MTU Mining Brochure (PDF, 8,2MB) - mtu-online-shop.com · I 1 2 3 1 technological leader As a...

Power. Passion. Partnership.

Mining

Designed for the future.Built for your success.

I A customer-orIented technologIcAl leAder

II the power to tAke you forwArd

8 Engines for Dump Trucks < 70 - 130 tn. sh.

10 Engines for Dump Trucks 150 – 500 tn. sh.

12 Engines for Excavators, Loaders and Dozers

14 Engines for Drilling Rigs and

Drilling Equipment

16 Engines for Underground Mining Machinery

III mtu dIesel engInes 20 Product Portfolio - at a glance

22 Series 900

23 Series 460

24 Series 500

25 Series 60

26 Series 1000/OM 934/936

27 Series 1100/OM 470

28 Series 1300/OM 471

29 Series 1500/OM 473

30 Series 2000

31 Series 4000

32 Emissions Reduction Technology

IV repowerIng solutIons

34 Repowering Solutions

V controllIng the power wIth IntellIgent electronIcs

38 We manage everything for you

40 MTU motivline – Automation System

42 CaPoS smart edition – Capacitor Power System

VI mtu VALUEcAre

44 Ensure a long, reliable life

46 Preventive Maintenance

48 MTU-certifiedsupport

50 Long-term Service Agreements

51 Extended Coverage

52 Data-enhanced Solutions

53 Remanufactured Products

VII locAl support. worldwIde.

54 Service Network

VIII serIes And emIssIons QuAlIfIcAtIon

Contents

Designed for the future. Built for your success. I Mining I 3

I

1 2

3

1 technological leader As a supplier of high-quality, performance drive solutions, MTU stands

for the highest level of technological expertise.

2 passion MTUispassionateaboutfulfillingtheneedsofitscustomerswiththeutmost

professionalism and precision.

3 partnership MTUisareliableandtrend-settingpartnerwhichactswithforesightin

a results-oriented manner.

MTU is the part of the Rolls-Royce Group and a world-leading provider of high- and medium-speed diesel and gas engines, complete drive systems and distributed energy systems for the most demanding requirements.

The product range of MTU is one of the widest andmostmoderninthesector.Weoffer comprehensive, powerful and reliable engine solutions for yachts, commercial ships and naval vessels, construction and industrial vehicles, agricultural machinery, mining, rail and military vehicles as well as for the oil and gas industry. We also provide a full line of service products to help you maximize uptime and performance.

For over 100 years, MTU has been known for cutting-edge innovation and technological leadership. That same spirit of innovation inspiresoursustainabilityefforts.Todayandin the future, our focus is on developing and implementing system solutions to maximize efficiencyandmeetemissionsstandards.

An expert in technologyMTUhasalwayssetstandardsintechnologicalexpertise for customized product and system solutions.Todeliveryoumaximumpowerdensity,weconcentrateourinnovationonthecontinuousadvancement of our core competencies: turbo charging, exhaust aftertreatment and electronics.

A passionate engine specialistWespendeverydayworkingtogetherwithyou,our customers, to deliver engines and systems thatbestfityourneeds.Whetherastandardsystemoracustomizedsolution–weare passionate about the art of engine creation.

A reliable partnerWeunderstandthespecificdemandsfordiverseapplications.Incollaborationwithyou,welookforthesolutionswhicharebestsuitedtoyourindividualrequirements.Everystepoftheway– from the start of project planning, during the design of your integrated system solution, at the point of delivery and commissioning and continuing through the care of your product – wearetherewithyoufortheentirelifecycle.

A customer-oriented technological leader.MTUsuppliesitscustomerswithtechnologically- advancedproductsthatareproveninthefield. MTU’srangeofproductsandservicesforoff-highwayapplications is extensive and includes both standard and customized solutions.


II

PowerforMining

The power to take you forward.Mininghasitsownlawsandchallenges.Hugestretches,immensemasses,extremetemperatures,unimaginabletasks:Whoeverwantstoprovethemselvesinthesesituations–whetherhumanor machine – must be strong, hard, tough, and persevering. Achallengethatonlyafewmaster.Weareamongstthem.

fully tried and tested Our engines have a long history of proving themselves in mining applications around the globe. Day in and day out, under extreme conditions, in hard continuous operation.

As leaders in quality and tested in practice a thousand timesover,ourenginesfirstofallfeatureimpressivereliabilityandavailability.Furthermore,lowlifecyclecostsduetoefficientoperation,lowfuelconsumption,long TBO intervals characterize MTU engines, just as much as environmentally friendly operation.

keep goingOur commitment to mining customers extends beyond the sale of our engines and systems. Through MTU ValueCareweofferafulllineofproductsandservicesdesigned to ensure maximum performance, uptime andvalue.Andourglobalservicenetworkisavailabletoprovideexpertsupportwhereveryouare.

Photo:Sandvik


EnginesforDumpTrucks<70-130tn.sh.

Everyday heroes tackle the toughest challenges.

no job is too heavyHeightsatwhichtheairisperceptiblythin.Shimmeringheatbyday,icycoldatnight.Constantlyswirlingdust,moisturethatpenetrateseverything,steephillsidesonwhichheavyloadsneedtobemoved.Theconditionsthatdumptrucks withMTUenginesbraveonadailybasisarebeyonddoubt thetoughestintheworld.

In an environment that places the highest demands on technology,vehiclesrunaroundtheclockwithminimal downtime–continuallyatfullcapacity.

Benchmark technologyThe combination of a rugged engine en hanced by a proven fuel injection system, refined engine management and a practicalarrangementoftheairandexhaustsystemmakesourdump-truckenginesabenchmarkfor these extreme applications. The most important advantages are built in: high torqueatlowenginespeedsyieldstremendousenginepower.

