MTU 12 V 2000 M72 Operating Instructions Manual
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MTU 12 V 2000 M72 Operating Instructions Manual

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Operating Instructions

Diesel Engine
12 V 2000 M72
16 V 2000 M72
M015650/05E

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Summary of Contents for MTU 12 V 2000 M72

  • Page 1: Operating Instructions

    Operating Instructions Diesel Engine 12 V 2000 M72 16 V 2000 M72 M015650/05E...
  • Page 2 All information in this manual 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

    Table of Contents 1 Safety 4.10 Emergency engine stop 4.11 After stopping the engine 1.1 Important requirements for all products 4.12 Fuel treatment system – Shutdown 1.2 Personnel and organizational requirements 4.13 Plant – Cleaning 1.3 Transport 1.4 Safety requirements for startup and 5 Maintenance operation 1.5 Safety requirements for maintenance and...
  • Page 4 8 Appendix A 7.15.8 Coolant filter – Replacement 8.1 Abbreviations 7.16 Raw Water Pump with Connections 8.2 MTU contact persons/service partners 7.16.1 Raw water pump – Relief bore check 7.17 Belt Drive 9 Appendix B 7.17.1 Drive belt – Condition check 9.1 Special Tools...

  • Page 5: Safety

    • With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubri- cants Specifications of the manufacturer) • With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU contact/Service partner) •...

  • Page 6: Personnel And Organizational Requirements

    1.2 Personnel and organizational requirements Organizational measures of the operator This manual must be issued to all personnel involved in operation, maintenance, repair or transporta- tion. Keep this manual handy in the vicinity of the product such that it is accessible to operating, mainte- nance, repair and transport personnel at all times.

  • Page 7: Transport

    Only set down engine on a firm, level surface. Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate. Never set an engine down on the oil pan unless expressively authorized to do so by MTU on a case-to- case basis.

  • Page 8: Safety Requirements For Startup And Operation

    1.4 Safety requirements for startup and operation Safety requirements for startup The product must be installed and accepted in accordance with manufacturers' specifications prior to initial startup. All the requisite regulatory approvals must have been granted and all startup requirements fulfilled prior to initial startup.

  • Page 9: Safety Requirements For Maintenance And Repair Work

    1.5 Safety requirements for maintenance and repair work Safety requirements before commencing 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 10 Pay particular attention to cleanliness at all times. Safety requirements after completing maintenance and repair work Ensure that all personnel is clear of danger zones before cranking. Check that all access ports/apertures which have been opened to facilitate working are closed again. Check that all safety equipment has been installed and that all tools and loose parts have been re- moved (especially the barring gear).
  • Page 11 Working on electrical/electronic assemblies Always obtain the permission of the duty supervisor before commencing maintenance or repair work or switching off any part of the electronic system required to do so. De-energize the appropriate areas prior to working on assemblies. Avoid damaging cabling during removal.

  • Page 12: Fire Prevention And Environmental Protection, Fluids And Lubricants, Auxiliary Materials

    The latest version can be found on the website on the "Technical Info" or "Spare Parts and Service" tabs at http://www.mtu-online.com. Consumable fluids and materials may also be hazardous or toxic. When using fluids, lubricants, consum- ables and other chemical substances, follow the safety regulations that apply to the product.

  • Page 13: Check

    Lead • Adopt suitable measures to avoid the formation of lead dust. • Switch on extraction system. • When working with lead or pastes that contain lead, avoid direct contact with the skin. Do not inhale lead vapors. • Wash hands after contact with lead or lead-containing substances. Compressed air Observe special safety precautions when working with compressed air: •...

  • Page 14: 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 15: General Information

    2 General Information 2.1 Tightening specifications for screws, nuts and bolts Tightening torques for setscrew and stud joints to MTN 5008 standard This standard applies to setscrews not subject to dynamic loads and the associated nuts according to: • MMN 384 •...
  • Page 16 Hand-tightening Machine-tightening Thread 8.8 M (Nm) 10.9 M (Nm) 8.8 M (Nm) 10.9 M (Nm) M22 x 1.5 M24 x 1.5 M24 x 2 1250 1175 M27 x 2 1350 1275 1200 1700 1100 1600 M30 x 2 1350 1900 1250 1800 = tightening torques...
  • Page 17 Not torsion-protected M (Nm) Torsion-protected M (Nm) Thread 1170 M27 x 2 1000 1230 1250 1575 *Protect screw shaft from torsion when tightening. = tightening torques Tightening torques for plug screws to MTN 5183-1 standard This standard applies to plug screws to DIN 908, DIN 910 and DIN 7604 with threaded end to DIN 3852 Form A (sealed with sealing ring to DIN 7603-Cu).
  • Page 18 Tightening torques M are given for screw plugs made of steel (St) with surface protected by a phos- phate coating and oiled or galvanized. Threads and mating faces beneath heads must be coated with engine oil prior to assembly. An assembly tolerance of +10% of the figures in the table is permitted due to unavoidable deviations during the tightening process.
  • Page 19 = tightening torques Tightening torques for plug screws to DIN 7604C (with long threaded end) Screwed into Thread Steel/gray cast iron M Al alloy M (Nm) (Nm) M8 x 1 M22 x 1.5 M26 x 1.5 M30 x 1.5 M38 x 1.5 M45 x 1.5 = tightening torques Tightening torques for banjo screws to MTN 5183-2 standard...
  • Page 20 The stated tightening torques M apply to steel (St) banjo screws with a phosphatized surface coating and oiled, or galvanized, and to banjo screws made of copper/aluminum alloys. Threads and mating faces beneath heads must be coated with engine oil prior to assembly. An assembly tolerance of +10% of the figures in the table is permitted due to unavoidable deviations during the tightening process.
  • Page 21 Tightening torques for male unions to MTN 5183-3 standard This standard applies to male unions to DIN 2353 Series L with threaded end to DIN 3852 Form A (sealed by sealing ring to DIN 7603-Cu). Tightening torques M are given for male unions made of steel (St) with phosphatized surface coating and oiled, or galvanized.
  • Page 22 Tightening torques for union nuts to DIN 3859-2 1 Union nut 2 Union body 3 O-ring 4 Ferrule Union nut: On installing the ball-type union, after tightening the union nut firmly by hand (noticeable increase in force), it should be tightened another 1/4 turn (90°) past this point. Tightening torques for spigot unions with O-ring to ISO 6149-2 Thread Torque (Nm) +10%...
  • Page 23 Thread Torque (Nm) +10% M33 x 2 M42 x 2 M48 x 2 M60 x 2 Only for sealing off installation spaces for screw-in valves (see ISO 7789) Tightening torques for spigot unions with O-ring to ISO 6149-3 Thread Torque (Nm) +10% M8 x 1 M10 x 1 M12 x 1.5...
  • Page 24 Tightening torques for plug screws to MTN 5183-6 Screwed into Thread Steel/gray cast iron M AI alloy M (Nm) (Nm) M10 x 1 10+ 2 M12 x 1.5 14+ 2 M14 x 1.5 15+ 3 M16 x 1.5 18+ 3 M18 x 1.5 23+ 3 M22 x 1.5...
  • Page 25 Sealing head/sealing cone with metric union nut Metric thread Pipe outer dia. Torque (Nm) M16 x 1.5 M18 x 1.5 M20 x 1.5 M22 x 1.5 M24 x 1.5 M26 x 1.5 M30 x 2 M36 x 2 M42 x 2 M45 x 2 M52 x 2 Sealing head with BSP union nut...

