DIESEL ENGINES

.llM3EnM "
1 CA90
SILNIKI WYSOKOPR~ZNE
2 CA90
Operation and service manual
2 CA90/I/b ~ HCTpYK ~~R no 00 CnY)I(~BaH~HJ
Instrukcia obslugi

, I

WYTWORNIA SILNIKOW WYSOKOPR~ZNYCH "AN DORIA" W ANDRYCHOWIE

ul. Obr. Stalingradu 128 34-120 Andrych6w
Tel.: 532-40 do 532-47 Telex: 035681 Telegraf: "ANDORIA"
Product designation ................... Nazwa wyrobu ..........................
Product type ........................... THrr H3.IlenH5I Typ wyrobu ..........................
Year of manufacture .................... rO.IlBblnYCKa Rok budowy ........................
Serial No .............................. 3aBO.IlCKoA:~ Nr fabryczny ...........................
Power output kW Moc ........................ kW
at crankshaft speed r.p.m. npH ~aCTOTe Bpa~eHH5I KoneH~aToro przy obrotach walu korbowego . obr/min
and adjusted to the following ambient Bana ............ 06!MHH i odniesiona do warunk6w
conditions: npH Cne.IlYID~HXBHelliHHXycnOBH5IX: otoczenia:
- temperature .................... c - TeMnepaTypa oKpy~aID~ero B03.Ilyxa .. c temperatura .................... c
- air pressure kPa - aTMocepHoe .IlaBneHHe Kila cisnienie ................... kPa
- relative humidity % - OTHOCHTenbHa5I Bna~HOCTb % wilgotnosc wzgl~dna ................ %

Product weight kg Macca H3.IlenH5I Kr Masa wyrobu kg

Technical Inspection Stamp . illTaMTI
TexHH~ecKoro KOHTpOn5I . Znak kontroli technicznej .
Warranty Certificate No . ~ rapaHTHA:HoA: KapTbI . Nr swiadectwa gwarancyjnego .

