MTU 12 V 1600 R50 Manuale utente

Operating Instructions

Diesel engine

12 V 1600 R50

MS15033/02E

Engine model kW/cyl. Application group

12V1600R50 58 kW/cyl. 2A, Continuous operation, unrestricted

Table 1: Applicability

This publication is protected by copyright and may not be used in any way, whether in whole or in part, without the prior

written consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, transla-

tion, microfilming and storage or processing in electronic systems including databases and online services.

All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen

GmbH reserves the right to change, delete or supplement the information provided as and when required.

Table of Contents

1 Safety

1.1 Important provisions for all products 5

1.2 Personnel and organizational requirements 7

1.3 Transportation 8

1.4 Safety regulations for startup and operation 9

1.5 Safety regulations for maintenance and

repair work 10

1.6 Fire prevention and environmental

protection, fluids and lubricants, auxiliary

materials 13

1.7 Standards for safety notices in the text 15

2 General Information

2.1 Engine side and cylinder designations 16

2.2 Engine overview 17

2.3 Sensors and actuators – Overview 18

3 Technical Data

3.1 Firing order 22

3.2 Engine – Main dimensions 23

3.3 12V1600R50 product data 24

4 Operation

4.1 Putting the engine into operation after

scheduled out-of-service-period 27

4.2 Putting the engine into operation after

extended out-of-service periods (>3 months) 28

4.3 Starting the engine 29

4.4 Operational checks 30

4.5 Engine – Stop 31

4.6 After stopping the engine 32

4.7 Plant – Cleaning 33

4.8 Engine – Barring manually 34

5 Maintenance

5.1 Maintenance task reference table [QL1] 36

6 Troubleshooting

6.1 Troubleshooting 37

6.2 Fault messages of engine governor ECU 9

for Series 1600, rail applications 40

7 Task Description

7.1 Valve Drive 83

7.1.1 Valve clearance – Check and adjustment 83

7.1.2 Cylinder head cover – Removal and

installation 86

7.2 Fuel System 87

7.2.1 Fuel system – Venting 87

7.3 Fuel Filter 89

7.3.1 Fuel filter – Replacement 89

7.3.2 Fuel prefilter – Drain condensate 91

7.3.3 Fuel prefilter – Filter element replacement 92

7.4 Air Filter 93

7.4.1 Air filter element – Removal and installation

(optional) 93

7.4.2 Air filter element and (optional) dust bowl ‒

Cleaning 94

7.4.3 Air filter – Replacement (option) 95

7.5 Air Intake 96

7.5.1 Service indicator – Signal ring position check 96

7.6 Lube Oil System, Lube Oil Circuit 97

7.6.1 Engine oil level – Check 97

7.6.2 Engine oil – Change 98

7.7 Oil Filtration / Cooling 99

7.7.1 Engine oil filter – Replacement 99

7.8 Coolant Circuit, General, High-Temperature

Circuit 100

7.8.1 Engine coolant – Level check 100

7.8.2 Engine coolant – Change 101

7.8.3 Engine coolant – Draining 102

7.8.4 Engine coolant – Filling 104

7.8.5 Engine coolant pump – Relief bore check 106

7.9 Low-Temperature Circuit 107

7.9.1 Charge-air coolant level – Check 107

7.9.2 Charge-air coolant – Change 108

7.9.3 Charge-air coolant – Draining 109

7.9.4 Charge-air coolant – Filling 110

7.9.5 Charge-air coolant pump – Relief bore check 112

7.10 Belt Drive 113

7.10.1 Coolant pump – Drive belt replacement 113

7.11 Battery-Charging Generator 115

7.11.1 Battery-charging generator – Belt tensioner

and diverter pulley replacement 115

7.11.2 Battery-charging generator – Drive belt

removal and installation 117

7.12 Drive Systems, Driving End and Free End

(Coupling) 118

7.12.1 Coupling – Checking (radial / axial) play 118

7.13 Wiring (General) for Engine/Gearbox/Unit 119

7.13.1 Еngine cabling ‒ Check 119

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7.14 Accessories for (Electronic) Engine

Governor / Control System 120

7.14.1 Injector functions 120

7.14.2 Engine governor and connectors – Cleaning 121

7.14.3 Engine governor – Checking plug-in

connections 122

7.14.4 NOx sensor – Replacement 123

7.14.5 Lambda sensor – Replacement 125

8 Appendix A

8.1 Abbreviations 127

8.2 MTU contact persons/service partners 129

9 Appendix B

9.1 Special Tools 130

9.2 Index 134

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1 Safety

1.1 Important provisions for all products

Nameplate

The product is identified by nameplate, model designation or serial number and must match with the

information on the title page of this manual.

