Operation Schedules nrtu Section 2 Peo Page i Contents 2.1 Engine condition check preceding W5 Maintenance or major overhaul 2.2. WS Maintenance Operations 2.3. Engine removal 2.4 Engine disassembly 2.5 Engine assembly 2.6 Running-in 2.7. Engine installation and startup 2.8 Appendix 0058/0 -12.88- sT (CPT) -05-89- EOperation Schedules Section nitu sect Engine Condition Check Preceding H5 Maintenance or Major Overhaul Prior to removal, a short test run should be conducted to check the condition and operation of the engine. Deviations from Engine Acceptance Test Record data discovered during the test run will provide important background information for subsequent overhaul services. Operations to be completed = For directions on performing operations refer to: B = Engine Operation Manual P = MTU Test Kit Perform before-start operations Start engine Warm up engine Operate engine at maximum power Record speed, fuel injection, temperatures and pressures and compare with Engine Acceptance Test Record Check running noises. No abnormal noise should be audible. Check engine and pipework for leaks (visual inspection) Check exhaust gas color Operate engine at idling speed Check fuel line connections for leaks Remove cylinder head covers Check valve gear lubrication Take oj] sample Analyze oi1 sample (spot test, water content, fuel dilution) Take coolant sample Analyze coolant sample (corrosion inhibitor oi1 and antifreeze content) Take fuel sample Analyze fuel sample (precipitation test) Shut engine down Check turbocharger rundown Lower coolant level in expansion tank Check coolant level monitor response Drain coolant Fill flushing solution Start engine Flush coolant system Shut engine down Remove HP fuel lines Remove fuel injection nozzles with retainers Check compression pressures 21 1 2 Gee 7 SEVER VES 2o 2003870 -12.88- T (CPT) -05.89- EOperation Schedules nitu Section 2.2 Or Page : WS Maintenance Operations For directions on performing operations refer to: ~ B = Engine Operation Manual = E = Parts Catalog ~ H = Manufacturer's Instructions Operations to be Completed Shut off fuel supply Shut off compressed air supply Shut off raw water supply Drain engine oi1 Drain oi] sludge from engine oi] filter Examine 011 sludge for metallic residues, check bearings if necessary oo Drain coolant (flushing solution) Wash engine (do not use chemicals) Remove temperature gauges and temperature monitoring sensors Suspend sensors in heated oi1 bath. Check trip settings, gauge readings against calibrated thermometer, Adjust or replace instruments as necessary. Remove pressure gauges and pressure monitoring instruments Connect instruments to oi] pump Check trip settings, gauge readings against calibrated pressure gauge, Adjust or replace instruments as necessary. Remove monitoring instruments measuring block Remove exhaust gas pyrometers Inspect thermocouples for cracks or pitting, replace if necessary Remove cylinder cutout changeover valve Remove tachometer and speed monitoring instruments Connect instruments to electric motor Check tachometer with calibrated tachometer, Adjust or replace instruments as necessary Remove air filter Clean air filter Remove coolant lines Remove engine of] lines Remove charge transfer lines Remove HP fuel lines Remove fuel lines PEREE Clean all lines Inspect lines for wear, replace as necessary 3.14.1.2 Check connecting flanges for regularity with ink-check plate reface as necessary. 2003870 -12-68- ST (CPT) -05-89- £Section 2.2 nitu Operation Schedules Page 2 Remove exhaust silencer Clean exhaust silencer Check exhaust silencer for leaks Remove axial bellows from carrier housing Inspect axial bellows for cracks, replace if necessary Remove pressure lines from changeover valve to solenoid valves and pneumatic cylinders Remove pneumatic cylinder with actuator for sequential turbocharging Remove sequential turbocharging solenoid valves from carrier housing Remove charge air preheater flap housing with actuator Remove charge air preheater Clean charge air preheater Check charge air preheater for leaks Remove sequential turbocharging air flow control flap housing Remove air Flow control flaps Replace air flow control