MTU 12V2000Gx5 Operating Instructions Manual
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MTU 12V2000Gx5 Operating Instructions Manual

MTU 12V2000Gx5 Operating Instructions Manual

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Operating Instructions

Diesel engine
12V2000Gx5, Gx5 TB
16V2000Gx5, Gx5 TB
18V2000Gx5, Gx5 TB
Application group 3B
MS15019/04E

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Summary of Contents for MTU 12V2000Gx5

  • Page 1: Operating Instructions

    Operating Instructions Diesel engine 12V2000Gx5, Gx5 TB 16V2000Gx5, Gx5 TB 18V2000Gx5, Gx5 TB Application group 3B MS15019/04E...
  • Page 2 All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen GmbH reserves the right to change, delete or supplement the information provided as and when required.

  • Page 3: Table Of Contents

    4.2 12/16/18V2000Gx5-TB engine data, fuel replacement optimized 8.3.2 Crankcase breather – Wire mesh cleaning 4.3 12V2000Gx5, engine data, emissions 8.4 Valve Drive optimized 8.4.1 Valve clearance – Check and adjustment 4.4 16/18V2000Gx5 engine data, emissions 8.4.2 Cylinder head cover – Removal and...
  • Page 4 8.14.1 Engine oil filter – Replacement 9 Appendix A 8.15 Coolant Circuit, General, High-Temperature 9.1 Abbreviations Circuit 9.2 MTU Contact/Service Partners 8.15.1 Engine coolant – Level check 8.15.2 Engine coolant – Change 8.15.3 Engine coolant – Draining 10 Appendix B 8.15.4 Engine coolant –...

  • Page 5: Safety

    The maintenance schedules of the manufacturer must be observed over the entire life cycle of the product. Replacing components with emission labels On all MTU engines fitted with emission labels, these labels must remain on the engine throughout its opera- tional life.

  • Page 6: Correct Use For All Products

    • With preservation approved by the manufacturer in accordance with the (→ Preservation and Represerva- tion Specifications of the manufacturer) • With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU con- tact/Service partner) • In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (in- cluding engine control/parameters) •...

  • Page 7: Personnel And Organizational Requirements

    1.3 Personnel and organizational requirements Organizational measures of the user/manufacturer This manual must be issued to all personnel involved in operation, maintenance, repair, assembly, installa- tion, or transportation. Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance, repair, assembly, installation, and transport personnel at all times.

  • Page 8: Safety Regulations For Startup And Operation

    1.4 Safety regulations for startup and operation Safety regulations for startup Install the product correctly and carry out acceptance in accordance with the manufacturer's specifications before putting the product into service. All necessary approvals must be granted by the relevant authorities and all requirements for initial startup must be fulfilled.
  • Page 9 Follow the applicable warning instructions pertaining to such devices. MS15019/04E 2016-02 | Safety | 9...

  • Page 10: Safety Precautions When Working On The Engine

    1.5 Safety precautions when working on the engine Safety regulations prior to maintenance and repair work Have maintenance or repair work carried out by qualified and authorized personnel only. Allow the product to cool down to less than 50 °C (risk of explosion for oil vapors, fluids and lubricants, risk of burning).
  • Page 11 Never bend lines and avoid damaging lines, particularly the fuel lines. Ensure that all retainers and dampers are installed correctly. Ensure that O-rings are not installed in a slanted/twisted condition. Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent contact with other components.
  • Page 12 During hydraulic installation/removal of components, ensure that no persons are in the direct vicinity of the component being pressed. Working with batteries Observe the safety instructions of the battery manufacturer when working with batteries. Gases released from the battery are explosive. Avoid sparks and naked flames. Do not allow battery acids to come into contact with skin or clothing.

  • Page 13: Fire Prevention And Environmental Protection, Fluids And Lubricants, Auxiliary Materials

    The safety data sheet may be obtained from the relevant manufacturer or from MTU. Take special care when using hot, chilled or caustic materials.

  • Page 14: Compressed Air

    Compressed air Observe special safety precautions when working with compressed air: • Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of con- tainers, risks causing an explosion. • Wear goggles when blowing dirt off workpieces or blowing away swarf. •...

  • Page 15: Standards For Safety Notices In The Text

    1.7 Standards for safety notices in the text DANGER In the event of immediate danger. Consequences: Death, serious or permanent injury! • Remedial action. WARNING In the event of a situation involving potential danger. Consequences: Death, serious or permanent injury! •...

  • Page 16: Transport

    Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate. Never set engine down on oil pan unless expressively authorized to do so by MTU on a case-to-case basis. 16 | Transport | MS15019/04E 2016-02...

  • Page 17: Lifting Requirements

    2.2 Lifting requirements Lifting requirements DANGER Suspended load. Danger to life! • Use appropriate lifting devices and appliances. • Never stand beneath a suspended load. 1 Lifting eye 2 Center of gravity Take note of the engine center of gravity See Installation/Arrangement drawings for details on engine center of gravity.

  • Page 18: General Information

    3 General Information 3.1 Engine side and cylinder designations 1 Left engine side (A-side) 3 Right engine side (B-side) 2 Engine free end in accord- 4 Engine driving end in ac- ance with DIN ISO 1204 cordance with (KGS = Kupplungsgegen- DIN ISO 1204 (KS = Kup- seite) plungsseite)

  • Page 19: Engine Overview

    3.2 Engine overview Engine with water-to-air charge-air cooling TB 1 Air filter 8 Oil filter 15 Cylinder head 2 Oil separator 9 Coolant pump 16 Flywheel housing 3 Intercooler 10 Fuel priming pump 17 Starter 4 Engine governor 11 Air outlet 18 Storage 5 Fuel filter 12 Exhaust turbocharger...
  • Page 20 Engine with air-to-air charge-air cooling TD 1 Air filter 7 Oil heat exchanger 13 Exhaust elbow 2 Oil separator 8 Oil filter 14 Charge-air manifold 3 Air outlet 9 Coolant pump 15 Cylinder head 4 Engine governor 10 Fuel priming pump 16 Flywheel housing 5 Fuel filter 11 Exhaust turbocharger...

  • Page 21: Sensors And Actuators - Overview

    3.3 Sensors and actuators – Overview Engines with water-cooled intercooler TB Item Name Monitoring of Lube oil temperature Lube oil pressure Charge-air coolant temperature Charge-air pressure Camshaft speed Crankshaft speed Coolant temperature Fuel temperature The coolant level sensor F33 is located in the coolant expansion tank at the cooler MS15019/04E 2016-02 | General Information | 21...
  • Page 22 Engine with air-cooled intercooler TD Item Name Monitoring of Lube oil temperature Lube oil pressure Charge-air coolant temperature Charge-air pressure Camshaft speed Crankshaft speed Coolant temperature Fuel temperature The coolant level sensor F33 is located in the coolant expansion tank at the cooler 22 | General Information | MS15019/04E 2016-02...

