MTU 12V 2000 G23 Use And Maintenance Manual
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MTU 12V 2000 G23 Use And Maintenance Manual

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Use and maintenance manual
MTU
Diesel Engine
12V 2000 G23/43/63/83
16V 2000 G23/43/63/83
18V 2000 G63/83
Réf. constructeur : M015560/00E
Réf. GPAO : 33522055801

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Summary of Contents for MTU 12V 2000 G23

  • Page 1 Use and maintenance manual Diesel Engine 12V 2000 G23/43/63/83 16V 2000 G23/43/63/83 18V 2000 G63/83 Réf. constructeur : M015560/00E Réf. GPAO : 33522055801...
  • Page 2 ã 2003 Copyright MTU Friedrichshafen GmbH Tout droit réservé pour cet ouvrage dans son intégralité. Toute utilisation ou exploitation requiert au préalable l’accord écrit de MTU Friedrichshafen GmbH. Ceci s’applique notamment à la reproduction, la diffusion, la modification, la traduction, l’archivage sur microfiches, la mémorisation et / ou le traitement sur des systèmes électroniques, y compris les bases de données et les services en ligne.
  • Page 3 Safety Safety, accident prevention and environmental protection instructions Product Summary Engine layout, technical data Operation Task descriptions Maintenance and Servicing Maintenance schedule Troubleshooting Malfunctions, causes, measures Task Description Inspection and maintenance tasks Annex Abbreviations Index...
  • Page 5 The Commissioning Note information serves as a basis for the contractually agreed logistic support (warranty, spare parts, etc.). Veuillez séparer la carte “Signalisation de mise en service“ et la renvoyer à la MTU Friedrichshafen GmbH. Les informations concernant la signalisation de mise en service constituent la base pour l'assistance en exploitation contractuelle (garantie, rechanges, etc.).
  • Page 6 ¡A rellenar en letras de imprenta! Scrivere in stampatello! Favor preencher com letras de forma! Motornr.: Auftragsnr.: Inbetriebnahmemeldung Engine No.: MTU works order No.: No du moteur: No de commande: No de motor: No de pedido: Motore N.: N. commessa: Commissioning Note No.
  • Page 7 Amendment Service! Any changes in contents will be sent to you in the form of an amendment, provided you complete the reverse of this receipt card and return it to us. Postcard MTU Friedrichshafen GmbH Department SCT 88040 Friedrichshafen GERMANY...
  • Page 8 Date Name Please mark all filed amendments here. Please use block capitals! Receipt Amendment No. Publication number: M015560/00E Name ............Manufacturer ............Department ................Telephone..... Street ............Postal box number ..........(Postal code) City ..........Country ............

  • Page 9: Table Of Contents

    1.6 Standards for warning notices in the publication ....... . 1 – 09 M015560/00E 03-05 © MTU...
  • Page 10 1 – II Table of Contents M015560/00E 03-05 © MTU...

  • Page 11: Safety

    Modifications or Conversions Modifications made by the customer to the engine may affect safety. MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or conversions. Spare parts Only genuine MTU spare parts must be used to replace components or assemblies. In the event of any damage caused by the use of other spare parts, no liability nor warranty claims vis-à-vis the engine manufacturer will be accepted.

  • Page 12: Personnel And Organizational Requirements

    Depending on the kind of work, use additional protective equipment, e.g. protective goggles, gloves, helmet, apron. Work clothing must be tight fitting so that it does not catch on rotating or projecting components. Do not wear jewelry (e.g. rings, chains etc.). M015560/00E 03-05 © MTU...

  • Page 13: Transport

    Place the engine only on an even, firm surface. Ensure appropriate consistency and load-bearing capacity of the ground or support surface. Never place an engine on the oil pan, unless expressively authorized by MTU on a case-to-case basis to do so. M015560/00E 03-05...

  • Page 14: Safety Precautions When Working On The Engine

    In order to prevent back injuries when lifting heavy components adults, depending on age and sex, should only lift weights between max. 10 kg and 30 kg, therefore: • Use lifting gear or seek assistance. M015560/00E 03-05 © MTU...
  • Page 15 It is not necessary to remove the connector and the connections when carrying out welding operation on MTU electronics if the master switch for power supply is switched from "ON" to "OFF" and the wire is disconnected from the negative and positive poles on the battery.
  • Page 16 5 mW, and in which the beam axis and surface are designed to prevent any risk to the eyes. Operation of electrical equipment When operating electrical equipment, certain components of this equipment are live. Noncompliance with the warning instructions given for this equipment may result in serious injury or damage to property. M015560/00E 03-05 © MTU...

  • Page 17: Auxiliary Materials, Fire Prevention And Environmental Protection

    Only fuels of the specified quality required to achieve emission limits must be used. In Germany, the VAwS (= regulations governing the use of materials that may affect water quality) is applicable, which means work must only be carried out by authorized specialist companies (MTU is such a company). Auxiliary materials Use only fluids and lubricants that have been tested and approved by MTU.
  • Page 18 • Do not blow dirty clothing with compressed air when being worn on the body. Used oil Used oil may contain health-threatening combustion residues. Rub barrier cream into hands! Wash hands after contact with used oil. M015560/00E 03-05 © MTU...

  • Page 19: Standards For Warning Notices In The Publication

    ANSI Z535, which begin with one of the above signal words according to the degree of danger: Warning notices 1. Read and become acquainted with all cautions and symbols before operating or repairing this product. 2. Pass on all safety instructions to your operating, maintenance, repair and transport personnel! M015560/00E 03-05 © MTU...
  • Page 20 1 – 10 Safety M015560/00E 03-05 © MTU...
  • Page 21 ......... . 2 – 70 M015560/00E 03-05 © MTU...
  • Page 22 2 – II Table of Contents M015560/00E 03-05 © MTU...

  • Page 23: Engine Layout

    040 Cylinder head 140 Exhaust system free end (couplings) 050 Valve gear 170 Starting equipment 500 Monitoring and control systems, 070 HP fuel system 180 Lube oil system general electric devices 080 LP fuel system 200 Cooling system M015560/00E 03-05 © MTU...
  • Page 24 2 – 02 Engine Layout Engine model designation Key to the engine model designations 812/16/18V 2000 Gxy 8/12/16/18 Number of cylinders Cylinder configuration: V engine 2000 Series Application Application segment (2, 4, 6, 8) Design index (0,1, 2,...) M015560/00E 03-05 © MTU...

  • Page 25: Engine Side And Cylinder Designations

    The cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end. The numbering of engine components is also from the driving end, starting with No. 1. KGS = Free end KS = Driving end Right side Left side M015560/00E 03-05 © MTU...

  • Page 26: Main Engine Dimensions

    18V 2000 Gxy Length (A) approx. 2020 mm approx. 2365 mm approx. 2400 mm Width (B) approx. 1580 mm approx. 1580 mm approx. 1580 mm Height (C) approx. 1690 mm approx. 1925 mm approx. 1605 mm M015560/00E 03-05 © MTU...

  • Page 27: Engine Data

    Fuel stop power ISO 3046 FSP GENERAL CONDITIONS (for maximum power) Number of cylinders Intake air depression (new filter) mbar (design) Intake air depression (limit mbar value) Exhaust backpressure (design) mbar Exhaust backpressure (limit mbar value) M015560/00E 03-05 © MTU...
  • Page 28 Number of exhaust valves, per cylinder Standard flywheel housing flange (engine main PTO) Flywheel interface DISC 18" 18" 18" 18" 18" COMBUSTION AIR / EXHAUST GAS Number of cylinders Charge air pressure before bar ABS cylinder FSP M015560/00E 03-05 © MTU...
  • Page 29 Lube oil temperature before engine, alarm Lube oil temperature before engine, shutdown Lube oil operating press. bef. engine, from Lube oil operating press. bef. engine, to Lube oil pressure before engine, alarm Lube oil pressure before engine, shutdown M015560/00E 03-05 © MTU...
  • Page 30 (standard oil system) (Option: max. operating inclinations) Oil pan capacity, dipstick mark liter min. (standard oil system) (Option: max. operating inclinations) Oil pan capacity, dipstick mark liter max. (standard oil system) (Option: max. operating inclinations) M015560/00E 03-05 © MTU...
  • Page 31 ACOUSTICS Number of cylinders Exhaust noise, unsilenced FSP db(A) (sound power level LW, ISO 6798) Engine surface noise with db(A) attenuated FSP intake noise (filter) (sound power level LW, ISO 6798) M015560/00E 03-05 © MTU...

