MTU MS15025/00E Operating Instructions Manual
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MTU MS15025/00E Operating Instructions Manual

MTU MS15025/00E Operating Instructions Manual

Diesel engine 12 v 1600 r50
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Operating Instructions

Diesel engine
12 V 1600 R50
MS15025/00E

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Summary of Contents for MTU MS15025/00E

  • Page 1: Operating Instructions

    Operating Instructions Diesel engine 12 V 1600 R50 MS15025/00E...
  • Page 2 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.

  • Page 3: Table Of Contents

    7.11.1 Engine governor and connectors – Cleaning 5 Maintenance 7.11.2 Engine Control Unit – Plug connection check 5.1 Preface 5.2 Maintenance task reference table [QL1] 8 Appendix A 8.1 Abbreviations 6 Troubleshooting 8.2 MTU contacts/service partners 6.1 Troubleshooting MS15025/00E 2011-12 | Table of Contents | 3...
  • Page 4 9 Appendix B 9.2 Index 9.1 Special Tools 4 | Table of Contents | MS15025/00E 2011-12...

  • Page 5: Safety

    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.

  • Page 6: Personnel And Organizational Requirements

    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. 6 | Safety | MS15025/00E 2011-12...

  • Page 7: 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.

  • Page 8: 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: •...

  • Page 9: Safety Regulations For Maintenance And Repair Work

    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. MS15025/00E 2011-12 | Safety | 9...
  • Page 10 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.
  • Page 11 • 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. MS15025/00E 2011-12 | Safety | 11...

  • Page 12: Fluids And Lubricants, Fire Prevention And Environmental Protection

    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.
  • Page 13 • If such solutions are spilled onto clothing, remove the affected clothing immediately. • Rinse injured parts of the body thoroughly with clean water. • Rinse eyes immediately with eyedrops or clean tap water. MS15025/00E 2011-12 | Safety | 13...

  • Page 14: Conventions For Safety Instructions In The Text

    Safety instructions Read and familiarize yourself with all safety notices before starting up or repairing the product. Pass on all safety instructions to your operating, maintenance, repair and transport personnel. 14 | Safety | MS15025/00E 2011-12...

  • Page 15: General Information

    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 MS15025/00E 2011-12 | General Information | 15...

  • Page 16: Engine Layout

    8 Fuel filter 16 Engine governor Engine model designation Key to the engine model designations 12 V 1600 Rxy Number of cylinders Cylinder arrangement: V engine 1600 Series Application Application segment Design index 16 | General Information | MS15025/00E 2011-12...

  • Page 17: Sensors And Actuators

    2.3 Sensors and actuators Description Monitoring of B5.1 Lube oil pressure after filter Charge-air pressure B9.1 Charge-air temperature before EGR mixing B5.3 Lube oil pressure before filter Lambda MS15025/00E 2011-12 | General Information | 17...
  • Page 18 Description Monitoring of Camshaft speed B44.2 Turbocharger B speed Crankshaft speed B44.1 Turbocharger A speed 18 | General Information | MS15025/00E 2011-12...
  • Page 19 Description Monitoring of Lube oil temperature Charge-air coolant pressure Charge-air coolant temperature Level and temperature, lube oil Coolant temperature MS15025/00E 2011-12 | General Information | 19...

  • Page 20: Technical Data

    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) 20 | Technical Data | MS15025/00E 2011-12...

  • Page 21: Engine - Main Dimensions

    3.2 Engine – Main dimensions Item Dimensions Height (A) Approx. 1401 mm Length (B) Approx. 1873 mm Width (C) Approx. 1263 mm MS15025/00E 2011-12 | Technical Data | 21...

  • Page 22: 1600 R50 Engine Data

    Number of cylinders Cylinder arrangement: V angle Degrees (°) Bore Stroke Cylinder displacement liters 1.75 Total displacement liters Compression ratio 17.5 Number of inlet valves per cylinder Number of exhaust valves per cylinder 22 | Technical Data | MS15025/00E 2011-12...
  • Page 23 Engine surface noise with attenuated intake noise (filter) - DL dB(A) (free-field sound-pressure level Lp, 1m distance, ISO 6798) Engine surface noise with attenuated intake noise filter) - DL dB(A) (sound power level LW, ISO 6798) MS15025/00E 2011-12 | Technical Data | 23...

  • Page 24: Operation

    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. 24 | Operation | MS15025/00E 2011-12...

  • Page 25: Preparation For Startup After Extended Out-Of-Service Periods (>3 Months)

    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/..).

  • Page 26: Starting The Engine

    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. 26 | Operation | MS15025/00E 2011-12...

