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Operating Instructions

Diesel engine
12 V 1600 R50

MS15025/00E
Printed in Germany
© 2011 Copyright MTU Friedrichshafen GmbH
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior
written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, micro‐
filming and storage or processing on electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage
during operation.
Subject to alterations and amendments.
Table of Contents
1 Safety 7 Task Description
1.1 General conditions 5 7.1 Valve Drive 37
1.2 Personnel and organizational requirements 6 7.1.1 Valve clearance – Check and adjustment 37
1.3 Transport 7 7.1.2 Cylinder head cover – Removal and
1.4 Safety regulations for startup and operation 8 installation 39
1.5 Safety regulations for maintenance and 7.2 Fuel System 41
repair work 9 7.2.1 Fuel system – Venting 41
1.6 Fluids and lubricants, fire prevention and
environmental protection 12 7.3 Fuel Filter 42
1.7 Conventions for safety instructions in the 7.3.1 Fuel filter – Replacement 42
text 14 7.3.2 Fuel prefilter – Drain condensate 43

7.4 Air Filter 44


7.4.1 Air filter – Replacement 44
2 General Information 7.5 Air Intake 45
7.5.1 Service indicator – Signal ring position check 45
2.1 Engine side and cylinder designations 15
2.2 Engine layout 16 7.6 Lube Oil System, Lube Oil Circuit 46
2.3 Sensors and actuators 17 7.6.1 Engine oil level – Check 46
7.6.2 Engine oil – Change 47

7.7 Oil Filtration / Cooling 48


3 Technical Data 7.7.1 Engine oil filter – Replacement 48

3.1 Firing order 20 7.8 Coolant Circuit, General, High-


3.2 Engine – Main dimensions 21 Temperature Circuit 49
3.3 12V 1600 R50 engine data 22 7.8.1 Engine coolant – Level check 49
7.8.2 Engine coolant – Change 50
7.8.3 Engine coolant – Draining 51
7.8.4 Engine coolant – Filling 53
4 Operation 7.8.5 Engine coolant pump – Relief bore check 55

4.1 Preparation for startup after a scheduled 7.9 Low-Temperature Circuit 56


break in operation 24 7.9.1 Charge-air coolant level – Check 56
4.2 Preparation for startup after extended out- 7.9.2 Charge-air coolant – Change 57
of-service periods (>3 months) 25 7.9.3 Charge-air coolant – Draining 58
4.3 Starting the engine 26 7.9.4 Charge-air coolant – Filling 59
7.9.5 Charge-air coolant pump – Relief bore check 61
4.4 Operational checks 27
4.5 Stopping the engine 28 7.10 Wiring (General) for Engine/Gearbox/Unit 62
4.6 After engine shutdown 29 7.10.1 Engine wiring – Check 62
4.7 Plant – Cleaning 30
7.11 Accessories for (Electronic) Engine
Governor / Control System 63
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7.11.1 Engine governor and connectors – Cleaning 63


5 Maintenance 7.11.2 Engine Control Unit – Plug connection check 64

5.1 Preface 31
5.2 Maintenance task reference table [QL1] 33
8 Appendix A

6 Troubleshooting 8.1 Abbreviations 65


8.2 MTU contacts/service partners 68
6.1 Troubleshooting 34

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9 Appendix B 9.2 Index 71
9.1 Special Tools 69

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1 Safety
1.1 General conditions

General
In addition to the instructions in this publication, the applicable country-specific legislation and other com‐
pulsory regulations regarding accident prevention and environmental protection must be observed. This
state-of-the-art engine has been designed to meet all applicable laws and regulations. The engine may
nevertheless present a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Noncompliance with the Safety Instructions

Correct use
The engine is intended solely for use in accordance with contractual agreements and the purpose envis‐
aged for it on delivery. Any other use is considered improper use. The engine manufacturer accepts no
liability whatsoever for resultant damage or injury in such case. The responsibility is borne by the user
alone.
Correct use also includes observation of and compliance with the operating instructions and mainte‐
nance and repair specifications.

Modifications or conversions
Unauthorized modifications to the engine represent a safety risk.
MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or
conversions.

Spare parts
Only genuine MTU spare parts must be used to replace components or assemblies. MTU accepts no
liability whatsoever for damage or injury resulting from the use of other spare parts and the warranty shall
be voided in such case.

Reworking components
Repair or engine overhaul must be carried out in workshops authorized by MTU.
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1.2 Personnel and organizational requirements

Personnel requirements
Work on the engine must only be carried out by appropriately qualified and instructed personnel.
Observe the minimum legal age.
Responsibilities of the operating, maintenance and repair personnel must be specified by the operating
company.

Organizational measures
This publication must be issued to all personnel involved in operation, maintenance, repair or transporta‐
tion.
Keep it handy in the vicinity of the engine such that it is accessible to operating, maintenance, repair and
transport personnel at all times.
Use the manual as a basis for instructing personnel on engine operation and repair. In particular, person‐
nel must have read and understood the safety-relevant instructions.
This is especially important for personnel who work on the engine only on an occasional basis. These
persons shall receive repeated instruction.
Use the Spare Parts Catalog to identify spare parts during maintenance and repair work.

Working clothes and protective equipment


Wear proper protective clothing for all work.
Depending on the kind of work, use the necessary personal protective equipment.

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1.3 Transport
Transport
Lift the engine only with the lifting eyes provided.
Use only the transport and lifting equipment approved by MTU.
Take note of the engine center of gravity.
The engine must only be transported in installation position, max. permissible diagonal pull 10°.
In the case of special packaging with aluminum foil, suspend the engine on the lifting eyes of the trans‐
port pallet or transport with equipment for heavy loads (forklift truck).

Setting the engine down after transport


Place the engine only on an even, firm surface.
Ensure appropriate consistency and load-bearing capacity of the ground or support surface.
Never place an engine on the oil pan, unless expressively authorized by MTU on a case-to-case basis to
do so.
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1.4 Safety regulations for startup and operation

Safety requirements for initial operation


Prior to initial operation of the unit, install the assembly or unit according to the specifications and check
the installation according to the MTU specifications.
Before putting the device or plant into operation, always ensure:
• that all maintenance and repair work is completed,
• that all loose parts have been removed from rotating machine components,
• that nobody is in the danger area of moving machine parts.
Immediately after putting the device or plant into operation, make sure that all control and display instru‐
ments as well as the signaling and alarm systems work properly.

Safety requirements for operators


The procedures for cases of emergency must be practiced regularly.
The operator must be familiar with the control and display elements.
The operator must be familiar with the consequences of any operations performed.
During operation, the display instruments and monitoring units must be permanently observed with re‐
gard to present operating status, violation of limit values and warning or alarm messages.
The following steps must be taken if a malfunction of the system is recognized or reported by the system:
• inform supervisor(s) in charge,
• analyze the message,
• if required, carry out emergency operations e.g. emergency engine stop.

Engine operation
The following conditions must be fulfilled before starting the engine:
• Wear ear protection.
• Ensure that the engine room is well ventilated.
• Do not inhale engine exhaust gases.
• Ensure that the exhaust system is free of leaks and that the gases are discharged to atmosphere.
• Mop up any leaked or spilt fluids and lubricants immediately or soak up with a suitable binding agent.
• Protect battery terminals, battery-charger terminals and cables against accidental contact.
• When the engine is running, never release coolant, oil, fuel, compressed-air or hydraulic lines.

