MTU 12 V 2000 Gx6F Operating Instructions Manual
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MTU 12 V 2000 Gx6F Operating Instructions Manual

MTU 12 V 2000 Gx6F Operating Instructions Manual

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Operating Instructions

Diesel Engine
12 V 2000 Gx6F
MS150111/01E

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Summary of Contents for MTU 12 V 2000 Gx6F

  • Page 1: Operating Instructions

    Operating Instructions Diesel Engine 12 V 2000 Gx6F MS150111/01E...
  • 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 7 Task Description 1.1 Important requirements for all products 7.1 Engine 1.2 Personnel and organizational requirements 7.1.1 Engine – Barring manually 7.1.2 Engine – Barring with starting system 1.3 Transport 1.4 Safety requirements for maintenance and 7.2 Crankcase Breather repair work 7.2.1 Crankcase breather –...
  • Page 4 8 Appendix A 7.15 Battery-Charging Generator 7.15.1 Battery-charging generator drive – Drive belt 8.1 List of abbreviations replacement 8.2 MTU contact persons/service partners 7.16 Fuel Supply System 7.16.1 Water drain valve – Check 9 Appendix B 7.16.2 Differential pressure gauge – Check 7.16.3 Water level probe (3-in-1 rod electrode) –...

  • 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 Maintenance And Repair Work

    1.4 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 9 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 10 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 11: 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 12: Compressed Air

    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 13: 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 14: 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 15: Engine Overview

    2.2 Engine overview 12 V 2000 G56/66F 1 Exhaust turbocharger 7 Power supply 13 Valve gear 2 Air intake/air supply 8 Cooling air system 14 Cylinder head 3 EGR cooler 9 Coolant system 15 Exhaust pipework 4 Intercooler 10 Mounting/support 16 PTO system, driving end 5 Monitoring, control and 11 Fuel system (low pressure)

  • Page 16: Technical Data

    3 Technical Data 3.1 Engine data 12 V 2000 G56/66F Explanation: DL Reference value: Continuous power (CP) BL Reference value: Fuel stop power (FSP) 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 17 MODEL RELATED DATA (basic design) Number of cylinders Number of cylinders Cylinder arrangement: V angle Degrees (°) Bore Stroke Cylinder displacement Liters 2.233 2.233 Total displacement Liters 26.80 26.80 Inlet valves per cylinder Exhaust valves per cylinder COMBUSTION AIR / EXHAUST GAS Number of cylinders Charge-air pressure before cylinder bar abs...
  • Page 18 FUEL SYSTEM Number of cylinders Fuel pressure at engine inlet connection, min. (during engine start) L -0.5 -0.5 Fuel pressure at engine inlet connection, min. (when engine is run- -0.5 -0.5 ning) Fuel pressure at engine inlet connection, max. (during engine start) GENERAL OPERATING DATA Number of cylinders...

  • Page 19: Firing Order

    3.2 Firing order Firing order 12 V 2000 G56/66F Number of cylin- Firing order ders 12 V A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1 MS150111/01E 2014-05 | Technical Data | 19...

  • Page 20: Engine - Main Dimensions

    3.3 Engine – Main dimensions Item Engine model/dimensions Engine model/dimensions 12 V 2000 G56F 16 V 2000 G66F Length (A) Approx. 2028 mm Approx. 2028 mm Width (B) Approx. 1278 mm Approx. 1278 mm Height (C) Approx. 1493 mm Approx. 1493 mm Table 2: Engine model/dimensions 20 | Technical Data | MS150111/01E 2014-05...

  • Page 21: 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 Fluids and Lubricants Specifications (A001061/..) are available. Putting into operation after long out-of-service periods (>3 months) Item Action Engine Depreserve (→...

  • Page 22: Putting The Engine Into Operation After Scheduled Out-Of-Service-Period

    4.2 Putting the engine 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 71). Coolant circuit Check engine coolant level (→ Page 81), check charge-air coolant level (→...

  • Page 23: 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 25). Shut down fuel treatment system (→ Page 34). MS150111/01E 2014-05 | Operation | 23...

