MTU 12V2000Gx6x Operating Instructions Manual
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MTU 12V2000Gx6x Operating Instructions Manual

MTU 12V2000Gx6x Operating Instructions Manual

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Operating Instructions

Diesel engine
12V2000Gx6x
16V2000Gx6x
18V2000Gx6x
12V2000Bx6x
16V2000Bx6x
18V2000Bx6x
MS150118/01E

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Summary of Contents for MTU 12V2000Gx6x

  • Page 1: Operating Instructions

    Operating Instructions Diesel engine 12V2000Gx6x 16V2000Gx6x 18V2000Gx6x 12V2000Bx6x 16V2000Bx6x 18V2000Bx6x MS150118/01E...
  • 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

    Table of Contents 1 Safety 6.2 Engine Control Unit – ECU9 fault messages 1.1 Important provisions for all products 7 Task Description 1.2 Personnel and organizational requirements 1.3 Transport 7.1 Engine 1.4 Safety regulations for maintenance and 7.1.1 Engine – Cranking manually repair work 7.1.2 Engine –...
  • Page 4 7.14 Battery-Charging Generator 7.14.1 Battery-charger drive – Drive belt replacement 8.1 List of abbreviations 7.15 Fuel Supply System 8.2 MTU contact persons/service partners 7.15.1 Differential pressure gage – Check 7.15.2 Coolant level sensor – Check 9 Appendix B 7.15.3 Pump capacity – Check 7.15.4 Coalescer filter element –...

  • 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 Replacing components with emission labels Emission labels are attached to all MTU engines. These must remain on the engine throughout its op- erational life. Engines used exclusively in land-based, military applications other than by US government agencies are excepted from this proviso.

  • Page 7: Personnel And Organizational Requirements

    1.2 Personnel and organizational requirements Organizational measures of the user/manufacturer 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 8: Transport

    Transport • Lift the engine/genset/system only with the lifting eyes provided. • Only use transport and lifting devices approved by MTU. • The engine/genset/system must only be transported in installation position. • Max. permissible diagonal pull 10°.

  • Page 9: Safety Regulations For Maintenance And Repair Work

    1.4 Safety regulations for maintenance and repair work 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 10 Always seal connections with caps or covers if a line is removed or opened. Fit new seals when re-installing lines. 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 ina slanted/twisted condition.
  • Page 11 For a hydraulic installation/removal device with central expansion pressure supply, screw spindle into shaft end until correct sealing is established. During hydraulic installation/removal of components, ensure that no persons are in the direct vicinity of the component being pressed on. Working with batteries Observe the safety instructions of the battery manufacturer when working with batteries.

  • Page 12: 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 13: Compressed Air

    Lead • Adopt suitable measures to avoid the formation of lead dust. • Switch on extraction system. • When working with lead or pastes containing lead, avoid direct contact to the skin and do not inhale lead vapors. • Wash relevant areas 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

    1.6 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 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 16: Engine - Overview

    2.2 Engine – Overview 12V2000Gx6F/Bx6F/B76 switchable 1 Air intake/air supply 6 Engine coolant pump 11 Charge-air line 2 Charge-air pipe 7 Fuel system (low pressure) 12 Starting equipment 3 Monitoring, control and 8 Fuel filter 13 PTO system, driving end regulation system 9 Exhaust turbocharger KS Driving end...
  • Page 17 16V2000Bx6F/Gx6F/B76 switchable 1 Air intake/air supply 6 Engine coolant pump 11 Charge-air line 2 Charge-air pipe 7 Fuel system (low pressure) 12 PTO system, driving end 3 Monitoring, control and 8 Fuel filter KS Driving end regulation system 9 Exhaust turbocharger 4 Charge-air line 10 Fuel system (high pres- 5 Belt drive...
  • Page 18 18V2000Bx6F/Gx6F/B76 switchable 1 Air intake/air supply 6 Engine coolant pump 11 Charge-air line 2 Charge-air pipe 7 Fuel system (low pressure) 12 Starting equipment 3 Monitoring, control and 8 Fuel filter 13 PTO system, driving end regulation system 9 Exhaust turbocharger KS Driving end 4 Charge-air line 10 Fuel system (high pres-...

  • Page 19: Technical Data

    3 Technical Data 3.1 12V/16V/18V2000B26F – Engine data 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 changes (e.g. to power settings). N Value not yet defined - Not applicable X Applicable...
  • Page 20 Number of cylinders Fuel temperature at engine supply °C connection Fuel temperature at engine supply °C connection, max. Table 5: Boundary conditions (for maximum power) Consumption Number of cylinders Lube oil consumption after % of B 100 hrs runtime (B = hourly fuel consumption) Table 6: Consumption Model related data (basic design)
  • Page 21 Coolant system (HT circuit) Number of cylinders Coolant temperature (at engine °C connection: outlet to cooling sys- tem) Coolant temperature after engine, °C warning Coolant temperature after engine, °C shutdown Coolant antifreeze content, max. Cooling system: Coolant volume m³/h 31.6 41.6 46.3 flow...
  • Page 22 Number of cylinders Lube oil temperature before en- °C gine, warning Lube oil temperature before en- °C gine, shutdown Lube oil operating pressure before engine, from Lube oil operating pressure before engine, to Lube oil operating pressure before engine, warning Lube oil operating pressure before engine, shutdown Lube oil microfilter (main flow):...
  • Page 23 Inclined positions, standard oil system (reference: waterline) Number of cylinders Longitudinal inclination, continu- Degrees (°) ous max. driving end bottom (op- tion: max. operating inclination po- sitions) Longitudinal inclination, continu- Degrees (°) ous max. driving end top (option: max. operating inclination posi- tions) Transverse inclination continuous Degrees (°)
  • Page 24 Number of cylinders Engine surface noise with attenu- dB(A) ated intake noise (filter) - DL (free- field sound power level Lp, 1 m distance, ISO 6798, +2 dB(A) tol- erance) Engine surface noise with attenu- dB(A) ated intake noise (filter) - DL (sound power level LW, ISO 6798+2 db(A) tolerance) Table 17: Sound...

