Section 1.1, FRIEDRICHSHAFEN Technical Data Pogo 1 41, MAINDATA Operating method Combustion method Mode of supercharging CCooting method Arrangement of eylinders Boe Soke Cylinder displacement Number of eylinders ‘Toul displacement Compression ratio Sense of rotation viewing the main power output end firing order Injection pressure Comprestion pressure at 120 :pm and 736 mmHg Initial starting torque at 10 to 20 °C engine temperature with allowance for acceleration included ‘Cranking torque Flzing speed at 10°10 20°C engine temperature with allowance for acceleration included valve clearance Valve readjustment Avoyole, single acting Prechamiber Exhaust gas turbocharging Water-cooted 60° y-engine 185 mm 1200 mm 5,98 lines 16 86, 00 Lies 15.7 ‘Anti-clockwise (not reversible) 4 AR AR AW AR AT Ad Nl Naf asl Ng gg gy gal Ng 150! star a 28 to 28 bar 400 kgm 160 kgm 100 spm ° ‘Automatically i 7 Edition 10408 -01, 75-Section 1426 nitu Pago 2 Technical Data FReDal Peak rating 2480 kW (3950 PS) at 1900 to 1950 rpm. Overload rating 2280 kW (31.00 PS) at 1850 rpm Continuous rating £2080 kW (2800 PS) at 1780 rpm Reference. conditions Inake ait remperanme Raw water temperature in charge ait cooler Baromernic pressure ‘Mean piston speed at 1900 rpm. Injection ming 45°C 35°C 1 ber 12,6 m/s 12° bef, ude, ‘The peak rating fs the highest effective output of the engine which can be delivered for one half hour within six operating hours without mechanical and thermal overstress, ‘the overload rating is the highest effective output of the engine which can be delivered above the continuous rating for 2 hours, continuous or wich Intenruptions, within 6 operating hours, Edition 0419-07, 75-Section 1.2. FRIEDRICHSHAFEN Technical Data Page 1 Tao04 097 A= Length 200 mm B= Wich 1620 mm © = Hetgh 2060 mm D = Depth below crankshaft centre 600 mim Edition 10200 -12,71-Yr tu Technical Data Section Page 1.8, L 1.8, ENGINE WEIGHT, COOLING WATER AND OWL CAPACITY Bugine weight with basic accessories according co standard offer, section HI, without water and ofl Cooling water capacity fresh water capacity including the engine mounted piping Water capacity of the charge alr cooler it capacity to lower mark at the dipstick to upper mark at the dipsticl topping up after 5 minutes {dling ‘Total capacity approx, 6700 kg 1280 litres 10 Utes 52 kg 158 kg 60 kg 213 kg Edition 10035 -01, 72Section 14, FRIEDRICHSHAFEN Technical Data Page 1 et, OPERATIONAL VALUES. Presses, temperaties, and contummprions stated inthis wectlon ace standard values, For the respective engim the values stated on the acceptance test sheet are binding. 1.41, PRESSURES ‘Crankérive oll pressure measured after the fine filter ‘at continuous rating min, 7.0 bar at idling speed min, 6,0 bar Valve gear oll pressure measured st the eam and rocker housing at continuous rating min, 4.5 bar at idling speed min, 1,0 bar Piston cooling ofl pressure - measured at the oll distsbutor plate at continnous rating min, 4,5 bar at idling speed mia, 1,0 bar Cooling water pressure _~ values only entered after tials - Pusl feed pressure measured after the dual fuel filter at continuous raving min, 0,8 bar Charge atr pressure measured after the charge ait cooler approx, 1, 7 bar at 2450 kW (8850 PS) and 1900 spm overpressure Starting aft pressure starting through the cylinders, engine preheated approx, 49 bar Intake air undespressure measured at the turbocharger inlet max, 259 mm WS Exhaust gas backpressure _mearured at the turbocharger outlet max, 300 mm WS (WS = heacl of water) 14,2, TEMPERATURES . 011 wempersture measured before inlet inp czankdrive max, 80 Cooling water temperamre measured after discharge from engine (closed system) max, 90°C Exhaust gas temperature measured after wrbocharger max, 630 °C Exheust gas temperature measured after cylinder max, 830°C Charge air temperamre measured after charge air cooler max. 164.8, CONSUMPTIONS Fuel consumption {in the main operating range according to the load and employment of a fuel in accordance with the specification {in the MTU-Working Materials Specification approx, 171 g/PSh. (ff consumption at continuous operation after approx, 100 operating hours 2103 g/Psh ‘starting air consuinption upon starting through the cylinders, stazting attempts of Approx, 2 seconds, engine at operat, temp, approx, 200 1/5 Edition 10419 -07, 715+IEDRICHS! 2,1, ENGINE LAYOUT and Service Instructions Deseription ‘ Section 2.1. Page 1 Exhaust gas Charge air Starting air at of pan Engine housing ‘Gam and racker housing Stareing valve se¢ section 2. see section 2.15, a ‘aah fuel fitter soe rection 2.31. Edition 10016 -03, 72Section 2.1. Description Page 2 and Service Instructions FRIEDRICHSHAFEN. Designation of cylinders and engine sides. GA362008 For the designation of the engine sides the engine must principally be viewed from designed main power output end. Valid designation and abbreviations: Designed main power output end = KS Opposite main power eutput end = oKs Left B Right For the designation of the eylindes( according to DIN 6265) the oylinders of the left bank are marked cylinders of the right hank are marked "n", Each bank is numbered from 1 beginning at the RKS-end. Continuous numbering of other components begins also at the HKS-end with No, 1, Edition 10 016-12, 71Description in nitu and Service Instructions Section 2.1. Pago 3 Emergency air shut-off flap ‘Charge air cooier Exhaust gas turbocharger start pilot Engine suspension Engine cooling water pump ‘Marine reverse and