  • Page 26: Engine Side And Cylinder Designations

    2.2 Engine side and cylinder designations Engine sides are always designated as viewed from the driving end (KS) (4). For designation of the cylinders (to DIN ISO 1204) the letter "A" (1) is used to refer to the cylinders on the left-hand side of the engine and the letter "B"...

  • Page 27: Product Description

    2.3 Product description Description of the engine Engine The engine is a liquid-cooled four-stroke diesel engine with c.c.w. direction of rotation, direct injection, sequential turbocharging and charge-air cooling. An electronic management system provides engine control and monitoring. Fuel system with Common Rail injection Controlled by the electronic engine management system, the common rail injection system determines injection pressure, injection timing and injection quantity independently of the engine speed.
  • Page 28 • Interface to ECU and EMU • MCS5 dialog interface • Control of an MTU lube-oil priming pump (power components in separate MTU PPC Box) • Connection facility for an MTU Local Operating Station (LOS) Serial RS422 interface for diagnosis The engine interface is divided into two parts.
  • Page 29 Monitoring: • Exhaust gas temperature, A side • Exhaust temperature, B-side • Engine speed • Oil pressure • Differential oil pressure • Coolant temperature • Coolant level • Exhaust turbocharger speed • Leak fuel level • Oil temperature • Coolant pressure •...
  • Page 30 Plug-in pipe union The sleeve (3) covers the joint to prevent lateral spray. Only leak-off along the line is possible, the pressure decreases significantly if an O-ring (2) fault occurs. The connection is confirmed as compliant with SOLAS by DNV and GL. Plugs and sensors Screw-in plugs (4) are sealed toward the outside either with a copper sealing ring (1), according to DIN, or an O-ring (ISO).
  • Page 31 HP line between distributor and HP accumulator 1 Union nut 4 Thrust screw 7 Thrust ring 2 O-ring 5 O-ring 8 Pressure pipe 3 Thrust ring 6 O-ring 9 Jacket pipe M015650/05E 2014-03 | General Information | 31...
  • Page 32 HP line between distributor and HP accumulator 1 Jacket pipe 5 O-ring 9 HP line 2 O-ring 6 Thrust screw 10 Pressure pipe 3 O-ring 7 Thrust ring 4 Thrust ring 8 O-ring Leak-off fuel caused by leakages from the sealing cones or the HP lines is returned to the HP pump, from where it is routed at atmospheric pressure into a level-monitored leak-fuel tank.

  • Page 33: Engine Overview

    2.4 Engine overview Engine overview Also applies similarly to 12V. 1 Engine oil heat exchanger 14 Exhaust turbocharger (pri- 27 Engine Interface Module 2 Engine oil filter mary turbocharger) 3 Coolant filter 15 Exhaust turbocharger, left 28 Gearcase 4 Change-over lever for en- (secondary turbocharger) 29 Raw water pump gine oil filter...
  • Page 34 1 Exhaust turbocharger, left 11 Fuel filter 21 Oil dipstick (secondary turbocharger) 12 Engine oil heat exchanger 22 Drive flange 2 Exhaust turbocharger (pri- 13 Coolant distribution hous- 23 Flywheel housing mary turbocharger) ing with integrated expan- 24 Engine mounting 3 Air intake sion tank 25 Carrier housing middle...