The robust, individually adapted technology of MTU engines assuresthehighestavailabilityofthesevehicleswhichplay anintegralroleinworkingthemine.Furthermorelong maintenanceintervals,maintenance-friendlydesigns,andlow specificfuelconsumptionvalueskeeplifecyclecostslow.

Ourcomprehensive,worldwideservicenetworkensuresthehighest reliability, availability and optimal maintenance.

8 I Mining I Designed for the future. Built for your success.

EnginesforDumpTrucks150–500tn.sh.

Going the distance with the heavyweights.

ready for the challengeDumptrucksarebecomingbiggerandfaster. Nowadays,theyhavetotransportpayloadsupto 500shorttons–anextremechallengefortheengines in these ”heavy-weights.”Butitisataskthatoursuperheavy-dutydieselscopewithconvincinglyeveryday.Theirmountainsofpowermakesurethatthevehiclestheydrivecancarrylargerloads and handle steeper terrain than the competition. With the end result that they deliver higher productivity.

technology makes the differenceThe fact that our engines remain comparatively ”agile” throughout the entire perform ance map, despite their enormouspower,isatributetothetechnologicalgeniusof our designers and developers. The same can be said of their advanced combustion technology:itmakesourenginescheapertooperate,cleaner and quieter than most others. Three benefits thatmakeadifference–economicallyandecologically.


non-stop performanceThey move massive amounts of coal or ore containing valuable materials such as gold, copper, silver, platinum. And they transport almost unimaginable amounts of materialtotheplaceswhereitisprocessedorloadedondumptrucks.Inshort:Contemporaryminingwouldnotbepossiblewithoutthetremendouspowerofwheelloaders, dozers and excavators.

Thepowerfulmachinesdrivenbyourenginesworkwithtopreliability–andhighproductivity.PowerpackslikeourbrawnySeries4000canrunatmaximumpowerwithpracticallynobreaks.Forloadersanddozersthis meansthattheycanworkcontinuouslyatfullpower,and excavators can achieve the fastest load cycles — evenwithmaximumloads.Despitecontinuousoperation therunningcostsremainlow.

As tough as you areMTUenginesareknownassomeofthelowest- consumptionenginesintheworld.Furthermore, maintenance is so uncomplicated that your vehicles are fully operational again in record time.

Robust, stable, and cost-effective: These are the attributesthatmakeourenginesyourbestchoice. In a vehicle fleet that demands as much as it delivers. And in a competitive field as tough as the environment inwhichthevehicleswork.

support to keep you goingTo help ensure maximum performance and uptime, MTU specialistsarereadytoprovideexpertsupportwhereverandwheneveryouneedit.

Engines for Excavators, Loaders and Dozers

Carrying it all away.


Engines for Drilling Rigs and Drilling Equipment

Because only the strongest prevail.

reliable groundworkDrillingisnecessaryineverymine–itisataskthatshouldnotbeunderestimated.Regardlessofwhetheryouare searchingfornaturalresourcesordrillingblastholes,wesupplyenginesthatallowyourdrillingequipmenttoworkreliablyathighpower.

Machines that are subject to extreme burdens over long periods of operation must be able to provide extraordinary power.Ourenginesmakethatpossible,reliablyandwithoutrestrictions.Withtheirpower,longservicelivesandcost- effectiveness,theyhavesetstandardsagainstwhichotherhigh-performance diesels have to measure themselves.

strength and sensibilityElectronicenginemanagementensuresthatourengines,withalloftheirstrength,arefinelytunedtotheirtasks.Itprotectstheengine,optimizesperformanceandsimplifiesdiagnosticsand maintenance. Strength and sen sibility are combined into theidealcombinationthatassertsitselfeverywhere–evenunder the harshest conditions.


one of the hardest jobs in the worldUnderground mining is challenging for both people and machines. Massive drillingequipmentisdriventhroughrockwhilevehiclesandmachineswithheavyloadsmovearoundtheclockathightemperaturesindustandmoisture. Our engines are ideal for these situations.

Theexcellentpower-to-weightratioisonlyoneofmanyfactors. Relia bility, high availability, and the long service life of the engines are also crucial for effective operation. Maintenance-friendly engine designs keepunproductivedowntimetoaminimum,longTBOintervalsandlowfuelconsumptionkeepthelifecyclecostslow–formaximumeffectiveness.

Our engines meet the stringent safety criteria of underground mining withoutrestriction.

power with responsibility The emissions levels of our engines meet the especially important demandsofundergroundmining.Weareleadersinthisaspectaswell: Modern injection technologies and continually optimized combustion processesmakeourenginesasenvironmentallyfriendlyaspossible. SotheycomplywithEPATier4final/EUStageIVemissionsregulations.

worldwide support. Above and below ground.The performance of your MTU engines and systems is crucial for your successandcompetitiveness.Nomatterwhereyouoperate,even underground, MTU specialists are available through our global service networktoprovideexpertsupport.

Engines for Underground Mining Machinery

The harsher the environment, the stronger we are.

Photo:Sandvik

Photo:Sandvik

16 I Mining I Designed for the future. Built for your success. Designed for the future. Built for your success. I Mining I 17

IIIMTU Diesel Engines

Designed for the future.Built for your success.

The higher the requirements and tougher the conditions, the more the need for an MTU engine. That’s because wedeveloptheoptimumdrivesolutionsforallindividualtasks.ThelargerangeofMTUminingenginescontainstherightanswerforeveryapplication–asolutionincludingthe highest performance, greatest reliability, safety, environmentalfriendlinessandoperatingefficiency.

