen (1 Gaseintritt) kann der Motor bis max. 25% Motor-
last betrieben werden. Der Druck im Ladeluftreceiver darf 0.9 bar berdruck nicht ber-
schreiten.
2. Bei Stossaufladung (2...4 Gaseintritte) kann der Motor bis max. 20% Motorlast betrieben
werden. Der Druck im Ladeluftreceiver darf 0.5 bar berdruck nicht berschreiten.
Der Motor kann gemss Angaben des Motorenbauers betrieben werden. Es ist jedoch unbe-
dingt auf die Drehzahl des unbeschdigten Turboladers zu achten. Die Drehzahlgrenze nBmax
gemss Turbolader Rating Plate darf nicht berschritten werden.
10456_DE
-B- ABB
1 2
B5
3
B3
B7
3

B2
a1
a3
a2
B1
B4 B6
B8
5
4
Fig. 6-2
Stahlrohr Abschlussdeckel
10456_DE
ABB -B-
1.2
Abschlussdeckel anbringen
- Rotorblock gemss Angaben in Kap. 5 ausbauen.
- ffnung im Gasaustrittsgehuse mit dem Abschlussdeckel schliessen (s. Fig. 6-2).
- Abschlussdeckel mit Distanzhlsen und Muttern (61037) befestigen.
Vorsicht ! lleitungen verschliessen!
Hinweis Der Abschlussdeckel (Werkstoff: ST37) muss anhand der Zeichnung selbst gefer-
tigt werden.
5
Typ B1 B2 B3 B4 B5 B6 B7 B8 1 2 3 4 a1 a2 a3
min
TPL 61 278 6 8 61 529 596 567 14 21
TPL 65 325 30 30 8 10 6 70 616 694 660 16 22
TPL 69 385 8 10 84 726 818 779 18 25
TPL 73 13 450 9 12 94 844 948 905 20 28 4x90 37,5 24x15
TPL 77 535 9 12 107 1003 1124 1075 22 30
50 50 8
TPL 80 623 11 15 136 1164 1300 1248 24 32
TPL 85 774 14 18 167 1425 1586 1528 26 36
Alle Masse in mm
10456_DE
-B- ABB
Weitere Massnahmen und Hinweise fr den Betrieb mit einem Turbo-

lader mit Abschlussdeckel:
Es mssen verschiedene Flle unterschieden werden:

1. 2-Takt Motor mit einem Turbolader:
Es sind keine weiteren Massnahmen erforderlich. Der Motor kann gemss den Angaben des
Motorenbauers betrieben werden.
2. 2-Takt Motor mit mehreren Turboladern:

- Der Kompensator am Verdichteraustritt muss ausgebaut und die Luftleitung auf der
Motorenseite abgeblendet werden (unbeschdigte Turbolader bauen einen Receiverdruck
auf!)
- Durch zustzliches Abblenden des Gaseintritts kann die Betriebsgrenze des Motors deut-
lich angehoben werden.
Der Motor kann prinzipiell gemss den Angaben des Motorenbauers betrieben werden.
Es ist jedoch unbedingt auf die Drehzahl der unbeschdigten Turbolader zu achten. Die
Drehzahlgrenze nBmax gemss Turbolader Rating Plate darf nicht berschritten werden.
3. 4-Takt Motor mit einem Turboladern:

Es sind keine weiteren Massnahmen erforderlich. Der Motor kann als Saugmotor gemss
den Angaben des Motorenbauers betrieben werden.
4. 4-Takt Motor mit 2 Turboladern:

a) Getrennte Receiver:
Bei Motoren mit getrennten Luft- und Abgasreceivern sind keine weiteren Massnahmen
erforderlich. Der Motor kann als Saugmotor gemss den Angaben des Motorenbauers be-
trieben werden.
b) Gemeinsamer Receiver:
Wenn der Motor mit einem gemeinsamen Luftreceiver ausgestattet ist, dann muss unbe-
dingt der Kompensator am Verdichteraustritt des beschdigten Turboladers ausgebaut und
die Luftleitung auf der Motorenseite abgeblendet werden. Ansonsten kann der unbeschdig-
te Turbolader leer durchdrehen und auf berdrehzahl laufen.
Der Motor kann prinzipiell gemss den Angaben des Motorenbauers betrieben werden. Es ist
jedoch unbedingt auf die Drehzahl des unbeschdigten Turboladers zu achten. Die Drehzahl-
grenze nBmax gemss Turbolader Rating Plate darf nicht berschritten werden.
10456_DE
ABB -B-
2
Turbolader konservieren
2.1
Ausserbetriebnehmen
bis zu 12 Monaten
Wird ein Turbolader fr bis zu 12 Monate stillgelegt, so hngt eine eventuell notwendige
spezielle Konservierung des Laders in erster Linie vom Zustand des Schmierles vor der
Stillegung ab.
Ist die Neutralisationszahl (TAN) kleiner als 2 mg KOH/g, so mssen keine speziellen
Massnahmen getroffen werden. Ist die Neutralisationszahl jedoch grsser, muss der Lader
nach der Stillegung demontiert, gereinigt und die blanken Teile mssen mit Konservierungsl
eingelt werden.
Bleibt der Turbolader auf dem Motor angebaut und wird das Motorl vor der Stillegung durch
ein Konservierungsl ersetzt und mit der Vorschmierpumpe umgewlzt, so erbrigt sich jede
Massnahme am Turbolader. Reste von altem Motorenschmierl werden dadurch weggesplt
und die empfindlichen Lagerpartien weitgehend vor Korrosion geschtzt.
Dreht der Rotor wegen Kaminzuges, ist zwischen dem Verdichtergehuse und der Ladeluft-
leitung ein Blindflansch einzubauen.
2.2
Ausserbetriebnehmen
ber 12 Monate
Wird der Turbolader vom Motor abgebaut und fr lngere Zeit auf Lager gelegt, muss die
Zerlegung und die Konservierung des Turboladers von einer offiziellen Service-Stelle der ABB
Turbo Systems vorgenommen werden.
Als Lagerungsort eignen sich nur trockene Rume, in denen keine Kondenswasserbildung
mglich ist.
Hinweis Konservierter Turbolader jhrlich auf Korrosion berprfen.

Bei Rostanfall Teile reinigen und Korrosionsschutz erneuern.
10456_DE
-B- ABB
7
ABB
ABB Turbo Systems AG
Bruggerstrasse 71a
CH-5400 Baden
Switzerland
Charge Air Cooler C5.05.06.30.17.22
-
Charge Air Cooler
en / 04.02.2008 FD022685 1/15

GEA Maschinenkhltechnik GmbH
Geschftsbereich Sdstrae 48
Wrmetechnik D-44625 Herne
GEA CHARGE AIR COOLERS

GENERAL; OPERATION AND MAINTENANCE MANUAL
1
Contents
Item Title Page
1. General 3
2. Cooler design 3
2.1 Removable stack cooler with casing 3
2.2 Removable stack cooler without casing 3
2.3 Block cooler 3
3. Storage, Installation and Removing of Cooler Bundles 4

3.1 Storage 4
3.2 Installation of Cooler Bundles 4
3.3 Removing of Cooler Bundles 4
4. Commissioning 4
4.1 Pressure Test 4
4.2 Venting 4
4.3 Open Cooling Circuit 5
4.3.1 Cooling Water Flow 5
4.3.2 Protective Film 5
4.4 Closed Water Circuit 6
4.4.1 Cooling Water Flow 6
4.4.2 Protective Film 6
5. Standstill 7
5.1 Standstill in Case of Open Cooling Water Circuit 7
5.2 Standstill in Case of Closed Cooling Water Circuit 7
5.3 Standstill at Freezing Conditions 7
6. Service control 8
6.1 General 8
6.2 Performance Test 8
7. Cleaning 8
7.1 Cleaning at the air-side 8
7.2 Cleaning agents 8
7.3 Continues cleaning 9
7.4 Chemical cleaning 9
7.5 Mechanical cleaning 9
8. Possible Solutions for Operations errors 10/11

9. Tube Leaks 12
9.1 Repair of Water Leakage 12
10. Tightening Torque [Nm] 12

11. Stack cooler with housing (Drawing) 13
12. Block cooler (Drawing) 14
2
1. General
The GEA Charge air cooler is a finned tube heat exchanger. The hot air flows over the fins on
the outside of the tubes and the cooling fluid flows through the tubes. The heat exchange
surface of the cooler consists of round expanded tubes and continuous flat plate fins.
The bond between fin and tube is achieved by mechanical expansion of the tubes.
The tubes are rolled into the tube sheets at each end of the tubes by the use of
tube expanders. The sidewalls form an integral part of the cooler and are bolted to tube sheets.
Water headers are provided for water handling and pipe joints. The number of division rips are
conform to the number of water passes. The headers are bolted to the tube sheets, gaskets are
interposed for sealing. Plugs in the headers are provided for cooler venting and draining.
The materials for headers and tube are chosen in accordance to the cooling water specification
and also depend on the velocity in the tubes. Charge air coolers are designed as one stage,
two stage or three stage coolers according of the demand of the engine design and
performance.
2. Cooler design
The charge air cooler is an integral part of the diesel engine. Mounting situation inlet and outlet
water pipe connection as well as air duct connection are designed by the engine manufacture.
Further informations are given in the manual of the engine manufactures. Principle cooler
sketches see page 13 - 14.
2.1 Removable stack cooler with casing
A removable stack cooler refers to a design of a casing with a removable tube stack.
The cooler casing is bolted between the air ducts. The tube stack is pushed into the casing
and is bolted with the protruding tube sheet (fixed end). The lose end is bolted with a frame
which allows movements in horizontal direction to compensate extension coursed by
temperature.
2.2. Removable stack cooler without casing
Removable stack coolers are used where a casing is an integral design of the Diesel engine.
The tube stack is slided into the casing. The protruding tube sheet (fixed end) of the tube stack
is bolted to the casing.
2.3. Block cooler
A Block cooler refers to the design mounted, directly between the air ducts of engine.
The block cooler is bolted with the air ducts at the side walls and the tube sheets.
3
3. Storage, Installation and Removing of Cooler Bundles

3.1. Storage
The coolers have to be stored in a dry and vented hall. They have to be protected against
dirt and mechanical damages.
The cooler bundles are drained before dispatch. The water flanges are closed with plastic caps
and the fin bay is covered with a protection plate.
3.2. Installation of Cooler Bundles
Before first installation the protection plates have to be removed from the tube bundle.
The air connections have to be sealed with new gaskets provided at site.
The water connections have to be fitted to the water piping with new gaskets provided at site.
All connections must be free of tensions.
3.3. Removing of Cooler Bundles
Before removing the cooler has to be drained. Removing the cooler is carried out vice versa as
the mounting. The cooler has to be deposit at a suitable place. The fin bay has to be protected
against damages and dirt. For long term storage the water connections have also be closed.
4. Commissioning
4.1 Pressure Test
After the water pipes are connected, GEA/GMT recommends to check the tightness before
commissioning. Clean water (drinking water quality) has to be used for the pressure test.
If the cooler is not taken into operation immediately after the pressure test the cooler has
to be drained (see item 5 Standstill).
After a longer period of storage or extended stand still the header screws have to be checked
with the recommended torque and shall be tightened with the recommended torque if
necessary. After that the cooler has to be pressure tested. In case of leakage's the gaskets
have to be changed.
4.2 Venting
For cooler venting use the venting plugs which you will find on the nozzle header.
For continuously venting a venting pipe should be installed.
4
4.3 Open Cooling Circuit
4.3.1 Cooling Water Flow
The flow rate of the cooling water has to be in accordance to the layout values of the cooler.
Frequent fluctuations of the cooling water velocity prevent the formation of a natural protective
film against corrosion. In case of open cooling circuits a too low water velocity encourages
dangerous dirt deposits and too high velocity causes erosion. In case of open cooling water
circuits never operate at min. or max velocity for a prolonged period. The recommended
velocity for a prolonged period is 2 m/s.
The following water velocities have to be observed
Material DIN Material Comparable admissible Cooling Water Velocity m/s

ASTM-Nr./No. min max
Nr./No.
CuNi10Fe1Mn 2.0872 B-111 C70600 1,5 2,5
CuNi30Mn1Fe 2.0882 B-111 C71500 1,5 3,0
4.3.2 Protective Film
The good chemical resistance of copper/nickel alloys is due to their ability to form a
natural protection film which has the capability to prevent corrosion attacks.
New cooling tubes of which the protection coat has not yet fully developed shall not
come into contact with contaminated water. The immediately forming dirt deposit will
destroy the formation of a protective coat.
Water pressure test has to be done therefore only with clean water.
5
4.4 Closed Water Circuit
4.4.1 Cooling Water Flow
The flow rate of cooling water has to be in accordance with the layout values of the cooler.
It must be guaranteed that the circuit water is clean and no deposits in the tubes can occur.
(Drinking water quality).
The following water velocities have to be observed:
Material DIN Material Comparable admissible Cooling Water Velocity m/s

ASTM-Nr./No. max
Nr./No.
CuNi10Fe1Mn 2.0872 B-111 C70600 3,5
4.4.2 Protective Film
The good chemical resistance of copper/nickel alloys against corrosion is due to the
ability to form a natural protection film which is difficult to dissolve.
New cooling tubes of which the protection coat has not yet fully developed shall not
come into contact with contaminated water. The immediately forming dirt deposit will
destroy the formation of a protective coat.
Water pressure test has to be done therefore only with clean water.
6
5. Standstill
5.1 Standstill in Case of Open Cooling Water Circuit
In case of a standstills for more than 3 days the water side has to be drained.
A standstill is especially dangerous for copper alloy tubes in case of a not fully build up
protective coat or the risk of getting disturbed by corrosion under deposits.
If possible the cooler operation should not be interrupted during the first 2 months after
commissioning. However, if there is a failure in cooling water supply and operation is resumed
within three days time, the cooler can be left undrained. It must be guaranteed that the tubes
are free of deposits.
In case of deposits the cooler must be drained, the tubes have to be cleaned, flushed with clean
water and dried. A blow through with warm predried air through the pipes is recommended. The
cooler has to be sufficient vented. If sea water, brackish or saline water (reference value
chloride content 500 mg/l) is used as cooling water for flushing clean water
(drinking water quality) has to be used.
In case of standstills for more than 3 days during the start-up period of 2 months and later on
during standstills for more than 2 weeks the same cleaning procedure has to be used.
In case of short standstills operating with low water velocity is to be preferred to water standstill.
5.2 Standstill in Case of Closed Cooling Circuit
Drinking water quality is prescribed for closed cooling water circuits (see item 4.3).
Under this conditions no draining in case of standstill is necessary.
5.3 Standstill at Freezing Conditions
The cooler has to be drained in case of wintertime standstills, when a frost injury to the cooler
must be feared, also during short standstill periods.
7
6. Service control
6.1 General
For Service control, the manometers have to be installed in the air ducts and in the cooling
water piping. We recommend to keep record of the air and water temperatures in the machine
log book periodically. Further control instruments can be provided in accordance with the
individual requirement.
A possibility to drain the condensate must be assured for installation.
6.2 Performance Test
The performance guarantee given by GEA is mainly expressed by the temperature difference
between cold water and cold air during normal operation and should be checked from time to
time.
A differential pressure gauge can also be used to check whether or not cleaning of the air or
water side of the cooler is necessary. We recommend to install differential pressure gauges in
the air duct and water piping before and after the cooler.
7. Cleaning
7.1 Cleaning of the air-side
Cleaning of the air-side should be done early to avoid accumulations of sludge and oil. The
cleaning has to be done in regular intervals. The time interval of cleaning depends on the
ambience condition of the engine. Soiling of the air-side has a low influence on the thermal
capacity of the cooler but on the pressure drop. High pressure drop has an influence on the
thermal load of the engine. Limits of the allowable increase of the pressure drop are given by
the engine builder (see engine maintenance manual)
7.2 Cleaning agents
Use only agents which have no corrosive effect to copper and copper nickel alloys.
Wrong chemical cleaning agents may occur defects on the cooler. GEA GMT can not accept
responsibility for defects coursed by using wrong cleaning agents.
The requisite cleaning agent depends on the kind of soiling of the fins. Cleaning agents for
different soiling are offered by following expert companies:
Drew Ameroid Marine

