SB1204 C7 Inlet Manifold
Contents
1. TORQUE TO 25 4 Nm Ak REFER TO NOTES 1 amp 2 08 08 11 RELEASED FOR PRODUCTION REVISIONS ES EN 9075 12 05 08 B EN 9075 10 11 09 DESTROY ALL PREVIOUS COPIES DO NOT SCAL EJ EN 9075 03 02 10 ECN 988300307 E fo88302000 13 08 12 ISOMETRIC VIEW TORQUE TO 25 4 Nm 32 REFER TO NOTES 1 amp 2 A Note Removal of Fuel Transfer Pipe and Fitting for this Bolt Installation a R Se QQ NOTES 1 NEVERSEIZE OR SIMILAR LUBRICANT TO BE USED ON ALL THREADED FLAMEPATH JOINTS 2 ASSEMBLY TO BE CARRIED OUT IN ACCORDANCE WITH DES APPROVAL DRAWING e APPROX MASS 17 2kg Ne BU00000993 A FASTENER KIT SHCS M8 x 1 25 x 35 LG Grade 12 9 UNBRAKO 8 0 2 BU00000853 A 30_ 8000020705 A FASTENER KIT Washer Flat M10 CLASS 10 ZN PLATE 14 29 8D00020703 A FASTENER KIT Washer Flat M8 Class 10 CLASS 10 ZN PLATE 8 28 B000020702 A FASTENER KIT Hex Nut M10 x 150 crassi fef OO BD00020233 A FASTENER KIT SHCS M10 x 1 5 x 35 LG Grade 12 9 UNBRAKO 8 0 3 BD00020232 A FASTENER KIT 25 BD00020231 A FASTENER KIT SHCS M10 x 1 5 x 40 LG Grade 12 9 UNBRAKO 3 0 1 e 24 BD00020223 A FASTENER KIT SHCS M8 x 1 25 x 80 LG Grade 12 9 UNBRAKO 8 0 3 23 BD00020155 A 1 8 ALLEN KEY BSPP PLUG STAINLESS 2 22 BD00018800 B CUP SHROUD MIO HEX s Gr 304 e 21 Boooooo9s2 merman Er ape o Af fazuoo0 2912. A TORQUE TO 55 5 Nm REFER TO NOTES 1 amp 2 14 39 TORQUE TO 25 4 Nm A X7 REFER TO NOTES 1 amp 2 RS i We b A D gt gt x gt NYI 29 A TORQUE TO 5525 Nm f x N 31 A REFER TO NOTES 1 amp 2 4 sn eT g o f l f f di n oe l AN 29 49 21 15 Note A 32 A Removal of Fuel A Transfer Pipe and Fitting A TORQUE TO 25 4 Nm for this Bolt Installation REFER TO NOTES 1 amp 2 Image extracted from drawing A2U900 240102 See bill of materials BOM on following page Copyright Sandvik Mining and Construction 5 CAT C7 MAINTENANCE MANUAL CAT C7 ENGINE Bill of materials BOM Extracted from drawing A2U900 240102 e 32_ 8U00000993 A FASTENER KIT SHCS M8 x 1 25 x 35 LG AL 31 Washer Flat M10 Washer Flat M8 Class 10 27 BD00020231 A FASTENER KIT SHCS M10 x 1 5 x 40 LG BD00020223 A FASTENER KIT SHCS M8 x 1 25 x 80 LG _ Grade 12 9 UNBRAKO STAINLESS 21 FASTENER KIT FLAMETRAP HSG BD00001534 C GROUP AS3678 250 AS3679 300 17 Steel Bracket Bottom Support Steel Gasket Air Intake See Dwg 14 Gasket Adaptor Plate See Drawing Gasket Flametrap Housing See Drawing Gasket Flametrap NOVATECH PREMIUM 11 Flame Trap Housing Adaptor Plate Inlet Manifold AS3678 250 AS SUPPLIED 7 Hex Nut M10 X 1 5 Washer Spring 8 mm Steel Steel Washer Flat 10 mm Steel Steel GR 8 8 1 Bolt
3. and Flametrap Housing Group A2U900 240102 It is Sandvik s intention to apply for supplementary changes to DES Registrations to the respective statutory authorities Ensure a copy of this bulletin and attachments is stored with the Plant Safety Documentation for the machine Reference documents 1 Registration Drawing CAT C7 ACERT A2U900 830879 Rev B Australia 2 Registration Drawing CAT C7 ACERT BD00020101 Rev B South Africa List of attachments Drawing No Title Model a ee Installation Procedure for CAT C7 Rev A RevE Note The latest revisions of the above drawings are issued at the time of writing Request for Feedback For mines hirers or maintenance contractors that have implemented all of the above recommendations Sandvik is interested to hear from you Please contact your Sandvik representative to discuss any difficulties or to simply provide feedback on the condition of the Inlet Manifold and Gasket as you found it Approved by Product Line Manager Terry Marler Appendixes N A 2012 SANDVIK MINING AND CONSTRUCTION AUSTRALIA PTY LTD 431 Masonite Road ABN 62 003 771 382 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 acce