Operation of electrical equipment


When electrical equipment is in operation, certain components of these appliances are electrically live.
Observe the safety instructions for these devices.
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1.5 Safety regulations for maintenance and repair work

Safety regulations for maintenance and repair work


Have maintenance and repair work carried out by qualified and authorized personnel only.
Allow the engine to cool down before starting maintenance work (risk of explosion of oil vapors).
Before starting work, relieve pressure in systems and compressed-air lines which are to be opened.
Take special care when removing ventilation or plug screws from the engine. Cover the screw or plug
with a rag to prevent fluids escaping under pressure.
Take special care when draining hot fluids ⇒ Risk of injury.
When changing the engine oil or working on the fuel system, ensure that the engine room is adequately
ventilated.
Allow the engine / system to cool down before starting to work.
Observe the maintenance and repair instructions.
Never carry out maintenance and repair work with the engine running unless expressly instructed to do
so.
Secure the engine against accidental starting.
Disconnect the battery when electrical starters are fitted.
Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic
starters are fitted.
Disconnect the control equipment from the assembly or system.
Use only proper, calibrated tools. Observe the specified tightening torques during assembly/disassembly.
Carry out work only on assembles and/or units which are properly secured.
Never use lines for climbing.
Keep fuel injection lines and connections clean.
Always seal connections with caps or covers if a line is removed or opened.
Take care not to damage lines, in particular fuel lines, during maintenance and repair work.
Ensure that all retainers and dampers are installed correctly.
Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent con‐
tact with other components. Do not place fuel or oil lines near hot components.
Do not touch elastomeric seals if they have carbonized or resinous appearance unless hands are proper‐
ly protected.
Note cooling time for components which are heated for installation or removal ⇒ Risk of burning.
When working high on the engine, always use suitable ladders and work platforms. Make sure compo‐
nents are placed on stable surfaces.
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Observe special cleanness when conducting maintenance and repair work on the assembly or system.
After completion of maintenance and repair work, make sure that no loose objects are in/on the assem‐
bly or system.
Before barring the engine, make sure that nobody is standing in the danger zone. Check that all guards
have been reinstalled and that all tools and loose parts have been removed after working on the engine.
The following additional instructions apply to starters with beryllium copper pinion:
• Breathing protection of filter class P2 must be applied during maintenance work to avoid health haz‐
ards caused by the beryllium-containing pinion. Do not blow out the interior of the flywheel housing or
the starter with compressed air. Clean the flywheel housing inside with a class H dust extraction de‐
vice as an additional measure.

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Welding work
Never carry out welding work on the assembly, system, or engine-mounted units. Cover the engine when
welding in its vicinity.
Do not use the assembly or system as ground terminal.
Do not route the welding lead over or near the wiring harnesses of MTU systems. The welding current
may otherwise induce an interference voltage in the wiring harnesses which could conceivably damage
the electrical system.
Remove parts (e.g. exhaust pipes) which are to be welded from the engine beforehand.

Hydraulic installation and removal


Check the function and safe operating condition of tools and fixtures to be used. Use only the specified
devices for hydraulic removal/installation procedures.
Observe the max. permissible push-on pressure specified for the equipment.
Do not attempt to bend or apply force to lines.
Before starting work, pay attention to the following:
• Vent the hydraulic installation/removal tool, the pumps and the lines at the relevant points for the
equipment to be used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs).
• For hydraulic installation, screw on the tool with the piston retracted.
• For hydraulic removal, screw on the tool with the piston extended.
For a hydraulic installation/removal tool with central expansion pressure supply, screw spindle into shaft
end until correct sealing is established.
During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of the
component to be installed/removed.

Working on electrical/electronic assemblies


Always obtain the permission of the person in charge before commencing maintenance and repair work
or switching off any part of the electronic system required to do so.
De-energize the appropriate areas prior to working on assemblies.
Do not damage cabling during removal work. When reinstalling ensure that wiring is not damaged during
operation by contact with sharp objects, by rubbing against other components or by a hot surface.
Do not secure cables on lines carrying fluids.
Do not use cable binders to secure cables.
Always use connector pliers to tighten connectors.
Subject the device or system to a function check on completion of all repair work.
Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Pack de‐
fective electronic components and assemblies in a suitable manner when dispatched for repair, i.e. par‐
ticularly protected against moisture and impact and wrapped in antistatic foil if necessary.

Working with laser equipment


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When working with laser equipment, always wear special laser-protection goggles ⇒ Heavily focused ra‐
diation.
Laser equipment must be fitted with the protective devices necessary for safe operation according to
type and application.

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For conducting light-beam procedures and measurement work, only the following laser devices must be
used:
• Laser devices of classes 1, 2 or 3A.
• Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700
nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to prevent
any risk to the eyes.
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1.6 Fluids and lubricants, fire prevention and environmental
protection

Fire prevention
Rectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause fires -
therefore always keep the engine in a clean condition. Do not leave cloths soaked with fluids and lubri‐
cants lying on or near the assembly or unit. Do not store inflammable material near the assembly or unit.
Do not weld pipes and components carrying oil or fuel! Before welding, clean with a nonflammable fluid.
When starting the engine with an external power source, connect the ground lead last and remove it first.
To avoid sparks in the vicinity of the battery, connect the ground lead from the external power source to
the ground lead of the engine or to the ground terminal of the starter.
Always keep suitable firefighting equipment (fire extinguishers) at hand and familiarize yourself with their
use.

Noise
Noise can lead to an increased risk of accident if acoustic signals, warning shouts or noises indicating
danger are drowned.
Wear ear protectors in work areas with a sound pressure level in excess of 85 dB (A).

Environmental protection and disposal


Modification or removal of mechanical or electronic components or the installation of additional compo‐
nents as well as the execution of calibration processes that might affect the emission characteristics of
the engine are prohibited by emission regulations. Emission control units/systems may only be main‐
tained, exchanged or repaired if the components used for this purpose are approved by MTU or equiva‐
lent components. Noncompliance with these guidelines might represent a violation of the Clean Air Act
and involves the termination of the operating license by the emission authorities. MTU does not accept
any liability for violations of the emission regulations. MTU will provide assistance and advice if emission-
relevant components are intended to be modified. The MTU Maintenance Schedules ensure the reliabili‐
ty and performance of MTU engines and must be complied with over the entire life cycle of the engine.
Use only fuel of prescribed quality to comply with emission limit values.
Dispose of used fluids, lubricants and filters in accordance with local regulations.
Within the EU, batteries can be returned free of charge to MTU FN / MTU Onsite Energy where they are
subjected to proper recycling procedures.

Fluids and lubricants


Use only fluids and lubricants that have been tested and approved by MTU.
Keep fluids and lubricants in suitable, properly designated containers. When using fluids, lubricants and
other chemical substances, follow the safety instructions that apply to the product. Take special care
when using hot, chilled or caustic materials. When using flammable materials, avoid all sparks and do
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not smoke.

Used oil
Used oil contains harmful combustion residues.
Rub barrier cream into hands.
Wash hands after contact with used oil.

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Lead
• When working with lead or lead-containing compounds, avoid direct contact to the skin and do not
inhale lead vapors.
• Adopt suitable measures to avoid the formation of lead dust.
• Switch on extraction system.
• Wash hands after contact with lead or lead-containing substances.

Compressed air
Observe special safety precautions when working with compressed air:
• Pay special attention to the pressure level in the compressed air network and pressure vessel.
• Assemblies and equipment to be connected must either be designed for this pressure, or, if the per‐
mitted pressure for the connecting elements is lower than the pressure required, a pressure reducing
valve and safety valve (set to permitted pressure) must form an intermediate connection.
• Hose couplings and connections must be securely attached.
• Wear goggles when blowing off components or blowing away chips.
• Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).
• First shut off compressed air lines before compressed air equipment is disconnected from the supply
line, or before equipment or tool is to be replaced.
• Unauthorized use of compressed air, e.g. forcing flammable liquids (danger class AI, AII and B) out of
containers, results in a risk of explosion.
• Forcing compressed air into thin-walled containers (e.g. containers made of tin, plastic and glass) for
drying purposes or to check for leaks, results in a risk of bursting.
• Carry out leak test in accordance with the specifications.

Painting
• When carrying out painting work outside the spray stands provided with fume extraction systems, en‐
sure that the area is well ventilated. Make sure that neighboring work areas are not impaired.
• No open flames.
• No smoking.
• Observe fire prevention regulations.
• Always wear a mask providing protection against paint and solvent vapors.

Liquid nitrogen
• Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers.
• Avoid body contact (eyes, hands).
• Wear protective clothing, protective gloves, closed shoes and protective goggles / safety mask.
• Make sure that working area is well ventilated.
• Avoid all knocks and jars to the containers, fixtures or workpieces.

Acids and alkaline solutions


• When working with acids and alkalis, wear protective goggles or face mask, gloves and protective
clothing.
• If such solutions are spilled onto clothing, remove the affected clothing immediately.
• Rinse injured parts of the body thoroughly with clean water.
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• Rinse eyes immediately with eyedrops or clean tap water.

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1.7 Conventions for safety instructions in the text

DANGER
In the event of immediate danger.
Consequences: Death or serious injury
• Remedial action

WARNING
In the event of potentially dangerous situations.
Consequences: Death or serious injury
• Remedial action

CAUTION
In the event of dangerous situations.
Consequences: Minor injury or material damage
• Remedial action

Note: This manual contains highlighted safety warnings in accordance with the US ANSI Z535 standard which
begin with one of the signal words listed above depending on the severity of the hazard.