Nameplate, model designation or serial number can be found on the product.

All EU-certified engines delivered by MTU come with a second nameplate. When operating the machine

in the EU: The second nameplate must be affixed in a prominent position as described in the accompa-

nying specifications.

General information

This product may pose 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 and warning notices

Correct use

The product is intended for use in accordance with its contractually-defined purpose as described in the

relevant technical documents only.

Intended use entails operation:

• Within the permissible operating parameters in accordance with the (→ Technical data)

• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubri-

cants Specifications of the manufacturer)

• With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU

contact/Service partner)

• In the original as-delivered configuration or in a configuration approved by the manufacturer in writ-

ing (including engine control/parameters)

• In compliance with all safety regulations and in adherence with all warning notices in this manual

• With maintenance work performed in accordance with the (→ Maintenance Schedule) throughout the

useful life of the product

• In compliance with the maintenance and repair instructions contained in this manual, in particular

with regard to the specified tightening torques

• With the exclusive use of technical personnel trained in commissioning, operation, maintenance and

repair

• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul

Any other use is considered improper use. Such improper use increases the risk of injury and damage

when working with the product. The manufacturer shall not be held liable for any damage resulting from

improper, non-intended use.

Modifications or conversions

Unauthorized changes to the product represent a contravention of its intended use and compromise

safety.

Changes or modifications shall only be considered to comply with the intended use when expressly au-

thorized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from

unauthorized changes or modifications.

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Emission regulations and emission labels

Responsibility for compliance with emission regulations

Modification or removal of any mechanical/electronic components or the installation of additional com-

ponents including the execution of calibration processes that might affect the emission characteristics

of the product are prohibited by emission regulations. Emission control units/systems may only be

maintained, exchanged or repaired if the components used for this purpose are approved by the manu-

facturer.

Noncompliance with these regulations will invalidate the design type approval issued by the emissions

regulation authorities. The manufacturer does not accept any liability for violations of the emission reg-

ulations. The maintenance schedules of the manufacturer must be observed over the entire life cycle of

the product.

Replacing components with emission labels

Emission labels are attached to all MTU engines. These must remain on the engine throughout its op-

erational life.

Engines used exclusively in land-based, military applications other than by US government agencies are

excepted from this proviso.

Please note the following when replacing components with emission labels:

• Appropriate emission labels must be affixed on spare parts.

• Emission labels may not be transferred from old components to new ones.

• Emission labels on old components must be removed and destroyed.

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1.2 Personnel and organizational requirements

Organizational measures of the user/manufacturer

This manual must be issued to all personnel involved in operation, maintenance, repair or transporta-

tion.

Keep this manual handy in the vicinity of the product such that it is accessible to operating, mainte-

nance, repair and transport personnel at all times.

Personnel must receive instruction on product handling and maintenance on the basis of this manual

with a special emphasis on safety requirements and warnings.

This is particularly important in the case of personnel who only occasionally perform work on or around

the product. This personnel must be instructed repeatedly.

Personnel requirements

All work on the product shall be carried out by trained and qualified personnel only:

• Training at the Training Center of the manufacturer

• Qualified personnel specialized in mechanical and plant engineering

The operator must define the responsibilities of the personnel involved in operation, maintenance, re-

pair and transport.

Working clothes and personal protective equipment

Wear proper protective clothing for all work.

When working, always wear the necessary personal protective equipment (e.g. safety footwear, ear pro-

tectors, protective gloves, goggles, breathing protection). Observe the information on personal protec-

tive equipment in the respective activity description.

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1.3 Transportation

Transportation

Only use the lifting eyes provided to lift the engine.

Only use transport and lifting devices approved by MTU.

Take the engine's center of gravity into account.

Lift engines by approx. 10 mm and verify that the lifting ropes / chains between engine and lifting

equipment run vertically or in accordance with the specifications on the installation drawing.

If this is not the case, the lifting equipment must be re-adjusted.

The engine must only be transported in installation position, max. permissible diagonal pull 10°.

If the engine is supplied with special aluminum foil packing, lift the engine at the lifting eyes of the bear-

ing pedestal or use a means of transportation which is appropriate for the given weight (forklift truck).