Proper care of the engine is essential ilpaBHnbHoe o6cnY~HBaHHe 5IBn5IeTC5I OCHOBHbIM Prawidlowa obsluga jest zasadniczym warun-
for achieving many hours of trouble-free ycnoBHeM 6e30TKa3HoA: pa60TbI .IlH3en5I H npo- kiem sprawnego dzialania silnika i prze-
operation. Before operating the engine, .IlOn~HTenbHoro Me~peMOHTHoro npo6era. dluzenia okresu mi~dzynaprawczego .
thoroughly study this Operation and Ser- B CB5I3H C 3THM, npe~e ~eM npHcTynHTb K W zwiqzku z tym przed przystqpieniem do
vice Manual. Regulations contained herein 3KcnnyaTa~HH .IlH3en5I,Cne.IlyeT 03HaKOMHTbC5I eksploatacji silnika nalezy zapoznac si~
should be adhered to throughout the oper- c HaCT05I~eA: HHCTpYK~HeA:, a B npo~ecce z niniejszq instrukcjq.
ation of the engine. Hcnonb30BaHH5I .IlH3en5I C06nID.IlaTbBce ee yKa- W trakcie uzytkowania silnika stosowac
3aHI1H. przepisy w niej zawarte.
1. INTRODUCTION 5 1. BBE,I:\EHIiE
.................. 1. WST~P ........... 5
2. SPECIFICATION AND TECHNICAL 2. XAPAKTEPIiCTIiKA Ii TEXHliqECKOE 2. CHARAKTERYSTYKA I OPIS TECHNICZNY 10
DESCRIPTION .................... 6 OITIiCAHIiE,I:\1i3EnH
............. 2.1. Charakterystyka techniczna
2.1. Specification. ............ 6 2.1. TeXHHQeCKaff xapaKTepHCTHKa silnik6w ........... 10
2.2. Description of main engine ,llH3enefl.................. 2.2. Opis g~6wnych element6w sil-
elements .................. 13 2.2. OnHcaHHe OCHOBH~X 3neMeHTOB nika ................... 13
3.INSTRUKCJA TRANSPORTU ......... 21
3. IiHCTPYKUliH ITO YITAKOBKE Ii TPAHC-
4. INSTRUKCJA PRZECIWPOZAROWA .... 23
ITOPTIiPOBKE ,I:\1i3EnH
........ 21
4. ITPOTIiBOITO~PHAH IiHCTPYKUIiH .... 23 5. INSTRUKCJA BEZPIECZE~STWA I HIGIE-
5. IiHCTPYKUIiH ITO TEXHIiKE BE30ITACHO- NY PRACY ........ 24
6. INSTALLING AND SERVICING THE NEW CTIi Ii rlirliEHETPY,I:\A........... 24 6. PRACE PRZY NOWO OTRZYMANYM SILNIKU 25
ENGINE .......................... 25 6. ITO,I:\rOTOBKA
HOBoro ,I:\1i3EnH
K 3KC- 6.1. Ustawienie i odkonserwowanie
6.1. Installing and degreasing ITnYATAUli1i.................. 25 silnika ........... 25
the engine 25 6.1. YCTaHOBKa H paCKOHcepBaUHff 6.2. Przygotowanie paliwa i mate-
6.2. Fuel and lubricants ........ 29 ,llH
3enff ............. 25 ria~6w smarnych ....... 29
6.3. Preparing the engine for the 6.2. ITO,llrOTOBKarOpIDQe-CMa30QH~X 6.3. Przygotowanie silnika do pier-
first starting 31 MaTepHanOB ............ 29 wszego uruchomienia .... 31
6.4. Initial operation 34 6.3. ITO,llrOTOBKa,llH3enff
K nepBoMy 6.4. Pierwszy okres pracy silnika 34
7. OPERATION ...................... 34 nycKy ............... 31 7. OBSLUGA SILNIKA PODCZAS PRACY 34
7.1. Preparing the engine for 6.4. ITepB~flnepHO,llpa6oT~ ,llH3enH 34 7.1. Przygotowanie silnika do uru-
starting ................... 34 7. OBCnY*IiBAHIiE ,I:\1i3EnH
BO BPEMH chomienia ............ 34
7.2. Starting the engine 35 3KCITnYATAUIili ................. 34 7.2. Uruchomienie silnika ....... 35
7.3. Monitoring the engine opera- 7.1. ITO,llrOTOBKa,llH3enHK nYCKY 34 7.3. Doz6r silnika w czasie pracy 39
tion 39 7.2. ITYCK ,llH3enH .............. 35 7.4. Zatrzymanie silnika ...... 40
7.4. Stopping the engine ........ 40 7.3. Ha,ll30p3a pa6oTofl ,llH3enH . 39 7.5. Uzytkowanie silnika w okresie
7.5. Wintertime operation 40 7.4. OCTaHOBKa ,llH3enH ......... 40 zimowym .......... 40
8. MAINTENANCE SCHEDULE ........... 44 7.5. 3KcnnyaTaUHH ,llH3enHB 3HM- 8. TABELA OKRESOWYCH CZYNNOSCI OBSLU-
HHfl nepHO,ll ............... 40 GOWYCH .................... 46
9. DESCRIPTION OF THE SCHEDULED MAIN-
8. TABnliUA ITEPIiO,I:\liqECKIiX
TEXHliqEC- 9. OPIS OKRESOWYCH CZYNNOSCI OBSLUGO-
TENANCE OPERATIONS 47
KIiX YXO,I:\OB................... 45 WYCH ................... 47
9.1. Lubrication system 47
9. OITIiCAHIiEPABOT ITO ITEPIiO,I:\liqECKOMY 9.1. Obs~uga uk~adu smarowania ... 47
9.2. Fuel supply system and air
TEXHliqECKOMY OBCnY*IiBAHIi~ ,I:\1i3EnH47 9.2. Obs~uga uk~adu zasilania pali-
cleaner ................... 49
9.1. Yxo,ll3a CHCTeMofl CMa3KH ... 47 wem i filtru powietrza 49
3
 9.3. Valve gear 53 9.2. Yxo~ sa CHCTeMOn no~a~H 9.3. Obs3:uga uk3:adu rozrza.du ..... 53
9.4. Silencer 53 TonnHBa H BOS~YWH~ Hnb- 9.4. Obsl:uga tl:umika ............. 53
9.5. Electrical system 53 TpOM . 9.5. Obsl:uga instalacji elektrycz-

9.6. Checking and adjusting the in- 9.3. Yxo~ sa MexaHHSMOM rasopac- nej ...................... 53
jection timing 54 npe~eneHHH ............... 9.6. Sprawdzanie i regulacje po-
9.7. Replacing the cylinder head. 57 9.4. Yxo~ sa rnywHTeneM ....... cza.tku tl:oczenia 54