MTU Diesel Engines

All engines at a glance.

kW

500 1000 1500 2000 2500 30000

bhp

500 1000 1500 2000 2500 3000 3500 40000

Engine

Type Page kW

bhp

Series900

22101 – 322 bhp

75 – 240 kW

Series460

23295 – 503 bhp

220 – 375 kW

Series500

24349 – 644 bhp

260 – 480 kW

Series1000/OM 934/936

26134 – 349 bhp

100 – 260 kW

Series1100/OM 470

27375 – 429 bhp

280 – 320 kW

Series1300/OM 471

28429 – 523 bhp

320 – 390 kW

Series1500/OM 473

29536 – 617 bhp

400 – 460 kW

Series2000

31760 – 1340 bhp

567 – 1000 kW

Series60

25300 – 665 bhp

224 – 496 kW

Series4000

321542 – 4023 bhp

1150 – 3000 kW

MTUisyourglobalfull-linepartnerofferingsolutionsforall emissionsrequirementsaswellasthefullpowerrangefrom 75to3000kW(101to4023bhp).Ourenginessetthe benchmarkforwhatdieselenginesmustdeliverinmining applicationsaboveandbelowground.Theiruncompromisingoperationalavailabilityensuresthatminingoperationsrunwithabsolutereliability,whiletheirexceptionalefficiencyisakey factor in the economic success of mining operators.

manufactured by optimized by manufactured by optimized by

Series 900 Series 900 Enginemodel 904C01 906C01 924C01 926C01 4R 6R 4R 6R

PowerOutput kW 75–129 130–205 145 220–240 (bhp) (101–173) (174–275) (194) (295–322) PeakTorque Nm 400–675 675–1100 750 1200–1300 Speed rpm 2200 2200 2200 2200 Emissionsqualification EUNonroadStIIIAComp(97/68/EC),EPANonroadT3Comp(40CFR89), ChinaNRMMStageIII(GB20981-2014)

Series 900withSCRtechnology Enginemodel 924C02 926C02 4R 6R

PowerOutput kW 95–150 175–240 (bhp) (127–201) (235–322) PeakTorque Nm 500–800 850–1300 Speed rpm 2200 2200 Emissionsqualification EUNonroadStIIIBComp(97/68/EC), EPANonroadT4iComp(40CFR1039)

Series 460 Series 460 Enginemodel 460C01 6R

PowerOutput kW 220–375 (bhp) (295–503) PeakTorque Nm 1300–2200 Speed rpm 1800 Emissionsqualification EUNonroadStIIIAComp(97/68/EC), EPANonroadT3Comp(40CFR89), ChinaNRMMStageIII(GB20981-2014)

Series 460withSCRtechnology Enginemodel 460C02 6R

PowerOutput kW 265–375 (bhp) (355–503) PeakTorque Nm 1750–2200 Speed rpm 1800 Emissionsqualification EUNonroadStIIIBComp(97/68/EC), EPANonroadT4iComp(40CFR1039), ChinaOnroadStageV(GB17691-2005)

900 904C 906C 4R 6R

75–130 150–205 (101–174) (201–275) 400–675 750–1100 2200 2200 MSHA

for underground mining


Series 60 Enginemodel 12.7l 14l

PowerOutput kW 224–354 392–429 (bhp) (300–475) (525–575) PeakTorque Nm 1424–2102 2373 Speed rpm 2100 Emissionsqualification MSHA

for underground mining

Series 500

Series 500withSCRtechnology Enginemodel 501C02 502C02 6V 8V

PowerOutput kW 265–350 375–480 (bhp) (355–469) (503–644) PeakTorque Nm 1850–2300 2400–3000 Speed rpm 1800 1800 Emissionsqualification EUNonroadStIIIBComp(97/68/EC), EPANonroadT4iComp(40CFR1039), ChinaOnroadStageV(GB17691-2005)

Series 500 Enginemodel 501C01 502C01 6V 8V

PowerOutput kW 260–315 330–480 (bhp) (349–422) (442–644) PeakTorque Nm 1730–2000 2150–2800 Speed rpm 1800 1800 Emissionsqualification EUNonroadStIIIAComp(97/68/EC), EPANonroadT3Comp(40CFR89), ChinaNRMMStageIII(GB20981-2014)

Series 60 Series 60 Enginemodel 12.7l 14l

Poweroutput kW 224–373 336–496 (bhp) (300–500) (450–665) Peaktorque Nm 1424–2237 2237–2576 Speed rpm 2100–2300 Emissionscertification EUNonroadStIIComp(97/68/EC), EPANonroadT2Comp(40CFR89)

Series 60 Enginemodel 14l

Poweroutput kW 242–496 (bhp) (325–665) Peaktorque Nm 1559–2576 Speed rpm 2000–2300 Emissionscertification EUNonroadStIIIAComp(97/68/EC), EPANonroadT3Comp(40CFR89), China NRMM Stage III (GB20981-2014)uponrequest

manufactured by optimized by


Series 1000/OM 934/936 Series 1000withEGRandSCRtechnology Enginemodel 1000C00 4R/OM934 6R/OM936

PowerOutput kW 100–170 180–260 (bhp) (134–228) (241–349) PeakTorque Nm 600–900 1000–1400 Speed rpm 2200 2200 Emissionsqualification EUNonroadStIV(97/68/EC), EPANonroadT4(40CFR1039)

Series 1100withEGRandSCRtechnology Enginemodel 1100C00 6R

PowerOutput kW 280–320 (bhp) (375–429) PeakTorque Nm 1900–2100 Speed rpm 1700 Emissionsqualification EUNonroadStIV(97/68/EC), EPANonroadT4(40CFR1039)

Series 1100/OM 470

picture 6r







Series 1300/OM 471 Series 1500/OM 473



Series 2000 Series 4000

Series 2000withEGRtechnology Enginemodel 2000C06 12V 16V

PowerOutput kW 783 970 (bhp) (1050) (1301) PeakTorque Nm 4636 5286 Speed rpm 1800/2100 2100 Emissionsqualification EPANonraodT4iComp(40CFR1039)