  • Page 23: Technical Data

    4 Technical Data 4.1 12/16/18V2000Gx5 engine data, fuel optimized Explanation Abbr. Meaning Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated, without change (e.g. of power settings). Not yet defined value Not applicable Applicable...
  • Page 24 Model-related data (basic design) Description 12V 2000 12V 2000 16V 2000 16V 2000 18V 2000 Engine with exhaust turbo- charging (ETC) and charge-air cooling (CAC) Uncooled exhaust lines Operating method: Four- stroke cycle, diesel, single-ac- tion Combustion method: direct fuel injection Cooling method: conditioned water Direction of rotation: c.c.w.
  • Page 25 Coolant system (HT circuit) Description 12V 2000 12V 2000 16V 2000 16V 2000 18V 2000 Coolant temperature (at en- °C gine connection: outlet to cooling equipment) Coolant temperature after en- °C gine, alarm Coolant temperature after en- °C gine, shutdown Coolant antifreeze content, max.
  • Page 26 General operating data Description 12V 2000 12V 2000 16V 2000 16V 2000 18V 2000 Cold start capability: air tem- °C perature (w/o start aid. w/o preheating, tolerance +/- 5%) - (case A) Coolant preheating: preheat- °C ing temperature (min.) Firing speed, from Firing speed.
  • Page 27 Acoustics Description 12V 2000 12V 2000 16V 2000 16V 2000 18V 2000 Exhaust noise, unsilenced - DL dB(A) (sound power level LW, ISO 6798, +3 dB(A) tolerance) Engine surface noise with at- dB(A) tenuated intake noise (filter) - DL (sound power level LW, ISO 6798+2 dB(A) tolerance) MS15019/04E 2016-02 | Technical Data | 27...

  • Page 28: 12/16/18V2000Gx5-Tb Engine Data, Fuel Optimized

    4.2 12/16/18V2000Gx5-TB engine data, fuel optimized Explanation Abbr. Meaning Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated, without change (e.g. of power settings). Not yet defined value Not applicable Applicable...
  • Page 29 Model-related data (basic design) Description 12V 2000 12V 2000 16V 2000 16V 2000 18V 2000 G25-TB G65-TB G25-TB G65-TB G65-TB Engine with exhaust turbo- charging (ETC) and charge-air cooling (CAC) Uncooled exhaust lines Operating method: Four- stroke cycle, diesel, single-ac- tion Combustion method: direct fuel injection...
  • Page 30 Coolant system (HT circuit) Description 12V 2000 12V 2000 16V 2000 16V 2000 18V 2000 G25-TB G65-TB G25-TB G65-TB G65-TB Coolant temperature (at en- °C gine connection: outlet to cooling equipment) Coolant temperature after en- °C gine, alarm Coolant temperature after en- °C gine, shutdown Coolant antifreeze content,...
  • Page 31 Fuel system Description 12V 2000 12V 2000 16V 2000 16V 2000 18V 2000 G25-TB G65-TB G25-TB G65-TB G65-TB Fuel pressure at engine inlet -0.3 -0.3 -0.3 -0.3 -0.3 connection, min. (when en- gine is starting) Fuel pressure at engine inlet +0.5 +0.5 +0.5...
  • Page 32 Weights / main dimensions Description 12V 2000 12V 2000 16V 2000 16V 2000 18V 2000 G25-TB G65-TB G25-TB G65-TB G65-TB Engine weight, dry (basic en- 2570 2570 3180 3180 3580 gine configuration acc. to scope of delivery specifica- tion) Acoustics Description 12V 2000 12V 2000...

  • Page 33: 12V2000Gx5, Engine Data, Emissions Optimized

    4.3 12V2000Gx5, engine data, emissions optimized Explanation Abbr. Meaning Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated, without change (e.g. of power settings).
  • Page 34 Description 12V 2000 12V 2000 12V 2000 12V 2000 Operating method: Four-stroke cycle, die- sel, single-action Combustion method: direct fuel injection Cooling method: conditioned water Direction of rotation: c.c.w. (facing driving end) Number of cylinders Cylinder arrangement: V-angle degrees Bore Stroke Displacement, cylinder Liter...

  • Page 35: Fuel System

    Description 12V 2000 12V 2000 12V 2000 12V 2000 Lube-oil temperature before engine, alarm R °C Lube-oil temperature before engine, shut- °C down Lube-oil operating pressure before engine, from Lube-oil operating pressure before engine, Lube-oil operating pressure before engine, warning Lube-oil operating pressure before engine, shutdown Fuel system...

  • Page 36: R Liter

    Description 12V 2000 12V 2000 12V 2000 12V 2000 Oil pan capacity dipstick mark min. Liter (standard oil system) (design: max. oper- ating inclinations) Oil pan capacity dipstick mark max. Liter (standard oil system) (design: max. oper- ating inclinations) Weights / main dimensions Description 12V 2000 12V 2000...

  • Page 37: 16/18V2000Gx5 Engine Data, Emissions Optimized

    4.4 16/18V2000Gx5 engine data, emissions optimized Explanation Abbr. Meaning Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated, without change (e.g. of power settings). Not yet defined value Not applicable Applicable...
  • Page 38 Model-related data (basic design) Description 16V 2000 16V 2000 16V 2000 16V 2000 18V 2000 18V 2000 Engine with ex- haust turbocharg- ing (ETC) and charge-air cooling (CAC) Uncooled exhaust lines Operating meth- od: Four-stroke cycle, diesel, sin- gle-action Combustion method: direct fuel injection Cooling method:...
  • Page 39 Combustion air / exhaust gas Description 16V 2000 16V 2000 16V 2000 16V 2000 18V 2000 18V 2000 Charge-air pres- bar abs sure before cylin- der - DL Coolant system (HT circuit) Description 16V 2000 16V 2000 16V 2000 16V 2000 18V 2000 18V 2000 Coolant tempera-...
  • Page 40 Description 16V 2000 16V 2000 16V 2000 16V 2000 18V 2000 18V 2000 Lube-oil operating pressure before engine, warning Lube-oil operating pressure before engine, shutdown Fuel system Description 16V 2000 16V 2000 16V 2000 16V 2000 18V 2000 18V 2000 Fuel pressure at -0.3 -0.3...
  • Page 41 Description 16V 2000 16V 2000 16V 2000 16V 2000 18V 2000 18V 2000 Engine oil capaci- Liter ty, initial filling (standard oil sys- tem) (design: max. operating in- clinations) Oil change capaci- Liter ty, max. (standard oil system) Oil change quanti- Liter ty max.
  • Page 42 Acoustics Description 16V 2000 16V 2000 16V 2000 16V 2000 18V 2000 18V 2000 Exhaust noise, un- dB(A) silenced - DL (sound power lev- el LW, ISO 6798, +3 dB(A) toler- ance) Engine surface dB(A) noise with attenu- ated intake noise (filter) - DL (sound power level LW, ISO 6798,...