flap stop and air flap Inspect air flow control flap shaft bearing, replace if necessary Reassemble air fiow control flap housing Remove intercooler with air box Disassemble intercooler Clean intercooler Inspect soldered joints for leaks, re-solder as necessary Replace gaskets Reassemble intercooler Check intercooler for leaks Remove emergency air shut-off flaps Clean emergency air shut-off flaps Check emergency air shut-off flaps for freedom of movement Check emergency air shut-off flaps for proper seating and valve seat Grease lubrication points Remove carrier housing with turbocharger Remove exhaust manifold Clean housing, exhaust pipes and connecting pipes and inspect for cracks Inspect constant-pressure manifolds and connecting manifolds at sealed joints for wear Clean exhaust housing, carry out visual inspection of components Replace gaskets Remove exhaust flaps and flap bearings Clean exhaust flaps and flap bearings Inspect exhaust flaps and flap bearings Replace exhaust flap drive shaft Disassemble turbocharger Clean all components Inspect components for cracks Check bearing clearance Replace gaskets Reassemble turbocharger 4 H 3.10.5.2 3410.5.3 3.10.8.2 3.10.9.2 3.10.10.2 3410.10.64 2005870 -12.68- ST (CPT) -05.89- E COperation Schedules Section 2.2 Frconcnetaron Page 3 Remove air/coolant manifolds 3.10.2.2 Clean air/coolant manifolds Inspect air/coolant manifolds for cracks 3410.23 Check condition of connecting flanges, reface as necessary Check condition of connecting pipes, replace lines or O-rings as necessary E 10 Remove crankcase breather, 12V Remove crankcase breather, 16V Disassemble breather Clean all components Clean of] separator Check lines for cracks Replace gaskets Remove cooler housing with cooling core Disassemble cooler housing with cooling core Clean cooler housing with cooling core Check cooling core for leaks Replace gaskets and sealing rings Reassemble cooler housing with cooling core Remove coolant thermostat Remove thermostat Replace thermal actuator Check thermostat function Inspect components for wear Replace gaskets Reassemble coolant thermostat Check opening temperature Remove valve gear housing Remove rocker shafts Remove valve clearance adjusting screws Inspect rocker bearing bushings and shafts Inspect ball sockets and ball ends for wear Inspect rockers for cracks Check valve clearance adjusting screws for freedom of movement Remove push rods Inspect ball ends for wear Inspect push rods for cracks Check push rods for distortion Remove fuel duplex filter Remove filter element Clean filter housing Replace filter elements Replace sealing rings Reassemble fuel duplex filter 2005670 -12.88- T (CPT) -05.85- ESection 2.2 nrtu Operation Schedules Page 4 Feeneeare Remove fuel injection pumps, 12V 3 Remove fuel injection pumps, 16V 3 Install pump on test rig Check pump calibration Check for leaks Check cylinder cutout Inspect fuel injection pump coup] ing 3.11.3.5 Replace O-rings on plug-in sleeve Ell Remove fuel injection nozzles 3-11.5.2 Check injector opening pressure, replace nozzle bodies and needles as necessary Check for leaks B Check spray pattern B Remove roller tappets 3.6.2.2 Clean roller tappets Check rollers for freedom of movement Inspect roller surfaces for wear Inspect roller surfaces for pitting Check fit of roller pins Inspect ball sockets for wear Inspect cam faces for wear Check camshaft axial clearance Remove raw water pump Disassemble pump Clean all components Inspect pump housing and impeller for pitting Replace gaskets and sealing rings Reassembie raw water pump Remove engine coolant pump Disassemble pump Clean all components Inspect pump housing and impeller for pitting Replace gaskets and sealing rings Reassembie engine coolant pump Remove generator Inspect generator Inspect generator coupling Inspect coupling sleeve and element for wear, replace components as necessary or install resilient coupling Replace O-rings E 86 Remove bilge pump 3.13.2.2 Disassemble pump 3.13.2.3 Clean all components Inspect pump housing and impeller for pitting 3.13.2.4 Replace gaskets and sealing rings E14 Reassembie bilge pump 3.13.2.5 B Clean charge transfer valve and check for leaks 