Sample EX5500 IPAS Technical Specification and Scope of Supply

SmithDDA Marigold Mining Co per Dave

Technical Specification

and

Scope of Supply

12V4000C13R

Customer: Smith Power Products, Inc.

Project: 300140524MTU Order: 1300586

26.10.2009

Customer: Smith Power Products, Inc. SmithDDA Marigold Mining Co per DaveMTU Order: 1300586 26.10.2009Responsible: SCHAIB Page 2 of 14

I. Engine Description

Engine Model 12V4000C13RApplication Group 5A - Continuous operation, unrestricted

Power as per MTU Sales Program

Power per engine (ISO 3046) 1.193 kWEngine speed 1.800 rpmIntake air temperature 25 CCoolant temperature 45 CAltitude 100 m

On-site Power

Power per engine (ISO 3046) 1.193 kWEngine speed 1.800 rpmIntake air temperature 25 CCoolant temperature 45 CAltitude 100 m

Agreed Deviating Power

Power per engine (ISO 3046) 1.007 kWEngine speed 1.800 rpm

Requirements

Intake depression 15 mbarExhaust back pressure 30 mbar


Performance diagram:

1

kW

rpm1/min

Block. LeistungFuel stop power1193 kW1800 rpm

OptimumFuel Curve

Nm

Drehmoment (NmTorque Curve (Nm

MCR-KurveMCR-Curve

OptimumLoad Curve

0

200

400

600

800

1000

1200

1400

1600

500 700 900 1100 1300 1500 1700 19000

1000

2000

3000

4000

5000

6000

7000

8000

220

220

230

210

215

215

212

208

206

204

250

275

300

209

Load profile:

1 2 3 4 5Load / % 100 80 20 15 --Time / % 71 9 16 4 --TBO / h 15000

MCR OLC OFCnMOT[rpm] M [Nm] P [kW] M [Nm] P [kW] M [Nm] P [kW]600 3563 224 1200 75 1276 80700 3725 273 1519 111 1719 126800 3886 326 1838 154 2051 172900 4240 400 2063 194 2557 2411000 4593 481 2288 240 2963 3101100 5100 587 2644 305 3707 4271200 5800 729 3000 377 4330 5441300 6533 889 3388 461 5015 6831400 7265 1065 3825 561 5439 7971500 7595 1193 4313 677 5655 8881600 7120 1193 4725 792 5860 9821700 6700 1193 5325 948 6125 10901800 6330 1193 6330 1193 6330 1193


Technical Data:

DATA-RELEVANT ENGINE DESIGN CONFIGURATION* = contract value, L = limit value, G = guaranteed value, R = guideline value

Main dimensions (engine incl. standard accessories):


II. Quantities

Total of 1 object(s)2 engine(s) per object

Engine assignment

1 engine 12 engine 21) item appears only once per object

III. Selection Criteria for the Scope of Supply

Criteria Selection for Engine No.

Application group 5A - continuous power 1-2,Vehicle Type Excavator 1-2,Customer Hitachi 1-2,Speed 1800 rpm 1-2,Product usage Not military 1-2,production location Detroit 1-2,Engine(s) per Vehicle Twin-engine plant 1-2,Country of operation 000 still not known 1-2,Emission certifier 18 US EPA Agency 1-2,Instruction for exhaust emissions EPA Tier 2 1-2,Service altitude to 4600 m above sea level (15100 ft) 1-2,Starting method Electrical 1-2,Plant Automation Motiv Line 1-2,Publications Standard publications english 1-2,Painting Harbor blue 1-2,Packing T-cradle seaworthy 1-2,Shipment CIP customer 1-2,Thread adaptor JIC 1-2,Arrangement turbocharger Air intake from free end of engine 1-2,


IV. Scope of Supply

valid forengine No.

1 ENGINE CONFIGURATION 1-2,

1.1 Engine System 1-2,Basic Engine

Liquid-cooled, four-stroke diesel engine, anticlockwise direction of rotation (viewed on driving end) withthe following basic equipment:Grey cast-iron crankcase with inspection ports, flywheel housing SAE 00, flywheel SAE 00, oil pan,forged crankshaft, forged connecting rods, four-valve individual cylinder heads with exhaust valverotators Rotocap, composite pistons with aluminum skirt and steel crown, piston cooling via oil spraynozzle, gear train for accessory drives, water-cooled manifolds and turbo charger, vibration damper; allnecessary on-engine air, exhaust, coolant, fuel and oil pipe work; extraction valve for oil and fuel-assay-extraction, crankshaft transportation locking device

Engine standard factory acceptance testingEngine standard internal preservation

Second generation of Common-Rail fuel injection system, with low and high pressure fuel pumps,one-fuel pressure accumulator integrated in injector, high pressure fuel lines and electronicallycontrolled injection, fuel main filter, fuel priming pump for initial system filling and venting (low-pressuresystem), fuel extraction valve for removal by the fuel assay.