reduction gear KS 4120 Dual fuel Ster ‘Cooling water temperature regulator Cooling water tempezamre control switch Edition 1041907, 75- see section 2.12.3, see section 2,12,2, see section 2,12,1, see section 2,15, see section 2,19,1, see section 2,10, 1, see section 2,11, see section 2,10,4, see section 2,16,6, 139426Section 2.1. Page 4 Description and Service Instructions FRIEDRICHSAAPEN Engine actuation Engine eil gep filter (0,10 mm) Raw water pump Fuel delivery pump Speed transmnitier Engine ol gap filter (0, 06 mm) Edition 10419 01,75 see section 2,17, see section 2, see section 2, tee section 2: see section 2, see section 2,9,10, 39432FRIEDRICHSHAFEN Diesetmotor - Diesel Engine - Moteur Diesel - Motor Diesel v 538 TB Radertrieb - Gear-train - Train d’ engrenages - Trem de engrenagens 4 Vorderes Antriebszahnrad » Front drive gear wheel - Rove dentée fron= tale d antrainoment » Rueda frontal de accionamiento « Engrenagem de accionamento frontal 2 Zwischenrad - Intermediate gear wheel « Rove dentée intermédiaire Rueda intermedia » Engrenagem intermedia 9 Antiebszaharad der Leckslpumpe - Leak-off oll pump drive gear whee! Rove dentes dentrainement de la pompe a huile de fuite Rueda de lacclonamienta de la bomba de aceite de fuga Engrenagem de acciona- frento da bomba do leo de fuga 4. Antiobszahnrad der Fremdwaseerpumpe + Drive gear wheel for the non- freated. water pump © Rove dentee dentrainement de la pompe a eau hon taitée » Rueda de accionamiento para la bomba de agua no pre- parada + Engrenagem de accionamento da bomba de agua nao tratada 5 Antriebszahnrad der Motorkdhiwasserpumpe - Engine cooling water pump drive gear wheel ~ Roue dentée d'antrainement de Ia pompe a eau de Tefroidissement du moteur - Ruoda de accionamiento de la bomba de agua retrigerante del motor - Engrenagem de accionamento da bomba de agua 6 Zwischenrad des KUhlwasserpumpenantriebes » Idler gear wheel for the ‘water pump drive» Roue intermediaire d'entrainoment de Ia pompe a Dau de relroidissement - Rueda intermedia para el accionamiento de la Bomba de agua refrigerante » Engrenagem intermédia do accionamento da bomba de agua 7 2wischenrad des Kahiwasserpumpenantriebes : Idler goar wheel for the ‘valer pump dive - Rove intermédiaire d'entrainemont de la pompe & ‘eau de retroidissement Rueda intormadia para ol accionamionto do la Comba de aqua refrigerante » Engrenagam intermédia de accionamento da bomba de agua 8 Antriebszahnrider der Motorendlpumpen - Gear wheels for oll pump Give. Roves dentées dentrainement des pompes a huile » Ruedas dentadas para el uecionamionto de las bombas de aceite dol motor Engrenagens de accionamento das bombas de dleo 9 2wischenrad des Motorendloumpen-Antriobes « Intermediate gear whee! far of puro drive - Rous intermediaire pour l'entrainement des pompes A tulle. Rueda intermedia para accionamiento do las bombas do aceite Gel motor" Engrenagem intermedia do accionamento das bombas de leo 10 Kurbelwellenzahnrad » Crankshaft goar wheel - Rous dentée du vilebre- ‘quin = Rueda dentada del cigleral Engrenagem da cambota 1 GroBes Zwischenrad - Large intermediate gear wheel - Grande’ rove intermédiaire Rueda intermedia grande Engrenagem intermédia grande 12 Vorgalage-Zwischonrad Back gear wheel » Roue intermédiaire de renvoi Rueda dentada de contramarcha - Engrenagem de contraveio 13. Antriobezahnrad des Motorraglers + Governor drive gear wheel - Rove ‘entée dentrainement du régulsteur - Rueda de acclonamiento del regu- Jador del motor = Engranagem de accionamento do regulador do motor 14 Verstelinider - Adjustable intermediate gear wheels » Roues intermé- diaires ajustables » Ruedas intermedias ajustables - Engrenegens ajusta- 15. Aniriebszahnrad dor EinlaSnockenwelle » Drive gear wheel for the inlet camshalt: Roue dentée d'ontrainement de arbre a cames d'admission Rueda de accionamanto del érbol de levas de admision - Engrenagem de accionamenta da veio de excéntricot de admissdo 46 Antriebszehnrad dor AuslaBnockenwelle » Drive gear wheel for the exhaust camshaft" Rove dentse dentrainement de l'arbre cames déchaopement Rueda de accionamionto del arbol do lévas de escape Engrenagem de secionamento do voio do excéntricos de escape [Motoren- und Turbinen-Union Friedkichshafen GmbH: M.A.N. 17990 FriedrichshafeniGermany tsybach Mercedes-Benz o-3 190927 01 ©2077FRIEDRICHSHAFEN Dieselmotor - Diesel Engine - Moteur Diesel : Motor Diesel 1. V 538 Triebwerk - Crankdrive - Mécanisme-Embiellage - Meca- nismo - Mecanismo de accionamento 7 1 Olrohr mit Halter - Flanged oil pipe » Tube d'huile (partie supérieure du trombone} » Tuba de acgite con soporte - Tubo de éleo (parte superior do trombone), Kolbenbolzen : Gudgoon pin - Axo do piston » Bulén det pistén - Cava do émbolo Kolbanachat «Piston chit - 4upe de piston -Falda del patio - Corpo do Smbolo Kolbenboden - Piston crown Této de piston - Cabeza de pistén » Coroa do ambolo Zylindertautbuchse « Cylinder liner - Chemise de eylindre » Camisa de Clindro - Camiva do cifindeo Gogengowicht - Counter weight - Contre-poids » Contrapeso » Contra- Gchiiuserallenlager - Main roller beating » Roulement @ rouleaux rine cipal: Rodamiento de rodillos pri Rolamento de roles principal Sicherungssegment - Retainer for the outer race - Pidce de s0reté pour Vanneau extérieur -Pioza de seguridad » Peca de seguranga Kurbelwelle - Crankshaft : Vilebrequin - Arbol de clgionales - Cambota 10 Gabelpleuel Fork connecting rod: Biella-Biela principal Biela principal 11 Stancrohr - Stand pipe » Tube dhuile (partie inférieure du trombone) Tubo fijo de aceite Tubo de dloo (parts inferior do trombone) 12 Standrohrtciger » Stand pipe carrier » Pont de support du trombone Soporte del tubo de aceite » Ponte de suporte do trombone Innenpleuel - Blade connecting rod - Biellette - Biela secundaria - Biola secundaria 1 Farben-Erklatung - Colour Code « Signification des couleurs Significactin de los colores + Signifieapio das eéres EEE Motorkihlwasser - Engine cooling water - Eau de refroldiseement du moteur ~ Agua refrigerante del motor - Agua de arrefecimento do motor BEER Yotorenal - Engine il Huile du moteur Acsite del motor - Cleo io motor Motoren- und Turbinen-Union Friedrichshafen GmbH-M.A.N. Maybach Mercedes-Benz 17990 FriedrchshafeniGermany 3? 