TECHNICAL BULLETIN

1(3)

TB1509

June 16, 2015

© 2015 SANDVIK MINING AND CONSTRUCTION AUSTRALIA (PRODUCTION/SUPPLY) PTY LTD

431 Masonite Road ABN: 14 008 640 908

Heatherbrae NSW 2324, AUSTRALIA Issued Bulletins are available on the Sandvik website

www.sandvik.com at: www.miningandconstruction.sandvik.com/au

This document shall be incorporated in the "information of use" documentation and kept there for the life of the product. Unless otherwise specified, Sandvik accepts no responsibility for changes, labour or replacements incurred from this bulletin.

TOPIC: CAT 3126 DES DRAWING CHANGES

CONCERNS: SANDVIK LOADERS: LS160 (former name ED6), LS170 (ED7), LS170L (ED7LP), LS190 (ED10), LS190S SANDVIK SHIELD HAULERS: TS490 (former name ED40), TS490L, TS350 (ED25)

The Owner of machinery has a liability to inform and when necessary to train according to the content of this Bulletin all the

personnel (like operators, maintenance personnel) whom this Bulletin concerns.

BULLETIN NUMBER: TB1509

Possible occurrence of topic: Maintenance

Operation

Spare Parts

Transport

Tramming

Other:

Market area: Australia, New Zealand

Canada, USA

China

EU

RSA

Other:

Purpose

To inform the industry of alterations made to the General Arrangement DES CAT 3126DITA drawings.

Description

It has been brought to Sandvik’s attention that part of the CAT3126 diesel engine system did not conform to the DES approval drawing A2U220-830533 REV I. The After cooler / Flame trap is a CAT supplied part that is modified by Sandvik and refitted to the engine.

The After cooler Flame trap flange has a depth of 20.5mm +-0.1mm dimension on the DES drawing, and some of these parts supplied with the part number of A2U220-241041, have been manufactured to 20.0 +-0.1mm. This is an OPEN joint by definition.

The diametrical clearance allowance (max) is 0.2 mm. The FLAMEPATH length is approximately 20mm. AS3584.2 requires a minimum length of 12mm. Excluding the holes for the rods through the flame trap, this provides a 7mm margin of safety (ie

58% longer than it needs to be). Also, additional margins are built in to AS3584.2 over the electrical standard for OPEN joints. The

equivalent cylindrical open joint for Ex 'd' enclosures is permitted 0.4mm clearance.

TECHNICAL BULLETIN

2(2)

TB1509

June 16, 2015

© 2015 SANDVIK MINING AND CONSTRUCTION AUSTRALIA (PRODUCTION/SUPPLY) PTY LTD

431 Masonite Road ABN: 14 008 640 908

Heatherbrae NSW 2324, AUSTRALIA Issued Bulletins are available on the Sandvik website

www.sandvik.com at: www.miningandconstruction.sandvik.com/au

This document shall be incorporated in the "information of use" documentation and kept there for the life of the product. Unless otherwise specified, Sandvik accepts no responsibility for changes, labour or replacements incurred from this bulletin.

Recommendations

Sandvik recommends that the critical dimensions shown in the DES approval drawing A2U130-830553 (Attached) are checked at the next available opportunity.

Customers are also advised to check stock parts against the DES approval drawing.

This measurement of on the DES drawing of 20.5mm +-0.1mm or 20.0 +-0.1mm are considered as safe to use on this application of our 3126 registered DES systems, with the MDR 089003 DES-3 and MDR 140295 DES-0.

Approved by: Product Manager – Zane Swingler

FUEL PUMP/GOVERNOR CONTROL, OIL COOLER COVER, OIL FILTER HEAD, FUEL FILTER HEAD.

