ENGINES - SYSTEMS - SALES - SERVICE

ALL FROM ONE SOURCE.

Bad Bentheim, 03.07.2013
- Zeppelin Group is part of Zeppelin Foundation
- The Count's pioneering achievements in 1900 laid the
cornerstone for today's worldwide active Zeppelin Group
- Zeppelin Foundation was originally founded in 1908 in order
to continue with the airship activities of Ferdinand Count Zeppelin
- After World War II the foundation started with various business
areas in trading and industry
 Zeppelin
International

Zeppelin
Power Systems
MVS Zeppelin
Zeppelin
SkySails
MaK
Germany ZSB
Hyster ABS
Lift Trucks

…
1954 1990 1991 1992 1996 1998 2001 2002 2003 2004 2005 2007 2008 2009
West
Germany
Armenia
East
Germany Ukraine Belarus
Czech / SW Russia
Slovak R. NW Russia

Austria Uzbekistan
Turkmenistan
Tajikistan
Shareholders: Zeppelin Foundation/Luftschiffbau Zeppelin GmbH
Sales 2010: 2.00 billion €
Employees: 6,200
Locations: 190
Strategic Business Units: Construction Equipment EU
Construction Equipment & Agro International
Rental
Power Systems
Plant Engineering
 Germany
110 Locations
Poland Russia
2 Locations Belarus 14 Loctions
Germany
6 Locations
Ukraine
United Kingdom 7 Locations
2 Locations
Canada
Belgium Russia China
3 Locations
USA France Turkey
2 Locations Korea
Switzerland
Uzbekistan
Italy Hungary 4 Locations
Austria Saudi
Tajikistan
5 Locations Arabia
Turkmenistan
Czech Rep. Slovak Rep.
Brazil 3 Locations
12 Locations 5 Locations
Armenia

India Singapore

Construction Equipment, Rental & Power Systems

Engineering
Inlet Exhaust
Valve Valve
 Cylinder head
• Individual cylinder heads
• easy removal for maintenance

Piston
• Single piece monotherm design
• Forged steel for added strength
Poor cooland water treatment 5,300 h ELC - 10,103 h.
1. Coolant water pump
2. Oil cooler
3. Engine
4. Exhaust manifold
5. Charge air cooler
6. Thermostat
7. Outlet engine / inlet
Pump
1. Fuel outlet
2. Injector
3. Fuel inlet
4. Fuel manifold
5. Cylinderhead
FUEL FILTER/WATER SEPARATOR
A single valve on all of the double manifold
filters isolates one filter/separator for service
while the other keeps operating. This way, you
keep running while draining contaminants from
the collection bowl or while changing filter
elements.
Meshsize 30µm
• Secondary Fuel Filter Options
• Three capabilities
− Standard
(10 microns and up)
− Advanced
(4 to 10 microns)
− Ultra High
(less than 4 microns)*
• Advanced is shipped with new engines

*currently not measurable

Test-bed protocol Date:

Customer: Bentec Project: ENAFOR 3512A S/N: 67Z02300

Alarm
Measuring point Place Detector Unit Alarm Value Comments
checked
1Engine Speed 1 Engine Sensor rpm 1200
2Engine Speed 2 Engine Sensor rpm 1200
3Lube Oil Pressure Engine Switch kPa 270 no low
4Jacket Water Temperature (HT) Engine Switch °C 94 no high
5Cooling Water Level Jacket Water (HT) Exp-Tank Switch X no low
6Manual Fuel Shut Off Engine X tripped
7Hydra Mechanical Shut Off Engine X trpped
8Positioning Switch Air Intake Flap Engine Switch X no/nc tripped
9Generator Air Intake Differential Pressure Generator Switch X nc high
Caterpillar takes safety seriously New switch location.
Contacts only on gate
closure to prevent wear
• Electronically controlled with manual backup
air inlet shut off systems available on all
engines
• Updated design for 2006
• Hydra / Mechanical shut offs available on
mechanical engines only
• Setting of shutoff valves marked to ensure
proper resets before restarting
• Overspeed
18 % above full load speed
Overspeed condition is the result of a fuel system that fails to operate correctly.
For an overspeed condition the fuel control linkage is moved to the "SHUTOFF" position and the
engine combustion air supply is stopped.