  • Page 24: 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 25: Fuel Treatment System - Putting Into Operation

    4.5 Fuel treatment system – Putting into operation Overview of fuel treatment system 1 Pressure-free overflow 9 Ball valve, outlet 17 Automatic water drain 2 Bypass 1 10 Check valve 700 mbar 18 Water level electrode 3 Bypass 2 11 Check valve 5 mbar 19 Ball valve, sample extrac- 4 Safety valve, 3 bar 12 Return to overflow con-...
  • Page 26 Initial operation: HAT Replace fuel filter on engine (→ Page 60). Note: Determine the suction pressure upstream of the engine-mounted fuel delivery pump. Install pressure gage in fuel supply line from Yard fuel system to engine. Switch on fuel treatment system and operate it for some minutes (→ Page 29). Result: The fuel is drawn from tank (24), cleaned by the water separator filter (15) and then routed via overflow tank (14) back to tank (24).
  • Page 27 Simulation of power failure (emergency): SAT Switch on fuel treatment system (→ Page 29). Start engine (→ Page 28). Run engine at idling speed. Switch off pump (21) at switchgear cabinet (20). Result: The engine-mounted fuel delivery pump draws fuel via bypass (2) directly from tank (24). Check suction pressure at the engine-mounted fuel delivery pump.

  • Page 28: Starting The Engine

    4.6 Starting the engine Preconditions ☑Engine is not connected to 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 29: 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 30: Operational Checks

    4.8 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 31: Stopping The Engine

    4.9 Stopping the engine Preconditions ☑Engine is not connected to load. NOTICE Stopping the engine when it is running at full load subjects it to extreme thermal and mechanical stresses. Overheating of and, therefore, damage to components is possible! • Before shutting down the engine, allow it to idle until the engine temperatures decrease and constant levels are indicated.

  • Page 32: Emergency Stop

    4.10 Emergency 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. Emergency stop Item Action Emergency stop pushbutton Press EMERGENCY STOP pushbutton. • Engine is stopped by disconnecting the power supply to the ECU; •...

  • Page 33: After Stopping The Engine

    4.11 After stopping the engine Preconditions ☑MTU preservation and corrosion protection instructions (A001070/..) are available. NOTICE Coolant sensors may freeze if there is a risk of frost. Risk of sensor damage! • Protect sensors from frost. After stopping the engine...

  • Page 34: 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 35: 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 36: 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 37 Task Option Maintenance tasks W1547 Replace fine oil mist separator. (→ Page 44) W1636 Reset drift correction parameters (CDC) and (→ Page 54) enter injector coding (IIG). Table 3: Maintenance task reference table [QL1] MS150111/01E 2014-05 | Maintenance | 37...

  • Page 38: 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 39: Troubleshooting

    6.2 Troubleshooting Engine does not turn when starter is actuated Component Probable 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 40 Contact Service. Charge air temperature too high Component Probable 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...
  • Page 41 White exhaust gas Component Probable Cause Action Engine Not at operating temperature Run engine to reach operating tempera- ture. Fuel system Water in fuel Check fuel system at fuel prefilter Drain fuel prefilter (→ Page 62). Intercooler Leaking Contact Service. MS150111/01E 2014-05 | Troubleshooting | 41...

  • Page 42: Task Description

    7 Task Description 7.1 Engine 7.1.1 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 43: 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 44: 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 45: 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. Feeler gauge Y4345893 Barring device for engine F6783914...

  • Page 46: 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 47: 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 Ratchet F30027340 Gasket (→ Spare Parts Catalog) Preparatory steps On cylinder head covers with crankcase breather: Loosen clamps.

  • Page 48: 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) Injector – Replacement Remove injector and install new one (→ Page 49). 48 | Task Description | MS150111/01E 2014-05...

