1-Handout 1600_E - H
07.11.2012 Training presentation Series 1600 Genset engine Hardy Pfaff MTU Training Center © MTU Friedrichshafen GmbH
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07.11.2012
Training presentation Series 1600 Genset engine
Hardy Pfaff MTU Training Center © MTU Friedrichshafen GmbH | All rights reserved | STRICTLY CONFIDENTIAL
Notes
This training documentation is intended exclusively for training purposes and is not subject to regular amendment by MTU Friedrichshafen GmbH. Specified torques and procedures are correct at the time of writing but must be checked before use. The documentation and all illustrations contained in it are protected by copyright. Commercial exploitation and use of any kind requires the prior written consent of MTU Friedrichshafen GmbH.
1st Edition
06/2010
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07.11.2012
Series 1600
8 V 1600 6 R 1600
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10 V 1600 12 V 1600
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6 R 1600
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8 V 1600
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10 V 1600
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12 V 1600
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Features of Series 1600 PowerGen engine Modular engine design Robust design for long service life High torsional rigidity of crank-case Variable fan position Thermodynamics and turbocharging optimized for gendrive applications Maximum standardization within the engine family Different versions of radiator, alternator, etc. available Own consumables specifications Standardized interfaces within the engine family
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Facts and figures Engine type
No. of cylinders and configuration
Power output in KW
Total capacity
Engine oil/coolant capacity
Engine weight, dry
in liters
in liters
in kg
6R 1600 G F/S
6 cylinders
249-343
10.5
46/
1150
3B-3D application
in line
8V 1600 G F/S
8 cylinders
3B-3D application
In 90°V configuration
10V 1600 G F/S
10 cylinders
3B-3D application
In 90°V configuration
12V 1600 G F/S
12 cylinders
3B-3D application
In 90°V configuration
45 325-448
14
46/
1444
50 407-561
17.5
60.5/
1749
60 524-668
21
72.5/
2022
65
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Series 1600 engine data
Bore/Stroke:
122/150 mm
Cylinder capacity
1.75 ltr
Compression ratio: 17.5 : 1 Max. ignition pressure:
200 bar
Single-stage turbocharging:
1 x Garrett GT 35 on 6 R 1600 G 2 x Garrett GT 42 on 8+10 V 1600 G 2 x Garrett GT 45 on 12 V 1600 G
Emissions:
> 560 KW EPA Tier 2/EU IIIA TA Luft 1500 mg NOx < 560 KW EPA Tier 3/EU IIIB
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Series 1600 engine data
Turbocharger boost pressure
2.77-3.2 bar
Minimum cold-starting temperature without preheating
-20 °C
Valves
2 x inlet 2 x exhaust
Common rail fuel injection system:
1,600 bar
High-pressure injection pumps:
Bosch CP 3.3
Injector type:
Bosch CRIN 3
Electronic engine management
ECU-8
More information can be obtained from the following sources: Operating Instructions QL1: MS ................ D 6 R, 8 V+10 V 1600 G (not yet available) Operating Instructions QL1: MS 15007600 D 10 V+12 V 1600 G MTU Business Portal: Technical sales documentation (TVU) 6 R, 8 V,10 V+12 V 1600 G
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Engine designation and applications 12 V 1600 G 8 0 F
3B-3D Application Application
Additional information Design index Application Series Cylinder configuration Number of cylinders
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V = Vee engine, R = Inline engine H = Horizontal engine
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Application and application group
Additional information Frequency 50 Hz at 1500 rpm
F
Frequency 60 Hz at 1800 rpm
S
Application
Application type
3B
Continuous duty at variable load
3C
Peak-demand duty at variable load
3D
Emergency backup duty at maximum load
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Series 1600 genset engine (as installed)
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Designation of engine ends and cylinders Cylinder designation: 12V1600 A1-A6 B1-B6
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Tightening specifications for standard threaded fixings Tightening specifications for nuts and bolts Tightening torques for set-screws and studs to standard MTN 5008 This standard applies to dynamically unstressed set-screws to MMN 384, DIN 912, EN 24014 (DIN 931-1), EN 24017 (DIN 933), EN 28765 (DIN 960), EN 28676 (DIN 961), DIN 6912 and to stud bolts to DIN 833, DIN 835, DIN 836, DIN 938, DIN 939 and the matching nuts. It does not apply to heat-resistant bolts in the hot components zone. The tightening torques specified are MA ratings for strength class 8.8 (surface finish bare, phosphated or galvanized) and 10.9 (surface finish bare or phosphated). The figures in the table are based on a frictional coefficient of µtot. = 0.125. Requirement: threads and contact faces of the nuts and bolts must be lubricated with engine oil before fitting. When tightening by hand (defined tightening), a fitting tolerance of +10% is permissible to allow for the unavoidable divergence of the tightening torques from the table figures, e.g. due to inaccurate reading and overtightening when fitting.