Safety instructions
1. Read and familiarize yourself with all safety notices before starting up or repairing the product.
2. Pass on all safety instructions to your operating, maintenance, repair and transport personnel.

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2 General Information
2.1 Engine side and cylinder designations

Engine sides are always designated as viewed from the driving end (KS).
The cylinders of the left engine side are designated "A" and those of the right side "B" (as per DIN ISO
1204). The cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end of
the engine.
Other components are numbered in the same way, i.e. starting with No. 1 on driving end.

1 KGS = Free end 3 KS = Driving end


2 Right engine side 4 Left engine side
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2.2 Engine layout

1 Exhaust outlet 9 Thermostat housing 17 Oil pan


2 Air intake 10 Oil filter 18 Exhaust elbow
3 Intercooler 11 EGR flap in front of EGR 19 Intercooler
4 Lifting eye, driving end cooler 20 Flywheel housing
5 Oil dipstick 12 Lifting eye, free end 21 Flywheel
6 EGR flap in front of EGR 13 Cylinder head 22 Starter
cooler 14 EGR cooler 23 Exhaust turbocharger
7 Intercooler 15 Engine mounting
8 Fuel filter 16 Engine governor

Engine model designation


Key to the engine model designations 12 V 1600 Rxy
12 Number of cylinders
V Cylinder arrangement: V engine
1600 Series
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R Application
x Application segment
y Design index

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2.3 Sensors and actuators

No. Description Monitoring of


1 B5.1 Lube oil pressure after filter
2 B10 Charge-air pressure
3 B9.1 Charge-air temperature before EGR mixing
4 B5.3 Lube oil pressure before filter
5 B89 Lambda
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No. Description Monitoring of
1 B1 Camshaft speed
2 B44.2 Turbocharger B speed
3 B13 Crankshaft speed
4 B44.1 Turbocharger A speed

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No. Description Monitoring of
1 B7 Lube oil temperature
2 B43 Charge-air coolant pressure
3 B26 Charge-air coolant temperature
4 B93 Level and temperature, lube oil
5 B6 Coolant temperature
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3 Technical Data
3.1 Firing order
12 V A1–B2–A5–B4–A3–B1–A6–B5–A2–B3–A4–B6

Direction of rotation
Direction of rotation (as viewed on driving c.c.w., not reversible
end)

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3.2 Engine – Main dimensions

Item Dimensions
Height (A) Approx. 1401 mm
Length (B) Approx. 1873 mm
Width (C) Approx. 1263 mm
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3.3 12V 1600 R50 engine data

Explanation:
DL Ref. value: Continuous power
BL Ref. value: Fuel stop power
A Design value
G Guaranteed value
R Guideline value
L Limit value, up to which the engine can be operated, without change (e.g. of power setting)
N Not yet defined value
- Not applicable
X Applicable
* Estimated or extrapolated value

REFERENCE CONDITIONS
Engine model 12V 1600
R50
Application group 2A
Intake air temperature °C 25
Charge-air coolant temperature °C 45
Barometric pressure mbar 1000
Site altitude above sea level m 100

POWER-RELATED DATA (power ratings are net brake power to ISO 3046)
Number of cylinders 12V
Rated engine speed A rpm 1900
Mean piston speed m/s 9.5
Fuel stop power ISO 3046 A kW 690
Mean effective pressure (MEP) bar 20.4
(fuel stop power ISO 3046)

MODEL RELATED DATA (basic design)


Number of cylinders 12V
Number of cylinders 12
Cylinder arrangement: V angle Degrees 90
(°)
Bore mm 122
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Stroke mm 150
Cylinder displacement liters 1.75
Total displacement liters 21
Compression ratio 17.5
Number of inlet valves per cylinder 2
Number of exhaust valves per cylinder 2

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Number of cylinders 12V
Number of turbochargers 4
Number of intercoolers 3

CAPACITIES
Number of cylinders 12V
Engine coolant capacity, engine side (without cooling equip‐ R liters 50*
ment)
Engine oil capacity, initial filling (standard oil system)(Option: R liters 65
max. operating inclinations)
Oil change quantity, max. (standard oil system) (Option: max. R liters 63
operating inclinations)

WEIGHTS / MAIN DIMENSIONS


Number of cylinders 12V
Engine weight, dry (basic engine configuration acc. to scope of R kg 2200
delivery specification)

ACOUSTICS
Number of cylinders 12V
Engine surface noise with attenuated intake noise (filter) - DL R dB(A) 101
(free-field sound-pressure level Lp, 1m distance, ISO 6798)
Engine surface noise with attenuated intake noise filter) - DL R dB(A) 119
(sound power level LW, ISO 6798)
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4 Operation
4.1 Preparation for startup after a scheduled break in operation

Preconditions
☑ Engine is stopped and starting disabled.

Starting up
Item Action
Lube oil system Check engine oil level (→ Page 46).
Coolant circuit Check engine coolant level (→ Page 49);
Check charge-air coolant level (→ Page 56).
Coolant circuit Preheat engine coolant with coolant preheating unit (if fitted).
Fuel prefilter Drain fuel prefilter (→ Page 43).
Engine control system Switch on.

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4.2 Preparation for startup after extended out-of-service periods
(>3 months)

Preconditions
☑ Engine is stopped and starting disabled.
☑ MTU Fluids and Lubricants Specifications (A001063/..) are available.

Startup after long out-of-service periods (>3 months)


Item Action
Engine Depreserve (→ MTU Fluids and Lubricants Specifications A001063/..).
Lube oil system Check engine oil level (→ Page 46).
Fuel system Vent (→ Page 41).
Coolant circuit If engine is out of service for more than one year, change engine coolant
(→ Page 50).
Change charge-air coolant (→ Page 57).
Coolant circuit Check engine coolant level (→ Page 49);
Check charge-air coolant level (→ Page 56).
Coolant circuit Preheat engine coolant with coolant preheating unit (if fitted).
Engine governor Check plug-in connections (→ Page 64).
Engine control system Switch on.
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4.3 Starting the engine

Preconditions

☑ Engine is not connected to load.
☑ External start interlock is not active.

DANGER
Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
• Before barring or starting the engine, make sure that nobody is in the danger zone.

WARNING
Engine noise above 85 dB (A).
Risk of damage to hearing!
• Wear ear protectors.

Starting the engine


Item Action
Switchgear cabinet, control Press start button.
panel etc. (depending on • Automatic starting procedure is performed;
manufacturer) • Tachometer indicates increasing speed.
• After completion of starting sequence, the engine is running at idle
speed.

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4.4 Operational checks

DANGER
Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
• Take special care when working on a running engine.

WARNING
Engine noise above 85 dB (A).
Risk of damage to hearing!
• Wear ear protectors.

Operational checks
Item Action
Control and display panels Check readings of operational data (speed, temperature, pressures).
Engine oil Check engine oil level (→ Page 46).
Engine operation Check engine visually for leaks and general condition;
Check engine for abnormal running noises, exhaust color and vibra‐
tions (→ Page 34).
Air filter Check filter restriction indicator on the air filter (if fitted) (→ Page 45).
Exhaust system Check exhaust color (→ Page 34).
Engine coolant pump Check relief bore (→ Page 55).
Charge-air coolant pump Check relief bore (→ Page 61).
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4.5 Stopping the engine

Preconditions
☑ Engine is not connected to load.

CAUTION
Stopping the engine when it is running at full load causes extreme stress to the engine.
Risk of overheating, damage to components!
• Before stopping the engine, operate it at idle speed until operating temperatures decrease and
stable values are indicated.

Stopping the engine


Item Action
Temperature indications Wait until engine temperatures are constant.
Switchgear cabinet, control Press stop button.
panel etc. (depending on
• Automatic stopping procedure is performed.
manufacturer)
• Engine at a standstill.

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4.6 After engine shutdown

Preconditions
☑ MTU Fluids and Lubricants Specifications (A001063/..) are available.

Note: If freezing temperatures are to be expected: Coolant pressure sensors installed in vertical position may
be damaged if the coolant does not contain antifreeze additive.

After engine shutdown


Item Action
Coolant circuit Drain engine coolant (→ Page 51);
Drain charge-air coolant (→ Page 58) if:
• freezing temperatures are expected and the engine is to remain out of
service for an extended period, but engine coolant has no antifreeze
additive;
• the engine room is not heated;
• the coolant is not kept at a suitable temperature;
• the antifreeze concentration is insufficient for the engine-room tempera‐
ture;
• antifreeze concentration is 50 % and engine-room temperature is below
-40 °C.
Engine control system Switch off.
Air intake and exhaust sys‐ If the engine is to remain out of service for more than 1 week, seal the
tems engine's air and exhaust sides. If the engine is to remain out of service for
more than 1 month, carry out preservation (→ MTU Fluids and Lubricants
Specifications A001063/..).
TIM-ID: 0000031879 - 002

MS15025/00E 2011-12 | Operation | 29


4.7 Plant – Cleaning

Preconditions
☑ Engine is stopped and starting disabled.
☑ Operating voltage is not applied.