2003870 -12.88- ‘ST (CPT) -08.89- EOperation Schedules Section 2.2 Fone Page 5 Remove vibration damper end cover Remove end plates and spring packs Inspect spring packs for cracks, replace as necessary Install spring packs and end plates Remove cylinder heads 3.54162 Mark valves Remove valves Clean al] components Check cylinder head for leaks Inspect cylinder head bases for cracks Inspect cylinder head bases for wear Remove protective sleeve and replace O-rings Inspect injection nozzie seating surfaces for wear Reface valve seats on cylinder heads Remove carbon deposits from valves Check valve guides with bore gauge Measure valve stems Inspect valves for cracks Reface valve seats on valves Inspect valve collets for cracks Replace valve stem seals Reassemble cylinder heads Remove pistons Inspect cylinder liner inner surface Clean piston crown, carry out visual inspection Replace conrod bearing Install pistons Remove engine oil filter Remove filter elements Clean filter housing Replace filter elements Replace sealing rings Install engine oi] filter Drain of1 from engine oi1 heat exchanger Remove engine oil heat exchanger Remove filter mounting bracket Disassemble heat exchanger Clean heat exchanger housing Clean plate-core oi1 cooler Inspect plate-core o11 cooler for leaks, solder or replace as necessary Replace gaskets and sealing rings Reassembie heat exchanger Install filter mounting bracket Remove pressure relief and differential-pressure valves Disassemble valves Clean ali components Inspect valve seats for wear, replace as necessary Reassemble valves Check opening pressure 0036/0 ~12.88-Section 2.2 natu Page 6 Remove electric starter Inspect starter pinion for pitting and wear, replace as necessary Inspect carbon brushes for wear Check free movement of carbon brushes in guides Inspect commutator surface for contamination and scoring Remove air starter Inspect starter pinion for pitting and wear, replace if necessary Inspect air starter Bar engine slowly Inspect gears for wear and spalling Check fuel injection timer function Replace cylinder head gaskets Replace coolant transfer sealing rings and O-rings for sleeves Install roller tappets Install push rods Install cylinder heads Install rockers Adjust valve clearance Instal1 valve gear housing Install fuel injection nozzles Drain sludge from fuel prefilter Remove fuel prefilter Remove filter element Clean filter housing Clean filter element Inspect filter element for damage, replace if necessary Replace sealing rings Reassemble fuel prefilter Install charge transfer valves Install exhaust manifold Install carrier housing with turbocharger Install air/coolant manifolds Install emergency air shut-off flaps Install intercooler Install fuel injection pump 12V Install fuel injection pump i6V Adjust fuel injection pump timing 12V Adjust fuel injection pump timing 16V Operation Schedules 2003870 -12.88- ST (CPT) -08.89-Operation Schedules Install engine coolant pump Install raw water pump Install bilge pump Install cooler housing with cooling core Install coolant thermostat Install engine oi] heat exchanger with filter support, 12V Install engine oil heat exchanger with filter support, 16V Instal] fuel prefilter Install fue] filter Install fuel lines Install H.P. fuel lines Install leak-off fuel lines Install engine of] lines Instal] coolant lines Instal] vent lines Install charge transfer lines Install crankcase breather, 12V Install crankcase breather, 16V Install electric starter Install air starter Install generator Install pressure limiting and differential-pressure valves Install air filter Install measuring block for monitoring instruments Install axial bellows after turbocharger Install exhaust silencer Check cylinder cutout, 12V Check cylinder cutout, 16V Check engine alignment for vertical offset Check engine alignment for lateral offset Check engine alignment for inclination Check engine alignment for pitch Check tightness of engine fastening bolts Inspect rubber-metal elements for cracks, replace if necessary Inspect protective varnish on rubber Inspect Vulkan coupling for marking Inspect torsionally resilient coupling (visual inspection), replace if necessary