  • Page 32: 12/16/18V 2000 Standby Operation: Application Group 3D, Air-Cooled Charge Air, Optimized Exhaust Emission (Epa 40 Cfr89 / Tier 1)

    Fuel stop power ISO 3046 FSP 1000 1115 1250 GENERAL CONDITIONS (for maximum power) Number of cylinders Intake air depression (new filter) mbar (design) Intake air depression (limit mbar value) Exhaust backpressure (design) mbar Exhaust backpressure (limit mbar value) M015560/00E 03-05 © MTU...
  • Page 33 Number of exhaust valves, per cylinder Standard flywheel housing flange (engine main PTO) Flywheel interface DISC 18" 18" 18" 18" 18" COMBUSTION AIR / EXHAUST GAS Number of cylinders Charge air pressure before bar ABS cylinder FSP M015560/00E 03-05 © MTU...
  • Page 34 Lube oil temperature before engine, alarm Lube oil temperature before engine, shutdown Lube oil operating press. bef. engine, from Lube oil operating press. bef. engine, to Lube oil pressure before engine, alarm Lube oil pressure before engine, shutdown M015560/00E 03-05 © MTU...
  • Page 35 (standard oil system) (Option: max. operating inclinations) Oil pan capacity, dipstick mark liter min. (standard oil system) (Option: max. operating inclinations) Oil pan capacity, dipstick mark liter max. (standard oil system) (Option: max. operating inclinations) M015560/00E 03-05 © MTU...
  • Page 36 ACOUSTICS Number of cylinders Exhaust noise, unsilenced FSP db(A) (sound power level LW, ISO 6798) Engine surface noise with db(A) attenuated FSP intake noise (filter) (sound power level LW, ISO 6798) M015560/00E 03-05 © MTU...

  • Page 37: 12/16/18V 2000 Continuous Operation With Variable Load: Application Group 3B, Air-Cooled Charge Air, Optimized Fuel Consumption

    (10% overload CP cap., design power DIN 6280, ISO 8528) GENERAL CONDITIONS (for maximum power) Number of cylinders Intake air depression (new filter) mbar (design) Intake air depression (limit mbar value) Exhaust backpressure (design) mbar Exhaust backpressure (limit mbar value) M015560/00E 03-05 © MTU...
  • Page 38 Number of exhaust valves, per cylinder Standard flywheel housing flange (engine main PTO) Flywheel interface DISC 18" 18" 18" 18" 18" COMBUSTION AIR / EXHAUST GAS Number of cylinders Charge air pressure before CP bar ABS cylinder (abs.) M015560/00E 03-05 © MTU...
  • Page 39 Lube oil temperature before engine, alarm Lube oil temperature before engine, shutdown Lube oil operating press. bef. engine, from Lube oil operating press. bef. engine, to Lube oil pressure before engine, alarm Lube oil pressure before engine, shutdown M015560/00E 03-05 © MTU...
  • Page 40 (standard oil system) (Option: max. operating inclinations) Oil pan capacity, dipstick mark liter min. (standard oil system) (Option: max. operating inclinations) Oil pan capacity, dipstick mark liter max. (standard oil system) (Option: max. operating inclinations) M015560/00E 03-05 © MTU...
  • Page 41 ACOUSTICS Number of cylinders Exhaust noise, unsilenced CP db(A) (sound power level LW, ISO 6798) Engine surface noise with db(A) attenuated CP intake noise (filter) (sound power level LW, ISO 6798) M015560/00E 03-05 © MTU...

  • Page 42: 12/16/18V Continuous Operation With Variable Load: Application Group 3B, Air-Cooled Charge Air, Optimized Exhaust Emission (Ta-Luft)

    (10% overload CP cap., design power DIN 6280, ISO 8528) GENERAL CONDITIONS (for maximum power) Number of cylinders Intake air depression (new filter) mbar (design) Intake air depression (limit mbar value) Exhaust backpressure (design) mbar Exhaust backpressure (limit mbar value) M015560/00E 03-05 © MTU...
  • Page 43 Number of exhaust valves, per cylinder Standard flywheel housing flange (engine main PTO) Flywheel interface DISC 18" 18" 18" 18" 18" COMBUSTION AIR / EXHAUST GAS Number of cylinders Charge air pressure before CP bar ABS cylinder (abs.) M015560/00E 03-05 © MTU...
  • Page 44 Lube oil temperature before engine, alarm Lube oil temperature before engine, shutdown Lube oil operating press. bef. engine, from Lube oil operating press. bef. engine, to Lube oil pressure before engine, alarm Lube oil pressure before engine, shutdown M015560/00E 03-05 © MTU...
  • Page 45 (standard oil system) (Option: max. operating inclinations) Oil pan capacity, dipstick mark liter min. (standard oil system) (Option: max. operating inclinations) Oil pan capacity, dipstick mark liter max. (standard oil system) (Option: max. operating inclinations) M015560/00E 03-05 © MTU...
  • Page 46 ACOUSTICS Number of cylinders Exhaust noise, unsilenced CP db(A) (sound power level LW, ISO 6798) Engine surface noise with db(A) attenuated CP intake noise (filter) (sound power level LW, ISO 6798) M015560/00E 03-05 © MTU...

  • Page 47: 12/16/18V Continuous Operation With Variable Load: Application Group 3B, Air-Cooled Charge Air, Optimized Exhaust Emission (Epa 40 Cfr89 / Tier 1)

    DIN 6280, ISO 8528) GENERAL CONDITIONS (for maximum power) Number of cylinders Intake air depression (new filter) (design) mbar Intake air depression (limit value) mbar Exhaust backpressure (design) mbar Exhaust backpressure (limit value) mbar M015560/00E 03-05 © MTU...
  • Page 48 Number of exhaust valves, per cylinder Standard flywheel housing flange (engine main PTO) Flywheel interface DISC 18" 18" 18" COMBUSTION AIR / EXHAUST GAS Number of cylinders Charge air pressure before CP cylinder (abs.) bar ABS M015560/00E 03-05 © MTU...
  • Page 49 FUEL SYSTEM Number of cylinders Fuel pressure at supply connection to engine (when -0.3 -0.3 -0.3 engine is starting), min. admissible Fuel pressure at supply connection to engine (when +0.5 +0.5 +0.5 engine is starting), max. admissible M015560/00E 03-05 © MTU...
  • Page 50 3500 scope of supply specification) ACOUSTICS Number of cylinders Exhaust noise, unsilenced CP (sound power level LW, db(A) ISO 6798) Engine surface noise with attenuated CP intake noise db(A) (filter) (sound power level LW, ISO 6798) M015560/00E 03-05 © MTU...