  • Page 25: Engine Data 12V/16V/18V2000B76Switchable 1500 Rpm

    3.2 Engine data 12V/16V/18V2000B76switchable 1500 rpm 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 changes (e.g. to power settings). N Value not yet defined - Not applicable X Applicable...
  • Page 26 Number of cylinders Fuel temperature at engine supply °C connection Fuel temperature at engine supply °C connection, max. Table 20: Boundary conditions (for maximum power) Consumption Number of cylinders Lube oil consumption after % of B 100 hrs runtime (B = hourly fuel consumption) Table 21: Consumption Model related data (basic design)
  • Page 27 Coolant system (HT circuit) Number of cylinders Coolant temperature (at engine °C connection: outlet to cooling sys- tem) Coolant temperature after engine, °C warning Coolant temperature after engine, °C shutdown Coolant antifreeze content, max. Cooling system: Coolant volume m³/h 31.6 41.6 46.3 flow...
  • Page 28 Number of cylinders Lube oil temperature before en- °C gine, warning Lube oil temperature before en- °C gine, shutdown Lube oil operating pressure before engine, from Lube oil operating pressure before engine, to Lube oil operating pressure before engine, warning Lube oil operating pressure before engine, shutdown Lube oil microfilter (main flow):...
  • Page 29 Inclined positions, standard oil system (reference: waterline) Number of cylinders Longitudinal inclination, continu- Degrees (°) ous max. driving end bottom (op- tion: max. operating inclination po- sitions) Longitudinal inclination, continu- Degrees (°) ous max. driving end top (option: max. operating inclination posi- tions) Transverse inclination continuous Degrees (°)
  • Page 30 Number of cylinders Engine surface noise with attenu- dB(A) ated intake noise (filter) - DL (free- field sound power level Lp, 1 m distance, ISO 6798, +2 dB(A) tol- erance) Engine surface noise with attenu- dB(A) ated intake noise (filter) - DL (sound power level LW, ISO 6798+2 db(A) tolerance) Table 32: Sound...

  • Page 31: Engine Data 12V/16V/18V2000B76Switchable 1800 Rpm

    3.3 Engine data 12V/16V/18V2000B76switchable 1800 rpm 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 changes (e.g. to power settings). N Value not yet defined - Not applicable X Applicable...
  • Page 32 Number of cylinders Fuel temperature at engine supply °C connection Fuel temperature at engine supply °C connection, max. Table 35: Boundary conditions (for maximum power) Consumption Number of cylinders Lube oil consumption after % of B 100 hrs runtime (B = hourly fuel consumption) Table 36: Consumption Model related data (basic design)
  • Page 33 Coolant system (HT circuit) Number of cylinders Coolant temperature (at engine °C connection: outlet to cooling sys- tem) Coolant temperature after engine, °C warning Coolant temperature after engine, °C shutdown Coolant antifreeze content, max. Cooling system: Coolant volume m³/h 38.5 51.4 57.0 flow...
  • Page 34 Number of cylinders Lube oil temperature before en- °C gine, warning Lube oil temperature before en- °C gine, shutdown Lube oil operating pressure before engine, from Lube oil operating pressure before 10.0 engine, to Lube oil operating pressure before engine, warning Lube oil operating pressure before engine, shutdown Lube oil microfilter (main flow):...
  • Page 35 Inclined positions, standard oil system (reference: waterline) Number of cylinders Longitudinal inclination, continu- Degrees (°) ous max. driving end bottom (op- tion: max. operating inclination po- sitions) Longitudinal inclination, continu- Degrees (°) ous max. driving end top (option: max. operating inclination posi- tions) Transverse inclination continuous Degrees (°)
  • Page 36 Number of cylinders Engine surface noise with attenu- dB(A) ated intake noise (filter) - DL (free- field sound power level Lp, 1 m distance, ISO 6798, +2 dB(A) tol- erance) Engine surface noise with attenu- dB(A) ated intake noise (filter) - DL (sound power level LW, ISO 6798+2 db(A) tolerance) Table 47: Sound...

  • Page 37: 16V2000G16F - Engine Data

    3.4 12V/16V2000G16F – Engine data 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 changes (e.g. to power settings). N Value not yet defined - Not applicable X Applicable...
  • Page 38 Consumption Number of cylinders Lube oil consumption after 100 hrs runtime (B = hourly fuel con- % of B sumption) Table 51: Consumption Model related data (basic design) Number of cylinders Operating method: four-stroke cycle, diesel, single-action Combustion method: direct fuel injection Number of cylinders Cylinder arrangement: Vee angle Degrees...
  • Page 39 Coolant system (LT circuit) Number of cylinders Coolant temperature before charge-air cooler (at engine connec- °C tion: cooling system inlet) Coolant antifreeze content, max. Coolant pump: inlet pressure, max. Charge-air temperature after charge-air cooler, max. °C Breather valve (expansion tank) opening pressure at gauge pres- sure Cooling system: height above engine, max.
  • Page 40 Number of cylinders Firing speed, from Firing speed. to Table 58: General operating data Inclined positions, standard oil system (reference: waterline) Number of cylinders Longitudinal inclination, continuous max. driving end bottom (op- Degrees tion: max. operating inclination positions) (°) Longitudinal inclination, continuous max. driving end top (option: Degrees max.