Series 2000 Enginemodel 2000C02 12V 16V

PowerOutput kW 567–750 783–1000 (bhp) (760–1005) (1050–1341) PeakTorque Nm 3300–4100 4450–5250 Speed rpm 2100 1800/2100 Emissionsqualification EPANonroadT2Comp(40CFR89)

Series 4000 Enginemodel 4000C03 12V 16V 20V

PowerOutput kW 1193–1680 1492–2240 2375–3000 (bhp) (1600–2253) (2000–3000) (3185–4023) PeakTorque Nm 7595–9435 9520–12566 15120–16852 Speed rpm 1800/1900 1800/1900 1800 Emissionsqualification Fuelconsumptionoptimized, EPANonroadT2Comp(40CFR89), ChinaNRMMStageIII(GB20981-2014)uponrequest

Series 4000 Enginemodel 4000C01 4000C02 12V 16V 20V

PowerOutput kW 1193–1510 1492–2125 2720 (bhp) (1600–2025) (2000–2850) (3650) PeakTorque Nm 6985–8199 9313–11142 15159 Speed rpm 1900 1800/1900 1800 Emissionsqualification Fuelconsumptionoptimized, EPANonroadT1Comp(40CFR89)

4000withEGRtechnology 4000C05 12V 16V 20V*

1150–1864 2000–2400 2800–3000 (1542–2500) (2682–3218) (3755–4023) 7351–10409 10581–13403 15363–16753 1800/1900 1800/1900 1800 EPANonroadT4(40CFR1039)

* upon request


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egr technology

Emissions Reduction Technology

Low emissions.High performance.MTU has long established itself as a leader in the development of solutions foremissionsreduction.Thischallengeinvolveskeytechnologieswhichwecarry out in-house.

Inminingtheaimistocollectnaturalresourceswhilegeneratingprofit.Onebasicconditionforefficientoperationsistocomplywithemissions regulations. We care for the technology you need.

Inordertoachieveadvancedemissionsreductions,wehaveinvested our comprehensive expertise in core technologies: common-rail-fuel- injection, turbocharging, cooled exhaust gas recirculation, electronic engine controls for optimizing engine processes and preventing soot formation,aswellasexternaloptimization.

AdvancedemissionsregulationslikeEUStageIV/EPATier4finaldemandfurthersignificantreductioninthepollutantsemitted.Ourenginesandsystemsmeetcurrentlegislativerequirementswithproventechnologies.

We care for the optimal solution for the special demands of each applicationandpowerrangebychoosingtheidealtechnology.

Aftertreatment technology below 560 kw (750 bhp)BesideouremissionsreductiontechnologieslikeEGR,common-rail-fuel-injectionandcharge-air-coolingourenginesbelow560kW(750bhp)areequippedwithSCRaftertreatmenttechnology.

AdvantagesThe advantages of SCR in our engines: — Lowfuelconsumption— Uncompromising engine availability and operational safety— Substantial reduction in nitrogen oxide and greenhouse gas emissions– No DPF and no DOC required

Theperfectinterplayofdifferenttechnologiesfacilitatesoptimalresultsand the most important aim is achieved – a de crease in harmful emissions, alongwithareductioninfuelconsumption.Awin-winsituationforyourearnings and the en vironment.

no aftertreatment above 560 kw (750 bhp)Ourenginesabove560kW(750bhp)don‘tuseanyexhaustaftertreatmenttechnology.InsteadourlatestenginesareequippedwithstateoftheartEGRtechnologycombinedwithourcoretechnologies.Incombination thosetechnologiesenanbleenginecompliancewiththemoststringentemissionregulationssuchasEPATier4final.Thatmeansoptimumenginecharacteristicsandcost-efficientoperationwhilemeetingemissions standards.

Depending on the engine operating point, a certain quantity of exhaust gas is conveyed to the EGR cooler. As it passes through the cooler, thehotexhaustgasiscooledandthenmixedwithchargeair.Mixing theexhaustgaswithchargeairresultsinasignificantreductionin combustiontemperaturebycomparisonwithenginesthatarenotusingEGR.Inreturn,muchlowerrawemissionslevelsofnitrogenoxidearegeneratedinsidetheengine.ThehighlyefficientEGRcombustionprocessdevelopedbyMTUensurescompliancewithEPATier4finalemissionslegislationwithouttheneedforaftertreatment.

AdvantagesThecombinationofMTUcoretechnologieslikeEGRoffersmany advantages:— Lowfuelconsumption— Wide engine performance map – full torque curve— Exceptionallyhightorqueatlowspeeds— Excellenttransientbehaviour(loadacceptance/speedjumps)— Fullpoweroutputavailableevenathighaltitudes— Fullpoweroutputavailableevenathighambienttemperatures

No need for exhaust aftertreatment also means no need for additional operatingfluidssuchasDEF,norforDPForDOC,norforhydrocarbondosing.

egr technology (exampleSeries1500EPATier4final)

1 turbocharging assureslowfuelconsumptionacrosswidespeedrange,exceptionallyhigh torqueatlowspeeds,andcleancombustion

2 egr coolers bringaboutaloweringofthecombustiontemperature(andsubsequentlyof nitrogenoxidesgeneratedin-engine)andareintegratedintothehigh- temperaturecoolingcircuitsothatlessheatisintroduced,whichinturn permitslowercoolerdimensions

3 egr rate EGR valve regulates recirculated exhaust gas quantities. EGR rate is

optimized for all operating modes

AftertreatmentTechnologybelow560kW(750bhp)– exampleSeries1300EUStageIV/EPATier4final

1 urea tank withureafluid

2 def urea supply unit (pump) pumpsliquidureafromthetanktothedosingunit

3 Aftertreatment control module (Acm) controls and regulates functions of the aftertreatment system

4 dosing unit with urea nozzle prepares correct urea quantity in relation to untreated engine emissions and

providesforoptimalsprayingofurea/airmixtureintoexhaustline

5 scr-catalyst converts nitrogen oxids in exhaust gas into harmless air components

6 nox-sensors measure respective engine emissions in exhaust system

WewillbeavailableasapartnertohelpdesignyouroptimalSCRsystem.