  • Page 51: 12/16/18V 2000 Continuous Operation, Unrestricted: Application Group 3B, Air-Cooled Charge Air, Optimized Fuel Consumption, Optimized Exhaust Emission (Epa 40 Cfr89 / Tier 1)

    POWER-RELATED DATA (power ratings are net brake power to ISO 3046) Number of cylinders Engine rated 1500 1500 1500 1800 1800 1800 speed Continuous power ISO 3046 (10% overload CP cap., design power DIN 6280, ISO 8528) M015560/00E 03-05 © MTU...
  • Page 52 (CAC) Exhaust piping, non-cooled Working method: four-cycle, diesel, single-acting Combustion method: direct fuel injection Cooling system: conditioned water Direction of rotation: c.c.w. (facing driving end) Number of cylinders Cylinder degrees configuration: V angle Bore Stroke M015560/00E 03-05 © MTU...
  • Page 53 Standard flywheel housing flange (engine main PTO) Flywheel interface DISC 18" 18" 18" 18" 18" 18" COMBUSTION AIR / EXHAUST GAS Number of cylinders Charge air bar ABS pressure before CP cylinder (abs.) M015560/00E 03-05 © MTU...
  • Page 54 Coolant temperature after engine, shutdown Coolant antifreeze content, max. permissible Pressure loss in the external cooling system, max. permissible COOLING SYSTEM (LT circuit) Number of cylinders Pressure loss in the external cooling system, max. permissible M015560/00E 03-05 © MTU...
  • Page 55 Fuel pressure at -0.3 -0.3 -0.3 -0.3 -0.3 -0.3 supply connection to engine (when engine is starting), min. admissible Fuel pressure at +0.5 +0.5 +0.5 +0.5 +0.5 +0.5 supply connection to engine (when engine is starting), max. admissible M015560/00E 03-05 © MTU...
  • Page 56 2 – 34 Engine Data GENERAL OPERATING DATA Number of cylinders Cold start capability: air temperature (w/o start aid, w/o preheating) (case Coolant preheating: preheating temperature (min.) Firing speed, from Firing speed, to M015560/00E 03-05 © MTU...
  • Page 57 (standard oil system) (Option: max. operating inclinations) WEIGHTS / MAIN DIMENSIONS Number of cylinders Engine weight, 2490 3100 3500 2570 3150 3500 dry (basic engine configuration acc. to scope of supply specification) M015560/00E 03-05 © MTU...
  • Page 58 2 – 36 Engine Data ACOUSTICS Number of cylinders Exhaust noise, db(A) unsilenced CP (sound power level LW, ISO 6798) Engine surface db(A) noise with attenuated CP intake noise (filter) (sound power level LW, ISO 6798) M015560/00E 03-05 © MTU...

  • Page 59: 12/16/18V 2000 Standby Operation: Application Group 3D, Water-Cooled Charge-Air, Optimized Fuel Consumption

    Fuel stop power ISO 3046 FSP GENERAL CONDITIONS (for maximum power) Number of cylinders Intake air depression (new filter) mbar (design) Intake air depression (limit mbar value) Exhaust backpressure (design) mbar Exhaust backpressure (limit mbar value) M015560/00E 03-05 © MTU...
  • Page 60 Number of exhaust valves, per cylinder Standard flywheel housing flange (engine main PTO) Flywheel interface DISC 18" 18" 18" 18" 18" COMBUSTION AIR / EXHAUST GAS Number of cylinders Charge air pressure before bar ABS cylinder FSP M015560/00E 03-05 © MTU...
  • Page 61 Pressure loss in the external cooling system, max. permissible COOLING SYSTEM (LT circuit) Number of cylinders Coolant temperature before intercooler (at engine inlet from cooling equipment) Coolant antifreeze content, max. permissible Pressure loss in the external cooling system, max. permissible M015560/00E 03-05 © MTU...
  • Page 62 (when engine is starting), max. admissible GENERAL OPERATING DATA Number of cylinders Cold start capability: air temperature (w/o start aid, w/o preheating) (case A) Coolant preheating: preheating temperature (min.) Firing speed, from Firing speed, to M015560/00E 03-05 © MTU...
  • Page 63 ACOUSTICS Number of cylinders Exhaust noise, unsilenced FSP db(A) (sound power level LW, ISO 6798) Engine surface noise with db(A) attenuated FSP intake noise (filter) (sound power level LW, ISO 6798) M015560/00E 03-05 © MTU...

  • Page 64: Optimized Exhaust Emission (Epa 40 Cfr89 / Tier 1)

    Fuel stop power ISO 3046 FSP 1007 1115 1250 GENERAL CONDITIONS (for maximum power) Number of cylinders Intake air depression (new filter) mbar (design) Intake air depression (limit mbar value) Exhaust backpressure (design) mbar Exhaust backpressure (limit mbar value) M015560/00E 03-05 © MTU...
  • Page 65 Number of exhaust valves, per cylinder Standard flywheel housing flange (engine main PTO) Flywheel interface DISC 18" 18" 18" 18" 18" COMBUSTION AIR / EXHAUST GAS Number of cylinders Charge air pressure before bar ABS cylinder FSP M015560/00E 03-05 © MTU...
  • Page 66 Pressure loss in the external cooling system, max. permissible COOLING SYSTEM (LT circuit) Number of cylinders Coolant temperature before intercooler (at engine inlet from cooling equipment) Coolant antifreeze content, max. permissible Pressure loss in the external cooling system, max. permissible M015560/00E 03-05 © MTU...
  • Page 67 (when engine is starting), max. admissible GENERAL OPERATING DATA Number of cylinders Cold start capability: air temperature (w/o start aid, w/o preheating) (case A) Coolant preheating: preheating temperature (min.) Firing speed, from Firing speed, to M015560/00E 03-05 © MTU...
  • Page 68 ACOUSTICS Number of cylinders Exhaust noise, unsilenced FSP db(A) (sound power level LW, ISO 6798) Engine surface noise with db(A) attenuated FSP intake noise (filter) (sound power level LW, ISO 6798) M015560/00E 03-05 © MTU...

  • Page 69: 12/16/18V 2000 Continuous Operation With Variable Load: Application Group 3B, Water-Cooled Charge-Air, Optimized Fuel Consumption

    (10% overload CP cap., design power DIN 6280, ISO 8528) GENERAL CONDITIONS (for maximum power) Number of cylinders Intake air depression (new filter) mbar (design) Intake air depression (limit mbar value) Exhaust backpressure (design) mbar Exhaust backpressure (limit mbar value) M015560/00E 03-05 © MTU...
  • Page 70 Number of exhaust valves, per cylinder Standard flywheel housing flange (engine main PTO) Flywheel interface DISC 18" 18" 18" 18" 18" COMBUSTION AIR / EXHAUST GAS Number of cylinders Charge air pressure before CP bar ABS cylinder (abs.) M015560/00E 03-05 © MTU...
  • Page 71 Pressure loss in the external cooling system, max. permissible COOLING SYSTEM (LT circuit) Number of cylinders Coolant temperature before intercooler (at engine inlet from cooling equipment) Coolant antifreeze content, max. permissible Pressure loss in the external cooling system, max. permissible M015560/00E 03-05 © MTU...
  • Page 72 (when engine is starting), max. admissible GENERAL OPERATING DATA Number of cylinders Cold start capability: air temperature (w/o start aid, w/o preheating) (case A) Coolant preheating: preheating temperature (min.) Firing speed, from Firing speed, to M015560/00E 03-05 © MTU...
  • Page 73 ACOUSTICS Number of cylinders Exhaust noise, unsilenced CP db(A) (sound power level LW, ISO 6798) Engine surface noise with db(A) attenuated CP intake noise (filter) (sound power level LW, ISO 6798) M015560/00E 03-05 © MTU...

  • Page 74: 12/16/18V Continuous Operation With Variable Load: Application Group 3B, Water-Cooled Charge-Air, Optimized Exhaust Emission (Ta-Luft)

    (10% overload CP cap., design power DIN 6280, ISO 8528) GENERAL CONDITIONS (for maximum power) Number of cylinders Intake air depression (new filter) mbar (design) Intake air depression (limit mbar value) Exhaust backpressure (design) mbar Exhaust backpressure (limit mbar value) M015560/00E 03-05 © MTU...
  • Page 75 Number of exhaust valves, per cylinder Standard flywheel housing flange (engine main PTO) Flywheel interface DISC 18" 18" 18" 18" 18" COMBUSTION AIR / EXHAUST GAS Number of cylinders Charge air pressure before CP bar ABS cylinder (abs.) M015560/00E 03-05 © MTU...
  • Page 76 Pressure loss in the external cooling system, max. permissible COOLING SYSTEM (LT circuit) Number of cylinders Coolant temperature before intercooler (at engine inlet from cooling equipment) Coolant antifreeze content, max. permissible Pressure loss in the external cooling system, max. permissible M015560/00E 03-05 © MTU...
  • Page 77 (when engine is starting), max. admissible GENERAL OPERATING DATA Number of cylinders Cold start capability: air temperature (w/o start aid, w/o preheating) (case A) Coolant preheating: preheating temperature (min.) Firing speed, from Firing speed, to M015560/00E 03-05 © MTU...
  • Page 78 ACOUSTICS Number of cylinders Exhaust noise, unsilenced CP db(A) (sound power level LW, ISO 6798) Engine surface noise with db(A) attenuated CP intake noise (filter) (sound power level LW, ISO 6798) M015560/00E 03-05 © MTU...