Special tools, Material, Spare parts


Designation / Use Part No. Qty.
Steam jet cleaner - 1
Cleaner (Hakupur 312) 30390 1

WARNING
Compressed air
Risk of injury!
• Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.

WARNING
Water jet.
Risk of injury and scalding!
• Do not direct water jet at persons.
• Wear protective clothing, gloves, and goggles / safety mask.

CAUTION
Excessive reaction time of cleaning agents on components.
Damage to component!
• Observe manufacturer's instructions.
• Wear protective clothing, gloves, and goggles / safety mask.

Note: There is a risk of damaging sensors with compressed air.

Plant – Cleaning
1. Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental pro‐
tection).
2. Prior to putting the cleaning unit into operation, read the Operating Instructions of the water/steam jet unit
carefully and observe the safety precautions.
3. For external cleaning with high-pressure jet, use a flat-mouth nozzle only.
4. Carry out external cleaning as follows:
a) Remove coarse dirt.
b) Spray on cleaner sparingly and leave it for 1 to 5 minutes.
c) Use the high-pressure jet to remove the loosened dirt.
d) During external cleaning of the plant with water/steam-jet units, the pressure of the high-pressure jet
TIM-ID: 0000010171 - 019

(cleaning jet) must not exceed 50 bar. A minimum distance between spray nozzle and plant of 1 m
must be observed. The temperature of the cleaning medium must not exceed 80 °C.

30 | Operation | MS15025/00E 2011-12


5 Maintenance
5.1 Preface
MTU maintenance concept
The following applies in the case of engines which are subject to emissions regulations:
Emissions regulations prohibit alteration, removal or addition of any mechanical or electronic component
or calibration that could affect the emissions characteristics of the engine. Maintenance, replacement, or
repair of emissions-relevant components, e.g. control devices, sensors, cylinder heads and exhaust
flaps, can only be performed using MTU approved components or equivalents.
Failure to adhere to the maintenance instructions could result in violation of legal requirements.
The MTU Maintenance Schedules ensure the reliability and performance of MTU engines and must be
complied with over the entire life cycle of the engine.the case of engines which are not subject to any
emissions regulations, the maintenance intervals cited are to be regarded as guideline values.

This maintenance schedule includes preventive and on-condition maintenance.


The maintenance schedule is based on the load profile / load factor specified below. Special operating
conditions and technical requirements may require additional maintenance work and/or modification of
the maintenance intervals. The intervals according to which the maintenance tasks have to be carried out
are specified as operating hours and time limits. The limit which occurs first is applicable.In order to be
authorized to carry out the individual maintenance jobs, maintenance personnel must have achieved a
level of training and qualification appropriate to the complexity of the task in hand. The various Qualifica‐
tion Levels QL1 to QL4 reflect the levels of training offered in MTU courses and the contents of the tool
kits required:
QL1: Operational monitoring and maintenance which can be carried out during a break in operation
without disassembling the engine.
QL2: Component replacement (corrective only).
QL3: Maintenance work which requires partial disassembly of the engine.
QL4: Maintenance work which requires complete disassembly of the engine.
The maintenance schedule matrix finishes after 18 years at the latest. Following this, maintenance work
is to be continued at the intervals indicated.
The numbers specified in the measures list serve as reference to the required parts scope.

Notes on maintenance
Specifications for fluids and lubricants, guideline values for their maintenance and change intervals and
lists of recommended fluids and lubricants are contained in the MTU Fluids and Lubricants Specifications
A001063 and in the fluids and lubricants specifications produced by the component manufacturers. They
are therefore not included in the maintenance schedule (exception: deviations from the Fluids and Lubri‐
cants Specifications). All fluids and lubricants used must meet MTU specifications and be approved by
the relevant component manufacturer.
TIM-ID: 0000032679 - 002

Amongst other items, the operator/customer must carry out the following additional maintenance work:
• Protect components made of rubber or synthetic material from oil. Never treat them with organic deter‐
gents. Wipe with a dry cloth only.
• Fuel prefilter:
The maintenance interval depends on how dirty the fuel is. The paper inserts in fuel prefilters must be
changed every two years at the latest (Task 9998).
• Battery:
Battery maintenance depends on the level of use and the ambient conditions. The specifications of the
battery manufacturer apply.

MS15025/00E 2011-12 | Maintenance | 31


The relevant manufacturer's instructions apply with respect to the maintenance of any components which
do not appear in this maintenance schedule.
This Maintenance Schedule may include components which are not included in the MTU supply scope;
these may be disregarded.

Out-of-service periods
If the engine is to remain out of service for more than 1 month, carry out engine preservation procedures
in accordance with the Fluids and Lubricants Specifications, MTU Publication No. A001063.

Application group
2A Continuous operation, unrestricted

Load profile
Power 100% 60% 50% 30% <15%
Associated runtime 0,5% 4,5% 10% 20% 65%

TIM-ID: 0000032679 - 002

32 | Maintenance | MS15025/00E 2011-12


5.2 Maintenance task reference table [QL1]
The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The
Maintenance Schedule is a stand-alone publication.
The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance
Schedule.
Task Maintenance tasks
W0500 Check engine oil level (→ Page 46)
W0501 Visually inspect engine for leaks and general condition (→ Page 27)
W0502 Check intercooler drain (if fitted) (→ Page 27)
W0503 Check air filter service indicator (→ Page 27)
W0506 Check engine for abnormal running noises, exhaust color (→ Page 27)
and vibrations
W0507 Drain water and contaminants from fuel prefilter (if fitted) (→ Page 27)
W0508 Check reading on differential pressure gauge of fuel prefilter –
(if fitted)
W1001 Replace fuel filter or fuel filter element (→ Page 42)
W1008 Replace engine oil filter at each oil change or when the time (→ Page 48)
limit (years) is reached, at the latest
W1013 Replace drive belt
W1207 Check valve clearance, adjust if necessary.ATTENTION! (→ Page 37)
First adjustment after 1,000 operating hours!
W1586 Replace diesel oxidation catalyst –
W1659 Clean particle catalyst, replace if necessary –
Table 1: Maintenance task reference table [QL1]
TIM-ID: 0000035502 - 001

MS15025/00E 2011-12 | Maintenance | 33


6 Troubleshooting
6.1 Troubleshooting

Engine does not turn when starter is actuated


Component Cause Action
Battery Low or faulty Charge or replace (see manufacturer's
documentation).
Cable connections faulty Check if cable connections are proper‐
ly secured (see manufacturer's docu‐
mentation).
Starter Engine cabling or starter faulty Check cable connections for secure
seating ; Contact Service.
Engine wiring Faulty Check (→ Page 62).
Engine Control Unit Plug-in connections possibly loose Check plug-in connections
(→ Page 64).
Engine Running gear blocked (engine cannot Contact Service.
be barred manually)
Table 2: Engine does not turn when starter is actuated

Engine turns but does not fire


Component Cause Action
Starter Poor rotation by starter: Battery low or Charge or replace battery (see manu‐
faulty facturer's documentation).
Engine wiring Faulty Check (→ Page 64).
Fuel system Air in fuel system, if fault occurs after Vent fuel system (→ Page 41).
filling the system
Engine Control Unit Faulty Contact Service.
Table 3: Engine turns but does not fire

Engine fires unevenly


Component Cause Action
Fuel injection equip‐ Injector faulty Contact Service.
ment
Engine wiring Faulty Check (→ Page 62).
Fuel system Air in fuel system, if fault occurs after Vent fuel system (→ Page 41).
TIM-ID: 0000032516 - 002

filling the system


Engine Control Unit Faulty Contact Service.
Table 4: Engine fires unevenly

34 | Troubleshooting | MS15025/00E 2011-12


Engine does not reach rated speed
Component Cause Action
Fuel supply Fuel prefilter (if fitted) clogged Clean filter element (see manufactur‐
er's documentation).
Fuel filter clogged Replace (→ Page 42).
Air supply Air filter clogged Replace air filter (→ Page 44).
Fuel injection equip‐ Injector faulty Contact Service.
ment
Engine wiring Faulty Check (→ Page 62).
Engine Overloaded Contact Service.
Table 5: Engine does not reach rated speed