ROCKER COVER, AIR INLET MANIFOLD, TURBO COMPRESSOR, ENGINE TIMING CASE

ALUMINIUM/ALLOY COMPONENTS

AIR COMPRESSOR HOSE - CONSTRUCTION PTFE STEEL WIRE REINFORCED BRAIDED

MISCELLANEOUS

VEE BELT APPROVAL - No. MDA 860144, AS 2784 FRAS

VEE BELT (WATER PUMP DRIVE) - SANDVIK P/N - A2U220-267109

VEE BELT (MECHANICAL FAN DRIVE) - SANDVIK P/N - TBA

ENGINE COOLING SYSTEM

EXHAUST PURIFIER DOWNPIPE - SANDVIK P/N - A2U220-257008

EXHAUST CONDITIONER MAX. OPERATING ANGLE - +-15° FORE/AFT & SIDE TO SIDE

EXHAUST CONDITIONER MATERIAL - 316/SAF 2205 STAINLESS STEEL

EXHAUST CONDITIONER - SANDVIK P/N - A2U220-251089

ENGINE EXHAUST SYSTEM

FLAMETRAP APPROVAL - No. M77/3636

FLAMETRAP ELEMENT - SANDVIK P/N - A2U900-241033

AFTERCOOLER/FLAMETRAP ASSEMBLY - SANDVIK P/N - A2U220-241041

AIR CLEANER ASSEMBLY -

ENGINE AIR SYSTEM

COMPONENT SPECIFICATIONS

SYSTEM IS DESIGNED FOR CONTINUOUS OPERATION

MAX. INLET VACUUM - 6.2 kPa

GENERAL AIR SCHEMATIC - A2U220-830555

GENERAL SAFETY SHUTDOWN SYSTEM

REFERENCE DRAWINGS

COMPRESSOR

GEAR PUMP - HYDRAULIC FAN DRIVE

ENGINE AUXILLARIES

COOLANT BOILING POINT @RELIEF PRESSURE - 113°C

SURGE TANK RELIEF PRESSURE - 48 kPa

MAX. COOLANT OPERATING TEMPERATURE - 99°C

IN 40°C AMBIENT CONDITIONS.

COOLING SYSTEM

FUEL SETTING - 7.79mm

@ RATED MAX. TORQUE - 30.1 kg/hr

@ RATED MAX. POWER - 36.6 kg/hr

FUEL CONSUMPTION

MIN. OPERATING OIL PRESSURE - 100 kPa

MAX. EXHAUST PRESSURE - 10.0 kPa

HIGH IDLE - 2600 RPM

RATED TORQUE - 736 Nm

RATED TORQUE SPEED - 1900 RPM

RATED POWER @ RATED SPEED - 150 kW

RATED SPEED - 2300 RPM

STROKE - 127mm

BORE - 110mm

CAPACITY - 7.2 LITRES

ARRANGEMENT No. - 139-3317

SERIAL No. - 9ZR02262

CATERPILLAR MODEL - 3126DITA

DIESEL ENGINE SPECIFICATIONS

D.C

24-12-02

5

DIESEL ENGINE SYSTEMGENERAL ARRANGEMENT

1

CAT 3126DITA

1:10

1156

APP

ROX

1980 APPROX

APPR

OX. 2

000

AIR FILTER ASS'YAIR FILTER

BLOCKAGE INDICATORD0RBX00-2252

AIR INTAKEPIPE ASS'Y

FUEL SHUTDOWNGROUP

A2U220-220037

ENGINE COOLANTSENTINELS TRIGGEREDA2U900-694090@ APPROX. 103°C

EXHAUST CONDITIONERSHUTDOWN VALVE/FLOAT ASS'YA2U220-256034

EXHAUST CONDITIONERWATER SUPPLYWITH FILTER &WATERISOLATION VALVE

EXHAUST TEMP.SENTINEL

A2U936-694046

EXHAUST OUTLET

CLEANING PORTCOVER PLATEOR OPTIONAL

SCREW ON COVEREXHAUST COND.

LOW WATER LEVELTEST TAP

ENGINE COOLANTSURGE TANK

ENGINE COOLANTLOSS VALVEA2U913-694007

COOLANT SYSTEM RELIEF VALVE

RADI

ATOR

AFTERCOOLER/FLAMETRAP HOUSINGA2U220-241041WITH FLAMETRAP ELEMENTFLAMETRAP COVER (WATER COOLED)

ENGINE OILSUCTION PIPE

START PUMP CYLINDERENGINE SAFETY CIRCUIT

EXHAUST PURIFIERDOWNPIPEA2U220-257011

EXHAUST COND.WATER MAKE UPVALVE UNDER COVER

24.12

.0280

010

EXHAUST COND.WATER DRAIN VALVEWITH REMOVABLE PLUG

TURBO ASS'YMODIFIED(WATER COOLED)A2U220-259009

EXHAUSTCONDITIONERA2U220-251089

OPTIONAL MECHANICAL DRIVE FAN

EXHAUST PURIFIER DOWNPIPE - SANDVIK P/N - A2U220-257011

RADIATOR - SANDVIK P/N - A2U220-261073

FAN - SANDVIK P/N - A2U220-267111

SILICON HOSE CONNECTIONBETWEEN TURBO OUTLET & FLAMETRAPCOVER INLET

TURBO BOOST PRESSURE - 150 kPa

TURBO ASSEMBLY (MODIFIED) - SANDVIK P/N - A2U220-259009

TURBO ASSEMBLY (MODIFIED) - SANDVIK P/N - A2U220-259009

TURBO COMPRESSOR OUTLET HOSE - SILICON HOSE (TEMP. RATING - 230°C)

FAN AIR FLOW - 7 m^3 /s

FUEL TIMING - 65.34mm

GOVERNOR GRP - UNIT INJECTOR - C2A1333062

FUEL INJECTOR - C2A1278218

FUEL TRANSFER PUMP &UNIT INJECTOR GOVERNOR

COOLANT LOSS VALVE, COMPRESSOR AIR GOVERNOR, TURBO SAVIOUR HOUSING ASSEMBLY

FAN HUB MATERIAL - ZINC OR STEEL

FAN BLADE - ANTI STATIC

PLUGGED PORTSUNO THREAD

CERTIFICATE / APPROVAL Nos.