10. TROUBLESHOOTING CHART.. 58 9.5. Yxo~ sa 3neKTpoo6opy~oBa- 9.7. Wymiana g3:owicy .-. 57
11. STORAGE OVER LONG PERIODS 66 HHeM . 10. TABLICA NIEDOMAGA~ SILNIK6w I SPO-
9.6. npoBepKa H perynHpoBKa Ha- SOBY ICH USUWANIA .............. 63
~ana Bnp~CKa TonnHBa . 11. PRZECHOWYWANIE ORAZ KONSERWACJA
9.7. 3aMeHa ronOBKH UHnHH~pa . SILNIKA PO WYCOFANIU Z RUCHU NA
10. TASnHUA B03MO~HWX HEHCnPABHOCTEn DLU2SZY OKRES CZASU ........... 66
~H3EnH H cnOCOSOB HX YCTPAHEHHH
11. XPAHEHHE H KOHCEPBAUHH ~H3EnH
nPH nEPEPWBE B 3KCnnYATAUHH HA
~HTEnbHWn nEPHO~ BPEMEHH .
1 CA90 and 2 CA90 diesel engines have been
KOHCTPYK~HH ~H3eneA 1 CA90 H 2 CA90 pa3pa-
developed based upon experience acquired Konstrukcja silnik6w 1 CA90 i 2 CA90 zos-
60TaHa Ha OCHOBe ~onroneTHero on~Ta 3aBo-
by the PZL-ANDRYCHOW Works in the manufac- tala opracowana w oparciu 0 do~wiadczenia
~a, HaKonneHHoro npH npOH3BO~CTBe ~H3eneA
ture of 5301 and 5301 0 engines. zdobyte przez Wytw6rni~ podczas produkcji
silnik6w 5301 i 5301D.
1 CA90 and 2 CA90 engines are air-cooled
~H3enH HMeWT B03~YWHoe oxna*~eHHe C npH-
and an adequate rate of cooling air flow Silniki chlodzone Sq powietrzem, przy czyrn
HY~HTenbH~ nOTOKOM B03~yxa, C03~aBaeM~
is ensured by a centrifugal fan, mounted doplyw odpowiedniej jego ilo~ci zabezpie-
~eHTp06e*H~ BeHTHnHTopoM, YKpenneHH~
to the flywheel. cza wentylator od~rodkowy zamocowany do
kola zamachowego.
Air cooling offers the following advan-
tages: Zastosowany uklad chlodzenia zapewnia:
BaeT:
1. A considerably simplified engine design 1. Znaczne uproszczenie konstrukcji i ob-
1. 3HaqHTenbHYw npocToTy KOHCTpyKUHH H 06-
and maintenance. slugi silnika.
cnY*HBaHHH ~H3enH.
2. A high reliabil~ty of the engine. 2. Niezawodno~6 pracy silnika.
2. Ee30TKa3HocTb pa60T~ ~H3enH.
3. Independence of ambient air temperatu- 3. Znaczne uniezaleznienie sie od tempera-
3. 3HaQHTenbHYw CTeneHb He3aBHCHMOCTH OT
res. tury otoczenia.
TeMnepaTYP~ oKpy*awmeA cpe~~.
4. Independence of water availability. 4. Uniezaleznienie sie od braku wody w
4. He3aBHcHMoCTb OT HanHQHH BO~~ Ha MeCTe
5. Capability to operate the engine in miejscu pracy.
pa60T~.
various climatic conditions. 5. Prac~ w r6znych warunkach klimatycz-
5. Pa60TY B pa3nHQH~X KnHMaTHQeCKHX ycno-
6. An expanded range of the engine appli- nych.
BHHX.
cations. 6. Zwi~kszenie zakresu zastosowania sil-
6. YBenHQeHHe ~Hana30Ha npHMeHeHHH ~H3enH.
nika.
CA90 and 2 CA90 engines are designed to
drive the road construction machines, pump ~H3enH npe~Ha3HaQeH~ ~nH npHBo~a ~OPO*H~X 5ilniki przeznaczone Sq do napedu maszyn
units, power generating units, tractors, MaWHH, HaCOCH~X yCTaHoBoK, ~H3enb-reHepa- drogowych, zespo16w pompowych, zespo16w
mobile air compressor units, platform TOpOB, TpaKTopoB, nepeB03H~X KOMnpeccop- prqdotw6rczych, ciqgnik6w, przewoznych
trucks, boats, etc. H~X YCTaHoBoK, Tene*eK H KaTepOB. agregat6w spr~zarkowych, w6zk6w plat for-
mowych, lodzi roboczych.
Wytw6rnia 5ilnik6w Wysokopr~znych - H3rOTOBHTenb OCTaBnHeT 3a co-
Andrych6w reserves the right to in- 60A npaBO BBe~eHHH KOHCTpyK- Wytw6rnia 5ilnik6w Wysokopreznych
troduce any design and manufactur- ~HOHH~X H TeXHOnOrHQeCKHX H3- w Andrychowie zastrzeg~ sob~e pra-
ing process changes as well as the MeHeHHA H CBH3aHH~X c HHMH wo do zmian konstrukcYJnych ~ tech-
changes as the changes in operating cnoc060B 06cnY*HBaHHH CBOHX nologicznych oraz sposobu obslugi
and servicing procedures. The parts H3~enHA. BBH~y 3Toro QaCTH swoich wyrob6w. W zwiqzku z tym
shown on individual figures may, npe~CTaBneHH~e Ha OT~enbH~X cz~sci przedstawione na poszczeg61-
therefore, differ from those fitted pHcyHKax MorYT 6~Tb ~pyrHMH nych rysunkach mogq sie :6z~i6 od
in the engine, or may not be fitted QeM Ha ~BHraTene HnH Bo06me cz~sci wyst~pujqcych w s~ln~ku lub
at all. OTCyTcTBOBaTb. mogq w og6le nie wyst~powa6.
 - after final running-in
in operation
Maximum torque at maximum
Diesel, 4-stroke
with self-ignition rated power output 26 Nm 52 Nm