194.023 0 (03),Description 7 Becron ey POREHSHAPEN and Ssivice instructions Page 8 Connecting rods " fae wore ‘small end bush Ti Fork rod cover 2 Blade rod 32 Washer 3 Bade tod, complete 13 Fork rod nut Fork red , complete 14 Blade rod cover 4 Fork rod bolt 18 Blade rod nut 5 Smalt end bush 16 Washer 6 Fork red 17 Blade rod belt 1 Fotk rod bearing shell 18 Blade 10d, complete 8 Fork rod, complete 19 Blade sod bearing shell 8 Optinasicat pin 10 Fitted pin ‘The fork rods are tnstailed into the B-bank while the blade rods ate installed into the A-bank, All connecting tods are die-forged, machined all over, and at the big end divided horizontally, ‘The fork rods embrace the crankpins with their bearing shells, ‘The blade rods embrace with their beating shells the back of the fork rod beating shells, The seel-back, replaceable connecting rod beating shells have a thin lead bronze layer to which a lead flashing is applied galvanically for running~in purpose, The connecting rod bearing shells are lubricated by pressure ofl from the crankpins, ‘The connecting rod bolts ate stress bolts which ate being tightened to a certain elongation, ‘The boits are provided with a serratfon at their threaded ends to allow them to be retained during tightening of the nuts to keep away torsional stress, A bronze bush is pressed into the small end as bearing for the gudgeon pin. 1006-1172Section Page ae Description 4 and Service instructions FRIEDRICHSHAFEN Pistons —C> —< > sence nn qenne eee 1617 18 19 20 Edition’ ET 09 28 No. 1 compression ring No. 2 compression ring No, 8 compression ring ‘Upper ofl scraper ring Lower ofl soraper ring Protecting screw cap Piston crown fixing serew Piston crown ‘Threaded bush Fitted pin Sleeve Piston skirt il tbe with retainer ‘Tab washer Hex, screw Gudgeon pin Butting ring Ctrelip Cirelip Piston complete. 10016 “11,72 ‘The off cooled pistons consist of the piston skict and the piston crown, ‘The light alloy piston skirt ts provided with 2 bosses as support for the gudgeon pin, It also carties the 2 off serapet rings. The feed tube for the piston cooling oft 4 inserted into the piston skirt from below. ‘The steel Piston Crown is secured to the piston shirt by stress bolts, Threaded bushes Inserted into the piston shirt increase the reliability ofthis screwed connection, Screw ‘caps protect the heads ofthe stress bolts against the com Dustion gases, ‘The compression rings are all inserted into the piston crown, A piston ring examination can thos be carried out just by removal of the piston crown and without remova of the piston, Cooling Ofl Js fed into the piston by way of a standpipe from where tt enters the space between piston skirt and the piston By shaping the inside of the piston crown according ly an effective, uniform cooling of especially the compression ring ares {s being achieved and baking- ‘on of the compression rings prevented. Besides this the piston clearance can be held small which is of great importance for quiet running and low wear on pistons and cylinder Liners, “The Gudgeon Pin is fixed in the piston skirt against Iateral displacement by clrclips. It is lubricated by the free emer~ ging piston cooling ofl.GA 05 035 1 Gear case 2 cylinder head 3 End pieceSection 2.5+ Description ortu Pao 2 and Service Instructions FRIEDRICHSHAFER :—— See ot By een Ear g——__—___ | Senn REESEEEESEEESEES 30 8 epee 28 i a 28 < 27 26 28 24 23 22 21 20 19 18 u 1 18 u eT 08786 1 Rocker follower 37 Oyfinder head 2 ooking ring, exhaust 18 Groove pin 3 valve cap, exhaust 38 Seating ring 4 Valve keeper, exheust 20 Core plug 5 Spring retainer, exhaust 21 Valve guide, inlet 5 Valve spring, toner 22 Bumer 7 Yalve spring, outer 28 shouldered bush 8 Stress bott 24 Grooved nut 9 stress bott 25 Lower steel flange 19 cylindrical pin 26 Rocker follower guide 11 Gytindzical pin 21Distance bush 12 Valve guide, exhaust 28 sues bolt 13. Cylindrical pin 29 Spring retainer, inlet 14 Exhaust valve 30. Valve collet, inlet 15 let valve 51 Valve cap, inlet 16 Choke sleeve 32 locking ring, inlet Edition 10 026 10, 60-FRIEDRICHSHAFEN iesel Engine - Moteur Diesel - Motor Diesel Dieselmotor- MD...538 Zylinderkopf - Cylinder head - Culasse - Culata - Cabeca 1. Fahwungshilse - Rocker follower - Douille de guidage des ressorts de soupape ~ Manguito de guia de los rosortes do valvula Buche ge guia das moles de valvula Einsprtagert« Unit injector «Injecteur-pompe - Aparato bomba-inyoc- tor"Bomberinjoctor Flansch-Obertel » Rocker Tollower guide - Bride supbrioure = Platina ~ parte superior - Flange superior Flansch-Untertel - Mounting flange - Bride inféxiure « Pletina - parto inferior ~ Flange Inferior Dekompressionsventil Decompression valve - Soupapo de décompres- sion Valvula de descompresion - Valwia de decomprosato