4. Construction CAT C7 MAINTENANCE MANUAL CAT C7 ENGINE 1 2 Disassembly 1 Remove primary fuel filter assembly and fuel filter lines Shown in magenta 2 Remove fuel line and the adaptor fitting from the HUEI pump to cylinder head Shown in ma genta 4 Remove the Can Bus sensors located on the cover support rail being careful as to not dam age them shown in magenta Copyright Sandvik Mining and Construction CAT C7 MAINTENANCE MANUAL CAT C7 ENGINE 5 Remove the secondary fuel filter from the cover support rail and then remove the rail shown in magenta 6 Remove the flametrap housing from the strangler valve and the inlet manifold adaptor plate shown in magenta This can be done as a complete assembly or in two stages Please note that new gaskets will be needed for assembling these items back together 4 Copyright Sandvik Mining and Construction CAT C7 MAINTENANCE MANUAL CAT C7 ENGINE 1 3 Inspection and Cleaning 1 Remove all traces of the old gasket from the contact faces carefully so as not to mark or score the metal surfaces 2 Perform Code D component compliance check on the inlet manifold See separate dwg BDO0009952 sheet 2 2 3 Once the inlet manifold has passed proceed with the assembly of all components Ref 1 4 TORQUE TO 55 5 Nm 27 REFER TO NOTES 1 amp 2 A ISOMETRIC VIEW TORQUE TO 25 4 Nm REFER TO NOTES 1 amp 2 A
5. Hex Head M8 x 65mm Long GR 8 8 TEM PART No DESCRIPTION MATERIAL PP PPP gt gt p hettel s releele i O o N par QTY MASS kc 6 Copyright Sandvik Mining and Construction CAT C7 MAINTENANCE MANUAL CAT C7 ENGINE 1 4 Assembly 1 Please note the installation of the additional support bracket 31 on the HUEI pump end of the inlet manifold see image When installing make sure the fuel filter bracket 19 inlet manifold adaptor plate 9 and the new longer 40mm SHCS for the ends are in place before commencing the bolt torque procedure 2 Bolt torque procedure A Start the first sequence at 10Nm and work in the numbered pattern 1 to 16 as shown below B When you have achieved to above mentioned torque re tension them to 15nm using the same pattern as shown above Then proceed to 20Nm using the same pattern then to 25Nm Once all bolts are at 25Nm then repeat the tensioning sequence at 25Nm again to be sure that all fasteners have achieved the full 25Nm of torque 3 Reinstall remaining components in reverse order to removal Replace any damaged compo nents Ensure only new gaskets are used Note revised torque settings on the Assembly Sect ion 1 4 when compared to Rev B of the DES drawing Copyright Sandvik Mining and Construction CAT C7 MAINTENANCE MANUAL CAT C7 ENGINE 1 5 Test and Commission 1 Once the engine is completely reassembled remov
6. extreme example of crushing as witnessed during the testing after a number of tests Figure 2 shows a damaged gasket Note the outer edges are damaged and the inner edges are intact Figure 1 Figure 2 1 Pressure determination testing to AS3584 2 2008 on the intake system found the maximum pressure to be 68 1kPa Hydrostatic pressure testing of the Inlet System is therefore determined to be the greater of 1 5x68 1kPa 102 2kPa or 350kPa The test pressure nominated as 1000kPa for the Inlet System was due to market area requirements for South Africa 2 Turbo boost pressure at torque stall is approx 150kPa ie Approx 2 2 times Pressure Determination test value There have been no cases of Inlet Manifold cracking or Gasket Failure reported to Sandvik from the field 2012 SANDVIK MINING AND CONSTRUCTION AUSTRALIA PTY LTD 431 Masonite Road ABN 62 003 771 382 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 SAFETY BULLETIN eo SB1204 October 26 2012 Actions to be taken immediately A e Review all Attached documents and follow the recommendations RECOMMENDATIONS Inspect the Inlet Man