  • Page 79: 12/16/18V Continuous Operation With Variable Load: Application Group 3B, Water-Cooled Charge-Air, Optimized Exhaust Emission (Epa 40 Cfr89 / Tier 1)

    DIN 6280, ISO 8528) GENERAL CONDITIONS (for maximum power) Number of cylinders Intake air depression (new filter) (design) mbar Intake air depression (limit value) mbar Exhaust backpressure (design) mbar Exhaust backpressure (limit value) mbar M015560/00E 03-05 © MTU...
  • Page 80 Number of exhaust valves, per cylinder Standard flywheel housing flange (engine main PTO) Flywheel interface DISC 18" 18" 18" COMBUSTION AIR / EXHAUST GAS Number of cylinders Charge air pressure before CP cylinder (abs.) bar ABS M015560/00E 03-05 © MTU...
  • Page 81 FUEL SYSTEM Number of cylinders Fuel pressure at supply connection to engine (when -0.3 -0.3 -0.3 engine is starting), min. admissible Fuel pressure at supply connection to engine (when +0.5 +0.5 +0.5 engine is starting), max. admissible M015560/00E 03-05 © MTU...
  • Page 82 3500 scope of supply specification) ACOUSTICS Number of cylinders Exhaust noise, unsilenced CP (sound power level LW, db(A) ISO 6798) Engine surface noise with attenuated CP intake noise db(A) (filter) (sound power level LW, ISO 6798) M015560/00E 03-05 © MTU...

  • Page 83: 12/16/18V 2000 Continuous Operation, Unrestricted: Application Group 3B, Water-Cooled Charge-Air, Optimized Fuel Consumption, Optimized Exhaust Emission (Epa 40 Cfr89 / Tier 1)

    POWER-RELATED DATA (power ratings are net brake power to ISO 3046) Number of cylinders Engine rated 1500 1500 1500 1800 1800 1800 speed Continuous power ISO 3046 (10% overload CP cap., design power DIN 6280, ISO 8528) M015560/00E 03-05 © MTU...
  • Page 84 (CAC) Exhaust piping, non-cooled Working method: four-cycle, diesel, single-acting Combustion method: direct fuel injection Cooling system: conditioned water Direction of rotation: c.c.w. (facing driving end) Number of cylinders Cylinder degrees configuration: V angle Bore Stroke M015560/00E 03-05 © MTU...
  • Page 85 Standard flywheel housing flange (engine main PTO) Flywheel interface DISC 18" 18" 18" 18" 18" 18" COMBUSTION AIR / EXHAUST GAS Number of cylinders Charge air bar ABS pressure before CP cylinder (abs.) M015560/00E 03-05 © MTU...
  • Page 86 COOLING SYSTEM (LT circuit) Number of cylinders Coolant temperature before intercooler (at engine inlet from cooling equipment) Coolant antifreeze content, max. permissible Pressure loss in the external cooling system, max. permissible M015560/00E 03-05 © MTU...
  • Page 87 Fuel pressure at -0.3 -0.3 -0.3 -0.3 -0.3 -0.3 supply connection to engine (when engine is starting), min. admissible Fuel pressure at +0.5 +0.5 +0.5 +0.5 +0.5 +0.5 supply connection to engine (when engine is starting), max. admissible M015560/00E 03-05 © MTU...
  • Page 88 2 – 66 Engine Data GENERAL OPERATING DATA Number of cylinders Cold start capability: air temperature (w/o start aid, w/o preheating) (case Coolant preheating: preheating temperature (min.) Firing speed, from Firing speed, to M015560/00E 03-05 © MTU...
  • Page 89 (standard oil system) (Option: max. operating inclinations) WEIGHTS / MAIN DIMENSIONS Number of cylinders Engine weight, 2570 3150 3500 2570 3180 3500 dry (basic engine configuration acc. to scope of supply specification) M015560/00E 03-05 © MTU...
  • Page 90 2 – 68 Engine Data ACOUSTICS Number of cylinders Exhaust noise, db(A) unsilenced CP (sound power level LW, ISO 6798) Engine surface db(A) noise with attenuated CP intake noise (filter) (sound power level LW, ISO 6798) M015560/00E 03-05 © MTU...

  • Page 91: Firing Order

    Engine Data 2 – 69 2.4.13 Firing order Firing order 12 V A1-B2-A5-B4-A3-B1-A6-B5-A2-B3-A4-B6 16 V A1-B5-A3-A5-B2-B8-A2-A8-B3-A7-B4-B6-A4-A6-B1-B7 18 V A1-B6-A3-B4-A5-B2-A7-B1-A9-B3-A8-B5-A6-B7-A4-B9-A2-B8 M015560/00E 03-05 © MTU...

  • Page 92: Final Compression Pressure

    2 – 70 Engine Data 2.4.14 Final compression pressure Final compression pressure Final compression pressure at 120 rpm 30 bar to 36 bar M015560/00E 03-05 © MTU...
  • Page 93 3.9 After stopping the engine – putting the engine out of service ..... . 3 – 09 M015560/00E 03-05 © MTU...
  • Page 94 3 – II Table of Contents M015560/00E 03-05 © MTU...

  • Page 95: Operation

    Putting the engine into operation after extended out-of-service periods (>3 months) Preconditions • Engine is stopped and starting disabled. • MTU Fluids and Lubricants Specification (A001061/..) is available. Putting the engine into operation after extended out-of-service-periods (>3 months) Item Task Engine Depreserve (→...

  • Page 96: Putting The Engine Into Operation After Scheduled Out-Of-Service-Period

    Cooling system Preheat coolant with preheating unit. Fuel prefilter Drain (→ Page 6 – 28). Monitoring equipment Carry out lamp test (see manufacturer’s documentation). Engine/generator control system Switch ON; Select operating mode, e.g. MANUAL OPERATION, AUTOMATIC OPERATION. M015560/00E 03-05 © MTU...

  • Page 97: Starting The Engine In Manual Mode

    Close the generator circuit breaker. panel etc. (depending on manufacturer) Engine Run engine at 10 to 15 % of rated power to reach operating temperature. Apply full load only after engine has reached operating temperature (coolant temperature approx. 75 C). M015560/00E 03-05 © MTU...

  • Page 98: Emergency Start (Override Mode)

    • After the starting procedure is completed, engine is running at rated speed. Connecting the generator to network Item Task Switching cabinet, control If generator is not connected to network: Close the generator circuit breaker. panel etc. (depending on manufacturer) Engine Run at rated power. M015560/00E 03-05 © MTU...

  • Page 99: Operational Checks

    Check relief bore (→ Page 6 – 47). Compressed-air system (if Check operating pressure at pressure gauge. installed) Fill compressed-air tank to maximum pressure; Drain condensate from compressed-air tank, pressure drop must not exceed 1 bar. M015560/00E 03-05 © MTU...

  • Page 100: Stopping The Engine In Manual Mode

    Switching cabinet, control Press stop button. panel etc. (depending on • Automatic stopping procedure is performed; manufacturer) • Engine is stopped. After stopping the engine Item Task Cooling pump Operate for approx. 5 minutes after engine stop. M015560/00E 03-05 © MTU...

  • Page 101: Emergency Stop

    • Engine is stopped by switching off power supply to ECU; • Signalization (e.g. by horn, flashing lamp) is released. After emergency stop from LOP Item Task Switching cabinet, control Press button for alarm acknowledgement. panel etc. (depending on • Audible and visual signalization stops. manufacturer) M015560/00E 03-05 © MTU...