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Tightening specification for set screw and stud connections
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Tightening specification for set screw and stud connections
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Tightening specifications for plug bolts Tightening torques for plug bolts to standard MTN 5183-1 This standard applies to plug bolts to DIN 908, DIN 910 and DIN 7604 with DIN 3852 Form A threaded end (sealed by DIN 7603-Cu washer). The tightening torques specified are MA ratings for plug bolts made of steel (St) with a phosphated and oiled or galvanized protective surface finish. Threads and contact faces under the head must be lubricated with engine oil before fitting. A fitting tolerance of +10% is permissible to allow for the unavoidable divergence of the tightening torques from the table figures, e.g. due to inaccurate reading and overtightening when fitting. Tightening torques for plug bolts to DIN 908, DIN 910 and DIN 7604A (with short threaded end)
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Tightening specifications for plug bolts
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Tightening specifications for plug bolts
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Tightening specifications for banjo bolts Tightening torques for banjo bolts to standard MTN 5183-2 This standard applies to banjo bolts to standards MMN 223 and N 15011 with DIN 7603 Cu sealing washer. The tightening torques specified are MA ratings for banjo bolts made of steel (St) with a phosphated and oiled or galvanized protective surface finish and made of copper-aluminum alloys. Threads and contact faces under the head must be lubricated with engine oil before fitting. A fitting tolerance of +10% of the table figure is permissible to allow for the unavoidable divergence of the tightening torques from the table figures, e.g. due to inaccurate reading and overtightening when fitting.
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Tightening specifications for banjo bolts
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Tightening specifications for sleeve nuts Tightening torques for sleeve nuts to standard MTN 3859-2
1 Sleeve nut 2 Union body 3 O-ring 4 Ball sleeve
Sleeve nut: when fitting the ball sleeve, the sleeve nut should be hand tightened (to perceptible increase in resistance) and then tightened a further ¼ turn (90°) beyond that point.
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Overview of sensors and actuators on Series 1600 (pictures show 12 V 1600 G) B10
M8.2
B09
B48.2
M8.1
XY 39B2 B13 B01
XY 39B1
B01
Camshaft speed
B13
Crankshaft speed
B09
Boost air temp
B10
Boost air pressure
B48.2
B rail pressure
M8.1
Metering unit A
M8.2
Metering unit B
XY 39B1
Injector B1 connector
XY 39B2
Injector B2 connector
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Overview of sensors and actuators on Series 1600 (pictures show 12 V 1600 G) X2 B06
X1
B05
XY 39A1 B16
XY 39A2 B48.1
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B05
Oil pressure
B06
Coolant temp
B16
Coolant pressure
B48.1
A rail pressure
XY 39A1
Injector A1 connector
XY 39A2
Injector A2 connector
X1
Plant interface
X2
Sensor interface
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Oil pressure sensor & rail pressure sensor, bank A B05 Oil pressure sensor: Sensing range:
0-10 bar
Voltage:
5 V +/- 0.25 V
Signal:
0.5 – 4.5 V
B48.1
Rail pressure sensor,
bank A: Sensing range:
0-1800 bar
Voltage:
5 V +/- 0.25 V
Signal:
0.5 – 4.5 V
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Rail pressure sensor, bank B & coolant temperature sensor B48.2
Rail pressure sensor,
bank B: Sensing range:
0-1800 bar
Voltage:
5 V +/- 0.25 V
Signal:
0.5 – 4.5 V
B06 Coolant temperature sensor
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Sensor type:
PT 1000
Sensing range:
-40°...150 °C
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Sensors for boost air temperature and boost pressure B09 Boost air temperature sensor: Sensor type:
PT 1000
Sensing range:
-40°C...150°C
B10 Boost pressure: Sensing range:
0.5 – 6.0 bar
Voltage:
5 V +/- 0.25 V
Signal:
0.5 – 4.5 V
Measures absolute pressure!
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Speed sensors for camshaft and crankshaft
B01 Camshaft speed sensor: R = 860 Ohm +/-10% at 20 °C B13 Crankshaft speed sensor: R = 860 Ohm +/-10% at 20 °C
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Coolant pressure sensor
B16 Coolant pressure sensor: Sensing range:
0.0 – 6.0 bar
Voltage:
5 V +/- 0.25 V
Signal:
0.5 – 4.5 V
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PWM signal: control of high-pressure injection pumps ECU interfaces X1 and X2 X1 M8.1
X2
M8.2
PWM (pulse width modulation signal) M8.1 Metering unit, A-bank pump M8.2 Metering unit, B-bank pump Voltage:
24 V
Current:
3A
Frequency:
< 500 Hz
X1 Engine to plant:
62 pins
X2 Sensors and actuators: 92 pins
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Tightening specifications for sensors
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ECU-8 engine management ECU (electronic control unit) Functions of ECU-8
Converts the instructions from the remote monitoring and control system into signals for the engine management Controls the fuel injection system Controls other actuators on the engine Reads the sensor signals and analyzes the operating statuses of the engine Can be cooled using the approved fluids as per consumables specifications: connections 1 and 2
1. 2.
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ECU-8 engine management ECU (electronic control unit) Functions of ECU-8 Monitors readings for compliance with limits in abnormal conditions/ if readings are outside limits: • Initiates engine shutdown if necessary • Communicates fault signals to monitoring and control systems • Downloads engine and system-related settings • ITS self-monitoring system • Fault diagnosis using interactive device (laptop)
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Removing and refitting ECU-8 (electronic control unit)
Unplug connectors X1 and X2 from ECU-8. Remove the wiring loom. Detach the bracket from the fuel rail lead on A and B side. Remove the fixing screws (3). Remove ECU-8 and bracket from the engine. Refit in reverse order of removal.
