ntrtu Deutsche Aerospace MTU Friedrichshafen = Engine Series 183 8V183TA.2 OM442A Basis: Mercedes-Benz OM 440 8V183TE.2 OM442LA 12V183TA.2 OM444A 12V183TB.2 OM444LA 12V183TD.2 OM444LA 12V183TE.2 OM444LA Operating Instructions M015190/10E ———————Operation and maintenance are decisive tactors in determining whether an engine is always fully operational and remains in ser- viceable condition for many years. This Operating Instructions is, intended to provide answers to questions relating to operation and maintenance in a clearly arranged form. We urgently recom- mend you to perform the scheduled maintenance work with care and at the specified intervals. Proper consideration should be given to the engine operating conditions varying from normal Operating criteria. Failure to do so may invalidate the warranty. Lead seals affixed to the injection pump and to the governor must (on no account be removed ‘Should you have any quastions relating to service, repairs or parts of the engine, please first contact the equipment or system supplier. In all cases quote the complete engine number, which is stamped on the type plate of the engine. The supplying company will resort to the MTU or MERCEDES-BENZ service if necessary. The MTU Service Department will also be available to you at any time in an advisory capacity: MTU Motoren-und Turbinen-Union Friedrichshafen GmbH 88040 Friedrichshafen / Germany Telefon (07541) 90-0 Telex 734 280-Omtd Telefax (07541) 90-3928 eeContents Description of engine. General Explanation of type designation Illustrations of engines Location of ype piate Engine data card, Operation of engine Prior to starting engine. Slarting and shutting off engine Operation Winter operation : ‘Taking engine out of service Restoring engine to service Maintenance Maintenance Categories Maintenance Category | Maintenance Category I Maintenance Category I! Maintenance Intervals Maintenance Schedules Inspection Maintenance Service ‘Additional Jobs. Maintenance Work. |. - Engine oll ang fiter change ‘Checking. correcting coolant ievel ~ Checkang, comectng corrosion antreeze protection 21 22 24 26 27 28 28 8 28 SB B8ResssAdjusting engine mounts, 2 38 Checking and aujusting valve clearance 39 V-bett - Checking condition, tansioning 3 Checking and cleaning at fiter 48 Ghecking leaktighiness and condition 49 Checking tight fit of nuts and bolts 52 Checking batteries and cable connections 53 Throtile control and exhaust brake ~ Checking condition and setting 54 + Fuel prefille ~ Cleaning fter element 55 2 Renowing fuel iter elements 36 3 Greasing nng gear of flywhee! a7 4 Service Products 58 Engine oils 58 Contant 59 43° Diesel fuels 6 4.4 Survey of capacities 63 5 Technical data 64 5.1 Generaldata 64 52 Settings 64 52.1 Valve clearance os 522 — Startottuel delivery 6a 5.3 Dperating temperature and operating pressures. 65 5.4 Power output and eursumption data 66 8 Troubleshooting 67 6.1 Starterpinion does nt turn o turns too slowly 67 62 Engine docs not start or stops again immediately 68 ——_______63 64 65 66 67 68 63 610 611 17 74 72 73 Enaine run equi, cus outor has poor pertoxmane Black exhaust Bluest Wt exaust nae pining Engine knocking Coolant temperature to high Engine ol prossute crops Atemator mdiato lam doesnot ight up (whe engine ratvonnng) [tema incicator amp igh up (when engine running) Ingpection and inetallation work Checking start of delivery of injection pump Testing compression pressure Blocking viscous fan 68 60 70 70 70 70 a n 2 72 7” 3 75 801 Description of engine 1.1, General industrial engines are employed in the most varied applications and are thus designed to satisty specific requirements, ‘The complete Engine Number and the Engine Data Card No. 3 should always be quoted to precisely determina the production detals. 1.2. Explanation of type designation MTUsesianation MERCEDES BENZdesignation 12V 169 TE12L OM 444 LA }] || uprate | L-turbochargea \— Design index |= nternal charge air 1 Railroad cooling —| 3 Electic power generation Grinder (2 = 8 cyl) Lbearre ean Anno charge air cooling, wit piston cooling \__ Bexternal charge air cooling with piston cooling 440 ongine (series) LE charge air cooling by splt-circutt coolant system, wilh piston cooling ‘Turbocharged L Series _____Veengine Number of cylinders 1.3 Illustrations of engines In view of the fact that the ilustranons inthis Operating Instructions relate to a particular engine model in each case, the version of your engine may vary in respect of certain details16 10 om 442 Cylinder head air compressor Fue! fiter Righthand inlet manifold Injection pump Lethand inet manifold Fuel ines Gross inlet manitold Coolant connection pipe Oilpressure switch Viscous fan Alternator Inlet manifold Oilsump Oufiner Righthand exhauis! manifold Power cylinder of exhaust brake | |omaa2 Oi separator Cylinder head cover Letthand exhaust manitold Starter motor Oil fiter neck connection Dipstick Throttle control shaft Bett pulley of coolant pump10 15 14 18 12 " om 442 A 1 Oilfiler neck 2. Righthand inlet manifold 9. Cross inlet manifold 4 Injection pump regulator 5 Letthand inlet manifold 6 Dipstick 7 Fuel iter 8 Cylinder head cover 9. Lefthand exhaust turbocharger 10. Lefthand exhaust manifold 11 Starter motor 12 Fan 13 Belt pulley of coolant pump 14 Coolant temperature switch 15 Ollpressure switchOM 442A Righthand exhaust turbocharger Air compressor inlet line Fuel priming pump Cross inlet manitote Dipstick Fan Alternator Oilfiter10 OM 442 LA 1 Oilfiler neck 2 Coolant pipe 3. Intercooler 4. Crassinlet manitola 5 Coolant connection pipe 6 Fan 7 Alternator 8 Oilsump 9 Oilfiter 10 Suspension tug 11. Righthand exhaust turbocharger 12 Ollseparatorom 4a2La, Intercooler Inlet aie pipe Oil separator Lefthand exhaust turboctrarger Exhaust manifold Suspension Starter motor Dipstick Bet