Einlaventil: Inj valve - Soupape dadmission » Valvula de admisién Valvala ‘de admisedo Ventifubrung {Gr EinjaBventl« Valve guide, inet valve - Guide-soupape dadmission Guia de valvta para la vatula de admis - Guia da valuta de admissio Brenner - Burner - Bruleur - Quemador : Queimador Auslavonti- Exhaust valve - Soupape d'échappement « Vélvula de es- capo Vilvule de esca 10 Ventifahvung far AuslaBvent- Valve guide » Quide-soupape 6 échappe- ment » Guia'de vali para la vélvla de escape = Guia da valle do escape Bundbuchse - Shoulderod bush » Douille& collet - Casquillo con collar + Bucha com colar Nutmutter - Grooved nut - Ecrou crénelé - Tuerce ranurada - Porca de Ventifeder innen « Valve spring, inner - Ressort de soupape, intéieur Resorts de valle interior Mola de vélvula intoma Venitfedir auton - Valve spring, outer Ressort de soupepe,extéieur Resorte do valva exterior” Mola de valvla enter Yentifederellr- Spring rtainer- Godot des resorts de soupape “Plato de los resores de valwla Prato das moles Ventikappe «Valve cap - Chapoau de soupape - Casqu Capote de valvula 1 de valvula Farben-Erkla olour Code - Signification des couleurs - Significacién de los colores » Significagio das cbres Motorkihlwasser « Engine cooling water - Eau de refroidissement du moteur » Agua refrigerante del motor » Agua de arrefecimento do motor GRE Luft Air- Air Aire“ Ar (HERE —Abgase - Exhaust gases “Gaz d'échappement - Gases de escape Gases de escape Motoren- und Turbinen-Union Friedtichshafen GmbH -N.A.N. Maybach Mercedes-Benz 7980 FrledrichshetenvGermany IIS a 4-4 194 020 00/08!1 Section 26. Page Description and Service Instructions VALVE CONTROL GEAR 2.6. GA08 OT Cam and rocker housing Edition 10016 -12,71-Section 2 6. Description Page 2 and Service Instructions FRIEDRICHSHAFEN. Gam and rocker housing Cam and rocker housing of a6- and 12-cylinder engine, respectively. TET 068 08 ‘The cam and rocker housing covers the entire bank of cylinders, or 5 cylinder each of one engine side in the case of 20 cylinder MD engines, Ir is made of light metal and accommodates the valve gear components ‘The valve gear components are: Exhaust camshaft Inlet camsbafe Inlet and exhaust valve rockers Unit injector rockers Regulating parts for the unit injector For the oil supply the cam and rocker housing is provided with drilled passages and channels, A pressure relif valve is Installed laterally near the GKS-end, The fuel Lines are mounted at the outside of the cam and rocker housing, At the top it is closed by the intermediate frames and the top cover plates, Valve gear components ‘The inlet and exhaust camshafts are supported in the cam and rocker housing in friction bearings (with S-cylinder engines 5 timer, 12-cylinder engines 7 vimes, 16-cylinder engines 9 times, 20-cylinder engine 6 times), The bearing at the drive end is an end bearing which serves for the fixation of the camshaft, ‘The camshafts, which control the valves, are driven by the crankshaft through idler gear wheels, The inlet camshaft additionally actuates the unit injectors, ‘The rockers are supported in bronze bushings on the hollow rocker shafts while their rollers are running on needle bearings, All valve rockers are equipped with hydraulle automatical lash adjusters (section 2.6.1.) ‘The rockers are in direct contact with the cams on the camshaft and transmit their movements to the rocker followers, The unit injector rockers are provided with an adjusting screw for the adjustment of the commence ment of delivery. ‘The injector layshaft is suppoeted in deep groove ball bearings at both ends and in bushes inbetween, Tt wansmits the move~ ‘ments of the goveincr to the unit injecters, A separate ofl system supplies the valve gear components with pressure ofl, Edition 10026 ~04, 72>Description Section 2.6. FRIEDRICHSHAFEN and Service Instructions Page 3 Examination ‘After each refitting of the eam and rocker housing and at certain intervals (see maintenance plan) the valve gear must be examined as follows: GA 06 OTE Remove the top covers and run the engine at idling speed, Check of the lubrication of the valve gear components: At all points which are marked with an arrow on the above sHlustration, lubrication of) must emerge. Visual examination of the cam races: With improperly operating valve rockers the car race shows a dark colouring, For a correction the cam and rocker housing must be removed. Examination of the fuel Iine connections at the unit injectors: If a connection is Jeaking retighten the banjo plug, If the leak cannot be removed by retightening the unit injector must be removed and the jumper line seat in the connection tower of the unit injector be reconditioned by means of a special milling cutter (please refer to publication 1222/2 for this purpose), Refit the top covers, Edition 10016 -10,69-FRIEDRICHSHAFEN Dieselmotor - Diesel Engine - Moteur Diesel - Motor Diesel MD..V 538 Motor-Steuerung - Valve Controt Gear : Distribution du moteur - Distribucién del motor - Distribuigéo do motor 1. Zylindlerkopt-Obsrtell . Cam and rocker housing » Culasse supérieure Caja de los arboles de lavas ~ Caixa dos balanceiros 2. Einspritegerat - Unit injector: Injoctour-pompe - Bomba-inyector » Bomba: Injector 3. Schwinghebel far Einspritzgordt - Unit injector rocker » Culbuteur de f'in- jectour-pompe - Balancin dal bomba-inyector - Balancelro do bombe-in- Jector 4 Einstollschraube fur Kraftetof€i pritzboginn « Adjusting screw for the commencement of delivery * Vis de réglage du commencement