1. ECU-8 2. Bracket 3. Screw
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4. Vibration absorber 5. Screw 6. Washer
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Series 1600 starter motor
Starter motor:
Prestolite M105R300SE HD
Voltage:
24 V
Power:
8 KW
Starter relay mounted on starter motor
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Series 1600 alternator
Manufacturer: Prestolite MDP 3939H-P Rating:
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28 V/55 A
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Overview of intake and exhaust systems Schematic diagram of intake and (12 V 1600 G illustrated) exhaust systems: XZ57514000010 Air intake routing: The intake air is drawn in through the air filter and passes through the intake neck (4) into the turbocharger compressor housing (5). pressed air After beg compressed by the 1
turbocharger, the coinm – which is also heated by compression – passes from the boost air outlet (7) to the intercooler. After being cooled by the intercooler, the cooled and compressed air passes through the intake manifold (10) into the intake duct integrated in the cylinder head.
1
Referred to as TC from now on
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Air filter, standard version
Low-pressure indicator 1. 2. 3.
1. 2. 3.
Reset button Indicator ring Viewing window with scale
Connection socket Clip Air filter
With both types of air filter: After replacing the air filter, the reset button (1) must be pressed to reactivate the function of the low-pressure indicator.
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Air filter, high-performance version 1. 2. 3. 4. 5. 6. 7. 8. 9.
Service cover Snap fastener Coarse dirt valve Filter insert Filter element Filter housing Clean air outlet Low-pressure indicator connection Air inlet
With both types of air filter: Air filter insert must be replaced every 3000 hours of duty or every 3 years
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Intake and exhaust systems (12 V 1600 G illustrated) Exhaust routing: The boost air enters the combustion chamber where it is mixed with fuel and burned at high pressure. The exhaust gas produced (orange arrows) passes out through the exhaust manifold and into the turbocharger turbine housing where it drives the turbine. The turbine is connected by a shaft to the impeller, which in turn compresses the intake air drawn in. From that point the exhaust passes into the plant's exhaust system.
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Removing and refitting the air intake system (12 V 1600 G illustrated)
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Removing and refitting the turbocharger
1. Remove the air intake duct from the air filter and plant exhaust system. 2. Remove the crankcase vent pipe and oil supply and return pipes from the turbocharger 3. Undo the 4 hexagonal nuts (50) and remove these together with the turbocharger. 4. Remove the gasket and seal openings with suitable covers. 5. Clean the sealing faces and check for damage. 6. When fitting a new turbocharger, the position of the compressor and bearing housing has to be rotated on the right-hand side of the engine. 10 Turbocharger To do so proceed as follows:
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20 Gasket 30 Stud bolt 40 Washer 50 Hexagonal nut
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Removing and refitting the turbocharger Loosen the initially tightened setting and then tighten to approx. 5.6 Nm Set the turbine housing inlet/ bearing housing oil inlet to 47.5°. Set the turbine housing inlet/ compressor housing outlet to 68°. Retighten the nuts to between 14.6 and 16.9 Nm. 7. Replace the 4 stud bolts (30) if necessary. 8. Coat the thread of the stud bolt (30) with the fitting compound (Ultra-Therm MTU) 50547 on the turbocharger end and fit the turbocharger with the new gasket. 9. Refit all the components in reverse order of removal and tighten the turbocharger nuts in diagonal sequence to 21 + 2Nm.
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Removing and refitting the exhaust system (illustration: 12 V 1600 G)
Gasket X57514100086
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Note installation position
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Removing and refitting the exhaust system (illustration: 12 V 1600 G) Multilayer gasket annular slot openings must be offset at 180°to one another. Coat the fixing bolts with fitting compound (Ultra-Therm MTU) 50547 on the contact face and thread. Fit the exhaust system and insert the bolts by hand. Tighten the bolts in three stages according to the numbered sequence. Pretighten to 10 +/-2 Nm, initially tighten to 60 +6 Nm, finally turn a further 90°+10°.
Specified torques apply to 6 R, 8 V, 10 V and 12 V 1600 G
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Checking the condition of the drive belts for the fan and alternator/water pump Check the condition of the drive belts every 1000 hours of duty or every 2 years. Replace if necessary. Check the condition of the drive belts every 3000 hours of duty or every 2 years.
Position
Condition
Drive belt A
Isolated cracks
Action None
Drive belt B
Cracks over entire length
Replace
Drive belt C
Pieces broken off
Replace
Drive belt
Oily, overheated
Replace
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Checking/adjusting the tension of the drive belts for the fan and the alternator/water pump Tension gauge, 500-1400 N
Y20097430
1
Tension gauge, 1300-3100 N
Y20097431
1
Check the tension every 1000 hours of duty or every 2 years. Adjust the tension if necessary.
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Replacing and adjusting the tension of the fan drive belt
Testing point
Application
Initial assembly measured value
Measured value for operating voltage after 1 hour
Measured value for minimum operating voltage
Drive belt – fan
2250 N
1620 N
1080 N
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Replacing the alternator/water pump drive belt Drive belt with automatic tensioner pulley
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Replacing and adjusting the tension of the water pump drive belt Drive belt with mechanical belt tensioner
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Replacing and adjusting the tension of the water pump drive belt
Testing point
Application
Initial assembly measured value
Measured value for operating voltage after 1 hour
Measured value for minimum operating voltage
Drive belt – fan
1000 N
720 N
480 N
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Removing the flywheel 2
1. Remove the crankshaft speed sensor. 2. Attach the lifting bracket (1) T80092452. 3. Fit the locking device (2) F6790714 to the hole at the bottom of the flywheel housing on A-side.