  • Page 35: Sensors And Actuators - Overview

    2.5 Sensors and actuators – Overview Engine plan view Deviations from illustrations are insignificant. Also applies similarly to 12V. Item Designation Monitoring of Intake air temperature Charge-air temperature Lube oil temperature Charge-air pressure Turbocharger speed M015650/05E 2014-03 | General Information | 35...
  • Page 36 Engine free end Item Designation Monitoring of Fuel pressure after filter B5.3 (optional) Lube oil pressure before filter B5.1 Lube oil pressure after filter B5.2 (optional) Lube oil pressure after filter Engine coolant level, expansion tank B21 (optional) Raw water pressure B6.2 (optional) Coolant temperature B6.1...
  • Page 37 Engine driving end Item Designation Monitoring of B1 (ECU) Camshaft speed B13.2 (optional EMU) Crankshaft speed B13 (ECU) Crankshaft speed M015650/05E 2014-03 | General Information | 37...
  • Page 38 Engine, right side Item Designation Monitoring of 2-2-directional control valve YB33 Fuel temperature Fuel pressure (in rail) B16 (optional) Coolant pressure Leak fuel level Y27.2 4-2-directional control valve, B-side B4.22 Exhaust temperature, B-side 38 | General Information | M015650/05E 2014-03...
  • Page 39 Engine, left side Item Designation Monitoring of B4.21 Exhaust gas temperature, A-side Y27.1 4-2-directional control valve, A-side B54 (optional) Lube oil pressure, replenishment pump System sensors These sensors are fitted outside the engine. Designation Monitoring of Starting-air pressure Fuel prefilter water level Exhaust back pressure Start interlock, switching status M015650/05E 2014-03 | General Information | 39...

  • Page 40: Technical Data

    3 Technical Data 3.1 12V 2000 M72 engine data: Engine-mounted heat exchanger, EPA stage 2 Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
  • Page 41 Raw water circuit (open circuit) Number of cylinders Raw water pump: Inlet pressure, min. -0.4 Raw water pump: Inlet pressure, max. +0.5 Pressure loss in engine-external raw water system, max. Lube oil system Number of cylinders Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C...
  • Page 42 Oil and coolant capacity Number of cylinders Engine coolant capacity, engine side (with cooling equipment) Liters Engine oil capacity, initial filling (standard oil system) (option: max. operating Liters inclinations) Oil change quantity, max. (standard oil system) (option: max. operating inclina- Liters tions) Oil pan capacity at dipstick mark “min.”...

  • Page 43: 2000 M72 Engine Data: Separate Heat Exchanger, Epa Stage

    3.2 12V 2000 M72 engine data: Separate heat exchanger, EPA stage 2 Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
  • Page 44 Lube oil system Number of cylinders Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C Lube oil operating pressure before engine, from Lube oil operating pressure before engine, to Lube oil operating pressure (low idle) (meas. point: before engine) Fuel system Number of cylinders Fuel pressure at engine inlet connection, min.
  • Page 45 Number of cylinders Oil pan capacity at dipstick mark “min.” (standard oil system) (option: max. op- Liters erating inclinations) Oil pan capacity at dipstick mark “max.” (standard oil system) (option: max. Liters operating inclinations) Weights / main dimensions Number of cylinders Engine dry weight (with attached standard accessories, without coupling) 2770 Noise...

  • Page 46: 2000 M72 Engine Data: Engine-Mounted Heat Exchanger, Epa Stage

    3.3 16V 2000 M72 engine data: Engine-mounted heat exchanger, EPA stage 2 Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
  • Page 47 Raw water circuit (open circuit) Number of cylinders Raw water pump: Inlet pressure, min. -0.4 Raw water pump: Inlet pressure, max. +0.5 Pressure loss in engine-external raw water system, max. Lube oil system Number of cylinders Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C...
  • Page 48 Oil and coolant capacity Number of cylinders Engine coolant capacity, engine side (with cooling equipment) Liters Engine oil capacity, initial filling (standard oil system) (option: max. operating Liters inclinations) Oil change quantity, max. (standard oil system) (option: max. operating inclina- Liters tions) Oil pan capacity at dipstick mark “min.”...

  • Page 49: 2000 M72 Engine Data: Separate Heat Exchanger, Epa Stage

    3.4 16 V 2000 M72 engine data: Separate heat exchanger, EPA stage 2 Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
  • Page 50 Lube oil system Number of cylinders Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C Lube oil operating pressure before engine, from Lube oil operating pressure before engine, to Lube oil operating pressure (low idle) (meas. point: before engine) Fuel system Number of cylinders Fuel pressure at engine inlet connection, min.
  • Page 51 Number of cylinders Oil pan capacity at dipstick mark “min.” (standard oil system) (option: max. op- Liters erating inclinations) Oil pan capacity at dipstick mark “max.” (standard oil system) (option: max. Liters operating inclinations) Weights / main dimensions Number of cylinders Engine dry weight (with attached standard accessories, without coupling) 3337 Noise...

  • Page 52: Firing Order

    3.5 Firing order Firing order 12 V A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1 16 V A1-B5-A3-A5-B2-B8-A2-A8-B3-A7-B4-B6-A4-A6-B1-B7 52 | Technical Data | M015650/05E 2014-03...

  • Page 53: Engine - Main Dimensions

    3.6 Engine – Main dimensions Main dimensions Engine model Length (A) Width (B) Height (C) 12V 2000 M72 Approx. 2078 mm Approx. 1295 mm Approx. 1390 mm 16V 2000 M72 Approx. 2486 mm Approx. 1295 mm Approx. 1390 mm M015650/05E 2014-03 | Technical Data | 53...

  • Page 54: Operation

    4 Operation 4.1 Putting the engine into operation after extended out-of-service periods (>3 months) Preconditions ☑Engine is stopped and starting disabled. ☑MTU Preservation and Represervation Instructions (A001070/..) available. Putting the engine into operation (out-of-service period > 3 months) Item Action Engine Depreserve (→...

  • Page 55: Engine - Putting Into Operation After Scheduled Out-Of-Service-Period

    4.2 Engine – Putting into operation after scheduled out-of-service- period Preconditions ☑Engine is stopped and starting disabled. Putting into operation Item Action Lube oil system Check engine oil level (→ Page 110). Coolant circuit Check coolant level (→ Page 122). Coolant circuit Heat engine coolant with coolant preheating unit.

  • Page 56: Tasks After Extended Out-Of-Service Periods (>3 Weeks)

    4.3 Tasks after extended out-of-service periods (>3 weeks) Tasks after extended out-of-service periods (>3 weeks) Note: Operate fuel treatment system for at least 5 minutes. Start up fuel treatment system (→ Page 58). Shut down fuel treatment system (→ Page 66). 56 | Operation | M015650/05E 2014-03...