pulley of coolant pump Coolant connection pipe 1314 om aaa A. Righthand exraust turbocharger Righthand inlet connection Fuel fer Righthand inlet manitold Injection purnp Lefthand inlet connection Letthand inlot manifold Coolant connection pipe Belt pulley of coolant pump Fan Alternator i cooler OilfiterOM 444A Coolant connection Oil pressure switch Cylinder head cover Righthand inlet connection Fuel ines Fuel iter LLefthand inlet connection Lefthand exhaust turbocharger Lotthand exhaust manifold Starter motor Dipstickom 44a La Charge air pipes Intercooler Righthand charge air pipe Injection ines Lettnand charge air pipe Oil separator Lethand inlet connection Lothand exhaust turbocharger Lofthand exhaust manifold Starter motor Coolant pupom aaa La, Righthand exhaust turbocharger Righthand inlet connection Oil separator Righthand charge air pipe Cylinder head cover § Ollfller neck Intercooler Coolant connection pipe Charge air pipes Coolant pipe Beil pulley of coolant pump Fan Allernator Dipstick Oil cooler Oilfitor Righthand exhaust manifold 71.4 Location of type plate “The type plate contains the 15:position engine number in addition to other data. — Depending on version, on front right or rear eft of engine block. 181.5 Engine Data Card gine Data Curd contains essential data regarding the production details of ‘Pe engine. including the special equipment. Important: Always carry Fagine Nata Card No. 3 in the Maintonance Booklet ax atthe rear.— Check oillevel 20 — Check coolant level where no — Cheek fuel supply ‘monitoring device is provided. Note: Not neceseary if electrical coolant level ‘monitor fed. — Open shutoff vaive — where fitted22 Starting and shutting off engine Te Engine can be fitted with a “start pilot” lu facilitate starting at exterior ‘errperalires below ~20°C. Refer te Section 2.4 Starting engine — Open shutott valve — where fitted. ‘Insert key inthe control box and turn to Drive position, The charge indicator amp must light up. Start engine by turning the key in the steering lock without ‘depressing the accelerator pedal. Ifthe engine does net start within § seconds, siowly depress accelerator pedal. — Mengine sil does not star, intorrupt starting operation after not more than 20 ‘seconds and wall approx. 1 minute before again attempting to start engine — Tum key back to the stop before again attempting o start engine. Alter three attempts to start engine, wait some time. — Release key alter the engine has started. Release pressure on accelerator pedal and allow engine toile. — Check oll pressure gauge as soon as engine has started. Ine cl pressu Indicated, shut off engine again immediately Shutting off engine — Reduce engine load, disengage clutch, disconnect drive. — Slowly reduce engine speed — Run engine at idle speed for approx, | minute. — Depending on version, operate stop cable, engine speed control lever, shut-off ‘solenoid or exhaust brake, at2.3 Operation Keep a close check on the monitoring instruments, — Oilpressure atleast 06 barat idlespeed, A cuntinugus operation — Check engine ol avel evary 10 hours with engine shut of — Coolant temperature 70°C up to max. 95°C 22“enance indicator with detent r ] — Perform maintenance of filer ifthe red area of the maintenance inalcator ‘emains visible, ie, has engaged. when cngine is shutoff, Maintenance indicator without detent — Perform maintenance of teri the red area of the maimtenance indicator Is fully wsible when engine is running, Maintenance indicator with indicator lamp, — Perforin maintenance of fiterif indicator lamp lignts up when engine is run- ning, 224 Winter operation Refore starting engine — Change engine oil in good time as shown in table — Test antifreeze in good time with tester. Antieeze prxecoor must exist down to -37°Cin “normal case". Refer to Section 4.2. 28— Use winter-grade diesel tuel with adequate fluidity Rater to Section 4.3 Mako start pilot _ whore fitted — operational in good time. Open cover of start- ing fuel tank. Remove protective cap from filing bottle and press valve or bottle against valve of tank. Pour in starting fuel up to Max. mark on tank, Close tank and press protective cap onto bottle, The engine is started in the usual way. Reter to Section 2.2. Turn key or storing lock to Start poston and operate .atart pile at the same time unti engine is running. 1 ~ 2 Stokes ofa pump par Second ‘Starting fv! is eupaled oni in filing botos avaiable from any MTU or MERCEDES-BENZ Service Staton by quoting Part No, 000 555 00 10. Use only genuine Mercedes botes Staring fuels extremely tammaole ang should not be exposed to outside tomporaturs in excess of 50 °C for lengthy penods. Always remove starting {uel bots irom the vehicle dung the summer months Stora n'a coe plage away from fre and naked flames25 Taking engine out of service ‘The following operations require to be performed before taking an engine out of service for a period langer tnan ane month and not exceeding twelve months: Thoroughly clean engine — Run engine to normal operating temperature and drain oil from sump and oi filter (intial operation oil may remain in engine) Renew ol fiter cartridge Refer to Section 3.4.1 Pour in inilal operation ull conforming to Sheet 226.01.9.6 of Service Product Specifications, Pour in coalant contorming to specications. Refer to Sevlion 3.4.2 Fun engine untl warm (coolant temperature 75 95 °C) and alow to run for five minutes. Store engine ina dry and well-ventilated room, Pour ol into engine up to Max. mark, — Pour eitinto ol Bath ar titer ~ where ttted — up to Max. mark, — Fill uel tank completely. — Close shutoff valve — where fitted — Disconnect negative terminal of pattery. Batteries which are notin use should be recharged once a manth or maintained fon a continuous charge of 0.06 A. Fully discharge and cirarge every