dinjec tion du combustible « Tornillo de regulacién para ef comienzo. de inyec- ign de combustible - Parafuso de afinagéo do comego da Injeccao do combustivel 5. Zwischenrahmen « Intermediate frame » Cadre intermédiire » Bastidor intermedio - Moldura intormédia 5 AbschluBdeckel - Top cover plate - Couvercle de fermeture - Tapa de cierre « Tampa de fecho 7 Leckkraftstoff-Leitung - Leak-off fuel line » Conduite de combustible de {uit ~ Conducto del combustible de fuga Tubagem do combustvel de fuga 8 Kralistoff-Racklaufleitung - Fuel return line » Conduite de retour de com- buatibleConducto de reterne de combustible Tubagom de retorno do ‘combuetvel 9 Kraftstoff-Zulautleitung - Fuel foed line - Conduite diarrivse de com. bustible - Conducte de llegada de combustible Tubagem de chegada do combustivel 10 EinlaBnockenwelle - inlet camshalt Arbre & cames d'admission « Arbol de levas de admisién » Veio do excéntricos de admissto 11 Schwinghebelachse fr Einlafiventil- Axia for inlet valve rockers « Axe des culbuteurs des soupapes d'admission - Eje da los balancines de les vivulas de admision » Eixo dos balanceiros das vélvulas de admissao 12 Schwinghebe! far Einladventil« inlet valve rocker » Culbutour de la sou- Pape: dadinission « Balancin de la valvula de admisién - Balanceiro da vilvula de admissao 18 Schwinghebelachse fur Einepritzgerst Axe des culbuteurs des injectoure bombarinyectores * Eixo dos balar 14 Schwinghebel fr Auslefiventit» Exhaust valve rocker - Culbuteur de la soupape d échappement : Balancin de la valvula de escape - Balanceieo. da valvula de escape 18 Schwinghebelachs les soupapes d'échappemont - Eje do los balancinas do las valvulas de escape « Eixo dos balancoiros dae valvulas de escape 16 Regulisrwelle- Injoctor layshaft Arbre régulateur - Arbol de regulacién Velo de reguiagao 17 Auslatinockerwelle Exhaust camshaft » Arbre a cames 'échappement ‘Arbol de levas de oscapo « Veio do oxcéntricos de escape Farben-Erklirung . Colour Code - Signification des couleurs - Signficacién de los colores » Signilicagao das c6res MMM SYoiorend! - Engine oll - Hulle du moteur Aceite del motor - Oleo ‘motor Motoren- und Turbinen-Union Frechichshafon GmbH. MAN. Maybach Mercedes-Benz 1900 Friedrichshafon’Germany 7 16 5: 4 13: 12 n 10 5-5 194 037 00/08)FRIEDRICHSHAFEN Dieselmotor - Diesel Engine - Moteur Diesel - Motor Diesel MD..V 538 Motor-Steuerung - Valve Control Gear + Distribution du moteur « Distribucién del motor - Distribuigéo do motor 1 Zylinclerkopt-Oberteil » Cam and rocker housing » Culasse supérieure Caja de los drboles de lavas » Caixa dos balanceiros 2. Einspritagerat - Unit injector Injactour-pompe - Bombs-inyector : Bomba: Injector 3. Schwinghebel far Einspritagorit - Unit injector rocker » Culbuteur de f'in- jecteur-pompe - Balancin del bomba-inyector - Balancelro do homba-in- jector 4 Einstellschraube fir Kraftstofi-Einspritzboginn » Adjusting screw for the commencement of delivery * Vis de réglage du commencement Jinjec tion du combustible « Torillo do regulacién para of comienzo de inyec- ign de combustible « Parafuso de afinagio do comeco da injeccao do combustivel 5 Zwischenrahmen + Intermediate frame - Cadre intermédisire - Bastidor intarmedio + Moldura intormédia 5 AbschluBdeckel - Top cover plate - Couvercle de fermeture - Tapa de cierro - Tampa de fecho 7 Leckkraftatoft-Leitung « Leak-off fuel line » Conduite de combustible de {ult - Conducto del combustible de Fuga Tubagam do combustivel de fuga 8 Kraftstoff-Récklaufleitung - Fuel return line ~ Conduite de retour de com- bustible - Conducto de retorno de combustible “ Tubagom de retorne do combustivel 9 Kraftstoff-Zulaufleitung - Fuel feed line - Conduite diartivée de com- bustible - Conducte de liegada de combustible Tubagem de chegada do combustivel 10 EinlaBnockenwelle - Inlot camshatt Arbre & cames d’admission - Arbol de levas de admisién » Veio do excénticos de admissto 11 Schwinghebelachse fur Ei culbuteurs des soupapes c'admission « Eje da los balancines de les valvulas de admision - Eixo dos balanceiros das valvuias de admissao 12 Schwinghebel fur Einladventil « Inlet valve rocker » Culbutour de la sou- ape: d'adiission - Balancin de la vaivula de admisién » Balancoio da vélvula de admissao 18 Schwinghebelachse fur Einspritzgorat - Axis for unit injector rockers ‘Axe des culbuteurs des injecteurs-pompas - Eja de los balancines do los bombarinyectores » Eixo dos balanceiros dos bombs-injoctores til» Exhaust valve rockor - Culbuteur de la « Balancin de la valvula de escape - Balanceiro 4 1B fur Auslatventil« Axis for the exhaust valve rockers les soupapes d'échappemont- Eje de los bal de las valvulas de escape - Eixo dos balanceiros dae vélvulas de 16 Regulierwelte- Injector layshaft Arbre régulateur - Arbol de regulacién Velo de regulacao 7 Auslatinockenwello Exhaust camshaft» Arbre & cames ¢’échappement ‘Ato! de levas de oscape - Voio de oxcéintricas de escape Farben-Erklérung - Colour Gode - Signification des couleurs - Signficacién de los colores - Signficagao das cOres MAME Yotorend! - Engine oil: Hulle du moteur - Aceite del motor -Oleo ‘motor ‘Motoren- und Turbinen-Union Friedichchelon GmbH - MANN. Maybach Mercedes-Benz 1900 Friedrichshaten/Germany 5-5 194037 00/06)nytu Soseription Section 2.7. FRIEDRICHSHAFEN and Service Instructions Pope 1 2.7, UNIT INJECTOR (See drawing 194 039 D0) “GAT1020 1 Hold-down clamp 2 Unit injector Edition 10016 -11,71-Section 27. Description Instructions FREDRICHSHAPEN Page 2 Inserted: tnwo a well In the centre