Page 1: Operating Instructions
Operating Instructions Diesel engine 12V2000Gx6x 16V2000Gx6x MS15054/03E...
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 4.9 Product data 12V/16V2000Gx6S, 3G, continuous operation, time-limited, ICXN, 1.1 Important provisions for all products EPA Nonroad T2 (40CFR89) 1.2 Correct use of all products 4.10 Product data 12V/16V2000Gx6S, 3H, mains 1.3 Personnel and organizational requirements backup mode, special qualification, EPA 1.4 Initial start-up and operation –...
Page 4 8.14 Coolant Circuit, General, High-Temperature 8.4 Fan Drive Circuit 8.4.1 Drive belt – Condition check 8.14.1 Engine coolant – Level check 8.4.2 Drive belt – Tension check 8.14.2 Engine coolant – Change 8.4.3 Drive belt ‒ Tension adjustment 8.14.3 Engine coolant – Draining 8.4.4 Drive belt –...
Page 5 9.2 MTU Contact/Service Partners 8.21.1 Engine cabling – Check 8.22 Accessories for (Electronic) Engine 10 Appendix B Governor / Control System 8.22.1 Engine governor and connector – Cleaning 10.1 Special Tools 10.2 Index 9 Appendix A 9.1 List of abbreviations...
Page 6: Safety
Nameplates, model designation or serial number can be found on the product. All EU-certified engines delivered by MTU come with a second nameplate. This second nameplate is deliv- ered "loosely" with the engine. If the nameplate secured to the engine after installation in the vehicle/system is not visible without the removal of components, the system integrator must install the second nameplate in a clearly visible area on the vehicle/system.
Page 7 Replacing components with emission labels On all MTU engines fitted with emission labels, these labels must remain on the engine throughout its opera- tional life. Exception: Engines used exclusively in land-based, military applications other than by US government agen- cies.
Page 8: Correct Use Of All Products
• With preservation approved by the manufacturer in accordance with the (→ Preservation and Represerva- tion Specifications of the manufacturer) • With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU con- tact/Service partner) • In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (al- so applies to engine control/parameters) •...
Page 9: Personnel And Organizational Requirements
1.3 Personnel and organizational requirements Organizational measures of the user/manufacturer This manual must be issued to all personnel involved in operation, maintenance, repair, assembly, installa- tion, or transportation. Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance, repair, assembly, installation, and transport personnel at all times.
Page 10: Initial Start-Up And Operation - Safety Regulations
1.4 Initial start-up and operation – Safety regulations Safety regulations for initial start-up Install the product correctly and carry out acceptance in accordance with the manufacturer's specifications before putting the product into service. All necessary approvals must be granted by the relevant authorities and all requirements for initial startup must be fulfilled.
Page 11 Do not inhale the exhaust gases of the product. The following requirements must be fulfilled before the product is started: • Wear ear protectors. • Mop up any leaked or spilled fluids and lubricants immediately or soak up with a suitable binding agent. Operation of electrical equipment When electrical equipment is in operation, certain components of these appliances are electrically live.
Page 12: Assembly, Maintenance, And Repair Work - Safety Regulations
1.5 Assembly, maintenance, and repair work – Safety regulations Safety regulations for work prior to assembly, maintenance, and repair Have assembly, 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 from oil vapors, fluids and lubricants, risk of burning).
Page 13 When working high on the equipment, always use suitable ladders and work platforms. Special instructions for outdoor areas: There must be no risk of slipping e.g. due to icing. Removing, installing and cleanliness Pay particular attention to cleanliness at all times. Completely wipe up escaped fluids and lubricants due to the risk of slipping.
Page 14 Welding work Welding operations on the product or mounted units are not permitted. Cover the product when welding in its vicinity. Before starting welding work: • Switch off the power supply master switch. • Disconnect the battery cables or actuate the battery isolating switch. •...
Page 15 Do not damage wiring during removal work. When reconnecting, ensure that cabling cannot be damaged dur- ing operation by: • Contact with sharp edges • Chafing on components • Contact with hot surfaces. Do not secure cables on lines carrying fluids. Do not use cable ties to secure lines.
Page 16: Fire And Environmental Protection, Fluids And Lubricants
Process materials can also be or contain hazardous or toxic substances. When using process materials and other chemical substances, observe the associated safety data sheet. The safety data sheet may be obtained from the relevant manufacturer or from MTU. Only process materials approved by the manufacturer in accordance with the Fluids and Lubricants Specifi- cations must be used.
Page 17: Compressed Air
Particularly hazardous substances used with our products are named in a list: www.mtu-online.com/mtu/technische-info → SVHC as per REACH in MTU products Compressed air • Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of con- tainers, risks causing an explosion.
Page 18: Standards For Warning Notices In The Text And Highlighted Information
1.7 Standards for warning notices in the text and highlighted information 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 19: 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 the engine down on the oil pan unless this has been expressly authorized by MTU. MS15054/03E 2018-07 | Transport | 19...
Page 20: General Information
3 General Information 3.1 Engine side and cylinder designations 1 Left engine side (A-side) 3 Right engine side (B-side) 2 Engine free end in accord- 4 Engine driving end in ac- ance with DIN ISO 1204 cordance with (KGS = Kupplungsgegen- DIN ISO 1204 (KS = Kup- seite) plungsseite)
Page 21: Engine Overview
3.2 Engine overview 16V2000Gx6S Also applies similarly to 12V engines. 1 Air intake/air supply 6 Engine coolant pump 11 Exhaust turbocharger 2 Charge-air line 7 Charge-air coolant pump 12 HP fuel system 3 Monitoring, control and reg- 8 Exhaust pipe 13 Starting equipment ulation system 9 LP fuel system...
Page 22: Sensors And Actuators - Overview
3.3 Sensors and actuators – Overview Sensors and actuators – Driving end The following overviews are also applicable to 12V engines. Item Name Monitoring of Intake air temperature Table 3: Sensors and actuators – Driving end 22 | General Information | MS15054/03E 2018-07...
Page 23 Sensors and actuators – A-side Item Name Monitoring of B5.1 Oil pressure after oil filter Oil temperature B48.1 HP fuel system pressure, A-side M8.1 Fuel pump pressure, A-side Table 4: Sensors and actuators – A-side MS15054/03E 2018-07 | General Information | 23...