Nalfleet
Unitor
Vecom
8
7.3 Continues cleaning
Some cleaning companies offer continues cleaning systems. This systems may influence the
engine operation. Use continues cleaning only on release of the engine builder.
7.4 Chemical cleaning
GEA GMT recommend to contact a cleaning expert company.
For cleaning the cooler, the cooler stack has to be removed from the engine. The cooler is
immersed in a cleaning bath which has to be filled with the cleaning agent. The cleaning agent
has to be according to the recommendations of the engine builder or there suppliers.
Immersing the cooler in a cleaning bath may not have a satisfying cleaning result.
Using a circulation pump will improve the cleaning result.
The best cleaning result can be obtained by using ultra sonic transducer.
This cleaning system is normally performed by expert companies.
The time of cleaning depends on the degree of fouling as well as the kind of fouling.
It may be advisable to scour the cooler over night in the cleaning agent.
After cleaning the cooler, the fin stack has to be rinsed with tap water using a water jet.
The water jet has to be applied in minimum m distance from the fins and only parallel to fins.
Maximum water pressure is 120 bar. After rinsing the fin stack it has be dried with compressed
air before refitted on the engine.
7.5 Mechanical cleaning
Mechanical cleaning is done by the use of nylon brushes fitted to a rod. Tube brushes are
available at GEA/GMT service department. Regular cleaning is necessary, the cleaning
intervals depend on the used cooling water. The cleaning of the water side is not only required
to maintain the thermal performance of the cooler. Scaling increases the risk of pitting corrosion
and obstacles particles blocking the tubes and favours erosion. Mechanical cleaning can be
done on side or when the cooler is removed. At least one header has to be removed, the wet
tubes should be brushed clean one after the other by pushing the nylon brush through the
whole tube until all the dirt is flushed out and no residues are left. After finishing cleaning
activities the headers have to be re mounted with new gaskets. Venting must be repeated after
cooling water is refilled.
9
8. Possible Solutions for Operation errors
All remedies have to be done in conformity with the technical specifications of the engine
manual and Charge air cooler manual. Compare measured value with test bed values.
Difficulty Possible Cause Fault Location Remedy, see
Engine Manual
Charge air 1.1 Charge air High engine room Reduce engine load
temperature after temperature before temperature. according engine
cooler too high. cooler too high. manual.
Dirty, turbocharger. Clean turbocharger
according engine
manual.
1.2 Increased coolant Maladjusted cooling Readjust cooling
inlet temperature. system. system.
1.3 Increased coolant Maladjusted cooling Readjust cooling
outlet temperature, system. system.
Inadequate low Blocked sea-water Clean filter.
coolant flow. filter.
Cooler tubes are Clean air cooler.
partly blocked.
1.4 Low coolant outlet Fouling of the cooler Clean cooler tubes.
temperature, low tubes.
inlet
to out let Heavy fouling of air Clean cooler air
temperature side, high air side.
difference. pressure drop.
Charge air 2.1 Water inlet Maladjusted cooling Readjust cooling
temperature too low. temperature too low. system. system.
Low sea-water Recycle sea-water
temperature. into sea chest too
increase water inlet
temperature.
Reduce water flow
to allowable
amount, see water
velocities.
High pressure drop 3.1 Air side fouled. Check pressure Clean cooler air
on air side. gage. side.
Pressure gage Air temperature Repair or refit new
defect after cooler Ok, as pressure gage.
well as exhaust gas
temperature after
engine.
10
Difficulty Possible Cause Fault Location Remedy, see

Engine Manual
High pressure prop 4.1 Increased coolant Maladjusted cooling Readjust cooling
on water side amount, high water system. Low water system.
flow. temperature
difference.
4.2 Air cooler water side High water Clean cooler.
partly blocked temperature
difference
4.3 Heavy fouled water Low water Clean cooler tubes.
side of tubes. temperature
difference.
4.4 Pressure gage Water temperature Repair or refit new
defect difference OK. pressure gage.
External water 5.1 Leaking gasket Retighten cover and

leakage pipe connections,
see torque value on
data sheet. If
necessary replace
gasket
Internal water 6. High air humidity may cause water
leakage, condensation. Check always water quality
if treated circuit water or sea water.
6.1 Leaking gasket. Drain water is Retighten cover
treated water and connections, see
water lost in header torque value on data
tank. sheet. If necessary
In case off sea replace gasket.
water coolant drain
water is sea water.
6.2 Leakage between Use tube expander
tubes and tube to secure tube in
plate. tube plate.
6.3 Cooler tubes Leaking tubes have
leaking. to be plugged on
both ends.
11
9 Tube Leaks
9.1 Repair of Water Leakage's
Cause of a water leakage may be corroded tubes or a leaking rolled in tube end. To find out the
leaking tube it is helpful to remove the bundle and to deposit it on suitable benches.
The removed bundle has to be filled up with water and should be put under water pressure. The
area of the leaking can be estimated by the dripping water. To find out the real leaking tube it
could be necessary to do an individual pressure test of single tubes of the identified area.
Therefore the headers have to be dismantled.
10. Tightening Torque [Nm]
WITHOUT GASKET OR
SIZE WITHOUT GASKET OR KLINGERSIL GASKET
KLINGERSIL - GASKET WITH NORD LOCK WASHER
M 10 42 50
M 12 75 90
M 16 180 220
M 20 360 430
12
11. Stack cooler with housing
1. Air cooler housing

2. Fin tube bundle
3. Tube plate
4. Nozzle header brush
5. Return header
6. Cover
7. Water mist catcher
8. Cover
9. Sealing groove
10. Tube cleaning brush
13
12. Block cooler
1. Nut
2. Flange
3. Gasket
4. Bolt
5. Nozzle header
6. Header Bolt
7. Nozzle header
Gasket
8. Tube brush
9. Return header
Gasket
10. Return header
11. Header bolt
12. Drain / vent
13.
14. Tube plate
15.
14
Lub.-Oil Pump C5.05.08.07.22.93
-
VM43
Lub.-Oil Pump
en / 30.10.2007 FD035580 1/22

L3NG
Technical Documentation
Operation, Maintenance, Mounting and
Disassembly Instructions for the
Screw Pump L 3 N G
Mainluboilpump, direct driven
E 185 5253_e_Rev.1
L3NG
Contents
1. General Page 1
1.1. Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
1.2. Information about the Product . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
1.2.1. Addressing of the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
1.2.2. Manufacturing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
1.2.3. Names, Types and Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
1.2.4. Serial Number and Type Plate . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
1.2.5. Date of Manual Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
1.2.6. Change Notes and Manual Numbers . . . . . . . . . . . . . . . . . . . . . Page 1
1.2.7. Copy Rights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
1.2.8. Technical Documentation and Data Sheet . . . . . . . . . . . . . . . . Page 1
1.2.9. Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
1.2.10. Quality Assurance and Quality testing . . . . . . . . . . . . . . . . . . . . Page 1
1.2.11. Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
2. Safety ..................................................... Page 2

2.1. General Rules and Advice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2
2.2. Dangers of not observing the Safety Advice . . . . . . . . . . . . . . . Page 2
2.3. Safety conscious Working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2
2.4. Warning and Advice Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2
2.5. Safety Advice for the Operator . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2
2.6. Safety Advice for the Service, Inspection and Mounting . . . . Page 2
2.7. Denial of Modifications and Changes without Approval . . . . . Page 2
2.8. Unallowable Running Conditions . . . . . . . . . . . . . . . . . . . . . . . . Page 2
2.9. Other Operations and Safety Hazards . . . . . . . . . . . . . . . . . . . . Page 2
3. Transport and Intermediate Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3

3.1. Safety Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3
3.2. Transport Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3
3.3. Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3
3.4. Intermediate Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3
3.5. Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3
3.5.1. Aging of Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3
3.5.2. RePreservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3
3.5.3. Removal of the Preservation Fluid . . . . . . . . . . . . . . . . . . . . . . . Page 3
3.6. Protection from Surroundings . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3
4. Description of the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4

4.1. General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
4.2. Assembly and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
4.3. Construction of the Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
4.3.1. Pump casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
4.3.2. Rotor Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
4.3.3. Shaft Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
4.3.4. Casing Gasketing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
4.3.5. Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
4.3.6. End Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
4.3.7. Connection for an external pressure control valve . . . . . . . . . . Page 4
4.3.8. Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
4.3.9. Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
4.3.10. Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
4.4. Dimensioning and Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
4.4.1. Standard Dimension Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
4.4.2. Sectional drawing with parts list . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
E 185 5253_e_Rev.1
L3NG
4.5. Execution Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
4.5.1. Type key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
4.5.2. Standard Material of Construction . . . . . . . . . . . . . . . . . . . . . . . Page 5
4.6. Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
4.6.1. Operation acc. to specification . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
4.6.2. Temperature and Pressure Limitations . . . . . . . . . . . . . . . . . . Page 5
4.6.3. Performance Data and Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
4.6.3.1. Performance Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
4.6.3.2. Power Consumption Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
4.6.4. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
4.6.4.1. Required Space for Operating and Maintenance . . . . . . . . . . . Page 5
4.6.4.2. Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
4.6.4.3. Base, Foundation and Anchoring . . . . . . . . . . . . . . . . . . . . . . . . Page 5
4.6.4.4. Suction and Discharge Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
4.6.4.5. Support Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 6
5. Mounting and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 7

5.1. Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 7
5.2. Initial Installation of the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 7
5.3. Initial Installation of the Pump Unit . . . . . . . . . . . . . . . . . . . . . . . Page 7
6. Start up Shut down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8

6.1. Technical Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8
6.2. Pipe Schematic and Measuring Points . . . . . . . . . . . . . . . . . . . Page 8
6.3. Preparation for Start up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8
6.4. Start up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8
6.5. Shut down of the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8
6.6. Restarting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8
6.7. Still Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8
6.7.1. Shut down for up to 3 Months . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8
6.7.2. Shut down from 3 to 6 Months . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8
6.7.3. Shut down for more than 6 Months . . . . . . . . . . . . . . . . . . . . . . Page 8
6.8. Operation Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8
6.9. Bearing of the Power Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8
7. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 9
7.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 9
7.2. Maintenance and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 9
7.3. Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 9
7.3.1. General Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 9
7.3.2. Customer Service/Personnel/Danger . . . . . . . . . . . . . . . . . . . . . Page 9
7.3.3. Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 9
7.3.4. Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 9
7.4. Disassembly of the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 9
7.5. Assembly of the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 9
7.5.1. Notice to the valve adjusting pressures . . . . . . . . . . . . . . . . . . . Page 10
7.6. Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 11
8. Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 12

8.1. Table to define Reason and solving of Problems . . . . . . . . . . . Page 12
8.2. Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 13
8.3. Allowable pipe forces and moments . . . . . . . . . . . . . . . . . . . . . . Page 13
8.4 Amendments to this Technical Documentation. . . . . . . . . . . . . Page 13
9. Drawings, Data Sheets, Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 13
Appendix
E 185 5253_e_Rev.1
L3NG
1. General 1.2.10. Warranty
1.1. Application A complex quality assurance system guaranties high quality standard
This screw pump is used for pumping oils or other lubricating media at levels for Leistritz screw pumps. The quality assurance, according to
lowpressuresrange . DIN ISO 9001, covers all production steps, which are necessary to ful-
fill all quality requirements for this product.
1.2. Information about the Product
Quality assurance measures (i.e. size, type of test and certification)
1.2.1. Addressing of the Manual
are issued by the purchaser in writing, including the necessary forms
This manual was made for the pump series L 3 N G Mainluboilpump and documents. Prior to shipment all pumps are rigorously tested.
for engine , direct driven. Only pumps which fulfill the confirmed test data will be shipped.
For other executions and designs different manuals are valid. They Use of this manual will help to assure a troublefree operation and full
can be ordered from the manufacturer separately if not on hand. flow performance. The proof of test data on the bench follows the gen-
1.2.2. Manufacturing eral test recommendations for rotary positive displacement pumps per
The manufacturer of the screw pump type L 3 N G Mainluboilpump, VDMA 24284.
is LEISTRITZ Pumpen GmbH The proof of test and their results are documented in test protocols acc.
residing in the to DIN 55350 part 18 Inspection certificate M.
Federal Republic of Germany
1.2.11. Warranty
90459 Nrnberg, Markgrafenstrae 29 39
or 90014 Nrnberg, Postfach 30 41 Our liability for defects of shipped goods is outlined in our delivery and
DIN Parts, accessories and additional parts are purchased from payment conditions, which are part of our Sales Conditions and Terms.
subsuppliers.
Damages which may occur as a result of disregard of the instruction
1.2.3. Names, Types and Sizes manual and replacement conditions are not covered under warranty. If
Name: Threerotor screw pump at a later date operation conditions change, for example different prod-
Type: L 3 N G Mainluboilpump for engine, direct driven uct, viscosity, temperature, speed or inlet condition, these conditions
Sizes: 140, 160, 180, 200, 225, 250, (256), 275, 300 and 320 have to be reviewed and acknowledged by LEISTRITZ. If no other
For additional information see the type key. agreements have been made with LEISTRITZ the delivered pumps
can only be disassembled and modified by LEISTRITZ or LEISTRITZ
1.2.4. Serial Number and Type Plate Service Representatives. Otherwise the warranty for occurred dam-
Each unit is equipped with a standard type plate, which shows the ages will be voided.
manufacturers serial number and type key. Enlarged type plates are
available on request.
1.2.5. Date of Manual Execution
Dated August 8, 1997.
Technical and design changes, improvements and amendments may
be made without notice.
1.2.6. Change Notes and Manual Numbers
All executed changes are listed on the final page of this manual. The
type of change, date, executor and proof reader are noted.
Manual number E 185 5253 includes additional documentation in the
form of drawings.
1.2.7. Copy Rights
All manuals, documents and drawings are copy righted according to
DIN 34.
1.2.8. Technical Documentation and Data Sheet
For in depth explanations see the following chapters:
Safety Chapter 2.
Transport and Storage Chapter 3.
Description of the Pump Chapter 4.
Mounting and Installation Chapter 5.
Mounting at Startup and Shut down Chapter 6.
Maintenance Chapter 7.
Trouble Shooting Chapter 8.
Drawings and documents Chapter 9.
1.2.9. Customer Service