three months. — Coal al bright matal and unpainted pars of the engine, such as bell pulleys. linkages and levers, with grease — Relieve tension on all V-bels. Refer to Section 3 4 5 — Plug all openings, suen as exnaust pipe ano arr iter, anuight26 Restoring engine to service -move all plugs titted to engine parts move grease from keyways ot bett pulleys :nsion V-belts, Refer to Section 3.45, neck battery and connect terminals. Refer to Section 3.4.9. Greck level of engine oil, coolant and fuel. — nen shittoff valve— where fitted Run engine until wart (coolant temperature 75-95 °C) — Drain engine oil from sump and oil fiter the “Inspection” has nol yel been carried oul on the engine, do nol drain engine 31 from sump and ol fiter. — Pourin engine oil. Refer to Section 3.4.13 Maintenance 3.1. Maintenance Categories 9.4.1 Maintenance Category! : Arduous operation | (e.g. extreme short-haul operation, frequent ‘cold stars) 3.4.2. Maintenance Category Il: Nora! operation {intermittent engine speed and load) 3.1.3 Maintenance Category Ill: Continuous operation (e-9. long-naul trucks)3.2 Maintenance Intervals Rexretancace@O"' | MenenaneCaevont | Meciranen Caer | cree cro Ses gormcncrn [egronewes [ieeioenatass) | SSPE Riches __ Operating houre | Operating hours | Operating hours _|“*"| "(sat /35|-05/ Rt wnapection fat t00" 10-308 s[olefofole ine oll and fiter change 100 300) felt ne o and iter change _ 600 ofol Tele Maintenance Service | 200 | son el: neil and fiter change | 900 —*| i200 [fe Engne of and iter change | i500 of Seana ceca 400 1200 1800 afofelclcle Engine ofl and fiter change 500 [1400 2100 _ Engino oi and fiter change 1600) ao0 clo} fo Maintenance Service [ye00 270 e . Engine oil and filter change [2000 ‘3000 [ee o Engine olland iter change | 2200 a3 [o _ ores ote 00 2400 ‘300 ofole e inadvertent wn dani bt ~ Ser eT ee semutepm 25 dene crore arr ome eee cern S02 sy art es me organs te am shri om ee oe pe.3.3. Maintenance Schedules 3.3.1 Inspection — Engine ol and fiter change — Checking, correcting coolant level Checking, correcting corrasion/antitreaze protection — Adjusting rubber engine mounts — Adjusting valve clearance — Checking condition of V-betts,retensioning — Arr hiter il bath air fiter: Checking oilleve! — Checking leaktightness and condition (ensuring correctly laid and tree of chafing) Oiland fuel ines Inlet fines between air fiter and engine — Checking tight tt of nuts and bolts. lightening according to condition, Cxhaust flange and manifols 3033.2 Maintenance Service Engine oll and titer change Checking. correcting coolant level — Checking, correcting corrosion antifreeze protection Checking condition of V-belts. retensioning Air fiter (intervals may vary by virtue of operating conditions and fer design) (Oi Lath ir filer: Oil change, cleaning fiter Dry airfiter: Cleaning dust collecting bow! CCieaning or renewing paper element if maintenance indicator has tipped Renewing paper element after third cleaning ur aller two years al he latest. Checking leaktightness and condition (ensuring correctly laid and tree of chafing) Cooling and heating system: Pressure oss test Checking cundilion of radiator, pipes and hoses Oil and fuel lines Inlet ines between air titer and engine Protective caps ‘Checking batteries and cable connections Throttle control and exhaust brake ~ Checking condition and setting Fuol prefer Cleaning fiter eloment lenewing fuel filter elements with 2 fiters at 0.5 lire or fter at 1 live capacity, at3.3.3 Additional Jobs to Maintenance Service |. Additional jobs based on operating hours In adition to every 2nd Maintenance Service Adjusting valve clearance — Renewing fuel fier elements with2 filers a lite capacity I Time-based additional jobs (Once annually Adjusting rubber engine mounts — Greasing ring gear of flywheel Every 2years — Renewing cooiant — Airfiter: Renewing paper element ater third cleaning or aftor two years at the latest3.4 Maintenance Work 4.1 Engine oil and filter change Capacities with ol fiter in litres. a5 Lives ; 25 ws S 235 23 wow | or | ry oy ay mes to. rate Slr ‘Sea [ohosco] |e |enowee] [Sea [eee] | ts ete toare [owe rare [ote ae crane [eur e-ylnder e-yinder TO-ylnder 12-ylinder Use only MB-approved engine ols (er to Service Product Specifications Sheot 2060, 287 01 Sand 2280 12/9) Tightening torques in Nm i iter bow! oi iter suppor 50 Oi érain pug ool fiter bow 50 Ot.arain plug to oitsump 80 Special tol 20-100 Nm Torque wrencherento) (ear aatarent + Faseongoor is Pohick 2 Seis 2 thr Satin ng & Forsort = Drain cil rom oll sump and ol iter bowl when warm. — Unscrew fastening bol (1), take of iter bowl 2) and clean — Renew fier element (5) — Renew rubber sealing rng 4) and sealing rings of drain plugs — Cxamine sealing sng (2), renew according to condition — Inger fter element into bow! with sping facing down = instal titer bow! — Screw drain plugs for oil sump and iter bow tight 4‘Auesseoeu p 1901100 ‘68 10 yoeyo “seynUIW S Jey “eUIBUE Jo INS — ‘989) 10 SUBS 49) -o4UD puE wUIBUE UI — ‘uibua ways 0} Buydwane ube a1ojaq ain ‘2uo jem pue spud0es Oz UeY) s10W! ou Jaye auibua Ye}S 0} JduIaHE InUeIU| one poureigo st Suipea: aunsseud yo yun s9yeIs Ym auibue Yue) — exeia {sneyxe ejesedo J0 uoNIsod dog oqul duund uoH8fu Jo 4ene} jo.1U0D BAW — urbe oWut wo sno —3.42 Checking, correcting coolant level - Checking, correcting corrosion! antifreeze protection Commercial toot ‘Antifreeze protection tester cau Wait until coolant temperature is below ot ‘cooiing system. before opening cap af engine — Turn cap to 1st detent and allow pressiira to escape. Romove radiator cap Coolant level must extend up to mark in the filler neck (arrow) ‘Test antifreeze protection with tester a Antifreeze protection in “normal case” must exist down to ~97 °C all year round Refer to Section 4.2 Prepare missing cootant and pour in 36Renewing coolant With radiator cap removed — Open regulating valve of heating system — Open drain plugs — on radiator (Example) — onlett of crankcase = oncil cooler — Drain coolant completely — Clear Grain openings which are blocked by deposits Examine seals of drain plugs. renew according to condition — Install drain plugs — Prepare cova avvuruiny lu specications (refer o Section 4.2) and your it Lp to markin radiator filer neck — Seal engine cooling system — Siart engine and run for approx. 