Page 24 Sensors and actuators – Free end Item Name Monitoring of B5.3 Oil pressure before oil filter (optional) Table 5: Sensors and actuators – Free end 24 | General Information | MS15054/03E 2018-07...
Page 25 Sensors and actuators – B-side Overview is also valid for 16V engines. Item Name Monitoring of Charge-air coolant temperature Charge-air pressure XF70 Fuel filter level monitor (optional) XF57 Coolant level, low temperature XF33 Coolant level, high temperature Coolant temperature EIL, electronic label Coolant temperature XF46 Leak fuel level (optional)
Page 26: Technical Data
4 Technical Data 4.1 Product data 12V/16V2000Gx6S, 3B, continuous operation, variable load, ICXN, optimized fuel consumption Legend DL Reference value: Continuous power. Continuous driving power under standard conditions BL Reference value: Fuel stop power. Maximum engine power. In some applications, continuous power not possible (adjustment reserve) A Design value.
Page 27 Performance data Rated engine speed 1800 1800 1800 1800 Continuous power ISO 3046 (10% over- load possible) (power range DIN 6280, ISO 8528) Site conditions (for max. power) Intake depression (new filter) mbar Intake depression, max. mbar Exhaust overpressure mbar Exhaust gas overpressure, max.
Page 28 Coolant temperature after engine, limit 2 L °C Coolant antifreeze content, max. Pressure loss in engine-external cooling system, max. Coolant system (LT circuit) Coolant temperature before intercooler °C (at engine inlet from cooling equipment) Coolant antifreeze content, max. Pressure loss in engine-external cooling system, max.
Page 29 Engine oil capacity, initial filling (standard Liters oil system) (option: max. operating incli- nations) Oil change quantity, max. (standard oil Liters system) (option: max. operating inclina- tions) Weights / main dimensions Engine weight, dry (basic engine configu- 2710 2710 2710 3180 ration acc.
Page 30: Product Data 12V/16V2000Gx6S, 3D, Standby Power, Fuel Stop Power, Ifn, Optimized Fuel Consumption
4.2 Product data 12V/16V2000Gx6S, 3D, standby power, fuel stop power, IFN, optimized fuel consumption Legend DL Reference value: Continuous power. Continuous driving power under standard conditions BL Reference value: Fuel stop power. Maximum engine power. In some applications, continuous power not possible (adjustment reserve) A Design value.
Page 31 Performance data Rated engine speed 1800 1800 1800 1800 Fuel stop power ISO 3046 1097 1371 Site conditions (for max. power) Intake depression (new filter) mbar Intake depression, max. mbar Exhaust overpressure mbar Exhaust gas overpressure, max. mbar Model-related data (basic design) Engine with exhaust turbocharging (ETC) and charge-air cooling (intercooler) Uncooled exhaust lines...
Page 32 Coolant system (HT circuit) Coolant temperature (at engine connec- °C tion: outlet to cooling equipment) Coolant temperature after engine, limit 1 L °C Coolant temperature after engine, limit 2 L °C Coolant antifreeze content, max. Pressure loss in engine-external cooling system, max.
Page 33 General operating data Cold start capability: air temperature °C (w/o start aid. w/o preheating) - (case A) Coolant preheating: preheating tempera- °C ture (min.) Firing speed, from Firing speed, to Capacities Engine coolant capacity, engine side Liters (without cooling equipment) Charge-air coolant, engine side Liters Engine oil capacity, initial filling (standard...
Page 34: Product Data 12V/16V2000Gx6S, 3F, Mains Backup Mode, Unlimited, Icxn, Optimized Fuel Consumption
4.3 Product data 12V/16V2000Gx6S, 3F, mains backup mode, unlimited, ICXN, optimized fuel consumption Legend DL Reference value: Continuous power. Continuous driving power under standard conditions BL Reference value: Fuel stop power. Maximum engine power. In some applications, continuous power not possible (adjustment reserve) A Design value.
Page 35 Exhaust overpressure mbar Exhaust gas overpressure, max. mbar Model-related data (basic design) Engine with exhaust turbocharging (ETC) and charge-air cooling (intercooler) Combustion method: direct fuel injection Direction of rotation: c.c.w. (facing driving end) Cylinder arrangement: V-angle Degrees (°) Bore Stroke Displacement, cylinder Liters 2.233...
Page 36 Lube oil system Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C Lube oil temperature before engine, limit 1 °C Lube oil temperature before engine, limit 2 °C 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...
Page 37: Product Data 12V/16V2000Gx6S, 3G, Continuous Operation, Time-Limited, Icxn, Optimized Fuel Consumption
4.4 Product data 12V/16V2000Gx6S, 3G, continuous operation, time-limited, ICXN, optimized fuel consumption Legend DL Reference value: Continuous power. Continuous driving power under standard conditions BL Reference value: Fuel stop power. Maximum engine power. In some applications, continuous power not possible (adjustment reserve) A Design value.
Page 38 Exhaust overpressure mbar Exhaust gas overpressure, max. mbar Model-related data (basic design) Engine with exhaust turbocharging (ETC) and charge-air cooling (intercooler) Combustion method: direct fuel injection Direction of rotation: c.c.w. (facing driving end) Cylinder arrangement: V-angle Degrees (°) Bore Stroke Displacement, cylinder Liters 2.233...
Page 39 Lube oil system Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C Lube oil temperature before engine, limit 1 °C Lube oil temperature before engine, limit 2 °C 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...
Page 40: Product Data 12V/16V2000Gx6S, 3H, Mains Backup Mode, Special Qualification, Optimized Fuel Consumption
4.5 Product data 12V/16V2000Gx6S, 3H, mains backup mode, special qualification, optimized fuel consumption Legend DL Reference value: Continuous power. Continuous driving power under standard conditions BL Reference value: Fuel stop power. Maximum engine power. In some applications, continuous power not possible (adjustment reserve) A Design value.
Page 41 Site conditions (for max. power) Intake depression (new filter) mbar Intake depression, max. mbar Exhaust overpressure mbar Exhaust gas overpressure, max. mbar Model-related data (basic design) Engine with exhaust turbocharging (ETC) and charge- air cooling (intercooler) Uncooled exhaust lines Operating method: Four-stroke cycle, diesel, single- action Combustion method: direct fuel injection Cooling method: conditioned water...