Aftertreatment technology below 560 kw (750 bhp)


IV

A proven solution MTU stands alone as the premier engine supplier tomanyoftheworld’smostproductivemineoperations.Engineeredandbuiltspecificallyformining,theSeries4000iswidelyregardedastheindustry’sidealengineforhigh-horsepowerapplications, due to its superior durability, fuel economyandlowtotalcostofownership.Morethan800miningvehicleshavealreadybeenrepoweredwithSeries4000.

Series4000enginesprovideupto6%betterfueleconomyandupto3%higheravailabilitythan the engines they have replaced. It is thereforenosurprisethattheSeries4000 engineshavebeeninstalledinmosttruck models in place of all non-captive brands.

Many equipment operators have saved enough in fuel, maintenance and repair costs to return their repowerinvestmentbeforethefirstoverhaul.Installation detail and cost saving pro jections are available from any authorized MTU distributor.

Pre-engineeredrepowerkitsareavailableforthe most popular mining equipment models. TheefficiencyofMTU’srepowerprocess results in typical equipment outage of one weekorless.

much more than a new engineWe produce system designs and provide complete individual solutions for every possible requirement and any application.

Theheartofthesystemisalwaystheengine as the main component of a mining-vehicle powertrain.Itissupplementedbyawiderangeof auxiliary equipment that can be adapted to suit the basic engine in every particular and whichofcourseismanufacturedtothesamehigh quality standards.

the auxiliary systems include: — Electronic engine management: for safety,

reliability, versatility and data recording — Transmission/generator:thecomplete

solu tion – from a single source— Baseframe: for secure and permanent attachment/supportofsystemcomponents

— Acousticenclosure/exhaustsilencers: forconsistentlylownoiseemissions

— Coolingsystem:modernsystemswith intelligent management

— Mountings: for maximum safety and comfort

Tokeepthesystemeasytomanagedespite its technological complexity, the number of interfacesbetweentheengineandperipheral systems is deliberately limited. The entire powertrainmodulecanbequicklyinstalledandcommissioned using Plug&Play connections.Thisisanadvantageforrepoweringprojectsandparticularlywhenreplacingengines. Avail ability and economy are substantially improved,thusdowntimesareminimized.

A powerful advantage—Higherreliability:increaseduptimeachieved through improved engine reliability and ease of maintenance due to simplicity of engine configuration—Higheravailability:robustengineistime proven in mining— Enhanceoperatorproductivity:lowerengine noise level reduces operator fatigue— Lowesttotalcostofownership: · Bestfuelefficiencyintheindustry · Increasedtimebetweenoverhaul(TBO)& highly consistent overhaul intervals · Multiple rebuilds of original engine core throughout the engine life · Loweroperationcosts— Emissionandapplicationspecificengines: · Highaltitudespecificationengines · Emissionqualified · Fuel consumption optimized

We can help manage your projects right from the initial planning. We provide helpful, expert advice from the concept phase to production use.Inthisway,youbenefitfromourexperiencevery early on and develop a drive design that isjustrightforyourspecificequipmentandapplication.

MTURepoweringSolutions

MoreProfit.MorePower.More Productivity.

time is moneyDuetointelligentengineeringandefficientprocesseswerepoweryouquickly.Thedurationforthecompleteenginereplacementuptofinaltestingwillbe approximatelyoneweekonly.


VOurenginesarepowerfulandtechnologicallyadvanced.Butinordertoofferthebestefficiency,reliability,safetyand environmental friendliness, they need more than just power–theyneedintelligentelectronicmanagement.Modern engine management systems handle the control andmonitoringofthehardwareandenableperfectionofperformance.Thecombinationofpowerandprecision.

Automation Systems

Controlling the power with intelligent electronics.

Allourenginesareequippedwithelectronicenginecontrols. Intelligent electronics ensure that perform ance and efficient operation are achieved under all operating conditions.Innovative,high-endtechnologytakesoverthecontrol, regulation and monitoring of the drive system.The systems are modular in order to be able to adapt the diesel engine to the complex optimal operating conditions of the equipment. In addition, operating conditions that could lead to damage are detected in time.

your benefits:— Protection of the engine and therefore safety by: · Reporting critical operating conditions · Temporaryreductioninpower ·Automaticshutdown · Start inhibitor · Over speed regulation · Self-diagnosis and regulation for the system— Standard interfaces for external system connections, suchasCANdatabusandSAEJ1939

· Easyintegrationwiththevehicle · Flexible adjustment to the vehicle or vehicle

components and project specific needs · Interface for engine diagnosis—Highavailabilityandfail-safeoperation—Highpowerefficiency— Lowfuelconsumption— Minimal exhaust emissions that fully meet all legal

requirements

ForenginesequippedwithSCRsystems,weare your expert technology partner. The latest electronics integrate the necessary SCR components for the reduction of emissions intelligently into the overall system. This ensures optimal tuning of all engine and emission control functions.

EngineManagementSystemsforSeries460,Series500andSeries900

We manage everything for you.Scope of supply for current engine series with emissions regulations EU Stage III A/EPA Tier 3

Engine management system –TypicalconfigurationSeries460,500,900–

Additional components for current engine series with emissions regulations EU Stage III B/EPA Tier 4i

EnginemanagementsystemwithintegratedSCRsystem – Typical configuration –

Urea dosing unit; Heatingvalveand urea nozzle 1

Retarder Transmission Vehicleinstrumentpanel

Interface to SAEJ1939

ABS

Vehicle-CAN

Control unit 2 Vehiclecontrolcommands

Diagnosis interface

Engine Management 1

SCR-CAN

SCR control unit Frame module

SCRmufflerwithcatalyst2Ureatank2Urea supply unit 2

Engine sensors and control elements

1 Engine mounted2Vehiclemounted


Remote Services**

MTU motivline – Automation System

The management technology for mining applications with Series 4000.