NEW SOUTH WALES, AUSTRALIA MDR 089003 DES

LOW IDLE - 800 RPM

TEMP. LOCATIONAFTERCOOLER HOUSINGTURBO CENTRAL BODY

MAXIMUM ENGINE SYSTEM SURFACE TEMPERATURESMEASURED DURING TYPE TESTING WITH & WITHOUTMETHANE INJECTION

TEMP.(°C) WITH METHANE

FLANGE - DOWNPIPE TO EXH. CONDITIONERNOTE:ENGINE POWER WITH METHANE INJECTION WAS APPROXIMATELY 190 kW

GENERAL NOTES

1. COMPLIANCE / SPECIFICATION / WARNING NAMEPLATES AS REQUIRED BY

AS3584.2 TO BE FITTED IN CLOSE PROXIMITY TO THE DES.

2. BACKPRESSURE GAUGE TO BE FITTED IN A POSITION READILY VISIBLE TO

THE MACHINE OPERATOR. THIS MAY BE REMOTE FROM THE DES.

3. MAXIMUM EXHAUST BACKPRESSURE IS 10 kPa (FULL THROTTLE, NO LOAD)

FILTER ELEMENTS SHOULD BE CHANGED AT THIS PRESSURE.

4. ALUMINIUM ITEMS WILL BE PROTECTED BY COVERS COMPLYING WITH

AS3678.2 WHEN SUPPLIED FOR USE IN UNDERGROUND COAL MINES.

TURBO COMPRESSORWATER COOLED

DIESEL ENGINE SYSTEM MASS

APPROX. MASS - 1100 kg

APPROX. MASS - 1200 kg (WITH PARTICULATE FILT. HSG)

SINGLE POINT SMOKE MEASUREMENTS

BOSCH UNITSSPEED 1541 rpm

2.41656 rpm

1.752047rpm

0.452300 rpm

0.35

P.N.

24/12/2002

P.Nelthorpe

TEMP.(°C) WITHOUT METHANE146 117108 103

116133

26/7/

2003

8380

1

TEST PORT(EXHAUST)

1/8" BSP

PRIMARY AND SAFETY ELEMENTS REQUIRED

MINIMUM RATING - 18.5 m^3/min AT 10" W.G. PRESSURE DROP

NOTE: FILTER HOUSING OPTIONAL OUTSIDE AUSTRALIA

EXHAUST PARTICULATE FILTER HOUSING - SANDVIK P/N A2U220-252038

18/3/

2005

8823

2

NOTE: DIESEL PARTICULATE FILTERHOUSING NOT SHOWN IN DRAWINGS.

20/11

/0691

133

26.11

.0891

05E

EXHAUST SUPPORTBRAKET KITSBD00009809 (LS170/190, TS490)A2U550-213068 (TS350/390)BD00013342 (LS 170L)

ISO MOUNTA2U900-191929

20.09

.1091

05F

ECN

G98

8300

325

11/08

/11

ECN

H98

8300

572

18/10

/11

ECN

I98

8300

877

18/01

/12

ANGULAR ±FRACTIONAL ±DECIMAL ±

TOLERANCES O.N.O.

DESCRIPTION

SIGNATURE:

CHECKED:

ITEM

DATE:

DRAWN

DATE:

DO NOT SCALE. IF IN DOUBT,ASK.

PART No.This drawing and all information thereon is the property of Sandvik, and is confidential, and mustnot be made public or copied. This drawing is loaned subject to return upon demand, and is notto be used directly or indirectly in any way detrimental to our interests.

TITLE-

DWG. No.

SHEET OF SCALE:

SIZE

MATERIAL QTY WT

ECN

J98

4805

385

22/09

/14

VENT LINERESTRICTOR

A2U220-265063J

J

J

J

J

J

JREV x 6

D.C

24-12-02

5

DIESEL ENGINE SYSTEMGENERAL ARRANGEMENT

2

CAT 3126DITA

1:10

24.12

.0280

010

RADI

ATOR

ENGINE COOLANT FLOW CIRCUIT

RAD. TOP

RAD. BOT.