  • Page 57: Checks Prior To Start-Up

    Checks prior to start-up Check tank and the entire pipework for cleanness. If microorganisms are detected: a) Clean affected components. b) Disinfect affected components with biocides (→ MTU Fluids and Lubricants Specifications A001061/..). Close drain valves on housing. Open all supply and discharge valves.

  • Page 58: Fuel Treatment System - Putting Into Operation

    4.5 Fuel treatment system – Putting into operation Fuel treatment system – Overview Switch on fuel treatment system (→ Page 61). Check the differential pressure at differential pressure gauge (8). Differential pressure in a new system: 0.1 bar to 0.3 bar. Result: If no differential pressure is measured, the coalescer filter element is probably being bypassed.

  • Page 59: Check

    Simulation of filter replacement with the engine running: HAT Switch on fuel treatment system (→ Page 61). Start engine (→ Page 62). Run engine at idling speed. Close ball cock (5) at the inlet to the fuel treatment system. Result: The pressure upstream of the fuel treatment system increases until the overflow valve at the pump unit opens and fuel flows through bypass (3) and bypass (2).

  • Page 60: Operational Checks

    4.6 Operational checks 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 61: Fuel Treatment System - Switching On

    4.7 Fuel treatment system – Switching on Preconditions ☑The on-board power supply is switched on. NOTICE Risk of damage to engine/system. Risk of severe damage to property! • Before switching on, ensure that the engine/system is ready for operation. • Before switching on, ensure that all housings are closed. •...

  • Page 62: Starting The Engine

    4.8 Starting the engine Preconditions ☑External start interlock is not active. ☑Emergency air shut-off flaps (if fitted) are open. 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 en- gine's danger zone.

  • Page 63: Engine - Shutdown

    4.9 Engine – Shutdown Preconditions ☑Engine is running in Local mode NOTICE Stopping the engine when it is running at full load causes extreme stress to the engine. Risk of overheating, damage to components! • Before shutting down, disengage gear and run the engine at idle speed for at least 10 minutes until engine temperatures have dropped and constant values are displayed.

  • Page 64: Emergency Engine Stop

    4.10 Emergency engine stop NOTICE An emergency stop causes extreme stress to the engine plant. Risk of overheating, damage to components! • Initiate emergency stop only in emergency situations. An emergency engine stop can be initiated from the following points Item Action Control stand...

  • Page 65: After Stopping The Engine

    Switch off. Air intake and exhaust sys- Out-of-service-period > 1 week • Seal engine's air and exhaust sides. Engine Out-of-service-period > 1 month • Depreserve engine (→ MTU Preservation and Represervation Specifica- tions A001070/..) M015650/05E 2014-03 | Operation | 65...

  • Page 66: Fuel Treatment System - Shutdown

    4.12 Fuel treatment system – Shutdown Shutting down fuel treatment system Press the illuminated pushbutton "Water drain" on the switch cabinet until water discharge from the outlet stops. Switch off fuel treatment system. Close ball valve at the inlet to the fuel treatment system. Close ball valve at the outlet of the fuel treatment system.

  • Page 67: Plant - Cleaning

    4.13 Plant – Cleaning Preconditions ☑Engine is stopped and starting disabled. ☑Operating voltage is not applied. Special tools, Material, Spare parts Designation / Use Part No. Qty. Steam jet cleaner Cleaner (Hakupur 312) 30390 WARNING Compressed air gun ejects a jet of pressurized air. Risk of injury to eyes and damage to hearing, risk of rupturing internal organs! •...

  • Page 68: Maintenance

    5 Maintenance 5.1 Maintenance task reference table [QL1] The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Maintenance Schedule is a stand-alone publication. The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule.

  • Page 69: Fuel Treatment System - Troubleshooting

    6 Troubleshooting 6.1 Fuel treatment system – Troubleshooting Illuminated pushbutton 'water alarm' is lit. Cause Corrective action When the maximum water level 1. Press illuminated pushbutton 'Water alarm' for is reached, the water level acknowledgment. electrode opens the water drain 2.

  • Page 70: Troubleshooting

    6.2 Troubleshooting Engine does not turn when starter is actuated Cause Corrective action u Charge or replace (see manufacturer's documentation). Battery low or faulty Battery: Cable connections u Check if cable connections are properly secured (see faulty manufacturer's documentation). u Check firm seating of cable connections, contact Service. Engine cabling or starter faulty u Check (→...
  • Page 71 Engine Control Unit defective u Contact Service. Charge-air temperature too high Cause Corrective action Incorrect coolant concentration u Check (MTU test kit). u Contact Service. Intercooler dirty u Check fans and air supply/ventilation ducts. Engine room: Air-intake temperature too high...
  • Page 72 White exhaust gas Cause Corrective action Engine is not at operating u Run engine to reach operating temperature. temperature Water in fuel u Drain fuel prefilter (→ Page 99). u Contact Service. Intercooler leaking 72 | Troubleshooting | M015650/05E 2014-03...

  • Page 73: Task Description

    7 Task Description 7.1 SOLAS 7.1.1 SOLAS shielding as per MTN 5233 – Installation Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Shield A4 735233000100 Shield A5 735233000101 Shield A7 735233000103 Shield A8 735233000104...

  • Page 74: Solas Shielding - Installation

    7.1.2 SOLAS shielding – Installation Preconditions ☑Engine is stopped and starting disabled. ☑Engine is cooled down to ambient temperature. Special tools, Material, Spare parts Designation / Use Part No. Qty. Oil filter shield X00009628 Fuel filter shield X00009654 Installing SOLAS shield on oil fil- ter and fuel filter Pinpoint installation location (→...