  • Page 43: 12/16/18V2000Gx5-Tb Engine Data, Emissions Optimized

    4.5 12/16/18V2000Gx5-TB engine data, emissions optimized Explanation Abbr. Meaning Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated, without change (e.g. of power settings). Not yet defined value Not applicable Applicable...
  • Page 44 Model-related data (basic design) Description 12V 2000 12V 2000 16V 2000 16V 2000 18V 2000 G45-TB G85-TB G45-TB G85-TB G85-TB Engine with exhaust turbo- charging (ETC) and charge-air cooling (CAC) Uncooled exhaust lines Operating method: Four- stroke cycle, diesel, single-ac- tion Combustion method: direct fuel injection...
  • Page 45 Coolant system (HT circuit) Description 12V 2000 12V 2000 16V 2000 16V 2000 18V 2000 G45-TB G85-TB G45-TB G85-TB G85-TB Coolant temperature (at en- °C gine connection: outlet to cooling equipment) Coolant temperature after en- °C gine, alarm Coolant temperature after en- °C gine, shutdown Coolant antifreeze content,...

  • Page 46: Min. (Standard Oil System) (De- Sign: Max. Operating Inclina- Tions)

    Fuel system Description 12V 2000 12V 2000 16V 2000 16V 2000 18V 2000 G45-TB G85-TB G45-TB G85-TB G85-TB Fuel pressure at engine inlet -0.3 -0.3 -0.3 -0.3 -0.3 connection, min. (when en- gine is starting) Fuel pressure at engine inlet +0.5 +0.5 +0.5...
  • Page 47 Weights / main dimensions Description 12V 2000 12V 2000 16V 2000 16V 2000 18V 2000 G45-TB G85-TB G45-TB G85-TB G85-TB Engine weight, dry (basic en- 2570 2570 3180 3180 3500 gine configuration acc. to scope of delivery specifica- tion) Acoustics Description 12V 2000 12V 2000...

  • Page 48: Firing Order

    4.6 Firing order Firing order Number of cylinders Firing order A1-B2-A5-B4-A3-B1-A6-B5-A2-B3-A4-B6 A1-B5-A3-A5-B2-B8-A2-A8-B3-A7-B4-B6-A4-A6-B1-B7 A1-B6-A3-B4-A5-B2-A7-B1-A9-B3-A8-B5-A6-B7-A4-B9-A2-B8 48 | Technical Data | MS15019/04E 2016-02...

  • Page 49: Engine - Main Dimensions

    4.7 Engine – Main dimensions Engine model Length (A) Width (B) Height (C) 12V2000Gx5 approx. 1882 mm approx. 1580 mm approx. 1570 mm 16V2000Gx5 approx. 2226 mm approx. 1580 mm approx. 1572 mm 18V2000Gx5 approx. 2398 mm approx. 1580 mm approx.

  • Page 50: Operation

    5.1 Putting the engine into operation after extended out-of-service periods (>3 months) Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Preservation and Represervation Specifications (A001070/..) are available. Putting the PowerPack into operation after extended out-of-service-periods (>3 months) Item...

  • Page 51: Putting The Engine Into Operation After Scheduled Out-Of-Service-Period

    5.2 Putting the engine into operation after scheduled out-of- service-period Preconditions ☑ Engine is stopped and starting disabled. Putting the engine into operation Item Task Lube oil system Check oil level (→ Page 133); Cooling system Check engine coolant level (→ Page 136); Check charge-air coolant level (→...

  • Page 52: Engine - Starting In Manual Mode (Test Run)

    5.3 Engine – Starting in manual mode (test run) Preconditions ☑ Generator (if fitted) is not connected to network. ☑ External start interlock is not active. DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...

  • Page 53: Safety System - Override

    5.4 Safety system – Override NOTICE Safety functions and engine shutdown alarms will be disregarded. Severe material damage! • Initiate emergency start only in emergency situations. NOTICE Inadmissible operating status. Severe damage to property! • Use override function only in hazardous situations to ensure full capability in the event of engine faults.

  • Page 54: Operational Monitoring

    5.5 Operational monitoring DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running. Risk of damage to hearing! •...

  • Page 55: Engine - Stopping In Manual Mode (Test Run)

    5.6 Engine – Stopping in manual mode (test run) Preconditions ☑ Generator (if fitted) is not connected to network ☑ Engine in manual mode NOTICE Stopping the engine when it is running at full load subjects it to extreme thermal and mechanical stress- Overheating of and, therefore, damage to components is possible! •...

  • Page 56: Engine - Emergency Stop

    5.7 Engine – Emergency stop NOTICE An emergency stop subjects the engine system to an extremely high load. Risk of overheating, damage to components! • Trigger an emergency stop only in emergency situations. Emergency engine stop from LOP Item Action Emergency stop pushbutton Press pushbutton.

  • Page 57: After Stopping The Engine - Engine Remains Ready For Operation

    5.8 After stopping the engine – Engine remains ready for operation After stopping the engine Item Action Engine/generator/pump Select operating mode, e.g. MANUAL, AUTOMATIC OPERATION. control MS15019/04E 2016-02 | Operation | 57...

  • Page 58: After Stopping The Engine - Putting The Engine Out Of Operation

    5.9 After stopping the engine – Putting the engine out of operation Preconditions ☑ MTU Preservation and Represervation Specifications (A001070/..) are available. After stopping the engine Item Action Coolant circuit Drain engine coolant (→ Page 138); Drain charge-air coolant (→ Page 144) if: •...

  • Page 59: Maintenance

    6 Maintenance 6.1 Maintenance task reference table [QL1] The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Mainte- nance Schedule is a stand-alone publication. The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule.