  • Page 102: After Stopping The Engine - Engine Remains Ready For Operation

    3 – 08 Operation After stopping the engine – engine remains ready for operation After stopping the engine Item Task Engine/generator control system Select operating mode, e.g. MANUAL OPERATION, AUTOMATIC OPERATION. M015560/00E 03-05 © MTU...

  • Page 103: After Stopping The Engine - Putting The Engine Out Of Service

    If the engine is to remain out of service for more than 1 week, seal the engine’s air and exhaust sides. If the engine is to remain out of service for more than 1 month, carry out preservation (→ MTU Fluids and Lubricants Specification A001061/..).
  • Page 104 3 – 10 Operation M015560/00E 03-05 © MTU...
  • Page 105 ..........4 – 11 M015560/00E 03-05 © MTU...
  • Page 106 4 – II Table of Contents M015560/00E 03-05 © MTU...

  • Page 107: Maintenance And Servicing

    The specification of fluids and lubricants, guidelines for maintenance and change intervals as well as a list of approved fluids and lubricants are provided in the MTU Fluids and Lubricants Specification A001061. Use only fluids and lubricants which comply with the MTU Fluids and Lubricants Specification.

  • Page 108: Maintenance Schedule - Application Group 3D

    4 – 02 Maintenance Schedule – Application Group 3D Maintenance Schedule – Application Group 3D 4.2.1 Maintenance schedule Application group Standby operation, load factor: < 85% Load profile Load factor 100% Corresponding operating time M015560/00E 03-05 © MTU...
  • Page 109 Maintenance Schedule – Application Group 3D 4 – 03 Maintenance schedule matrix Maintenance level W2 W2 W3 W3 W3 W4 W4 W4 W4 Time limit, years Operating hours Daily 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 M015560/00E 03-05 © MTU...
  • Page 110 Replace air filter (→ Page 6 – 35). 3000 / 4 Combustion Perform endoscopic examination (→ Page 6 – 04). chambers 6000 / - Fuel injection pumps Replace fuel injection pumps (→ Page 6 – 14). M015560/00E 03-05 © MTU...

  • Page 111: Maintenance Schedule - Application Group 3B

    Maintenance Schedule – Application Group 3B 4 – 05 Maintenance Schedule – Application Group 3B 4.3.1 Maintenance schedule Application group Continuous operation with variable load, load factor: < 75% Load profile Load factor 110% 100% Corresponding operating time M015560/00E 03-05 © MTU...
  • Page 112 Maintenance Schedule – Application Group 3B Maintenance schedule matrix Maintenance level W2 W2 W3 W3 W3 W4 W4 W4 W4 Time limit, years Operating hours Daily 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 M015560/00E 03-05 © MTU...
  • Page 113 Replace air filter (→ Page 6 – 35). 3000 / 4 Combustion Perform endoscopic examination (→ Page 6 – 04). chambers 6000 / - Fuel injection pumps Replace fuel injection pumps (→ Page 6 – 14). M015560/00E 03-05 © MTU...

  • Page 114: Maintenance Schedule - Application Group 3B Tal

    Continuous operation with variable load, load factor: < 75% Load profile Load factor 110% 100% Corresponding operating time Maintenance schedule matrix Maintenance level W2 W2 W2 W3 W3 W3 W4 W4 W4 W4 Time limit, years Operating hours Daily 1000 1250 1500 1750 2000 M015560/00E 03-05 © MTU...
  • Page 115 Maintenance Schedule – Application Group 3B TAL 4 – 09 2250 2500 2750 3000 3250 3500 3750 4000 4250 4500 4750 5000 5250 5500 5750 6000 M015560/00E 03-05 © MTU...
  • Page 116 Replace air filter (→ Page 6 – 14). 3000 / 4 Combustion Perform endoscopic examination (→ Page 6 – 04). chambers 6000 / - Fuel injection pumps Replace fuel injection pumps (→ Page 6 – 14). M015560/00E 03-05 © MTU...

  • Page 117: Maintenance Schedule - Application Group 3A

    Maintenance Schedule – Application Group 3A 4 – 11 Maintenance Schedule – Application Group 3A 4.5.1 Maintenance schedule Application group Continuous operation, unrestricted, load factor: 100% Load profile Load factor 110% 100% Corresponding operating time M015560/00E 03-05 © MTU...
  • Page 118 Maintenance Schedule – Application Group 3A Maintenance schedule matrix Maintenance level W2 W2 W3 W3 W3 W4 W4 W4 W4 Time limit, years Operating hours Daily 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 M015560/00E 03-05 © MTU...
  • Page 119 Replace air filter (→ Page 6 – 35). 3000 / 4 Combustion Perform endoscopic examination (→ Page 6 – 04). chambers 6000 / - Fuel injection pumps Replace fuel injection pumps (→ Page 6 – 14). M015560/00E 03-05 © MTU...
  • Page 120 4 – 14 Maintenance Schedule – Application Group 3A M015560/00E 03-05 © MTU...

  • Page 121: Troubleshooting

    ............. . . 5 – 04 M015560/00E 03-05 © MTU...
  • Page 122 5 – II Table of Contents M015560/00E 03-05 © MTU...
  • Page 123 Replace (→ Page 6 – 18). Injection pump defective Replace (→ Page 6 – 15). Engine wiring Defective Check (→ Page 6 – 62). Fuel system Not vented Vent fuel system (→ Page 6 – 23). Defective Contact Service. M015560/00E 03-05 © MTU...
  • Page 124 Contact Service. Charge-air temperature too high Component Probable Cause Task Coolant Incorrect coolant concentration Check (MTU test kit). Intercooler Contaminated Contact Service. Engine room Air-intake temperature too high Check fans and air supply / ventilation ducts. Charge air pressure too low...
  • Page 125 Probable Cause Engine Not at operating temperature Run engine to reach operating temperature. Fuel system Water in fuel Check fuel system on fuel prefilter. Drain fuel prefilter (→ Page 6 – 28). Intercooler Leaking Contact Service. M015560/00E 03-05 © MTU...