• Low Engine Oil Pressure

Idle speed min. 1,4 bar
Max speed min. 2.1 bar
For a low oil pressure condition, the protective system activates an alarm or moves the fuel control
linkage, through the governor, to the "SHUTOFF" position. The combustion air supply is not
shutoff for this condition.
• For furhter maintenace recommandation see

KATO
• Air Shutoff - Test
• Cooling System Coolant Sample (Level 1) Obtain
• Engine Oil and Filter - Change
• Bearing (Spherical Roller) - Lubricate
• Cooling System Coolant Sample (Level 2) – Obtain
• Engine - Clean
• Engine Crankcase Breather - Clean
• Engine Protective Devices - Check
• Fuel System Primary Filter
• Clean/Inspect/Replace
• Fuel System Secondary Filter - Replace
• Insulation - Test
• Rotating Rectifier - Check
The Zeppelin diagnosis of oil and coolants provides valuable information on the
condition of engine, axles, gears, hydraulic and coolant system of each construction
machine. Thus you can prevent failures and may even extend the intervals of oil
changes. Your machines work better, live longer and are thus as a total more
economic.

www.zeppelin-cat.zod.de
(A) Inlet valves
(B) Exhaust valves
(C) Flywheel
• Longer for increased cylinder spacing
• High Cam Position
• Cross-Flow Design
• Single-Piece Design
1. Valve
2. Valve guide
3. Spring
4. Rotorcoil
5. Valve lash
6. Rockerarm
7. Camshaft
Monotherm® Piston
• Single-Piece Forged Steel Design
• High strength
• Light weight
• Simplicity
1. Oil spray tube piston
2. Inlet
3. Outlet
4. Oil spray tube piston pin
5. Piston
 • Provides Better Liner Contact with Piston
• Two-Step Honing Process:
Rings and Skirt
• Deep cut grooves improve oil retention
on the liner surface • Reduces Combustion Blow-by
• Smoothed groove tops reduce wear of • Improves Control of Oil Consumption
cylinder liner and piston rings
Poor coolant treatment 5,300 h
ELC - 10,103 h
(1) Cylinder head
(2) Water temperature regulators
(3) Outlet hose
(4) Vent line
(5) Vent tube
(6) Shunt line
(7) Elbow
(8) Water pump
(9) Cylinder block
(10) Oil cooler
(11) Inlet hose
(12) Radiator
1. Coolant water outlet
2. Plug
3. Thermostat housing
4. Water pump
5. Plug
A: Thermostat housing
B. Thermostat 98 C
(1) Oil manifold
(2) Oil supply line
(3) Oil return line
(4) Oil filter
(5) Bypass valve for the oil filter
(6) Oil pan
(7) Oil pump
(8) Bypass valve for the oil cooler
(9) Suction lines
(10) Bypass valve for the oil pump
(11) Oil cooler
(12) Camshaft bearing journals
(13) Rocker arm shaft
(14) Oil passage to adjustable idler gear
(15) Oil passage to air compressor
(16) Oil passage to the fixed idler stub shaft
(17) Piston cooling jet
(18) Oil passage to cluster idler gear
(19) Crankshaft main bearings
(20) Oil passage from filter
(21) Oil manifold
• Revolutionary Filter Design
• Reduces Oil Contaminant Particle Size and
Quantity
• Increased contamination control
• Double the efficiency without
decreasing the filter change interval
• Reduces wear on all oil lubricated
surfaces
• Captures the Most Harmful Particles:
5 – 10 Microns in Size
• Series Filtration
• Fuel Filter Efficiency Options
• Standard (10 microns and up)
• Advanced (4 to 10 microns)
− Shipped with new engines
• Ultra high (less than 4 microns)*