Page 42 Coolant system (LT circuit) Coolant temperature before intercooler (at engine in- °C let from cooling equipment) Coolant antifreeze content, max. Pressure loss in engine-external cooling system, max. L Lube oil system Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C Lube oil temperature before engine, limit 1 °C...
Page 43 Weights / main dimensions Engine weight, dry (basic engine configuration acc. to 2710 3180 3180 scope of delivery specification) Acoustics Exhaust noise, not attenuated - DL (sound power lev- dB(A) el LW, ISO 6798, +3 dB(A) tolerance) Engine surface noise with attenuated intake noise (fil- dB(A) ter) - DL (sound power level LW, ISO 6798, +2 db(A) tolerance)
Page 44: Product Data 12V/16V2000Gx6S, 3B, Continuous Operation, Variable Load, Icxn, Epa Nonroad T2 (40Cfr89)
4.6 Product data 12V/16V2000Gx6S, 3B, continuous operation, variable load, ICXN, EPA Nonroad T2 (40CFR89) Legend DL Reference value: Continuous power. Continuous driving power under standard conditions BL Reference value: Fuel stop power. Maximum engine power. In some applications, continuous power not possible (adjustment reserve) A Design value.
Page 45 Performance data Rated engine speed 1800 1800 1800 1800 Continuous power ISO 3046 (10% over- load possible) (power range DIN 6280, ISO 8528) Site conditions (for max. power) Intake depression (new filter) mbar Intake depression, max. mbar Exhaust overpressure mbar Exhaust gas overpressure, max.
Page 46 Coolant temperature after engine, limit 2 L °C Coolant antifreeze content, max. Pressure loss in engine-external cooling system, max. Coolant system (LT circuit) Coolant temperature before intercooler °C (at engine inlet from cooling equipment) Coolant antifreeze content, max. Pressure loss in engine-external cooling system, max.
Page 47 Engine oil capacity, initial filling (standard Liters oil system) (option: max. operating incli- nations) Oil change quantity, max. (standard oil Liters system) (option: max. operating inclina- tions) Weights / main dimensions Engine weight, dry (basic engine configu- 2710 2710 2710 3180 ration acc.
Page 48: Product Data 12V/16V2000Gx6S, 3D, Standby Power, Fuel Stop Power, Ifn, Epa Nonroad T2 (40Cfr89)
4.7 Product data 12V/16V2000Gx6S, 3D, standby power, fuel stop power, IFN, EPA Nonroad T2 (40CFR89) Legend DL Reference value: Continuous power. Continuous driving power under standard conditions BL Reference value: Fuel stop power. Maximum engine power. In some applications, continuous power not possible (adjustment reserve) A Design value.
Page 49 Reference conditions Intake air temperature °C Charge air coolant temperature °C Barometric pressure mbar 1000 1000 1000 1000 Site altitude above sea level Performance data Rated engine speed 1800 1800 1800 1800 Fuel stop power ISO 3046 1097 1371 Site conditions (for max. power) Intake depression (new filter) mbar Intake depression, max.
Page 50 Air / exhaust Charge-air pressure before cylinder - DL bar abs Coolant system (HT circuit) Coolant temperature (at engine connec- °C tion: outlet to cooling equipment) Coolant temperature after engine, limit 1 L °C Coolant temperature after engine, limit 2 L °C Coolant antifreeze content, max.
Page 51 General operating data Cold start capability: air temperature °C (w/o start aid. w/o preheating) - (case A) Coolant preheating: preheating tempera- °C ture (min.) Firing speed, from Firing speed, to Capacities Engine coolant capacity, engine side Liters (without cooling equipment) Charge-air coolant, engine side Liters Engine oil capacity, initial filling (standard...
Page 52: Product Data 12V/16V2000Gx6S, 3F, Mains Backup Mode, Unlimited, Icxn, Epa Nonroad T2 (40Cfr89) And Epa Stationary Emerg T2 (40Cfr60)
4.8 Product data 12V/16V2000Gx6S, 3F, mains backup mode, unlimited, ICXN, EPA Nonroad T2 (40CFR89) and EPA Stationary EMERG T2 (40CFR60) Legend DL Reference value: Continuous power. Continuous driving power under standard conditions BL Reference value: Fuel stop power. Maximum engine power. In some applications, continuous power not possible (adjustment reserve) A Design value.
Page 53 Site conditions (for max. power) Intake depression (new filter) mbar Intake depression, max. mbar Exhaust overpressure mbar Exhaust gas overpressure, max. mbar Model-related data (basic design) Engine with exhaust turbocharging (ETC) and charge-air cooling (intercooler) Combustion method: direct fuel injection Direction of rotation: c.c.w.
Page 54 Coolant system (LT circuit) Coolant temperature before intercooler (at engine inlet from cool- °C ing equipment) Coolant antifreeze content, max. Pressure loss in engine-external cooling system, max. Lube oil system Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C Lube oil temperature before engine, limit 1 °C...
Page 55 Acoustics Exhaust noise, not attenuated - DL (sound power level LW, ISO dB(A) 6798, +3 dB(A) tolerance) Engine surface noise with attenuated intake noise (filter) - DL dB(A) (sound power level LW, ISO 6798, +2 db(A) tolerance) MS15054/03E 2018-07 | Technical Data | 55...
Page 56: Product Data 12V/16V2000Gx6S, 3G, Continuous Operation, Time-Limited, Icxn, Epa Nonroad T2 (40Cfr89)
4.9 Product data 12V/16V2000Gx6S, 3G, continuous operation, time-limited, ICXN, EPA Nonroad T2 (40CFR89) Legend DL Reference value: Continuous power. Continuous driving power under standard conditions BL Reference value: Fuel stop power. Maximum engine power. In some applications, continuous power not possible (adjustment reserve) A Design value.
Page 57 Exhaust overpressure mbar Exhaust gas overpressure, max. mbar Model-related data (basic design) Engine with exhaust turbocharging (ETC) and charge-air cooling (intercooler) Combustion method: direct fuel injection Direction of rotation: c.c.w. (facing driving end) Cylinder arrangement: V-angle Degrees (°) Bore Stroke Displacement, cylinder Liters 2.233...