  • Page 60: Fault Indication On Sam Display - Genset Applications

    7 Troubleshooting 7.1 Fault indication on SAM display – Genset applications SAM fault messages 1 2-line LC display 3 Fault type 2 Time indicator for alarms 4 Node number The structure of the display is as follows: • First line –...
  • Page 61 Fault type – fault message text SE no. Error message text Sensor Temperatur Defect Temperature failure Sensor Voltage Defect Voltage failure CAN Bus- 1 Error/Bus Defec CAN Bus- 1 Overrun CAN Bus- 2 Error/Bus Defec CAN Bus- 2 Overrun Temperatur Compensation Error I/O-Module Slot2 Defect I/O-Module Slot3 Defect I/O-Module Slot4 Defect...
  • Page 62 The fault code (1) comprises three digits. Fault messages can also be caused by faulty sensors/actuators. Contact Service to have sensors/actuators checked and replaced as necessary if the troubleshooting measures listed in the table below prove unsuc- cessful. IMPORTANT NOTE: The information provided in the columns “Meaning”...
  • Page 63 Fault Setting parame- code no. Full designation Meaning Action ter no. SS T-Charge Air Main warning: Charge-air Check cooler, check 2.0121.932 temperature too high (limit intercooler, contact value 2, alarm configuration Service if no fault parameter, see PR detected. 2.8008.100 for explanation). HI T-Coolant Intercool- Prewarning: Coolant temper- Check cooler, con-...
  • Page 64 Fault Setting parame- code no. Full designation Meaning Action ter no. LO P-Fuel Fuel inlet pressure too low Check filter, check 2.0102.921 (limit value 1, alarm configu- genset fuel supply. ration parameter, see PR 2.8008.100 for explanation). Warning. SS P-Fuel Fuel inlet pressure too low Check filter, check 2.0102.922...
  • Page 65 Fault Setting parame- code no. Full designation Meaning Action ter no. SS Release Speed Not Runup speed not reached Check for additional 2.1090.924 Reached (alarm configuration parame- messages. Recharge ter, see PR 2.8008.100 for battery. Engine un- explanation). Start terminat- der load: Check fuel supply;...
  • Page 66 Fault Setting parame- code no. Full designation Meaning Action ter no. HI ECU Power Supply Supply voltage too high (limit Check batteries and 2.0140.931 Voltage value 1, alarm configuration generator. parameter, see PR 2.8008.100 for explanation). Warning. HIHI ECU Power Sup- Supply voltage too high (limit Check batteries and 2.0140.932...
  • Page 67 Fault Setting parame- code no. Full designation Meaning Action ter no. AL CAN No PU-Data The selected CAN mode initi- Check devices con- 2.0500.683 alizes communication by nected to CAN. means of the PU data mod- ule. However, the required PU data module is unavaila- ble or invalid (alarm configu- ration parameter, see PR...
  • Page 68 Fault Setting parame- code no. Full designation Meaning Action ter no. SD T-Charge Air SD alarm configuration, Check sensor and 1.8004.571 charge-air temperature sen- wiring (B9), replace sor faulty, short circuit or as necessary. wire break. SD T-Coolant Intercool- SD alarm configuration, cool- Check sensor and 1.8004.574 ant temperature sensor of in-...
  • Page 69 Fault Setting parame- code no. Full designation Meaning Action ter no. AL Stop Camshaft Sen- Engine stop due to camshaft Check connector 1.8004.562 sor Defect sensor fault (and a previous and wiring to sensor crankshaft sensor fault in the B1, replace as nec- same operating cycle).
  • Page 70 Fault Setting parame- code no. Full designation Meaning Action ter no. SD Frequency Input SD alarm configuration, fre- Contact Service. 2.8006.590 quency input faulty, short cir- cuit or wiring damage. AL Timing Cylinder A1 Time-of-flight measuring fault Replace plug-in 1.8004.500 injector cylinder A1: Time-of- pump if this occurs flight value measured ex-...
  • Page 71 Fault Setting parame- code no. Full designation Meaning Action ter no. AL Timing Cylinder A8 Time-of-flight measuring fault Replace plug-in 1.8004.507 injector cylinder A8 Time-of- pump if this occurs flight value measured ex- frequently. tremely small or large (alarm configuration parameter, see PR 2.8008.100 for explana- tion).
  • Page 72 Fault Setting parame- code no. Full designation Meaning Action ter no. AL Timing Cylinder B5 Time-of-flight measuring fault Replace plug-in 1.8004.514 injector cylinder B5: Time-of- pump if this occurs flight value measured ex- frequently. tremely small or large (alarm configuration parameter, see PR 2.8008.100 for explana- tion).
  • Page 73 Fault Setting parame- code no. Full designation Meaning Action ter no. AL Wiring Cylinder A2 Wiring fault in injector wiring Check injector wir- 1.8004.521 cylinder A2. Result: Misfiring ing, rectify injector (alarm configuration parame- solenoid valve short ter, see PR 2.8008.100 for circuit (positive to explanation).
  • Page 74 Fault Setting parame- code no. Full designation Meaning Action ter no. AL Wiring Cylinder A8 Wiring fault in injector wiring Check injector wir- 1.8004.527 cylinder A8. Result: Misfiring ing, rectify injector (alarm configuration parame- solenoid valve short ter, see PR 2.8008.100 for circuit (positive to explanation).
  • Page 75 Fault Setting parame- code no. Full designation Meaning Action ter no. AL Wiring Cylinder B4 Wiring fault in injector wiring Check injector wir- 1.8004.533 cylinder B4. Result: Misfiring ing, rectify injector (alarm configuration parame- solenoid valve short ter, see PR 2.8008.100 for circuit (positive to explanation).
  • Page 76 Fault Setting parame- code no. Full designation Meaning Action ter no. AL Wiring Cylinder B10 Wiring fault in injector wiring Check injector wir- 1.8004539 cylinder B10. Result: Misfir- ing, rectify injector ing (alarm configuration pa- solenoid valve short rameter, see PR 2.8008.100 circuit (positive to for explanation).
  • Page 77 Fault Setting parame- code no. Full designation Meaning Action ter no. AL Open Load Cylinder Disruption fault in injector Check injector wir- 1.8004.545 wiring cylinder A6. Result: ing, exclude disrup- Misfiring (alarm configuration tion in solenoid parameter, see PR valve (e.g. by injec- 2.8008.100 for explanation).
  • Page 78 Fault Setting parame- code no. Full designation Meaning Action ter no. AL Open Load Cylinder Disruption fault in injector Check injector wir- 1.8004.551 wiring cylinder B2. Result: ing, exclude disrup- Misfiring (alarm configuration tion in solenoid parameter, see PR valve (e.g. by injec- 2.8008.100 for explanation).
  • Page 79 Fault Setting parame- code no. Full designation Meaning Action ter no. AL Open Load Cylinder Disruption fault in injector Check injector wir- 1.8004.557 wiring cylinder B8. Result: ing, exclude disrup- Misfiring (alarm configuration tion in solenoid parameter, see PR valve (e.g. by injec- 2.8008.100 for explanation).
  • Page 80 Fault Setting parame- code no. Full designation Meaning Action ter no. AL Stop MV-Wiring Injector wiring fault. Engine Check wiring, re- 1.8004.561 Ground stop configurable (alarm con- place wiring harness figuration parameter, see PR as necessary. 2.8008.100 for explanation). Possible causes: 1. Short cir- cuit of injector positive con- nection to ground of one or more injectors.
  • Page 81 Fault Setting parame- code no. Full designation Meaning Action ter no. AL Open Load Digital Line disruption at digital in- Check wiring. 2.8006627 Input 3 put 3, wiring faulty or no re- sistance via switch, (alarm configuration parameter, see PR 2.8008.100 for explana- tion).
  • Page 82 Fault Setting parame- code no. Full designation Meaning Action ter no. HIHI U-PDU Injector voltage too high (lim- Execute engine gov- 2.0141.932 it value 2, alarm configura- ernor self-test, re- tion parameter, see PR place engine gover- 2.8008.100 for explanation). nor in case of fault.
  • Page 83 External engine protection Contact Service. 2.0291.921 tion function active (alarm config- uration parameter, see PR 2.8008.100 for explanation). AL Call MTU Field Serv- Power reduction caused by Contact Service. 2.0555.001 maintenance function (main- tenance concept, alarm con- figuration parameter, see PR 2.8008.100 for explanation).