  • Page 27: Operational Checks

    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). MS15025/00E 2011-12 | Operation | 27...

  • Page 28: Stopping The Engine

    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. 28 | Operation | MS15025/00E 2011-12...

  • Page 29: After Engine Shutdown

    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/..). MS15025/00E 2011-12 | Operation | 29...

  • Page 30: Plant - Cleaning

    During external cleaning of the plant with water/steam-jet units, the pressure of the high-pressure jet (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...

  • Page 31: Maintenance

    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.
  • Page 32 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.

  • Page 33: Maintenance Task Reference Table [Ql1]

    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] MS15025/00E 2011-12 | Maintenance | 33...

  • Page 34: Troubleshooting

    Check (→ Page 62). 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 4: Engine fires unevenly 34 | Troubleshooting | MS15025/00E 2011-12...
  • Page 35 Contaminated Contact Service. Exhaust turbocharger Faulty Contact Service. Table 8: Charge-air pressure too low 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...
  • Page 36 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 36 | Troubleshooting | MS15025/00E 2011-12...

  • Page 37: Task Description

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

  • Page 38: Adjusting Valve Clearance

    Check if the feeler gauge just passes through between valve bridge and rocker arm (3). Result: If not, adjust valve clearance. Final steps Remove barring device. Install cover. Install cylinder head cover (→ Page 39). 38 | Task Description | MS15025/00E 2011-12...

  • Page 39: Cylinder Head Cover - Removal And Installation

    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 Screw with twin Preload torque 10 Nm collar MS15025/00E 2011-12 | Task Description | 39...
  • Page 40 Tighten screws at positions 1 to 18 to specified tightening torque using a torque wrench. Name Size Type Lubricant Value/Standard Screw with twin Tightening torque 20 Nm ±2 Nm collar Consecutive tightening sequence starting at po‐ 1 to 18 sition 1: 40 | Task Description | MS15025/00E 2011-12...

  • Page 41: Fuel System

    (1). 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 MS15025/00E 2011-12 | Task Description | 41...

  • Page 42: Fuel Filter

    Screw in drain plug (3) and tighten with torque wrench to the specified tightening torque. Name Size Type Lubricant Value/Standard Drain plug Tightening torque (Engine oil) 6.5 Nm ±1.3 Nm Vent fuel system (→ Page 41). 42 | Task Description | MS15025/00E 2011-12...

  • Page 43: Fuel Prefilter - Drain Condensate

    • Do not smoke. Draining condensate from fuel prefilter Provide a suitable container to collect the water. Open drain screw (1). Allow water to drain off. Screw in and close drain screw (2). MS15025/00E 2011-12 | Task Description | 43...

  • Page 44: Air Filter

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

  • Page 45: Air Intake

    Replace air filter, if the signal ring (2) is completely visible in the red area of the service indicator control window (3) (→ Page 44). After installation of new filter, press reset button (1). Result: Signal ring returns to initial position. MS15025/00E 2011-12 | Task Description | 45...

  • Page 46: Lube Oil System, Lube Oil Circuit

    Insert oil dipstick (1) into guide tube up to the stop, withdraw after approx. 10 seconds and check oil lev‐ Oil level must be between “min.” and “max.” marks. If necessary, top up to "max." mark (→ Page 47). Insert oil dipstick (1) in guide tube up to the stop. 46 | Task Description | MS15025/00E 2011-12...

  • Page 47: Engine Oil - Change

    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.

  • Page 48: Oil Filtration / Cooling

    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 Replace other engine oil filters in the same way. Check oil level (→ Page 46) 48 | Task Description | MS15025/00E 2011-12...

  • Page 49: Coolant Circuit, General, High-Temperature Circuit

    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! •...

  • Page 50: Engine Coolant - Change

    7.8.2 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine coolant Changing engine coolant Drain engine coolant (→ Page 51). Fill with engine coolant (→ Page 53). 50 | Task Description | MS15025/00E 2011-12...

  • Page 51: Engine Coolant - Draining

    Continue to turn breather valve counter‐ clockwise and remove. Draw off precipitated corrosion inhibitor oil from the expansion tank through filler neck. Open drain screw and drain off coolant at engine coolant pump (1). MS15025/00E 2011-12 | Task Description | 51...
  • Page 52 Open drain screws and drain coolant at crankcase, right side (1,2). Open drain screws and drain coolant at crankcase, left side (1,2). Install drain screw with new sealing ring. Place breather valve on filler neck and close. 52 | Task Description | MS15025/00E 2011-12...

  • Page 53: Engine Coolant - Filling

    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.
  • Page 54 Final steps Start the engine and operate it at idle speed for some minutes. Check coolant level (→ Page 49), top up if required. 54 | Task Description | MS15025/00E 2011-12...