  • Page 75: Installation Locations For Solas Shielding

    7.1.3 Installation locations for SOLAS shielding General information Primarily fit SOLAS shielding as per MTN 5233 (→ Page 73). Free end B-side Item Type of shielding Comments 1 (free end, B-side) Shield (A7) On fuel delivery pump 2 (free end, B-side) Shield (A7) On HP fuel pump Free end...
  • Page 76 Item Type of shielding Comments 1 (free end) Shield (A8) On fuel filter 2 (free end) Shield (A7) Above fuel priming pump 3 (free end) Shield (A7) Below fuel priming pump Driving end A-side Item Type of shielding Comments 1 (Driving end, A-side) Shield (A5) On air flap 2 (driving end, A-side)
  • Page 77 Item Type of shielding Comments 1 (Driving end, A-side) Shield (A5) To turbocharger lubrication 2 (driving end, A-side) Shield (A5) On valve plate Driving end Item Type of shielding Comments 1 (driving end) Shield (A4) Turbocharger lubrication, left side 2 (driving end) Shield (A4) Turbocharger lubrication, center Driving end...
  • Page 78 Driving end B-side Item Type of shielding Comments 1 (driving end, B-side) Shield (A5) Turbocharger flap 2 (driving end, B-side) Shield (A5) Turbocharger flap 3 (driving end, B-side) Shield (A4) On brazed-on union 4 (driving end, B-side) Shield (A5) On air flap 5 (driving end, B-side) Shield (A4) To turbocharger lubrication...
  • Page 79 Driving end A-side Item Type of shielding Comments 1 (Driving end, A-side) Shield (A5) To flap control Driving end B-side Item Type of shielding Comments 1 (driving end, B-side) Shield (A5) To flap control M015650/05E 2014-03 | Task Description | 79...

  • Page 80: Engine

    7.2 Engine 7.2.1 Engine – Barring manually Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine barring gear F6783914 Ratchet F30006212 DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...

  • Page 81: Engine - Cranking On Starting System

    7.2.2 Engine – Cranking on starting system Preconditions ☑Clutch is disengaged. ☑Engine start is disabled. ☑LOP is accessible and open. DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...

  • Page 82: Cylinder Liner

    7.3 Cylinder Liner 7.3.1 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 91). Remove injector (→ Page 93). Positioning crankshaft at BDC Using barring gear, turn crankshaft until crankshaft journal of the cylinder to be inspected has reached BDC.
  • Page 83 Final steps Install injector (→ Page 93). Install cylinder head cover (→ Page 91). M015650/05E 2014-03 | Task Description | 83...

  • Page 84: Instructions And Comments On Endoscopic And Visual Examination Of Cylinder Liners

    7.3.2 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 ex- amination 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 85 Evaluation of findings and further measures The findings in the start phase of oxidation discoloration and heat discoloration are similar. A thorough investigation and compliance with the above evaluation criteria allow an unambiguous evaluation. To avoid unnecessary disassembly work, it is recommended that another inspection be carried out after further operation of the engine.

  • Page 86: Crankcase Breather

    7.4 Crankcase Breather 7.4.1 Crankcase breather – Cleaning oil pre-separator element Preconditions ☑Engine is stopped and starting disabled. WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. WARNING Compressed air gun ejects a jet of pressurized air.

  • Page 87: Crankcase Breather - Oil Separator Element Replacement, Diaphragm Check And Replacement

    7.4.2 Crankcase breather – Oil separator element replacement, diaphragm check and replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 6-50 Nm F30027336 Ratchet F30027340 Engine oil Filter element (→...

  • Page 88: Check

    Checking diaphragm Remove cover (4). Remove spring (5), gasket (2) and dia- phragm (3). Check diaphragm (3) for damage, fit new diaphragm if used one is damaged. Install diaphragm (3) on housing (1). Install new seal (2) and spring (5) together with cover (4).

  • Page 89: Valve Drive

    7.5 Valve Drive 7.5.1 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. Feeler gage Y4345893 Engine barring gear F6783914...

  • Page 90: Adjusting Valve Clearance

    Checking valve clearance at two crankshaft positions Check TDC position of piston in cylinder A1: • If the rocker arms are unloaded on cylinder A1, the piston is in firing TDC. • If the rocker arms are loaded on cylinder A1, the piston is in overlap TDC. Check valve clearance with cold engine: •...

  • Page 91: Cylinder Head Cover - Removal And Installation

    7.5.2 Cylinder head cover – Removal and installation Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Centering jig F6783025 Sealing (→ Spare Parts Catalog) Preparatory steps Remove air filter (→ Page 107). Remove air guide housing.

  • Page 92: Injection Valve / Injector

    7.6 Injection Valve / Injector 7.6.1 Injector – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Injector (→ Spare Parts Catalog) Remove injector and install new one. (→ Page 93) 92 | Task Description | M015650/05E 2014-03...

  • Page 93: Injector - Removal And Installation

    7.6.2 Injector – Removal and installation Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Socket wrench 0005896803/00 Puller F6790629 Double-head box wrench F30011450 Open-end wrench bit F30025897 Box wrench F30451199 Alignment device F6790507 Grease(Kluthe Hakuform 30-11C)
  • Page 94 Installing injector Prior to installation, remove all blanking plugs. Fit new O-rings onto injector and coat with grease. Fit new sealing ring with grease on injector, observe installation position of sealing ring. Clean sealing surface on cylinder head and protective sleeve. Insert injector (1) in cylinder head, ensuring that it is correctly aligned with the HP line connection.

  • Page 95: Fuel System

    7.7 Fuel System 7.7.1 Fuel system – Venting Preconditions ☑Engine is stopped and starting disabled. WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Venting fuel system Unlock fuel priming pump, unscrew handle.