  • Page 49: 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. Installation device F6790085 Puller F6790636 Fuel suction device F30378207 Torque wrench, 20-100 Nm F30026582 Torque wrench, 0.5-5 Nm 0015384230 Ratchet F30027340...
  • Page 50 Removing injector Remove HP fuel line (1). Unscrew union nut (2). Pull off pressure pipe neck (3). Extract fuel from the exposed bores using the suction device. Disconnect terminals (arrow) on injector and pull out cable lugs. Remove gasket. Remove screw (3). Note: Screw (3) may be installed only once.
  • Page 51 Installing injector Remove all covers before installation. Clean sealing surface on cylinder head and protective sleeve. Coat sealing ring on injector (1) with as- sembly compound. Note: Use either the installation tool or the hold- down clamp (2) to press injector (1) into the cylinder head.
  • Page 52 Use torque wrench to tighten screw (3) for hold-down clamp (2) to the specified tightening torque. Name Size Type Lubricant Value/Standard Screw Tightening torque (Engine oil) (Engine 40 Nm +4 Nm oil) Tighten union nut (2) on pressure pipe neck (3) with torque wrench to the specified tightening torque. Name Size Type...
  • Page 53 Tighten union nut of HP fuel line (1) on rail to specified tightening torque using a torque wrench. Name Size Type Lubricant Value/Standard Union nut Tightening torque (Engine oil) 50 Nm +5 Nm Tighten union nut of HP fuel line (1) on pressure pipe neck (3) to the specified tightening torque using a torque wrench.

  • Page 54: Injector Functions

    7.4.3 Injector functions Preconditions ☑Engine is stopped and starting disabled. Note: Failure to reset drift compensation parameters (CDC) will void the emissions certification for the en- gine. Resetting drift correction parameters (CDC) with DiaSys® (→ Dialog system DiaSys® E531920/..). If no DiaSys® is available, contact Service. Entering injector coding (IIG) (→...

  • Page 55: Fuel System

    7.5 Fuel System 7.5.1 HP fuel line and pressure pipe neck ‒ Replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 20-100 Nm F30026582 Ratchet F30027340 Plug-in open-end wrench, 19 mm F30025897 Crowfoot wrench, 19 mm F30027424...
  • Page 56 HP fuel line and pressure pipe neck ‒ Replacement Remove union nuts (1, 3) on HP fuel line (2). Remove HP fuel line (2). Remove nozzle union nut (4). Pull out pressure pipe neck (5). Coat sealing ring of new pressure pipe neck (5) with assembly compound.
  • Page 57 Final steps Clean mating faces on cylinder head and charge-air manifold. Check gaskets for damage and replace them, if required. Coat gaskets with assembly compound and place onto cylinder head. Install leak-off-fuel lines. Install charge-air pipes. Install engine governor (→ Page 107). Open fuel supply line.

  • Page 58: Fuel System - Venting

    7.5.2 Fuel system – Venting Preconditions ☑Engine is shut down. WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Venting fuel system Open threaded vent plug (2) at filter head. Actuate hand pump (1) until bubble-free fuel emerges at the threaded vent plug.

  • Page 59: Fuel - Draining

    7.5.3 Fuel – 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. Fuel – Draining Provide a suitable container in which to collect the fuel. Remove fuel filter (→...

  • Page 60: 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 Diesel fuel Easy-change filter (→ Spare Parts Catalog) WARNING Fuels are combustible. Risk of fire and explosion! •...

  • Page 61: 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 62: 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 Sealing (→ Spare Parts Catalog) WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. •...

  • Page 63: Fuel Prefilter - Flushing

    7.6.4 Fuel prefilter – Flushing Special tools, Material, Spare parts Designation / Use Part No. Qty. Fuel Seal (→ Spare Parts Catalog) DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...
  • Page 64 Open threaded vent plug (5) of the filter to be flushed. Unlock drain cock (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 threaded vent plug (5) and drain cock (6).

  • Page 65: 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) Gasket (→ Spare Parts Catalog) WARNING Fuels are combustible. Risk of fire and explosion! •...

  • Page 66: 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 67: Air Filter - Removal And Installation

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

  • Page 68: Air Intake

    7.8 Air Intake 7.8.1 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 66). After installation of new filter, press reset button (1).

  • Page 69: Exhaust Gas Recirculation

    7.9 Exhaust Gas Recirculation 7.9.1 Exhaust gas recirculation flaps – Overview MS150111/01E 2014-05 | Task Description | 69...