If service is required or questions need to be answered, please contact
our headquarters or someone in our sales organization.
E 185 5253_e_Rev.1 Page 1 of Page 13

L3NG
2. Safety 2.6. Safety Advice for the Service, Inspection and Mounting
2.1. General Rules and Advice
This manual includes general rules which have to be observed for The entire scope of service, including inspection and
installation, operation and maintenance. Therefore, this manual has to mounting, has to be done by an authorized specialist, who
be read before installation and operation by the installer, as well as by has knowledge of this manual. Any work on the machine
the responsible specialist/user. It has to be made available at the job is only allowed when the unit is standing still. The shut
site for reference at a later date. down of the unit described in the manual has to be fol-
2.2. Dangers of not observing the Safety Advice lowed.
Ignoring the safety advice can endanger people, the environment and
the pump unit. For example:
Damage to the pump units or certain functions of these units, can en-
danger personnel through electric, mechanical and chemical in- Immediately at the end of any work all safety and protec-
fluences, endangering the environment by leakage of harmful prod- tion devices have to be installed completely. Before
ucts and other pollutants. startup, points mentioned under 6.4 have to be followed.
2.3. Safety conscious Working
The safety rules listed in this manual, applicable preventive practices
as well as internal safety rules of the user always have to be followed.
2.4. Warning and Advice Signs 2.7. Denial of Modifications and Changes without Approval
In this manual safety symbols are mentioned which can help to prevent
accidents to personnel. A general safety sign identifies hazards which Changes or modifications on the unit which have not been confirmed
will endanger the unit and its function. by Leistritz, are not allowed.
2.8. Unallowable Running Conditions
The operational safety of the delivered unit is only assured by opera-

tion according to the confirmed design and data. Units should not be
used under different operating conditions without the manufacturers
approval. The limitation of the performance data sheets should never
be exceeded. Safety hazards may result if they are exceeded.
The word Attention is inserted in the text to note these additional ad-
vice signs and is labeled directly on the unit.
2.9. Other Operations and Safety Hazards
Attention All packing material of the pump or the unit shall only be
For example: removed right before the installation of the pump.
Direction of Rotation and Flow No foreign particles are allowed to enter the pump!
Electrical Current Warning The danger of an accident at installation and mounting of
Marking of the Nozzles (inlet, outlet arrows) the unit has to be observed at any time.
Marking Vent and Drain Opening Balance stability always has to be existing, assembly
No rubdry sign and others. parts have to be secured against falling.
2.5. Safety Advice for the Operator Loose parts have to be properly secured.
Hot or extremely cold machine parts are potential dangers and

must be protected against access.
Guards, which protect the rotating parts and shaft from assess,
The pump must not be lifted or let down at the addon
shall NOT be removed during running of the equipment.
Leakage of hazardous products at the seal, by such as, explosive, piece or the supply pipes. Use lifting lugs (see dimension
toxic or hot fluids have to be collected and drained to a safe place sheet). The mounting has to be carried out by trained em-
not to endanger operating personnel and the environment. ployees. Ensure a sufficient dimensioning of the lifting de-
All general rules of law, applicable to the site have to be followed. vice. Any danger has to be eliminated.

L3NG
3. Transport and Intermediate Storage The listed preservative agent are meant to be a recommendation.
3.1. Safety Measures Other manufacturers can be used as well. Preserving the internals of
the pump is achieved by filling the pump with the preservation fluid.
During filling the Page 6., power rotor has to be rotated in reverse very
slowly. Continue filling the pump until the preservation fluid the suction
nozzle with any air bubbles.
Larger screw pumps and all pump/driver units have to be transported

to the installation site by means of lifting devices. Lifting and lowering of
3.5.1. Aging of Preservation
the unit have to be done in a balanced manner. Cranes and Lifting de-
vices have to be large enough. It has to be assured that the unit will According to the preservation fluid manufacturer, the shelf life of TEC-
NOT tip over. Shelves and racks used for storage of the units have to TYL 506 is 4 to 5 years at inside storage and 1224 months at outside
be designed to accommodate the weight and size.
storage; TECTYL 511 M is approx. 18 months at indoor storage only.
3.2. Transport Precautions By mixing TECTYL 506 and 511 M 50/50, conservation preservation
time of 21/2 4 years indoors and 12 months outdoors can be ex-
pected.
Additional packing will extend the preservation time accordingly. The

ingredients in these preserving agent will allow proper corrosion
Damage during transport of the unit should NOT occur. Do not lift at protection even at high humidity, independent of any temperature.
parts as flanged valves, supply pipes etc. (use lifting lugs). Sufficient
care should be taken that the unit cannot slide or fall during the trans-
port. The packing material of the unit shall not be damaged. Any advise
3.5.2. RePreservation
on the packing crate or box have to be strictly followed.
For longer storage the user of the pump has
3.3. Unpacking
Attention to check the preservation of the pump regu-
Upon receipt of the pump, immediately inspect the unit for potential larly. Avoid damages which occur due to im-
transport damage. Transport damages have to be reported immedi- proper preservation.
ately to the Insurance Company.
Before installing the unit all packing material has to be removed com-
pletely. All uncovered openings of the unit, for example, the access
3.5.3. Removal of the Preservation Fluid
hole on the bracket between pump and motor has to be inspected for
loose material, such as wooden splinters, nails, bolts, metals clamps
Before startup of the pump the preservation fluid needs to be re-
and others. Such items need to be removed. End covers, blind plugs,
moved. The fluid which was used for preservation inside of the pump
etc., have to be removed as well.
can normally be removed by flushing the pump with the product, pro-
3.4. Intermediate Storage vided the medium is there by not being contaminated. In addition
proper solvents can be used to remove the inner and outer preserva-
The delivered screw pumps are already preserved for shorter storage tives. Proper solvents are e.g. Kerosene, Diesel or demineralized
time. For longer shutdown time, the pumps have to be further pro- spirits, industrial solvents, cleaners and other paraffin solvents. Hot
tected from corrosion. An outside/inside preservation needs to be steam cleaners with according admixtures can be used as well.
done as outlined under 3.5.
The pump always needs to be filled with the
3.5. Preservation Attention product to avoid seizing the spindles at
startup. If the piping, tanks and other parts
The time limitation of the preserving material is dependent on the com- in various circulation systems are covered with paraffin containing
position of the material. Therefore, preserving materials should be preservation material at the installation site, the whole system needs to
used which will be stable for at least 12 months. The following materi- be flushed. This is necessary because paraffin lowers the degassing
als can be used for an inside and outside preservation. capability of the products. This might cause a rough running of the
pump in connection with loud noise development (aeration).
Preservation Points: Preservation agents:
All machined and unpainted TECTYL 506
surfaces like shaft end and or compound
flange covers TECTYL 506 and 3.6. Protection from Surroundings
TECTYL 511M (*)
When storing the screw pump, the discharge and suction flange al-
Pump casing internals, rotor compound
set and end covers TECTYL 506 and ways need to be covered by blind flanges, blind plugs or similar mate-
TECTYL 511M (*) rial. The storage shall take place in a dust free and dry room. During
storage , it is recommended to turn the inner parts of the pump manu-
(*) Manufacturing: VALVOLINE OEL GmbH & Co.
ally every 4 weeks. The rotor set and bearing change their position dur-
The preservative agent shall be spread by means of brushing or ing this process. If the storage and packing is done properly, the unit
spraying. can be preserved for a very long time.

L3NG
4. Description of the Pump 4.3.3. Shaft Sealing
4.1. General Description The shaft entrance of the driving spindle from the pump casing to the
The Leistritz Screw Pump of the L3NG Series is a low pressure pump. driving pin is designed sealless. Medium leakage due to the operating
It is a self priming positive displacement pump and used to move oils or conditions is being conveyed directly to the lubrication system of the
other lubricating products. diesel motor.
4.2. Assembly and Operation

4.3.4. Casing Gasketing
Due to the special profile of the three turning spindles, sealed cavities
are produced. The doublelead power rotor (position 150) rotates, The pump is sealed off using gasket (pos. 031, 210), oring (pos. 46)
sealing with the doublelead idler rotor (position 151) in the rotor bore and seals rings (pos. 004, 006) depending on the operating conditions
of the pump casing (position 001) which encloses the rotor set with and the pumped products.
tight tolerances.
The motion of the two idler rotors is caused by the calculated hydraulic
forces leaving only the resulting moment caused by the fluid friction to 4.3.5. Bearing
be transmitted over the flanks of the rotor profile. Therefore, the rotor
set is almost without any load and will not wear out. With this principal Axially through a maintenancefree deep groove ball bearing,
the pumps continually move fluid without sheer and turbulence from mounted inside the sealed area of the pump, located on the driving
the suction to the discharge side. This constructive design in working spindle and the pump housing. This bearing is continually being
principle assures a low noise level and an almost pulsation free dis- flushed and lubricated with the flow medium.
charge.
The complete spindle geometry is chosen in a way that no axial thrust
is effected on the ball bearing (position number 170). The ball bearing 4.3.6. End Cover
(position number 170) fixes the driving spindle (position number 150) in
axial direction. The end side cover (position number 030) shuts the pump casing
The bearing application of the idler spindles (position number 151) is (position number 001) on suction side.
effected in the pump casing (position number 001).
Depending on the operating pressure, an appropriate choke gap is
built between the balancing piston of the driving spindle (position num- 4.3.7. Connection for an external pressure control valve
ber 150) and the idler spindles (position number 151), which guaran-
The pump casing can be equipped with a pressure and recirculation
tees the hydrodynamic bearing of the idler spindles.
connection for an external pressure control valve (see pump dimen-
The successive area is balanced in direction to the driving side. Pene-
sion sheet). This pressure control valve of a positive displacement
trating leakage oil is being inducted to the luboil circle on motor side.
pump has to keep the discharge pressure at the delivery connection
By this geometric design of the spindle package the axial thrust bal-
steady and to regulate it respectively, regardless of total delivery.
ancing is guaranteed.
4.3. Construction of the Parts
4.3.8. Pressure Relief Valve
4.3.1. Pump casing
The pump casing has been designed specially for mounting on diesel The pump can be designed with an integrated or an externally
motors. Design and dimensions can be seen from the particular valid mounted pressure relief valve as described on 4.3.1. (option).
dimension sheets.The suction area will be closed off with the non For the variant without valve the valve connection is locked.
drive side cover (position number 30). The pump casing has a fixing Exceeding the adjusted values, the poppet (position number 219) lifts
flange on driving side which enables a direct mounting. The pump is from the seat and the product circulates into the suction area of the
designed with an integrated or an externallymounted pressure relief pump casing. The opening pressure is adjusted by compressing the
valve and has a second connection for mounting an external pressure valve spring (position number 235) with the adjustment screw (posi-
control valve. tion number 222) at the factory or at the user, depending on the require-
The relief valve protects the pump only against overload ment.
and is not meant to be used as a pressure regulating Notice to the valve adjusting pressures see chapter 7.5.1
valve! Operation and manual of the pressure regulating Using the pump with a pressure limitation valve, care
valves, see section 4.3.8. The pump casing can be should be taken that the poppet will always stay movable
drained . Therefore, check before start up on eventually not plugged in its axis. A complete closing of the valve bore by means
openings. its of locking the adjustment screw and the connected
On the suction and pressure connection the casting is valves spring by complete compression, shall not be al-
executed with a flow direction arrow. Before start up the lowed, since this could cause damage to the pump.
flow direction needs to be checked. Pay attention that the In order to set the pressure the previewed external pres-
pump can drain during alignment of the pumps (hanging sure control valve has to be used.
downwards) (see chapter 6 commissioning).
4.3.9. Nozzles
Suction and discharge connection are executed as a DIN flanged

4.3.2. Rotor Set connection, marked with flow direction arrows . Weldneck counter
The power rotor (position number 150) is doublelead, hardened and flanges according DIN can be supplied with a price adder.
axially positioned with a ball bearing (position number 170). The idler Maximum allowable forces and moments depend on the
rotors (position number 151) doublelead as well, hardened or un pump size, and are listed on the dimension sheets or on
hardened, are paired to the power rotor. During operation both idler installation drawings. These values shall never be ex-
spindles are pushed in axial direction against the driving side balanc- ceeded. Connections for drain, vent or heating, if not
ing piston of the driving spindle (position number 150). needed, need to be plugged before start up.
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L3NG
4.3.10. Drive before the pumps are delivered, the measured values and values cal-
The pump is being driven directly by a gear of the diesel motor. The culated on the basis of operating data will be listed in an acceptance
driving torque is being transferred with the gear to the driving pin of the certificate. Only pumps with performance values falling within the per-
driving spindle (pos. 150) by a particular clamping unit. mitted tolerances will be supplied.
Pay attention to a correct sense of rotation
and a proper fitting position of the pump ! 4.6.3.2. Power Consumption Diagrams
Performance curves for each particular pump size and pitch for vari-
ous speeds and viscosities can be supplied on request.
4.4. Dimensioning and Geometry 4.6.4. Installation

4.4.1. Standard Dimension Drawings 4.6.4.1. Required Space for Operating and Maintenance
The main dimensions of the pump with the connection dimensions are The mounting site shall be selected to ensure that an undisturbed
stated on the diverse dimensional sheets. The documents valid for this operation and an uncomplicated maintenance of the unit is guaran-
project are attached to the appendix. teed. All safety regulations shall also be adhered to.
4.4.2. Sectional drawing with parts list 4.6.4.2. Environmental Conditions

The sectional drawing with parts list for each particular project is at- Existing ambient influences, as far as they vary from
tached to the appendix. those known and confirmed during planning, can affect
All stated drawings can be supplied in german and english language. operation adversely; e.g., protection should be given
against high radiating temperatures from adjacent com-
4.5. Execution Modifications ponents, water spray, and the like.
4.5.1. Type key 4.6.4.3. Base, Foundation and Anchoring