Grease lubrication points Lubricate engine and gearbox control teleflex cable Check engine and gearbox controls for freedom of movement Inspect engine coolant preheater 2003870 -12.86- 2 waeSection 2.2 Page 8 PNCOReS FER Operation Schedules Remove raw water filter Clean filter element Inspect filter element for damage Replace gaskets Install raw water filter Drain engine oi1 storage tank Drain engine coolant storage tank Drain fuel storage tank Drain leak-off fuel tank Clean tanks Inspect protective coating Check for leaks Inspect al] lines Remove engine oi! priming pump Inspect carbon brushes for wear Check free movement of carbon brushes in guides Inspect conmutator surface for contamination and scoring Check pump flow Check running noise Fill engine o11 system Fill engine coolant system Fill starting air bottle Fill fuel tank Perform before-start operations Start engine Carry out checks with engine running Install cylinder head covers =rarr ppp 2 2003870 -12.88- ST (CPT) -05.88- EOperation Schedules Section 2.3 Fema Page 1 Engine Removal Shut off fuel supply. Shut off compressed air supply. Shut off raw water supply. Drain engine oi1 (if possible, with engine warm). Drain oil sludge from engine oi1 filter. Examine 011 sludge for metallic residues. Drain engine coolant (coolant temperature must not exceed 60°C). Wash engine plant (do not use chemicals). Loosen all connections. Loosen engine fastening bolts. Remove engine and place on supporting feet. Seal all open connections with lint-free plugs and covers. Approximate dry weight of engine ~ 12 V 396 = 5140 kg ~ 16 V 396 = 6510 kg 2003870 -12.88- ST (CPT) -05.89- EOperation Schedules mrtu Section 24 bit Page t Engine Disassembly The following sequence of operations represents a practical method for performing engine disassembly. Detailed instructions will be found in the relevant Task Descrip- tion section. No. Description Section Place engine on pallet dolly = Remove engine coolant vent line 34d Remove monitoring instruments Remove resilient engine mounts Remove engine coolant lines and raw water lines onen 6 Remove cooler housing and cooler core 7 Remove engine oi] lines 8 Remove H.P. fuel lines 9 Remove compressed air lines from changeover valve to solenoid valves and pneumatic cylinders 10 Remove fuel duplex filter, timing end 11 Remove axial bellows after exhaust turbocharger 12 Remove pneumatic cylinder with actuator for sequential turbocharging 13 Remove charge air preheater flap housing with actuating cylinder 14 Remove charge air preheater 15 Remove intercooler with air box 16 Remove emergency air shut-off flaps 17 Remove turbocharger air flow control flaps 18 Remove carrier housing with exhaust turbocharger 19 Remove exhaust manifolds 20 Remove cylinder cutout changeover valve 21 Remove charge transfer lines 22 Remove H.P. fuel lines with damping strips 26 Remove air feed at cylinder heads 27 Remove fuel injection pump, 12V 28 Remove fuel injection pump, 16V 28 Remove cylinder cutout, 12V 30 Remove cylinder cutout, 16V 31 Remove leak-off fuel lines 32 Remove generator 33. Remove generator coupling 34 Remove speed transmitter with drive, timing end 35 Remove speed transmitter from engine coolant pump shaft, timing end 36 Remove valve gear housing 37 Remove engine oi] return lines at cylinder head 38 Remove rockers with push rods 39. Remove charge transfer valves 40 Remove injection nozzies 41 Remove crankcase breather, 12V 42 Remove crankcase breather, 16V 43 Remove cylinder heads 44° Remove roller tappets 45° Remove valve seat lubrication of] pump 003870 -12.86- ST (CPT) -05.65- Esect Page No. Description 46 Remove vibration damper 47 48, 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 22 73 74 ory 76 71 78 79 80 81 82 83 84 85 86 87 88 89 90 fon 2.4 Operation Schedules 2 mtu Remove vibration damper flange, 16V Remove vibration damper bearing retaining plate, 16V Remove coupling halves, fuel injection pump I, i2V, 16V Remove coupling flange, fuel injection pump I, 16V Remove coupling flange, fuel injection pump Ii, 16V Remove electric starter Remove air starter Remove flywheel with track ring (order-specific) Remove oi] seal carrier, flywheel end