  • Page 41: 16V/18V2000G26F - Engine Data

    3.5 12V/16V/18V2000G26F – Engine data 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 changes (e.g. to power settings). N Value not yet defined - Not applicable X Applicable...
  • Page 42 Consumption Number of cylinders Lube oil consumption after % of B 100 hrs runtime (B = hourly fuel consumption) Table 66: Consumption Model related data (basic design) Number of cylinders Operating method: four-stroke cy- cle, diesel, single-action Combustion method: direct fuel in- jection Number of cylinders Cylinder arrangement: Vee angle...
  • Page 43 Number of cylinders Coolant pump: inlet pressure, max. Pressure loss in external cooling system outside engine Breather valve (expansion tank) opening pressure at gauge pres- sure Cooling system: height above en- gine, max. Table 69: Coolant system (HT circuit) Coolant system (LT circuit) Number of cylinders Coolant temperature before °C...
  • Page 44 Number of cylinders Lube oil operating pressure before engine, shutdown Lube oil microfilter (main flow): number of cartridges per unit Table 71: Lube oil system Fuel system Number of cylinders Fuel pressure at engine supply -0.5 -0.5 -0.5 connection, min. (during engine start) Fuel pressure at engine supply connection, max.
  • Page 45 Capacities Number of cylinders Engine coolant capacity, engine Liters side (without cooling system) Charge-air coolant, engine side Liters Fuel, engine side Liters Engine oil capacity, initial filling Liters (standard oil system) (option: max. operating inclination positions) Oil change quantity max. (standard Liters oil system) (option: max.

  • Page 46: 16V2000G36F - Engine Data

    3.6 16V2000G36F – Engine data 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 changes (e.g. to power settings). N Value not yet defined - Not applicable X Applicable...
  • Page 47 Consumption Number of cylinders Lube oil consumption after 100 hrs runtime (B = hourly fuel consumption) % of B Table 81: Consumption Model related data (basic design) Number of cylinders Operating method: four-stroke cycle, diesel, single-action Combustion method: direct fuel injection Number of cylinders Cylinder arrangement: Vee angle Degrees (°)
  • Page 48 Coolant system (LT circuit) Number of cylinders Coolant temperature before charge-air cooler (at engine connection: cool- °C ing system inlet) Coolant antifreeze content, max. Coolant pump: inlet pressure, max. Charge-air temperature after charge-air cooler, max. °C Breather valve (expansion tank) opening pressure at gauge pressure Cooling system: height above engine, max.
  • Page 49 Inclined positions, standard oil system (reference: waterline) Number of cylinders Longitudinal inclination, continuous max. driving end bottom (option: max. Degrees (°) operating inclination positions) Longitudinal inclination, continuous max. driving end top (option: max. op- Degrees (°) erating inclination positions) Transverse inclination continuous max. (option: max. operating inclination Degrees (°) positions) Table 89: Inclined positions, standard oil system (reference: waterline)

  • Page 50: Firing Order

    3.7 Firing order Firing order Number of cylinders Firing order A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1 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 50 | Technical Data | MS150118/01E 2015-05...

  • Page 51: Engine - Main Dimensions

    3.8 Engine – Main dimensions Height (C) Engine model Length (A) Width (B) 12V2000B26F approx. 2044 mm approx. 1522 mm approx. 1470 mm 16V2000B26F approx. 2394 mm approx. 1570 mm approx. 1421 mm 18V2000B26F approx. 2569 mm approx. 1572 mm approx.

  • Page 52: Operation

    4 Operation 4.1 Preparing startup after long out-of-service periods (>3 months) Preconditions ☑Engine is stopped and starting disabled. ☑MTU Fluids and Lubricants Specifications (A001061/..) are available. Startup after long out-of-service periods (>3 months) Item Action Engine Remove preservative (→ Preservation and Represervation Specifications (A001070/…)).

  • Page 53: Preparations For Startup After Scheduled Out-Of-Service-Period

    4.2 Preparations for startup after scheduled out-of-service-period Preconditions ☑Engine is stopped and starting disabled. Startup Item Action Lube oil system Check engine oil level (→ Page 121). Coolant circuit Check engine coolant level (→ Page 126). Coolant circuit Preheat engine coolant with coolant preheating unit, if fitted. Fuel prefilter (if fitted) Drain water, see manufacturer's documentation.

  • Page 54: Starting The Engine

    4.3 Starting the engine Preconditions ☑Engine with no load. 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 55: Operation Monitoring

    4.4 Operation 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 56: Engine Shutdown

    4.5 Engine shutdown Preconditions ☑Engine is not connected to load. CAUTION Shutting down from full-load operation may cause hot water to escape from the expansion tank. Risk of scalding! • Allow engine to cool down. • Wear protective clothing, protective gloves, and safety goggles / safety mask. NOTICE Stopping the engine when it is running at full load subjects it to extreme thermal and mechanical stresses.

  • Page 57: Emergency Engine Stop

    4.6 Emergency engine stop CAUTION Shutting down from full-load operation may cause hot water to escape from the expansion tank. Risk of scalding! • Allow engine to cool down. • Wear protective clothing, protective gloves, and safety goggles / safety mask. NOTICE An emergency stop causes extreme stress to the engine plant.

  • Page 58: After Stopping The Engine

    4.7 After stopping the engine Preconditions ☑MTU Preservation and Represervation Instructions (A001070/..) are available. NOTICE Engine coolant with inadequate freeze protection. Water remaining in the pressure sensors freezes at temperatures below 0 °C. Risk of sensor damage! • Remove pressure sensors and shake off residual water.