of each cylinder head {sa mit injector, It is held in the head by a hold~down clamp with a spherical washer and bolt, ‘A copper gasket effects sealing between the combustion chamber and the unit injector which is a vombined fuel pump and injector unit, ‘This combination of fuel pump and injector unit to a complete unit has’the advantage of eliminating high pressure fuel lines and thus also the unfavourable in- fluence of the lattet on fuel injection. Banjo plug. ‘Sealing ring (rubber) shim Push rod Hold-down clamp'bote Spherical washer Hold-down clamp Unit injector Copper gasket vET 1120 “The unit injector const ofa see] body into which the plunger and the plunger guide are installed, ‘The upper portion of the steel body caries the regulating sleeve with worm whee! and accommodates the push red, The nozale cap and the nozzle element are fitted to the stee! body fiom below. A connecting tower with the feed return and leak-off pastages fs rounted to injector body tsteratly. Controtled by the inlet carnshaft the fuel pump of the unit injector is operated by a rocker, The movement of the rocker 4s transmitted to the plunger by way of the push rod, guide block, and the distance plate. ‘The regulating sleeve fs connected with the Injector layshaft through the worm wheel, It transmits the governor movements to the plunger by way of the wansmitting block, According tothe position of the helix at the plunger a certain amount of fuel is being injected, {A detailed description of the unit injector together with technical data, hints for maintenance, assembly instructions and @ spate parts list are contained in publication No, 1222/2, 4 Edition 10016 “1172FRIEDRICHSHAFEN Dieseimotor - Diesel Engine - Moteur Diesel - Motor Diesel MD... 538 Kraftstoff-Einspritzgerat - Unit injector « Injecteur-pompe - Aparato bomba-inyector - Bomba-injector 1. StaBel - Guide block - Poussoir - Taqué - Jungo 2 Ausgleichsplatte » Distance plato Disque de compensation - Plato de ‘compensacién - Placa de compeneagao 3 Schraubsenrad - Worm goar whoo! - Roue hélie Roda helicoidal 4 Verdratsfeder Coil (retum) spring - Ressort de rappel - Muelle de torsi¢n Mola de torpedo 5 SteBelfeder - Spring « Ressort du poussoir - Muelle del taqué - Mola do Junge 8 Saugventil - Suction valve » Soupape d'aspiration - Valvula de aspitacion Vaivula de aspiragio 7 Kolben » Plunger - Plongour - Embolo - Emboto 8. Druckventilkegal - Prossure valve cone » Céne de la soupape de pression ‘Gono de a valvula de presién - Cone da valvuia de pressio 8 Druckventisit » Pressure valve seat - Siege de la soupape de pression Asiento de la valvula de prosién » Sede da valvula do pressio. 10 Hubbogrenzer «Stroke limiter - Limiteur de course Limitador de des- plazamiento + Limitador do curso 11 Dusenventilkegel + Nozzle valve cone - Céne de la soupape-injecteur Cono de Ia vaivula de tebera » Cone da valvula de bico 12. Disenventilfdhrung - Nozzle valve body » Guidage de la soupape-injec- tour Guia de la valvula de tobera » Guia da valuta de bico 18 Kolbenftihrung . Plunger guide - Guidage du plongeur Guia del émbolo Guia do émbalo 14 Kardan - Transmitting block - Cardan - Cardan - Pega de transmissao 18 AnschluBlurm - Connecting tower » Tour de connexion « Torre de cone xién « Torte de ligagio 16. Filter Filter - Filtre -Filtr »Filtro le - Rueda helicoidal Farben-Erilérung - Colour code « Signification des couleurs Significacién de los colores: Significagao das céres R__Kraftsioff-Ricklauf - Return flow channel Retour de combustible - Retorno de combustible » Retorno do combustivel Z _Krattstoff-Zulauf - Feed channel - Arrivée de combustible - Llegada de combustible - Chegada do combustivel L Leckkraftstoff - Leakcoff fuel - Combustible de fuite » Combustible de fuga » Combustivel de fuga S__Steuerbohrung - Control bore - Forure de commande ° Taladro de mando “Furo de comando Motoren- und Turbinen-Union Friedrichshefen GmbH - MLA.N, Maybach Mercedes-Benz 17090 Fredsichshafen/Germany yt 184.03800(100470>HSHAFEN esel Engine - Moteur Diesel - Motor Diesel aut - Circulating Oil System - Circuit d'huile Circuito de aceite de circulacién + Circuito lagdo Circulating oi! pump « Pompe & hulle de circulation e de circulacién* Bomba do leo de clreulacso Pressure relief valve Soupape de surpression Valvula Valvula de alivio de prossdo 1 (Grobfilte:) © Engine ail gap filter (coarse filter) huile du moteur (fire gros) Filtra da rendijae para ‘or (filtro, basto) » Filtro de fendas do éleo do motor Non-return valve - Soupape de retenue - Valvula de a de ratengio schluBfilter » Engine oll by-pass filter Filtra a huile pass :Fillro de derivacién para ol aceite del motor ‘motor em by-pass utoff valve - Soupape d'arrét - Valvula de bloquee tauschor » Engine oil heat exchanger - Réfrigérant Cambiader de calor para el aceite del motor Arre- lo motor aturreglor « Engino oil temperature regulator « Régu: rgcature cthuile du moteur» Regulader de la tempe- ite del motor - Regulador da temperatura do éleo do luge « Centrifugal oil fier » Centrifuge dhuila & fibre » aceite a chorro libre - File centrifuge do cleo @ point - Point de mesurage - Punto de medicién ee aeFRIEDRICHSHAFEN Dieselmotor - Diese! Engine » Moteur Diesel : Motor Diesel 16 V 538 TB Triebwerkél-Kreislauf - Crankdrive Oil System - Systeme d'huile du mécanisme : Circuito del aceite del mecanismo- Circuito do dleo da cambota 1 Motorregler Engine governor « Régulateur du moteur - Regulador del motor » Regulador do motor 2 Triobwerks- und Stouerungsélpumpe Crankdrive and valve gear cil pump Pompe & tuile du mécanismo ot de la distribution Bomba del accite del mecanismo y de la distribuci6n - Bomba do Sieo da cambola e da distribuigho 3 Von der Umlaulélpumpe : From the circulating olf pump ~ Venant de ta pompe & hulle de circulation - Desde Ia bomba de aceite de circulacion Desde a bomba de éleo de cireulagao 4. Oberdruckventl - Pressure relief valve - Soupaps de surpression » Valvula de sobrepresisn - Valvula de alivia de press. 