  • Page 70: Exhaust Gas Circulation - Checking Flap Operation

    7.9.2 Exhaust gas circulation ‒ Checking flap operation Preconditions ☑Engine is stopped and starting disabled. WARNING Component is hot. Risk of burning! • Wear protective gloves. Checking exhaust flap operation For installation position of exhaust flaps, refer to overview (→ Page 69). Check operability and ease of movement of exhaust flaps and control linkage by mov- ing the assembly at the points (arrowed)

  • Page 71: 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 72: 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 73: 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 74: 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, 4-20 Nm F30044239 Torque wrench, 10-60 Nm F30452769 Cold cleaner (Hakutex 60) X00056750 Filter sleeve (→...
  • Page 75 Centrifugal oil filter – Cleaning and filter-sleeve replacement Remove clamp (14). Release Tommy nut (2) and take off cov- er (1). Carefully lift rotor (11), allow oil to drain and remove from housing. Holding the rotor (11) firmly, release rotor cover nut (3).

  • Page 76: Coolant Circuit, General, High-Temperature Circuit

    7.12 Coolant Circuit, General, High-Temperature Circuit 7.12.1 Drain and vent points Plan view 1 Coolant venting, HT and LT circuit 76 | Task Description | MS150111/01E 2014-05...
  • Page 77 Left side 1 Coolant drain plug, crank- 2 Coolant drain plug, crank- 3 Oil drain plug, oil pan case free end case driving end MS150111/01E 2014-05 | Task Description | 77...
  • Page 78 Right side 1 Coolant drain plug, crank- 3 Coolant drain plug, coolant case driving end line 2 Coolant drain plug, crank- 4 Oil drain plug, oil pan case free end 78 | Task Description | MS150111/01E 2014-05...
  • Page 79 Driving end (KS) 1 Oil drain plug, oil pan MS150111/01E 2014-05 | Task Description | 79...
  • Page 80 Free end (KGS) 1 Coolant drain plug, lube-oil 3 Coolant filling plug heat exchanger 4 Oil drain plug, oil pan 2 Oil drain plug, lube-oil heat exchanger 80 | Task Description | MS150111/01E 2014-05...

  • Page 81: Engine Coolant – Level Check

    7.12.2 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. • Wear protective clothing, gloves, and goggles / safety mask.

  • Page 82: Engine Coolant – Change

    7.12.3 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change Drain engine coolant (→ Page 83). Fill with engine coolant (→ Page 84). 82 | Task Description | MS150111/01E 2014-05...

  • Page 83: Engine Coolant ‒ Draining

    7.12.4 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 a suitable receptacle to catch the coolant.

  • Page 84: Engine Coolant – Filling

    7.12.5 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. Coolant WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...
  • Page 85 Final steps Start the engine and operate it at idle speed for some minutes. Check coolant level (→ Page 81), top up with coolant if required. MS150111/01E 2014-05 | Task Description | 85...

  • Page 86: Engine Coolant Pump – Relief Bore Check

    7.12.6 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 87: 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 88: Low-Temperature Circuit

    7.13 Low-Temperature Circuit 7.13.1 Intercooler – Venting and draining Intercooler – Venting and draining 1 Intercooler vent plug 2 Coolant drain plug 88 | Task Description | MS150111/01E 2014-05...

  • Page 89: Charge-Air Coolant – Level Check

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

  • Page 90: Charge-Air Coolant – Change

    7.13.3 Charge-air coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Charge-air coolant – Change Drain charge-air coolant (→ Page 93). Fill with charge-air coolant (→ Page 91). 90 | Task Description | MS150111/01E 2014-05...

  • Page 91: Charge-Air Coolant – Filling

    7.13.4 Charge-air coolant – Filling Preconditions ☑Engine is stopped and starting disabled. ☑MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Sealing ring (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure.
  • Page 92 Final steps Start the engine and operate it at idle speed for some minutes. Check coolant level (→ Page 89). 92 | Task Description | MS150111/01E 2014-05...

  • Page 93: Charge-Air Coolant ‒ Draining

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

  • Page 94: Charge-Air Coolant Pump – Relief Bore Check

    7.13.6 Charge-air 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 95: Belt Drive

    7.14 Belt Drive 7.14.1 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 96: Drive Belt – Tension Check

    7.14.2 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 Fan drive – Checking belt ten- sion Remove protective cover. Set belt tension tester onto the drive belt in the middle between the belt pulleys (ar- rowed).

  • Page 97: Drive Belt – Tension Adjustment

    7.14.3 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 F30027340 Torque wrench, 40-200 Nm F30027337 Engine oil Adjusting drive belt tension Undo screws (1).