  • Page 126: Ecu Alarms

    Lube-oil pressure too low (2nd 1. Check engine-oil level and top up, if limit) required; (→ Page 6 – 41); 2. Try to re-start the engine automatic engine shutdown (→ Page 3 – 03). 3. Contact Service. M015560/00E 03-05 © MTU...
  • Page 127 1. Allow the engine to cool down. (2nd limit); 2. Check coolant cooler (elements etc.) and clean contaminated parts (see automatic engine shutdown manufacturer’s documentation). 3. Re-start the engine (→ Page 3 – 03). 4. If fault occurs repeatedly: Contact Service. M015560/00E 03-05 © MTU...
  • Page 128 HP fuel system leaking, Contact Service. system contains air RAIL Pressure in HP fuel system Contact Service. PRESSURE exceeds specified value; HIGH Solenoid valve of HP fuel control block jamming or wiring to solenoid valve defective M015560/00E 03-05 © MTU...
  • Page 129 CONS. 1 accumulated fuel consumption data in EDM (redundant data record 1) INVALID FUEL Check sum error of If fault occurs repeatedly: Contact Service. CONS. 2 accumulated fuel consumption data in EDM (redundant data record 2) M015560/00E 03-05 © MTU...
  • Page 130 3. Contact Service. L1 TE BUFFER Internal electronic fault Contact Service. TEST (temperature sensors) TE BUF. ECU Internal electronic fault Contact Service. DEFECT (temperature sensors) BANK1 ECU Internal electronic fault; Contact Service. DEFECT Engine does not start M015560/00E 03-05 © MTU...
  • Page 131 Error during project design Contact Service. CAN PU-DATA EE-FAIL data download in EEPROMs CAN LESS Error during CAN initialization. Contact Service. MAILBOXES CAN1 BUS OFF Severe fault on Default CAN Contact Service. bus; automatic change-over to Redundant CAN bus M015560/00E 03-05 © MTU...
  • Page 132 1. Check wiring. SPEED speed) 2. Contact Service. SD P-FUEL Sensor defect (fuel pressure) 1. Check wiring. 2. Contact Service. SD POWER Sensor defect (ECU operating Contact Service. SUPPLY voltage) Sensor defect (temperature in Contact Service. T-ELECTRONIC ECU) M015560/00E 03-05 © MTU...
  • Page 133 Injection timing fault cylinder If fault occurs repeatedly: Contact Service. CYLINDER A4 TIMING Injection timing fault cylinder If fault occurs repeatedly: Contact Service. CYLINDER A5 TIMING Injection timing fault cylinder If fault occurs repeatedly: Contact Service. CYLINDER A6 M015560/00E 03-05 © MTU...
  • Page 134 2. Contact Service. Misfiring WIRING Faulty wiring to solenoid valve 1. Check wiring. CYLINDER A4 cylinder A4; 2. Contact Service. Misfiring WIRING Faulty wiring to solenoid valve 1. Check wiring. CYLINDER A5 cylinder A5; 2. Contact Service. Misfiring M015560/00E 03-05 © MTU...
  • Page 135 2. Contact Service. Misfiring Faulty wiring to solenoid valve WIRING 1. Check wiring. CYLINDER B8 cylinder B8; 2. Contact Service. Misfiring WIRING Faulty wiring to solenoid valve 1. Check wiring. CYLINDER B9 cylinder B9; 2. Contact Service. Misfiring M015560/00E 03-05 © MTU...
  • Page 136 Disconnection in wiring to OPEN_LOAD 1. Check wiring. CYL. B2 solenoid valve cylinder B2; 2. Contact Service. Misfiring OPEN_LOAD Disconnection in wiring to 1. Check wiring. CYL. B3 solenoid valve cylinder B3; 2. Contact Service. Misfiring M015560/00E 03-05 © MTU...
  • Page 137 PLANT DEF defective TRAN.OUT2 Binary transistor output plant 2 Contact Service. PLANT DEF defective TRAN.OUT3 Binary transistor output plant 3 Contact Service. PLANT DEF defective TRAN.OUT4 Binary transistor output plant 4 Contact Service. PLANT DEF defective M015560/00E 03-05 © MTU...
  • Page 138 5 – 16 Troubleshooting Fault code Alarm text Meaning Task TRAN.OUT5 Binary transistor output plant 5 Contact Service. PLANT DEF defective TRAN.OUT6 Binary transistor output plant 6 Contact Service. PLANT DEF defective M015560/00E 03-05 © MTU...

  • Page 139: Task Description

    ..........6 – 41 M015560/00E 03-05 © MTU...
  • Page 140 6.21.3 ECU – checking plug-in connections ........6 – 65 M015560/00E 03-05 © MTU...

  • Page 141: Engine

    3. Rotate crankshaft in engine direction of rotation. Apart from the normal compression resistance, there should be no abnormal resistance. Result: If the resistance exceeds the normal compression resistance, contact Service. 4. For barring-tool removal follow reverse sequence of working steps. M015560/00E 03-05 © MTU...

  • Page 142: Engine - Barring With Starting System

    If necessary, re-start the engine after approx. 20 seconds. 5. Plug connector X4 (3) and use connector pliers (2) to secure the bayonet ring (4) by turning it clockwise until it latches into place. M015560/00E 03-05 © MTU...

  • Page 143: Engine Test Run

    1. Start engine (→ Page 3 – 03). 2. Perform test run at not below 1/3 load and at least until steady-state temperature is reached. 3. Carry out operational checks (→ Page 3 – 05). 4. Stop engine (→ Page 3 – 06). M015560/00E 03-05 © MTU...

  • Page 144: Cylinder Liner

    2. For description of findindings on cylinder liner surface use the specified terms (→ Page 6 – 06). 3. Depending on the findings: • Do not take any measures, or • Conduct endoscopic examination of another liner in the course of maintenance work; or • Contact Service: Cylinder liner must be replaced. M015560/00E 03-05 © MTU...
  • Page 145 Cylinder Liner 6 – 05 Final steps 1. Install injector (→ Page 6 – 19). 2. Install cylinder-head cover (→ Page 6 – 13). M015560/00E 03-05 © MTU...

  • Page 146: Instructions And Comments On Endoscopic And Visual Examination Of Cylinder Liner

    Liners with heat discoloration starting in the TDC-ring 1 have to be replaced. Corrosion Corrosion traces have irregular circumferential length and depth. They can be caused by either the piston skirt or crown. The material deposit on the liner (smear) shows heavy discoloration and heavy scoring. Replace liner. M015560/00E 03-05 © MTU...
  • Page 147 The findings in the start phase of oxidation discoloration and heat discoloration are similar. A definite opinion can first be made after a careful inspection and reference to the above criteria. To avoid unnecessary disassembly work, it is recommended that another inspection be carried out after further operation of the engine. M015560/00E 03-05 © MTU...

  • Page 148: Crankcase Breather

    (2) with new sealing ring. 4. Tighten screws of cover (2) to 6 Nm + 2 Nm. 5. Replace filter elements of further oil separators in the same way. M015560/00E 03-05 © MTU...
  • Page 149 5. Mount diaphragm (3) on housing (2). 6. Install new seal (4) and spring (6) together with cover (5). 7. Tighten screws of cover (5) to 6 Nm + 2 Nm. 8. Check diaphragms in further oil separators in the same way. M015560/00E 03-05 © MTU...

  • Page 150: Valve Gear

    Feeler gauge Preparatory steps 1. Remove cylinder-head cover (→ Page 6 – 13). 2. Use barring tool to bar engine manually in engine direction of rotation (→ Page 6 – 01), until the markings are aligned. M015560/00E 03-05 © MTU...
  • Page 151 4. Tighten locknut (1) to 50 Nm, holding adjusting screw (2) firmly. 5. Check if the feeler gauge just passes through between valve bridge and rocker arm. Result: If not, adjust valve clearance. M015560/00E 03-05 © MTU...
  • Page 152 6 – 12 Valve Gear Final steps 1. Remove barring tool. 2. Install cylinder-head cover (→ Page 6 – 13). 3. Install cover. M015560/00E 03-05 © MTU...

  • Page 153: Cylinder-Head Cover - Removal And Installation

    4. Check condition of gasket in cylinder-head cover. 5. Replace damaged gasket(s). 6. Place cylinder-head covers onto crankcase and tighten screws to 20 Nm. Final steps 1. Slide rubber sleeves onto the relevant pipe connection. 2. Tighten all clamps. M015560/00E 03-05 © MTU...

  • Page 154: Injection Pump / Hp Pump

    Injection Pump / HP Pump Injection Pump / HP Pump 6.5.1 Injection pump replacement Spare parts Designation / Use Part No. Qty. Injection pump Remove injection pump and install new one (→ Page 6 – 15). M015560/00E 03-05 © MTU...

  • Page 155: Injection Pump Removal And Installation

    Preparatory steps 1. Shut off fuel supply line before fuel filter. 2. Remove engine control system (→ Page 6 – 63). 3. Drain fuel (→ Page 6 – 22). 4. Remove charge-air manifold and all seals. M015560/00E 03-05 © MTU...
  • Page 156 8. Tighten injection pump to 60 Nm + 12 Nm. 9. Install fuel line (2). 10. Tighten locknuts of the fuel line (2) to 20 Nm + 5 Nm. 11. Install injection pump wiring (1). 12. Tighten screws to 1.0 Nm +/- 0.2 Nm. M015560/00E 03-05 © MTU...
  • Page 157 4. Set gasket onto cylinder head. 5. Install charge-air manifold. 6. Install engine control system (→ Page 6 – 63). 7. Open fuel supply line before fuel filter. 8. Vent fuel system (→ Page 6 – 23). M015560/00E 03-05 © MTU...