1
4. Lock the crankshaft with the locking tool and loosen the fixing bolts. 5. Unscrew the 2 fixing bolts and screw in the two F30452741 guide bolts (3)
3
7. Unscrew the remaining bolts. 8. Remove the flywheel using the lifting bracket (1).
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Fitting the flywheel
1. Screw in the two F30452741 guide bolts (3). 2. Place the flywheel in the correct position using the lifting bracket and paying attention to the locating dowel. 3. Check that the bolt length is within the limit of 96 mm
1
and replace the bolts if necessary. 4. Lubricate the bolt threads and contact faces with engine oil. 5. Screw in the bolts and tighten evenly in diagonal sequence. 3
6. Unscrew the guide bolts and remove the lifting bracket (1). 7. Screw in the remaining bolts. 8. Lock the crankshaft with the locking device. 9. Tighten the bolts to the specified torque in diagonal sequence using a torque wrench. 10. Pretighten to 200 Nm + 20 Nm then turn a further 90°+ 5°; test torque: 300 Nm + 20 Nm. 11. If a bolt turns further when the test torque is applied, the procedure must be repeated. 12. Remove the locking device.
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Replacing the shaft seal on the main PTO end 1. Remove the flywheel. 2. Remove the shaft seal using a suitable tool. 3. Do not damage the flywheel housing or crankshaft. 4. Check the seat in the flywheel housing and crankshaft for damage and that they are clean. 5. Fit the shaft seal with the lip facing outwards on the seal fitting tool F6789655. 6. Coat the shaft seal lip with engine oil. 7. Clean the shaft seal seat in the flywheel housing with ethanol to remove all grease and leave to dry. Note: oil the contact area of the crankshaft, lightly coat the seat in the flywheel housing with ethanol. 8. Fit the shaft seal into the flywheel housing using the seal fitting tool. 9. Remove the seal fitting tool. 10. Refit the flywheel.
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Removing the vibration damper
50. Vibration damper 100. Belt pulley 200. Bolt
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Fitting the vibration damper
1. Screw in the two F30373474 alignment bolts (1). 2. Check that the bolt length is within the limit of 101 mm and replace the bolts if necessary.. 3. Lubricate the bolt threads and contact faces with engine oil. 4. Screw in the bolts and unscrew the two alignment bolts (1) 1
5. Screw in the remaining bolts. 6. Tighten the bolts to the specified torque. Pretighten to: 50 Nm + 5 Nm Then turn a further: 90°+ 5° Test torque: 70 Nm + 5 Nm 7. Refit all the parts.
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Replacing the shaft seal on the auxiliary PTO end 1. Remove the belt pulley and vibration damper. 2. Remove the shaft seal using a suitable tool. 3. Do not damage the sealing flange or crankshaft. 4. Check the seat in the sealing flange and crankshaft for damage and that they are clean. 5. Fit the shaft seal with the lip facing outwards on the seal fitting tool F6789668. 6. Coat the shaft seal lip with engine oil. 7. Clean the shaft seal seat in the sealing flange with ethanol to remove all grease and leave to dry. Note: Oil the contact area of the crankshaft, lightly coat the seat in the sealing flange with ethanol. 8. Fit the shaft seal into the sealing flange using the seal fitting tool. 9. Remove the seal fitting tool and refit the belt pulley and vibration damper.
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Engine coolant circulation system Cooling system diagram: XZ57520000001 Additional information and data can be obtained from the consumables specifications A001063/00D. 1. Use only approved coolant additives. 2. Mixing different coolant additives or supplementary additives is not allowed! 3. Check the composition of the coolant once a year and adjust as necessary. 4. The coolant must be replaced every 9000 hours of service or after 5 years at the latest. 5. Only check the coolant level when the engine is not running and is cold (mark on expansion tank). Coolant flow through crankcase: The coolant flows directly from the water pump to the oil coolers (arrowed). It then circulates around the cylinder liners and finally through the cylinder heads.
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Engine coolant circulation system Coolant from cylinder heads on A and B-sides To radiator
To crankcase The diagram on the left shows the flow of coolant when the engine is cold; the thermostats are closed and the coolant flows straight back to the oil coolers. The diagram on the right shows the flow when the engine is warm; the thermostats are open and the coolant flows out to the radiator and comes back cooled.
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From radiator
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Replacing the engine coolant 1. Open the cap on the expansion tank. 2. Drain off the coolant via the drain plugs (1) and (2). 7. Fit the new sealing washers to the drain plugs, apply a coat of oil to the threads and sealing washers and tighten the drain plugs to 100 Nm. 8. Mix the coolant as per the consumables specifications and pour into the expansion tank until it reaches the mark. 9. Check the cap is in perfect condition and clean the seal faces if necessary. 10. Refit the cap and start the engine. 11. Run the engine for approx. 10 minutes at idling speed and then recheck the coolant level.