  • Page 84: Troubleshooting

    7.2 Troubleshooting Engine does not turn when starter is actuated Cause Corrective action Battery flat or faulty. u Charge or replace battery (see manufacturer's documentation). u Check if cable connections are properly secured (see Cable connections on battery are faulty. manufacturer's documentation).
  • Page 85 Engine governor is faulty. Charge-air temperature too high. Cause Corrective action Incorrect engine coolant u Check (MTU test kit). concentration. u Contact Service. Charge-air cooler is contaminated. u Check fans and air supply / ventilation ducts. Air inlet temperature in engine room is too high.
  • Page 86 Blue exhaust gas Cause Corrective action u Drain engine oil (→ Page 134). Too much engine oil in the engine u Replace (→ Page 94). Oil separator of crankcase breather contaminated. Exhaust turbocharger is faulty. u Contact Service. Cylinder head is faulty. u Contact Service.

  • Page 87: Task Description

    8 Task Description 8.1 Engine 8.1.1 Engine – Barring manually Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring device for 12V engines F6558556 Barring device for 16V, 18V engines F6558557 DANGER Rotating and moving engine parts.

  • Page 88: Engine - Barring With Starting System

    8.1.2 Engine – Barring with starting system Preconditions ☑ External pushbutton 'Bar engine without starting' is provided. DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Before cranking the engine with starter system, make sure that there are no persons in the engine's danger zone.

  • Page 89: Engine - Test Run

    8.1.3 Engine – Test run DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Before cranking the engine with starter system, make sure that there are no persons in the engine's danger zone.

  • Page 90: Cylinder Liner

    8.2 Cylinder Liner 8.2.1 Cylinder liner – Endoscopic examination Preconditions ☑ Engine is stopped and starting disabled Special tools, Material, Spare parts Designation / Use Part No. Qty. Rigid endoscope Y20097353 Preparatory steps Remove cylinder head cover (→ Page 100). Remove injector (→...
  • Page 91 Final steps Install injector (→ Page 106). Install cylinder head cover (→ Page 100). MS15019/04E 2016-02 | Cylinder Liner | 91...

  • Page 92: Instructions And Comments On Endoscopic And Visual Examination Of Cylinder Liners

    8.2.2 Instructions and comments on endoscopic and visual examination of cylinder liners Terms used for endoscopic examination Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic examina- tion report. Findings Explanations/Action Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing products, particles, broken-off burrs).
  • Page 93 Evaluation of findings and further measures The findings in the start phase of oxidation discoloration and heat discoloration are similar. A thorough inves- tigation and compliance with the above evaluation criteria allow an unambiguous evaluation. To avoid unnec- essary disassembly work, it is recommended that another inspection be carried out after further operation of the engine.

  • Page 94: Crankcase Breather

    8.3 Crankcase Breather 8.3.1 Crankcase breather – Oil separator replacement, diaphragm check and replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 8–40 Nm F30043446 Ratchet adapter F30027340 Engine oil Filter element...
  • Page 95 Checking diaphragm Remove cover (4). Remove spring (5), gasket (2) and dia- phragm (3). Check diaphragm (3) for damage, fit new dia- phragm if used one is damaged. Install diaphragm (3) on housing (1). Install new gasket (2) and spring (5) together with cover (4).

  • Page 96: Crankcase Breather - Wire Mesh Cleaning

    8.3.2 Crankcase breather – Wire mesh cleaning Special tools, Material, Spare parts Designation / Use Part No. Qty. Cleaner Diesel fuel Petroleum jelly Sealing ring (→ Spare Parts Catalog) WARNING Fuels are combustible and explosive. Risk of fire and explosion! •...

  • Page 97: Valve Drive

    8.4 Valve Drive 8.4.1 Valve clearance – Check and adjustment Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine coolant temperature is max. 40 °C. ☑ Valves are closed. Special tools, Material, Spare parts Designation / Use Part No. Qty.

  • Page 98: Adjusting Valve Clearance

    Check clearance of all valves at two crankshaft positions (firing TDC and overlap TDC at cylinder A1) in ac- cordance with the table: Position Cylinder Firing TDC at cylinder A1 Side A I – – X I – – X – – Side B –...
  • Page 99 Insert feeler gage between valve bridge and rocker arm to verify that the gage just passes through the gap. Result: Adjust valve clearance if this is not the case. Final steps Remove barring tool (→ Page 87). Install cylinder head cover (→ Page 100). Install cap.

  • Page 100: Cylinder Head Cover - Removal And Installation

    8.4.2 Cylinder head cover – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 8–40 Nm F30043446 Ratchet adapter F30027340 Gasket (→ Spare Parts Catalog) Preparatory steps On cylinder head covers with crankcase breather: Loosen clamps.