The motivline automation system is an innovative highendtechnology developed by MTU for mining vehicles. motivline performs the control and monitoring functions for the entire engine plant. The modular system guarantees optimum adaptation of the diesel engine to the diversity of operating conditions in mining.

motivline supports:— flexibleadaptationtothevehicleand/oritscomponentsandproject-specificrequirements

— automaticpoweroutputadjustmentoroptionalengine shutdownbytheintegratedsafetysystemandallother necessary monitoring and safety functions — Interface – MTU telemetric device for GSM* – for MTU ValueCareproductRemoteServices(optionalwithuseragreement),whichprovidesdirectaccesstothedataof your MTU engine

— Easy adaptation by means of MTU interface module SAM

motivline harmonizes the engine integration into the vehicle. Because of that optimized conditions generates: — high power-efficiency— low fuel consumption— minimal exhaust emissions that are substantially below

the legal limits

For the Series 4000 engines,anewenginemanagement system ADEChasbeendeveloped,whilstthereisalsoan extensiverangeofstandardizedsolutionsavailable–with optionsforflexibleinterfaces.TheEngineMonitoringUnitEMU provides further enhanced availability by means of additional monitoring and diagnostic options for the engine. Complementing the SAM interface module, POM optimizes thestartprocessandsimplifiescablingtothestarterand alternator. The complete Plug&Playsystemmakesinstallationof the engine in the vehicle considerably simpler and faster.

* Global System for Mobile Communications

System highlights and benefits:— Complete system supplied from a single source— Modular design— Minimalwiringonengine— Improved diagnostic functions— Intelligent bus technology— Plug&Play equipment

that means:— Lowcostsforlogisticsandtraining— Lowrisk— Rapidprojectprocessingandshortfittingtimes— Trouble free integration

Adec = Advanced diesel engine controlemu** = engine monitoring unitpom** = power output modulesAm = service and Application module capos = capacitor power system

BatteryCaPoSsmart edition**

Vehicle Control system

Interface CAN open or J 1939 or parallel wired

CAN

CANBattery

ChargingAlternator

EMU**

TelemetricDevice**

POM** ADEC

Starter

Panel instruments**Pedal** Display**

Cab control desk with monitoring and control system

SAMService and Applications Module

ADECEngine Management

POM**PowerOutputModule

Engine with control systems

EMU**Engine Monitoring Unit

SAM

** Optional40 I Mining I Designed for the future. Built for your success.

Cab

Vehiclecontrolsystem

Loksteuerung

4)

ADEC

POM Starter

3)

ADEC

Starter

2)

MDEC

Starter

1)

DDEC

Starter

OnboardBattery24VDC

CaPoS

CaPoS smart edition

1to5Modules

1)Series400001,Series2000022)Series4000023)Series400003/05,Series2000064)OptionalforSeries400003, Series200006

CaPoS smart editionfor new vehicles or repowering

Module1

Module5

CaPoS smart edition – Capacitor PowerSystemforSeries2000,4000

Reliable power right from the start.CaPoSsmarteditionwasespeciallydevelopedforheavydutyapplicationsandprovidesthehighenergyrequiredbythe24VDC starters during the starting sequence.

CaPoS smart edition uses capacitor technology to optimize startup behavior. The number of modules to be used depends on thetypeofengineinvolvedanditsbreakawaytorque.CaPoSsmarteditionmaybeusedautonomouslyorinconjunctionwiththe motivline automation system.

the most important features at a glance:— Autonomous and modular construction— Maintenance-free system—Significantreductionsinweightandvolumecomparedwithconventionalstarterbatteries— Optimized cold-starting capabilities — Lowlife-cyclecosts— No voltage interruption during start-up—Onboardvoltageof24VDC— Integratedself-monitoringsystemwithinterfacetovehiclecontrolsystem— IntegratedDC-/DCconverterforautomaticalrecharging— IP66protectionandambienttemperatureoptimizedfrom-40°Cto+60°C(-40°Fto+140°F)

CaPoS smart edition


VI

1 EXTENDED COVERAGE

5 REMAN / REBUILD

3

4

•••

•

Planning reliability throughout your equipment's lifeMTU ValueCare

2 DIGITAL SOLUTIONSVALUECARE AGREEMENT

GENUINE PARTS & CONSUMABLES

TRAININ

G

MTU-CERTIFIED TECHNICIANS

MAI

NTE

NAN

CE

Start of equipment operation & standard warranty

MTU ValueCare

Ensure a long, reliable life. As your equipment ages, its needs—and yours—change. MTU ValueCarewrapsaroundyourMTUinvestment,providing 360degreesofcustomizedsupport,foroptimalvalueateverystage of life.

1. Avoidtheunexpectedwithaddedprotectionbeyondthestandardwarranty.2. Makebetterdecisionsfasterwithdata-enhancedtools.3. MaximizeavailabilityandoptimizelifecyclecostswithanindividuallytailoredLong-termServiceAgreement.4.Improvesystemperformanceandextendequipmentlifewithon-demandsupportfromMTU.5.KeepagoodthinggoingwithMTUreman/rebuildsolutions.


Preventive Maintenance

Look beneath the surface for lasting value.Upfront costs are only a small part of your engine investment. Long-term value can only be realized by considering the big picture. We’ve found that preventive maintenance yields tremendous savings in cost and time throughout the life of yourequipment.There’ssimplynobetterwaytooptimizefueleconomy, maximize uptime and avoid the unexpected.