Remove flywheel housing Remove oi] seal carrier, timing end, 12V Install engine on roll-over assembly dolly Remove engine oi] filter with support Remove engine oi] heat exchanger, 12V Remove engine oi] heat exchanger, i6V Remove bilge pump Remove fuel delivery pump Remove raw water pump Remove speed transmitter, left side Remove fuel injection pump drive Remove camshaft chamber cover Remove camshaft Remove oi] pan pressure relief valve, 12V Remove of] pan pressure relief valve, 16V Remove 011 pan Remove engine 01] pump idler gear, 12V Remove engine oi] pump idler gear, 16V Remove engine oi] pump, 12V Remove engine oi] pump, 16V Remove engine oi] suction and delivery lines with strainer at intermediate frame, 16V Remove engine 011 pump from intermediate frame Remove engine coolant pump Remove pistons and conrods Remove crankshaft with bearing cap Remove crankshaft with intermediate frame Remove of] nozzies Remove cylinder liners Remove idler gears Remove camshaft bearing bushings Remove generator drive Remove crankshaft bearing cap studs Remove fuel injection pump drive bearing bushing Remove engine of! heat exchanger pressure limiting and differential-pressure valves Remove coolant thermostat from cooler housing 2003 870 -12.68- ST (CPT) -05.89- EOperation Schedules mrtu Section 2.5 Pon Page 1 Engine Assembly The following sequence of operations represents a practical method for performing en- gine assembly. Detailed instructions will be found in the relevant Task Description section. Operations to be Completed Section Measure crankcase and inspect for cracks Check cleanliness of oilways in crankcase 3.1.1.7 Install crankshaft bearing cap studs Install injection pump drive bearing bushings Install camshaft bearing bushings Install cylinder liners Mount crankshaft bearing caps without bearing shells Mount intermediate frame without bearing shells Measure crankshaft main bearing bore Measure crankcase locating bores Check crankcase for leaks Install crankcase in roll-over assembly dolly Install piston cooling oi1 nozzies Instal] and measure main bearing shells Install idler gears Install crankshaft, 12V Install crankshaft, 16V Measure cylinder liner bores Install camshaft with drive gear Install camshaft chamber cover Install pistons and conrods Install engine of] pump in oi] pan, 12¥ 3.15.1.6 Instal] engine o11 pump in of] pan, 16V 3.15.2.6 Instal] engine oi] pump in intermediate frame, 16V 3.15.3.6 Engine oi] pump idler gear in of] pan, 12V Engine oi1 pump idler gear in of] pan, 16V Engine oi] pump idler gear in intermediate frame, 16V Install engine oi] delivery and suction lines, 12V Install engine oi] delivery and suction lines, 16V Install engine oi1 delivery and suction lines in intermediate frame, 16V Install pressure relief valve at elbow, 12V Install pressure relief valve at elbow, 16V Mount of1 pan on crankcase Remove engine from roll-over assembly dolly and set on pallet dolly Install crankshaft axial bearing clamp ring Install oi7 seal carrier, flywheel end Install flywheel housing Install flywheel with track ring Install filter support on engine of] heat exchanger Install engine oi] heat exchanger with filter support, 12V Install engine oi1 heat exchanger with filter support, 16V Install electric starter Install air starter Install roller tappets Install engine coolant pump Install generator drive ‘2003870 -12.88- ST (CPT) -05-89-ESection 2.5 Operation Schedules section 2 nttu Install fuel injection pump drive Install speed transmitter with drive in gear case, 12¥ Install speed transmitter with drive in gear case, 16V Install fuel delivery pump Install cylinder heads Install engine of] line at cylinder head Install oil seal carrier, timing end, 12V Install bearing retaining plate and flange, timing end, 16V Install vibration damper, 16V Install push rods and rockers Install fuel injection pump coupling halves, timing end Install coupling flange, fuel injection pump I, 16V Install coupling flange, fuel injection pump 11, 16V Install crankcase breather, timing end Install valve seat lubrication pump, flywheel end Install fuel injection nozzles Install constant-pressure manifold housing Install leak-off fuel