7. 102 sz Seno ape W S 16 05 08 saan sa RON para APPROVED W S 16 05 08 naa Ad
8. 829A BracketzFuel Fiter asasre 250 Ji 17 A2ug00 291286 A_ Bracket Top Support stel Jif A 8 _ A2u900 291285 A___ Bracket Bottom Support _ Steel fif A s azu900 243020 12 A2U900 243007 D_ Gasket Flametrap NOVATECH PREMIUM 1 p E E 10 fA2u900 241079 E Flame Trap Housing Sof a 9 A2ug00 241078 H Adaptor Plate inlet Manifold AS3678 250 1 28 8 A2U900 241033 E FLAMETRAP ELEMENT AS SUPPLIED 4 07 7 455309034 A FASTENER KIT Hex Nut M10 X45 e 6 450081120 A FASTENER KIT Washer Spring 8 mm stel f2 f 5 450081022 A FASTENER KIT Washer Spring 10mm stel f2 4 450062508 A FASTENER KIT Washer Flat 10mm Steel A 3 450062506 A FASTENER KIT Washer Flat mm stel 2 ITEM PART No DESCRIPTION MATERIAL QATYIMASS kg Sandvik Underground Mining This drawing and all information thereon is the property of Sandvik SAN DVI K Underground Mining Flameproof Equipment and is confidential and Flameproot Equipment must not be made public or copied This drawing is loaned subject ae l to return on demand and is not to be used directly or indirectly REN I peels ne in any way detrimental to our interests SIGNATORIES DATE TOLERANCES U N O TITLE FLAMETRAP HOUSING GROUP FABRICATION 0 1000 1 0 DESIGNED A M 08 09 08 Dra ENGINE CRADLE GROUP Raw BF 12 05 08 _ wachwng 02 gy j ppt ACER CHECK A M 115 05 08 MACHINE SURFACES DWG No A2U900 240
9. EFER TO A2U900 240102 Reference APPROX MASS 1 kg 6 BU00000993 SHCS M8 x 1 25 x 35 LG Grade 12 9 UNBRAKO 8 0 2 Reference 5 Bu00000853 AS3678 250 1 0 4 4 A2U900 243026 Gasket Air Intake SeeDwo i oa 3 A2U900 243021 Gasket Adaptor Plate See Drawing 1 04 2 Aa2u900 243020 Gasket Flametrap Housing SeeDrawing 1 0 2 1 A2U900 243007 Gasket Flametrap NOVATECH PREMIUM tee QTY Sandvik Underground Mining This drawing and all information thereon is the property of Sandvik SAN DVI K FI Underground Mining Flameproof Equipment and is confidential and ameproof Equipment must not be made public or copied This drawing is loaned subject Be to return on demand and is not to be used directly or indirectly ABN 14 008 640 908 in any way detrimental to our interests senarones oate Touenances uno TME INLET MANIFOL FABRICATION 0 1000 1 0 pesauen EC 05 09 12 1000 1 0 FLAMETRAP HOUSING GROUP Ia MACHINING 0 2 CAT C7 ACERT 07 09 12 2 a 3 MACHINE SURFACES wi DWG No BU00001018 RELEASED FOR PRODUCTION cre E 10 09 12 HOME ae 110 DESTROY ALL PREVIOUS COPIES slain ron for O eer REVISIONS TORQUE TO 55 5 Nm REFER TO NOTES 1 amp 2 LA v TORQUE TO 25 4 Nm REFER TO NOTES 1 amp 2 AN TORQUE TO 55 5 Nm REFER TO NOTES 1 amp 2 a TORQUE TO 55 5 Nm PAN REFER TO NOTES 1 amp 2
10. SB1204 October 26 2012 1 4 SADRAK SAFETY BULLETIN TOPIC OVER TENSIONING OF INLET MANIFOLD FASTENERS LEADING TO GASKET FAILURE APPLICABLE TO ALL SANDVIK CAT C7 ACERT EXPLOSION PROTECTED DIESEL ENGINE SYSTEMS SANDVIK LS171 LS191 LOADERS 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 SB1204 Possible occurrence of topic LI Transport Maintenance x Operation _ Spare parts L Tramming L Others Market area x South Africa x Australia New Zealand EU _ Canada USA Supplementary safety information including new hazard s identified how to avoid the hazard s and the potential consequences of not avoiding the hazard DANGER Over tensioning of the Inlet Manifold fasteners can lead to crush of the gasket at the corner and may jeopardise the flameproof integrity of the inlet system 2012 SANDVIK MINING AND CONSTRUCTION AUSTRALIA PTY LTD 431 Masonite Road ABN 62 003 771 382 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