Page 58 Lube oil system Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C Lube oil temperature before engine, limit 1 °C Lube oil temperature before engine, limit 2 °C 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...
Page 59: Product Data 12V/16V2000Gx6S, 3H, Mains Backup Mode, Special Qualification, Epa Nonroad T2 (40Cfr89) And Epa Stationary Emerg T2 (40Cfr60)
4.10 Product data 12V/16V2000Gx6S, 3H, mains backup mode, special qualification, EPA Nonroad T2 (40CFR89) and EPA Stationary EMERG T2 (40CFR60) Legend DL Ref. value continuous power: Continuous driving power under standard conditions BL Ref. value fuel stop power (FSP): Maximum engine power; In some applications, continuous power not possible (adjustment reserve) A Design value: Value is required to design an external systems (plant).
Page 60 Performance data Rated engine speed 1800 1800 1800 Fuel stop power ISO 3046 1097 1371 Site conditions (for max. power) Intake depression (new filter) mbar Intake depression, max. mbar Exhaust overpressure mbar Exhaust gas overpressure, max. mbar Model-related data (basic design) Engine with exhaust turbocharging (ETC) and charge- air cooling (intercooler) Uncooled exhaust lines...
Page 61 Coolant system (HT circuit) Coolant temperature (at engine connection: outlet to °C cooling equipment) Coolant temperature after engine, limit 1 °C Coolant temperature after engine, limit 2 °C Coolant antifreeze content, max. Pressure loss in engine-external cooling system, max. L Coolant system (LT circuit) Coolant temperature before intercooler (at engine in- °C...
Page 62 Engine oil capacity, initial filling (standard oil system) Liters (option: max. operating inclinations) Oil change quantity, max. (standard oil system) (op- Liters tion: max. operating inclinations) Oil pan capacity at dipstick mark “min.” (standard oil Liters system) Oil pan capacity at dipstick mark “max.” (standard oil Liters system) Weights / main dimensions...
Page 63: Firing Order
4.11 Firing order Firing order Number of cylinders Firing order A1-B2-A5-B4-A3-B1-A6-B5-A2-B3-A4-B6 A1-B5-A3-A5-B2-B8-A2-A8-B3-A7-B4-B6-A4-A6-B1-B7 MS15054/03E 2018-07 | Technical Data | 63...
Page 64: Engine - Main Dimensions
4.12 Engine – Main dimensions Item Dimensions Length (A) for 12V approx. 1928.3 mm Length (A) for 16V approx. 2278.3 mm Width (B) for 12V approx. 1545.6 mm Width (B) for 16V approx. 1568.4 mm Height (C) for 12V approx. 1420.2 mm Height (C) for 16V approx.
Page 65: Operation
5.1 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 66: Putting The Engine Into Operation After Scheduled Out-Of-Service-Period
5.2 Putting the engine into operation after scheduled out-of- service-period Preconditions ☑ Engine is stopped and starting disabled. Putting into operation Item Action Lube oil system Check engine oil level (→ Page 166). Coolant circuit Check engine coolant level (→ Page 169), check charge-air coolant level (→...
Page 67: Engine - Starting
5.3 Engine – Starting Preconditions ☑ Engine is not under 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 engine's danger zone.
Page 68: Re-Starting The Engine Following An Automatic Safety Shutdown
5.4 Re-starting the engine following an automatic safety shutdown NOTICE Re-starting the engine following an automatic safety shutdown. Risk of severe engine damage! • Before starting the engine, make sure the root cause of the safety shutdown was eliminated. • If the root cause cannot be identified or eliminated, contact Service. Note: •...
Page 69: Operational Checks
5.5 Operational checks DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING High level of engine noise when the engine is running.
Page 70: Emission Label - Check
5.6 Emission label – Check Emission label – Check Note: If there are any irregularities, notify your MTU contact person/service partner without delay. Check that emission labels are present (there can be more than one). Check emission label for intactness.
Page 71: Engine Shutdown
5.7 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 stress- Overheating of and, therefore, damage to components is possible!
Page 72: Emergency Engine Shutdown
5.8 Emergency engine shutdown WARNING Exhaust gases are harmful to health and may cause cancer. Risk of poisoning and suffocation! • Keep the engine room well-ventilated at all times. • Repair leaking exhaust pipework immediately. CAUTION Shutting down from full-load operation may cause hot water to escape from the expansion tank. Risk of scalding! •...
Page 73: After Stopping The Engine
5.9 After stopping the engine Preconditions ☑ MTU Preservation and Represervation Specifications (A001070/..) are available. ☑ Engine is stopped and starting disabled. NOTICE Engine coolant with inadequate freeze protection. Water remaining in the pressure sensors freezes at temperatures below 0 °C.
Page 74: Plant - Cleaning
5.10 Plant – Cleaning Preconditions ☑ Engine is stopped and starting disabled. ☑ No operating voltage applied. Special tools, Material, Spare parts Designation / Use Part No. Qty. High-pressure cleaner (→ Tools Catalog) 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 75: Maintenance
6 Maintenance 6.1 Maintenance task reference table [QL1] for Non-EPA regions The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Mainte- nance Schedule is a separate publication. The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule.
Page 76: Maintenance Task Reference Table [Ql1] For Epa Regions
6.2 Maintenance task reference table [QL1] for EPA regions The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Mainte- nance Schedule is a separate publication. The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule.
Page 77: Troubleshooting
7 Troubleshooting 7.1 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 78 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 79 Exhaust gas blue Component Cause Action Engine oil Too much engine oil in the engine Drain engine oil (→ Page 167). Oil separator of crankcase breather con- Replace (→ Page 115). taminated Exhaust turbocharger, Faulty Contact Service. cylinder head, piston rings, cylinder liner White exhaust gas Component...
Page 80: Engine Control Unit - Ecu9 Fault Messages
7.2 Engine Control Unit – ECU9 fault messages Possible engine responses to yellow alarm: Warning, power limitation/reduction, speed limitation, engine shutdown. Possible engine responses to red alarm: Engine shutdown, power limitation/reduction, speed limitation, warning. Procedure following an automatic safety shutdown (→ Page 68) 5 –...