These pumps have been designed for the special operation as flange The fastening down of the unit is to be done as per the details in the
pumps for diesel motors . installation drawings. All the elements provided for fastening down
The pump type designation of this design is : must be used.
IFOGVO In general, the type of fastening is to be selected in such
I = Roller bearing inside manner that no movement, displacement or stressing of
F = Flange fixing the overall unit can occur. All addon pieces have to al-
O = Without heating low a statically perfect fixing. There must be no vibration
G = Big flange from other machines or components that would affect the unit, and any
V = Staggered suction and pressure flange alignment vibration prevailing must be dealt with by the use of antivibration
mountings.
O = Without shaft sealing If the pump casing is fixed on the hub flange as previe-
wed, special care has to be paid to a sufficient dimensio-
4.5.2. Standard Material of Construction ning of the total arrangement. All the fastening holes of
Pump casing 0.6025 the pump must be used and a well fitting position has to
End cover 1.0038 be provided. We assume no liability whatsoever for damage to the unit
Driving spindle 1.7139 hardened caused by inadequate fastening.
idler spindle 1.7139 hardened or 0.6025
Gasket CENTELLEN WS 3820 4.6.4.4. Suction and Discharge Piping
O rings Viton The pump unit is not permitted to act as a mounting point
for piping. The maximum allowable forces and moments
4.6. Operating on the flanges mentioned in the dimension sheets and
4.6.1. Operation acc. to specification assembly drawings may not to be exceeded. This is true
for possible temperature forces as well, see section 8.3. Vibrations and
The corresponding pumps have been designed and constructed for in
impacts from the conduction system on the pump have to be avoided,
each case prevailing operation.
we recommend the installations of compensators.
The pipe sizes on the suction and discharge side should be at least the
4.6.2. Temperature and Pressure Limitations
size of the pump connections. The selection of the pipe has to be done
by using the existing flow velocity. The flow velocity in the suction line
should not exceed 1 meter per second and in the discharge line, 3 me-
ters per second. When piping up suction and discharge lines, care
should be taken that the flow of the medium is not disturbed by mount-
Pay attention to the stated nominal pressure, viscosity and tempera- ing short radius elbows, right angle valves or check or back pressure
ture values. If no contrary values have been given, the values valves in the suction line. Unavoidable diameter changes in the flow
stated have to be considered as limit values and shall not be ex- lines have to be executed with smooth reducers. Any sudden direction
ceeded. If protective measures are required as a result of the oper- changes should be avoided. The suction and discharge lines have to
ating temperatures or temperature limits to prevent disturbance of be sealed tightly and piped in such a manner that no air bubbles can
the surface, these are to be applied by the customer and may not build up. Therefore the piping must always be layed in a rising manner.
be removed in operation. The spindles of gate valves should be positioned horizontally or verti-
cally downward to allow venting of the lines at the highest point. Flange
4.6.3. Performance Data and Speeds
gaskets cannot be permitted to protrude into the I.D. of the pipe and
4.6.3.1. Performance Tables installation of isolation valves before and after the pump as well as a
Evaluation formulas are available for the pumps of this serie. They pro- check valve at the discharge side is recommended. The isolation
vide the basis for projectrelated planning. In testing the performance, valves are only used to close the lines for pulling the unit out of service.
E 185 5253_e_Rev.1
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L3NG
They have to be completely open during normal operation. All pipes
and valves have to be cleaned thoroughly before the pump is mounted
in order to flush out weld slag, weld beads and possible mounting de-
bris, like bolts, nuts and so forth. No liability can be claimed for dam-
ages to the pump which have been caused by solid particles in the
product. The tank has to be designed in the area of the suction pipe of
the pump in this way, that air locks and foam carpets arising in the fluid
are being segregate from the flow medium and are no longer being
primed by the pump.
The tank has to be dimensioned and mounted in such

fashion that the use of maximum allowable flow and media
temperatures are not exceeded, proper installations mea-
sures achieve this goal.
The lifetime of a screw pump is determined by the cleanliness of the
product and its relationship to the tight tolerances between the rotors
and the rotor sleeve. We recommend the installation of suction strain-
ers with the following mesh sizes:
Mesh size viscosity

0.3 0.5 mm >150 mm2/s
0.1 0.3 mm 37 150 mm2/s
0.06 0.1 mm <37 mm2/s
During the connection of the piping to the pump the flow direction
through the pump has to be observed (arrows on the pump). The con-
nection of a pressure gauge on the pump body should be planned.
The cleaning of the pipework should not be executed with water

or with fluids with minimum viscosity below the minimum indica-
ted viscosity shown in the pump data sheet. During hydrostatic
test of the whole pipework system, the pump must be isolated.
The hydrotest of the pump (dynamic or static) will cause damage
to the pump (especially to the shaft sealing system). If this proce-
dure is not maintained, the guarantee is not void.
4.6.4.5. Support Connections
All other support connections have to be dimensioned properly and
brought towards the unit. The user is solely responsible for the sizing
and material selection. In principal no mechanical forces are allowed to
take place. Damaged support pipes have to be repaired or exchanged
immediately.
E 185 5253_e_Rev.1
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L3NG
5. Mounting and Installation furthermore cause damage to the pump. Mounting the
pump to a driver, care should be taken that the max. axial shift (dis-
5.1. Tools
tance between shafts) the maximum eccentricity (center offset be-
For the total mounting or disassembly standard tools are necessary: tween the shafts) and the maximum angularity of the two shafts do not
Allen head wrenches according to DIN 911 exceed the recommended data of the manufacturers. Axial forces are
Open end wrenches according to DIN 838 ISO 3318 not allowed to be transmitted into the pump.
Open end wrenches according to DIN 3110 Impacts and knocks on the driving spindle have to be avoided.
Machinist hammer according to DIN 1041 All rotating parts have to be protected against uninten-
Rubber mallet tional touch! Damages caused by improper mounting or
Screw driver according to DIN 5.264/A adjustment of the pump and motor, are not covered under
Gear puller 2 or 3 armed warranty.
Pliers for snap rings according to DIN 5254
Snap ring pliers according to DIN 5256
Mounting sleeves for ball bearings
Spindle set clamp device
5.3. Initial Installation of the Pump Unit

5.2. Initial Installation of the Pump
The pump unit has to be inspected at the job site for probable dam-
The shaft end of the pump and driver have to be aligned ages. If the unit is assembled at the job site, follow 5.2. After proper
carefully, since eccentricity, nonparallelisms and plain alignment, the complete unit has to be anchored accordingly. Base and
arrows will fast destroy transmission elements and can foundations, see 4.6.

L3NG
6. Start up Shut down case, cavitation will arise. The level of the media in the tank shall be
checked from time to time. Media level for submerged units shall not
6.1. Technical Documentation
fall below the level of the suction input stub.
Before start up check all technical demands
Attention and documentations. Especially check the To the save and troublefree operation, the valve adjusting pres-
sure is to be examined see chapter 7.5.1
pump unit on:
serial no. 6.5. Shut down of the Pump
type and size
flow direction and operation type For the shut down of the driver no preparations are needed. As the
pump is being driven directly from the diesel motor, the pump only
6.2. Pipe Schematic and Measuring Points comes to a standstill when the diesel motor has been switched off (this
The total piping arrangement, proper connection and dimension of is harmless for the pump). It is recommended to install a check valve
measuring and control devices have to be observed. between the isolation valve and discharge line. At longer shut down the
The cleaning of the pipework should not be executed with water isolation valves should be closed. If a change of the fluid concentra-
or with fluids with minimum viscosity below the minimum indication, crystallization, solidification and others have to be taken into con-
ted viscosity shown in the pump data sheet. During hydrostatic sideration, the pump has to be drained and flushed with a proper fluid.
test of the whole pipework system, the pump must be isolated. 6.6. Restarting
The hydrotest of the pump (dynamic or static) will cause damage
to the pump (especially to the shaft sealing system). If this proce- After a short shut down, the pump can be restarted without any prepa-
dure is not maintained, the guarantee is not void. rations. After longer still standing time or reinstallation of the pump,
Damages which occur due to improper positioning or di- the procedure according to section 6.3, preparation for start up has to
mensioning of measuring and control devices, are not be followed.
covered under warranty. 6.7. Still Stand
6.7.1. Shut down for up to 3 Months
6.3. Preparation for Start up If the start up of the pump is carried out within 3 months of installation or
Before initial start up the following scopes have to be the shut down of the pump is less than 3 months, no special preserva-
completed: tion is required.
Cleaning of the piping, section 4.7.4.4 6.7.2. Shut down from 3 to 6 Months
Checking of the anchoring, section 4.7.4.3 Before the initial start up the suction and discharge port
Checking on power supply to the motor have to be covered with a blank. At shut down, suction
Direction of rotation on driver. Check the direction of and discharge insulation valves have to be closed. With
rotation of the gear, the direction of rotation must cor- that measure the pump remains filled with product. If the
respond to the direction of rotation arrow on the pump. product includes aggressive particles which might attack the materials
By an incorrect direction of rotation, the pump will proof construction of the pump, follow according section 6.7.3.
duce no suction, this will cause the pump to be dama-
ged. 6.7.3. Shut down for more than 6 Months
Remove blind plugs on suction and discharge lines, section 3.3 The pump has to be closed off and sealed off according to
Check piping according to flow direction, section 4.3.9 and 4.7.4.4 6.7.2. and has to be filled with preservation material. To
Visual checking of the pump unit, section 6.1 protect the running surfaces of the bearings against com-
Opening of the separation valves pression marks caused by vibrations or shocks, the
Fill the pump with product to insure protection against dry run. power rotor is to be turned regularily. (e.g. every 4 weeks rotated
Take pre lubricating pump into operation. manually, so that parts like the rotor set and the bearing should change
All adjusting and control equipment has to be checked on function their position each time.)
after installation ( i.e., emergency switch off, needle pressure
gauge and others ) 6.8. Operation Monitoring
To protect people, all equipment has to be according to the rules Monitoring of Leistritz screw pumps can be kept to a mini-
and regulations mum by correct mounting and operation. At regular inter-
6.4. Start up vals, the operating pressure, media flow, excessive
power consumption, gaskets and filter soiling shall be ob-
Before start up, the rotation direction and speed has to be
served. Any unusual pump noises shall be investigated. The useful life
checked. Suction and pressure gauges have to be ob-
cycle of the pump depends upon the degree of purity of the flow me-
served and compared to order and operation data. Tem-
dia.A visual check of the pump unit shall be carried out at least once per
perature and viscosity of the product should be checked.
month. The pump shall operate smoothly without undue vibration. The
In the area on the driving side of the pump casing, the tem-
pump shall not be allowed to run dry!
perature can exceed the flow medium by approx.
1015C. However, it should not exceed 100C. If standby pumps are installed, these must be put into operation occa-
sionally so as to ensure that they are fully operational when needed. In
addition, the spindles shall be manually rotated at regular intervals acc.
The discharge line has to be vented until product flows out of the vent to Para. 6.7.3.
valve or vent screw. The venting devices have to be closed after this
6.9. Bearing of the Power Rotor
procedure.
After the pump has been switched on, the total flow pressure, media The bearing of the driving spindle is a service free,
flow, viscosity, temperature, speed and current consumption shall be grooved ball bearing that is flushed by the pump media.
compared with the order, resp. the operating data. Care shall be taken This bearing is designed for a working life cycle of 17500
to ensure that the drive motor is not overloaded due to transporting a operating hours under the operating conditions as de-
flow media with a higher specific gravity or higher viscosity than that of scribed in Para. 4.6.2. Due to rough operating conditions, high temper-
the media for which the pump was designed originally, and also that the atures, soiled media, abrasive particles in the flow media,etc.,the life
suction head is not higher than that of the capacity of the pump. In this time will be considerably reduced.

L3NG
7. Maintenance 7.3.3. Disassembly and Assembly
7.1. General The most important disassembling and mounting steps
The maintenance work almost exclusively includes checking of pump are described as follows:
parts for wear and damage. Leistritz Screw Pumps of the Series L3NG No warranty claims can be accepted if all necessary as-
need minimum maintenance, as long as the confirmed operating data sembly steps have not been kept in order, or damages due
is adhered to and the fluid is as free as possible from abrasive particles. to improper disassembly or assembly have occurred.
The cleanliness and the capability to lubricate the product, are domi-
nant in the expectancy life of a pump. If a high operation safety is nec- 7.3.4. Tools
essary, we recommend the following maintenance intervals according
Necessary Assembly Tools (see Section 5.1)
to section 7.2.
7.2. Maintenance and Inspection
7.4. Disassembly of the Pump
After 500 hours of operation the pump should be ex- Motor or driver have to be made unfunctional.
amined, the pump should be checked for unusual noises
Check the insulation valves in suction and discharge
and it shall be checked with a temperature sensor. The line, they have to be closed.
temperature difference between the area on driven and
Let pump cool down to surrounding environment tem-
driving side has to be determined. The temperature dif- perature.
ference should not exceed 1015C.
Disconnect suction and discharge flanges.
After 24.000 hours the pump should be disassembled and all inner Disconnect pressure control valve unit and remove.
parts should be examined for damage and wear. The running sur-
Loosen fixing screws at the mounting flange, press
faces on the face of the driving spindle have to be checked whether the pump with pullingoff screws from the hub flange
they are probably worn out. Parts which are worn out always have to
and detach it with lifting device.
be exchanged. Release and remove driving gear on pump side.
Check the casing and the flow pockets in the relief valve for dirt con-
Relieve the valve spring (pos. 235) with an adjusting
tamination. If dirt deposits are noted, it needs to be cleaned out. screw (only for variant with valve).
7.3. Disassembly and Assembly loosen screws (pos. 211) and take off the valve cover,
7.3.1. General Precaution carefully (attention: residual tension through valve
spring possible)
With proper supervision of the pump, operation interruptions which Remove valve spring (pos. 235).
might make a disassembly necessary, are very rare. If an interruption In order to remove end side cover (position number 30) take out
occurs, the possible cause should be determined before disassembly, bolts (position number 32) and remove gaskets (position number
if at all possible. The trouble shooting table in section 8.1 gives hints 31).
about possible causes. During disassembly and assembly, all parts Remove valve cone (pos. 219)
have to be handled with care. Shocks and impacts always have to be Remove circlip (pos.174)
avoided. All parts have to be cleaned carefully, possibly reconditioned Draw the spindle set including the ball bearing with takeoff device
or exchanged for spare parts. After assembly the power rotor has to halfway up.
rotate freely, otherwise the bearing could be damaged. The proper sec- Fix idler spindles and driving spindle with a spindle set clamp de-
tional drawing has to be used as a work basis for all works which have vice. See Section 5.1 Tools
to be carried out. Remove spindle set completely out of the casing (use lifting de-
7.3.2. Customer Service/Personnel/Danger vice).
For mounting and repair LEISTRITZ personnel can be made available Loosen spindle set clamping device and remove idler spindles
to the user upon request. (pos.151) from the driving spindle (pos.150) .
If repairs are carried out the user or LEISTRITZ personnel, Remove circlip (pos.173) and distance ring (pos.172).
the pump always has to be under atmospheric pressure, Draw the groove ball bearing with takeoff device from the driving
completely emptied and cleaned. This is essential for spindle
pumps which have to be shipped to our factory for repair. Attention: The shaft nut at the driving spindle must not be loos-
Receipt of pumps which are filled with product, has to be rejected to ened (manufacturing depending connection)
protect the fellow worker and for environmental reasons. Otherwise we
would have to charge the user for an environmental improper disposal. 7.5. Assembly of the Pump
A reassembly can only be permitted if full functional and
Attention For Pumps handling dangerous material or envi-
ronmental endangering products the user has to undefective parts are used. We recommend as well a
inform the personnel at the job site or at a back to cleaning of heavily stained parts
the factory shipment, the factory has to be informed with-
out asking. In this case, the user has to supply a DIN Check groove ball bearing (pos. 170) on probable damages such
safety sheet to identify the pump product. us eccentricity stiffness etc. carry to a temperature of approx.
Dangerous products are: 80C (degrees) and slide or press it onto the driving spindle my
means of a sleeve or a ring bush. Do not apply heavy strokes in
Toxic, cancer creating, noxious to unborn life and gene
order to fix the groove ball bearing. This would cause damage to
changing materials, which endanger in other ways
the running surface and the balls. Lock it afterwards with a dis-
peoples health. Acids, irritating materials, explosion en-
tance ring (pos. 172) and circlip (pos. 173).
dangering, flame exhilarating, high and light flammable
Align the idler spindles (pos. 151) in pairs around the driving
materials
spindle and join it with the spindle set clamp device.
Slighly lub the spindle fixing borings in the pump casing slightly
The user is solely responsible for the site with oil.
warnings signs and these signs have to be Insert the complete spindle set into the pump casing (use lifting
observed. At all work at the job site, your own device). Remove spindle set clamp device again and push the
or LEISTRITZ personnel has to be advised spindle set completely into the ball bearing. Attention : Press in
about all dangers which might occur during slightly the ball bearing over outer ring with sleeve . Do not
disassembly and repair. use hammer strokes !
E 185 5253_e_Rev. 1 Page 9 of Page 13