*currently not measurable

(1) Fuel supply line
(2) Electronic unit injectors
(3) Fuel gallery
(4) Electronic Control Module (ECM)
(5) Fuel pressure sensor
(6) Fuel temperature sensor
(7) Pressure regulating valve
(8) Secondary fuel filter
(9) Fuel priming pump
(10) Fuel transfer pump
(11) Primary fuel filter
(12) Fuel tank
• Captures the Most Harmful Particles:
5 – 10 Microns in Size
• Series Filtration
• Fuel Filter Efficiency Options
• Standard (10 microns and up)
• Advanced (4 to 10 microns)
− Shipped with new engines
• Ultra high (less than 4 microns)*

*currently not measurable

• Secondary Fuel Filter Options
• Three capabilities
− Standard
(10 microns and up)
− Advanced
(4 to 10 microns)
− Ultra High
(less than 4 microns)*
• Advanced is shipped with new engines

*currently not measurable

Solenoid
controled from ECM ~ 110 Volt DC

• By changing the fuel rate (controlling the injectors),

ECM Controls and Regulates the speed and engine
power.
1. Coolant air to engine
2. Charge air cooler
3. Air befor cooler
4. Turbo outlet
5. Xxx
6. Xxx
7. Air filter
 Electro-Mechanical EMCP II EMCP II+P EMCP 4.x

1970 1975 1980 1985 1990 1995 2000 2005 2010

EMCP I EMCP II+ EMCP 3.x

 New Event New Event Log
Reset Button Navigation Button

Button Text Added

New Navigation Button

Layout & Style

New Engine Overview New Main Menu

Button Symbol Navigation Button
Daily Initial 20 to 40 Service Hours
- Coolant Level - Check - Belts - Inspect/Adjust/Replace
- Electrical Connections – Check Every Week
- Engine Air Cleaner Service Indicator - Inspect - Generator - Inspect
- Engine Oil Level - Check - Generator Bearing Temperature - Test/Record
- Fuel System Primary Filter/Water Separator -Drain - Generator Lead (Flat Braided Cable) - Check
- Generator Load - Check Initial 250 Service Hours
- Jacket Water Heater - Check -Engine Valve Rotators – Inspect
- Power Factor - Check
Every 250 Service Hours
- Voltage and Frequency - Check
- Coolant Sample (Level 1) - Obtain
- Walk-Around Inspection
Every 250 Service Hours or 6 Months
- Battery Electrolyte Level - Check
- Engine Oil Sample - Obtain
- Fuel Tank Water and Sediment - Drain
- Hoses and Clamps - Inspect/Replace
Every 500 Service Hours or 1 Year Every Year
- Belts - Inspect/Adjust/Replace - Coolant Sample (Level 2) - Obtain
- Cooling System Supplemental Coolant Additive (SCA) - - Rotating Rectifier - Check
Test/Add - Varistor - Check
- Engine Oil and Filter - Change Every 3 Years
- Engine Protective Devices - Check - Coolant Temperature Regulator - Replace(FFJ1-Up)
- Fuel System Primary Filter (Water Separator) Element -
Every 3000 Service Hours or 3 Years
Replace
- Alternator - Inspect
- Fuel System Secondary Filter - Replace
- Coolant Temperature Regulator - Replace
Every 2000 Service Hours or 1 Year - Crankshaft Vibration Damper - Inspect
- Engine Crankcase Breather - Clean - Engine Mounts - Inspect
- Generator Lead (Round Cable) - Check - Engine Valve Rotators - Inspect
- Generator Set Vibration - Inspect - Starting Motor - Inspect
- Radiator - Clean - Turbocharger - Inspect
- Stator Lead - Check - Water Pump - Inspect
Every 4000 Service Hours or 2 Years
- Coolant (DEAC) - Change(FFJ1-Up)
Every 4500 Service Hours
- Generator Bearing – Lubricate
Every 6 Years
- Coolant (ELC) - Change(FFJ1-Up)
Every 12 000 Service Hours or 6 Years
- Coolant (ELC) - Change
When Required
- Batteries - Replace
- Battery - Recycle
- Battery or Battery Cable - Disconnect
-Engine Air Cleaner Element (Dual Element) -
Clean/Replace
-Engine Air Cleaner Element (Single Element) -
Clean/Replace
- Fuel System - Prime
- Generator - Dry
- Generator Set - Test
- Rotating Rectifier - Test
- Varistor - Test
- Winding - Test