  • Page 158: Fuel Injector

    6 – 18 Fuel Injector Fuel Injector 6.6.1 Injector replacement Spare parts Designation / Use Part No. Qty. Injector Remove injector and install new one (→ Page 6 – 19). M015560/00E 03-05 © MTU...

  • Page 159: Injector Removal And Installation

    • Do not direct compressed-air jet at persons. • Wear protective goggles / safety mask and ear protectors. Preparatory steps 1. Remove cylinder head cover (→ Page 6 – 13). 2. Drain fuel (→ Page 6 – 22). M015560/00E 03-05 © MTU...
  • Page 160 6. Seal all connections with appropriate plugs. 7. Remove screw (2). 8. Take off clamp (1). 9. Screw extractor into injector. 10. Remove injector using the impact extractor. 11. Remove sealing ring using a self-made hook. M015560/00E 03-05 © MTU...
  • Page 161 18. Tighten union nut on pressure pipe neck to 20 Nm + 5 Nm. 19. Install leak-off-fuel lines. Final steps 1. Install cylinder head cover (→ Page 6 – 13). 2. Vent fuel system (→ Page 6 – 23). M015560/00E 03-05 © MTU...

  • Page 162: Fuel System (Low Pressure)

    3. Unscrew non-return valve on end piece (arrow) and drain fuel into a suitable container. 4. When the fuel flow has stopped, install non-return valve with new sealing ring and tighten. 5. Install fuel line. 6. Tighten nut on banjo union. M015560/00E 03-05 © MTU...

  • Page 163: Fuel System - Venting

    1. Unlock fuel priming pump, unscrew handle. 2. Loosen nut (arrow) on banjo union. 3. Operate the pump with the handle until fuel without bubbles comes out of the vent plugs. 4. Tighten nut on banjo union. M015560/00E 03-05 © MTU...
  • Page 164 10. Operate the pump with the handle until fuel without bubbles comes out of the nipple. 11. Tighten non-return valve. 12. Tighten union nut of fuel return line. 13. Lock fuel priming pump, screw in handle. M015560/00E 03-05 © MTU...

  • Page 165: Fuel Filter

    1. Remove easy-change filter using the strap wrench. 2. Clean the sealing surface on the bracket. 3. Fill the new easy-change filter with clean fuel. 4. Install and tighten new filter by hand. 5. Vent fuel system (→ Page 6 – 23). M015560/00E 03-05 © MTU...

  • Page 166: Fuel Prefilter Cleaning

    7. Insert filter element into filter housing and secure with nut. 8. Place new sealing ring into groove in filter head. 9. Fit cover with seal and secure it with nuts crosswise. 10. Open fuel supply. M015560/00E 03-05 © MTU...

  • Page 167: Fuel Prefilter - Differential Pressure Check And Adjustment Of Gauge

    1. With the engine running at full load or rated power, read off pressure at gauge (1). 2. If differential pressure as indicated between position of adjustable pointer (2) and pressure-indicating pointer (3) of pressure gauge is ≥ 0.3 bar, flush filter element of the cut-in filter (→ Page 6 – 30). M015560/00E 03-05 © MTU...

  • Page 168: Fuel Prefilter - Draining

    Risk of fire and explosion! WARNING • Avoid naked flames, electrical sparks and ignition sources. • Do not smoke. Fuel prefilter – draining 1. Cut out the filter to be drained. Left filter cut in Right filter cut in M015560/00E 03-05 © MTU...
  • Page 169 7. Fill filter housing with clean fuel. 8. Place new gasket in cover (2). 9. Fit cover with gasket and secure it with screws. 10. Cut the cut-out filter in again. 11. When fuel emerges from system, close vent plug (5). M015560/00E 03-05 © MTU...

  • Page 170: Fuel Prefilter - Flushing

    • Do not smoke. Engine noise above 85 dB (A). Risk of damage to hearing! WARNING • Wear ear protectors. Fuel prefilter – flushing 1. Cut out the contaminated filter. Left filter cut in Right filter cut in M015560/00E 03-05 © MTU...
  • Page 171 5. Fit cover with gasket and secure it with screws. 6. Check differential pressure (→ Page 6 – 27). Result: If flushing did not lead to an improvement of the differential pressure, replace filter element (→ Page 6 – 32). M015560/00E 03-05 © MTU...

  • Page 172: Fuel Prefilter - Filter Element Replacement

    Risk of fire and explosion! WARNING • Avoid naked flames, electrical sparks and ignition sources. • Do not smoke. Fuel prefilter – filter element replacement 1. Cut out the contaminated filter. Left filter cut in Right filter cut in M015560/00E 03-05 © MTU...
  • Page 173 11. Fit cover with gasket and secure it with screws. 12. Cut the cut-out filter in again. 13. Close vent plug (5) when fuel emerges. 14. Align adjustable pointer of differential pressure gauge with pressure-indicating pointer. (→ Page 6 – 27). M015560/00E 03-05 © MTU...

  • Page 174: Charge-Air Cooling, General, Left Side

    1. Remove injectors (→ Page 6 – 19). 2. Bar engine manually (→ Page 6 – 01). 3. Bar engine with starting system to blow out combustion chambers (→ Page 6 – 02). 4. Install injectors (→ Page 6 – 19). M015560/00E 03-05 © MTU...

  • Page 175: Air Filter

    Air filter replacement Spare parts Designation / Use Part No. Qty. Air filter Remove air filter and install new one (→ Page 6 – 36). Reset signal ring of service indicator (→ Page 6 – 37). M015560/00E 03-05 © MTU...

  • Page 176: Air Filter Removal And Installation

    (1). 3. Verify that there are no objects in the flange of the intake housing (1) and clean it. 4. Place new air filter (3) with clamp (2) onto intake housing (1). 5. Tighten clamp (2). M015560/00E 03-05 © MTU...

  • Page 177: Air Intake

    1. If the signal ring is completely visible in the control window (2), replace air filter (→ Page 6 – 35). 2. After installation of new filter, press reset button (1). Result: Engaged piston with signal ring moves back to initial position. M015560/00E 03-05 © MTU...

  • Page 178: Starting System

    WARNING • Wear ear protectors. Air starter – manual operation 1. Press pushbutton for manual start and hold it. 2. Allow compressed air to enter the air starter until the engine fires evenly. 3. Release pushbutton. M015560/00E 03-05 © MTU...

  • Page 179: Lube Oil System

    Lube Oil System 6.13.1 Engine oil change Preconditions • Engine is stopped and starting disabled. • Engine is at operating temperature. • MTU Fluids and Lubricants Specification (A001061/..) is available. Material Designation / Use Part No. Qty. Engine oil Spare parts Designation / Use Part No.
  • Page 180 3. Pour oil in at filler neck up to "max." mark at oil dipstick. 4. Close cover of filler neck. 5. Check oil level (→ Page 6 – 41). 6. After oil change and oil filter replacement, bar engine with starting system (→ Page 6 – 02). M015560/00E 03-05 © MTU...

  • Page 181: Engine Oil Level Check

    2. Insert dipstick into guide tube to stop, withdraw after approx. 10 seconds and check oil level. 3. Oil level must be between "min." and "max." marks. 4. If necessary, top up to "max." mark (→ Page 6 – 39). 5. Insert dipstick into guide tube to stop. M015560/00E 03-05 © MTU...

  • Page 182: Oil Filtration / Cooling

    5. Replace further oil filters in the same way. 6. After each oil change and filter replacement, bar the engine using the starting device (→ Page 6 – 02). 7. Check oil level (→ Page 6 – 41). M015560/00E 03-05 © MTU...

  • Page 183: Cooling System, General, Ht Circuit

    6.15 Cooling System, General, HT Circuit 6.15.1 Engine coolant filling Preconditions • Engine is stopped and starting disabled. • MTU Fluids and Lubricants Specification (A001061/..) is available. Material Designation / Use Part No. Qty. Engine coolant Coolant is hot and under pressure.

  • Page 184: Engine Coolant - Draining

    • On the crankcase, right side. 5. Draining of residual coolant: • On crankcase, left side; On oil heat exchanger. 6. Seal all open drain points. 7. Set breather valve onto filler neck and close it. M015560/00E 03-05 © MTU...