L3NG
Install the circlip (pos. 174) to be followed and the pressure limitation valve, safety valve, if existing
Insert valve cone (pos. 219) in the valve seat (pos. 217) (only for has to be adjusted.
variant with valve). Slightly preload the valve spring (Pos. 235) with the setting screw
Place gasket (pos. 031) onto the end side cover of the pump cas- (Pos. 222).
ing (pos. 001). Let the pump run, and open throttle slide A (delivery side).
Bolt up tightly the end side cover (pos. 030) with the mounting Close throttle slide C at the inlet point so that the pressure display
screws (pos. 032) indicates approx. 0.4 to 0.5 bar.
Close throttle slide A slowly while constantly watching pressure
Place the valve spring (pos. 235) in the valve cone (pos. 219)
gauge B (delivery side) and D (inlet side).
Insert the gasket (pos. 210) into the cover, end side (pos. 030).
If the pressure at D moves slightly towards atmospheric pressure,
Insert valve cover (pos. 209) with preassembled adjusting screw
then the valve has opened at value B.
(pos. 222) and spring collar (pos. 220) into the valve room. Pay
If the desired value has not been reached yet, open throttle slide A
attention that the valve spring fits into the spring collar and the again and change the opening pressure with the setting screw
grooved pin (pos. 221) locks into the nut of the pump casing. (Pos. 222).
Fix the valve cover with the screws (pos. 211). Turning clockwise sets the opening pressure lower, and turning
The pump has to be mounted again onto the outer casing of the diesel anticlockwise sets it higher.
motor and to be fixed acc. section 5.2. after complete reassembling. Adjustment has to be repeated as many times as necessary
There after the discharge suction, supply lines and pressure control until the correct settingpressure isreached.
valve have to be connected properly. At the restartup, section 6.0 has Further steps see section 6.4.
Inlet side
Delivery side
A B
D
Suction line
C
Pressure line
7.5.1. Notice to the valve adjusting pressures Valve actuating pressure; this is the pressure at which the valve be-
Like all positivedisplacement pumps, this screw pump requires a gins to open.
pressure relief valve to protect against overloading. This valve can be Valve shortcircuit pressure; this is the pressure at which the entire
installed externally, as an external valve in the piping system, or directly pump feed quantity flows off via the valve.
as an attached part on the pump. The respective model is specified in Valve closing pressure; this is the pressure at which the valve has
the data sheet or the valid drawings. closed again following relief.
If no other agreement has been made, the valve actuation pressure is It must be noted that at low operation pressures, the adjustment values
preset at the factory on the test bench. The opening pressure is ap- are selected so that the valve closing pressure is always above the
prox. 10 to 20 % above the operating pressure. However, the values on operating pressure and the valve shortcircuit pressure does not
the system must be checked prior to commissioning. lead to overloading of the pump and drive.
The following distinction is made for valves:

L3NG
If this is not observed, damage to the pump and drive may result. We
shall assume no liability whatsoever for damage resulting from a failure
to observe this fact.
7.6. Spare Parts
In general we recommend the user to put a complete pump on the shelf
for stock. Furthermore, all spare parts can be selected separately ac-
cording to sectional drawing with parts list by the individual user. By do-
ing so each order needs to be accompanied by the following informa-
tion from the purchaser:
Pump Type
Pump Size
Leistritz Serial Number
Cross Sectional Drawing Number
Purchaser / User
Name
Address and Telephone Number
An interchangeability can only be guarantied
Attention if accurate information is given.
Conserving and intermediate storage of spare parts or spare pumps,

see section 3.4. and 3.5.

L3NG
8. Trouble Shooting Solving all of the particular disturbances the pump needs
8.1. Table to define Reason and solving of Problems to be without system pressure and needs to be drained.
The table below is used to define possible disturbances at the pump

unit. If problems occur during operation of the unit, which are not listed
in the trouble shooting list, we recommend a check back with the fac-
tory or the sales forces.
Problems at the pump unit

Pressure and flow rate too low
Pump does not lift discharge
Noise creation in the pump
Motor over loaded

Fluctuating flow
Pump is seized
Unit vibrates
Pump leaks
Reasons and Resolution
Compare rotation direction arrow of the pump with the motor direction of rotation,
probably incorrect pump arrangement.
Check suction pipelines, stopcocks for leaks and setting of pressure relief valve.
Vacuum suction head to high, shorten suction pipeline, mount pump at a lower
position. Reduce flow turbulence, lay suction pipelines straighter.
System and pump are empty. Fill tank with media.
Discharge pressure too high. Check operating data of pump, media viscosity.
Compare operating data. Heat media if necessary.
Viscosity too low. Compare operating data, increase drive speed as required.
Select a pump with steeper spindle pitch or next larger size of motor. Increase
media viscosity by changing media temperature.
During operation the media tank was not filled with media.
Air bubbles in suction and discharge system. Vent pump at highest point. Select
a larger media tank with better deaerating characteristics. Submerge return line
under the media level in the tank.
Shafts or spindles have seized in the housing borings. If the surfaces are only
slightly damaged these can be honed or lapped. Check operating data and do no
exceed.
Internal parts of pump worn, fit spare parts, fill with media or change filter insert,
monitor operating characteristics and do not exceed.
Pump not proper aligned and mounted, new alignment,check centering.
Connection lines are under tension. Refit lines in a tension free manner. If neces-
sary fit compensators into the lines. Support and secure pressure lines.
Ball or roller bearings defective, dismantle and replace.

L3NG
8.2. Torque Requirements
Necessary torque requirements according BDI 2230, sheet 1, (me- 8.3. Allowable pipe forces and moments
dium friction) factor 0.14 for shafts, screws and metric standard thread Forces and moments shown on assembly and dimensional drawings
according to DIN 13, part 13, and head dimension of hex head screws shall not be exceeded.
according to DIN 913 or Allen head screws according to DIN 912
Violating and exceeding these values can damage the
thread size property class starting torque in Nm
pump causing operating problems. Eventually occurring
M6 8.8 10.4 thermo tensions have to be corrected by design modifica-
M8 8.8 25 tion ( flexible piping).
M10 8.8 51
M12 8.8 87
M16 8.8 215
M20 8.8 430
M24 8.8 740
M30 8.8 1500
(M33) 8.8 2000
M36 8.8 2600
8.4 Amendments to this Technical Documentation.
RevNo. Chapter Page Modification Date Name Checked

1 Document updated 10.7.06
First edition Prepared Checked .......................... Approval ............................ ........

Date 8.August.1997 ............................. .......................... ....................................
Department KDP..................... ......................... ....................................
9. Drawings, Data Sheets, Appendix
10.

Auftragsbesttigung
Abnahmeprfzertifikat M Orderconfirmation KB1472600200
Ausgabe Seite
Inspection Test Certificate M Edition 0 Page 1/1
Datum
Pumpen GmbH nach/acc. to DIN 55 350 Teil/part 18 Date 11.09.07
Anlage Ktr:nicht bek. Schmierldruckpumpe Endkunde
Equipment D 1686461 Customer
Besteller Auftrags-Nr.
Purchaser Caterpillar Order No. 75669/215 Sachnr.283730203
Artikel Serien-Nr.
Object L3NG-200/180-IFOGVA-O Serial No. 120436-000
Betriebsbedingungen / Operating conditions Messergebnisse / Test results

Frderflssigkeit Frderflssigkeit
Flow liquid SAE 40 Flow liquid Shell Morlina 68
Viskositt Viskositt
Viscosity mm/s 26,0 Viscosity mm/s 56,2
Betriebstemperatur Temperatur
Op. Temperature C 80,00 Temperature C 26,0
Frderstrom Frderstrom
Delivery l/min 4621,0 Delivery l/min 4668,00
Frderdruck gesamt Druck
Tot. man. Pressure bar 10,00 Pressure bar 10,00
Drehzahl Drehzahl
Speed min-1 1500,0 Speed min-1 1500
NPSH Max. Saugdruck
NPSH mWs 5,50 Max.suct.pressure bar -0,50
Leistungsbedarf Leistungsbedarf
Power input kW 95,00 Power input kW 100,10
Test Toleranz NPSH
Test tolerance VDMA 24284 II NPSH mWs 4,88
Umgerechnet auf Betriebsdaten / Calculated to operating conditions

Viskositt
Viscosity mm/s 26,0
Frdermenge
Capacity l/min 4611,8
Druck
Pressure bar 10,0
Drehzahl
Speed min-1 1500
Leistungsbedarf
Power input kW 95,8
NPSH
NPSH mWs
Sicherheitsventil / Safety valve

ffnet bei Offen bei Schliet bei
Opens at bar Open at bar Closed at bar
Statische Druckprfung nach/ Hydrostatic test / acc. QSP 114

Prfteil / Test part Werkstoff / Material Prfdruck / Test pressure
Pumpengehuse/Pump casing 0.7040 20 bar
bar
bar
bar
bar
Prfmedium Prfdauer
Test fluid KSS Test duration 15 min
Geprft/Tested Abnahme Bemerkungen
Unterschrift/Signature Acceptance Blanco Remarks xmass
Breuer
Datum/Date
10.09.07
Das Protokoll ist elektronisch erstellt und ohne Unterschrift gltig. Der Aussteller ist QS- autorisiert.
The certificate was written electronically and is valid without signature. The issuer is quality assurance - authorized.
Oil Mist Detector C5.05.11.02.03.00
-
Oil Mist Detector
en / 27.04.2004 FD020002 1/47

VISATRON VN 115 / 87 EMC, VN 115 / 87
Operating Instructions VN 116 / 87 EMC, VN 116 / 87

Article No.: 10024
Edition: 04 U VN 215 / 87 EMC, VN 215 / 87
SCHALLER-AUTOMATION
INDUSTRIAL AUTOMATION TECHNOLOGY KG
D - 66440 Blieskastel / Saar . Industriering 14 . Germany / SW

Tel. ++ 49 (0) 6842 508 - 0 . Telex 44 685 . Fax ++ 49 (0) 6842 508 - 260
It is recommended to read this instruction manual
before commencing the repair, assembly or
commissioning of the oil mist detector system!
!
CAUTION: The manufacturers warranty will become

void if these instructions are not followed!
Unless notified to the contrary, these operating

instructions are applicable for:
VN 115 / 87 - EMC
VN 116 / 87 - EMC
VN 215 / 87 - EMC
VN 115 / 87
VN 116 / 87
VN 215 / 87
In case of an oil mist alarm, the oil mist

detector (OMD) must be in condition to react
within the next few seconds and shut down
the engine, in order to minimise immediate or
consequential damages!
The corresponding relay contacts are instantly

connected to trigger the alarm safety system!
Safety Signs
! in general
Safety Signs
electrical
Cmos
Inhalt,
Index
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1. Product Description
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......................................................................
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2. Installation ................................................................................
3. Commissioning ...........................................................................
4. Performance Test / Maintenance ........................................................
5. Failures and Corrective Action ...........................................................
6. Repairing .................................................................................
7. Spare Parts ...............................................................................
8. Service Facility Addresses ...............................................................
9. Brochures, Leaflets, etc. .................................................................
10. General Information ......................................................................
11. Notes .....................................................................................

.
12. Options ...................................................................................