  • Page 101: Injection Pump / Hp Pump

    8.5 Injection Pump / HP Pump 8.5.1 Injection pump – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Injection pump (→ Spare Parts Catalog) Injection pump – Replacement Remove injection pump and install new one (→ Page 102). MS15019/04E 2016-02 | Injection Pump / HP Pump | 101...

  • Page 102: Injection Pump - Removal And Installation

    8.5.2 Injection pump – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 20–100 Nm F30026582 Ratchet adapter F30027340 Adapter F30006234 Crowfoot wrench, 19 mm F30027424 Crowfoot box wrench, 22 mm F30027425...
  • Page 103 Removing injection pump Mark installation position of injection pump. Disconnect cabling (1) from injection pump. Disconnect fuel line (2). Unscrew securing screws of injection pump by approx. 6 mm. Result: The preloaded compression spring presses the injection pump out of the crankcase. If not: •...
  • Page 104 Install injection pump securing screws and tighten to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Screw Tightening torque (Engine oil) 60 Nm +12 Nm Coat the mating face between union nut and fuel line, ball seal and thread on both ends of the fuel line (3) with engine oil.

  • Page 105: Injection Valve / Injector

    8.6 Injection Valve / Injector 8.6.1 Injector – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Injector (→ Spare Parts Catalog) Replacing injector Remove injector and install new injector (→ Page 106). MS15019/04E 2016-02 | Injection Valve / Injector | 105...

  • Page 106: Injector - Removal And Installation

    8.6.2 Injector – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring tool F6557929 Puller 3555890163/00 Fuel suction device F30378207 Torque wrench, 20–100 Nm F30026582 Ratchet adapter F30027340 Adapter F30006234...
  • Page 107 Removing injector Disconnect leak-off fuel line from cylinder head. Disconnect fuel line (1). Remove thrust screw (2). Pull off pressure pipe neck (3). Extract fuel from the exposed bores using the suction device. Remove sealing ring from pressure pipe neck (3). Remove screw (1).
  • Page 108 Remove sealing rings (1) and (2) of injec- tor (3) with a self-made hook. After removal, seal all openings with suitable covers. Remove sealing cap from cylinder head with screwdriver. Remove sealing ring. Installing injector Remove all covers before installation. Clean sealing surface on cylinder head and protective sleeve.
  • Page 109 Use engine barring device to turn engine sev- eral times to blow out remaining fuel. Fit sealing ring (2) with assembly compound on to injector (3). Coat sealing ring (1) with assembly com- pound to secure it on injector (3). Press injector (3) into cylinder head by hand.
  • Page 110 Tighten thrust screw (4) with torque wrench to the specified tightening torque. Name Size Type Lubricant Value/Standard Thrust screw M22 x 1.5 Tightening torque (Engine oil) 45 Nm ±2.5 Nm Loosen thrust screw (4) and tighten it again with torque wrench to the specified tightening torque. Name Size Type...

  • Page 111: Fuel System

    8.7 Fuel System 8.7.1 Fuel injection line – Pressure pipe neck replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 20–100 Nm F30026582 Ratchet adapter F30027340 Adapter F30006234 Open-end socket wrench, 19 mm F30025897...
  • Page 112 Replacing pressure pipe neck Disconnect fuel line (2). Blow out fuel line (2) with compressed air. Remove thrust screw (4). Withdraw pressure pipe neck (5). Coat sealing ring with grease and fit on new pressure pipe neck (5). Coat the tape of the pressure pipe neck (5) with engine oil.
  • Page 113 Final steps Clean mating faces on cylinder head and charge-air manifold. Check gaskets for damage and replace them, if required. Coat gaskets with grease and place onto cylinder head. Install charge-air pipes. Install engine governor (→ Page 157). Open fuel supply line. Vent fuel system (→...

  • Page 114: Fuel - Draining

    8.7.2 Fuel – Draining Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 8–40 Nm F30043446 Plug-in open-end wrench, 17 mm F30028341 Engine oil WARNING Fuels are combustible and explosive. Risk of fire and explosion! •...
  • Page 115 When fuel no longer emerges, install non-return valve and tighten to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Non-return valve Tightening torque (Engine oil) 10 Nm +1 Nm Install fuel line. Tighten nut on banjo union. MS15019/04E 2016-02 | Fuel System | 115...

  • Page 116: Fuel Pressure Relief Valve - Removal And Installation

    8.7.3 Fuel pressure relief valve – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Pressure relief valve (→ Spare Parts Catalog) Sealing ring (→ Spare Parts Catalog) Sealing ring (→...

  • Page 117: Fuel System - Venting

    8.7.4 Fuel system – Venting Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil WARNING Fuels are combustible and explosive. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. •...
  • Page 118 Loosen banjo screw (arrowed). Operate the pump with the handle until bub- ble-free fuel emerges. Tighten banjo screw. Loosen union nut of fuel return line. Loosen non-return valve (arrowed). Operate the pump with the handle until bub- ble-free fuel emerges. Tighten non-return valve to specified torque using a torque wrench.

  • Page 119: Fuel Filter

    8.8 Fuel Filter 8.8.1 Fuel filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Diesel fuel Easy-change filter (→ Spare Parts Catalog) WARNING Fuels are combustible and explosive. Risk of fire and explosion! •...

  • Page 120: Check And Adjustment Of Gage

    8.8.2 Fuel prefilter – Differential pressure gage check and adjustment of gage DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running.

  • Page 121: Fuel Prefilter – Draining

    8.8.3 Fuel prefilter – Draining Preconditions ☑ Engine is stopped and starting disabled (only in the case of single fuel prefilter). Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel Seal (→ Spare Parts Catalog) DANGER Rotating and moving engine parts.
  • Page 122 Open threaded vent plug (5) of the filter to be drained. Unlock drain valve (6) by pressing toggle and open it. Drain water and contamination from the filter until pure fuel emerges. Close drain valve (6). Remove screws securing the cover and take off cover (2).

  • Page 123: Fuel Prefilter – Flushing

    8.8.4 Fuel prefilter – Flushing Preconditions ☑ Engine is stopped and starting disabled (only in the case of single fuel prefilter). Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel Seal (→ Spare Parts Catalog) DANGER Rotating and moving engine parts.
  • Page 124 Fuel prefilter – Flushing Note: Only in the case of double fuel prefilter: Cut out the contaminated filter. 1 Left filter cut in 2 Right filter cut in Open threaded vent plug (5) of filter to be flushed. Unlock drain valve (6) by pressing toggle, open it and drain fuel.