  • Page 185: Engine Coolant Change

    Cooling System, General, HT Circuit 6 – 45 6.15.3 Engine coolant change Material Designation / Use Part No. Qty. Coolant Drain engine coolant (→ Page 6 – 44). Fill engine coolant system (→ Page 6 – 43). M015560/00E 03-05 © MTU...

  • Page 186: Engine Coolant-Level Check

    Cooling System, General, HT Circuit 6.15.4 Engine coolant-level check Preconditions • Engine is stopped and starting disabled. • MTU Fluids and Lubricants Specification (A001061/..) is available. Coolant is hot and under pressure. Risk of injury and scalding! WARNING • Let the engine cool down.

  • Page 187: Cooling Pump - Relief Bore Check

    3. Clean the relief bore with a wire if it is dirty. • Permissible coolant discharge: up to 10 drops/hour; • Permissible coolant discharge: up to 5 drops/hour; 4. If coolant discharge exceeds the specified limits, contact Service. M015560/00E 03-05 © MTU...

  • Page 188: Cooling System, Lt Circuit

    Cooling System, LT Circuit 6.16 Cooling System, LT Circuit 6.16.1 Charge-air coolant filling Preconditions • Engine is stopped and starting disabled. • MTU Fluids and Lubricants Specification (A001061/..) is available. Material Designation / Use Part No. Qty. Coolant Spare parts Designation / Use Part No.
  • Page 189 Cooling System, LT Circuit 6 – 49 Final steps 1. Start the engine and operate it at idle speed for some minutes. 2. Check coolant level (→ Page 6 – 52). M015560/00E 03-05 © MTU...

  • Page 190: Charge-Air Coolant - Draining

    • at the LT cooling pump; • at the coolant line (customer’s equipment). 6. Draining of residual coolant: • at charge-air cooler. 7. Screw in drain plugs with new sealing rings. 8. Fit breather valve onto filler neck and close it. M015560/00E 03-05 © MTU...

  • Page 191: Charge-Air Coolant Change

    Cooling System, LT Circuit 6 – 51 6.16.3 Charge-air coolant change Material Designation / Use Part No. Qty. Coolant Drain charge-air coolant system (→ Page 6 – 50). Fill charge-air coolant system (→ Page 6 – 48). M015560/00E 03-05 © MTU...

  • Page 192: Charge-Air Coolant Level Check

    6.16.4 Charge-air coolant level check Preconditions • Engine is stopped and starting disabled. • MTU Fluids and Lubricants Specification (A001061/..) is available. Coolant is hot and under pressure. Risk of injury and scalding! WARNING • Let the engine cool down.

  • Page 193: Battery-Charging Generator

    • Specified belt tension for new drive belt: 450 N –50 N • Specified belt tension for used drive belt: 350 N –50 N 7. If the measured value deviates from the specified belt tension, readjust belt tension. 8. Install guard cover. M015560/00E 03-05 © MTU...
  • Page 194 2. Tension ribbed drive belt with tensioning nut (1) and check belt tension 3. Tighten securing screw (2). • Tightening torque: 40 Nm +4 Nm 4. Tighten securing screw (3). 5. Check drive belt tension. 6. Install guard cover. M015560/00E 03-05 © MTU...

  • Page 195: Battery-Charging Generator Drive - Drive Belt Condition Check

    • If ribs are broken around the entire circumference (A); • If ribs are broken around the entire circumference and material is broken off in some places (B) (→ Page 6 – 56). 4. Install guard cover. M015560/00E 03-05 © MTU...

  • Page 196: Battery-Charging Generator Drive - Drive Belt Replacement

    (→ Page 6 – 53). 8. Tighten securing screw (2). • Tightening torque: 40 Nm +4 Nm 9. Tighten securing screw (3). 10. Install ventilator drive belt (→ Page 6 – 60) 11. Install guard cover. M015560/00E 03-05 © MTU...

  • Page 197: Ventilator Drive

    "KG" scale. • Specified belt tension for new V-belt: 660 N • Specified belt tension for used V-belt: 510 N 5. If the measured value deviates from the specified belt tension, readjust belt tension. M015560/00E 03-05 © MTU...
  • Page 198 (B). 2. Screw in tensioning screw (2) to tension V-belt. 3. Check V-belt tension. 4. Tighten securing screws (1 and 4) with torque wrench. • Tightening torque: 69 Nm 5. Check V-belt tension. M015560/00E 03-05 © MTU...
  • Page 199 Ventilator Drive 6 – 59 Final steps 1. Install guard cover. 2. Fit screws and tighten. M015560/00E 03-05 © MTU...

  • Page 200: Ventilator Drive - Drive Belt Replacement

    4. Fit new set of drive belts. 5. To check V-belt tension, the ventilator bearing pedestal must rest against the gearcase. 6. Adjust and check V-belt tension (→ Page 6 – 57). Final steps 1. Install ventilator. 2. Install guard cover. M015560/00E 03-05 © MTU...

  • Page 201: Engine Mounts

    3. Have cracked elements replaced, contact Service. Setting dimension check 1. Measure setting dimension: • Dimension (a) = 55 mm. 2. If dimension (a) is less than 55 mm, resilient elements must be replaced. Contact Service. M015560/00E 03-05 © MTU...

  • Page 202: General Wiring, Engine / Gearbox / Plant

    5. Inspect electrical components visually for damage: • connector housings; • contacts; • connector sockets; • cables and terminals; • plug-in contacts. 6. If conductors are damaged, contact Service. 7. Clean dirty connector housings, sockets and contacts with isopropyl alcohol. M015560/00E 03-05 © MTU...

  • Page 203: Engine Governor (Electronic) Control System

    1. Follow reverse sequence of operations as described for removal. Ensure correct assignment of connectors to sockets. 2. Use connector pliers to turn the bayonet union nuts of the connectors clockwise until they lock into place. M015560/00E 03-05 © MTU...

  • Page 204: Ecu And Connectors Cleaning

    2. Clean connector housings, connector socket housings (1) and all contacts with isopropyl alcohol. 3. When connectors, sockets and all contacts are dry: Install connectors and check plug-in connection on ECU (→ Page 6 – 65). M015560/00E 03-05 © MTU...

  • Page 205: Ecu - Checking Plug-In Connections

    ECU are securely seated. 2. Tighten loose bayonet union nuts (2) with connector pliers (3) by turning them clockwise until they lock into place. 3. Ensure that unassigned connector sockets are protected with covering caps. M015560/00E 03-05 © MTU...
  • Page 206 6 – 66 Engine Governor (Electronic) Control System M015560/00E 03-05 © MTU...
  • Page 207 ..............7 – 03 M015560/00E 03-05 © MTU...
  • Page 208 7 – II Table of Contents M015560/00E 03-05 © MTU...
  • Page 209 Engine Data Module EEPROM Electrically Erasable and Programmable Read-Only Memory Engine Monitoring Unit Fluids and Lubricants Specification MTU Publication No. A01061/.. High Alarm: Measured value exceeds 1st maximum limit HIHI High High Alarm: Measured value exceeds 2nd maximum limit High Temperature...
  • Page 210 7 – 02 Annex Abbrevia- Meaning Explanation tion Spare Parts Catalog T-xyz Temperature-xyz Temperature measuring point xyz Tools Catalog Transmitter Deviation Unterer Totpunkt Bottom dead center (BDC) M015560/00E 03-05 © MTU...
  • Page 211 ....6 – 08 Air filter removal and installation ..6 – 36 M015560/00E 03-05 © MTU...
  • Page 212 ......6 – 22 air, Optimized fuel consumption ..2 – 05 M015560/00E 03-05 © MTU...
  • Page 213 Main engine dimensions ....2 – 04 Valve clearance – Check and adjustment ..6 – 10 M015560/00E 03-05 © MTU...
  • Page 214 ......6 – 57 Ventilator drive – Drive belt replacement ..... 6 – 60 M015560/00E 03-05 © MTU...

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