Optimize fuel economy.Fuelconsumptionaccountsforupto90percentoftotallifecyclecostsdependingontheapplication—byfaroneofthemostsignificantcostsassociatedwithyourequipment.Well-maintainedMTUenginesdeliverindustry-leadingfuelefficiency,helpingyoukeepfuelcostsdownover the long term.

Maximize uptime.Preventive maintenance services can be planned around your schedule, soyourequipmentisavailablewhenyouneeditmost.

Avoid the unexpected.Planned maintenance helps solve problems before they start, helping youavoidunexpecteddowntimeandresolveproblemsearlybefore they escalate.

Work with one source.MTUkeepsmaintenancesimple,safeandefficient.Ourfactory-approvedmethods and expert technicians ensure everything is done correctly according to proprietary MTU preventive maintenance schedules, optimizing the availability of your equipment, reducing lifecycle costs and helping you avoid unforeseen problems.

MTUfocusesonpreventivemaintenancetoreducethedowntime and added costs of corrective maintenance.

Delaying maintenance increases unexpected failures and decreases performance and fuel economy.

More Preventive

Maintenance

1. Scheduled stops2. Improved performance3. Better control over operation

1. Nonscheduled stops2. Inability to plan3.Lower performance

When preventive maintenance is a high priority.

When preventive maintenance isalowpriority.

Less Corrective

Maintenance

More Corrective

Maintenance

Less Preventive

Maintenance

the Importance of preventive maintenance

Efficiency

Time

Availability

Higherprobabilityoffailure;lowerefficiency

Preventive Maintenanceshould begin here


MTU-certifiedsupport

Rely on MTU expertise. To give your equipment a long and productive life, choose a partner you can trust. OnlyMTU-certifiedtechniciansknowhowtogetthejobdonerightusingproven servicemethods,MTU-specifiedmaintenanceschedulesandgenuineOEMparts.

From preventive maintenance to complete rebuild, MTU is your true lifecyclepartner.Whateverlevelofsupportyouneed,ourglobalnetwork offactory-trainedprofessionalsknowsallaboutyourequipmentandisready to prepare a customized plan to help you maximize performance and minimize life-cycle-costs.

Never compromise. MTUenginesandsystemsarebuilttolastwithlegendaryhighstandards.When it’s time for service, don’t settle for anything less. To get the most from your equipment, there are no shortcuts. For maximum reliability, performance and uptime, choose a name you can trust—MTU.

Learn from the best. TrainingisagreatwaytobecomeproficientwithMTUenginesandsystemsandgetmaximumefficiencyfromyourequipment.Frompreventive maintenance to diagnostics and repair, our training programs provide a hands-onlearningexperiencewithknowledgeable,experttrainers.Weofferawiderangeofcustomizedtrainingprogramsaroundtheworldtomaximize your return on investment.

On-Demand Support—including professional inspections and preventive maintenance recommendations from MTU – helps you identify and address problems early, save on repairs or unexpected downtime,andoptimizeyourequipment’sperformanceandlongevity.Inspectionsincludevisualassessment,testrunandleakcheck,on-site oil and coolant analysis, diagnostic evaluation and reporting.

Long-term Service Agreementsforminingapplicationsmakeit easy to plan the cost of maintenance and maximize availability throughout your MTU equipment’s lifecycle. The details, terms and periodsofeachpackagearepreciselytailoredtomatchyour individualneeds,withmaintenanceperformedbyMTU-certified techniciansusingonlygenuineneworremanufacturedparts.

If you need us a little:

If you need us a lot:


Long-term Service Agreements

Plan ahead.Theannualcostofmaintenancecanvarydramaticallydependingonhow andwhereyourequipmentisused.Atminesiteswhereoptimalequipment availability and performance are essential, and predictable costs are preferred, wecanhelp.

Example: Scheduled Maintenance Costs

year 1 year 2 year 3 year4 year5 year6 year7 year8 year9 year10

Long-term Service Agreement*

Preventive Maintenance

Financial InvestmentAnnualcostsaremorepredictableandconsistentwithLong-termServiceAgreements.

Optimize availability. Long-term Service AgreementsfromMTUmakeiteasytoplanthecost of maintenance and maximize availability throughout the lifecycle of your MTU equipment. The details, terms and periods of each agreement are preciselytailoredtomatchyourindividualneeds,withmaintenance performedbyMTU-certifiedtechniciansusingonlygenuinenewor remanufactured parts.

Extended Coverage

Protect your investment. MTUminingengines—backedbyExtendedCoverage—provideinvaluablepeaceofmindbeyondthestandardwarranty.WithExtendedCoverage,youcanbeassuredthatthecostsofunplannedrepairsarecovered,withserviceperformedbyMTU-certifiedtechnicians—upholdingresalevalueandensuringlong-termconfidenceinyour MTU investment.

Cover the unexpected. Extended Coverage protects you from the cost of unexpected repairs beyondyourstandardwarranty,withprofessionalservicefromMTU-certifiedtechniciansandcoveragetailoredtoyourneeds.Packagescanalsobeextendeduptofiveyearsandarefullytransferable,enhancingresalevalue.Coverage includes all materials and labor for troubleshooting, fault clearance, and corrective services to engines and on-engine electronics (excludinggearbox,alternatorsorsimilarcomponents).Toensuremaximumquality, all repairs are conducted using only genuine MTU parts.

* Excludes corrective services


Data-enhanced Solutions

Make better decisions – faster. Digitizationismorethanabuzzword–gooddatafuelssmarterdecisions. Available for mining applications, Data-enhanced Solutions from MTU harness that power,givingyouvitalinformationandhelpfultoolstosimplifyandstreamlineMTUequipmentownership,operationandmaintenance.

Monitor activity from afar.Identifyfaultsearlyandmakeinformeddecisionsquickly–eventhousandsofmilesfromtheworksite–byaccessingvitalengineandsysteminformationonlinewithRemoteServices.