Forced-feed lubrication system with piston cooling, lube oil circulation pump with safety valve,automatic lube oil filter, lube oil heat exchanger, oil filler neck and oil dipstick for measurement on non-running and running engine.

2 Exhaust turbochargers, 1 Intercooler

2 exhaust bellows, 2 compensators

Coolant circulation pump and coolant thermostat for jacket water cooling circuit, coolant circulationpump and coolant thermostat for charge air cooling circuit, coolant filter bypass-arranged at basiccoolant circuit

Engine flywheel, designed for configuration with flange-mounted alternator or flanged distributorgearbox

Integrated electronic engine control and monitoring system consisting from ADEC engine control andSAM-function- and communication-interface Engine speed control Engine monitoring and display of engine operating parameters and alarms Engine protection function against exceeding critical motor operating parameters Automatic start sequence control Acquisition and display of plant-related measured data of the motor CAN-communication with an external system with MTU-protocol Activation and monitoring possible for external functions

1-2,

exhaust emission-optimized engine version EPA Tier 2(acc. to EPA 40 CFR 89 / Tier 2)

1-2,

Crankshaft transportation locking device 1-2,


valid forengine No.

Crankshaft transportation locking device to attach to the sides of the flywheel housing

1.2 Starting 1-2,Electric Starting System

Electric starter with thermo switch(24 VDC / 2 x 12 kW / 2-pole)

1-2,

1.3 Oil System 1-2,

DenominationOIL SYSTEM BASIC SCOPE

Basic Equipment

Lube-oil pump with safety valve Forced-feed lubrication Piston cooling via oil spray nozzles

1-2,

DenominationOIL PUMP

Spherulitic graphite cast-iron oil pan 1-2,

Special design deep oil pan for excavator applicationCheck drawing XZ52618300027 for further information.

1-2,

Oil pan configuration

This oil pan configuration is from installation prospective subject of verification.This listprice consider the price of the deep oil pan from LFR: X59401400005.

If this oil pan doesnt fit the EX5500 and a new oil pan is required, than:- the list price is the same- the generated one-time-costs must be compensated by anumber of oilpans to be defined.

1-2,

Denominationhier fehlt lwanneOIL PAN

Oil replenishment and oil drain

Connection parts for oil replenishment and oil drain, mounted by customer at oil pan according theinstallation drawing

1-2,

Thread adapters, JIC external thread Check installation drawing for further information

1-2,

Oil dipstick and oil filler neck 1-2,


Crankcase ventilation closed

Closed crankcase ventilation with oil separator

1-2,

DenominationCRANKCASE BREATHER

Automatic oil filter maintenance-free with 2 x 4liter lube-oil centrifuges (12V/16V/20V) 1-2,

DenominationOIL FILTER AUTOMATIC

lube oil heat exchanger with housing 1-2,

DenominationOIL. DISTR. HOUSINGOIL SUPPLY FOR HP PUMP- 20V4000LH

centrifugal lube oil filter mounted on automatic lube oil filter 1-2,

DenominationCENTRIFUGAL OIL FLTR AUTOMATIC- 20V4000LH

Electrical pre-lubrication pump

Electrical pre-lubrication pump mounted on engine complete with electrical and oil connections.Activation integrated in automatic starting process

1-2,

DenominationT/CHARGER OIL SUPPLY

Oil assay removal, JIC external thread

Connection neck for oil assay removal, JIC external thread analogical the installation drawing andlocked with sealing cap (for transport)

1-2,

DenominationTHREAD ADAPTER FOR LUBE OIL SYSTEM

1.4 Fuel System 1-2,fuel filter-head

fuel filter-head with connecting-port for 2 filter-cartridges and valve for assay extraction

1-2,

Fuel prefilter with connecting parts with 25 Micron filter device (before low pressure pump)

fuel prefilter with connecting parts for assembly with integrated water separator and connectorfacility for MTU water level sensor

1-2,


For fuel prefilter after low-pressure pump are the requirements to consider according the Installation-directive.

1-2,

Fuel prefilter with 6 Micron filter device (after low pressure pump)

Primary filter (6m) installed after low pressure fuel pump. Filter includes shut-off valves, retainer(for vehicle side installation) and an integrated electric differential pressure indicator.