Page 81 16 – SS P-Lube Oil Red alarm; emergency stop Cause Corrective action Lube oil pressure too low (Level 1. Check oil level, top up as necessary (→ Page 166). 2. Contact Service if no malfunction can be detected. 23 – LO Coolant Level Red alarm;...
Page 82 34 – SS P-Diff-Fuel Yellow alarm; warning Cause Corrective action u Check fuel filter, replace as necessary. Differential pressure at fuel filter too high (Level 2). 44 – LO Coolant Level Intercooler Red alarm; emergency stop Cause Corrective action Intercooler coolant level too low. 1.
Page 83 65 – LO P-Fuel Yellow alarm; warning Cause Corrective action Fuel supply pressure too low 1. Check fuel lines for leakage. (Level 1). 2. Drain water from fuel prefilter (not switchable) (→ Page 143). Drain water from fuel prefilter (switchable) (→ Page 145). 3.
Page 84 82 – HI P-Fuel (Common Rail) Yellow alarm; warning Cause Corrective action Rail pressure > Set value => HP 1. Check wiring of HP fuel control block. fuel control block jamming or 2. Contact Service if no fault can be detected. wiring faulty.
Page 85 93 – SS T-Preheat Red alarm; engine start interlock Cause Corrective action Preheating temperature too low 1. Extend preheating period. (Level 2); coolant temperature too 2. Check preheater. low for engine start. 94 – LO T-Preheat Yellow alarm; warning Cause Corrective action Preheating temperature too low 1.
Page 86 120 – HI ECU Power Supply Voltage Yellow alarm; warning Cause Corrective action u Check batteries, charge as necessary; check alternator. Supply voltage too high (Level 1). 121 – HIHI ECU Power Supply Voltage Yellow alarm; warning Cause Corrective action u Check batteries, charge as necessary;...
Page 87 183 – AL CAN No PU-Data Yellow alarm; warning Cause Corrective action The selected CAN mode initializes 1. Check devices connected to CAN. communication by means of the 2. Contact Service. PU data module. However, the required PU data module is not available or not valid.
Page 88 201 – SD T-Coolant Yellow alarm; warning Cause Corrective action u Check sensor B6 and wiring, replace as necessary (→ Page 221). Coolant temperature sensor faulty. 203 – SD T-Charge Air Yellow alarm; warning Cause Corrective action Charge-air temperature sensor u Check sensor B9 and wiring, replace as necessary (→...
Page 89 219 – SD T-Intake Air Yellow alarm; warning Cause Corrective action u Check sensor B3 and wiring, replace as necessary (→ Page 221). Intake air temperature sensor faulty. 220 – SD Level Coolant Water Yellow alarm; warning Cause Corrective action Coolant level sensor faulty.
Page 90 229 – AL Stop Camshaft Sensor Defect Red alarm; emergency stop Cause Corrective action Engine stop due to camshaft 1. Check sensor and wiring to connectors B1 and B13, replace as sensor fault and a previous necessary (→ Page 221). crankshaft sensor fault in the 2.
Page 91 266 – SD Speed Demand Yellow alarm; warning Cause Corrective action Analog speed setting faulty. 1. Check speed setting transmitter and wiring, replace as necessary (→ Page 221). 2. Fault is rectified when engine is restarted. 269 – SD Loadp. Analog fil. Yellow alarm;...
Page 92 324 – AL Wiring Cylinder A4 Yellow alarm; warning Cause Corrective action Short circuit in cylinder A4 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. 325 –...
Page 93 329 – AL Wiring Cylinder A9 Yellow alarm; warning Cause Corrective action Short circuit in cylinder A9 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. 331 –...
Page 94 335 – AL Wiring Cylinder B5 Yellow alarm; warning Cause Corrective action Short circuit in cylinder B5 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. 336 –...
Page 95 341 – AL Open Load Cylinder A1 Yellow alarm; warning Cause Corrective action Open circuit in cylinder A1 1. Check injector wiring, exclude disruption in solenoid valve (e.g. by injector wiring. Result: Misfiring. exchanging injectors). 2. Fault is rectified after each working cycle. 342 –...
Page 96 347 – AL Open Load Cylinder A7 Yellow alarm; warning Cause Corrective action Open circuit in cylinder A7 1. Check injector wiring, exclude disruption in solenoid valve (e.g. by injector wiring. Result: Misfiring. exchanging injectors). 2. Fault is rectified after each working cycle. 348 –...
Page 97 354 – AL Open Load Cylinder B4 Yellow alarm; warning Cause Corrective action Open circuit in cylinder B4 1. Check injector wiring, exclude disruption in solenoid valve (e.g. by injector wiring. Result: Misfiring. exchanging injectors). 2. Fault is rectified after each working cycle. 355 –...
Page 98 361 – AL Power Stage Low Yellow alarm; warning Cause Corrective action Internal electronic fault, 1. Start engine governor self-test. electronics possibly faulty. 2. Replace ECU in case of fault; if self-test diagnoses “Electronics OK” check for additional fault messages (e.g. wiring fault). 362 –...
Page 99 383 – AL Wiring TOP 3 Yellow alarm; warning Cause Corrective action u Check wiring (→ Page 221). Short circuit or wire break on transistor output 3 plant-side (TOP 3). 384 – AL Wiring TOP 4 Yellow alarm; warning Cause Corrective action Short circuit or wire break on u Check wiring (→...
Page 100 404 – AL Open Load Digital Input 5 Yellow alarm; warning Cause Corrective action u Check wiring (→ Page 221). Line disruption at digital input 5. 405 – AL Open Load Digital Input 6 Yellow alarm; warning Cause Corrective action u Check wiring (→...
Page 101 413 – HIHI U-PDU Yellow alarm; warning Cause Corrective action u Perform Engine Control Unit self-test, replace as necessary. Injector voltage too high (Level 2). 414 – HI Level Water Fuel Prefilter Yellow alarm; warning Cause Corrective action u Empty fuel prefilter. Water level in fuel prefilter too high.
Page 102 439 – HI P-Fuel 2 (Common Rail) Yellow alarm; warning Cause Corrective action Rail pressure above specified 1. Check wiring of HP fuel control block. value. 2. Contact Service if no fault can be detected. Suction restrictor of HP fuel block jamming or HP fuel control block wiring faulty.