Engine speed not steady


Component Cause Action
Fuel injection equip‐ Injector faulty Contact Service.
ment
Speed sensor Faulty Contact Service.
Fuel system Air in fuel system, if fault occurs after Vent fuel system (→ Page 41).
filling the system
Engine Control Unit Faulty Contact Service.
Table 6: Engine speed not steady

Charge-air temperature too high


Component Cause Action
Engine coolant Engine coolant treatment incorrect Check (MTU test kit).
Intercooler Contaminated Contact Service.
Engine room Air-intake temperature too high Check fan;
check air inlet/outlet ducts.
Table 7: Charge-air temperature too high

Charge-air pressure too low


Component Cause Action
Air supply Air filter clogged Replace air filter (→ Page 44).
Intercooler Contaminated Contact Service.
Exhaust turbocharger Faulty Contact Service.
Table 8: Charge-air pressure too low
TIM-ID: 0000032516 - 002

Coolant leaks at intercooler


Component Cause Action
Intercooler Leaking, major coolant discharge Contact Service.
Table 9: Coolant leaks at intercooler

MS15025/00E 2011-12 | Troubleshooting | 35


Black exhaust gas
Component Cause Action
Air supply Air filter clogged Replace air filter (→ Page 44).
Fuel injection equip‐ Injector faulty Contact Service.
ment
Engine Overloaded Contact Service.
Table 10: Black exhaust gas

Blue exhaust gas


Component Cause Action
Engine oil Too much oil in engine Drain engine oil (→ Page 47).
Oil mist fine separator of crankcase Contact Service.
breather clogged
Exhaust turbocharger Faulty Contact Service.
Cylinder head
Piston rings
Cylinder liner
Table 11: Blue exhaust gas

White exhaust gas


Component Cause Action
Engine Not at operating temperature Run engine to reach operating temper‐
ature.
Fuel system Water in fuel Check fuel system at fuel prefilter
Drain fuel prefilter (→ Page 43).
Intercooler Leaking Contact Service.
Table 12: White exhaust gas

TIM-ID: 0000032516 - 002

36 | Troubleshooting | MS15025/00E 2011-12


7 Task Description
7.1 Valve Drive
7.1.1 Valve clearance – Check and adjustment

Preconditions
☑ Engine is stopped and starting disabled.
☑ Engine coolant temperature is max. 40 °C.
☑ Valves are closed.

Special tools, Material, Spare parts


Designation / Use Part No. Qty.
Feeler gauge Y20010128 1
Torque wrench, 20-100 Nm F30026582 1
Box wrench, 14 mm F30028346 1
Allen key, 5 mm F30002815 1
Barring device F6790714 1

Preparatory steps
1. Remove cylinder head cover (→ Page 39).
2. Remove cover on the bottom of flywheel housing, A side.
3. Install barring device at opening.
4. Rotate crankshaft with barring device in engine direction of rotation until "OT-A1" mark and pointer are
aligned.

Diagram for 12V engines (two


crankshaft positions)
1 Cylinder A1 is in firing TDC
2 Cylinder A1 is in overlap TDC
I Inlet valve
X Exhaust valve
TIM-ID: 0000035352 - 001

MS15025/00E 2011-12 | Task Description | 37


Checking valve clearance at two crankshaft positions
1. Check TDC position of piston in cylinder A1:
• If the rocker arms are unloaded on cylinder A1, the piston is in firing TDC.
• If the rocker arms are under load on cylinder A1, the piston is in overlap TDC.
2. Check valve clearance with cold engine:
• Inlet = 0.3 +/- 0.05 mm;
• Exhaust = 0.6 +/- 0.05 mm.
3. Check all valve clearances in two crankshaft positions (firing TDC and overlap TDC of cylinder A1) as
per diagram.
4. Use feeler gauge to determine the distance between valve bridge and rocker arm.
5. If the deviation from the reference value exceeds 0.1 mm, adjust valve clearance.

Adjusting valve clearance


1. Loosen locknut (1) and unscrew adjusting
screw (2) by a few threads.
2. Insert feeler gauge between valve bridge
and rocker arm (3).
3. Readjust adjusting screw (2) so that the
feeler gauge just passes through the gap.

4. Tighten locknut (1) with torque wrench to specified torque, holding adjusting screw (2) firm with Allen
screw.
Name Size Type Lubricant Value/Standard
Nut M10 x 1 Tightening torque 43 Nm +4 Nm
5. Check if the feeler gauge just passes through between valve bridge and rocker arm (3).
Result: If not, adjust valve clearance.

Final steps
1. Remove barring device.
2. Install cover.
3. Install cylinder head cover (→ Page 39).
TIM-ID: 0000035352 - 001

38 | Task Description | MS15025/00E 2011-12


7.1.2 Cylinder head cover – Removal and installation

Preconditions
☑ Engine is stopped and starting disabled.

Cylinder head cover – Removal


and installation
Note: Cover the engine beneath the cylinder head
with cloths to collect emerging oil.
1. Remove screws (2).
2. Remove cylinder head cover (1).
3. Clean mating faces.
4. Check condition of profile gasket and re‐
place if required.

5. Position cylinder head cover and screws at positions 1 to 4 and tighten with torque wrench to the prescri‐
bed initial tightening torque.
Name Size Type Lubricant Value/Standard
TIM-ID: 0000035536 - 001

Screw with twin M8 Preload torque 10 Nm


collar

MS15025/00E 2011-12 | Task Description | 39


6. Tighten screws at positions 1 to 18 to specified tightening torque using a torque wrench.
Name Size Type Lubricant Value/Standard
Screw with twin M8 Tightening torque 20 Nm ±2 Nm
collar

Consecutive tightening sequence starting at po‐ 1 to 18


sition 1:

TIM-ID: 0000035536 - 001

40 | Task Description | MS15025/00E 2011-12


7.2 Fuel System
7.2.1 Fuel system – Venting

Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts


Designation / Use Part No. Qty.
Torque wrench, 4-20 Nm F30044239 1
Ratchet F30027340 1

WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

Venting fuel system


1. Open vent plug (1).
Note: Catch emerging fuel with a suitable cloth.
2. Operate the pump with the handle (2) until
bubble-free fuel emerges from the vent plug
(1).

3. Close vent plug (1) and tighten with torque wrench to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Threaded vent plug 12 Tightening torque 6.5 Nm ±1.3 Nm
TIM-ID: 0000028012 - 002

MS15025/00E 2011-12 | Task Description | 41


7.3 Fuel Filter
7.3.1 Fuel filter – Replacement

Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts


Designation / Use Part No. Qty.
Torque wrench, 4-20 Nm F30044239 1
Torque wrench, 10-60 Nm F30510423 1
Ratchet adapter F30027340 1
Socket, 32 mm F30006120 1
Engine oil
Fuel filter element (→ Spare Parts Catalog) 2

WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

Fuel filter – Replacement


1. Provide a suitable container in which to col‐
lect the fuel.
2. Unscrew drain screw (3).
Note: Do not completely remove drain screw.
3. Loosen screw cap (1) on fuel filter and un‐
screw it approx. 3 to 4 turns.
4. Wait 10 minutes, until fuel emerges from fil‐
ter housing (2).
5. Remove screw cap (1) with fuel filter ele‐
ment and remove element by pressing it to
the side at the lower edge.
6. Check condition of the sealing ring on the
screw cap (1).
7. Replace damaged sealing ring.
8. Coat sealing ring with engine oil.
9. Insert new oil filter element in screw cap (1)
and press in until it locks in place.
TIM-ID: 0000035537 - 002

10. Screw on the cap (1) with oil filter element and tighten to the specified torque with a torque wrench.
Name Size Type Lubricant Value/Standard
Cover Tightening torque (Engine oil) 40 Nm ±5 Nm
11. Screw in drain plug (3) and tighten with torque wrench to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Drain plug 10 Tightening torque (Engine oil) 6.5 Nm ±1.3 Nm
12. Vent fuel system (→ Page 41).

42 | Task Description | MS15025/00E 2011-12


7.3.2 Fuel prefilter – Drain condensate

Preconditions
☑ Engine is stopped and starting disabled.

WARNING
Fuels are combustible.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

Draining condensate from fuel


prefilter
1. Provide a suitable container to collect the
water.
2. Open drain screw (1).
3. Allow water to drain off.
4. Screw in and close drain screw (2).
TIM-ID: 0000031021 - 002

MS15025/00E 2011-12 | Task Description | 43


7.4 Air Filter
7.4.1 Air filter – Replacement

Preconditions
☑ Engine is stopped and starting disabled.