5 Olverteilerplatte - Oil distributor plate » Plague de distribution hulle Placa distribuidora de aceite - Placa distibuidora do dle 6 Motorenal-Spaltfiter (Fainfter) - Engine oil gap filter (fine. filter) Filtre & fentes & hulle du moteur (fire fin) - Filtro den rendijas para fl aceite del motor ifitco Tino) ~ Fillro de fendas do dleo de motor {filtro fino) 7 Motorendl-Druckwichter - Engine oil pressure control switch » Mano-con- tact & huile du moieur - Manocontacto para el aceite de! motor Mano- contacto do dleo de motor M_ MeBstelle » Measuring point » Point de mesurage ~ Punto de medicién Ponto de medi¢zo 1) kglem? Motoren- und Turkiven-Union Friedrichshalen GmbH - M.A.N. Maybach Mercedes-Bonz 7980 Frieckichshafe. Germany eee ato 194 242 00116) 0172FRIEDRICHSHAFEN Dieselmotor - Diesel Engine - Moteur iesel - Motor Diesel 16 v 538 TB Vorpumpél-Kreislauf - Primi graissage - Circuito de tubs pré-lubrificagao Oil System acién pret uit de pré- ja * Circuito de 1 Motorentl-Diuckwachter « Engine oil pressure control switch » Mano-con- fact @ hulle du moteur « Manccontacto para el aceite del motor“ Mano. contacto do éleo de motor 2 Absporwentl « Shutoff valve - Soupape darrét « Vélvula de blequeo Valvula de bloquelo 3 Motoren6l-Spaltfilter (Feinfiter) - Engine oil gap filter (fine filter) Filtre @ fentes & huile du moteur (flve fin) - Filto den rendijas para el aceite de! motor (iro fino) - Filtto de fendas do éleo de motor (filtro Fina) 4 Zur TriebworksBipumpe - To the crankdiive oll pump - Vers In pompe & huila du mécanisme = A la bomba de aceite del mecanismo ° Pore a bomba do dlec dos orgios de movimento 9 Uberlruckventl -Prossure relief valve » Soupape de surpression Vaivula de sobrepresin + Vélvula de alivio de presse Non-return vaive « Soupape da retenue - Valuula de retencién Valvula de reteneze 7 Motorend-Vorpumpe - Priming oil pura - Pompe de pragraissage Bomba previs para el accite del motor Bomba de pré-lubrificagae 8 Zum DBR - To the DBR: Vors la OBR - Al DBR - Para o DBR 9 Zur Startbegrenzung - To the starting fuel injection limitation - Vers la limitation du débit de démarrago - A la fimitacion de lenado ds come bustible de arranque - Para a limitagao do dbito de combustivol de arranque 10 Disieb » Oil strainer - Tamis & hulle» Tamiz de actite - Tamis de dle 11 Motorregler « Engiie governor » Régulatour du motour » Regulador del motor - Regulador do motor M_ Meflotelle - Measuring point » Point de mosurage - Punto de medicién Ponto de medigao O kgfem® po-fe 194 24000(16)0172Section 2-9. Description Page 12 and Service Instructions FRIEDRICHSHAFEN Engine off change 1 Ratchet lever) 2 Sealing ring ) Engine off gap filter (Fine filter 3 Drain plug) GAIGO 1 Seating ringy 2 Drain plug ) 2 Ratchet lever) Engine gap filter (coarse filter) The ofl change should be cartied out with the engine ofl sti at operating temperature. rein the ted off from che ofl sump, heat exchanger and of filters, ‘The sump off can either be drawn off by gay of the oil draw-off line or drained at the ofl drain plug, In order to remove the impurities adhering to the gop filter inserts the ratchet levers at the off filters should >be operated before and during draining of the ofl, Nom! ‘f At an ofl change the filzers must not be removed from the engine... ‘The oll drained from the fine gap filter must be exa~ mined according to section 2.9.10, ‘After draining the of! clean the drain plugs and refit them, Employ only proper sealing rings for the drain plugs. Fill in fresh engine ofl, ‘The brand of oil must comply with the specifications in the "Working Materials Specification " No, 1061, Edition 10028 -11,72-nitu Description Section 29:2, FRIEDRICHSHAFEN and Service Instructions Page 1 29,4, ENGINE OL, GAP FILTER COARSE FILTER) (0e craving 194 086 D0) 29,114 Technical Data Manufactured bys Mess, Knecht Gmbli, Sougert ‘Types FO 523/3 MTU-item-No,: 002 184 86 01 Gap widths 0,4 mm Floy eapactty: 34 000 limes/nour Pressure drop in the coll inserts 0,4 bar at oil of 9,5 °F Texting presun 22,5 bar Weight: approx. 16 ig 2.9.1.2 Description ‘The engine ofl gap filter is fitued to the engine howsing, ‘Phe major components of tbe filter are: Filter bead Filter housing Round-wire coil inert ‘The off enters through the filter housing and penetrates the cofl insert from ouside to inside, Impurities suspended by the ofl thus adhere to the outside of the coll insert, For the cleaning of the coll inert the ratchet lever must be operated, Thus the coll invert is being rotated and the impurities adhering to the latter wiped off by the wiping combs, The oll sludge collects in the filter housing and can be drained by way of the oil draln plug, ‘The filtered ofl flows inside the coll insert to the filter head from where it is discharged, Edin 10432 -06,75-nitu Description Section 2.9.3. RIEL and Service Instructions Page 3 2.9.1.5, Removal of a leak at the filter ratchet Ifthe gland of the filter ratchet is leaking it should be retightened lightly, NOTE: ‘After rotfghtening of the gland it must