1-2,

Connection neck, JIC External thread and ISO8434-3 O-ring

Connection neck (fuel-in- and return) for fuel prefilter (after low pressure pump), according toinstallation drawing mounted on the engine and locked with a sealing cap.

1-2,

Fuel hand pump for filling and venting of the low-pressure fuel system 1-2,

Fittings for engine fuel supply

Fittings (fuel supply and return) for fuel delivery, according to installation drawing mounted on theengine and locked with a sealing cap

1-2,

Connection neck, JIC External thread 1-2,

Fuel filter cartridge

2 filter cartridges mounted at filter head

1-2,

1.5 Cooling System 1-2, coolant supply and vent line mounted at engine 1-2,

Coolant remove filter for high-temperature circuit mounted at engine 1-2,

Thread adapters for coolant preheating 1-2,

1.6 Combustion air system 1-2,Combustion Air System

Air inlet vertical for 16/20V 2 intake elbow 90 degree

1-2,

1.7 Exhaust System 1-2, 2 turbocharger , single-stage 1-2,

2 exhaust turbochargers, single staged and water-cooled 1-2,

2 exhaust bellows 90, 2 axial compensators with gaskets without companion flanges for verticalexhaust

1-2,

2 Exhaust bellows with an integrated Diffuser without companion flange 1-2,

2 companion flanges for exhaust bellows 1-2,

1.8 Engine mounting 1-2,Four point mounting 1-2,


Set of rigid engine mounts without dampers at free end

1.9 Power Transmission 1-2,

DenominationSTEEL-SPRING COUPLG

1.10 Auxiliary PTO 1-2,

DenominationV-BELT FOR FAN DRIVE

Fan Drive

Fan coupling S270 Rockford Fan coupling to operated above engine control accordingly engine operation state

1-2,

DenominationFAN DRIVE

V-belt drive for Fan drive S270 Fan coupling

V-belt drive for fan drive i=0,44(with Poly-V belt, without fan wheel)

1-2,

DenominationBELT PULLEYGOVERNOR CONFIG FROM SALES

Battery Charging Generator

Release of Leece Neville alternator 175 A Numbers: 8SC3009ZA, MTU p/n 23520958

1-2,

DenominationCOVER FOR GENERATOR- BR4000ALTERNATOR RIGHT SIDE

Auxiliary PTO for air conditioning compressor

with single Vee belt pulley

1-2,

DenominationAUXILIARY PTOCOVER FOR DDC COMPRESSOR- 20V4000C22

1.11 Engine Management System 1-2,


Calibration Request Form

Please request separately by Dept. EAI

1-2,

Harness / Sensor Guard plates

here is following a text

1-2,

On-Engine Sensors and Wiring

Set of sensors, engine-mounted and wired to the Engine Control Unit ADEC

1-2,

Engine Speed Sensor for Non-MTU Control

Additional engine speed sensor for Non-MTU Control, engine-mounted, with connecting cable with plugconnector at one end, length 0.7 m

1-2,

1.12 Governor Configuration 1-2,Basic calibration engine governor

C&I standard calibration

1-2,

2 ELECTRONICS CONFIGURATION 1)

2.1 Plant Automation 1)Motiv Line Automation for Engine(Scope according to MTU-specification for Mining Vehicles)

1)

Notes to the Scope of Supply of the Automation: 1)

The Automation relate to following Propulsion Plant Configuration:

Mining Vehicle Propulsion Plant, consisting of:

1)

2 x MTU Diesel Engine, Series 4000 (ADEC) 1)

Level Probe for Engine Coolant and MTU-System Cable WF33 for Level Probe - EngineConnection

Level probe for engine coolant (Bedia probe: magnetic-inductive, loose supplied) for installation invehicle-mounted engine coolant expansion tank as well as connecting cable WF33 with plug connectorat both ends for connection of Level Probe F33 with Plug Connector XF33 (mounted at engine)

1)

cable length 10 m 1)

Level Probe for Water in Fuel Prefilter and MTU-System Cable WF70 for Level Probe - EngineConnection

Level probe for water in fuel prefilter (Bedia probe: magnetic-inductive, loose supplied) for installation invehicle-mounted RACOR fuel prefilter as well as connecting cable WF70 with plug connector at bothends for connection of Level Probe F70 with Plug Connector XF70 (mounted at engine)

1)

cable length 5 m 1)

Connecting Module (SAM) 1)


Connecting module for installation in switchboard cabinet, with following components/functions: extensive customer interface (e.g. warnings, alarms, operating signals and fault codes) redundant ADEC data storage possibility for web server access and remote control as well as life data storage fan resp. jalousie control (PI control or 2 state control) preheating control for coolant and intercoolant circuit monitoring of combined exhaust gas temperature (A/B side) monitoring of air and fuel filter

Memory Card in Transportation Box(programmed with plant software)

Memory card (Compact-Flash) for installation in Connecting Module SAM, programmed with plantsoftware for MTU plant automation

Note:A project-specific adaptation of the plant configuration during commissioning of the vehicle is possible.