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1. 01
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Product Description
Application
Oil mist detectors of the VISATRON series protect large diesel engines of all
operation classes against serious damages originating from crankdrive bearing or
piston component overheating.
Functional Description
The atmosphere of the crankcase compartments is continuously drawn out by
means of headers and directed through an optical opacity measuring track. In this
measuring track the opacity (turbidity) of the drawn crankcase atmosphere is
determined by means of infrared light.
Main Structural Components ( see Fig. 1.01 / 1 to 1.01 / 3 )

1. Base plate with air jet pump for generating the required negative
pressure ( 1 ) and main connector plug ( 5 )
2. Measuring head with electronic module, display window ( 2 )
and inspection cover ( 3 )
3. Connection for headers ( 4 ) or individual pipes ( 6 )
Connection for headers designed as:
VN 115 / 87, VN 115 / 87 - EMC ( see Fig. 1.01 / 1 )

Connecting box for connecting two header pipes
(This type of oil mist detector may show an oil mist alarm, without identifying
the individual compartment of damaged engine side )
VN 116 / 87, VN 116 / 87 - EMC ( see Fig. 1.01 / 2 )
Valve box for connecting two header pipes
(This type of oil mist detector may show an oil mist alarm, identifying in the
valve box window whether a damage has occurred in compartments located
either to the left side or the right side of the detector )
VN 215 / 87, VN 215 / 87 - EMC ( see Fig. 1.01 / 3 )
Valve box for connecting up to ten individual pipes
(This type of oil mist detector may show an oil mist alarm, identifying in the
valve box window in which individual compartment the damage has occurred )
VN 115 / 87- EMC VN 116 / 87- EMC VN 215 / 87- EMC

VN 115 / 87 VN 116 / 87 VN 215 / 87
3 3 3
2
2 2 6
4 4
1 1
1
5 5 5
1. 01 / 1 1. 01 / 2 1. 01 / 3 12.95
jlgslkgs tpiz
1. 02
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Technical Data
Operating voltage: 24 V DC +/- 25%, with reverse battery protection

Electrical Data
Power consumption: Maximum 3 A
Electromagnetic
compatibility: Wiring failures:
50 Hz to 10 kHz, 3 V eff. /10 kHz to 50 MHz, 1 V eff.
Only
Electromagnetic fields:
VN 115 / 87
30 kHz to 200 MHz, field strength 10 V / m,
VN 116 / 87 Damped oscillation:
VN 215 / 87 1 MHz,1 kV, 400 pulses per second,
High- energy pulses:
0.5 joule, 5 kV, Ri = 500
Electrom agnetic fields:

30 kHz to 1 GHz with 10 V/m, Acc. to IEC 801 - 3
VN 115 / 87 - EMC ( ambient class 3, 10 V / m, 30kHz - 16Hz )
VN 116 / 87 - EMC Fast transients ( burst ):
VN 215 / 87 - EMC Acc. to IEC 801 - 4, ( ambient class 3 )
In addition: Electrostatic discharge:
Acc. to IEC 801 - 2
Load to relay outputs: Maximum 60 V AC / DC, 2 A AC / DC, 60 W, 125 VA
Sensitivity: 1st row: switch position, 2nd and 3rd row: required
opacity for triggering an alarm
Switch position: 1 2 3 4 5 6 7 8 9 10
Alarm level: (% of opacity)

of VN 115 / 87 - EMC 0,5 1,0 1,5 2,0 3,0 5,0 7,0 10,0 15,0 25,0
and VN 115 / 87
Alarm level: (% of opacity)

of VN 116 / 87 - EMC
and VN 116 / 87 0,7 1,1 1,6 2,4 3,7 5,5 8,2 12,4 18,5 27,8
of VN 215 / 87 - EMC
and VN 215 / 87
12. 95
jlgslkgs tpiz
1. 03
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Technical Data
Negative
pressure measured: At least 60 mm, maximum 80 mm W.G.
in Measuring Unit
Pneumatic Data
Driving air for air jet pump: 0.3 to 0.5 bar
Air consumption: Dependent on the number of

suction points, however, max. 1 normal m3 / h
Protection: IP 44
Admissible operating
temperature range: 0 C bis +70 C
Admissible oil mist

temperaturerange: Maximum +70 C
Ambient Conditions
Admissible storage and
transport temperature range: - 25 C bis +80 C
Humidity: Maximum 90% relative humidity
Vibration: Maximum acceleration 6 g
Dimensions: ( see drawings 1.04 / 1, 1.04 / 2, 1.05 / 1 )
Weights: VN 115 / 87, VN 115 / 87 - EMC 7.5 kg

VN 116 / 87, VN 116 / 87 - EMC 9.4 kg
VN 215 / 87, VN 215 / 87 - EMC 9.6 kg
Mechanical
Pipe connections for Data

suction system: VN 115 / 87, VN 115 / 87 - EMC and
VN 116 / 87, VN 116 / 87 - EMC
Header ( two pieces, 22 x 2 ( i.d. 18 mm )
maximum length: 9 m, R 1/2" and R 3/4"
VN 215 / 87, VN 215 / 87 - EMC
Individual pipes (maximum 10 pieces ),
14 x 2 ( i.d. 10mm ) maximum length: 9 m
12.95
jlgslkgs tpiz
1.04
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Dimensions
ca.159
453
113,5
175
G 1/2 A
VN 115 / 87 - EMC
50
G 1/2 A
G 3/4 A
VN 115 / 87 G 3/4 A
Pg 21
174
111
158
RESET
53
43 140
49 146
172,5 171
1. 04 / 1
ca.159
146
120,5
175
453
VN 116 / 87 - EMC
G 1/2 A
VN 116 / 87
50
G 3/4 A
G 1/2 A
G 3/4 A
174
Pg 21
158
111
RESET
53
43 140
49
172,5 171
12.95 1. 04 / 2
jlgslkgs tpiz
1. 05
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ca.159
146
18 111,5
175
453
VN 215 / 87 - EMC
5 6
4 7
3 8 VN 215 / 87
56
28
G 3/4 A
2 9
G 1/2 A
1 10
174
155
Pg 21
111
RESET
53
43 140
49
171
172,5
1. 05 / 1
4 threads or holes for screws M8
Fastening
VN 115 / 87 - EMC
VN 116 / 87 - EMC
VN 215 / 87 - EMC
175
VN 115 / 87
VN 116 / 87
VN 215 / 87
120
1. 05 / 2
12.95
2. 01
Installation
General
It is important to emphasize cleanliness during the assembly work!

Clean pipelines and fastening parts before assembly. !
Lay pipes in a stress- free manner!
Installation position of the device:

Locate the oil mist detector in a vertical position!
Make sure not to install the device within the airflow of blowers or air deflectors.
Suction pipes VN 115 / 87 - EMC and VN 116 / 87 - EMC ( see Fig. 2.1 / 1 )
Material: Seamless steel pipes,
header ( 1 ) 22 x 2 mm ( i.d. 18mm ), max. length: 9 m
suction pipes ( 2 ) 10 x 2 mm ( i.d. not less than 6mm )
Pipe Laying: Ascending to the device,

Ascending
ascending gradient 2% to 4%, without sagging, avoid oil collection
Gradient 2% to 4%!
( see Fig. 2.01 / 1 )
Consider toavoid oil

collection when laying
the headers! Oil must
always drain back to
engine
2% bis 4%
VN 115 / 87- EMC

VN 116 / 87- EMC
VN 115 / 87
VN 116 / 87
2 1
2. 01 / 1 12.95
2. 02
VN 115 / 87 - EMC Headers above suction points for:
VN 116 / 87 - EMC und

VN 115 / 87
VN 116 / 87
! 1
without 2
pipe end- siphon
Lay headers in
ascending direction
to the detector! 2. 02 / 1
Headers below suction points:
with
pipe end- siphon
1
Lay headers in
2
asccending direction
3
to the detector!
2. 02 / 2
1 Header pipe 22 mm x 2 mm ( i.d. 18mm )
2 Compartment suction pipes to header 10 mm x 2 mm
( i.d. not less than 6mm )
3 Pipe end- siphon 100 mm with oil return back to the engine,
or 200 mm with oil discharge outside the engine
12.95
2. 03
VN 215 / 87 - EMC
VN 215 / 87
!
Lay suction pipes in
descending manner!
Suction funnel
2. 03 / 1
Suction pipes VN 215 / 87 - EMC, VN 215 / 87
Material: Seamless steel pipes, 14 mm x 2 mm ( i.d. 10mm )
Pipe Laying: Ascending to the device, ascending gradient 2 - 4%

( see Fig. 2. 03 / 1 )
Siphon blocks
!
Pipes can be
mounted horizontally
Avoid sagging or
oil collection
Suction funnel
2. 03 / 2
12.95
2. 04
Suction funnel in 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 Fig. 2. 04 / 1 ).
Caution: Make sure funnels are not interfering with
rotating or moving parts of the engine.
Sense of
engine rotation
Suction funnel Suction funnel Suction funnel

for siphons and for sipons and only for
engine wall connection engine wall connection engine wall connection
2. 04 / 1
Suction funnel with

oil discharge labyrinth
Sense of
engine rotation
Push in
suction funnel pipe
firmly to the stop
Oil mist
during assembly!
Crankcase
compartment
Oil return
Engine wall
2. 04 / 2
Straight engine wall connection Engine wall connection LL - type
!
Observe mounting
position!
Engine wall connection L - type
12.95 2. 04 / 3
2. 05
Installation of siphon blocks
cutting ring
2. 05 / 1 2. 05 / 4
2. 05 / 2 2. 05 / 5
Tightening torque: 30 Nm
2. 05 / 3 2. 05 / 6
12.95
2. 06
Suction piping of VN 215 / 87 - EMC
Connecting flange,
Valve box
left right
5 6
4 7
3 8
2 9
1 10
4 - cylinders 1 2 3 4
5 6
4 7
3 8
2 9
1 10
5 - cylinders 1 2 3 4 5
5 6
4 7
3 8
2 9
1 10
5 - cylinders 1 2 3 4 5
5 6
4 7
3 8
2 9
1 10
6 - cylinders 1 2 3 4 5 6
5 6
4 7
3 8
2 9
1 10
7 - cylinders 1 2 3 4 5 6 7
Connection numbers
5
to valve box
Closed by
drain plug
Connection for Unused pipe connection bores in flangeare to be plugged
suction pipe
with the supplied viton plugs.
12.95
2. 07
Suction piping of VN 215 / 87 - EMC
Connecting flange,
Valve box
left right
5 6
4 7
3 8
2 9
1 10
1 2 3 4 5 6 7 7 - cylinders
5 6
4 7
3 8
2 9
1 10
1 2 3 4 5 6 7 8 8 - cylinders
5 6
4 7
3 8
2 9
1 10
1 2 3 4 5 6 7 8 9 9 - cylinders
5 6
4 7
3 8
2 9
1 10
1 2 3 4 5 6 7 8 9 9 - cylinders
5 6
4 7
3 8
2 9
1 10
1 2 3 4 5 6 7 8 9 10 10 - cylinders
Connection numbers
5
to valve box
Closed by
drain plug
Connection for
Unused pipe connection bores in flangeare to be plugged
suction pipe
with the supplied viton plugs.
12.95
2. 08
Air supply
3 6
!
No back pressure
and no oil collection
is allowed in
exhaustair pipe!
1 2 4 5
2. 08 / 1
1 Discharge funnel
2 Draft air connection set
Parts are not included 3 Exhaust air connection
in the scope of supply, Pressure regulator unit consisting of:
but they can be 4 Throttle block
purchased as an option! 5 Pressure connection 2 - 12 bar
6 Pressure regulator
If parts are not included in the scope of supply they can be purchased as an option!
To avoid backpressure, lay exhaust pipes without any reducers (DN 22).
Avoid sagging and oil collection in pipes ( See drawing 2. 08 / 1 )
Electrical connection ( see Fig. 2. 09 / 1 )

Connection: 24 V DC
min. 18 V
max. 30 V
Power consumption: 3A
Protection: 4 A with semi time- lag
!
When power is supplied by batteries, charging voltages of more than 30 V
might occur. These voltages are not permitted. Device will go into failure mode.
Voltage limiters must be installed! ( See Fig. 2. 09 / 2 )
12.95
2. 09
Terminal Plan
Oil mist detector Ship system /

Alarm system
2 A with semi time-lag 4 A with semi time-lag
1
Heating +
24 V DC 25%, maximum 3 A
system 2
-
Ready relay 3 Oil mist detector in operation

Contact load
Device in operation: green READY LED on,
Voltage: 4 contacts 4 and 5 closed,
maximum 60 V AC / DC contacts 3 and 5 open
Current: Device faulty: green READY LED off,
maximum 2 A 5 contacts 3 and 5 closed
maximum 60 W / 125 VA contacts 4 and 5 open
6 Oil mist alarm for alarm system

Alarm relay
Oil mist alarm: green READY LED on,
Resistor for 7 red ALARM LED on,
wire break contacts 7 and 8 closed
(Interrupted circuit contacts 6 and 8 open
monitoring) 8 No oil mist alarm: contacts 6 and 8 closed
contacts 7 and 8 open
9
2 lines shielded:
+
Analog display, Art. No. 150 066
10 - 0 - 1 mA
Ri 400
11
12 Reserved for the manufacturer,

do not utilise!
13
14 Oil mist alarm for safety system

Alarm relay Oil mist alarm: green READY LED on,
15 red ALARM LED on
Resistor for contacts 15 and 16 closed
wire break inspection contacts 14 and 16 open
16 No oil mist alarm: contacts 14 and 16 closed
contacts 15 and 16 open
2. 09 / 1
Power supply connection for battery supply
+ -
2. 09 / 2 12.95
3. 01
Commissioning
Adjust suction pressure

The suction pressure must be calibrated by adjusting the pressure regulator when
the engine is at a standstill. Make sure ventilation of the engine room is in operation
( pressure difference in room ). An increase or decrease of the pressure
in the crankcase compartment during operation and its effect on the flow velocity
of the oil mist in the suction pipes, is largely compensated by the internal restriction
integrated in the device. (e.g., +25 mm W. G. in the crankcase compartment against
the atmosphere account for an increase of the oil mist flow velocity in the suction
pipes of approx. 8%; +50 mm W. G. of approx. 14%, a negligible figure).
This is important because precipitation of minute oil droplets of the oil mist
increases with a too high flow rate, thus reducing the sensitivity of the device.
Pressure regulator unit
1
3
3. 01 / 1
1. Connect U-tube pressure gauge at inspection cover. ( See Fig. 3. 01 / 1 )

( Pressure gauge is included in the service box, available as an option )
2. Loosen nut (1) and turn setscrew (2) in clockwise direction gently up to the stop. !
3. Open safety cover ( 3 ) at the throttle ( 5 ) and manually turn setscrew ( 4 )
in clockwise direction gently up to the stop. Adjust 60 mm W. G.!
4. Switch on compressed air supply with inlet pressure ( range 2 to 12 bar ).

The pressure gauge should now read zero pressure. After adjustment,
5. Turn setscrew ( 4 ) in counterclockwise direction until the U- tube remove U- tube
pressure gauge indicates a negative pressure of 80 mm W. G. pressure gauge
6. Close safety cover. and screw in the
7. Turn setscrew ( 2 ) in counterclockwise direction until the negative pressure previously removed
is only 60 mm W. G. plug
8. Tighten counternut ( 1 ).
12.95
3. 02
Exhaust air connection
3. 02 / 1
Filling of siphons
1 2 3
Slide pump filling

pipe up to the stop!
3. 02 / 2
1. Remove plug ( 1 ) and seal ring ( 2 ).