lines at cylinder heads Install charge transfer valves Install cylinder cutout, 12V Install cylinder cutout, 16V Install fuel injection pump 12V Install fuel injection pump 16V Install air manifold Connect oi] lines to valve seat lubrication system Connect oii lines to fuel injection pump Install H.P, fuel lines Install cylinder cutout changeover valve Install emergency air shut-off flaps at manifold Install exhaust manifolds Install carrier housing with turbocharger Install intercooler with air box Install charge air preheater Install charge air preheater flap housing with actuator Install pneumatic cylinder with actuator for sequential turbocharging Install axial bellows after turbocharger Install sequential turbocharging air flow control flaps Install charge transfer Vines Install bilge pump Install generator coupling Install generator Install raw water pump Install fuel feed and return lines Install coolant thermostat Install cooler housing with cooling core Install coolant lines Pressure test coolant system Install connecting piece with plug-in pipes to fuel supply pump Fill valve adjusting screws with engine oi! Install cylinder head covers Install resilient engine mounts Install monitoring instruments Install coolant vent lines Install drain lines Install vent lines 2003870 -12.88- oT (CPT) -05.89-Operation Schedules nitu Section 2.6 FREEROSAPEN Page i Running-In If pistons, piston rings or cylinder liners have been replaced, the engine must be run in according to the specified schedule. Careful running-in is of vital importance to the service life and operational reliability of the engine. A hydraulic dynamometer or a generator should be used to absorb the power produced during running-in trials. Power transmission from engine to dynamometer can be accomplished by a universal shaft with resilient coupling. The following settings apply: - Fuel temperature before engine: 24 to 30°C - Raw water temperature before engine: 24 to 30°C - Coolant temperature after engine: 80 to 86°C - Intake air temperature before engine: 24 to 30°C - Exhaust back pressure after engine: 27 to 33 mbar Operations to be completed For directions on performing operations refer to: - A= MTU Engine Acceptance Test Record - B = Engine Operation Manual - C = MTU Fluids and Lubricants Specification - H = Manufacturer's Instructions Install engine on test stand. Connect engine to hydraulic dynamometer. Connect air intake, exhaust gas, starting air, engine coolant, oft and fuel lines. Fill expansion tank to Max mark with coolant containing 2% corrosion preventive oi1 Vent air from coolant lines via vent cock or vent lines until bubbie-free coolant emerges Check that fuel in storage or service tank conforms to specification Vent fuel system with handpump Fill new engine oi] to Max mark Before engine startup, perform function check on engine governor, governor linkage and fuel injection pump control rack B Check that starting air tank is full Check governor Stop position and fuel injection pump full-load Setting through sight lens on shutdown housing A Check cylinder cutout Check flap position indicator (see Electronics Manual) wwom o Check function of emergency air shut-off flaps B Check function of shutdown system Check function of actuating cylinders, exhaust flaps and air flow control flaps = B Check starter batteries capacity # Remove cylinder head covers B Fill rocker adjusting screw bores with engine 041 Start engine B Check Tow-idie speed, adjust governor if necessary A Check coolant, of and fuel lines, crankcase gaskets, Air manifolds and exhaust pipes for leaks 8 After 15 minutes engine operation, check valve gear At idling speed, check that o11 emerges from rocker arm sides and bearing points B 003870 -12-66- ST (CPT) -05.69- £Section 2.6 natu Operation Schedules page 2 ony Check 01] supply to ball sockets in adjusting screws Perform engine run-in and measurement in accordance with schedule Measure engine speed and dynamometer loading Measure fuel temperature before engine or measuring glass, Specific gravity, consumption and control rack travel Measure engine oi] pressure before filter and engine Measure engine oil temperature before and