  • Page 59: Plant - Cleaning

    4.8 Plant – Cleaning Preconditions ☑Engine is stopped and starting disabled. ☑No operating voltage is applied. Special tools, Material, Spare parts Designation / Use Part No. Qty. High-pressure cleaning unit Cleaner (Hakupur 50/136) X00056700 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 60: Maintenance

    5 Maintenance 5.1 Maintenance schedule task reference table [QL1] The maintenance tasks and intervals for this product are defined in the maintenance schedule. The maintenance schedule is an independent publication. The task numbers in this table provide reference to the maintenance tasks specified in the maintenance schedule.

  • Page 61: Troubleshooting

    6 Troubleshooting 6.1 Troubleshooting Engine does not turn when starter is actuated Component Cause Action Battery Low or faulty Charge or replace (see manufacturer's documentation). Cable connections faulty Check if cable connections are properly secured (see manufacturer's documen- tation). Starter Engine cabling or starter faulty Check if cable connections are properly secured, contact Service.
  • Page 62 Faulty Contact Service. Charge-air temperature too high Component Cause Action Engine coolant Engine coolant treatment incorrect Check (MTU test kit). Intercooler Contaminated Contact Service. Engine room Air-intake temperature too high Check fans and intake/exhaust lines. Charge-air pressure too low Component...
  • Page 63 Blue exhaust gas Component Cause Action Engine oil Too much engine oil in the engine Drain engine oil (→ Page 122). Oil separator of crankcase breather con- Replace (→ Page 94). taminated Exhaust turbocharger, Faulty Contact Service. cylinder head, piston rings, cylinder liner White exhaust gas Component...