VENT LINE

ENGINE COOLANT SENTINELS

THERMOSTAT HSG

ENGINECOOLANTPUMP

ENGINE COOLANTSURGE TANK

P.N.

P.Nelthorpe

24/12/2002

26/7/

2003

8380

1

VENT LINE

18/3/

2005

8823

2

20/11

/0691

133

26.11

.0891

05E

COOLING CIRCUIT DESCRIPTION

- MAIN COOLANT FLOW FROM PUMP IS DIRECTED INTO ENGINE OIL COOLER & ENGINE

BLOCK/CYLINDER HEAD. SOME FLOW THEN PASSES THROUGH EXHAUST MANIFOLD &

THENRETURNS TO REGULATOR HOUSING.

- ADDITIONAL FLOW IS ALSO DIRECTED THROUGH TURBO & EXHAUST PURIFIER DOWNPIPE

BEFORE RETURNING TO REGULATOR HOUSING.

- ADDITIONAL FLOW DIRECTLY FROM WATER PUMP IS DIRECTED THROUGH THE AFTERCOOLER

& THEN RETURNED TO REGULATOR HOUSING.

- A SMALL AMOUNT OF ADDITIONAL FLOW IS ALSO DIRECTED TO TURBO COMPRESSOR HSG

& AIR INLET FLAMETRAP COVER HOUSING FOR SURFACE TEMPERATURE COOLING.

VENT LINES ARE LOCATED AT TOP OF EXHAUST PURIFIER DOWNPIPE & RADIATOR & ARE

DIRECTED TO SURGE TANK.

ECN

G98

8300

325

11/08

/11

ECN

H98

8300

572

18/10

/11

ANGULAR ±FRACTIONAL ±DECIMAL ±

TOLERANCES O.N.O.

DESCRIPTION

SIGNATURE:

CHECKED:

ITEM

DATE:

DRAWN

DATE:

DO NOT SCALE. IF IN DOUBT,ASK.

PART No.This drawing and all information thereon is the property of Sandvik, and is confidential, and mustnot be made public or copied. This drawing is loaned subject to return upon demand, and is notto be used directly or indirectly in any way detrimental to our interests.

TITLE-

DWG. No.

SHEET OF SCALE:

SIZE

MATERIAL QTY WT

ECN

I98

8300

877

18/01

/12

20.09

.1091

05F

ECN

J98

4805

385

22/09

/14

FUEL SYSTEM SCHEMATIC

M

PRIMARY FUELFILTER

FUEL TANK

PRESSURE RELIEFVALVE

PRESSUREREGULATING VALVE

FUEL INJECTORPUMP

CHECK VALVE

CHECK VALVE

CHECK VALVE

SECONDARYFUEL FILTER

PRIMINGPUMP

TRANSFERPUMP

SCREEN

NOTES:1. FUEL SETTING & FUEL TIMING ADJUSTMENT POINTS (FACTORY SET & LOCATED UNDER ROCKERCOVER) ARE TAMPER-PROOF SEALED.2. HIGH IDLE ADJUSTMENT POINT TO BE TAMPER-PROOF SEALED BEFORE SHIPMENT TO CUSTOMER.

M

FUEL INJECTIONNOZZLES

JREV x 2

J

J

EMERGENCY FUELSHUTOFF VALVE

D.C

24-12-02

5

DIESEL ENGINE SYSTEMGENERAL ARRANGEMENT

3

CAT 3126DITA

1:10

24.12

.0280

010

A2U220-241041NAME: AFTERCOOLER/FLAMETRAPMATERIAL SPECS.MILD/STAINLESS STEELCONE SECT. - 3mm PL.

10

A2U220-241042INLET FLAMETRAP COVER (WATER COOLED)MATERIAL SPECS.MILD/STAINLESS STEEL

A2U220-259009TURBO ASSEMBLY (MODIFIED)MATERIAL SPECS.MILD STEEL, CAST IRON, ALUMINIUM 3mm PL.

A2U220-257011NAME: PURIFIER DOWNPIPE (WATER COOLED)MATERIAL SPECS.MILD/STAINLESS STEELPIPE/CONE SECT. - 3mm PL.