11. e all tools consumables rags etc from the engine bay Perform a check of the area and inform all personnel involved in the repair operation to stand clear Ensure the wheels are chocked the brakes are applied and there is adequate ventilation If safe to do so remove isolation tags and locks open the fuel isolation valve and start the engine Allow the engine a few minutes to come up to temperature Per form a Torque Stall Test whilst an assistant sprays a soapy water solution around the fixed joints that have been disturbed for this repair WARNING Be careful not to overheat the torque converter or engine Observe closely for bubbles around the joints for signs of leakage If leakage occurs check the se curity of all fasteners to the correct torque There must be no leaks for the machine to be returned to service If no leaks occur the machine may be returned to service Ensure all repair and com missioning documents are stored in the filing system for the machine 1 6 Disposal of Waste 1 Dispose of any waste materials metals recycle gaskets waste bins oils lubricant contain ers waste containers etc in an approved manner 8 Copyright Sandvik Mining and Construction Reference ISOMETRIC VIEW D A a N N I s Ak ON 4 Re ESN S gt lt lt D s A SES a x z N 0 F S B Reference i Reference FOR COMPLETE FLAMETRAP HOUSING GROUP amp BOLT TENSION R
12. ifold and gasket edges at the corners Radiator end The inspection must include 1 A visual inspection for extrusion of the gasket from between the faces of the Inlet Manifold BD00009952 and Cylinder Head 2 A visual inspection for cracking of the Inlet Manifold at the corners nearest the radiator NB Possible where severe extrusion of the Gasket has occurred 3 A soapy water test around the radiator end of Inlet Manifold conducted at torque stall Note The vehicle must be in a non explosive gas environment at the time of this test Based on this inspection the following options may be implemented 1 Ifthe manifold is not cracked and the gasket appears not to have been extruded from the joint OR Fit the additional support bracket 1 x BU00000853 and Fasteners 4 x BU00000993 see attachments and replace the Fasteners 4 x BU00000993 at the Fuel Filter Bracket end without the removal of the inlet manifold A full description to remove and install the Inlet Manifold is provided in the attachments A portion of this procedure may be used for the fitting of the support bracket and fasteners Once complete perform soapy water test refer Inspection Step 3 around the Inlet Manifold to Cylinder Head Fixed Joint 3 with the engine at Torque Stall to detect leaks If leaks occur proceed to option 2 2 Ifthe manifold is cracked and or the gasket appears to have extruded from the joint Following the Service Man