  • Page 64: Engine Control Unit - Ecu9 Fault Messages

    6.2 Engine Control Unit – ECU9 fault messages 5 – HI T-Charge Air Yellow alarm; warning Cause Corrective action Charge-air temperature too high 1. Check coolant cooler and intercooler. (Level 1). 2. Contact Service if no malfunction can be detected. 6 –...
  • Page 65 23 – LO Coolant Level Red alarm; emergency stop Cause Corrective action Coolant level too low. 1. Check coolant circuit for leaks. Check coolant level in expansion tank, top up as necessary. 2. Contact Service if no malfunction can be detected. 25 –...
  • Page 66 44 – LO Coolant Level Intercooler Red alarm; emergency stop Cause Corrective action Intercooler coolant level too low. 1. Check coolant circuit for leaks. 2. Check coolant level in expansion tank, top up as necessary. 3. Contact Service if no malfunction can be detected. 51 –...
  • Page 67 65 – LO P-Fuel Yellow alarm; warning Cause Corrective action Fuel inlet pressure too low 1. Check fuel lines for leakage. (Level 1). 2. Drain fuel prefilter (→ Page 111). 3. Replace filter element of fuel prefilter (→ Page 114). 4.
  • Page 68 83 – LO P-Fuel (Common Rail) Yellow alarm; warning Cause Corrective action Rail pressure < set value; HP fuel 1. Check wiring of HP fuel control block. control block faulty or leakage in 2. Check high-pressure system for leaks. HP fuel system. 3.
  • Page 69 94 – LO T-Preheat Yellow alarm; warning Cause Corrective action Preheating temperature too low 1. Extend preheating period. (Level 1); coolant temperature 2. Check preheater. too low for engine start. 95 – AL Prelubrication Fault Yellow alarm; warning Cause Corrective action u Contact Service.
  • Page 70 121 – HIHI ECU Power Supply Voltage Yellow alarm; warning Cause Corrective action u Check batteries, charge as necessary; check alternator. Supply voltage too high (Level 122 – HI T-ECU Yellow alarm; warning Cause Corrective action Temperature of the electronics u Check engine room ventilation.
  • Page 71 183 – AL CAN No PU Data Yellow alarm; warning Cause Corrective action The selected CAN mode 1. Check devices connected to CAN. initializes communication by 2. Contact Service. means of the PU data module. However, the required PU data module is not available or not valid.
  • Page 72 189 – AL CAN2 Error Passive Yellow alarm; warning Cause Corrective action CAN controller 2 has signaled a 1. Check CAN bus for short circuit, rectify short circuit as warning. necessary. 2. Check shielding, improve shielding as necessary. 3. Contact Service. 201 –...
  • Page 73 215 – SD P-HD Yellow alarm; warning Cause Corrective action u Check sensor B48.1 and wiring, replace as necessary Rail pressure sensor faulty; High pressure regulator emergency (→ Page 148). operation mode. 216 – SD T-Lube Oil Yellow alarm; warning Cause Corrective action u Check sensor B7 and wiring, replace as necessary...
  • Page 74 223 – SD Level Coolant Intercooler Yellow alarm; warning Cause Corrective action Coolant level sensor for 1. Check sensor F57 and wiring, replace as necessary intercooler defective. (→ Page 148). 2. Fault is rectified when electronics are switched back on. 227 –...
  • Page 75 239 – SD P-Diff Fuel Yellow alarm; warning Cause Corrective action u Check sensor B34.2, sensor 34.3 and wiring, replace as Fuel pressure sensors faulty. necessary (→ Page 148). 240 – SD P-Fuel Yellow alarm; warning Cause Corrective action Fuel pressure sensor before u Check sensor B34.3 and wiring, replace as necessary intermediate filter faulty.
  • Page 76 321 – AL Wiring Cylinder A1 Yellow alarm; warning Cause Corrective action Short circuit in cylinder A1 1. Check injector wiring. injector wiring. Result: Misfiring. 2. Rectify injector solenoid valve short circuit (positive to negative) (e.g. by exchanging injectors). 3. Fault is rectified when engine is restarted. 322 –...
  • Page 77 326 – AL Wiring Cylinder A6 Yellow alarm; warning Cause Corrective action Short circuit in cylinder A6 1. Check injector wiring. injector wiring. Result: Misfiring. 2. Rectify injector solenoid valve short circuit (positive to negative) (e.g. by exchanging injectors). 3. Fault is rectified when engine is restarted. 327 –...
  • Page 78 332 – AL Wiring Cylinder B2 Yellow alarm; warning Cause Corrective action Short circuit in cylinder B2 1. Check injector wiring. injector wiring. Result: Misfiring. 2. Rectify injector solenoid valve short circuit (positive to negative) (e.g. by exchanging injectors). 3. Fault is rectified when engine is restarted. 333 –...
  • Page 79 337 – AL Wiring Cylinder B7 Yellow alarm; warning Cause Corrective action Short circuit in cylinder B7 1. Check injector wiring. injector wiring. Result: Misfiring. 2. Rectify injector solenoid valve short circuit (positive to negative) (e.g. by exchanging injectors). 3. Fault is rectified when engine is restarted. 338 –...
  • Page 80 344 – AL Open Load Cylinder A4 Yellow alarm; warning Cause Corrective action Open circuit in cylinder A4 1. Check injector wiring, exclude disruption in solenoid valve (e.g. injector wiring. Result: Misfiring. by injector replacement). 2. Fault is rectified after each working cycle. 345 –...
  • Page 81 351 – AL Open Load Cylinder B1 Yellow alarm; warning Cause Corrective action Open circuit in cylinder B1 1. Check injector wiring, exclude disruption in solenoid valve (e.g. injector wiring. Result: Misfiring. by injector replacement). 2. Fault is rectified after each working cycle. 352 –...
  • Page 82 357 – AL Open Load Cylinder B7 Yellow alarm; warning Cause Corrective action Open circuit in cylinder B7 1. Check injector wiring, exclude disruption in solenoid valve (e.g. injector wiring. Result: Misfiring. by injector replacement). 2. Fault is rectified after each working cycle. 358 –...
  • Page 83 365 – AL Stop SV-Wiring Ground Red alarm; Self-restoring Cause Corrective action u Check wiring, replace wiring harness as necessary. Injector wiring fault. 381 – AL Wiring TOP 1 Yellow alarm; warning Cause Corrective action Short circuit or wire break on u Check wiring (→...
  • Page 84 400 – AL Open Load Digital Input 1 Yellow alarm; warning Cause Corrective action u Check wiring (→ Page 148). Line disruption at digital input 1. 401 – AL Open Load Digital Input 2 Yellow alarm; warning Cause Corrective action Line disruption at digital input 2.
  • Page 85 408 – AL Open Load Emerg. Stop Input ESI Yellow alarm; warning Cause Corrective action u Check wiring (→ Page 148). Open circuit at input for emergency stop. 410 – LO U-PDU Yellow alarm; warning Cause Corrective action Injector voltage too low (Level u Perform Engine Control Unit self-test, replace as necessary.
  • Page 86 416 – SS P-Coolant Intercooler Yellow alarm; warning Cause Corrective action Coolant pressure in intercooler 1. Check coolant level in expansion tank, top up as necessary. too low (Level 2). 2. Check coolant circuit for leaks. 3. Check coolant pump. 417 –...
  • Page 87 445 – SD P-Ambient Air Yellow alarm; warning Cause Corrective action u Replace Engine Control Unit (sensor is in the ECU). Ambient air pressure sensor faulty. 446 – SD P-HD2 Yellow alarm; warning Cause Corrective action Rail pressure sensor faulty, high- u Check sensor B48.2 and wiring, replace as necessary pressure regulator emergency (→...
  • Page 88 474 – AL Wiring FO Yellow alarm; warning Cause Corrective action u Contact Service. Wire break or short circuit at FO channel. 476 – AL Crash Rec. Init. Error Yellow alarm; warning Cause Corrective action Initialization error of crash u Contact Service. recorder.
  • Page 89 549 – AL Power Cut-Off detected Entered in fault memory only. Cause Corrective action u Instruct the operator only to disconnect the power supply when The operating voltage of the Engine Control Unit was the engine has stopped. switched of with the engine running.
  • Page 90 610 – AL Wiring HP Control Block 1 Yellow alarm; warning Cause Corrective action u Check wiring or HP fuel control block, replace as necessary . Wire break or short circuit at PWM channel HP fuel control block. 611 – AL Wiring HP Control Block 2 Yellow alarm;...
  • Page 91 851 – AL Extern Start and HD too high Entered in fault memory only Cause Corrective action u Contact Service. An external start is pending and high pressure is too high. 852 – AL Max. Blankshot Time Expired Yellow alarm; warning Cause Corrective action High pressure could not be...

  • Page 92: Task Description

    7 Task Description 7.1 Engine 7.1.1 Engine – Cranking manually Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring tool F6792910 Ratchet F30006212 DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...

  • Page 93: Engine - Barring With Starting System

    7.1.2 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 en- gine's danger zone.

  • Page 94: Crankcase Breather

    7.2 Crankcase Breather 7.2.1 Crankcase breather – Oil mist fine separator replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil Oil mist fine separator (→ Spare Parts Catalog) O-ring (→...

  • Page 95: Valve Drive

    7.3 Valve Drive 7.3.1 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. Valve clearance gauge Y4345893 Barring device F6792910...
  • Page 96 Checking valve clearance at two crankshaft positions Check TDC position of piston in cylinder 1. Check A-side: • If the rocker arms are relieved at cylinder 1, A-side, the piston is in firing TDC. • If the rocker arms are loaded at cylinder 1, A-side, the piston is in overlap TDC. Check valve clearance with engine cold (at max.