  • Page 98: Drive Belt – Replacement

    7.14.4 Drive belt – Replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Drive belt (→ Spare Parts Catalog) Fan drive – Drive belt replace- ment Remove protective cover from radiator. Remove fan.

  • Page 99: Battery-Charging Generator

    7.15 Battery-Charging Generator 7.15.1 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 100: Fuel Supply System

    7.16 Fuel Supply System 7.16.1 Water drain valve – Check Water drain valve – Check Open water drain valve. Check water outlet for obstructions. Close water drain valve. 100 | Task Description | MS150111/01E 2014-05...

  • Page 101: Differential Pressure Gauge – Check

    7.16.2 Differential pressure gauge – Check WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Differential pressure gauge – Check Switch on fuel treatment system (→ Page 25). Set the alarm points at the differential pressure gauge to zero.

  • Page 102: Water Level Probe (3-In-1 Rod Electrode Check

    7.16.3 Water level probe (3-in-1 rod electrode) – Check Preconditions ☑System is put out of service and emptied. WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Water level probe (3-in-1 rod electrode) –...

  • Page 103: Pump Capacity – Check

    7.16.4 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 104: Coalescer Filter Element – Replacement

    7.16.5 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 105 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 106: Engine Governor

    7.17 Engine Governor 7.17.1 Engine governor – Overview 1 Screw 4 Engine governor 7 Connector X1 2 Washer 5 Connector X3 8 Screw for grounding strap 3 Damper 6 Screw 106 | Task Description | MS150111/01E 2014-05...

  • Page 107: Engine Governor – Removal And Installation

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

  • Page 108: Engine Governor Plug Connections – Check

    7.17.3 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 109: Wiring (General) For Engine/Gearbox/Unit

    7.18 Wiring (General) for Engine/Gearbox/Unit 7.18.1 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 110: Lambda, Nox And Humidity Sensors Overview

    7.18.2 Lambda, NOx and humidity sensors – Overview 1 Humidity sensor 2 Lambda sensor 3 NOx sensor 110 | Task Description | MS150111/01E 2014-05...

  • Page 111: Lambda Sensor – Replacement

    7.18.3 Lambda sensor – Replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10-60 Nm F30510423 Ratchet F30027340 Assembly compound (Molykote P 37) 50564 Lambda sensor (→ Spare Parts Catalog) WARNING Component is hot.
  • Page 112 Installing Lambda sensor Note: When the sensor was subjected to shock or impact load, it is deemed to be defective and may not be used. Remove protective cap on thread only just before installation. Note: Do not wipe off the thread lubricant applied by the manufacturer.

  • Page 113: Nox Sensor – Replacement

    7.18.4 NOx sensor – Replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10-60 Nm F30510423 Ratchet F30027340 Assembly compound (Molykote P 37) 50564 NOx sensor (→ Spare Parts Catalog) WARNING Component is hot.
  • Page 114 Note: Always replace NOx sensor together with control unit. Installing NOx sensor Note: Install control unit. Note: When the sensor was subjected to shock or impact load, it is deemed to be defective and may not be used. Remove protective cap on thread only just before installation.

  • Page 115: Humidity Sensor – Replacement

    7.18.5 Humidity sensor – Replacement Preconditions ☑Engine is stopped and starting disabled. ☑Preparatory steps are completed. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10-60 Nm F30510423 Ratchet F30027340 Assembly compound Kluthe Hakuform 30-11C/Emulgier X00059351 Humidity sensor (→...
  • Page 116 Installing humidity sensor Note: Apply assembly compound for O-ring spar- ingly. Insert sensor (2) in bore, ensuring correct installation position. Note: Observe air flow direction. Screw in screws (1). Use torque wrench (1) to tighten screws to specified tightening torque. Name Size Type...