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Water pump and attached components
50 Water pump with two Behr 83°thermostats 60 Bolt 70 Pipe insert 80 Coolant pipe (from radiator) 90 A-side coolant pipe with socket for pipe insert 100 B-side coolant pipe with socket for pipe insert 130 Water pump gasket 140 Gasket 150 Bolt 160 Bolt 170 Temperature sensor 180 Gasket (fitted on A-side and B-side) 190 Flow restrictor (fitted on A-side and B-side)
190
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Removing/refitting the water pump
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Removing/refitting the water pump
Coolant pump manufacturer: GPM Flow rate: 526 l/min at 1500 rpm
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Cylinder head cover and cover gasket (4) Cylinder head cover (A-side and B-side identical) (5) Fixing bolts with flanged head (tighten in diagonal sequence working from inside to outside) Step 1 = 10 Nm Step 2 = 20 Nm
1
2
4 5
3
(1) Cover gasket (A-side and B-side identical, backing material plastic with integral rubber molding) (2) Fuel injector wiring loom integrated in cover gasket (3) Fixing nuts are attached to the wiring loom Tightening torque: 1.5 Nm
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07.11.2012
Removing and refitting the cylinder head cover and cover gasket
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Fuel system: Low pressure system
Fuel system diagram: XZ57507000001
6 1
5
2
(8) Fuel return from fuel injector header pipe (9) Fuel return from high-pressure pumps (10) Fuel return from safety valve (11) Fuel return from engine to tank (fuel cooler recommended)
3
4
10
7 8 (1) Fuel supply from tank (2) Fuel inlet to low-pressure pump (3) Fuel outlet from low-pressure pump (4) Fuel inlet to fuel filter (5) Fuel outlet from fuel filter (6) Fuel inlet to high-pressure pump; transfer to metering unit (7) Fuel filter
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11
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Fuel system: Low pressure system Replacing the fuel filter: (replace every 500 hours of duty or at least every 2 years). 1. Loosen the filter cartridge using filter remover F30379104 and then remove by hand. 2. Clean the sealing face on the filter head and check for damage. 3. Apply a thin coat of oil to the seal of the new filter cartridge. 4. Screw on the filter cartridge by hand until the seal is in contact then tighten by hand. 5. Bleed the fuel system.
F30379104
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Fuel system: Low-pressure system Bleeding the fuel system 1. Unlock the fuel hand pump and unscrew the handle (1). 2. Undo the nut (2) on the banjo bolt connection. Note: catch escaping fuel with a suitable cloth. 3. Using the handle (1), pump the pump until the fuel exiting at the nut (2) contains no bubbles. 4. Retighten the nut (2) on the banjo bolt connection. 5. Lock the fuel hand pump by screwing in the handle (1).
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07.11.2012
Fuel system: High-pressure system
Fuel system diagram: XZ57507000001
Complete high-pressure system supplied by Bosch (max. 1600 bar) 3
2
(1) High-pressure pumps identical on A-side and B-side 6 R 1600
1 High-pressure pump
8 V 1600
2 High-pressure pumps
10 V 1600
2 High-pressure pumps
12 V 1600
2 High-pressure pumps
4
(2) Fuel rails identical on A-side and B-side
6
(3) 12 CRIN 3 fuel injectors (6 fuel outlet jets) (4) 12 high-pressure fuel lines
7
(5) 12 high-pressure connecting spigots (6) A-side high-pressure fuel line (7) B-side high-pressure fuel line 1
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Fuel system: Common rail fuel injector for Series 1600 genset engine
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07.11.2012
Fuel system: Removing the high-pressure system 1. Remove the cylinder head cover and disconnect the wiring. 2. Disconnect and remove the high-pressure fuel lines (1). 3. Remove the high-pressure fuel line from the high-pressure pump to the fuel rail on A-side and B-side. 4. Undo the sleeve nut (2) and remove the high-pressure connecting spigot (3). 5. Undo the shackle and unscrew the bolt then remove the fuel injector using the extractor tool F6790992 (4). 6. If the same fuel injectors are to be reused, then the sealing ring between the cylinder head and the fuel injector and the O-ring for sealing off the low-pressure system must be replaced. If new fuel injectors are to be used, new items of those components are supplied. 7. Remove the sealing ring from the fuel injector or use a self-fashioned wire hook to remove it from the cylinder head.
4
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Fuel system: Removing the high-pressure system 8. Remove the O-rings from the fuel injector. 9. Seal off the openings with suitable covers. 10. Unplug the wiring from the fuel pressure sensor B48.1 (A-side) and B48.2 (B-side). 11. Undo the pipe brackets and remove the fuel rail. 12. If necessary, use the milling tool F30452390 (5)
Fuel rail: Single-wall design Safety valve integrated in rail Opening pressure 1950 (-100) bar
to remove oil coking from the rail bore. Note: Shackle bolt, high-pressure connecting spigot, high-pressure fuel lines and injector seal should only be used once.
5
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Fuel system: Refitting the high-pressure system 13. Before fitting the components, remove all covers. 14. If a used injector is to be refitted, fit a new O-ring on the injector and fit a new sealing ring. 15. Apply a coat of grease (Kluthe Hakuform 30-10/Emulsion) to the O-ring on the injector and use fitting paste 40477 (Optimoly Paste White T) to hold the sealing ring on the injector. 16. Slide the injector and shackle together into the cylinder head. Caution: pay attention to the installation position of injector (port/rounded side facing upwards) 17. Fit the injector into the cylinder head using the fitting tool F6790085 (6), lubricate the new shackle bolt with engine oil and screw in by hand.
6
Result: it should still be possible to the rotate injector.