after engine Measure coolant temperature before engine, after coolant pump Measure coolant temperature after engine in air/coolant manifold Measure coolant pressure before pump, after pump and after Engine in air/coolant manifold Measure raw water temperature before and after engine Measure raw water pressure before pump and before heat exchanger Measure charge air temperature before engine and before cylinder Measure charge air pressure before turbocharger (intake air depression) and before cylinder Measure exhaust temperature after turbocharger Measure exhaust pressure after engine (exhaust back pressure) and Check exhaust color Measure control air pressure before actuator Measure crankcase breather performance at end of run-in with a gasometer Check barometer Check running noises, combustion and governor function at different speeds and’ loads After run-in, perform engine acceptance test run in accordance with MTU Engine Acceptance Test Record Enter operational data in accompanying Test Record Compare data with Engine Acceptance Test Record Shut engine down o>> Check function of fuel injection pump control rack After run-in, check high and low-idle speeds and full-load and STOP positions of governor, readjust as necessary and Recheck idle and full-load positions For extended lay-up, and especially for transport by sea, Take appropriate protective measures c Remove engine from test stand Install monitoring equipment Paint engine 2003870 -12.88- ST (CPT) -05.89- EOperation Schedules Section 2.6 AEE Page 5 Running-In Schedule for 12 V 396-04 natu funning-in Schedule for 12¥ 396 TC/TB/TO/TE a= ee with injection tiner anes Engine speed asl sasl rel asel arc asa ze aie! anes ezol eal ers sal sod sae ua Fw tem [eof a7] 5.51 6.21 7.01 70 ese) st) sul dl 1,9 sd 13,5 501 16.8 2 abe rom sd ‘00 208 10 et | oe 355 | 306 | 395 [a5 [a6 [se far [aro | eee [ria | vex |a55 | 9] 098] 0s a 1300 319 [360 [356 | «32 [ase [sos [sus [ae [sre [665 [772 [249 | 927 [100d 10] 15e 123 1209, asa [427 [ns [0s [a {sno [28 668 [748 [002 | 5 [0 | 001] 164 ree al 1500 456 [asp [sax [sea |sa0 | 71 [713 | 02 | ant [seo foes | 185d 42071964 142 1600 a2 [577 [6a | 72 [716 | vet | e85 | 960 fons a0 | 120d 195d aad 1824 | rey et 1700 i 13 [oso [714 | 76 | oe | abo hove vss fava | t91d sett 161 7800 { 1599 [756 | 605 | 058 | 962 [)ose [176 fze3 | 139] 1497 1604 471 71900 | 798 | a50 | 903 fiovs |ire9 hi2at fase | raed t50d 1604 r0c 2000 355 [950 06s tee fa fees [ed 1654 17ed 180 20 956 fee [207 far iar | 162d ed 1074 18% 2200 2360 2a Hime () EERE CA a a aaa Tae a = Remarks: Engine speed and output snould be Increased every 20 minutes up to vated speed, afte! Wich [p, an ‘output only should be increased until contractually agreed power is reached. If not listed above, appoach from the nearest speed and output, e.g. for 980KW at 1650 rp engine up to 1600 rpm/ 9S0kW ,and then increase Until engine produces contractually agreed power. operate ESJGHE(E) Hibteoo 2003870 -12.88- ST (CPT) -05.85- £Section 2.6 Operation Schedules Page 4 Fuocseeut Running-In Schedule for 16 V 396-04 Running~in Schedule for 16V 396 TC/TB/TD/TE ear a with injection timer eS Engine speed [2110|2482|2a00|3275[3700| 4070] 4435] 8r0|5178| 5500) s965|6235|7125|7015[3710)ssco) osods toadh aedvasrd | F iwi wpm [io] 47] 5.51 6.2] 7.0) 7716.4 [9,1 [9,8 [10,6] 11,3/12,0/13,51 18,0) 16,5) 10,01 19,5] 21 cl22,si2a.0) a, Boo [Coco Tan 1700) za 1209 34a 393[ aaa] ven|sse [577 [ez1 ove [re [760 [255 [oso |i00s| 1140] 1236330) 142s! rez 1300 25| 4e0| s20|577 lees Jara [ree [776 eae [oer |ros0l1133] 1236] 1930 401 isa) 1607 100) ‘517| $69 [621 |e73 [rea |7as |e25 lear [gos |1109{ 1220/1231] 1401 15521 ve63] 1774 1500) 510665 |rer_|776 |avo [ess |o50_|10s9|1ve5]1307|t¢z6{ 1546 1653]1782|1901 a i710 [758 Jaze lass [oss |rore|sieo|r267|1396] 1525] 1687]1776| r901[z029] | eytawt 1700 jai7_fseo_[ast_[tore|uor7|r2v2|13¢5| 1481 | rete] 1750) 12862020] 215 1800 les1_|roor| 107s 1140 26s 1426] 558 [1711 | tes5| 1995] 2130 2st 1900) 10631136 [1208 [135615051655 | 106] 19552107] 2257] e407 2000 1193 [1267 (1426 [1584 [1742 [1901 [2059] 2017] 2376] 2534] 2100 331 [14971653] 1830|1996|2162| 23262495] 2661 2200 [ 