13. pts no responsibility for changes labour or replacements incurred from this bulletin SERVICE MANUAL CAT C7 ENGINE Inlet Manifold Installation Procedure for 07 4 E 7A a aE MAINTENANCE MANUAL CAT C7 ENGINE Inlet Manifold Installation Procedure for Cat C7 Engine Read ENTIRE document before commencing job The inlet manifold is an integral part of the Explosion Protected C7 Diesel Engine System DES Ensuring the correct installation of the inlet manifold will ensure the flameproof integrity of the DES should an ignition of combustible gases occur in the inlet tract between the inlet valve and the Flametrap Ensure the LHD is parked with wheels chocked in a suitable service area This should be in a sur face workshop with adequate light shelter and ventilation Apply the appropriate site isolation tags and or locks so the LHD cannot be operated PERSONAL INJURY HAZARD Ensure all required personal protective equipment PPE including gloves and eyewear is worn BURNS HAZARD HOT FLUIDS AND ENGINE COMPONENTS Wait until the engine has cooled before commencing disassembly The procedure for inlet manifold replacement is as follows 1 1 Preparation 1 Raise the engine covers 1 on the side of the machine to access the engine lB ee A VARNES 2 Clean the area of coal oil dust before removing any components 3 Isolate the fuel supply 2 2 Copyright Sandvik Mining and
14. replacements incurred from this bulletin WII 2 4 SAFETY BULLETIN es October 26 2012 Background information The Engineering Department responsible for Load amp Haul Products continues to undertake work to improve documentation used for component assessments Code D Overhauls Explosion Protected Diesel Engine Systems During the course of this exercise the inlet manifold of the CAT C7 Engine was machined to minimum tolerances and pressure tested with test backing plates fitted and gaskets and fasteners as nominated on the Diesel Engine System Drawing Registered with NSW Department of Trade and Investment A problem was discovered when tensioning the corner fasteners to the maximum tolerance Due to the lack of stiffness in the Inlet Manifold the gasket is crushed locally at the corners The same lack of stiffness prevents proper sealing of the fixed joint at the end of the manifold This would not normally be noticed when neoprene rubber is used for Pressure Testing due to the added flexibility and sealing properties of the neoprene test gasket Further testing resolved the issue by using an additional support plate to spread the load of the fasteners All C7 engines already have a Fuel Filter Bracket on one end which adequately performs this function The testing also showed that as little as 1 5mm of gasket width adjacent to the bolt hole is sufficient to contain the full pressure of 1000kPa of the pressure test Figure 1 shows an
15. ual information provided remove the Inlet Manifold and Inlet System components Perform a dimensional check and pressure test Code D inspection of the Inlet Manifold using critical details noted on pages 1 amp 4 of drawings A2U900 830879 Rev B 1 or BD00020101 Rev B 2 Note At Dimension 3 3 the minimum allowable dimension is 1 5mm Reinstall the Inlet system including the additional support bracket fasteners and new gaskets shown in Inlet Manifold Kit BU00001018 All work should be supervised by a responsible person and in accordance with Code D requirements Once complete perform soapy water test refer Inspection Step 3 2012 SANDVIK MINING AND CONSTRUCTION AUSTRALIA PTY LTD 431 Masonite Road Heatherbrae NSW 2324 AUSTRALIA www sandvik com ABN 62 003 771 382 Issued Bulletins are available on the Sandvik website 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 SB1204 October 26 2012 4 4 SADRAK SAFETY BULLETIN IMPORTANT NOTES Disregard the intake system fastener torque settings on the relevant Registration drawings 1 2 Instead use the fastener torques nominated in the Service Manual Inlet Manifold Installation Procedure for CAT C7 Engine
Download Pdf Manuals
Related Search