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Fuel system: Refitting the high-pressure system 18. Apply a coat of engine oil to the conical sealing face at the tip and the contact face of the new high-pressure connecting spigot. 19. Lubricate the O-ring on the high-pressure connecting spigot (3) with grease (Kluthe Hakuform 30-10/Emulsion) and press the high-pressure connecting spigot by hand into the hole facing the right way round (key). 20. Coat the sleeve nut (2) with engine oil on the thread and sealing face and screw on by hand. 21. Using the torque wrench, tighten the sleeve nut (2) to the specified pretightening torque of 15 Nm +5 Nm. Result: the injector should be fixed in position. 22. Tighten the new shackle bolt using the torque wrench to the specified tightening torque of 18 Nm +2 Nm and then turn a further 90°+5°.
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07.11.2012
Fuel system: Refitting the high-pressure system 23. Tighten the sleeve nut (2) on the high-pressure connecting spigot to the specified tightening torque of 45 Nm +5 Nm. 24. Fix the fuel rail to the cylinder head using the pipe brackets (3). 25. Apply a coat of engine oil to the sealing faces of the new high-pressure fuel lines (1) and screw on by hand. 26. Lubricate the new high-pressure fuel lines (4) from the high-pressure pump to the fuel rail and screw on by hand.
2 3
Result: the fuel rail and high-pressure lines should be
1
fixed without being under strain. 26. Tighten the fixing bolts on the pipe brackets (3) to fix the fuel rail to the specified torque. 27. Tighten the high-pressure fuel lines to a torque of 30 Nm +3 Nm. 28. Refit the cylinder head cover gasket and cover and
4
reconnect the wiring.
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Fuel system: Removing/refitting the high-pressure pump Nut tightening torque 105 Nm ±5 Nm.
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07.11.2012
Fuel system: Removing/refitting the high-pressure pump • Refit the high-pressure pump with the new O-ring and tighten to a torque of 30 Nm ±5 Nm. • High-pressure lines from the high-pressure pump to the fuel rail on A-side and B-side must be replaced. • Tightening torque for high-pressure line connection to the rail and high-pressure pump 30 Nm ±3 Nm.
Note: The low-pressure fuel pump (1) is mounted on the high-pressure pump and both are driven by a common pump shaft.
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Bosch CP 3.3 high-pressure pump
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40
07.11.2012
Camshaft and pump gear train
Spur-gear gear train B-side camshaft sprocket is fitted in a defined position on the shaft. The remaining gears do not have defined installation positions. The gear bearings are pressure-lubricated. The bearing journals can only be fitted in one position.
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Removing the camshaft on A-side and B-side 1. Fit the locking device F6790714 to the flywheel housing. 2. Set the engine to ignition TDC using the locking device (mark and pointer must be aligned) 3. Lock the flywheel using the locking device. 4. Remove the fuel filter together with the bracket and pipes. 5. Remove the camshaft speed sensor. 6. Remove the from the camshaft sprocket housings. 7. Loosen the camshaft sprocket bolt and unscrew it. 8. Remove the camshaft sprocket using the sprocket puller F30452747.
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41
07.11.2012
Refitting the camshaft sprocket on A-side and B-side (setting timing) 1. The precondition for fitting the camshaft sprockets is that the crankshaft is at ignition TDC. 2. If the crankshaft position has not been moved, reassembly can be started from this point. 3. If the crankshaft position has been moved, it must be reset using apparatus Y4347481 and a dial gauge. 4. Rotate the camshaft so that the part number and the three machined flats are facing upwards and lock in position at ignition TDC using the locking device F6790717. 5. Clean the camshaft taper and the inside of camshaft sprocket hub and fit the camshaft sprocket dry. Important: The B-side camshaft sprocket must be fitted in a defined position relative to the shaft. The recess must be aligned with the center of the hole for the speed sensor.
Y4347481
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Refitting the camshaft on A-side and B-side 6. Screw in the bolt and washer by hand. 7. Lock the crankshaft using the attached locking device. 8. Tighten the bolt to the specified torque of 105 Nm ±5 Nm using a torque wrench. 9. Clean the sealing faces on the camshaft sprocket housing and cover to remove all grease and coat with Loctite 573. 10. Reassemble the components in reverse order of removal and tighten to the specified torque.
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07.11.2012
Camshaft sprocket housings on A-side and B-side 210 Housing for camshaft sprocket (LH side of engine) 270 Bolt (cover to housing) 320 Bolt (housing to crankcase) 330 Bolt (housing to crankcase) 360 Cover for housing (A-side) 370 Sealant (Loctite 573) 380 Bolt (cover to housing) 510 Housing for camshaft sprocket (RH side of engine) 570 Bolt (housing to cylinder head) 580 Stud bolt (speed sensor alignment) 620 Bolt (housing to crankcase) 630 Bolt (housing to crankcase) 660 Cover for housing (B-side) 670 Sealant (Loctite 573) 680 Bolt (cover to housing) 710 Speed sensor 720 Bolt (speed sensor to housing) 730 Gasket for housing (seal with cylinder head) 740 Gasket for housing (seal with crankcase, RH side of engine) 750 Gasket for housing (seal with crankcase, LH side of engine)
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Removing/refitting the camshaft sprocket housings on A-side and B-side 1. Remove the camshaft sprockets on A-side and B-side. 2. Remove the camshaft sprocket housings on A-side and B-side, remove the old gaskets and clean the sealing faces. 3. Stick the new gaskets (items 730, 740, 750 ) in place and refit the camshaft sprocket housings and bolts by hand. Important: the camshaft sprocket housing on B-side only fits in one position. This serves to define the distance between the camshaft speed sensor and the pin in the camshaft sprocket. 4. Tighten the bolts to the specified torque in the following sequence: Camshaft sprocket housing to cylinder head:
pretighten to 5 Nm
Camshaft sprocket housing to crankcase:
pretighten to 15 Nm
Camshaft sprocket housing to crankcase:
tighten to 31 Nm
Camshaft sprocket housing to cylinder head:
tighten to 31 Nm
5. Refit the camshaft sprockets on A-side and B-side.
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07.11.2012
Overall view: Rockers, camshaft and cylinder head 52 Cylinder head 60 Bearing shell 70 Valve yoke 80 Camshaft 130 Cylinder head gasket 135 Bolt 360 Rocker pedestal
Features: • Cylinder heads for inline 6 and V12 engines identical • A-bank and B-bank have identical cylinder heads • 2 inlet and 2 exhaust valves • SOHC - single overhead camshaft
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Valve gear and cylinder head: Removing rockers, camshaft and cylinder head 1. Drain off the engine coolant. 2. Remove the ECU-8 engine management ECU and bracket. 3. Remove the intake manifold. 4. Remove the turbocharger and exhaust system on A-side and B-side. 5. Remove the coolant pipe to water pump on A-side and B-side. 6. Remove the cylinder head cover and gasket on A-side and B-side. 7. Dismantle the low-pressure fuel system on A-side and B-side in the fuel return area. 8. If replacing the cylinder head, the entire high-pressure fuel system must be removed and swapped over. If the same cylinder head is to be refitted, only the high-pressure fuel line between the fuel rail and the high-pressure pump is removed. 9. Remove the engine lifting eyes and sealing covers. 10. Remove the camshaft sprockets and camshaft sprocket housings on A-side and B-side. 11. Remove the rocker bearing pedestals as shown in the illustration. 12. Undo the camshaft in reverse order of tightening sequence as per drawing no. XZ57504000015. 13. Remove the camshaft bearing pedestals and fixing bolts and then remove the camshaft.
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07.11.2012
Valve gear and cylinder head: Removing rockers, camshaft and cylinder head 14. Undo the cylinder head bolts in reverse order of the specified tightening sequence and unscrew all except two bolts. 15. Fit the lifting beam T80092463 and attach it to the crane. 16. Unscrew the last two cylinder head bolts. 17. Lift the cylinder head off the crankcase with the aid of lifting beam T80092463 and a crane. 18. Seal off all openings by suitable means.
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Valve gear and cylinder head: Refitting cylinder head, camshaft and rockers 1. Remove all sealing caps and adhesive tape from the openings. 2. Clean the crankcase mating surface. 3. Place the new cylinder head gasket in position (gaskets identical on both sides). 4. Screw the two F30451398 guide bolts into crankcase. 5. Lower the cylinder head on to the crankcase using the lifting beam T80092463. 6. Check that the cylinder head bolt length is within the maximum limit (282 mm). 7. Lubricate the cylinder head bolt threads and contact faces with engine oil. 8. Screw in the cylinder head bolts by hand. 9. Remove the lifting beam from the cylinder head and unscrew the guide bolts. 10. Screw in the missing cylinder head bolts. 11. Tighten the fixing bolts in the specified sequence from A-Z. 12. Cylinder head bolt tightening specifications: pretighteing torque: 300 +30 Nm Then turn a further: 180° 13. Special tool F6790757 is recommended for applying the additional turn.
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07.11.2012
Schematic diagram of the cylinder head bolt tightening sequence 2
4
3
6
5
8
7
10
9
12
14
11
1
13 17
15 18 16
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Valve gear and cylinder head: Refitting cylinder head, camshaft and rockers 14. Clean the camshaft bearing seats and fit the camshaft bearings (same camshaft bearings top and bottom). 15. Oil the camshaft bearings and fit the camshaft in the cylinder head 16. Clean the outer camshaft bearing caps on the contact faces where they meet the cylinder head using cleaner (Loctite 7061). 17. Apply sealant (Loctite 518) and screw the bearing caps in place by hand using fixing bolts. 18. Clean the remaining camshaft bearing caps and similarly screw in place by hand using fixing bolts. 19. Note: pay attention to the camshaft bearing cap numbering. 20. Tighten the camshaft bearing caps as follows: step 1: 10 Nm, step 2: 30+3 Nm 1-18 shown by red arrows. 21. Place the rocker bearing pedestals and fixing bolts in place by hand. 22. Note: relieve pressure on open valves by unscrewing valve clearance adjustment screws. 23. Tighten the rocker bearing pedestal fixing bolts to a torque of 100 Nm +10 Nm. 24. Refit the components in reverse order of removal. 25. Adjust the clearance of the inlet and exhaust valves.
Inlet: 0.3 mm Exhaust: 0.6 mm 26. Refit the components in reverse order of removal. 27. Refill the cooling system.