For air filter replacement, carry out operations as specified by the manufacturer –
filter is plant/vehicle manufacturer's supply.

TIM-ID: 0000013387 - 003

44 | Task Description | MS15025/00E 2011-12


7.5 Air Intake
7.5.1 Service indicator – Signal ring position check
Preconditions
☑ Engine is stopped and starting disabled.

Checking signal ring position


1. Replace air filter, if the signal ring (2) is
completely visible in the red area of the
service indicator control window (3)
(→ Page 44).
2. After installation of new filter, press reset
button (1).
Result: Signal ring returns to initial position.
TIM-ID: 0000000985 - 002

MS15025/00E 2011-12 | Task Description | 45


7.6 Lube Oil System, Lube Oil Circuit
7.6.1 Engine oil level – Check

Preconditions
☑ Engine is stopped and starting disabled.

Checking oil level prior to engine


start
1. Remove oil dipstick (1) from guide tube and
wipe it.
2. Insert oil dipstick (1) into guide tube up to
the stop, withdraw after approx. 10 seconds
and check oil level.
3. Oil level must be between “min.” and “max.”
marks.
4. If necessary, top up to "max." mark
(→ Page 47).
5. Insert oil dipstick (1) in guide tube up to the
stop.

Checking oil level after the engine is stopped


1. 5 minutes after stopping the engine, remove oil dipstick (1) from the guide tube and wipe it.
2. Insert oil dipstick (1) into guide tube up to the stop, withdraw after approx. 10 seconds and check oil lev‐
el.
3. Oil level must be between “min.” and “max.” marks.
4. If necessary, top up to "max." mark (→ Page 47).
5. Insert oil dipstick (1) in guide tube up to the stop.

TIM-ID: 0000035570 - 001

46 | Task Description | MS15025/00E 2011-12


7.6.2 Engine oil – Change

Preconditions
☑ Engine is stopped and starting disabled.
☑ Engine is at operating temperature.
☑ MTU Fluids and Lubricants Specifications (A001063/..) are available.

Special tools, Material, Spare parts


Designation / Use Part No. Qty.
Engine oil

WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.

Draining oil via drain plug on oil


pan
1. Provide a suitable container to collect the
oil.
2. Remove drain plug (2) and drain oil.

3. Insert drain plug (2) and use torque wrench to tighten to specified tightening torque.
Name Size Type Lubricant Value/Standard
Drain plug Tightening torque (Engine oil) 100 Nm
TIM-ID: 0000035571 - 001

4. Replace engine oil filter (→ Page 48).

Filling with new oil


1. Open cap (1) on cylinder head cover.
2. Fill with oil, oil filling capacity (→ Product Summary - Technical Data).
3. Close cap (1) on cylinder head cover.
4. Check engine oil level (→ Page 46).

MS15025/00E 2011-12 | Task Description | 47


7.7 Oil Filtration / Cooling
7.7.1 Engine oil filter – Replacement

Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts


Designation / Use Part No. Qty.
Torque wrench, 10-60 Nm F30510423 1
Ratchet adapter F30027340 1
Socket, 32 mm F30006120 1
Engine oil
Oil filter element (→ Spare Parts Catalog)

WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.

Engine oil filter – Replacement


1. Unscrew the oil filter covers (1) approx. 3 to
4 revolutions.
2. Wait 10 minutes until the oil has drained
from the filter housings.
3. Remove cover (1) with oil filter element (3)
and remove oil filter element (3) by pressing
on the bottom edge from the side.
4. Check condition of sealing ring (2) on cov‐
er.
5. Replace sealing ring (2) if damaged.
6. Coat sealing ring (2) with oil.
7. Insert new oil filter element (3) in cover (1)
and press in until it locks in place.
TIM-ID: 0000035560 - 001

8. Screw on cover (1) with oil filter element (3) and tighten to the specified torque with a torque wrench.
Name Size Type Lubricant Value/Standard
Cover Tightening torque (Engine oil) 35 Nm ±3.5 Nm
9. Replace other engine oil filters in the same way.
10. Check oil level (→ Page 46)

48 | Task Description | MS15025/00E 2011-12


7.8 Coolant Circuit, General, High-Temperature Circuit
7.8.1 Engine coolant – Level check
Preconditions
☑ Engine is stopped and starting disabled.
☑ MTU Fluids and Lubricants Specifications (A001063/..) are available.

WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.

Coolant-level check at filler neck:


1. Turn breather valve on coolant expansion
tank counterclockwise to the first stop and
allow pressure to escape.
2. Continue to turn breather valve counter‐
clockwise and remove.
3. Check coolant level (coolant must be visible
at the lower edge of the cast-in eye or at
the marking plate).
4. Top up with treated coolant as necessary
(→ Page 53).
5. Check breather valve (visual inspection)
and clean if necessary.
6. Place breather valve on filler neck and
close.

Coolant-level check by means of level sensor:


1. Switch on engine control system and check readings on the display.
2. Top up with treated coolant as necessary (→ Page 53).
TIM-ID: 0000000911 - 003

MS15025/00E 2011-12 | Task Description | 49


7.8.2 Engine coolant – Change

Special tools, Material, Spare parts


Designation / Use Part No. Qty.
Engine coolant

Changing engine coolant


1. Drain engine coolant (→ Page 51).
2. Fill with engine coolant (→ Page 53).

TIM-ID: 0000000036 - 025

50 | Task Description | MS15025/00E 2011-12


7.8.3 Engine coolant – Draining

Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts


Designation / Use Part No. Qty.
Engine coolant
Sealing ring (→ Spare Parts Catalog)

WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.

Preparatory steps
1. Provide an appropriate container to drain the coolant into.
2. Switch off preheater, if installed.

Engine coolant – Draining


1. Turn breather valve of filler neck on coolant
expansion tank counterclockwise to first
stop and allow pressure to escape.
2. Continue to turn breather valve counter‐
clockwise and remove.
3. Draw off precipitated corrosion inhibitor oil
from the expansion tank through filler neck.
4. Open drain screw and drain off coolant at
engine coolant pump (1).
TIM-ID: 0000035572 - 001

MS15025/00E 2011-12 | Task Description | 51


5. Open drain screws and drain coolant at
crankcase, right side (1,2).

6. Open drain screws and drain coolant at


crankcase, left side (1,2).
7. Install drain screw with new sealing ring.
8. Place breather valve on filler neck and
close.

TIM-ID: 0000035572 - 001

52 | Task Description | MS15025/00E 2011-12


7.8.4 Engine coolant – Filling
Preconditions
☑ Engine is stopped and starting disabled.
☑ MTU Fluids and Lubricants Specifications (A001063/..) are available.

Special tools, Material, Spare parts


Designation / Use Part No. Qty.
Engine coolant

WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.

WARNING
Engine noise above 85 dB (A).
Risk of damage to hearing!
• Wear ear protectors.

CAUTION
Cold coolant in hot engine can cause thermal stress.
Formation of cracks in components!
• Fill / top up coolant only into cold engine.

Preparatory steps
1. Turn breather valve of filler neck on coolant
expansion tank counterclockwise to first
stop and allow pressure to escape.
2. Continue to turn breather valve counter‐
clockwise and remove.
TIM-ID: 0000000909 - 003

Engine coolant – Filling


1. Fill coolant through filler neck on expansion tank or through filling line until coolant level reaches lower
edge of cast-in eye or marking plate.
2. Check proper condition of breather valve, clean sealing faces if required.
3. Fit breather valve and close it.

MS15025/00E 2011-12 | Task Description | 53


Final steps
1. Start the engine and operate it at idle speed for some minutes.
2. Check coolant level (→ Page 49), top up if required.

TIM-ID: 0000000909 - 003

54 | Task Description | MS15025/00E 2011-12


7.8.5 Engine coolant pump – Relief bore check

DANGER
Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
• Take special care when working on a running engine.

WARNING
Engine noise above 85 dB (A).
Risk of damage to hearing!
• Wear ear protectors.

Engine coolant pump – Relief bore


check
1. Check relief bore (1) for coolant discharge.
• Permissible coolant discharge quantity:
Up to 0.1 ml per hour respectively 100 ml
per 1,000 operating hours.
2. Stop engine (→ Page 28) and disable en‐
gine start.
3. If discharge exceeds the specified limits,
contact Service.
TIM-ID: 0000032404 - 001

MS15025/00E 2011-12 | Task Description | 55


7.9 Low-Temperature Circuit
7.9.1 Charge-air coolant level – Check

Preconditions
☑ Engine is stopped and starting disabled.
☑ MTU Fluids and Lubricants Specifications (A001063/..) are available.

WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.

Checking charge-air coolant level


at filler neck:
1. Turn breather valve on coolant expansion
tank counterclockwise to the first stop and
allow pressure to escape.
2. Continue to turn breather valve counter‐
clockwise and remove.
3. Check coolant level (coolant must be visible
at marking plate).
4. Top up coolant if necessary (→ Page 59).
5. Check proper condition of breather valve,
clean sealing faces if required.
6. Fit breather valve and close it.

Checking charge-air coolant level by means of level sensor:


1. Switch on engine control system and check display (coolant level is automatically monitored by engine
control system).
2. Top up coolant if necessary (→ Page 59).
TIM-ID: 0000031873 - 002

56 | Task Description | MS15025/00E 2011-12


7.9.2 Charge-air coolant – Change

Special tools, Material, Spare parts


Designation / Use Part No. Qty.
Charge-air coolant

Charge-air coolant – Change


1. Drain charge-air coolant (→ Page 58).
2. Fill with charge-air coolant (→ Page 59).
TIM-ID: 0000000041 - 010

MS15025/00E 2011-12 | Task Description | 57


7.9.3 Charge-air coolant – Draining

Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts


Designation / Use Part No. Qty.
Sealing ring (→ Spare Parts Catalog)
Sealing ring (→ Spare Parts Catalog)

WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.

Charge-air coolant – Draining


1. Provide an appropriate container to drain
the coolant into.
2. Turn breather valve on coolant expansion
tank counterclockwise to the first stop and
allow pressure to escape.
3. Continue to turn breather valve counter‐
clockwise and remove.
4. Draw off precipitated corrosion inhibitor oil
from the expansion tank through filler neck.
5. Open drain screw and drain off coolant at
the charge-air coolant pump (1).

6. Open drain plugs and drain coolant on the


intercooler, right (1) and left side (2).
7. Screw in drain plugs with new sealing rings.
8. Place breather valve on filler neck and
close.
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58 | Task Description | MS15025/00E 2011-12


7.9.4 Charge-air coolant – Filling

Preconditions
☑ Engine is stopped and starting disabled.
☑ MTU Fluids and Lubricants Specifications (A001063/..) are available.

Special tools, Material, Spare parts


Designation / Use Part No. Qty.
Charge-air coolant
Sealing ring (→ Spare Parts Catalog)

WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.

WARNING
Engine noise above 85 dB (A).
Risk of damage to hearing!
• Wear ear protectors.

CAUTION
Cold coolant in hot engine can cause thermal stress.
Formation of cracks in components!
• Fill / top up coolant only into cold engine.

Preparatory steps
1. Turn breather valve on coolant expansion
tank counterclockwise to the first stop and
allow pressure to escape.
2. Continue to turn breather valve counter‐
clockwise and remove.
3. Remove plug screw from filling point on
coolant line to intercooler.
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MS15025/00E 2011-12 | Task Description | 59


Filling charge-air coolant
1. Fill treated coolant through filling line or through filler neck of coolant expansion tank until coolant level
reaches marking plate.
2. Install plug screws of filling points with new sealing rings.
3. Check proper condition of breather valve, clean sealing faces if required.
4. Fit breather valve and close it.

Final steps
1. Start the engine and operate it at idle speed for some minutes.
2. Check coolant level (→ Page 56).

TIM-ID: 0000031875 - 002

60 | Task Description | MS15025/00E 2011-12


7.9.5 Charge-air coolant pump – Relief bore check

DANGER
Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
• Take special care when working on a running engine.

WARNING
Engine noise above 85 dB (A).
Risk of damage to hearing!
• Wear ear protectors.

Charge-air coolant pump – Relief


bore check
1. Check relief bore (1) for coolant discharge.
• Permissible coolant discharge: Up to
0.1 ml per hour respectively 100 ml per
1,000 operating hours.
Result: If discharge exceeds the specified limits,
contact Service.
2. If relief bore (1) is clogged:
• Stop engine (→ Page 28) and disable en‐
gine start.
• Clean relief bore (1) with wire.
TIM-ID: 0000035574 - 001

MS15025/00E 2011-12 | Task Description | 61


7.10 Wiring (General) for Engine/Gearbox/Unit
7.10.1 Engine wiring – Check

Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts


Designation / Use Part No. Qty.
Isopropyl alcohol X00058037 1

Engine wiring – Check


1. Check securing screws of cable clamps on engine and tighten loose threaded connections.
2. Ensure that cables are fixed in their clamps and cannot swing freely.
3. Check that cable ties are firm, tighten loose cable ties.
4. Replace faulty cable ties.
5. Visually inspect the following electrical line components for damage:
• connector housings;
• contacts;
• sockets;
• cables and terminals;
• plug-in contacts.
6. (→ Contact Service) if cable conductors are damaged.
Note: Close male connectors that are not plugged in with the protective cap supplied.
7. Clean dirty connector housings, sockets and contacts with isopropyl alcohol.
8. Ensure that all sensor connectors are securely engaged.

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62 | Task Description | MS15025/00E 2011-12


7.11 Accessories for (Electronic) Engine Governor / Control
System
7.11.1 Engine governor and connectors – Cleaning

Preconditions
☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts


Designation / Use Part No. Qty.
Isopropyl alcohol X00058037 1

Note: Always use test connectors to enter the connectors. Never use test leads for this purpose.Otherwise the
contacts could be bent.

Engine governor and connectors – Cleaning


1. Remove coarse dirt from housing surface with isopropyl alcohol.
2. Remove dirt from connector and cable surfaces with isopropyl alcohol.
3. Check legibility of cable labels. Clean or replace illegible labels.

Cleaning severely contaminated connectors on the engine governor


Note: Seal unused connectors with the supplied protective cap.
1. Release the latch and pull off connectors.
2. Clean connector housings, connector socket housings and all contacts with isopropyl alcohol.
3. When connectors, sockets and all contacts are dry: Fit connectors and lock them.
TIM-ID: 0000000047 - 009

MS15025/00E 2011-12 | Task Description | 63


7.11.2 Engine Control Unit – Plug connection check

Preconditions
☑ Engine is stopped and starting disabled.

Checking Engine Control Unit plug


connections
1. Check firm seating of all connectors on the
Engine Control Unit. Make sure that the
clips (2) are engaged.
2. Check firm seating of all screws (1) on En‐
gine Control Unit cable clamps. Make sure
that cable clamps are not defective.

TIM-ID: 0000032518 - 002

64 | Task Description | MS15025/00E 2011-12


8 Appendix A
8.1 Abbreviations

Abbreviation Meaning Explanation


A/D Analog/Digital Transformer: transforms sensor voltages into
numeric values
ADEC Advanced Diesel Engine Controller Engine management system
AFRS Air Filter Restriction Sensor
ANSI American National Standards Institute Association of American standardization or‐
ganizations
ATL Abgasturbolader Exhaust turbocharger (ETC)
ATS Air Temperature Sensor
BR Baureihe Series
BV Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU
Publication No. A01063/..
CAN Controller Area Network Data bus system, bus standard
CDC Calibration Drift Compensation Setting of drift compensation in engine gov‐
ernor with DiaSys
CEL Check Engine Light 1st function: Warning lamp (rectify fault as
soon as possible)
2nd function: Read out fault codes
CKT Circuit
CLS Coolant level sensor Monitors coolant level
CPS Coolant pressure sensor Monitors coolant pressure
CTS Coolant temperature sensor Monitors coolant temperature
DDEC Detroit Diesel Electronic Controls Engine control system made by Detroit Die‐
sel
DDL Diagnostic Data Link Diagnostic lines
DDR Diagnostic Data Reader Diagnostic unit
DIN Deutsches Institut für Normung e. V. At the same time identifier of German stand‐
ards (DIN = “Deutsche Industrie-Norm”)
DL Default Lost Alarm: Default CAN bus failure
DOC Diesel Oxidation Catalyst Oxidation catalyst upstream of the diesel
particulate filter
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DPF Diesel Particulate Filter


DT Diagnostic Tool Diagnostic unit
ECM Electronic Control Module Electronic control unit of the DDEC system
ECU Engine Control Unit Engine governor
EDM Engine Data Module Memory module for engine data
EEPROM Electrically Erasable Programmable
Read Only Memory
EFPA Electronic Foot Pedal Assembly