Setting the engine down after transport

Only set down engine on a firm, level surface.

Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.

Never set an engine down on the oil pan unless expressively authorized to do so by MTU on a case-to-

case basis .

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1.4 Safety regulations for startup and operation

Safety requirements for startup

Install the product correctly and carry out acceptance in accordance with the manufacturer's specifica-

tions before putting the product into service. All necessary approvals must be granted by the relevant

authorities and all requirements for initial startup must be fulfilled.

When putting the product into operation, always ensure that

• All personnel is clear of the danger zone surrounding moving parts of the machine.

Electrically-actuated linkages may be set in motion when the Engine Control Unit is switched on.

• All maintenance and repair work has been completed.

• All loose parts have been removed from rotating machine components.

• All safety equipment is in place.

• No persons wearing pacemakers or any other technical body aids are present.

• The service room is adequately ventilated.

• Keep clear of the service room during the first operating hours. Hazardous gases may occur as a re-

sult of the combustion of paints or oils.

• The exhaust system is leak-tight and that the gases are vented to atmosphere.

• Protect battery terminals, generator terminals or cables against accidental contact.

• Check that all connections have been correctly allocated (e.g. +/- polarity, direction).

Immediately after putting the product into operation, make sure that all control and display instruments

as well as the monitoring, signaling and alarm systems are working properly.

Safety requirements for operation

The operator must be familiar with the controls and displays.

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.

Malfunctions and emergency stop

The procedures for emergencies, in particular, emergency stop, must be practiced regularly.

The following steps must be taken if a malfunction of the system is detected or reported by the system:

• Inform supervisor(s) in charge.

• Analyze the message.

• Respond to the emergency appropriately, e.g. execute an emergency stop.

Operation

Do not remain in the operating room when the product is running for any longer than absolutely neces-

sary.

Keep a safe distance away from the product if possible. Do not touch the product unless expressly in-

structed to do so following a written procedure.

Do not inhale the exhaust gases of the product.

The following requirements must be fulfilled before the product is started:

• Wear ear protectors.

• Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binder

agent.

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 prior to maintenance and repair work

Have maintenance or repair work carried out by qualified and authorized personnel only.

Allow the product to cool down to less than 50 °C (risk of explosion for oil vapors, fluids and lubricants,

risk of burning).

Relieve pressure in fluid and lubricant systems and compressed-air lines which are to be opened. Use

suitable collecting vessels of adequate capacity to catch fluids and lubricants.

When changing the oil or working on the fuel system, ensure that the service room is adequately venti-

lated.

Never carry out maintenance and repair work with the product in operation, unless:

• It is expressly permitted to do so following a written procedure.

• The product is running in the low load range and only for as long as absolutely necessary.

Lock-out the product to preclude undesired starting, e.g.

• Start interlock

• With hydraulic starting system: shut off supply line.

Attach “Do not operate” sign in the operating area or to control equipment.

Disconnect the battery. Lock out circuit breakers.

Close the main valve on the compressed-air system and vent the compressed-air line when air starters

are fitted.

Disconnect the control equipment from the product.

Use special tools if they are specified for the relevant work.

Elastomer components (e.g. engine mounts, damping elements, couplings and V-belts) must not be

painted. They may only be installed after painting the engine or must be covered before painting work is

carried out.

The following applies to starters with copper-beryllium alloy pinions:

• Wear a respirator mask (filter class P3). 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 device.

• Observe the safety data sheet.

Safety regulations during maintenance and repair work

Take special care when removing ventilation or plug screws from the product. Cover the screw or plug

with a rag to prevent fluids escaping under pressure.

Take care when draining hot fluids and lubricants (risk of burning).

Use only proper and calibrated tools. Observe the specified tightening torques during assembly or dis-

assembly.

Carry out work only on assemblies or plants which are properly secured.

Make sure components or assemblies are placed on stable surfaces. Adopt suitable measures to avoid

that components/tools fall down .Use the specified lifting equipment for all components.

Never use lines for climbing.

Keep fuel injection lines and connections clean.

Carry out appropriate cleaning procedures to clean and inspect components requiring special cleanness

(e.g. components carrying oil, fuel, or air).

Always seal connections with caps or covers if a line is removed or opened.

Fit new seals when re-installing lines.

Avoid damaging lines, particularly the fuel lines.

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