  • Page 125: Fuel Prefilter – Cleaning

    8.8.5 Fuel prefilter – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel Sealing ring (→ Spare Parts Catalog) WARNING Fuels are combustible and explosive. Risk of fire and explosion! •...

  • Page 126: Fuel Prefilter – Filter Element Replacement

    8.8.6 Fuel prefilter – Filter element replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel Filter element (→ Spare Parts Catalog) Gasket (→ Spare Parts Catalog) WARNING Fuels are combustible and explosive.
  • Page 127 Open threaded vent plug (5) of contaminated filter. Unlock drain valve (6) by pressing toggle and open it. Drain water and contamination from filter. Close drain valve (6). Remove screws securing the cover and take off cover (2). Remove spring housing (4) and filter ele- ment (3).

  • Page 128: Charge-Air Cooling General, Left-Hand Side

    8.9 Charge-Air Cooling General, Left-Hand Side 8.9.1 Intercooler – Checking condensate drain for coolant discharge and obstructions Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Sealing ring (→ Spare Parts Catalog) WARNING Compressed air gun ejects a jet of pressurized air.

  • Page 129: Air Filter

    8.10 Air Filter 8.10.1 Air filter – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Air filter (→ Spare Parts Catalog) Filter insert (→ Spare Parts Catalog) Filter element (→ Spare Parts Catalog) Air filter – Replacement Remove air filter(s) and install new one(s) (→...

  • Page 130: Air Filter – Removal And Installation

    8.10.2 Air filter – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Variant A Loosen clamp (2). Remove air filter (1) and clamp (2) from con- necting flange of intake housing (3). Verify that there are no objects in the flange of the intake housing (3) and clean it.

  • Page 131: Air Intake

    8.11 Air Intake 8.11.1 Service indicator – Signal ring position check Preconditions ☑ Engine is stopped and starting disabled. Checking signal ring position Replace air filter if the signal ring (2) is com- pletely visible in the red area of the observa- tion window (3) (→...

  • Page 132: Starting Equipment

    8.12 Starting Equipment 8.12.1 Air starter – Manual operation DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Before cranking the engine with starter system, make sure that there are no persons in the engine's danger zone.

  • Page 133: Lube Oil System, Lube Oil Circuit

    8.13 Lube Oil System, Lube Oil Circuit 8.13.1 Engine oil – Level check Preconditions ☑ Engine is stopped and starting disabled. Oil level check prior to engine start Withdraw oil dipstick from guide tube and wipe it. Insert oil dipstick into guide tube up to the stop, withdraw after approx.

  • Page 134: Engine Oil – Change

    8.13.2 Engine oil – Change Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine is at operating temperature. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil Sealing ring (→...

  • Page 135: Oil Filtration / Cooling

    8.14 Oil Filtration / Cooling 8.14.1 Engine oil filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Engine oil Oil filter (→ Spare Parts Catalog) WARNING Hot oil.

  • Page 136: Circuit

    8.15 Coolant Circuit, General, High-Temperature Circuit 8.15.1 Engine coolant – Level check Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...

  • Page 137: Engine Coolant – Change

    8.15.2 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change Drain engine coolant (→ Page 138). Fill with engine coolant (→ Page 139). MS15019/04E 2016-02 | Coolant Circuit, General, High-Temperature Circuit | 137...

  • Page 138: Engine Coolant – Draining

    8.15.3 Engine coolant – Draining Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Sealing ring (→ Spare Parts Catalog) Sealing ring (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...

  • Page 139: Engine Coolant – Filling

    8.15.4 Engine coolant – Filling Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant WARNING Coolant is hot and under pressure.
  • Page 140 Final steps Start the engine and operate it at idle speed for some minutes. Check coolant level (→ Page 136), top up with coolant if required. 140 | Coolant Circuit, General, High-Temperature Circuit | MS15019/04E 2016-02...

  • Page 141: Coolant Pump – Relief Bore Check

    8.15.5 Coolant pump – Relief bore check DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running.

  • Page 142: Low-Temperature Circuit

    8.16 Low-Temperature Circuit 8.16.1 Charge-air coolant – Filling Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Sealing ring (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure.
  • Page 143 Charge-air coolant – Filling Fill treated coolant through filling line or through filler neck of coolant expansion tank until coolant level reaches marking plate. Install plug screws of filling points with new sealing rings. Check proper condition of breather valve (1), clean sealing faces if required. Fit breather valve (1) and close it.

  • Page 144: Charge-Air Coolant – Draining

    8.16.2 Charge-air coolant – Draining Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Sealing ring (→ Spare Parts Catalog) Sealing ring (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...

  • Page 145: Charge-Air Coolant – Change

    8.16.3 Charge-air coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Charge-air coolant – Change Drain charge-air coolant (→ Page 144). Fill with charge-air coolant (→ Page 142). MS15019/04E 2016-02 | Low-Temperature Circuit | 145...

  • Page 146: Charge-Air Coolant – Level Check

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

  • Page 147: Battery-Charging Generator

    8.17 Battery-Charging Generator 8.17.1 Battery-charging generator drive – Drive-belt check and adjustment Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Belt tension tester, 150–600 N Y20097429 Torque wrench, 20–100 Nm F30026582 Ratchet adapter F30027340...
  • Page 148 Checking drive belt tension Position pretension gage on drive belt mid- way between belt pulleys. Actuate pushbutton to press the tester uni- formly on the drive belt surface until the spring disengages. Do not press any further, otherwise the dis- play value will be falsified.

  • Page 149: Battery-Charging Generator Drive – Drive Belt Replacement

    8.17.2 Battery-charging generator drive – Drive belt replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 20–100 Nm F30026582 Ratchet adapter F30027340 Engine oil Drive belt (→ Spare Parts Catalog) Battery-charging generator drive –...

  • Page 150: Fan Drive

    8.18 Fan Drive 8.18.1 Fan drive – Drive-belt check and adjustment Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Belt tension tester 5505890119/00 Torque wrench, 20–100 Nm F30026582 Ratchet adapter F30027340 Engine oil Preparatory steps...
  • Page 151 Drive belt – Tension check, var- iant B Place belt-tension tester onto drive midway between the belt pulleys (arrowed). Actuate pushbutton to press the tester uni- formly on the drive belt surface until the spring disengages. Do not press any further, otherwise the dis- play value will be falsified.
  • Page 152 Drive belt – Tension adjustment, variant B Release screws (1, 4). Note: Bolt (3) is in position A for variant 50 Hz, and in position B for variant 60 Hz. Screw in screw (2) to tension drive belt. Check drive belt tension. Tighten screws (1) and (4) to specified torque using a torque wrench.