WATER JACKET

WATER JACKET

FUEL GOVERNOR SIGNAL(BOOST) &CO2 INJECTION POINT1/8" BSPP

AIR FLOW FROMFLAMETRAP COVER

AIR FLOW FROMTURBO COMPRESSOR

COOLANT IN

AIR FLOW TOFLAMETRAP ELEMENT

AIR FLOW INTOENGINE VIA INLETMANIFOLD

EXHAUST GAS INFROM EXHAUSTMANIFOLD

EXHAUST GASOUT TO PURIFIERDOWNPIPE

AIR IN FROM AIRFILTER ASSEMBLY

AIR OUT TOFLAMETRAP COVER

ADDITIONAL WATERJACKET FOR HOT SPOT

9

A2U900-243007NAME: GASKET - FLAMETRAP HOUSINGMATERIAL SPECS.NOVATECH PREMIUM 1.5mm THK ORGRAFOIL GHR, FLEXIBLE GRAPHITEWITH 316 SS INSERT 1.5mm THK

TEST PORT7/16" UNOOR 1/8" BSP

DETAIL A

TEST PORTS(EXHAUST)

1/8" BSPT

TEST PORTS(EXHAUST)

1/8" BSPT

COOLING WATERIN/OUT

COOLINGWATERIN/OUT

EXHAUST GAS FLOW

DETAIL 'C'TYPICAL FORA2U220-257008 &A2U220-257011

PART VIEW DETAIL 'B'TYPICAL FORA2U220-257008 &A2U220-257011

FIXED JOINT 7

A2U220-254091NAME: GASKET - EXHAUST DOWNPIPEMATERIAL SPECS.NOVATECH PREMIUM 1.5 mm THK

20

A2U220-254092NAME: GASKET - TURBO OUTLETMATERIAL SPECS.NOVATECH PREMIUM 1.5 mm THK

30

FIXED JOINT 10

MOUNTING FLANGEFIXED JOINT 6

FIXED JOINT 2

PURIFIER ELEMENT

WATER COOLEDTURBO HSG

WATER COOLEDCOMPRESSOR HSG

ENGINE AIR INLET SYSTEM

ENGINE EXHAUST SYSTEM

WATER OUT

WATER IN

WATERSTRAINER

WATER ISOLATIONVALVE CLOSED FORLOW WATER TESTING

WATER LEVELS FOR15° FORE & AFT15° SIDE TO SIDE

WATER MAKE UPVALVE

SHUTDOWNFLOAT/VALVE ASS'Y

DRAIN VALVEWITH REMOVAL PLUG

A2U220-251089NAME: EXHAUST CONDITIONER

Ø566

798

LOW WATERTEST VALVE

SHUTDOWNFLOAT/VALVE ASS'Y

A

WATER SUPPLY

A

MINIMUM LOW WATERSHUTDOWN LEVEL

STATICWATER LEVEL

LOW WATERTEST LEVEL

SECTION A - A

WATER IN

430 A

PPRO

X

250

242

EXHAUST GAS FLOW

OUT IN

20

30

607 APPROX

481 A

PPRO

X

A2U220-252038NAME: EXHAUST PARTICULATE FILTER HOUSINGMANDATORY FOR NSW. OPTIONAL FOR QLD AND OUTSIDE AUSTRALIA.

EXHAUST GASINLET

EXHAUST GASOUTLET

A2U900-292008NAME: EXHAUST PARTICULATE FILTER ELEMENTSPECIFICATIONS1. MAX. OPERATING TEMPERATURE - 175°C2. FILTER MEDIA - FILTRETE, GRD SP4055F2.1 APPROX. IGNITION TEMP. (NEW FILTER) - 960°C2.2 APPROX. IGNITION TEMP. (DIRTY FILTER) - 650°C

EXHAUST GASOUTLET

CONNECTED TOEXHAUST OUTLETPIPE VIA FLANGE

OR CLAMP CONNECTION

MANUFACTURER -

FILTER P/N - A2U900-292008SAFE OPERATING TEMP.-150°C

FILTER HOUSING

A2U220-171727

FILTER HSG &FILTER ELEMENTSPECIFICATIONS

NAMEPLATE

P.N.

P.Nelthorpe

24/12/2002

26/7/

2003

8380

1

EXHAUST TEMP.SENTINEL

A2U936-694046

TEST PORTS(EXHAUST)

1/8" BSP

18/3/

2005

8823

2

20/11

/0691

133

FILTER BYPASSWASTEGATE

BACKPRESSUREDIAPHRAGM

26.11

.0891

05E

9mm MIN

FIXED JOINT 6

12.5 MIN 9 MINCOOLANT OUT

3.2

0.2

205 MIN CHECK

0.2

5 MIN

3.2

0.2

25 MIN

JOINT A

FIXED JOINT 10 FIXED JOINT 7

JOINT A

JOINT A

25mm

MIN

DETAIL ' D '

0.2DETAIL D

02

0.5mm MINFROM WATER JACKET

FIXED JOINT 10

FIXED JOINT 7

FIXED JOINT 7

20.09

.1091

05F

0.2

26.5

MIN

TYP

NOTE: THE MINIMUM VALUES STATED ON THE FIXED JOINTFLANGES ARE A GUIDE FOR CODE D MACHINING ONLY.