  • Page 96: Fuel Filter

    7.8 Fuel Filter 7.8.1 Fuel filter – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Oil filter wrench F30379104 Diesel fuel Easy-change filter (→ Spare Parts Catalog) DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...

  • Page 97: Check

    Replacing easy-change fuel filter with the engine running Cut out the filter to be replaced. Open the threaded vent plugs at the filter head of the cut-out filter and make sure that the fuel filter is not pressurized. Note: New version has two threaded vent plugs, old version has four threaded vent plugs.

  • Page 98: Fuel Prefilter - Differential Pressure Check And Adjustment Of Gauge

    7.8.2 Fuel prefilter – Differential pressure check and adjustment of gauge 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 99: Fuel Prefilter - Draining

    7.8.3 Fuel prefilter – Draining Preconditions ☑Engine is stopped and starting disabled. WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Draining fuel prefilter Switch off filter which is to be drained (A or 1 Filter A switched off 2 Filter B switched off Open threaded vent plug (1) of the filter to...
  • Page 100 Connect filling pump to filling connection (1) on suction side of filter. Open vent valve (2) and fill with fuel until it emerges from the vent pipe (3). Close vent valve (2). Turn slide (4) a little (approx. 30°) and open vent valve(s) (2) until fuel emerges from the vent pipe (3).

  • Page 101: Fuel Prefilter - Flushing

    7.8.4 Fuel prefilter – Flushing Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel 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 Fuels are combustible.

  • Page 102: Check

    Open threaded vent plug (1) of filter to be flushed. Open drain valve (2) and drain fuel. Result: Fuel flows from filtered side back to the un- filtered side, flushing the filter deposits downwards out of the filter. Close threaded vent plug (1) and drain valve (2).

  • Page 103: Fuel Prefilter - Filter Element Replacement

    7.8.5 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) Sealing (→ Spare Parts Catalog) WARNING Fuels are combustible. Risk of fire and explosion! •...
  • Page 104 Open threaded vent plug (1) of contaminat- ed filter. Unlock drain valve (5) by pressing toggle and open it. Drain water and dirt from filter. Close drain valve (5). Remove screws securing cover (2) and take off cover. Remove spring cartridge (3) and filter ele- ment (4).

  • Page 105: Check

    7.9 Charge-Air Cooling 7.9.1 Intercooler – Checking condensate drain line for coolant discharge and obstruction 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 106: Air Filter

    7.10 Air Filter 7.10.1 Air filter – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Air filter (→ Spare Parts Catalog) Replacing the air filter Remove old air filter and install new air filter (→ Page 107). Reset signal ring of contamination indicator (→...
  • Page 107 7.10.2 Air filter – Removal and installation Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 4-20 Nm F30044239 Air filter – Removal and installa- tion Release clamp (2). Remove air filter (1) and clamp (2) from connecting flange of intake housing (3).

  • Page 108: Air Intake

    7.11 Air Intake 7.11.1 Service indicator – Signal ring position check (optional) Preconditions ☑Engine is stopped and starting disabled. Checking signal ring position If the signal ring is completely visible in the control window (2), replace air filter (→ Page 106). After installation of new filter, press reset button (1).

  • Page 109: Starting Equipment

    7.12 Starting Equipment 7.12.1 Starter – Condition check Preconditions ☑Engine is stopped and starting disabled. Checking starter condition Check securing screws of starter for secure seating and tighten if required. Check wiring (→ Page 138). M015650/05E 2014-03 | Task Description | 109...
  • Page 110 7.13 Lube Oil System, Lube Oil Circuit 7.13.1 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 111 7.13.2 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 WARNING Hot oil.
  • Page 112 7.14 Oil Filtration / Cooling 7.14.1 Engine oil filter – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Oil filter wrench F30379104 Engine oil Oil filter (→ Spare Parts Catalog) SOLAS shield (→ Spare Parts Catalog) DANGER Rotating and moving engine parts.
  • Page 113 Unscrew cut-out oil filter with oil filter wrench. Clean sealing surface on connecting piece. Check condition of new oil filter sealing ring and coat it with oil. Fit SOLAS shield (→ Page 73). Screw on and tighten new oil filter by hand. Replace other oil filters in the same way.
  • Page 114 7.14.2 Centrifugal oil filter and filter sleeve – Cleaning and replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Oil filter wrench F30379104 Cold cleaner(Hakutex 50) X00056751 Filter sleeve (→ Spare Parts Catalog) O-ring (→...
  • Page 115 Cleaning centrifugal oil filter and replacing filter sleeve Remove nut, holding the rotor with an oil filter wrench. Remove nut (1), washer (2), rotor cap (3) and O-ring (4). Remove filter sleeve (1). Measure the layer thickness of the oil resi- due.
  • Page 116 Fit new O-ring (4). Set on rotor cap (3), observe marks. Fit washer (2). Hold rotor (new design) with oil filter wrench and tighten nut (1) to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard M18 x 1.5 Tightening torque 10 Nm Hold rotor (old design) with oil filter wrench and tighten nut (1) to specified torque using a torque wrench.
  • Page 117 7.15 Coolant Circuit, General, High-Temperature Circuit 7.15.1 Drain and venting points 12 V, 16 V 1 Overflow line, expansion 2 Filler neck tank M015650/05E 2014-03 | Task Description | 117...
  • Page 118 Free end (KGS) 1 Fuel filter vent screws 3 Raw water pump filling 5 Raw water pump drain 2 Engine coolant drain plug plug plug 4 Measuring point, pressure 6 Connection for oil extrac- before raw water pump tion 118 | Task Description | M015650/05E 2014-03...
  • Page 119 Left side 1 Engine coolant drain plug 2 Engine coolant drain plug (M14x1.5) M015650/05E 2014-03 | Task Description | 119...
  • Page 120 Right side 1 Engine coolant drain plug 3 Oil dipstick (connection on (M14x1.5) left or right engine selecta- 2 Oil filler neck (connection ble) on left or right engine se- 4 Leak-fuel tank lectable) 120 | Task Description | M015650/05E 2014-03...
  • Page 121 Driving end (KS) 1 Engine coolant drain plug 2 Connection for oil extrac- tion M015650/05E 2014-03 | Task Description | 121...
  • Page 122 7.15.2 Engine coolant – Level check Preconditions ☑Engine is stopped and starting disabled. ☑MTU Fluids and Lubricants Specification (A001061/..) is available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask.
  • Page 123 7.15.3 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change Drain engine coolant (→ Page 124). Fill with engine coolant (→ Page 125). M015650/05E 2014-03 | Task Description | 123...