  • Page 117: Accessories For (Electronic) Engine Governor / Control System

    7.19 Accessories for (Electronic) Engine Governor / Control System 7.19.1 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 118: Engine Governor Plug Connections – Check

    7.19.2 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 119: 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 120 Abbrevia- Meaning Explanation 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 121: 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 122: Special Tools

    9 Appendix B 9.1 Special Tools Angular screw driver Part No.: F30002816 Qty.: Used in: 7.3.1 Valve clearance – Check and adjustment (→ Page 45) Barring device for engine Part No.: F6783914 Qty.: Used in: 7.3.1 Valve clearance – Check and adjustment (→...
  • Page 123 Crowfoot wrench, 19 mm Part No.: F30027424 Qty.: Used in: 7.4.2 Injector – Removal and installation (→ Page 49) Qty.: Used in: 7.5.1 HP fuel line and pressure pipe neck ‒ Replace- ment (→ Page 55) Double box wrench Part No.: F30002800 Qty.: Used in:...
  • Page 124 Feeler gauge Part No.: Y4345893 Qty.: Used in: 7.3.1 Valve clearance – Check and adjustment (→ Page 45) Filter wrench Part No.: F30379104 Qty.: Used in: 7.6.1 Fuel filter – Replacement (→ Page 60) Qty.: Used in: 7.11.1 Engine oil filter – Replacement (→ Page 73) Fuel suction device Part No.: F30378207...
  • Page 125 Measuring instrument Part No.: Y4345888 Qty.: Used in: 7.3.1 Valve clearance – Check and adjustment (→ Page 45) MTU test kit Part No.: 5605892099/00 Qty.: Used in: 7.12.7 Engine coolant – Sample extraction and analysis (→ Page 87) Open-end socket wrench, 19 mm Part No.:...
  • Page 126 Open-end socket wrench, 24 mm Part No.: F30453238 Qty.: Used in: 7.4.2 Injector – Removal and installation (→ Page 49) Plug-in open-end wrench, 19 mm Part No.: F30025897 Qty.: Used in: 7.5.1 HP fuel line and pressure pipe neck ‒ Replace- ment (→...
  • Page 127 Ratchet Part No.: F30027340 Qty.: Used in: 7.3.2 Cylinder head cover – Removal and installation (→ Page 47) Qty.: Used in: 7.4.2 Injector – Removal and installation (→ Page 49) Qty.: Used in: 7.5.1 HP fuel line and pressure pipe neck ‒ Replace- ment (→...
  • Page 128 Ring socket, 24 mm Part No.: F30501562 Qty.: Used in: 7.5.1 HP fuel line and pressure pipe neck ‒ Replace- ment (→ Page 55) Socket wrench Part No.: F30030450 Qty.: Used in: 7.3.1 Valve clearance – Check and adjustment (→ Page 45) Steam jet cleaner Part No.: Qty.:...
  • Page 129 Torque wrench, 10-60 Nm Part No.: F30510423 Qty.: Used in: 7.3.1 Valve clearance – Check and adjustment (→ Page 45) Qty.: Used in: 7.18.3 Lambda sensor – Replacement (→ Page 111) Qty.: Used in: 7.18.4 NOx sensor – Replacement (→ Page 113) Qty.: Used in: 7.18.5 Humidity sensor –...
  • Page 130 Torque wrench, 40-200 Nm Part No.: F30027337 Qty.: Used in: 7.14.3 Drive belt – Tension adjustment (→ Page 97) Torque wrench, 6-50 Nm Part No.: F30027336 Qty.: Used in: 7.16.5 Coalescer filter element – Replacement (→ Page 104) Torque wrench, 8-40 Nm Part No.: F30043446 Qty.:...

  • Page 131: Index

    9.2 Index After stopping the engine 33 Data  Air filter  – Engine  16 – Removal and installation  67 Differential pressure   – Replacement  66 – Pressure gauge   – Check  101 Differential pressure gage  Battery-charging generator drive  – Adjustment   – Drive belt   –...
  • Page 132 – Engine  20 Firing order 19 Maintenance schedule  Flaps  – Maintenance task reference table [QL1]  36 – Exhaust gas circulation   MTU contact persons 121 – Function check  70 – Exhaust gas recirculation   – Overview  69 NOx sensor  Fuel  – Replacement  113...
  • Page 133 Putting the engine into operation after extended out-of- service periods (>3 months) 21 Putting the engine into operation after scheduled out-of- service-period 22 Safety notices, standards 13 Safety regulations  – Auxiliary materials  11 – Environmental protection  11 – Fire prevention  11 – Fluids and lubricants  11 –...

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