Be proactive.Remote Services can improve your engine’s performance, and your profitability,byhelpingyouavoiddowntime.Usingatelemetricdevice, importantdatasuchasfluidpressuresandtemperatures,alarms,currentlocation and hours of duty is recorded and transmitted in near real-time or at predetermined intervals.

ThroughearlyfaultidentificationandaconfigurableeCall,youcanactdecisivelyandproactivelytoincreaseengineefficiency,preventdamage,reducedowntime,identifynecessaryreplacementparts,andsaveonserviceandrepairs.AllyouneedisacomputerwithanInternetconnection.

Get everything you need.MTUsuppliesthecompletepackage:

— Telemetric device — Connection cable and antenna — SIMcardfordatatransmissionviathemobilephonenetwork — Installation documentation — Web-based operating instructions — Storage capability on an MTU remote server

Remanufactured Products

Exchange and save. Factory remanufactured MTU products deliver the same high standards of performance, servicelifeandqualityasnewMTUproducts,alongwithidenticalwarrantycoverage– atafractionofthecost.Andwithdesignandmodel-relatedupdates,theyalsofeaturesimilar technological advancements. Developed by R&D engineers, the remanufacturing processsavesyoutimeandmoney,whilebenefitingtheenvironmentthroughthereuse ofmaterials.Tohelpyouworkefficiently,awiderangeofremanufacturedparts,engines andsystemsareavailableworldwide.

Reduce lifecycle costs.Asyouevaluateyourlong-termpowerneeds,youmustconsideravarietyof factors. Factory remanufactured products are a smart solution, helping you reduce the total lifecycle cost of your equipment.

Save time.Factoryremanufacturedproductsputyourequipmentbacktoworkfasterthananoverhaul,whichreducesdowntime,servicetimeandindirectcosts such as storage.

Maintain MTU standards. AllproductsareremanufacturedtostrictMTUstandardsbyMTU-certifiedtechnicians at regional MTU reman centers. Only MTU can remanufacture MTUparts,enginesorsystemstooriginalMTUfactoryspecifications.

Protect the environment.Sinceremanufacturingisanefficientuseofresourcesandenergy, factoryremanufacturedproductsbenefittheenvironmentaswell.

5 Remanufactured product 4 Accepted cores

3 Receive core credit

Collection center

Core acceptance check

Customer

MTU service location

1 Purchase remanufactured product; pay core 2 Return original core

✔

Exchange Process 1 Customer purchases remanufactured product from local MTU service partner and pays the core deposit.2 Customer’s original core is returned to collection center by local MTU service partner for coreacceptancecheck.3 Customer receives core credit based on the core’s technical condition. 4 Acceptedcoresaresentto regional MTU reman centers, wheretheremanufacturing processtakesplace.5 Remanufacturedproductsare delivered to MTU service partners and made available for purchase.

Remanufacturing Process- Disassembly- Cleaning- Reconditioning- Model-related updates and assembly- Quality check (including dynamometer test)

Regional MTU

reman center

An onboard telemetric device transmits vital equipment data, accessible in near real-time on your computer screen.

VIILocal support. Worldwide.Wheneverandwhereveryouneedexpertsupport,MTUspecialistsareavailable. Ourglobalservicenetworkofmorethan1,200locations–backedbyourcutting-edge PartsLogisticsCenters–providesyouthisassurance.TofindyourlocalMTUdistributor, visit www.mtu-online.com.

local support. worldwide.Weensurethatyoureceiveindividualizedsupportfromourglobalnetworkof morethan1,200servicecenters—anywhere,anytime.

GlobalHeadquarters RegionalHeadquarters

Sales and Customer Service Center

Customer Assistance CenterAgentsareavailable24/7forfastresponse to your inquiries and any service needs.

Europe,MiddleEast,Africa+49754190-77777Asia/Pacific+6568609669NorthandLatinAmerica+12485608888info@mtu-online.com

VIIIVII

Enginemodel EUNonroadStII EUNonroadStIIIA EUNonroadStIIIB MSHA EPANonroadT2 EPANonroadT3 EPANonroadT4i ChinaNRMMStageIII ChinaOnroadStageV

Comp(97/68/EC) Comp(97/68/EC) Comp(97/68/EC) Comp(40CFR89) Comp(40CFR89) Comp(40CFR1039) (GB20981-2014) (GB17691-2005)

Series 900

4R904C01

6R906C01

4R924C01

6R926C01

4R924C02

6R926C02

Series 460

6R460C01

6R460C02

Series 500

6V501C01

6V501C02

8V501C01

8V501C02

Series 60

12.7l

14l

OverviewofMTUengines

SeriesandEmissionsQualification.


OverviewofMTUengines

SeriesandEmissionsQualification.

Enginemodel EUNonroadStIV EPANonroadT1 EPANonroadT2 EPANonroadT4i EPANonroadT4 EPANonroadT4 Fuelconsumption ChinaNRMMStageIII

(97/68/EC) Comp(40CFR89) Comp(40CFR89) Comp(40CFR1039) Comp(40CFR1039) (40CFR1039) optimized (GB20981-2014)

Series 1000

4R/6R1000C00

Series 1100

6R1100C00

Series 1300

6R1300C00

Series 1500

6R1500C00

Series 2000

12V/16V2000C02

12V/16V2000C06

Series 4000

12V/16V4000C01

20V4000C02

12V/16V/20V4000C03

12V/16V/20V4000C05


Subjecttochange.|306

1641

|Edition01

/18|EPC20

18-06CM

|PrintedinGermanyonchlorine-fre

ebleachedpaper.

mtu friedrichshafen gmbh I mtu Asia pte ltd I mtu America Inc.Part of the Rolls-Royce Group

www.mtu-online.com

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