1 minute at altemating speeds — Shut off engine and replen'sh coolant up to speclied coolant level a73.4.3 Adjusting engine mounts Setting inmm Clearance of stop bar Tightening torque in Nm Fastening nuts of stop bar ‘Special tool “Torque wrench ‘Shop-made too! Metal strip — Examine clearance (A) IWthe clearances are unequal, re-set — Slacken fastening nuts (4) and pull stop bar (5) down — Insert metal strip in the gap — Push stop bar up fully Tighton fastening nuts Remove metal sro 38 ea2s 90 80-300Nm 2.8%30x 100mm3.4.4 Checking and adjusting vaive clearance Settings Refer to Section § 2.1 lightening torque in Nm Fasiening bolts for cylinder head cover Ey Special tools Torque wrerich 20-100 Nm Valve adjusting wrench 321 $89°00 11 00 Device for cranking engine 407 589 00 63 00 Foeler gauge holder 617 583 00 40 00 Feeler gauge leaves 040mm 617 589 04 23-00 060mm 422 589 01 23 ov Examine and adjust valve clearance when engine cold. Wait at least 20 minutes alter shutting off engine — Remove cylinder head covers and clean — Altach cranking device to timing caseMetiud 1 ~ Adjusting each cylinder individually according to injection sequence Injection sequence 1-4-2-5 9 6 Engine — Gxylinder evap _ Injection sequence eeyinger —_[neton to.eyinamr _Inpeton sequence aayimanr econ sequence 1-19-RL8-8-10-6-7-2-11-4-9 ylinder Overlap 6-7-2-11-4-3-1-12-5-8-3-10 — Crank engine until piston ot cylinder to be adjusted is exactly at top dead centre of Compression stake. The vaives must be closed and the tappet rods must rotate easily. ‘This is the position reached when the valvas ot the cylinder Overiap withthe synchronous piston. 10.cylineer angine Arrangement of cylinders and valves 6-cylinder engine B-cylinder engine 42-cylinder engine B= inlet valve ae exhaustvaive X= Fiywneelend—_X 40Method 2 ~ Adjusting all valves in 2 crankshaft positions ! yinderswahves to be adjusted Engine €rankhaf positon 7 No. | eyinder ry2;afa]s]}e]7]sjs| wij uj inder _1gniton TOO wfelrle 1 | | Seevinder Gyerian TOC =|tlefilwele tinder _‘grton TOC le rfel—le Sind Groep Te | eli jae i | socyinder Wein TOS le ifele w | ec | O-evinder — Bverian TOC al e{i|[t | -[1 ; Ignivon TOG, ve ie i ~luilfe Beyinder — Gverlap TOC = e| i |wle |wele] i Crank engine unti the TDC marking on fywnee! is aligned with adjusting edue at inspection hve. — Check whether No, 1 cylinder isin ignition TDC or in overlap TDC (bath valves are closed in ignition TDC). © Agjust: when No. 1 cylinder in ignition TOC ‘Adjust: when No. 1 cylinder in overtap TDC ‘Reylinder engine 10-cylinder engine Beoyinder engine fa $e of fe 6-oylinder engine X — Flywheel end— Measuring valve clearance between rocker arm and valve stem (arrow) Valve clearance is enrtectly adjusted it the teeler gauge leaf can be drawn through wilh sight resistance — Slacken locking nut (2) for adjustment — Adjust vaive clearance by turning the adjusting screw (1) ~ Tighten locking nut — Re-check valve clearance, correct if necessary — Renew gaskets of cyinder head covers — Fiton cylinder head covers — Detach cranking device from timing case and attach cos cover 423.4.5 Checking condition of V-bolt, tensioning Settings Vebelt New V-belt Used V-belt {profile wieth in mm) (KG scale on instrument) (KG scale on instrument) 125 40-45, ‘30-40 Special oo! Instrument for measuring bell tension 001 $89 69 21 UW raatChecking condition of V-belt — Examine V-belt for signs of ecacking, oil stains, overheating and wear Checking V-belt tension — Lower indicating arm in instrument — Position instrumert in the middle between two belt pulleys on the belt so that the stop (arrow) i resting against side af batt — Apply even (vertical) pressure to the pushbutton until the spring is heard or felt ) tadisengage _— Take ott instrument without altering the position ofthe indicator arm — Take reading of bott tension (arrow) ithe reading obtained does not cortespond othe setting coract V-belt tension | keTensioning V-belt A~ Crankshaft, coolant pump, alternator — Slacken clamping bott (1) — Slacken locking nut (3) — Adjust to specitied tension with tensioning nut (2) — Tighten allnute and bolts Tension 19 V-belt B - crankshaft, fan, tensioning pulley — Slacken clamping bolt (1) — Agjust to spectied tension with tensioning nut 2) — Tighten all nuts and boits Renewing V-belts Release tension on all V-belts and take olf over belt pulleys — Fiton new V-belts and tension Check belt tension with special tool 1 Gianpington3.4.6 Checking and cleaning air filter ll bath air filter Service product Engine oil Capacities Depending on fier version — Remove bottom section (1), empty and clean — Clean filter element (2) with diesel fuel and blow out with compressed air — Examine rubber gaskets, renew according to conatton — Examine top section (3) for fouling Pour engine oilinto bottom section upto the Max. mark (arrow) — Install bottom section with fter element 46Dry ai filter — Perform maintenance only wnen required in accordance wtn Sector 23 — Onversion with detent: Alter cleaning, press pusnavtor (arrow) for red panel to asengage — Empty dust collecting bow - aneve fitted — Remove fiter cartridge — Blow out fter cartridge in direction offold Maximum pressure: § bar a7— Blow out titer cartndge rom inside — Examine filer cartridge with roo