Page 103 454 – SS Power Reduction Active Yellow alarm; warning Cause Corrective action u Observe any other messages. Power reduction activated. 470 – SD T-ECU Yellow alarm; warning Cause Corrective action u Replace Engine Control Unit at next opportunity. Temperature sensor for engine governor faulty.
Page 104 479 – AL Comb. Alarm Red (Plant) Yellow alarm; warning Cause Corrective action u Observe any other fault messages. Combined alarm initiated by plant (red). 480 – AL Ext. Engine Protection Yellow alarm; warning Cause Corrective action External engine protection u Contact Service.
Page 105 582 – AL Emergency Stop Failed Entered in fault memory only. Cause Corrective action u Contact Service. Emergency stop command was not executed. 596 – AL Cons. Parameter Record Yellow alarm; warning Cause Corrective action Standard production data record u Contact Service. available.
Page 106 762 – AL Smart Connect Lost Yellow alarm; warning Cause Corrective action u Check wiring or Smart Connect, replace as necessary. Smart Connect device has failed on CAN bus. 832 – AL EIL Different Engine Number Yellow alarm; warning Cause Corrective action Alarm when fault numbers differ u Contact Service.
Page 107 1130 – AL Short Circuit Analog Out 1 Yellow alarm; warning Cause Corrective action u Check cabling. The value output at analog output 1 deviates excessively from the value read back. 1131 – AL Short Circuit Analog Out 2 Yellow alarm; warning Cause Corrective action The value output at analog output...
Page 108: Task Description
8 Task Description 8.1 Engine 8.1.1 Engine – Test run DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING Exhaust gases are harmful to health and may cause cancer.
Page 109: Engine - Barring Manually
8.1.2 Engine – Barring 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 110: Engine - Barring With Starting System
8.1.3 Engine – Barring with starting system Preconditions ☑ External pushbutton “Bar engine without starting” is provided. DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Before cranking the engine with starter system, make sure that there are no persons in the engine's danger zone.
Page 111: Cylinder Liner
8.2 Cylinder Liner 8.2.1 Cylinder liner – Instructions and comments on endoscopic and visual examination Terms used for endoscopic examination Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic examina- tion report. Findings Explanations/Action Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing products,...
Page 112 Evaluation of findings and further measures The findings in the start phase of oxidation discoloration and burn marks are similar. A thorough investigation and compliance with the above evaluation criteria allow an unambiguous evaluation. To avoid unnecessary disassembly work, it is recommended that another inspection be carried out after further operation of the engine.
Page 113: Cylinder Liner - Endoscopic Examination
8.2.2 Cylinder liner – Endoscopic examination Preconditions ☑ Engine is stopped and starting disabled Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring tool F6792910 Ratchet with extension F30006212 Endoscope Y20097353 Preparatory steps Remove cylinder head cover (→ Page 124). Remove injector (→...
Page 114 Final steps Install injector (→ Page 127). Install cylinder head cover (→ Page 124). 114 | Cylinder Liner | MS15054/03E 2018-07...
Page 115: Crankcase Breather
8.3 Crankcase Breather 8.3.1 Crankcase breather – Oil mist separator replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil Oil mist separator (→ Spare Parts Catalog) O-ring (→...
Page 116: Fan Drive
8.4 Fan Drive 8.4.1 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 117: Drive Belt - Tension Check
8.4.2 Drive belt – Tension check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Test device Y4345711 Preload gauge, 150–600 N Y20097429 Measuring belt tension with frequency meter Remove protective cover. Tap against the belt with the handle of a hammer or with a wrench to initiate belt vibration.
Page 118 Belt length ‒ Application Measured value Measured value Initial installation (new belt, (used belt, runtime 500 h) runtime 0.5-2 h) Drive belt 1800 mm – Fan Depression depth: 7 mm Depression depth: 8 mm Test force: 188 N Test force: 188 N Drive belt 1520 mm –...
Page 119: Drive Belt - Tension Adjustment
8.4.3 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 bit F30027340 Torque wrench, 40–200 Nm F30027337 Ring socket, 24 mm F30501562 Engine oil Drive belt ‒...
Page 120: Drive Belt - Replacement
8.4.4 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 121: Valve Drive
8.5 Valve Drive 8.5.1 Valve clearance – Check and adjustment Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine coolant temperature is max. 40 °C. ☑ Valves are closed. Special tools, Material, Spare parts Designation / Use Part No. Qty.
Page 122: Adjusting Valve Clearance
Checking valve clearance at two crankshaft positions Check TDC position of piston in cylinder 1 side A: • When the rocker arms are relieved on cylinder 1 side A, the piston is at firing TDC. • When the rocker arms are loaded on cylinder 1 side A, the piston is at overlap TDC. Check valve clearance with engine cold (at max.
Page 123 Tighten locknut (1) with torque wrench to the specified tightening torque, using an Allen wrench to hold the adjusting screw (2) to prevent it from turning. Name Size Type Lubricant Value/Standard Locknut M12x1 Tightening torque 50 Nm +5 Nm Insert feeler gauge between valve bridge and rocker arm to verify that the gauge just passes through the gap.
Page 124: Cylinder Head Cover - Cylinder Head Cover
8.5.2 Cylinder head cover – Cylinder head cover 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 bit F30027340 Engine oil Seal (→...
Page 125 Check condition of gasket (1). Replace gasket (1) if damaged. Place gasket (1) in correct position on cylin- der head. Push spade lugs under the terminals on the injector and tighten to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard...
Page 126: Injector
8.6 Injector 8.6.1 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 127). 126 | Injector | MS15054/03E 2018-07...
Page 127: Injector - Removal And Installation
8.6.2 Injector – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Press-in tool F6790085 Extraction device F6790636 Fuel suction pipe F30378207 Torque wrench, 20–100 Nm F30026582 Torque wrench, 0.5–5 Nm 0015384230 Ratchet bit...
Page 128 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 Close fuel supply line.
Page 129 Installing injector Remove all covers before installation. Clean sealing surface on cylinder head and protective sleeve. Note: Use a new sealing ring whenever the injector is installed. Coat sealing ring on injector (1) with assem- bly compound. Note: Use either the press-in tool or the hold-down clamp (2) to press the injector (1) into the cylinder head.