  • Page 55: Engine Coolant Pump - Relief Bore Check

    • Permissible coolant discharge quantity: Up to 0.1 ml per hour respectively 100 ml per 1,000 operating hours. Stop engine (→ Page 28) and disable en‐ gine start. If discharge exceeds the specified limits, contact Service. MS15025/00E 2011-12 | Task Description | 55...

  • Page 56: Low-Temperature Circuit

    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.

  • Page 57: Charge-Air Coolant - Change

    7.9.2 Charge-air coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Charge-air coolant Charge-air coolant – Change Drain charge-air coolant (→ Page 58). Fill with charge-air coolant (→ Page 59). MS15025/00E 2011-12 | Task Description | 57...

  • Page 58: Charge-Air Coolant - Draining

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

  • Page 59: Charge-Air Coolant - Filling

    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.
  • Page 60 Check proper condition of breather valve, clean sealing faces if required. Fit breather valve and close it. Final steps Start the engine and operate it at idle speed for some minutes. Check coolant level (→ Page 56). 60 | Task Description | MS15025/00E 2011-12...

  • Page 61: Charge-Air Coolant Pump - Relief Bore Check

    Result: If discharge exceeds the specified limits, contact Service. If relief bore (1) is clogged: • Stop engine (→ Page 28) and disable en‐ gine start. • Clean relief bore (1) with wire. MS15025/00E 2011-12 | Task Description | 61...

  • Page 62: Wiring (General) For Engine/Gearbox/Unit

    (→ Contact Service) if cable conductors are damaged. Note: Close male connectors that are not plugged in with the protective cap supplied. Clean dirty connector housings, sockets and contacts with isopropyl alcohol. Ensure that all sensor connectors are securely engaged. 62 | Task Description | MS15025/00E 2011-12...

  • Page 63: Accessories For (Electronic) Engine Governor / Control System

    Seal unused connectors with the supplied protective cap. Release the latch and pull off connectors. Clean connector housings, connector socket housings and all contacts with isopropyl alcohol. When connectors, sockets and all contacts are dry: Fit connectors and lock them. MS15025/00E 2011-12 | Task Description | 63...

  • Page 64: Engine Control Unit - Plug Connection Check

    Engine Control Unit. Make sure that the clips (2) are engaged. Check firm seating of all screws (1) on En‐ gine Control Unit cable clamps. Make sure that cable clamps are not defective. 64 | Task Description | MS15025/00E 2011-12...

  • Page 65: Abbreviations

    Electronic Control Module Electronic control unit of the DDEC system Engine Control Unit Engine governor 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...
  • Page 66 Monitors oil temperature Oberer Totpunkt Top Dead Center (TDC) Panel Control panel Peripheral Interface Module Modulated signal P-xyz Pressure-xyz Pressure measuring point, xyz specifies the measuring point designation Redundancy Lost Alarm: Redundant CAN bus failure 66 | Appendix A | MS15025/00E 2011-12...
  • Page 67 Throttle Position Sensor Timing Reference Sensor T-xyz Temperature-xyz Temperature measuring point, xyz specifies the measuring point designation Unterer Totpunkt Bottom Dead Center (BDC) Variable Nozzle Turbine Variable-Speed Governor Vehicle Speed Sensor Werkzeugkatalog Tool Catalog MS15025/00E 2011-12 | Appendix A | 67...

  • Page 68: Mtu Contacts/Service Partners

    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.

  • Page 69: Special Tools

    Socket, 32 mm Part No.: F30006120 Qty.: Used in: 7.7.1 Engine oil filter – Replacement (→ Page 48) Socket, 32 mm Part No.: F30006120 Qty.: Used in: 7.3.1 Fuel filter – Replacement (→ Page 42) MS15025/00E 2011-12 | Appendix B | 69...
  • Page 70 7.1.1 Valve clearance – Check and adjustment (→ Page 37) Torque wrench, 4-20 Nm Part No.: F30044239 Qty.: Used in: 7.2.1 Fuel system – Venting (→ Page 41) Qty.: Used in: 7.3.1 Fuel filter – Replacement (→ Page 42) 70 | Appendix B | MS15025/00E 2011-12...
  • Page 71 – Check after stopping the engine  46 Troubleshooting 34 – Check prior to engine start  46 Engine side and cylinder – Designations  15 Valve clearance Engine wiring – Adjustment  37 – Check  62 – Check  37 MS15025/00E 2011-12 | Appendix B | 71...
  • Page 72 Wiring - engine – Check  62 72 | Appendix B | MS15025/00E 2011-12...

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