2300 2400 Time (PSEA pa ba Pa a aaa a acm — pe Remiatks, Engine speed and output should be Increased every 20 minutes up fo rated speed, after WRICH [pa] jaw) Cubput chiy should be increased until cntactualy agreed power i feachee, Ir hot lsieg Shove, approach ftom the nearest speed and cutput e.g. for 1O10KW at 1880 rpm, operate TRIED Hitxo tnglne up to 1600 rpm/LIGTHO, and then increase unl efgine produces centactaly speed pov. 2003870 -12.88- st (CPT) -08.89- EJnejeqosdsy9m, OOW}aS810-NLWoOa FRIEDRICHSHAFEN 5) Power calculation P gy =F on K ‘9 Fuel grade © Power calculation Pea _10 SINS3p 10) Specific gravity at 15°C Fuel delivery pres, 7) Brake constant K = 11) Lower Heating Value (LHV) Fuel return press. 8) Factor @ 12) Lube oil Time Power Fuel Lube Erosive (sores, Consumption coat Faster fauen| Temp] Fiow — [Specific | par hour [Specit- Bet Jovi, Jeet [re iy rmaosur| gravity aside | titor| engine cooler count. Bat ® Pet | @ | Pra] ¥ ment |g 8 Run] Vae [inet himin | tem ww ror [ems] oc | € | lem | balm aval oer [enrol 2 a | «| =| ely |e |e | © a 44 | ae= Engine Acceptance Test Record 2 ‘Coolant Supereharging Pressure Temperature Presse ie —_[Waver] Ak | Ai [AR |Bet. |Betore [Setoral anor ro" re ee Arigelsas: [TEA [Ace Bsise|B rise pa HEB |esde °C. |eC |mmigt cer se | so | | er2) Engine med. 3) ng ser. No. 4} Order No, [221 Berometric pressure bar __| 26) Page 23) Relative humility % | 27 Dae 24) Direction of rotation (DIN 6265) ewlecw | 26) Test stand 25)_Inject, pump celivery/degres before TOC | 28) Becorded by Exhaust gas Temperature ter eylind Before wurbocharger As | As] a7 | A8 | a8 | Ato 35 ce61 87 [ee Tas [e10] Gl Ig Control ai ‘Throrte position alOQOperation Schedules nrtu Section PREEReNSOrEN Page Engine Installation and Startup Operations to be completed = For directions on performing operations refer to: B D Engine Operation Manual Special manual Open a1] connections, remove covers and plugs Suspend engine by white lifting eyes and install in plant Make necessary connections Align engine Fill coolant Fill engine of1 Perform before-operation services Start engine Perform during-operation services Perform trial run Shut engine down Perform after-operation services If an extended lay-up is intended, engine preservation is required worm womEES 2003870 -12.88- T (CPT) -05.89- EOperation Schedules natu Section 2.8 Page 1 Appendix Engine Engine Engine Engine Engine Engine cross section 12V cross section 16V longitudinal section, flywheel end, 12V, with Geislinger coupling longitudinal section, timing end, 12V, with coolant cooler longitudinal section, flywheel end, 16V, with Geislinger coupling longitudinal section, timing end, 16V, with vibration damper ‘2003870 12, 88- ST (CPT) -05.89- ESection 2.8 nmrtu Operation Schedules Page 2 eetosor Engine Cross Section 12V 190511220] 2005870 -12.88- ST (CPT) -05-85- E2.8 Section Page Operation Schedules Engine Cross Section 16V 7.905 74020| -85- E 2003870 -12.88-Section 2.8 natu Operation Schedules Page 4 FRED iFON Engine Longitudinal Section, Flywheel End, 12V, with Geislinger Coupling (eee | Sl 1906 1180) T (CPT) -05.89- EOperation Schedules Engine Longitudinal Section, Timing End, 12V, with Coolant Cooler Section 2.8 Page 5 eS B 1.907 074.20] ‘2003870 -12.88- ST (CPT) -05.85- £Section 2.8 motu Operation Schedules Page 6 enter Engine Longitudinal Section, Flywheel End, 16V, with Geislinger Coupling Q \ 19061109 20] 003670 -12.68- oT (CPT) -08.88- EOperation Schedules nirtu Section 2.8 ore Page 5 Engine Longitudinal Section, Timing End, 16V, with Vibration Damper 190707220| 2003670 =1: T (CPT) -05.89- ETask Description Group Summary Page 1 344 341 31 340 312 384 35 hea Vee iB wee C (aN Ae 318 3.84 3.4 3.1 Crankcase 3.2 Gear train 3.3 Running gear 3.4 End cover (timing end) 3.5 Cylinder head 3.6 Valve gear 3.7. Governor 3.8 Governor linkage * 3.9 Exhaust turbocharger 3.10 Air/exhaust systems 3.11 Fuel injection equipment * not shown 3.84 3.86 3.10 Fuel system Coolant pump * Coolant system 041 pump Oi1 system Speed transmitter drive * Starter Engine mounts Monitoring system Accessories (electric, pneumatic) Accessories (mechanical) * 2003870 -10.68- ST (CPT) -05.89- E