3.2

ECN

G98

8300

325

11/08

/11

0.2

ECN

H98

8300

572

18/10

/11

ECN

I98

8300

877

18/01

/12

ANGULAR ±FRACTIONAL ±DECIMAL ±

TOLERANCES O.N.O.

DESCRIPTION

SIGNATURE:

CHECKED:

ITEM

DATE:

DRAWN

DATE:

DO NOT SCALE. IF IN DOUBT,ASK.

PART No.This drawing and all information thereon is the property of Sandvik, and is confidential, and mustnot be made public or copied. This drawing is loaned subject to return upon demand, and is notto be used directly or indirectly in any way detrimental to our interests.

TITLE-

DWG. No.

SHEET OF SCALE:

SIZE

MATERIAL QTY WT

ECN

J98

4805

385

22/09

/14

FIXED JOINT 1

DETAIL C

DETAIL B

FIXED JOINT 9

FIXED JOINT 8

Ø157.73

0.00

-0.25

21 APPROX.RIM WIDTH

A2U900-241033FLAMETRAP ELEMENTMATERIAL SPECS.STEEL

3.2

DETAIL ' A 'OPEN JOINT A

(Ø 210) Ø

157.7

315

7.68

0.2 M

AXDI

AMET

RICA

LFL

AMEP

ATH

GAP

FLAMETRAPELEMENT (REF)

20.5±0.1

(HOU

SING

)

635 MIN

26.5 MINFLANGE

THICKNESS

4 HOLES M12ON Ø185 PCDMIN DEPTH 16mm

HYDROSTATIC TEST PRESSURESGAS PATH: 410 kPa FOR 3 MINUTES* *NOTE: PRESSURISE INTERNAL HEAT EXCHANGER WITH AIR TO 172 kPa DURING TEST. WATER PATH (HEAT EXCHANGER): 250 kPa FOR 3 MINUTES

HYDROSTATIC TEST PRESSUREWATER PATH: 250 kPa FOR 3 MINUTES

HYDROSTATIC TEST PRESSURESCOMPRESSOR HSG WATER PATH: 250 kPa FOR 3 MINUTESTURBINE HSG WATER PATH: 250 kPa FOR 3 MINUTES

HYDROSTATIC TEST PRESSURESGAS PATH: 1,900 kPa FOR 3 MINUTESWATER PATH: 250 kPa FOR 3 MINUTES

MATERIAL SPECS.316 / SAF 2205 STAINLESS STEELHYDROSTATIC TEST PRESSUREBODY: 100 kPa FOR 3 MINUTES

JJ

JJ

J

J

J

J

JREV x 8

COOLANT IN

COOLANT OUT

NOTE: NO SERVICE WORK TO BEPERFORMED TO THE TURBOCHARGER.RETURN TO SANDVIK FOR ANYOVERHAUL REQUIREMENTS.

D.C

24-12-02

5

DIESEL ENGINE SYSTEMGENERAL ARRANGEMENT

4

CAT 3126DITA

1:10

24.12

.0280

010

ENGINE AIR INLET SYSTEM

ENGINE EXHAUST SYSTEM

P.N.

P.Nelthorpe

24/12/2002

26/7/

2003

8380

1

18/3/

2005

8823

2

20/11

/0691

133

26.11

.0891

05E

20.09

.1091

05F

ECN

G98

8300

325

11/08

/11

ECN

H98

8300

572

18/10

/11

ECN

I98

8300

877

18/01

/12

ANGULAR ±FRACTIONAL ±DECIMAL ±

TOLERANCES O.N.O.

DESCRIPTION

SIGNATURE:

CHECKED:

ITEM

DATE:

DRAWN

DATE:

DO NOT SCALE. IF IN DOUBT,ASK.

PART No.This drawing and all information thereon is the property of Sandvik, and is confidential, and mustnot be made public or copied. This drawing is loaned subject to return upon demand, and is notto be used directly or indirectly in any way detrimental to our interests.

TITLE-

DWG. No.