Page 130 Coat thread and shoulder of union nut (2) with engine oil and tighten to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Union nut Preload torque (Engine oil) 15 Nm +5 Nm Tighten screw (3) for hold-down clamp (2) to specified torque using a torque wrench. Name Size Type...
Page 131 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. Position HP fuel line (1) with union nut (2) in correct position between rail and pressure pipe neck (3), then tighten by hand.
Page 132: Injector Functions
8.6.3 Injector functions Preconditions ☑ Engine is stopped and starting disabled. Note: Failure to reset the drift correction parameters (CDC) and enter injector coding will render the emissions cer- tification of the engine null and void. Resetting drift correction parameters (CDC) with DiaSys® Note: Document can be found on the service PC in C:\DiaSys\Doku after successful installation of DiaSys®.
Page 133: Fuel System
8.7 Fuel System 8.7.1 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 bit F30027340 Plug-in open-end wrench, 19 mm F30025897 Crowfoot wrench, 19 mm...
Page 134 Preparatory steps Close fuel supply line. Remove fuel return line . Replacing HP fuel line and pres- sure pipe neck Remove union nuts (1, 3) on HP fuel line (2). Remove HP fuel line (2). Remove union nut (4). Pull out pressure pipe neck (5). Coat sealing ring of new pressure pipe neck (5) with assembly compound.
Page 135 Final steps Clean mating faces on cylinder head and charge-air pipe. Check gaskets for damage and replace as necessary. Coat gaskets with assembly compound and place on cylinder head. Install leak-off-fuel lines. Install charge-air pipes. Install Engine Control Unit (→ Page 219). Open fuel supply line.
Page 136: Fuel System - Venting
8.7.2 Fuel system – Venting Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine is cooled down to ambient temperature. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 8–40 Nm F30043446 Ring socket, 22 mm F30038494 WARNING Fuels are combustible and explosive.
Page 137: Fuel - Draining
8.7.3 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 Liquid or gaseous media, e.g.
Page 138: Fuel Cooler - External Contamination And Leak-Tightness Check
8.7.4 Fuel cooler – External contamination and leak-tightness check Preconditions ☑ Engine is stopped and starting disabled. ☑ All fuel cooler power sources are disconnected. WARNING Fuels are combustible and explosive. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. •...
Page 139: Fuel Cooler - Cleaning
8.7.5 Fuel cooler – Cleaning Preconditions ☑ Engine is stopped and starting disabled. ☑ All fuel cooler power sources are disconnected. WARNING Hot components/surfaces. Risk of burns! • Allow the engine to cool down to below 50 °C before beginning work. •...
Page 140 Cleaning with a compressed-air pistol Blow out cooler elements with a jet of compressed air working against the direction of the cooling air parallel to the cooling fins. Remove and dispose of dirt before putting engine into operation. Use industrial high-pressure cleaner to clean fuel cooler in case of stubborn contamination. Cleaning with industrial high-pressure cleaner Note: •...
Page 141: Fuel Filter
8.8 Fuel Filter 8.8.1 Fuel filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Easy-change filter (→ Spare Parts Catalog) WARNING Fuels are combustible and explosive. Risk of fire and explosion! •...
Page 142: Fuel Prefilter - Draining
8.8.2 Fuel prefilter – Draining Note: The descriptions also apply to heavy-duty fuel prefilters Fuel prefilter (non-switchable) Drain water and contaminants from fuel prefilter (→ Page 143). Fuel prefilter (switchable) Drain water and contaminants from fuel prefilter (→ Page 145). 142 | Fuel Filter | MS15054/03E 2018-07...
Page 143: Fuel Prefilter (Non-Switchable) - Draining
8.8.3 Fuel prefilter (non-switchable) – Draining DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING Fuels are combustible and explosive.
Page 144 Open threaded vent plug (1) of filter to be serviced. Open drain plug (1). Allow water to drain until fuel emerges. Close drain plug (2) again. Drain second filter on module, from (→ Step 4). Close threaded vent plug again. Open fuel supply.
Page 145: Fuel Prefilter (Switchable) - Draining
8.8.4 Fuel prefilter (switchable) – Draining DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING Fuels are combustible and explosive.
Page 146 During engine operation, turn the switchover level as far as the stop (arrow) to cut out the filter module to be serviced. Result: • Filter module (1) is cut in • Filter module (2) is cut out Open threaded vent plug (1) of filter to be serviced.
Page 147 Draining fuel prefilter with high pressure, version B Note: The filter modules can be drained without switchover during engine operation and at engine stand- still! Provide a suitable container to collect the water. Take care when opening drain plug (1) be- cause fuel or water can spurt out.
Page 148: Fuel Prefilter - Pressure Ratios
8.8.5 Fuel prefilter – Pressure ratios 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 Liquid or gaseous media, e.g.
Page 149: Fuel Prefilter (Switchable) - Low Pressure Indicator Check
8.8.6 Fuel prefilter (switchable) – Low pressure indicator check Low pressure indicator on switchable fuel prefilter Check low pressure indicator reading at low pressure gauge (3): • Red zone (1): -1.0 bar to -0.4 bar (low pressure) • Green zone (2): -0.4 bar to +0.5 bar (nor- mal operation) Switch over the fuel prefilter or replace a fil- ter element (→...
Page 150: Fuel Prefilter (Non-Switchable) - Filter Element Replacement
8.8.7 Fuel prefilter (non-switchable) – Filter element replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 20–100 Nm F30026582 Ratchet bit F30027340 Diesel fuel Filter parts kit (→ Spare Parts Catalog) WARNING Fuels are combustible and explosive. Risk of fire and explosion! •...
Page 151 Open threaded vent plug and ensure that fuel does not emerge continuously. Result: The filter can now be replaced! If fuel emerges continuously, check shutoff valve in fuel supply, contact Service. Note: • As soon as the filter housing is opened, absolute cleanness is imperative! •...
Page 152: Fuel Prefilter (Switchable) - Filter Element Replacement
8.8.8 Fuel prefilter (switchable) – Filter element replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 20–100 Nm F30026582 Ratchet bit F30027340 Diesel fuel Filter parts kit (→ Spare Parts Catalog) DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! •...
Page 153 During engine operation, turn the switchover level as far as the stop (arrow) to cut out the filter module to be serviced. Result: • Filter module (1) is cut in • Filter module (2) is cut out Check fuel level in filter. Result: If the fuel level is stable, the filter can be re- placed!