be possible to actuate the ratchet lever without undue force, 2.9,146, Cleaning of the ofl gap filter ‘The filter has to be cleaned at regular intervals (tee maintenance plan), Drain the off sludge ftom the filter housing, Remove the complete flter unit (with filter housing) from the engine, CAUTION: (On account of the danger of comtamtnation of the clean ofl side never dismantle the filter at the engine. Clamp the fitter housing in a vice. For protection of the filter housing use aluminium jaws, Unscrew the housing fixing nuts and withdraw the filter housing, ‘Unscrew the 4 brush holder fixing screws and the nut on the central shaft end withdraw the coil insert, NOTE; ‘The coil bearing and the wiping brushes are Tote on the cotl insert. ‘Clean the coil insert and the brushes in a fat dissolving cleaning agent. Examine all fMter components thoroughly, renew defective parts and all sealing rings. ‘The filter ts reassembled in reversed sequence of the dismantling operation, Refit the filter at the engine employing @ proper gasket, GA16 023 Edition 10 016-02, 72Description Section 2.9.3, Pre and Service Instructions Pago 3 2.9.1.5, Removal of a leak at the filter ratchet Ifthe gland of the filter ratchet is leaking it should be retightened Ifghtly, Nore: ‘After retightening of the gland it must be possble to actuste the ratchet lever without undve force, 2.9.1.6. Cleaning of the off gap filter The filter has to be cleaned at regular intervals (tee maintenance plan), Drain the off sludge ftom the filter housing, Remove the complete filter unit (with filter bousing) from the engine, CAUTION: (On account of the danger of contamination of the clean ofl side never dismantle the filter at the engine, Clamp the filter housing in a vice. For protection of the filter housing use alumfnium jaws, Unscrew the housing fixing nuts and withdraw the filter housing, ‘Unscrew the 4 brush holder fixing screws and the nut on the central shaft end withdraw the coil insert, NOTE; ‘The coil beating and the wiping brushes are Toote on the cotl insert. Clean the cofl insert and the brushes in a far dissolving cleaning agent, Examine all Miter components thoroughly, tenew defective parts and all sealing rings. ‘The filter is reassembled in reversed sequence of the dismantling operation, Refit the filter at the engine employing a proper gasket, GA16 023 Edition 10016-0272FRIEDRICHSHAFEN Dieselmotor - Diesel Engine « Moteur Diesel - Motor Diesel v538 MotorenéI-Spaltfilter - Engine Oil Coarse Gap Filter - Filtre & fentes 4 huile du moteur: Filtro de rendijas para el aceite del motor - Filtro de fendas do dleo do motor 1 Filterkopf - Filter head - Téte de filtro » Cabeza del filtro » Cabega do do filtro 2 Filtergehsuse - Filtor housing + Corps do fillre » Caja del filtro --Caxa do files 3 Filterepule - Filter wire. coll - Elémont fltrant a fentes (bobine) - Elemento filtrante de rendijas - Elemento filante de fendas (bobina) 4 Ablatlschraube'« Drain plug » Vie de vidange - Tornillo de evecuacién Parafuso de dreno 5 Abstreifkamm - Cleaning brush - Peigne-racleir- Cepillo rascador Penta de limpeza 6 Dichtring - Sealing ring - Anneau de joint - Anillo de junta » Anel de vodagiio de borracha 7 Ratschenhebel « Ratchot lever « Levier @ rochet » Palanca dé carraca Alavanea de catraca 8 Abdricksohraube - Lifting screw - Boulon & chasser - Tornilo de extrac cién » Parafuso de oxtraccae 9 Stoptbuchse Sting box Presse-étoupe - Prenswestopas : Bucim de vedagéo Motoren- und Turbinen-Union Friedbichshafon GmbH - HLANN. Maybach Mercedes-Benz 7990 Friedichshafon'Germany het 194 03500(16)0975Section 2.9.5. Deseription natu Page 2 and Service Instructions FRIEDRICHSH 2.9,5,8, Cleaning ‘The centrifugal ofl {Iter must be cleaned at regular intervals (see maintenance plan). Cleaning is to Be carried out with the engine stationary. Should a stop valve, however, be installed ahead of the centri fugal filter, cleaning may take place with the engine in operation, CAUTION: ‘Take eare fot to interchange the rotors of different centrifugal ofl filters. ‘The operations are carried out as described in the following: t Looten fastening nuts and remove cover. Withdraw the complete rotor, Be sure not to damage the bearings. Loosen center nut and remove rotor cap. Do not clamp in a vise, Remove paper insert. Determine both thickness and weight of the sludge layer adhering to the paper insert, If no paper Insert had been fitted, use a spatula to remove the sludge from the inner wall of the bowl, Do not take the strainers off the ver= ‘tleal tubes to prevent dirt from entering the ‘ tubes and nozzles, ‘Then remove the strainers, Clean te strainers, tubes and nozzles and blow / out with compressed air. Spare Refit the strainers, Insert a few paper tnsert, Be sure that the markings on both cap and lower Place the rotor assembly back into the bowl, Do not damage the bearings. ——3 4 cl to see that the rotor assembly can freely move. ot heck y y Refit the cover. a ea Use a proper sealing rng. 1 Paper insert 10 Rotor, lower portion 2 Nozzle 11 Strainer 3 Valve 12° Seating ring 4 Valve spring 18 Rotor cap 5 Sealing ring 14 Washer 8 Screwed plug 15 Hex. nut 1 bowl 36 Cover seal 8 Pin Yi Cover 9 bye hott 18 Not wb Eton 10016 -03. 73 part coincide. Tighten the fastening aut carefully.(i i WS a SSS —_— AL 190521 06(16)0770 FRIEDRICHSHAFEN aceite a chorro libre « ge; Centrifugal Oil Filter - Filtre ntrif le entrifuga d éleo + ‘Maybach Friedrchshat Motoren- und Turbinen-Union 7990 FriedrchshatoniGermany