MS15025/00E 2011-12 | Appendix A | 65


Abbreviation Meaning Explanation
EGR Exhaust Gas Recirculation
EMU Engine Monitoring Unit
ETK Ersatzteilkatalog Spare Parts Catalog (SPC)
EUI Electronic Unit Injector
FPS Fuel Pressure Sensor Monitors fuel pressure
FRS Fuel - Differential Pressure Sensor
FTS Fuel Temperature Sensor Monitors fuel temperature
FWCP Fire Water Control Panel
GND Ground
HI High Alarm: Measured value exceeds 1st maxi‐
mum limit
HIHI High High Alarm: Measured value exceeds 2nd maxi‐
mum limit value
HP High Pressure
HT High Temperature
IDM Interface Data Module Memory module for interface data
INJ Injector
ISO International Organization for Stand‐ International umbrella organization for all na‐
ardization tional standardization institutes
KGS Kraftgegenseite Engine free end in accordance with DIN ISO
1204
KS Kraftseite Engine driving end in accordance with DIN
ISO 1204
LED Light Emitting Diode
LO Low Alarm: Measured value lower than 1st mini‐
mum limit value
LOLO Low Low Alarm: Measured value lower than 2nd mini‐
mum limit value
LSG Limiting Speed Governor
N/A Not Applicable
LP Low Pressure
OEM Original Equipment Manufacturer
OI Optimized Idle
OLS Oil Level Sensor Monitors oil level
OPS Oil pressure sensor Monitors oil pressure
TIM-ID: 0000035533 - 001

OTS Oil Temperature Sensor Monitors oil temperature


OT Oberer Totpunkt Top Dead Center (TDC)
PAN Panel Control panel
PIM Peripheral Interface Module
PWM Modulated signal
P-xyz Pressure-xyz Pressure measuring point, xyz specifies the
measuring point designation
RL Redundancy Lost Alarm: Redundant CAN bus failure

66 | Appendix A | MS15025/00E 2011-12


Abbreviation Meaning Explanation
SAE Society of Automotive Engineers U.S. standardization organization
SD Sensor Defect Alarm: Sensor failure
SEL Stop Engine Light 1st function: Warning lamp (stop engine and
rectify fault)
2nd function: Read out fault codes
SID System Identifier
SRS Synchronous Reference Sensor TDC cylinder 1
SS Safety System Safety system alarm
TBS Turbocharger Boost Sensor Monitors charge-air pressure
TCI Turbo Compressor Inlet
TCO Turbo Compressor Outlet
TD Transmitter Deviation Alarm: Deviation in transmitter values
TPS Throttle Position Sensor
TRS Timing Reference Sensor
T-xyz Temperature-xyz Temperature measuring point, xyz specifies
the measuring point designation
UT Unterer Totpunkt Bottom Dead Center (BDC)
VNT Variable Nozzle Turbine
VSG Variable-Speed Governor
VSS Vehicle Speed Sensor
WZK Werkzeugkatalog Tool Catalog
TIM-ID: 0000035533 - 001

MS15025/00E 2011-12 | Appendix A | 67


8.2 MTU contacts/service partners

Service
Our worldwide sales network with its subsidiaries, sales offices, representatives and customer service
centers ensures fast and direct support on site and the high availability of our products.

Local support
Experienced and qualified specialists place their knowledge and expertise at your disposal.

For locally available support, go to the MTU internet site: http://www.mtu-online.com

24h hotline
With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist you
- either during operation, for preventive maintenance, corrective work in case of malfunction or changed
operating conditions, or for spare parts supply.
Your contact at Headquarters:Service-support@mtu-online.com

Spare parts service


Fast, simple and correct identification of spare parts for your drive system or vehicle fleet. The right spare
part at the right time at the right place.
With this aim in mind, we can call on a globally networked spares logistics system
- a central depot at Headquarters, as well as decentralized depots among our subsidiaries, representa‐
tives and contractual workshops.
Your contact at Headquarters:
E-mail: spare.parts@mtu-online.com
Phone: +49 7541 908555
Fax: +49 7541 908121

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68 | Appendix A | MS15025/00E 2011-12


9 Appendix B
9.1 Special Tools
Allen key, 5 mm
Part No.: F30002815
Qty.: 1
Used in: 7.1.1 Valve clearance – Check and adjustment (→ Page 37)

Barring device
Part No.: F6790714
Qty.: 1
Used in: 7.1.1 Valve clearance – Check and adjustment (→ Page 37)

Box wrench, 14 mm
Part No.: F30028346
Qty.: 1
Used in: 7.1.1 Valve clearance – Check and adjustment (→ Page 37)

Feeler gauge
Part No.: Y20010128
Qty.: 1
Used in: 7.1.1 Valve clearance – Check and adjustment (→ Page 37)

Ratchet
Part No.: F30027340
Qty.: 1
Used in: 7.2.1 Fuel system – Venting (→ Page 41)

Ratchet adapter
Part No.: F30027340
Qty.: 1
Used in: 7.3.1 Fuel filter – Replacement (→ Page 42)
Qty.: 1
Used in: 7.7.1 Engine oil filter – Replacement (→ Page 48)

Socket, 32 mm
DCL-ID: 0000015960 - 001

Part No.: F30006120


Qty.: 1
Used in: 7.7.1 Engine oil filter – Replacement (→ Page 48)

Socket, 32 mm
Part No.: F30006120
Qty.: 1
Used in: 7.3.1 Fuel filter – Replacement (→ Page 42)

MS15025/00E 2011-12 | Appendix B | 69


Steam jet cleaner
Part No.: -
Qty.: 1
Used in: 4.7 Plant – Cleaning (→ Page 30)

Torque wrench, 10-60 Nm


Part No.: F30510423
Qty.: 1
Used in: 7.3.1 Fuel filter – Replacement (→ Page 42)
Qty.: 1
Used in: 7.7.1 Engine oil filter – Replacement (→ Page 48)

Torque wrench, 20-100 Nm


Part No.: F30026582
Qty.: 1
Used in: 7.1.1 Valve clearance – Check and adjustment (→ Page 37)

Torque wrench, 4-20 Nm


Part No.: F30044239
Qty.: 1
Used in: 7.2.1 Fuel system – Venting (→ Page 41)
Qty.: 1
Used in: 7.3.1 Fuel filter – Replacement (→ Page 42)

DCL-ID: 0000015960 - 001

70 | Appendix B | MS15025/00E 2011-12


9.2 Index
A F
Abbreviations 65 Filter
Actuators – Air  
– Overview  17 – Replacement  44
After engine shutdown 29 Fire prevention and environmental protection 12
Air filter Fluids and lubricants 12
– Replacement  44 Fuel filter
– Replacement  42
C Fuel prefilter
Charge-air coolant – Drain condensate  43
– Change  57 Fuel system
– Draining  58 – Vent  41
Charge-air coolant
– Fill  59 G
Charge-air coolant level General conditions 5
– Check  56
Charge-air coolant pump M
– Relief bore check  61 Main engine dimensions 21
Connectors Maintenance and repair work
– Cleaning  63 – Safety regulations  9
Contact persons 68 MTU contact persons 68
Coolant - charge-air
– Change  57 O
Cylinder head cover Operational checks 27
– Installation  39 Overview 16
– Removal  39 – Actuators  17
– Sensors  17
E
Engine P
– Overview  16 Personnel and organizational requirements 6
– Start  26 Plant
– Stop  28 – Cleaning  30
– Wiring check  62
R
Engine Control Unit
– Plug connection check  64 Relief bore
Engine coolant – Engine coolant pump – Check  55
– Change  50
S
– Draining  51
Engine coolant pump Safety instructions 14
– Relief bore check  55 Sensors
Engine data – Overview  17
– 12V 1600 R50  22 Service partners 68
Engine governor Startup
– Cleaning  63 – After a scheduled break in operation  24
Engine oil – After extended out-of-service periods (>3 months)  
DCL-ID: 0000015960 - 001

– Change  47 25
Engine oil filter Startup and operation
– Replacement  48 – Safety regulations  8
Engine oil level
T
– Check after stopping the engine  46
– Check prior to engine start  46 Troubleshooting 34
Engine side and cylinder
V
– Designations  15
Engine wiring Valve clearance
– Check  62 – Adjustment  37
– Check  37

MS15025/00E 2011-12 | Appendix B | 71


W
Wiring - engine
– Check  62

DCL-ID: 0000015960 - 001

72 | Appendix B | MS15025/00E 2011-12

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