  • Page 153: Fan Drive – Drive Belt Replacement

    8.18.2 Fan drive – Drive belt replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Drive belt (→ Spare Parts Catalog) Preparatory steps Remove protective cover from cooler. Remove fan. Drive belt replacement, variant Loosen securing screwsBelt replacement (3).

  • Page 154: Wiring (General) For Engine/Gearbox/Unit

    8.19 Wiring (General) for Engine/Gearbox/Unit 8.19.1 Engine cabling – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Solvent (isopropyl alcohol) X00058037 Engine cabling – Check Check securing screws of cable clamps on engine and tighten loose screw connections. Ensure that cables are securely seated in clamps and cannot move freely.

  • Page 155: Accessories For (Electronic) Engine Governor / Control System

    8.20 Accessories for (Electronic) Engine Governor / Control System 8.20.1 Engine governor and connector – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Solvent (isopropyl alcohol) X00058037 NOTICE Insertion of unsuitable test probe, e.g.

  • Page 156: Engine Governor Plug Connections – Check

    8.20.2 Engine governor plug connections – Check Preconditions ☑ Engine stopped and starting disabled. ☑ Electronic engine management system is de-energized. NOTICE Insertion of unsuitable test probe, e.g. test prod. The contacts in the plug connection can be bent! • Carry out check of plug connection only with test connectors. Checking plug connections at engine governor Check all plug connections for secure seating.
  • Page 157 8.20.3 Engine governor ECU 7 – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine electronics is powered off. NOTICE Wrong engine governor installed. Engine damage! • When reassembling an engine, make sure that the governor with the data record for the given engine is installed.

  • Page 158: Abbreviations

    Association of American standardization organiza- tions Abgasturbolader Exhaust turbocharger (ETC) Baureihe Series Betriebsstoffvorschrift MTU Fluids and Lubricants Specifications, Publication No. A01061/.. Controller Area Network Data bus system, bus standard Cross Connection Gear Transfer gearbox CODAG Combined Diesel (engine) And Gas (tur-...
  • Page 159 Abbrevia- Meaning Explanation tion International Organization for Stand- International umbrella organization for all national ardization standardization institutes Kraftgegenseite Engine free end in accordance with DIN ISO 1204 Kraftseite Engine driving end in accordance with DIN ISO 1204 Liquid Crystal Display, Liquid Crystal Device Local Control Unit LOP subassembly...
  • Page 160 Abbrevia- Meaning Explanation tion Werkzeugkatalog Tool Catalog (TC) Zugehörigkeit-Kategorie-Parameter Assignment category parameter; number scheme for signals from the ADEC engine governor 160 | Appendix A | MS15019/04E 2016-02...

  • Page 161: Mtu Contact/Service Partners

    Local Support Experienced and qualified specialists place their knowledge and expertise at your disposal. For locally available support, go to the MTU Internet site: http://www.mtu-online.com 24h Hotline With our 24h hotline and high flexibility, we're your contact around the clock: during each operating phase, preventive maintenance and corrective operations in case of a malfunction, for information on changes in conditions of use and for supplying spare parts.

  • Page 162: Special Tools

    10 Appendix B 10.1 Special Tools Adapter Part No.: F30006234 Qty.: Used in: 8.5.2 Injection pump – Removal and installation (→ Page 102) Qty.: Used in: 8.6.2 Injector – Removal and installation (→ Page 106) Qty.: Used in: 8.7.1 Fuel injection line – Pressure pipe neck replacement (→...
  • Page 163 Barring tool Part No.: F6557929 Qty.: Used in: 8.6.2 Injector – Removal and installation (→ Page 106) Belt tension tester Part No.: 5505890119/00 Qty.: Used in: 8.18.1 Fan drive – Drive-belt check and adjustment (→ Page 150) Belt tension tester, 150–600 N Part No.: Y20097429 Qty.:...
  • Page 164 Crowfoot box wrench, 22 mm Part No.: F30027425 Qty.: Used in: 8.5.2 Injection pump – Removal and installation (→ Page 102) Qty.: Used in: 8.6.2 Injector – Removal and installation (→ Page 106) Qty.: Used in: 8.7.1 Fuel injection line – Pressure pipe neck replacement (→...
  • Page 165 Filter wrench Part No.: F30379104 Qty.: Used in: 8.8.1 Fuel filter – Replacement (→ Page 119) Qty.: Used in: 8.14.1 Engine oil filter – Replacement (→ Page 135) Fuel suction device Part No.: F30378207 Qty.: Used in: 8.6.2 Injector – Removal and installation (→ Page 106) Open-end socket wrench, 19 mm Part No.: F30025897...
  • Page 166 Puller Part No.: 3555890163/00 Qty.: Used in: 8.6.2 Injector – Removal and installation (→ Page 106) Ratchet adapter Part No.: F30027340 Qty.: Used in: 8.3.1 Crankcase breather – Oil separator replacement, di- aphragm check and replacement (→ Page 94) Qty.: Used in: 8.4.1 Valve clearance –...
  • Page 167 Rigid endoscope Part No.: Y20097353 Qty.: Used in: 8.2.1 Cylinder liner – Endoscopic examination (→ Page 90) Torque wrench, 0.5–5 Nm Part No.: 0015384230 Qty.: Used in: 8.5.2 Injection pump – Removal and installation (→ Page 102) Torque wrench, 20–100 Nm Part No.: F30026582 Qty.:...
  • Page 168 Torque wrench, 8–40 Nm Part No.: F30043446 Qty.: Used in: 8.3.1 Crankcase breather – Oil separator replacement, di- aphragm check and replacement (→ Page 94) Qty.: Used in: 8.4.2 Cylinder head cover – Removal and installation (→ Page 100) Qty.: Used in: 8.7.2 Fuel –...

  • Page 169: Index

     139 Contact persons 161 Engine coolant level  Coolant  – Check  136 – Change  137, 145 Engine data  – Charge air   – 12V2000Gx5   – Draining  144 – Emissions optimized  33 – Filling  142 – Fuel optimized  23 – Filling  139 –...
  • Page 170 – Removal  157 Engine oil  – Change  134 Maintenance schedule  Engine oil filter  – Maintenance task reference table [QL1]  59 – Replacement  135 MTU contact persons 161 Engine oil level  – Check  133 Engine sides  Operational checks  54 – Designation  18 Overview ...

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