  • Page 124: Draining Engine Coolant

    7.15.4 Engine coolant – Draining Preconditions ☑Engine is stopped and starting disabled. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask. Preparatory steps Provide an appropriate container to collect the coolant or Switch on the extraction device.
  • Page 125 7.15.5 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. Engine coolant WARNING Coolant is hot and under pressure.
  • Page 126 7.15.6 HT 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 127: Engine Coolant – Sample Extraction And

    • corrosion inhibitor concentration; • pH value. Fit breather valve and close it. Change engine coolant according to the coolant operating times specified in the (→ MTU Fluids and Lu- bricants Specifications A001061/..)(→ Page 124). M015650/05E 2014-03 | Task Description | 127...
  • Page 128 7.15.8 Coolant filter – Replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Oil filter wrench F30379104 Coolant filter (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...

  • Page 129: Raw Water Pump With Connections

    7.16 Raw Water Pump with Connections 7.16.1 Raw water 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 130: Belt Drive

    7.17 Belt Drive 7.17.1 Drive belt – Condition check Preconditions ☑Engine is stopped and starting disabled. ☑Guard is removed. Drive belt – Condition check Item Findings Action Drive belt A Singular cracks None Drive belt B Cracks on entire circumference Replace (→...

  • Page 131: Battery-Charging Generator

    7.18 Battery-Charging Generator 7.18.1 Battery-charging generator drive – Drive belt replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Mandrel 8205892861/08 Preparatory steps Remove safety equipment (if fitted). Remove screws of protective cover (engine free end). Remove protective cover.

  • Page 132: Fuel Supply System

    7.19 Fuel Supply System 7.19.1 Water drain valve – Check Water drain valve – Check Open water drain valve. Check water outlet for obstructions. Close water drain valve. 132 | Task Description | M015650/05E 2014-03...
  • Page 133 7.19.2 Differential pressure gauge – Check WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Checking differential pressure gauge Switch on fuel treatment system (→ Page 61). Set the alarm points at the differential pressure gauge to zero.
  • Page 134 7.19.3 Water level probe (3-in-1 rod electrode) – Check Preconditions ☑System is put out of operation and emptied. WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Checking water level probe (3-in-1 rod electrode) Disconnect connector from water level probe.
  • Page 135 7.19.4 Pump capacity – Check WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Pump capacity – Check Install suitable pressure gauge in the intake connection of the pump. Check pump pressure.
  • Page 136 7.19.5 Coalescer filter element – Replacement Preconditions ☑System is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 6-50 Nm F30027336 Ratchet F30027339 Diesel fuel Engine oil Coalescer filter element (→ Spare Parts Catalog) Gasket (→...
  • Page 137 Tighten nut (3) to specified tightening torque using a torque wrench. Name Size Type Lubricant Value/Standard Tightening torque (Engine oil) 30 Nm +3 Nm Fit gasket (10). Install cover. Install screws (1), washers (2) and nuts (9). Tighten nuts (9). Open ball valve at the inlet and outlet of the fuel treatment system.
  • Page 138 7.20 Wiring (General) for Engine/Gearbox/Unit 7.20.1 Engine wiring – Check Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol X00058037 Engine wiring – Check Check securing screws of cable clamps on engine and tighten loose threaded connections. Ensure that cables are fixed in their clamps and cannot swing freely.
  • Page 139 7.21 Accessories for (Electronic) Engine Governor / Control System 7.21.1 Engine governor and connectors – Cleaning Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol X00058037 Note: Always use test connectors to enter the connectors. Never use test leads for this purpose. Otherwise the contacts could be bent.
  • Page 140 7.21.2 EMU and connectors – Cleaning Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol X00058037 Cleaning EMU and connectors Remove coarse dirt from housing surface using a cloth moistened with isopropyl alcohol. Remove dirt from the connector and cable surfaces with isopropyl alcohol.
  • Page 141 7.21.3 Engine governor plug connections – Check Preconditions ☑Engine stopped and starting disabled. 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 142 7.21.4 Engine Monitoring Unit EMU 7 – Plug connection check Preconditions ☑Engine is stopped and starting disabled. Checking EMU plug connections Check both connectors on EMU (2) for firm seating. Ensure that the clips (1) are engag- Check screws (3) of cable clamps on EMU (2) for firm seating.
  • Page 143 7.21.5 Interface module EIM plug connections – Check Preconditions ☑Engine is stopped and starting disabled. Checking EIM plug connections Check both Tyco plugs (62-pole) (2) on EIM for firm seating. Ensure that clips (3) are engaged. Check screws (1) of cable clamps on EIM for firm seating.
  • Page 144 7.21.6 Engine Control Unit – Self-test DANGER Electric voltage supply for operation. Danger of burns and fatal electric shock! • Make certain that the power supply to the product is switched off before starting work. Secure against unintentional switching on! ECU7 self-test Switch off power supply to system.
  • Page 145 7.21.7 Engine Control Unit ECU 7 – Removal and installation Preconditions ☑Engine is stopped and starting disabled. 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 146 7.21.8 Engine Monitoring Unit – Removal and installation Preconditions ☑Engine is stopped and starting disabled. 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. Removing Engine Control Unit with Engine Monitoring Unit from engine...
  • Page 147 7.21.9 Engine Interface Module EIM – Removal and installation Preconditions ☑Engine is stopped and starting disabled. Removing EIM from the engine Note or mark assignment of cables and connectors. Unscrew all screws (1). Undo clips (2) on connectors. Disconnect all connectors. Unscrew power and starter cable.