Number of cylinders Minimum idling speed 700 r.p.m.

Arrangement of cylinders vertical Rated crankshaft speed 3000 r.p.m.

Bore 90 mm Sense of crankshaft rota- Clockwise when looking from the fly-
Stroke 90 mm tion wheel end
Cubic capacity
Compression ratio
1. V-belt or flat belt pulley
Maximum rated power output,
2. Flexible coupling between
no allowance for over-
the engine and a driven machine
loading
provides direct drive
according to DIN 6270
Permissible engine tilt
- after factory running-in
NB1 - longitudinal
- after final running-in - transversal
in operation NB Engine starting electrical-starting motor;
decompressor engaged if necessary
manual-hand crank; decompressor
Continuous power output
always engaged
with overloading allowance,
Electrical equipment
according to DIN 6270
- alternator
- after factory running-in
- starter motor 12 V, 0.6 kW 12 V, 1.3 kW
NA1
- battery 45 Ah 120 Ah
- after final running-in
- battery charging indi-
in operation NA
cator W Pl-2, 30 A, 90
Power output at continuous
- voltage regulator RC2/12B or RC2/12D
running, according to DIN
Dry engine weight
6270, no allowance for
- electrical starting
overloading
system 107 kg 145 kg
- after factory running-in
- hand starting 91 kg 124 kg
NB/C/1
 2 I 3
I
Lubrication system - intake valve closes 5230' after BDC
Type - exhaust valve opens 5230' before BDC
Specific oil consumption - exhaust valve closes 18 after TDC
for the run-in engine Valve clearance 0.2 mm
Oil pressure in hot engine
at rated speed
piston pump, driven by the engine
Oil pressure in hot engine
camshaft
at idle speed 100 kPa
two-section
Maximum oil temperature 105C, short-time 120
Speed governor multi-range
Capacity four-holed
Injector nozzle
- minimum oil level 2.5 litre 3.9 litre
Injection pressure 21.1'::0.5MPa
- maximum oil level 3.7 litre 5.4 litre Minimum injection pressure 19.6 MPa
Oil filters Primary - oil pump strainer fine
in operation
- oil filter with replaceable paper
Injection timing
element
Specific fuel consumption
Oil pump
at rated power output
Cooling system air cooling, air flow induced by for finally run-in engine
the fan attached to the flywheel
Fuel tank capacity 9 litres
Timing gear
Oil filter with replaceable paper element
Type
dry
Valve timing
- intake valve opens

Note: In case of necessity to take off power from timing gear (reduc- even breaking of crankshaft, or breaking of the teeth of timing
tion gear) shaft by means of a gear or chain transmission, use gear-wheels)
a flexible or overload coupling at timing gear (reduction gear) Taking the power off the timing gear (reduction gear) shaft by
shaft end. If power is to be taken off the timing gear (reduc- means of a gear or chain transmission is unadvisable.
tion gear) shaft by means of a coupling only, this coupling Maximum torque of overload couplings:
should in such case by of the flexible or overload type. Using - for 1 CA90 engines 208 Nm
in the above cases another coupling than a flexible or overload - for 2 CA90 416 Nm
one may result in serious engine damage (permanent torsion or