2. Introduce filling pump ( 3 ) against the stop.
3. Secure filling pump with fitting and slightly tighten union nut.
4. Pump 10 to 12 times with fast strokes.
5. After the filling process has been completed, remove pump and tighten
plug ( 1 ) and seal ring ( 2 ).
6. Measure negative pressure in the last siphon.
Apply power supply

Switch on power supply after checking the wiring.
12.95
3. 03
Device Operation
Control and display elements

After the preparation work has been carried out ( commissioning ) the device sets
itself to normal operation in approx. 30 seconds, after the power supply has been
switched on. This phase is indicated by a blinking LED No. 1.
The device only needs to be controlled, if:
- an oil mist alarm is recognized

- a malfunction of the oil mist detector is recognised
- the oil mist detector has to be maintained.
The present state of the device is indicated in the display window:
Visatron Display Window
Left side: LED No. (= error code) Right side: opacity in %

( flashlight ) (steady burning light)
No %
Alarm 14 7
Alarm LED
5
Opacity display
10
( Opacity )
Test 1
Test LED 7
0,6
4
0,3
Ready
Ready LED
1 0
4 6
Alarm level switch
Alarm Level
1 9
3. 03 / 1
12.95
3. 04
Display and function during normal operation:
The basic state ( oil mist opacity below alarm level ) is marked by
( see Fig. 3. 03 / 1 ):
- green READY LED is on

- the percentage of change in oil mist opacity with regard to basic opacity is
shown on the opacity display
- TEST LED is off
- ALARM LED is off
- READY relay switched on
Alarm Level
4
1
6
9 - ALARM relay switched off

- RESET button showing no function
- all valves in the valve box are opened, visible by the symbols displayed in the
inspection windows of the valve box
( only VN 116 / 87 - EMC, VN 116 / 87 and VN 215 / 87 - EMC, VN 215 / 87 )
only Opacity increase beyond search run level
VN 116 / 87 - EMC The search run level is fixed to 10 % of the adjusted alarm level. Valves in the
VN 116 / 87 valve box are activated according to a defined algorithm in order to find the
VN 215 / 87 - EMC corresponding engine side or compartment showing an increasing opacity
VN 215 / 87 ( search run ). The search run can be interrupted by pressing the RESET button.
Further opacity increase beyond alarm level marked by:

- blinking red ALARM LED
- READY relay is switched on
- ALARM relay is switched on
- 3 red symbols in the inspection window of the valve box showing the
engine side on which the damage has occurred
( only VN 116 / 87 - EMC, VN 116 / 87 )
Alarm Level
4
1
6
9
- a red symbol in the inspection window of the valve box showing the
compartment in which there is the highest opacity.
( only VN 215/ 87- EMC, VN 215/ 87 )
Alarm condition reset to basic state

- By pressing the RESET button
- If there is a device failure, e. g. breakdown of driving air supply
( READY LED is off )
12.95
3. 05
Display and function in case of a failure
A failure is shown by:
- green READY LED switched off
- the LED assigned to the failure is blinking in the opacity display
- TEST LED switched off
- ALARM LED switched off
- READY relay switched off
- ALARM relay switched off
- RESET button toggling from fault indication to opacity display and vice versa
Oil mist opacity exceeds alarm level

- TEST LED is additionally switched on
-
-
READY LED remains switched off
ALARM LED remains switched off!
!
Assignment of blinking LEDs on the opacity display showin device failure:
LED No. Cause of failure

14 Negative pressure in the measuring compartment too low
13 Infrared filter dirty
12 Not assigned
11 Ambient temperature < = 0 C
10 Ambient temperature > = 70 C
9 Electronics temperature < = 0 C
8 Electronics temperature > = 75 C
7 Reset button defective
6 Not assigned
5 Switch for adjusting sensitivity defective
4 Infrared light track defective
3 Flow control defective
2 Electronic module defective
1 Blinking for about 30 seconds after the oil mist detector
has been switched on ( warm-up phase )
To eliminate malfunctions see chapter Failures!
12.95
3. 06
ALARM LEVEL Switch
! Meaning of switch positions:
Modifications
only permitted by 1 = Highest sensitivity
consultation with the 4 = Factory-set sensitivity
manufacturer! 10 = Lowest sensitivity
To change sensitivity
( this must be done by authorized personnel only! ):
- Pull out plug with RESET button
Touch electronic - Unscrew measuring head casing
module only at - Remove electronic module (see Fig. 5.06/2)
exterior edges - Adjust new sensitivity at ALARM LEVEL switch by means of a screwdriver
of printed circuit - Reinsert electronic module
board! - Screw on measuring head casing

- Reconnect plug with RESET button
12.95
3. 07
Function of relay outputs
Function of READY relay

( corresponding to the state READY LED ) ( see Fig. 2. 09 / 1 )
- The relay is switched on when the oil mist detector is in operation
Function of ALARM relay

- The relay is switched on when the opacity exceeds the adjusted alarm level.
- Wire break monitoring by the alarm system is made possible by wire break
resistors installed between contacts 7 and 8 as well as between 14 and 16
( 33 k factory-preset ).
- To replace the line break resistors the electronic module must be removed.
The resistors are located near the relay on the lowest printed electronic board
(R222, R 223).
Attention:
In case of an oil mist alarm, the oil mist detector (OMD) must be in condition
to react within the next few seconds and shut down the engine,
in order to minimise immediate or consequential damages
!
12.95
3. 08
Performance Test
! Attention
The engine is uncontrolled during this performance test!
A performance test of the device without an alarm being indicated externally

can be carried out as follows:
- Open the cover of the measuring head casing
- Wait until the READY LED is switched off ( after about 10 seconds ) and LED14
Search Run only: is blinking ( negative pressure in the measuring compartment too low )
VN 116 / 87 - EMC - Darken the measuring track with filter glass or another object
VN 116 / 87 - Search run ( as described in 3. 04 ) is started
VN 215 / 87 - EMC - TEST LED lights up when alarm level is reached
VN 215 / 87 - Alarm reset by pressing the RESET button

- By pressing the RESET button once again the display switches over
from fault indication to opacity display
- Close cover again
- Device is again ready for operation after about 15 seconds
( READY LED is switched on )
Attention
!
Take care that the cover of the measuring head casing is definitely closed
after the performance test has been carried out in order to ensure that the
engine is controlled again!
12.95
3. 09
When painting works are carried out near the device,

the draft air supply to the device has to be turned off,
in order to prevent the scavenging air filters from clogging.
!
Shut Down
- Stop driving air supply

- Do not switch off the power supply
Storage
in closed rooms
T min -25 C Avoid

T max +80 C condensation!
Maximum air humidity 85%
12.95
4. 01
Performance Test / Maintenance
Performance test
(To be preformed before the engine is started):
- Pull out the main supply plug,

green READY LED will go off
- Re- install main supply plug,
LED No. 1 is blinking for about 30 seconds, then:
the green READY LED and LED No. 1 light up.
Device is ready for operation
- Open inspection cover at the measuring head.
After about 15 seconds the green READY LED and
LED No. 1 turn off simultaneously.
LED No. 14 is blinking
( meaning: negative pressure in the measuring compartment is too low )
- Close inspection cover at the measuring head again.
LED No. 1 is blinking for about 15 seconds.
The green READY LED subsequently switches on.
Device is ready for operation.
Performance test with test vapour, e. g. vapour distillate from the service box
( to be performed only when engine is not running )
- Open crankcase - cover of a compartment in order to access

a suction pipe or sampling funnel.
- Fill the plastic bag ( found in the service box ) with vapour
- Affix the plastic bag to suction pipe or sampling funnel.
!
- Allow the oil mist detector to draw in the distillate vapour for
a minimum of 20 seconds.
- It depends on the vapour density and suction time ( at least 20 seconds )
1. whether an oil mist alarm is triggered, or
2. whether an oil mist alarm is triggered, and a search run is started, or during Search Run only:
the search run only one half or the engine or the VN 116 / 87 - EMC
affected compartment is indicated. VN 116 / 87
( If the amount of vapour is insufficient or the suction time is too short, a wrong and
compartment may be indicated in the display window of the valve box. ) VN 215 / 87 - EMC
VN 215 / 87
12.95
4. 02
Maintenance work to be carried out regularly. In case of non-compliance, the
!
manufacturers liability expires. Maintenance work has to be documented.
Monthly: Check the negative pressure in the measuring head

( range 60 - 80 mm H2O )
Rough filter side Quarterly: Replace the sintered bronze filter in the measuring head.
outwards! Attention: Filters cannot be cleaned.

( see Fig. 5. 03 / 1 )
Use cotton sticks only, Clean the two fresh air bores in the measuring head
otherwise the glasses ( see Fig. 5. 03 / 2 )
may be damaged! Clean the infrared filter glasses in the measuring head
( see Fig. 5. 04 / 1 )
Every 6 months: ( only with siphon block assembly system,

optional for all OMD device types )
4. 02 / 1
In order to do so:
Remove header pipes from the connecting box,
( VN 115 / 87 - EMC, VN 115 / 87 ) or from the valve box of
VN 116 / 87 - EMC, VN 116 / 87, or individual pipes from
valve box of VN 215 / 87 - EMC, VN 215 / 87
(to ensure that the device is not contaminated during the
cleaning operation). Remove siphon block plug, blow-clean the
siphons with compressed air (max. 7 bar), mount the header or
the individual suction pipes and siphon block plug,
tighten accordingly.
Subsequently fill the siphon blocks with lubricating oil
( see Fig. 3. 02 / 1 )
12.95
4. 03
Annually: Replace the sintered bronze filter in the pressure reducer

(see Fig. 4. 03 / 1 )
3 2 1
4. 03 / 1
In order to do so:
Turn off control air supply, remove plug ( 1 ) with O- ring ( 2 ),
detach sintered bronze filter (3), insert new filter, install and
tighten plug ( 1 ) with O-ring ( 2 ) and turn on the air supply.
12.95
5. 01
Malfunctions
Failures and corrective action

A malfunction in the operation of the oil mist detector has occurred if:
- the green READY LED is off

- an LED assigned to the failure mode is blinking in the opacity display
A pending oil mist alarm is reset.
Failure:
No display in the inspection window, all LEDs off.
Possible cause: Remedy:
Breakdown of power supply Check power supply

or voltage too low by: pulling off the main supply plug.
Between terminals 1 and 2 in the socket
on the base plate, check if 18V to 30V
is available.
Push on main plug and lock into place.
Make sure that the power supply does not
break down under the load of the
oil mist detector. ( voltage not below 18V )
Fuse in the measuring head Replace fuse in the measuring head

defective ( see Fig.5. 06 / 1 ) ( 2 A, semi time lag )
by: pulling off the main supply plug.
Detach measuring head ( 8 screws )
Replace fuse by a new one.
Mount measuring head into position.
Push on main supply plug
and lock into place.
Should there still be no indication Replace the electronic module

( see Fig. 6. 02 / 1 )
12.95
5. 03
Possible causes: Remedy:
Fresh air bores for Clean both bores ( see Fig.5. 03 / 2 )

flow control clogged by: opening the inspection cover.
Press cleaning pin contained in the
service box into the left or right fresh air
bore, respectively,
The bores can be seen from the side
of the scavenging air chamber.
Close inspection cover.
Leakage at the device Check all pipes and seals

by: checking flexible expansion bellows
( accessible after the measuring head
has been dertached )
Replace damaged seals or
expansion bellows.
Exhaust air pipe malfunction Eliminate blockage of the exhaust air pipe,
the air must flow without restriction.
Needle length
maximum 11 mm
Trash
5. 03 / 1 5. 03 / 2
12 .95
5. 04
Failure
LED No. 13 is blinking - infrared filter clogged -
No %
14 7
10
5
Possible causes: Remedy: ( see Fig. 5. 04 / 1 )
1
Infrared filter clogged Clean infrared filter
7
0,6
4
0,3
1 0
by: opening the inspection cover.
4 6
Alarm Level
1 9
Soak cotton stick (plastic only!) with alcohol.
Clean infrared filter with
cotton stick several times.
Rub infrared filter dry by means of
cotton stick. Make sure no fluff remains on
the infrared filter
Close inspection cover again.
If failure continues: Replace electronic module

( see Fig. 6. 02 / 1 )
5. 04 / 1
Failure:
No %
LED No. 11 is blinking - ambient temperature below 0 C

14 7
5
10
7 1
0,6
4
0,3
1 0
Alarm Level
4
1
6
9
Engine compartment ventilator Change blowing direction of ventilator,
blows cold air onto the device. away from oil mist detector.
Failure:
No %
14 7
5 LED No. 10 is blinking - ambient temperature above 70 C

10
7 1
0,6
4
1
0,3
0
Source of heat radiates Protect device against sources of heat
4 6
Alarm Level
1 9
on the device. radiation, ensure an improved fresh air
12.95
5. 05
Failure
LED No. 9 is blinking - electronic temperature below 0 C No
14
%
7
5
10
7 1
Possible causes: Remedy: 4

0,6
0,3
Engine room ventilator blows Change blowing direction of the ventilator to 1
4 6
0
Alarm Level
cold air onto the device. ensure that cold air it is not directed to the oil
1 9
mist detector
Failure No %
14 7
LED No. 8 is blinking - electronic temperature above 70 C 10

5
7 1
0,6
4
0,3
Possible causes: Remedy: 1 0
4 6
Protect device against sources of heat

Alarm Level
Source of heat radiates 1 9
on the device. radiation, improve fresh air circulation.
No %
14 7
Failure 5
10
LED No. 7 is blinking - RESET button defective 7 1

0,6
4
0,3
1 0
Remedy:
6
Possible causes: Alarm Level

1 9
Blocked RESET button Eliminate blocking
No %
14 7
Failure 5
10
LED No. 5 is blinking - OMD sensitivity switch defective 7 1

0,6
4
0,3
1 0
Possible causes: Remedy: Alarm Level

4
1
6
Switch defective Replace electronic module

( see Fig. 6. 02 / 1 )
No %
Failure 14 7
5
10
LED No. 4 is blinking - infrared light track defective 7 1
0,6
4
0,3
1 0
Possible causes: Remedy: Alarm Level

4 6
1 9
Infrared filter clogged Clean infrared filter ( see failure LED No. 13 )
If failure continues Replace electronic module ( see Fig. 6. 02 / 1 )
No %
Failure 14 7
LEDs No. 3 and 2 are blinking

10
7 1
0,6
4
0,3
1 0
Possible causes: Remedy: 4 6

Alarm Level
1 9
Electronic module defective Replace electronic module ( see Fig. 6. 02 / 1 )
12.95
5. 06
Replace fuse
in the measuring
head!
5. 06 / 1
12.95
6. 01
Repairing
Replace electronic module / measuring head