lamp for signs of damage — Severely fouled cartridges can be washed out (up to § times) — Clean beforehand by blowing out — Prepare washing solution from mixture of lukewarm water and cleaning agent of filter manufacturer (or alternatively washing-up liquid) — Sudh varridye for 10 minutes and then smi back and forward for S minutes — Rinse out titer cartridge in clear water and dry at room temperature Important: The cartridge must he dry betoreits re-used 483.4.7 Checking leaktightness and condition Special toot Toster (hand pump) 124 689 15 21 00 ‘Tester (compressed air) 001 589 71 21 00 Double connection (000 589 73 63 00 ‘Check coolant level, correct. Refer to Section 9.4.2 — Open heating valve — Attach tester to radiator cap and bulld up pressure equal to opening pressure (of cooling system ‘The opening pressure ofthe cooling system is recognisable from the code umber ofthe radiator cap Example: Code number 70 ~ 0.7 bar gauge prossure — Check radiator, radiator pump, ol cooler, core plug, heat exchanger of heating ‘system as well as pipes and hoses for signs of leaks.— Check outside of radiator for signs of fouling ‘The radiator must not be clogged with uit between the fins — Check the pipes and hoses to ensure they are in proper condition, are laid without chafing and are properly secured — Detach tester — Assemble tester (1), double vonnection (2) and radiator cap (3) — Create test pressure and check whether the pressure ree! valve biows off at ie specified pressure. Renew radiator cap, if faulty Example: Code number 70 ~ 0.7 bar gauge pressure Disassernble tester, double connection and radiator cap ~ Fit cap onto radiator 50tines Exam) Frntnes (Foote) — Oillings: Ensure they are laid with Fucl lines: Ensure thoy are laid — Inlet lines between airfiter and ‘out chafing without chafing engine: Ensure they are laid without hating — Check connections and joints for — Check connections and joints for signs of feaks| signs of leaks. Ae ST 513.4.8 Checking tight fit of nuts and bolts Tightening torques in Nem Exhaust manifold 50 Exhaust flange 50 Special too! “Torque wienclt 20-100Nm ~ lighten nuts and bolts of exhaust manifolds and flanges igitana nace ran ean emen ars 823.4.9 Checking batteries and cable connections: Setting in mm Electrolyte level above top of plate 10-45 Service products ‘Anii-corrosion groase 0.9: Bosch Fdovt Distileg water Special toot Hyarometer Correct clectroiyte level of battery Pour in disilled water only Check electrolyte gravity with hydrometer Itaistiled water has been added, wait 30 minutes betore testing Voits Electrolyte gravity’ Spec. gravity parcellatcall Charge state Normal Tropical Normal Tropical tester otbattery $2786 27°86 128 123 26-27 24 — wellcharged BaeBe 16°B6 120 1:12 21.22 20 hafchargod, recharge JOBE 117BE 1.12 1081.8 1,75 ischarged, charge atonce lect tamparatve of 20°C 533.4.10 Throttle control and exhaust brake — Checking condition and setting Throttle control — Depress accelerator pedal ‘The control lever (1) of the injection pump must be resting agains the full load stop screw (2) — If there is a gap between control lever and stop serew, adjust linkage — Grease linkage and bearing points of throttle control linkage with engine oil or grease Exhaust brake — Remove lock on ball joint and detach ball socket — Check ball joint and throttc valve shaft for ease of movement and wear — Check preload of exhaust brake cylinder ‘The pretoad is correctly set the throttle valve 1s open tothe stop— thenotch (arrow) of the throttle vaive shaft must be parallel to the exhaust pipe and the piston rod must be withdrawn 2-3 mm out ofthe exhaust brake cylinder for ~allaching the ball socket — Attach ball socket and secure — Run engine atidle speed — Oporato oxhauet brako ‘The notch ofthe throttle valve shaft must be at right angles to the exhaust pipe 54 |~Cleaning filter element 3.4.11 Fuel prof Close shutoff valve —where fitted — Slacken knurled nut (3) of lamp — Remove sight glass (1) and fiter element (2) and clean in cleaning fluid Renew titer element which is severely fouled or damaged, and also renew sight { ' glass if itis damaged at sealing surface — Install fiter element and sight glass Seta Ensure sight glass is properly located before tightening knurled nut. — Open shutoff valve where titted 1cken (turn) handle of priming pump (4) and pump for long enough until the pressure rele! valve of injection pump is heard to. open — Tighten handle of priming pump — Run engine; check for signs of leaks 553.4.12 Renewing fuel filter elements — Close shutoff valve where fitted — Unscrew fastening screws (1) and remove filer Lowis together with fiter elements. — Clean fter bowls — Renew rubber seals in fiter head and sealing rings for fastenings screws — Insert new titer elements into fiter bowls and install, — Open vent screws (2) — Open shutott valve — where ited — Slacken handle of priming pump and pump for long enough for fuel to flow out free of bubbles atthe vent screws — Close vent screws — Tighten handie of priming pump — Run engine; check for signs of leaks 56 2 Norse he nace: seme er3.4.13. Greasing ring gear of tlywneel Service product Longife grease conforming to Service Product Spectications Sheet 266 2 g — Detach cover from clutch housing — Apply grease to four points evenly spaced around circumference of ring gear 7 a 7 2D Sy | 574 Service Products Design components and lubricants must be optimally matched. Thats why only ‘Service producte which have boen tested and approved by us may be used. ‘These are contained in he MERCEDES-BENZ Service Product Specifications. Further information is availabe from any MTU or MERCEDES-BENZ Service Station, 4.1 Engine oils Engine oils are specifically tested to ensure compatibility with our engines. That is, \why only engine ols approved by us should be used. The appropriate Shest Nos. are given in Section 3.2 .Maintenance Serrvice Intervals”. Caution: Selected an engine oil viscosity (SAE Grades) matching the outside temperature toensure that the crank assembly components are adequately lubricated. On no ‘account may engine oils without additives be used. tis normal practice to operate the engines Juriny tne first 1030 and 20-100 ‘operating hours, respectively, with intial operation oil. Ifthe oil evel drops to the ‘minimum mark on the dipstick prior to the inspection, iis permitted to add an ap- Proved engine oil fno intial operation oilis availabe. 