SHEET OF SCALE:

SIZE

MATERIAL QTY WT

BD00012861NAME: EXHAUST MANIFOLDMATERIAL SPECS.CAST IRONHYDROSTATIC TEST PRESSURESGAS PATH: 1,900 kPa FOR 3 MINUTESWATER PATH: 250 kPa FOR 3 MINUTES

EXHAUST GASOUT TO TURBO

EXHAUST GASIN FROMCYLINDER HEAD

FIXED CONNECTION 5

FIXED CONNECTION 60.25 6 SURFACES TOGETHER0.2 2 SURFACES TOGETHER (GASKETED FACE)0.15 EACH SURFACE

GRADE H AS3584.3:2012,TABLE 3.5.4.23.2

PLUGGED FACE MUST NOTPROTRUDE ABOVE GASKET FACE

(100

)

(188)

(93)

(135)

C2A1136200NAME: GASKET - EXHAUST MANIFOLDJOINT: FIXED CONNECTION 5SPEC.GENUINE CATERPILLAR GASKET 2 mm THK,w/ METALLIC FACES

C2A4P7704NAME: GASKET - TURBO INLETJOINT: FIXED CONNECTION 6SPEC.GENUINE CATERPILLAR GASKET 1.5 mm THK

A

SECTION A - A

BU00004518NAME: INLET MANIFOLDMATERIAL SPECS.CAST ALUMINIUMHYDROSTATIC TEST PRESSUREGAS PATH: 410 kPa FOR 3 MINUTES

FIXED CONNECTION 3

AIR FLOW FROMAFTERCOOLER/FLAMETRAP HOUSING

AIR FLOW INTOCYLINDER HEAD

6 MIN

6 MIN

0.2

MATERIAL REMOVALFROM THIS FACENOT PERMITTED

0.25

1.6

FIXED CONNECTION 2

FIXED CONNECTION 4A

OPEN JOINT BBOLTS IN THREADED

THRU HOLES (11 OFF)

(94)

(670)

(243

)

(807)

C2A1136250NAME: GASKET - AIR INLET MANIFOLDJOINT: FIXED CONNECTION 4SPEC.GENUINE CATERPILLAR GASKET 1 mm THK

C2A7C1152NAME: GASKET - AIR INLET MANIFOLDJOINT: FIXED CONNECTION 2SPEC.GENUINE CATERPILLAR GASKET 1.5 mm THK

ECN

J98

4805

385

22/09

/14

635 MIN

0.5 MINFACE TOWATER JACKET

.

JREV x 2

J

J

D.C

24-12-02

5

DIESEL ENGINE SYSTEMGENERAL ARRANGEMENT

5

CAT 3126DITA

1:10

24.12

.0280

010

P.N.

P.Nelthorpe

24/12/2002

EXHAUSTCONDITIONER WATERMAKE UP TANK

EXHAUST CONDITIONER(WATER BASED FLAMETRAP)

(SPARK ARRESTOR)

(EXHAUST COOLING WATER BATH)

EXHAUSTTEMPERATURESENSOR

ENGINE COOLING SYSTEM

ENGINE COOLANTTEMPERATURESENSORS

ENGINE COOLANTLOSS SENSOR

PRIMARY & SECONDARYLOW WATER SENSORS

DES BLOCK DIAGRAM

RADIATOR WITHCOOLING FAN

AIRFLOW

26/7/

2003

8380

1

STRAINER

18/3/

2005

8823

2

PARTICULATEFILTERASSEMBLY

OPTIONALSEE NOTE 1

ATMOSPHERE

EXHAUSTTEMPERATURESENSOR

WASTEGATE(PARTICULATEFILTER)

20/11

/0691

133

26.11

.0891

05E

20.09

.1091

05F

ECN

G98

8300

325

11/08

/11

ECN

H98

8300

572

18/10

/11

ECN

I98

8300

877

18/01

/12

ANGULAR ±FRACTIONAL ±DECIMAL ±

TOLERANCES O.N.O.

DESCRIPTION

SIGNATURE:

CHECKED:

ITEM

DATE:

DRAWN

DATE:

DO NOT SCALE. IF IN DOUBT,ASK.

PART No.This drawing and all information thereon is the property of Sandvik, and is confidential, and mustnot be made public or copied. This drawing is loaned subject to return upon demand, and is notto be used directly or indirectly in any way detrimental to our interests.

TITLE-

DWG. No.

SHEET OF SCALE:

SIZE

MATERIAL QTY WT

ECN

J98

4805

385

22/09

/14

AIR FILTER ASSEMBLYWITH VACUUM INDICATOR

AIR INLETFLAMETRAPASSEMBLY

ATMOSPHERE

'1'

'6'

'4''A'

'5'

'2'

ENGINE BLOCK

TURBO CHARGERCOMPRESSOR

EXHAUST MANIFOLD

AIR

INLE

T MA

NIFO

LD

AFTE

RCOO

LER

TURBO CHARGERTURBINE

'3'

'B'

'7' '8' '9'

'10'