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07.11.2012
Engine lifting eyes and sealing covers on cylinder head
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Lubrication system Lubrication system diagram: XZ57518000003 Main oil channel
Clean oil from oil module
Oil supply to cylinder head
Oil injectors for cooling pistons
Oil supply to turbocharger
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07.11.2012
Lubrication system Oil supply to camshaft bearings and valve gear
Oil channel in cylinder head
Oil supply from cyl. head oil channel Oil supply from crankcase
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Lubrication system Oil module Oil filter
Manufacturer of oil module: MAHLE Filters Oil filter Oil separators
Crankcase venting
Oil cooler Oil pressure sensor Oil cooler
Bypass valve for Filter Oil cooler
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07.11.2012
Lubrication system: Oil module and attached components 10 Oil module 20 Gasket 30 External Torx head bolt
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Lubrication system Removing and refitting the oil module 1. Drain the cooling system. 2. Remove the intake manifold. 3. Disconnect the crankcase vent pipes. 4. Remove the oil module. 5. Clean the sealing faces on the crankcase and check for damage. 6. Refit the oil module with a new gasket and screw in the bolts by hand. 7. Tighten the fixing bolts in the specified sequence to a torque of 28 Nm ±3 Nm. 8. Refit the components in reverse order of removal. 9. Refill the cooling system.
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07.11.2012
Lubrication system Oil module and bypass valves Bypass valve for oil cooler 2.5 bar
Bypass valve for oil cooler 2.5 bar ± 0.5 bar
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Lubrication system: Oil supply to turbocharger Oil inlet to turbocharger
Single-stage turbocharging: 1 x Garrett GT 35 on 6R 1600 G 2 x Garrett GT 42 on 8+10 V 1600 G 2 x Garrett GT 45 on 12 V 1600 G Return
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07.11.2012
Lubrication system Plastic sump Oil pump
To oil module
Pressure relief valve
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Lubrication system Plastic sump
Plastic sump: Manufacturer: HUMMEL-Formen GmbH Material: Ultramid Standing the engine on the sump is not allowed! Follow the specified tightening sequence.
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07.11.2012
Lubrication system Removing and refitting the sump 1. Drain off the engine oil 2. Remove the dipstick 3. Loosen the sump bolts and unscrew them. 4. Clean the sealing face with easy cleaner (Loctite 7061). 5. Check the sealing face and molding and if necessary replace the molding. 6. At the junctions apply silicon rubber (Loctite 5970). 7. Fit four F30452998 guide pins in and place the sump in position. 8. Tighten the bolts 1-16 in order to a torque of 10 Nm ±1.5 Nm.
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Lubrication system Removing and refitting the sump 9. Unscrew the four guide pins from the positions marked 2. 10. Screw in the remaining bolts and similarly tighten to a torque of 10 Nm ±1.5 Nm. 11. Tighten all bolts in the specified sequence to a torque of 21 Nm ±2 Nm. 12. Refit the attached components in reverse order of removal. 13. Refill the engine with oil (oil capacity as per data sheet, oil quality to consumables specifications A001063/00D).
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07.11.2012
Lubrication system Changing the oil The oil change interval depends on the oil grade used and the quality of the fuel used. The oil change interval is 1,000 hours of duty or a maximum of 1 year if using Category 3 engine oils and approved fuels as per Section 4. The oil change interval is 500 hours of duty or a maximum of 1 year if using Category 2 engine oils and approved fuels as per Section 4. For additional information, refer to the consumables specifications A001063/00D.
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Crankshaft drive gear: Removing the pistons and cylinder liners 1. Remove the cylinder head carrying out all associated preliminary work. 2. Remove the sump. 3. Remove the coke scraper rings and clean off the coke deposits from the cylinder liner. 4. Loosen the big-end bearing cap bolts and unscrew them. 5. Pull the piston out from the cylinder liner. 6. Remove the cylinder liner from the liner seat using the extractor tool F6786514.
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07.11.2012
Series 1600 pistons/con rods Piston and cracked big end
Con rod and big-end bearing cap are marked with the same code
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Crankshaft drive gear: Refitting the pistons and cylinder liners 1. The cylinder liner seat must be checked for damage and that it is clean before refitting the cylinder liner. 2. Fit the new sealing rings to the cylinder liner and lubricate with grease (Kluthe Hakuform 30-10/Emulsion). 3. Fit the liner flush in the crankcase using the fitting tool F6786513 and fit the coke scraper ring. 4. Apply a coat of oil to the cylinder liner and piston with piston rings. 5. Insert the fitting sleeve F6790145 into the cylinder liner. 6. Compress the piston rings using the ring compressor F6786492 and refit the pistons. 7. Note: the fitting requires two persons in order to prevent damage to the big-end bearing shell and oil injector. 8. It is essential to ensure that the con-rod/big-end bearing cap pairing matches. The con rods are stamped with consecutive numbers. 9. Big-end bolts must be checked for compliance with a maximum length of 67 mm. 10. Tighten the big-end bolts to the specified torque of 150 Nm + 90°of additional turn.
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Crankshaft drive gear: Refitting the pistons and cylinder liners 11. Refit the sump. 12. Refit the cylinder head carrying out all operations involved in reverse order of removal. 13. Refill the engine with oil. 14. Refill the cooling system.
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Outlook for Series 1600 C&I engine Series 1600 C&I/Agricultural – Summary • Power output from 340 – 730 kW • 2-stage turbocharging • Tough, modular design engines • Tier 4 emissions compliance • Minimized exhaust emissions achieved by EGR system on V10 and V12 models. • First prototypes (12V1600) have already completed testing.
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Series 1600 Assembly line in Überlingen
C
A
E
B 3 Logistics: A) Goods inwards B) Warehouse C) Engine dispatch D) Customer Service E) Offices
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Production process: 1) Assembly line 2) Test bench 3) Paintshop
2 D
B
Assembly line Truck route
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