  • Page 97: Adjusting Valve Clearance

    Adjusting valve clearance Undo locknut (1) and unscrew adjusting screw (2) a few turns. Insert feeler gauge between valve bridge and rocker arm (3). Readjust adjusting screw (2) so that the feeler gauge just passes through the gap. Tighten locknut (1) with torque wrench to the specified tightening torque, holding the adjusting screw (2) with Allen key to prevent it from turning.

  • Page 98: Cylinder Head Cover - Removal And Installation

    7.3.2 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 Torque wrench, 0.5–5 Nm 0015384230 Ratchet adapter F30027340 Engine oil Gasket (→...

  • Page 99: Injection Valve / Injector

    7.4 Injection Valve / Injector 7.4.1 Injector ‒ Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Injector (→ Spare Parts Catalog) Screw for hold-down clamp (→ Spare Parts Catalog) Replacing injector Remove injector and install new one (→ Page 100). MS150118/01E 2015-05 | Task Description | 99...

  • Page 100: Injector - Removal And Installation

    7.4.2 Injector – Removal and installation Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Press-fitting tool F6790085 Puller F6790636 Fuel suction device F30378207 Torque wrench, 20-100 Nm F30026582 Torque wrench, 0.5–5 Nm 0015384230 Ratchet adapter F30027340...
  • Page 101 WARNING Compressed air gun ejects a jet of pressurized air. Risk of injury to eyes and damage to hearing, risk of rupturing internal organs! • Never direct air jet at people. • Always wear safety goggles/face mask and ear defenders. Preparatory steps Shut off fuel supply line.
  • Page 102 Remove screw (3). Take off hold-down clamp (2). Note: Support ring on injector must likewise be removed if it does not come out with the injector. Use the puller to pull out injector (1). After removal, seal all openings with suita- ble covers.
  • Page 103 Installing pressure pipe neck Note: Minimize contamination! Visually inspect HP line (1) and replace if necessary. Note: Pressure pipe neck may be reused twice at most. Visually check sealing surfaces and pins on pressure pipe neck for plastic deformation and replace if necessary. Coat sealing ring with assembly compound.
  • Page 104 Tighten union nut (2) on pressure pipe neck (3) to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Retaining screw Tightening torque 50 Nm +5 Nm Installing fuel line Coat thread and shoulder of union nuts on HP fuel line (1) with engine oil. Note: Position fuel line, ensuring it is free of tension.
  • Page 105 Fitting gasket and connecting injector cable Place gasket on cylinder head, ensuring correct installation position. Name Size Type Lubricant Value/Standard Union nut Tightening torque (Engine oil) 37 Nm +3 Nm Push cable lugs under the terminals (arrowed) on the injector and tighten to specified torque using a torque wrench.

  • Page 106: Injector Functions

    7.4.3 Injector functions Preconditions ☑Engine is stopped and starting disabled. Note: The engine will lose its emissions certification of the drift correction parameters (CDC) are not reset. Resetting drift correction parameters (CDC) with DiaSys® Note: After successful installation of DiaSys®, document can be found here: C:\DiaSys\Doku auf ihrem Serv- ice-PC.

  • Page 107: Fuel System

    7.5 Fuel System 7.5.1 Fuel system – Venting Preconditions ☑Engine is stopped. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 6-50 Nm F30027336 Ring socket, 22 mm F30038494 WARNING Fuels are combustible and explosive. Risk of fire and explosion! •...

  • Page 108: Fuel - Draining

    7.5.2 Fuel – Draining Preconditions ☑Engine is stopped and starting disabled. WARNING Fuels are combustible and explosive. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. • Wear protective clothing, protective gloves, and safety glasses / facial protection. WARNING Gaseous or liquid diesel fuel is toxic.

  • Page 109: Fuel Filter

    7.6 Fuel Filter 7.6.1 Fuel filter – Replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Easy-change filter (→ Spare Parts Catalog) WARNING Fuels are combustible and explosive. Risk of fire and explosion! •...

  • Page 110: Fuel Prefilter - Differential Pressure Gage Check And Adjustment Of Gage

    7.6.2 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 111: Fuel Prefilter - Draining

    7.6.3 Fuel prefilter – Draining Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel WARNING Fuels are combustible and explosive. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. •...

  • Page 112: Fuel Prefilter - Flushing

    7.6.4 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. Fuel Gasket (→ Spare Parts Catalog) DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...
  • Page 113 Open vent plug (5) of filter to be flushed. Unlock drain valve (6) by pressing toggle, open it 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 vent plug (5) and drain valve (6).

  • Page 114: Fuel Prefilter - Filter Element Replacement

    7.6.5 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 and explosive. Risk of fire and explosion! •...

  • Page 115: Air Filter

    7.7 Air Filter 7.7.1 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 116: Air Filter - Removal And Installation

    7.7.2 Air filter – Removal and installation Preconditions ☑Engine is stopped and starting disabled. Air filter – Removal and installa- tion Release clamp (2). Remove air filter (1) and clamp (2) from connecting flange of intake housing (3). Clean the connecting flange of the intake housing (3) and check it for free passage.

  • Page 117: Air Intake

    7.8 Air Intake 7.8.1 Service indicator – Signal ring position check 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 115). After installation of new filter, press reset button (1).

  • Page 118: Starting Equipment

    7.9 Starting Equipment 7.9.1 Electric starter ‒ Overview 1 Starter 4 Gasket 7 Nut 2 Gasket 5 Stud 3 Flange 6 Washer 118 | Task Description | MS150118/01E 2015-05...

  • Page 119: Starter - Removal

    7.9.2 Starter – Removal Preconditions ☑Engine is stopped and starting disabled. 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! WARNING The component is very heavy and may fall or tip over if unstable.