!
Attention
If these factory pre- settings (resistors) are replaced by those with other values,
it must be ensured that a spare electronic module or the one in a
replacement measuring head is also modified accordingly!
Modifications have to be printed on the protecting cover plate on the rear side of the
measuring head casing, in the fields provided for this purpose.
( see Fig. 6. 01 / 1 )
Examine Module or
spare when received
Type Serial No. from shipment.
VN 115/87
VN 116/87
VN 215/87 If you return the
M/V
Oilmist - detector mounted on
electronic module,
Main engine Aux. engine
ensure that the
completed form
Display No %
Panel Alarm 14 7
5 Why do you declare

10
Adjustment by manufacturer: Test

7
4
1
0,6 this unit faulty
Alarm Level ( swich S1 )Position
0,3
Resistor between alarm contact 7 - 8 k Ohm
is included!
Ready
1 0
Mode ( swich S2, Option ) Position 4 6
Alarm Level
Altered adjustment for H / V: 1 9

Resistor between alarm contact 7 - 8 k Ohm S1
Resistor between alarm contact 15 - 16
Mode ( swich S2, Option ) Position
k Ohm
If the electronic module
14 15 16 6 7 8 is replaced, take care
For manufacturer
only R 223
that the same wire break
Lower
PCB R 222
resistors are used and
that the Alarm Level
6. 01 / 1 switch is set on the
same position!
The wire break resistors are located on the first visible printed circuit board,
Observe locks!
which is under the protecting cover plate, near the relays (R 222 and R 223)!
The resistors are designed as plug- in resistors and can be replaced
without soldering!
You find the ALARM LEVEL switch on the front display plate of the
electronic module ( see Fig. 3. 03 / 1 ).
12.95
6. 02
Procedure: ( see Fig. 6. 02 / 1 )
- Pull off the main supply plug

- Dismantle the measuring head ( 8 screws )
If the electronic module is replaced or needs to be modified:
- Remove protecting cover plate ( 3 screws )
- Remove the 3 hexagon distance bolts
- Remove defective electronic module from the casing, first pulling off the
lateral flat cable plug from the socket in the casing.
- Mount new electronic module in reverse order
- Install protecting cover plate, fasten 3 screws
- Fasten measuring head, tighten 8 screws moderately.
- Push on main supply plug and lock it into place
- Carry out performance test ( see chapter 4.01 )
Detach electronic
module!
1 2 3
Examine Module or
spare when received
from shipment.
Type Serial No.
VN 115/87
VN 116/87
VN 215/87
M/V
Oilmist - detector mounted on
Main engine Aux. engine
If you return the Adjustment by manufacturer:

Display
Panel Alarm
Test
No
14
10
7
%
7
1
0,6
4
0,3
Resistor between alarm contact 7 - 8 k Ohm Ready
1 0
electronic module,
Mode ( swich S2, Option ) Position 4 6
Alarm Level
Altered adjustment for H / V: 1 9

Resistor between alarm contact 7 - 8 k Ohm S1
Mode ( swich S2, Option ) Position
6 7 8 14 15 16
For manufacturer
ensure that the

only R 223
Lower
PCB R 222
completed form
Why do you declare
this unit faulty
6. 02 / 1
is included!
1 Dismantle cover plate by removing 3 screws
2 Loosen 3 hexagonal screws of module
3 Extract module
Attention:
The electronic module is equipped with components which are sensitive
against electrostatic discharges. A replacement must be carried out by
skilled personnel only! Do not touch infrared lenses or circuitry! Utilise
grounding strap on your wrist.
12.95
6. 03
Leaks or failure of the valve box of VN 115 / 87 - EMC, VN 115 / 87
Remedy: ( see Fig. 6. 03 / 1 )

Disconnect header pipes on the left and right side of connecting box ( 1 ),
push pipes aside to get free access.
Loosen the two screws ( 2 ) and ( 3 ) of the connecting box
Detach the connecting box and remove the gasket On principle, use new
Check if bores 1, 2 and 3 are free from dirt, blow them free with connecting box gasget!
compressed air
Clean the base plate cavity from oil.
Assembly in reverse order, utilising new gasket.
3 1 2
Bore 1
Bore 2
Bore 3 VN 115 / 87 - EMC

VN 115 / 87
RESET RESET
6. 03 / 1
Leaks or failure of the valve box of VN 116 / 87 - EMC, VN 116 / 87

Remedy: ( see Fig. 6. 04 / 1 )
Dismantle the pipe connecting blocks with the headers on the
right and left side
Push away the header pipes for free access to the valve box
Unscrew the valve control cable plug and loosen the four screws On principle, use new
( 3 ), ( 4 ), (5 ) und ( 6 ) of the valve box. valve box seals!
Detach valve box and remove seal
Check if bores 1, 2 and 3 are free from dirt, blow them free
with compressed air.
Assembly in reverse order, utilising new seals and gasket
12.95
6. 04
1 4 3 5 6 2
Bore 1
Bore 2
Bore 3
VN 116 / 87 - EMC
VN 116 / 87
RESET RESET
6. 04 / 1
Leak or failure of the valve box of VN 215 / 87 - EMC, VN 215 / 87

Remedy: ( see Fig.. 6. 04 / 2 )
Release the pipe connecting blocks ( 1 ) und ( 2 )
on the right and on the left side.
Push away blocks with with individual suction pipes for free access
to the valve box.
On principle, use new Unscrew valve control cable plug and loosen screws (3), (4), (5) und (6)
valve box seals and of the valve box
gasket! Detach valve box and remove seal

Check if bores 1, 2 and 3 are free from dirt, blow them free with
compressed air.
Assembly in reverse order, on principle, use new valve box seals and gasket.
1 4 3 5 6 2
Bore 1
5 6
4 7 Bore 2
3 8
VN 215 / 87 - EMC 2 9 Bore 3
1 10
VN 215 / 87
RESET RESET
12.95 6. 04 / 2
6. 05
False alarm in the case of fire with smoke development in the engine room
In case of a fire with smoke development in the engine room, a false alarm cannot
be prevented since smoke may pass into the measuring track through the sintered
!
bronze filters in the measuring head. This condition induces an opacity which can
trigger an oil mist alarm.
Remedy:Install optional pressurised air scavenging system, available from the

manufacturer ( Press RESET button to reset the alarm )
Further possible failures

Sudden false alarms in very warm or cold climatic areas can be triggered by
humidity ( in the crankcase ) falling below the dew point:
water droplets passing the measuring track or dew on the filter glasses may trigger
!
a false alarm.
Remedy:Check negative pressure and calibrate to 60 mm W. G., if required.

Caution!
Ventilation air fans, if any, blowing towards the device and
Danger of burns
its suction pipes.
T max = 120 C
Change blowing direction ( install deflectors ) of the ventilator to ensure
that cold air it is not directed to the oil mist detector or suction pipes.
Check VISATRON heating system. ( The heating element is located in
the base plate and is hooked up with the connector plug
to the 24 V power supply!)
Furthermore, a measuring head heating system is available as an option
(see chapter Options!).
12.95
10. 01
Informations gnrales
Recyclage
Formulaires
Description des erreurs
12.95
Options
x 12. 01
List of Options for VN 87
As an option, the following device extensions can be supplied for

the oil mist detectors of series 87:
Item Description Article No.
1 Protecting cover 10015

2 Pressure control unit with input throttle 10001
3 Typhoon filter 10632
4 Measuring head heating system 10671
5 Pressurised air scavenging 10752
6 Analog opacity indicator 10058
7 Siphon block assembly systems
Description of the individual items
Item 1, Protecting cover

The protecting cover can easily be mounted on the four provided threads on the
base plate of the VN device. It serves to protect the device against mechanical
damage and contamination.
Item 2, Pressure regulator unit

The pressure reducer unit consists of a pressure reducer and a throttle block.
Both parts are mounted together on a frame which is fastened by 3 screws, M8.
The pressure reducer device is especially designed to supply the draft air to the
VISATRON ( VN ) device. The throttle block ensures that the negative pressure
in the VN is limited and does not surpass 25% above of the calibrated negative
pressure, should a failure occur in the pressure reducer ( e. g. rupture of the
diaphragm, etc. ).
In addition, the throttle block is equipped with a filter to retain impurities
from the plant air supply.
12.95
12. 02 x
Item 3, Typhoon filter
The typhoon filter serves as a pre- filter for supplying fresh air to the scavenging
air chambers of the VN device.
The typhoon filter is laterally affixed to the protecting cover of the VN device.
The filter outlet and is joined to the air inlet at the inspection cover of the VN device
by means of a flexible hose.
The typhoon filter considerably increases the service life of the fresh air filter
(sinter bronze ), in particular, if the power plant is operated under contaminated
ambient air conditions, such as dusty air, or if the plant is operated in regions
where the air humidity is high. The typhoon filter is furnished with a filter cartridge
which can be cleaned with compressed air ( blowing from inside outwards )
or, if required, be replaced with by unscrewing the top cover.
The typhoon filter consists of:

- a complete filter
- a special inspection cover for the measuring head
- a connecting hose
Item 4, Measuring head heating system

A standard heating element is installed in all the VN 87 series, in the base plate.
This heating unit might not be sufficient to cover all cases ( cases of extreme
humidity in the crankcase, higher water content in the lubricating oil or lower than
normal ambient temperatures ).
The measuring head heating system serves to warm up the top of the measuring
head and the crankcase gas flowing through the VN device, in order to avoid
condensation of water, especially in climatic zones with high humidity or low
temperatures. Condensation of water may trigger a false high oil mist alarm when
small droplets of water are detected by the optical measuring track and shut down
the engine.
The measuring head heating system can be mounted on top of the measuring
head and replaces the heating system in the base plate. The power supply is
connected in the same way as the heating system of the base plate by means of a
plug under the main Harting plug on the base plate.
12.95
Item 5, Pressurised air scavenging
x 12. 03
By means of driving air scavenging it is possible to provide filtered air to the

scavenging air chambers independent of the ambient air.
This option is recommended to prevent false alarms with consequential
engine shut downs due to a fire with smoke development in the engine room.
The smoke may reach the VN device, entering through the fresh air slots in the
inspection cover, passing through the fresh air filters ( sinter bronze filters ) to the
optical measuring track, triggering a high oil mist alarm. The pressurised air
scavening receives the air through the nozzle of the draft pump which is connected
with a hose to the special inspection cover on the measuring head. The air flow is
metered by special jets located in the nozzle and inspection cover.
Item 6, Analogue opacity indicator

The analogue square shaped opacity indicator may be utilised for all VN 87 devices.
Its dimensions are 96 x 96 mm and it is appropriate for the installation into
0,4 0,6
switchboards or panels. The analogue opacity indicator is connected to the
0,2 0,8
terminals 9 (+) and 10 (-) of the VN 87 device. The relative distance to the adjusted
alarm level is indicated on a scale from 0 to 1, meaning 0% to 100% beeing away Opacity
relative to
Alarm Level
0 Alarm
from the alarm level.
Example: If the measured opacity has reached a value corresponding to 50%
of the adjusted alarm level, the analogue opacity indicator will display the value 0.5.
Item 7, Siphon block assembly systems

Siphon blocks are devices which enable to drain the accumulated oil, from the oil
mist suction pipes, directly back to the engine crankcase. The siphon blocks allow
a horizontal suction pipe installation, from compartment to compartment.
Conventional suction pipe systems, without siphon blocks, require to be installed

with a gradient of 2% to 4% ascending to the VN device, in order to drain the
precipitated oil back to the engine.
It is imperative to drain the oil to the crankcase and avoid potential clogging.
Special engine-oriented assembly systems in modular design are available for

VISATRON Oil Mist Detectors for a large number of two- and four- stroke engine
types of various manufacturers.
12.95
Ambiguous Document References X0
en / 16.12.2008 QV020011 1/6

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en / 16.12.2008 QV020011 2/6

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External Documentation C0

Engine No.: Record No.:

en / 16.12.2008 AA027305 1/2

Please note the copyright notice pursuant to ISO 16016

Caterpillar Motoren GmbH & Co. KG

en / 16.12.2008 AA027305 2/2

Engine Operating Instructions A0

Technical Engine Data A1

Spare Parts Catalogue B0

en / 16.12.2008 AA020077 1/2

en / 16.12.2008 AA020077 2/2

Example: Electrical Equipment

Electrical engine equipment

Book C Chapter Engine Regulation

Ordering Spare Parts:

1. All spare parts orders must be placed with your dealer.

2. In case of multi-engine plants please do not place a collective order.

P.O. number/Customer ref. No.

en / 28.11.2006 AA035841 1/7

Exhaust thermocouple cylinder 1

Measuring point No. 8211.1

en / 28.11.2006 AA035841 2/7

By means of the drawings Sensor - Actuators - Arrangement / Engine General View

8211.1 Thermocouple type K 273 450 450

en / 28.11.2006 AA035841 3/7

K9 Attaching type relay 213 480 770

en / 28.11.2006 AA035841 4/7

7301 Level probe 213 483 016

en / 28.11.2006 AA035841 5/7

en / 28.11.2006 AA035841 6/7

Anfrage/Ersatzteilbestellschein / Spare Parts Inquiry or Order Sheet

Markierung, spezielle Anweisungen, z. B. vollstndige Lieferung

Schiffsname/Anlage/Ship's name/Plant Motor-Typ/Engine Type Motor-Nr./Engine No. *) Versandart/Shipping Instructions

Bitte stets angeben Nur von Caterpillar auszufllen

Table of contents C5.01

Engine, measuring points C5.05.02

Engine, control C5.05.04

Engine, regulation C5.05.05

Engine, exhaust gas system/supercharging C5.05.06

Engine, lubricating oil system C5.05.08

Engine control equipment C5.05.11

en / 16.12.2008 AA020086 1/1

List of Measuring Points Engine

Sensors and Actuators

en / 15.03.2004 FD027294 1/4

1104 Pressure switch 20 400 kPa 350 kPa

5201/5202* Resistance thermometer

8231B Thermocouple type K -200-1300 C -

en / 13.09.2007 FD035270 1/36

FOR SERIES 2223 - 1G ACTUATOR

The contents of this document are the exclusive property of

Operational Schematic Drawing & Index 12

Initial Starting Procedure 17

Before carrying out any repairs, adjustments or maintenance to any equipment by

1. The equipment may contain one or more of the following:

2. All of the above items represent a potential danger or hazard to operating

3. Before carrying out any repairs, adjustments or maintenance to the equipment or

4. In the case of electrical/electronic control systems, the operator should make

This equipment contains components that are electrostatic sensitive. Electrostatic

Servicing PCBs at component level should be done at an electrostatic free workstation.

x All tool tips must be earthed.

To ensure prompt and satisfactory attention to customers enquiries, all

Customer training can be provided either in Roden, in Colchester or on site. Contact

Tel: +31 (0)5050 19888 Fax: +31 (0)5050 13618

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