  • Page 148: Diagnostic Features Of Eim

    7.21.10 Diagnostic features of EIM Diagnostic lamp (DILA) A diagnostic lamp (LED, blue) is integrated in the housing of the Engine Interface Module (EIM). It indicates the operating status of the EIM. Functions of diagnostic lamp DILA DILA lights Engine Interface Module (EIM) is OK. DILA dark EIM supply voltage missing or diagnostic lamp activation is faulty.
  • Page 149 1 Preamble 6 VSP current path failed 11 ES pushbutton current 2 ECU current path failed (S5) path failed – 24V external (S1) 7 SLD current path failed (S10) 3 MCS current path failed (S6) 12 Key switch current path (S2) 8 DDV current path failed failed (S11)
  • Page 150 Sample flashing sequences A Fuse S5 failure (1/2 sec- B Fuse S1 and fuse S4 fail- ond steps) ure (1/2 second steps) Note: These bit sequences are transmitted constantly. Information about the status of the current paths of the EIM is also provided in the CAN message “Sta- tus internal power supply”.

  • Page 151: Abbreviations

    American National Standards Institute Governing body for US American standards Exhaust turbocharger Baureihe (Series) Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Publication No. A01061/.. Controller Area Network Data bus system, bus standard Calibration Drift Compensation Setting for drift correction with DiaSys in engine gov-...
  • Page 152 Abbrevia- Meaning Explanation tion Kraftseite Engine driving end in accordance with DIN ISO 1204 Liquid Crystal Display, Liquid Crystal Device Local Control Unit LOP subassembly Light Emitting Diode Local Monitoring Unit LOP subassembly Alarm: Measured value lower than 1st minimum limit LOLO Low Low Alarm: Measured value lower than 2nd minimum limit...

  • Page 153: Mtu Contact Persons/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 the outstanding flexibility of our service staff, we are always ready to assist you –...

  • Page 154: Appendix B

    9 Appendix B 9.1 Special Tools Alignment device Part No.: F6790507 Qty.: Used in: 7.6.2 Injector – Removal and installation (→ Page 93) Box wrench Part No.: F30451199 Qty.: Used in: 7.6.2 Injector – Removal and installation (→ Page 93) Centering jig Part No.: F6783025...
  • Page 155 Double-head box wrench Part No.: F30002800 Qty.: Used in: 7.5.1 Valve clearance – Check and adjustment (→ Page 89) Double-head box wrench Part No.: F30011450 Qty.: Used in: 7.6.2 Injector – Removal and installation (→ Page 93) Engine barring gear Part No.: F6783914 Qty.:...
  • Page 156 Measuring instrument Part No.: Y4345888 Qty.: Used in: 7.5.1 Valve clearance – Check and adjustment (→ Page 89) MTU test kit Part No.: 5605892099/00 Qty.: Used in: 7.15.7 Engine coolant – Sample extraction and analysis (→ Page 127) Offset screwdriver Part No.:...
  • Page 157 Oil filter wrench Part No.: F30379104 Qty.: Used in: 7.8.1 Fuel filter – Replacement (→ Page 96) Qty.: Used in: 7.14.1 Engine oil filter – Replacement (→ Page 112) Qty.: Used in: 7.14.2 Centrifugal oil filter and filter sleeve – Cleaning and replacement (→...
  • Page 158 Ratchet Part No.: F30027340 Qty.: Used in: 7.4.2 Crankcase breather – Oil separator element re- placement, diaphragm check and replacement (→ Page 87) Ratchet Part No.: F30027339 Qty.: Used in: 7.19.5 Coalescer filter element – Replacement (→ Page 136) Rigid endoscope Part No.: Y20097353 Qty.:...
  • Page 159 Socket wrench Part No.: 0005896803/00 Qty.: Used in: 7.6.2 Injector – Removal and installation (→ Page 93) Steam jet cleaner Part No.: Qty.: Used in: 4.13 Plant – Cleaning (→ Page 67) Torque wrench, 10-60 Nm Part No.: F30510423 Qty.: Used in: 7.5.1 Valve clearance –...
  • Page 160 Torque wrench, 6-50 Nm Part No.: F30027336 Qty.: Used in: 7.4.2 Crankcase breather – Oil separator element re- placement, diaphragm check and replacement (→ Page 87) Qty.: Used in: 7.19.5 Coalescer filter element – Replacement (→ Page 136) 160 | Appendix B | M015650/05E 2014-03...
  • Page 161 9.2 Index Numerics 12V 2000 M72 engine data: Engine-mounted heat ex- Designations  changer, EPA stage 2 40 – Engine sides and cylinders  26 12V 2000 M72 engine data: Separate heat exchanger, Differential pressure gauge  EPA stage 2 43 – Check  133 16 V 2000 M72 engine data: Separate heat exchanger, Drain and venting points 117 EPA stage...
  • Page 162 – Check  143 Tasks  Maintenance Schedule  – After extended out-of-service periods  56 – Reference table  68 Tasks after extended out-of-service periods (>3 weeks) 56 MTU contact persons 153 Tightening specifications  – Screws, nuts and bolts  15 Transport 7 Oil filter  Troubleshooting 70 – Replacement  112 –...
  • Page 163 Valve clearance  – Adjustment  89 – Check  89 Water drain valve  – Check  132 Water level probe (3-in-1 rod electrode)  – Check  134 M015650/05E 2014-03 | Appendix B | 163...

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