1)

MTU-System Cables W001 and W005 for ADEC - Plant Automation / Power Supply (24VDC)Connection

Connecting cable W001 with plug connector at one end (ADEC side) for connection of Engine ControlUnit ADEC and components of plant automation and vehicle control as well as connecting cable W005with plug connector at one end (ADEC side) for connection of Engine Control Unit ADEC and powersupply 24VDC

1)

cable length 10 m 1)

Interface Card (CCB)(MTU CAN-bus to SAE J1939 and/or CANopen)

Interface card for installation in Connecting Module SAM, with following function/specification: Coupler from MTUs CAN-bus to SAE J1939 or CANopen for data communication between the

MTU components and a Non-MTU Control

Note:The CAN-bus interface for Non-MTU Control is configurable to SAE J1939 or CANopen duringcommissioning of the vehicle.

1)

3 SPARE PARTS 1-2,

3.1 Spare Parts 1-2,Spare parts and tools are not included in this scope of supply.

If they are required, they can be ordered separately from global After Sales Service

1-2,

4 SPARE PARTS ELECTRONICS 1)

4.1 Spare Parts 1)Spare parts (Electronics) are not included in this scope of supply.

Note:If spare parts for the plant automation were needed, they can be separately asked / ordered at theglobal After Sales Service.

1)


5 TOOLS 1-2,

5.1 Tools 1-2,Spare parts and tools are not included in this scope of supply.

If they are required, they can be ordered separately from global After Sales Service

1-2,

6 TOOLS ELECTRONICS 1)

6.1 Tools 1)Tools (Electronics) are not included in this scope of supply.

Note:If tools for the plant automation were needed, they can be separately asked / ordered at the global AfterSales Service.

1)

7 SUNDRIES 1-2,

7.1 Documentation 1-2,Standard Drawings (Engine/Plant)(1 set per engine, free of charge)

Set of standard drawings (German/English), comprising: Engine installation drawing Diagrams for all systems (e.g. coolant, lube oil, fuel, electrical wiring, monitoring, etc.) Installation drawings for accessories supplied loose

1-2,

Standard Publications in English-Language (Engine)- paper version -(1 set per engine free of charge)

Set of standard publications, comprising: Operation Manual Fluids and Lubricants Specification

1-2,

1 x Engine Operation Manual in English language 1-2,

1 x Fluids and Lubricants Specification in English language 1-2,

7.2 Painting 1-2,Standard Paintwork, Single Color (Engine)(Single-coat, water-based paint)

1-2,

7.3 Packing 1-2,Transportation Cradle for Engine(seaworthy, container transport;shipment storable for up to 6 months)

1-2,

7.4 Additional Options 1-2,Exhaust emission optimization

acc. to EPA 40 CFR 89 / Tier 2

1-2,


Our present scope of supply and additional services does not include the torsional-vibrationcalculation (TAR). We recommend that this be ordered separately in order to avoid damage.

1-2,

8 SUNDRIES ELECTRONICS 1)

8.1 Documentation 1)The descriptions as well as the drawings of the plant automation are included in the enginedocumentation

1)

8.2 Packing 1)The electronic components and MTU-system cables of the plant automation will be packed togetherwith the engine accessories

1)

9 FUNCTIONAL TESTING 1-2,

9.1 Acceptance Testing 1-2,Factory Acceptance Testing 1-2,

Engine test under load on the dynamometer, followed by MTUs series acceptance testing inaccordance with DIN/ISO with Acceptance Test Record. After completion of the factory testing,engine operation in accordance with the technical specification, is possible without restriction. On-site running-in is not required.

1-2,

Engine standard factory acceptance testing 1-2,

10 FUNCTIONAL TESTING ELECTRONICS 1)

10.1 Acceptance Testing 1)Factory Acceptance Testing

Factory acceptance testing of the electronic components

1)

11 SHIPPING CONDITIONS 1-2,

11.1 Freight 1-2,CIP customer (Incoterms 2000) 1-2,

12 SHIPPING CONDITIONS ELECTRONICS 1)

12.1 Freight 1)The electronic components and MTU-system cables of the plant automation will be shipped togetherwith the engine accessories

1)

Documents

Sample EX5500 IPAS Technical Specification and Scope of Supply