JOINTS FASTENER SPECIFICATIONFIXED CONNECTION THREAD LENGTH CLASS DESCRIPTION QTY PART NO TORQUE

1 7/16"-20 - - HEX HEAD UNO PLUG 1 C2A9S4182 -1 - - - O-RING 1 C2A3J7354 -1 7/16"-20 - - (OPTIONAL) IN-HEX UNO PLUG w/ O-RING 1 BU00012404 -2 M8 x 1.25 40 mm 10.9 HEX HEAD BOLT 22 C2A6V5219 24+- 3 Nm2 - - - M8 FLAT WASHER 22 C2A9M1974 -3 3/4"-16 - - IN-HEX UNO PLUG 3 C2A9S8005 30 - 35 Nm3 - - - O-RING 3 C2A3K0360 -4 M8 x 1.25 70 mm 10.9 HEX HEAD BOLT 15 C2A5P8347 24+- 3 Nm4 M8 x 1.25 100 mm 10.9 HEX HEAD BOLT 5 C2A6V5223 24+- 3 Nm4 M8 x 1.25 35 mm 10.9 HEX HEAD BOLT 1 C2A6V5218 24+- 3 Nm4 - - - M8 FLAT WASHER 21 C2A9M1974 -5 M10 x 1.5 110 mm 10.9 HEX HEAD BOLT 10 C2A8T0355 54+- 5 Nm5 M10 x 1.5 90 mm 10.9 HEX HEAD BOLT 2 C2A8T0644 54+- 5 Nm5 - - - M10 FLAT WASHER 12 C2A6V5839 -6 M10 x 1.5 45 mm - STUD - TAPERLOCK 4 C2A1860870 35+- 5 Nm6 M10 x 1.5 40 mm - (OPTIONAL) STUD - TAPERLOCK 1 C2A8T7044 35+- 5 Nm6 M10 x 1.5 - SS CONELOC NUT 4 BD00011509 54+- 5 Nm7 M10 x 1.5 45 mm 8.8 HEX HEAD BOLT 4 445502807 40+- 5 Nm7 - - - M10 FLAT WASHER 4 450062508 -

8, 9 1/8" BSPT - - HEX HEAD PLUG 4 D59-02 3 TURNS FROM FINGERTIGHT8, 9 1/8" BSPT - - (OPTIONAL) HEX SOCKET PLUG 4 BD00023743 3 TURNS FROM FINGERTIGHT10 M12 x 1.75 45 mm 8.8 HEX HEAD BOLT 4 445502848 69+- 5 Nm10 - - - M12 FLAT WASHER 4 450061619 -

OPEN JOINT THREAD LENGTH CLASS DESCRIPTION QTY PART NO TORQUECOVER - A M10 x 1.5 30 mm 8.8 HEX HEAD BOLT 6 445502799 45+- 5 NmCOVER - A - - - M10 FLAT WASHER 6 450062508 -

B FIXED CONNECTION 2 LOWER FASTENERS (11 OFF). THREAD SEALANT TO BE USED UPON ASSEMBLY.

EXPLOSION PROTECTED JOINTSAIR INLET SYSTEM

FIXED CONNECTIONS1. -TEST PORT @ TOP OF AFTERCOOLER/FLAMETRAP HSG2. -AFTERCOOLER/FLAMETRAP HSG TO AIR INLET MANIFOLD3. -PORTS (3 OFF) @ TOP OF AIR INLET MANIFOLD4. -AIR INLET MANIFOLD TO CYLINDER HEAD

OPEN JOINTSA. -FLAMETRAP ELEMENT TO HOUSINGB. -THREADED THRU HOLES (11 OFF) @ BOTTOM OF AIR INLET MANIFOLD

EXPLOSION PROTECTED JOINTSEXHAUST SYSTEM

FIXED CONNECTIONS5. -CYLINDER HEAD TO EXHAUST MANIFOLD6. -EXHAUST MANIFOLD TO TURBO7. -TURBO TO EXHAUST PURIFIER DOWNPIPE8. -TEST PORT @ PURIFIER DOWNPIPE GAS INLET9. -TEST PORT @ PURIFIER DOWNPIPE GAS OUTLET10. -EXHAUST PURIFIER DOWNPIPE TO EXHAUST CONDITIONER

NOTES:1. ALL JOINTS MUST BE PROPERLY ALIGNED DURING ASSEMBLY.2. NO THREAD LUBRICANTS OR ANTI-SIEZE TO BE USED.3. REPLACE ALL GASKETS WITH GENUINE SANDVIK PARTS UPON RE-ASSEMBLY.4. FOR OTHER ENGINE JOINTS REFER TO CATERPILLAR PARTS BOOK AND MAINTENANCE MANUAL.

STRANGLEREXHAUST CATALYTIC PURIFIERDOWNPIPE ASSEMBLY(NON-REGENERATIVE)

SEE NOTE AT JOINT B

NOTE

JREV x 6

J

J

J

J

J

J