  • Page 120: Starter - Installation

    7.9.3 Starter ‒ Installation Preconditions ☑Engine is stopped and starting disabled. 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! WARNING The component is very heavy and may fall or tip over if unstable.

  • Page 121: Lube Oil System, Lube Oil Circuit

    7.10 Lube Oil System, Lube Oil Circuit 7.10.1 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 122: Engine Oil - Change

    7.10.2 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 123: Oil Filtration / Cooling

    7.11 Oil Filtration / Cooling 7.11.1 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 124: Centrifugal Oil Filter - Cleaning And Filter-Sleeve Replacement

    7.11.2 Centrifugal oil filter – Cleaning and filter-sleeve 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 F30027340 Cold cleaner(Hakutex 60) X00056750 Filter sleeve (→...
  • Page 125 Centrifugal oil filter – Cleaning and filter-sleeve replacement Slacken off nuts (4) crosswise. Remove housing cover (1). Carefully remove rotor (3) from lower part of housing (5). Remove nut (2). Carefully remove rotor cap. Remove filter sleeve from rotor cap. Measure thickness of oil residues on filter sleeve.

  • Page 126: Coolant Circuit, General, High-Temperature Circuit

    7.12 Coolant Circuit, General, High-Temperature Circuit 7.12.1 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! • Let the engine cool down.

  • Page 127: Engine Coolant Change

    7.12.2 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change Drain engine coolant (→ Page 128). Fill with engine coolant (→ Page 129). MS150118/01E 2015-05 | Task Description | 127...

  • Page 128: Draining Engine Coolant

    7.12.3 Engine coolant ‒ Draining Preconditions ☑Engine 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 a suitable container to catch the coolant.

  • Page 129: Engine Coolant – Filling

    7.12.4 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. Risk of injury and scalding! •...
  • Page 130 Final steps Start the engine and operate it at idle speed for some minutes. Check coolant level, top up coolant if necessary (→ Page 126). 130 | Task Description | MS150118/01E 2015-05...

  • Page 131: Engine Coolant Pump – Relief Bore Check

    7.12.5 Engine 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 132: Engine Coolant – Sample Extraction And Analysis

    Draw off precipitated corrosion inhibitor oil from expansion tank and dispose of oil. Draw off approx. 1 liter coolant and drain into a clean container. Using the equipment and chemicals from the MTU test kit, examine coolant for: • antifreeze concentration;...

  • Page 133: Belt Drive

    7.13 Belt Drive 7.13.1 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 134: Drive Belt – Tension Check

    7.13.2 Drive belt – Tension check Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Tester Y4345711 Belt tension tester, 150-600 N Y20097429 Measuring depression depth with preload measuring device Note: The frequency measurement procedure is the preferred one because it provides more exact measure- ment results.
  • Page 135 Measured value Belt length ‒ Application Measured value Operating tension (used belt) Initial installation (new belt) Drive belt 1800 mm – Fan Frequency: 88 ±1 Hz Frequency: 77 ±1 Hz Drive belt 1520 mm – Fan Frequency: 104 ±1 Hz Frequency: 92 ±1 Hz Table 99: Set-point values ‒...

  • Page 136: Drive Belt ‒ Tension Adjustment

    7.13.3 Drive belt ‒ Tension adjustment 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 Torque wrench, 40-200 Nm F30027337 Ring socket, 24 mm F30501562 Engine oil Drive belt ‒...

  • Page 137: Drive Belt – Replacement

    7.13.4 Drive belt – Replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Ring socket, 24 mm F30501562 Drive belt (→ Spare Parts Catalog) Replacing fan drive belt Remove protective cover from cooler. Remove protective grill from fan.

  • Page 138: Battery-Charging Generator

    7.14 Battery-Charging Generator 7.14.1 Battery-charger drive – Drive belt replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Tester Y4345711 Belt tension tester, 150-600 N Y20097429 Engine oil Drive belt (→...
  • Page 139 Measured value Belt ‒ Application Measured value Operating tension (used belt) Initial installation (new belt) Drive belt – Battery-charging gen- Depression depth: 7.8 mm Depression depth: 8.9 mm erator Test force: 60 N Test force: 60 N Table 101: Set-point values ‒ Measurement with preload measuring device Tighten screws (1).

  • Page 140: Fuel Supply System

    7.15 Fuel Supply System 7.15.1 Differential pressure gage – Check WARNING Fuels are combustible and explosive. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. • Wear protective clothing, protective gloves, and safety glasses / facial protection. Checking differential pressure gage Switch on fuel treatment system (optional).

  • Page 141: Coolant Level Sensor – Check

    7.15.2 Coolant level sensor – Check Preconditions ☑Plant has been put out of operation. WARNING Fuels are combustible and explosive. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. • Wear protective clothing, protective gloves, and safety glasses / facial protection. Checking coolant level sensor Drain coolant slowly.

  • Page 142: Pump Capacity – Check

    7.15.3 Pump capacity – Check WARNING Fuels are combustible and explosive. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. • Wear protective clothing, protective gloves, and safety glasses / facial protection. Checking pump capacity Install suitable pressure gage in the intake connection of the pump.

  • Page 143: Coalescer Filter Element – Replacement

    7.15.4 Coalescer filter element – Replacement Preconditions ☑System is switched off and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 6-50 Nm F30027336 Ratchet adapter F30027339 Diesel fuel Engine oil Coalescer filter element (→...
  • Page 144 Use torque wrench to tighten nut (3) to the specified tightening torque. Name Size Type Lubricant Value/Standard Tightening torque (Engine oil) 30 Nm +3 Nm Fit seal (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 145: Engine Governor

    7.16 Engine Governor 7.16.1 Engine control system – Overview 1 Connector X2 3 Connector X3 5 Screw 2 Engine control system 4 Washer 6 Damper MS150118/01E 2015-05 | Task Description | 145...