58 SE lomay be yoo prolonged ude epee Mestorelo'siee42 Coolant ‘The coolant ie a mixture of water and anticorosion/antitreeze agent. The coolant ‘must remain inthe system all the year round to ensure adequate corrosion protec tion and to increase the boling point. Renew coolant every two years, as the cor, Tosion protection diminishes. Water {tio not permitted to use waler alone as a coolant aven if antifreeze properties are ‘ot required. The water in the coolant has to satisfy cerlain requirements, which are frequently, bul not always. met By drinking water. If the quality of waters in. sufficient, the water has to be treated. Information regarding this can be obtained from any MTU or MERCEDES-RENZ Service Station, ‘Anti-corrosion/antifreezeagent The portion of ant-corrosion/antfreeze agent in the coolant must not drop below 40% by vol, during operation (equals antifreeze protection down 1o approx. 7.28.10). A lower portion does not adequately ensure the ant-corrosive proper. ties. To avoid any damage tothe cooling system: — Use only approved ant-corrosion/antireeze agents. Information is available from any MTU or MERCEDES- DENZ Service station. — When replenishing system (after loss of coolant) itis essential to ensure an anti-corrosion/antireeze portion o! 50 % by vol, (antiirea7e protection down t0-37°C).— Vo not use more than 55% by vol. of anticorrosionvanttreeze agent (= max. anifreeze protection) otherwise the antifreeze properties willbe reduced and the heat dissipation impaired, Mixing ratio of coolant Antitrosze Water Anticortosion/antifreeze protection % by vol ‘agent downto °C. 3% by vol =37 50 30 approx. 45 45 max. 55 In exceptional cases, where itis evident that no anticorrosion/anlireeze agent can be obtained and no antifreeze protection is required (8.9 tropics), 1 % by vol. = 10.em*ltre of comesion protection oll must be added. In Such cases, renew coolant annually 604.3 Diesel fuels Use onty commercial-grade diese! fuels. On no account may grades such as. Marine Diesel Fuel, heating ols etc. be used. Itthe diasel fuel used has a sulfur content higher than 1,0% by wt. refer to section3.2. When refueling from barrel, insert a fiter, a chamois leather cloth or atleast a lean flannel cioth in the funnel for fitering the fue. lf diese! fuel has been spilled, contaminated areas can be cleaned with a mixture of 25 to 50% vinegar and 75 to 50 % water (depending on degree of contamina tion). This helps to get rid of the unpleasant smell Diesel fuels at low temperatures The fluidity of diesel fuel at ow temperatures may be insufficient as a result of waxbuild-up. Diesel fuels with improved CFPP are available in the winter months to avoid ope- rational problems. Winter-grade diesel uel can normally be used down an outside temperature of approximately ~15 °C without any problems, \feummer-grade diesel fuel ie used, or a winter grade diesel with insufficiont CCFPP and also at outside temperatures lower than ~15 °C, add a certain quant- ty, depending on outside temperatures, of kerosene or regular gasoline (leaded ‘or unleaded). Refer to table on p. 62. Do not add premium gasoline Engine ouput my be reduced depending on the portion added. itis best to add as litle as possible, taking into account the outside temperature. 6Portion added: — Kerosene max. 50 % — Regular gasoline max. 30% Flow improvers may also be added to enhance the fluidity. They are not fully ef- fective with every type of diesel fuel, Flow improvers may also be used in combi- nation with regular gasoline or kerosene. Pay attention to the manutacturer’s recommendations, Further information regarding flow improvers can be obtained from any MTU or MERCEDES. BENZ Service Station Important: ‘Mix the additives to the diesel (uel before the formation of wax reduces the fluid ty. Fuol problems relating to the formation of wax crystals can only be eliminated by heating the entire fuel system. For safety reasons, mix kerosene or regular gasoline to the diesel fuel only in the fuel tank First pour in kerasene or regular gasoline an then diesel fuel. Run the engine for some lime to ensure the additive flows into the entire fuel systom. Caution: “The flame point ofthe diesel fuels lowered by adding kerosene or gasoline. In- ‘creased care should be taken when handling this fuel mixture. Observe the appro- priate safely regulations. Outside Summer-grade Winter: temperature ~ gleseltuel——AgotIVe diesel uel Auitive % % % % de 1 70 20 100 =10 to-15 50 50 100 = “15 10-20 7 - 70 30 20 10-25 - = 5 504.4 Survey of capacities G-oylinder Beoylinder 10-cylinder 12-cylinder Naturally Turbo- Naturally Turbo- Naturally Turbo- Naturally’ Turbo- aspirated charged aspirated charged agpirated charged aspirated charged engine engine engine engine engine engine engine engine Engine oil with fiter in tres 7 7 23 27 5 056 85S Coolant in engine in litras? 