  • Page 146: Engine Governor – Removal And Installation

    7.16.2 Engine governor – Removal and installation Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine governor (→ Spare Parts Catalog) Resilient mount (→ Spare Parts Catalog) NOTICE Wrong engine governor installed. Engine damage! •...

  • Page 147: Engine Governor Plug Connections – Check

    7.16.3 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 148: Wiring (General) For Engine/Gearbox/Unit

    7.17 Wiring (General) for Engine/Gearbox/Unit 7.17.1 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 149: Accessories For (Electronic) Engine Governor / Control System

    7.18 Accessories for (Electronic) Engine Governor / Control System 7.18.1 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. test prod. The contacts in the plug connection can be bent! •...

  • Page 150: List Of Abbreviations

    Abgasturbolader Exhaust turbocharger (ETC) Backup Data Module Baureihe Series Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Publication No. A01061/.. Controller Area Network Data bus system, bus standard Controllable Pitch Propeller Deutsches Institut für Normung e. V. At the same time identifier of German standards (DIN = “Deutsche Industrie-Norm”)
  • Page 151 Explanation Abbrevia- Meaning tion Monitoring and Control System Message Microprocessor Unit, Microprocessing Unit Oberer Totpunkt Top dead center (TDC) Panel Control panel PCU/PMU Propeller Control Unit Propeller controller Peripheral Interface Module Priming Pump Control Remote Control System Redundancy Lost Alarm: Redundant CAN bus failure Sea Acceptance Test Sensor Defect Alarm: Sensor failure...

  • Page 152: 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 153: Special Tools

    9 Appendix B 9.1 Special Tools Barring device Part No.: F6792910 Qty.: Used in: 7.3.1 Valve clearance – Check and adjustment (→ Page 95) Barring tool Part No.: F6792910 Qty.: Used in: 7.1.1 Engine – Cranking manually (→ Page 92) Belt tension tester, 150-600 N Part No.: Y20097429...
  • Page 154 Crowfoot wrench, 19 mm Part No.: F30027424 Qty.: Used in: 7.4.2 Injector – Removal and installation (→ Page 100) Double box wrench Part No.: F30011450 Qty.: Used in: 7.4.2 Injector – Removal and installation (→ Page 100) Double-end box wrench Part No.: F30002800 Qty.:...
  • Page 155 Measuring device Part No.: Y4348409 Qty.: Used in: 7.3.1 Valve clearance – Check and adjustment (→ Page 95) MTU test kit Part No.: 5605892099/00 Qty.: Used in: 7.12.6 Engine coolant – Sample extraction and analysis (→ Page 132) MS150118/01E 2015-05 | Appendix B | 155...
  • Page 156 Offset screwdriver Part No.: F30453001 Qty.: Used in: 7.3.1 Valve clearance – Check and adjustment (→ Page 95) Plug-in open-end wrench, 19 mm Part No.: F30453236 Qty.: Used in: 7.4.2 Injector – Removal and installation (→ Page 100) Plug-in open-end wrench, 24 mm Part No.: F30453238 Qty.:...
  • Page 157 Puller Part No.: F6790636 Qty.: Used in: 7.4.2 Injector – Removal and installation (→ Page 100) Ratchet Part No.: F30006212 Qty.: Used in: 7.1.1 Engine – Cranking manually (→ Page 92) Qty.: Used in: 7.3.1 Valve clearance – Check and adjustment (→...
  • Page 158 Ratchet adapter Part No.: F30027339 Qty.: Used in: 7.15.4 Coalescer filter element – Replacement (→ Page 143) Ring socket, 22 mm Part No.: F30038494 Qty.: Used in: 7.4.2 Injector – Removal and installation (→ Page 100) Qty.: Used in: 7.5.1 Fuel system – Venting (→ Page 107) Ring socket, 24 mm Part No.: F30501562...
  • Page 159 Tester Part No.: Y4345711 Qty.: Used in: 7.13.2 Drive belt – Tension check (→ Page 134) Qty.: Used in: 7.14.1 Battery-charger drive – Drive belt replacement (→ Page 138) Torque wrench, 10-60 Nm Part No.: F30510423 Qty.: Used in: 7.3.1 Valve clearance – Check and adjustment (→...
  • Page 160 Torque wrench, 6-50 Nm Part No.: F30027336 Qty.: Used in: 7.5.1 Fuel system – Venting (→ Page 107) Qty.: Used in: 7.15.4 Coalescer filter element – Replacement (→ Page 143) Torque wrench, 8-40 Nm Part No.: F30043446 Qty.: Used in: 7.3.2 Cylinder head cover –...

  • Page 161: Index

    9.2 Index Differential pressure gage  – Adjustment   After stopping the engine 58 – Fuel prefilter  110 Air filter  – Check   – Installation  116 – Fuel prefilter  110 – Removal  116 Drift correction parameters  – Replacement  115 – Reset  106 Drive belt ...
  • Page 162 – Check  121 – Engine  51 Engine sides  Maintenance schedule  – Designation  15 – Task reference table [QL1]  60 MTU contact persons 152 Fault messages  – Engine Control Unit  64 Operation monitoring 55 Filter  Overview  – Coalescer element   – Electric  ...
  • Page 163 Pump capacity  – Check  142 Safety notices, standards 14 Safety regulations  – Auxiliary materials  12 – Environmental protection  12 – Fire prevention  12 – Fluids and lubricants  12 – Important provisions  5 – Maintenance work  9 – Organizational requirements  7 – Personnel requirements  7 –...

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