145 175 19 23 1 Te gues ste estan a er > Capasy ay ary coping on vrson5 Technical Data 5.1 General Data 6-cylinder B-oytinder 10-cylinder 12-oytInder Naturally Turbo- Naturally Turbo- Naturally Turbo- Naturally Turbo aspirated charged aspirated charged aspirated charged aspirated charged engine engine engine engine engine engine engine engine Tee (ylindarsin 90° Vee arrangement Operating method ‘A-stroke dieselinjection Cylinder bore mm 130 128 130 128 130 128 130 128 Cylinder stroke rom 142 Displacement om 11903 10964 16070-14618 «= tgaga_ 18273-22606 21900 Injection sequence 1-4-2 1-6-6-10-2 5-3-6 8-4-9 5.2 Settings 5.2.4 Valve clearance in 1m Engine Valve clearance inet Brhaust Onnaai-eaata ao 060 522 Startof fuel delivery G-cylinder B-oylinder 10-cylindor 12-oyinder Naturally Turbo Naturally Turho- Naturally” Tirho- Naturally” Turbo~ aspirated charged aspirated charged aspirated charged aspirated charged fengine engine __engino_ engine engine engine engine engina. Start ot delvery° BIDC. 4 1 rn 14 4 ry 16 4 645.3 Operating temperature and operating preseures 6-cylinder S-cylindor 10-cylinder 12-oytinder {iaturaly” Turbo Naturally Turbo: Naturally “erg. Naturally” Turbo Strona Tred aspirated charged aspirated charged acral charged “ane __engre ermine _engre “engine ‘engine “engine engine Coolant temperature 70 tomax.95 Oil pressure at 600 mpm bar 06 at n> 2000 rpm bar 25 Overpressure in cooling bar or system Compression pressure bar 20" minimum Opening pressure of bar 200+8 injection nozzles (used nozztes 186) 655.4 Power output and consumption data Marine main propulsion vaio or cane oe Tam rae |e Train Dagens Tampere | Be Power ange at ghar peed aon request Terns [ememmare |sotonen | 00m ews lemwewe |tmore lo ‘pplication GFoUD 1A Apgeston 50 — = Trae non | Sani Farmep sewer | [an Liane one | _ une we une ee Me wa) ‘av 169 TET2 OM 442 LA 2100 908 | ‘31 ‘wv 169 TEE? OM 442 LA "20001 Fal 4968 40v 183 TE72_| OM 444 LA 2100 610 Swuswstesz [oma tA we) Sl te! Capoten aru 5 aad Raine ree oe | umin[ aw) He oust oto] omen ool___ros|__so00 Rail traction and train electricity generation a oars Sor pens] saa a en [an on | eee [umemmsts [iene | om sc [emearess |sownee | i8 —— = {applcation roup a Tran aiecely generallon rer a ‘Engine model | Based on: ‘UIC rated power, Engine meas! | BEAT Te red power aoreaveey - . wsbeer | [xm eceoestone | tal sm HL tne] erodes ene | Yn| ‘BV 169 TATE | OM 112A Te] 20 ses | sooo | 2807 ayes Tae [Oma He | ar] [Remit oma, | sso) as 30] sxo| ae Qvissrets | oMsaLA vipo| ar) -| |vicotara Jousca, | ran] 30 ae] tw) oe Gwiatata [Omen two) 32.) :) [ipvamsrerz Lowest, | so|_ar_at]_wznl o_o Wvqwsrew |omeats wore) fab) oans| [eins ih ower ings abo 8 Up EL Witsoe [omecta ee] | Savwsorta [oMeuta fool ee] 70" Wviwstoia [oman Woo] faoe| aej Drive of stationary alternators Power output and consumption data, Drive of marine alternators ; Trae Tagearaeat | om pee | Mie Tear Chae wont [em pres] Ase terpwawe 25-0 | wnpoanses°C_| row om imepeatz5°¢_| wrpwranres2-c_| oon wom [Application group, 3A 3. ‘Application group 3a 3¢ Engine medel | based on: ‘Gon. power"y | Gonin.power"y| [Engine model | Based on: | Contn. power) | Conn. power) wu Morceder-Bonz ew aw wu Mereodoe Bons w ke sone) sone] sobz| eone| sone] sora | sonz| sone suman | “‘500| “tenn | “i526 “taao| min| “1800| “tooo “1500 | “see ev ies Tase | OWMEA ass] 2st) aor] [evieaTess [oman 2a3[ 367] — 200] 307 aviestexe |omagla zas| 67] aoa] |savimates | omacera ass| sso ass] o20 sav seo Tage | OM 444 222] 77] 400] [Power mtings for shi’ service machinery ve upon request sav ws Tex2 | OMA LA as] a7] ai] U = ~ yaviesToaa | oMAdLA. {82| 654] |) Denon pow for acne pownr gnnarton par OIN 6280 (over sav tas Tea. | OM 44 LA =|] wars] saps] capably 10%), sweesTema_| owas =| =| “soe “ees ‘Cogeneration and special appicaton power atngs upon request ‘Specie tue consumplion wy 1410225 gt¥h(+ 5% oar © ON) 1 Desi power for eeene pow aoe capably 10%n 96:54) — Drive of industrial machiner ry eaon pe DIN 6280 (overoad ‘veroad capably 10% Tana] aparentnt uo pee | [nceenin2s-o_[iewentos© [ibm | tate Application g 4 ma Enns modo] Baas] Falpasa'T | Ratan wu Mecadertene | Siw aw iia | an | | | av yeavasa—[Owara | ger] ta] au] aoe] a0 ae Aviwates2 | omeaca | 260| 2a7| 00) 20! fat) os favaastasa [Owecea, | Sue|aet| ee] ape] en] 23 Kivams ear |Ontececa | es| fey] te] Sea) son| Se davis |Succcia | ata| aos] es] ane] | a3 "Skier SONG Aree” won ees on Luba eonaumption (rund angina: 46:4 05 ot hl coeungson Fe Powe ag ar pct tl csugton ae asd on etal per ON ED ‘Application Groupe as per MTU Definition: 1A Conner ess wi uid preg ra acer mei crn 18 Fat em ssw po aos :05 Fas naa vse ae oo yas wh ow crs 2NDA Ral pain eect goon SA. Bostic ower gern, cons tyro wer] 30 Beare pore rrr carina yen {Cine gene ans, raven, Sowa, eg ce pone 46 Store open: Fre puree, Dw Russ, een wa spy 66a a6. Troubleshooting Fault 61 Starter pinion does not turn or turns too slowly \n addition to property operating and ‘amiaining te engine. fis important tommediately rectty any faults which ‘may suddenly occur, Further informa- ‘von regarding the measures listed under Remedy" can be obtained from Cause Battery insufficiently charged Connecting cable to starter loose Carbon brushes shorting to ground, jamming in guides, or poor contact Solenoid switch of starter faulty Freewheel clutch of starter slipping the sectons Mamtenance" or Jnspec- Von and assembly work". We recom- ‘mand that you contact your MTU or MERCEDES-BENZ Serce Staton for major work, Remedy Chargebatiery Tighten cable at terminal, if necessary, solder on new terminal Clean carbon brushes wih a clean cloth moistened in gasoline (do not use ‘emery paper):renew brushes, it neces. sary Have examined by qualified person 67Troubleshooting Fault 6.2. Engine does not start, or stops again immediately 63. Engine runs irregularly, cuts out or has poor per- formance 68 Cause Fue! tank almost or completely empty Fuo! fitor clogged Fuel ine, precleaner or strainer in fuel tank clogged ‘Leak in fuel system or in seals of fiters, Fue! with insutticiant ticity (Outside temperature too low All causes listed in 6.2 Bypass valves in tuel iter or in injec tion pump do net maintain pressure Vent in fuel tank filler cap clogged Remedy Refuel and bleed fuel syster Clean fier; renew element, if neces sary Clean and bleed system Seal, bleed Wash off wax deposits on strainers and filers, or enew filler element and use winter-grade fuel matched to outside temperature Observe measures for winter operation Check, renew if necessary Clean capTroubleshooting Fault 6.4 Black exhaust Cause Start of dalivery of injection pump incorrectly set Injection nozzles jam or do not atomise Insutticient air at higher speeds because air filter fouled ‘Trottle linkage or control lever not at full stop Exhaust valve for exhaust brake, one ‘or both cylinder banks, or valve at end ‘of exhaust lin is closed or jammea Injection nozzles are damaged or fouled by carbon deposits ‘Sart of delivery of Injection pump incorrectly set Excessive fuel delivery Air filter fouled Exhaust valve for exhaust brake, one ‘or both cylinder banks, or valve at end it exhauict ine ig elosed ar jammed Remedy Sot correctly Henew nozzles Clean air fiter (Check, set correctly itnecessary Check position of exhaust valves: clear jamming valves Renew nozzles Set correctly Check injection pump Clean Check position of exhaust valves: lear jamming valves 60Troubleshooting Fault Cause Remedy 6.5 Blue exhaust 6.6 White exhaust 6.7. Engine pinking 6.8 Engine knocking 70 Cl love! in engine or in oll bath air fiter too high Engine-cil getting into combustion ‘chamber because piston rings jamm- ming, eylinder liners have scoring or ‘excessive play n valve guides, or valve sem seals leaking Gylinder head or cylinder head gasket leaking, coolant getting into combus: tion chamber Leak in nozzle holder or nozzies not property atomising Start of delivery of injection pump Incorrectly sel ‘Bearing damage to crankshatt or dam- age to piston Correct cil evel Have examined in Service Station Measure compression pressure to determine defective cylinder and rectty ‘damage or contact Service Station Renew nozzles Tighten nut of nozzle holder (Check and adjust start of delivery ‘Switch off engine at once and contact Service StationTroubleshooting Fault 6.9 Coolant temperature too high’ 6.10 Engine-oil pressure drops Caution: It pressure drops rapidly. switon off engine at once Cause Insutficient cootant or cooling system ‘not properly vented Belt fox driving coolant pump or fan ingutfcienty tensioned or broken Radiator fouled or clogged with ime on inside; radiator hadly fouled on outside ‘Automatic fan coupling of viscous fan faulty Thermostats faulty il levelin sump too low Engine-oil too thin-bodied Pressure reliel valve blocked or leaking when open, oil pump faulty, of pressure gauge faulty, wear causing excessive bearing play, damage to bearings, Remedy Replenish, vent Tension, or new Clcan or clean out ime deposits Block fan temporarily and contact Ser vice Station at earllest opportunity Renew Pourrin oil up to specified mark on dip- stick Pour in specitied SAE Grades. Check addition of water or fuel. Contact Service Station nTroubleshooting Fault 6.11 Alternator indicator lamp does not light up when ‘engine not running 6.12 Alternator indicator lamp lights up when engine running 2 Cause Bulb tautty or electric tead interrupted V-belt not sutficiently tensioned V-belt broken Alternator, rectifier or regulator fauty Remedy Replace bulb or ectty interruption Check, correct belt tension Renew V-belt ‘Check, have faulty parts renewed in ‘Service Station or other authorised workshop, ifnecossary, |7 Inspection and Installation Work 7.1 Checking start of delivery of injection pump (visual inspection) Setting Stam of delivery Refer to Sectinn 52.2 ‘Special tool Cranking device 407 589 00 63 00 — Reemove cover from inspection hole on clutch housing — Attach eranking device — Read off start of doivary in table of settings (Section 6.2.2) — Position engine to start of dekvery at flywheel with ranking device— Remove plug of inspection hole frm timing case cover Start of delivery marking on input gear and marking on pump flange must be ‘exaclly aligned. ‘Sat ofan ran ae i 747.2 Testing compression pressure Setting Compression pressure at 120 rpm Ditlerence in pressure of individual cylinders Tightening torques in Nm ‘Thrust bolt for nozzle holder Injection ine to pump and nozzle Special tools ‘Compression pressure recorder Connector Pinwrench Pinwrench Slugging tool Wranch socket Serrated wrench Box wrench Refer to Section 5:3 max. 4 bar 70 25 (001 589 47 21 00 403 689 00 21 00, 40 509 02 07 00' 403 589 04 07 00° 355 589.01 63.00, (000 689 68 03 00 (000 589 50 03 00 (000 589 07 03 00 5— Run engine until warm — Unscrew union nut of injection line at nozzie holder with special tool — Slacken union nut at injection pump with box wrench, while holding the pipe ‘connection tight withthe serrated wranch Caution ‘Take care to ensure injection lines are not bent 76— Detach fuel hoses for leak ol or sealing suber from the hose connection — Use pin wrench to unserew thrust bot of nozzle holder— Knock nozzle holder out with slugging too! Note: Leave sealing ring on sealing surtace of cylinder head — Insert connector into cylinder head and tighten thrust bolt with special wrench 18— Screw compression pressure recorder with extension onto connector — Crank engine and continue cranking with injection pump completely switched off. unti the pointer in the compression pressure recorder does not rise any further 97.3 Blocking viscous fan Note: The engine can continue to be operated for a certain period (up to 1000 km wher driving) with the viscous fan blocked. — Turn nut of blocking device counter-clockwise (looking from flywheel) as far as the stop — Slowly rotate fan by hand unl itis felt to engage 80