Page 154 Open threaded vent plug and ensure that fuel does not emerge continuously. Result: The filter can now be replaced! If fuel emerges continuously, check shutoff valve in fuel supply, notify Service. Note: • As soon as the filter housing is opened, absolute cleanness is imperative! •...
Page 155: Fuel Prefilter - Venting
8.8.9 Fuel prefilter – Venting DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING Fuels are combustible and explosive.
Page 156 Release threaded vent plugs (2, 3) and un- screw at least one rotation. Note: • Only operate the fuel priming pump man- ually! • Only hold the pump plunger vertically to avoid damaging the pump! Unlock fuel priming pump, screw out han- dle (1).
Page 157: Air Filter
8.9 Air Filter 8.9.1 Air filter – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Air filter (→ Spare Parts Catalog) Filter element (→ Spare Parts Catalog) Filter element (→ Spare Parts Catalog) WARNING The engine draws in large volumes of ambient air for combustion. This air intake results in a strong vac- uum.
Page 158: Air Filter - Removal And Installation
8.9.2 Air filter – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque screwdriver, 1–5 Nm F30452774 WARNING The engine draws in large volumes of ambient air for combustion. This air intake results in a strong vac- uum.
Page 159: Air Intake
8.10 Air Intake 8.10.1 Service indicator – Signal ring position check Preconditions ☑ Engine is stopped and starting disabled. Checking signal ring position When the yellow piston (2) has reached the red-shaded Service lettering (3), replace air filter (→ Page 157). After installation of new filter, press reset button (1).
Page 160: Starting Equipment
8.11 Starting Equipment 8.11.1 Electric starter ‒ Overview 1 Starter 4 Gasket 7 Nut 2 Gasket 5 Stud 3 Flange 6 Washer 160 | Starting Equipment | MS15054/03E 2018-07...
Page 161: Starter - Removal
8.11.2 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 Starter heats up during the starting procedure.
Page 162: Starter - Installation
8.11.3 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 Heavy part, risk of falling or overturning due to lack of stability.
Page 163: Pneumatic Starter - Overview
8.11.4 Pneumatic starter – Overview 1 Pressure reducing valve 5 Gasket 9 Threaded adapter 2 Starting valve 6 Stud 10 Pneumatic starter 3 Gasket 7 Washer 4 Flange 8 Hex nut MS15054/03E 2018-07 | Starting Equipment | 163...
Page 164: Starter - Removal
8.11.5 Starter – Removal Preconditions ☑ Preparatory steps have been completed. DANGER Rotating, moving engine parts. Danger of crushing, danger of body parts being drawn in or caught! • Ensure that the engine can not be started. • After completion of work, make sure that all protective devices are installed. WARNING Compressed-air pipes may still be under pressure, although the shut-off valve is closed.
Page 165: Starter - Installation
8.11.6 Starter ‒ Installation Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 8–40 Nm F30043446 Ring socket, 24 mm F30501562 Lubricating grease (Molykote Longtherm 2 Plus NLGI 2) X00057299 Sealing tape 50155 WARNING Heavy part, risk of falling or overturning due to lack of stability. Risk of crushing body or limbs! •...
Page 166: Lube Oil System, Lube Oil Circuit
8.12 Lube Oil System, Lube Oil Circuit 8.12.1 Engine oil level – Check Preconditions ☑ Engine is stopped and starting disabled. Checking oil level prior to en- gine start Pull out dipstick from guide tube and wipe it. Insert dipstick into guide tube up to the stop, pull it out after approx.
Page 167: Engine Oil - Change
8.12.2 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 168: Oil Filtration / Cooling
8.13 Oil Filtration / Cooling 8.13.1 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 Oil is hot.
Page 169: Coolant Circuit, General, High-Temperature Circuit
8.14 Coolant Circuit, General, High-Temperature Circuit 8.14.1 Engine coolant – Level check Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...
Page 170: Engine Coolant Change
8.14.2 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change Drain engine coolant (→ Page 171). Fill with engine coolant (→ Page 172). 170 | Coolant Circuit, General, High-Temperature Circuit | MS15054/03E 2018-07...
Page 171: Engine Coolant - Draining
8.14.3 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 container to catch the coolant.
Page 172: Engine Coolant - Filling
8.14.4 Engine coolant – Filling Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant WARNING Coolant is hot and under pressure.
Page 173 Final steps Start the engine and operate it at idle speed for some minutes. Check coolant level, top up coolant if necessary (→ Page 169). MS15054/03E 2018-07 | Coolant Circuit, General, High-Temperature Circuit | 173...
Page 174: Engine Coolant Pump - Relief Bore Check
8.14.5 Engine coolant pump – Relief bore check DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING High level of engine noise when the engine is running.
Page 175: 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 176: Low-Temperature Circuit
8.15 Low-Temperature Circuit 8.15.1 Charge-air coolant – Filling Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Sealing ring (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure.
Page 177 Charge-air coolant – Filling Fill treated coolant through filling line or through filler neck of coolant expansion tank until coolant level reaches marking plate. Install plug screws of filling points with new sealing rings. Check proper condition of breather valve (1), clean sealing faces if required. Fit breather valve (1) and close it.
Page 178: Charge-Air Coolant - Draining
8.15.2 Charge-air coolant – Draining Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Sealing ring (→ Spare Parts Catalog) Sealing ring (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...
Page 179: Charge-Air Coolant - Change
8.15.3 Charge-air coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Charge-air coolant – Change Drain charge-air coolant (→ Page 178). Fill with charge-air coolant (→ Page 176). MS15054/03E 2018-07 | Low-Temperature Circuit | 179...
Page 180: Charge-Air Coolant Level - Check
8.15.4 Charge-air coolant level – Check Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. DANGER Falling from great heights. Risk of serious injury – danger to life! • When working high on the equipment, always use suitable ladders or work platforms.
Page 181: Charge-Air Coolant Pump - Relief Bore Check
8.15.5 Charge-air coolant pump – Relief bore check DANGER Components are moving or rotating. Risk of crushing, danger of parts of the body being caught or pulled in! • Operate the engine at low load only. Keep clear of the danger zone of the engine. WARNING High level of engine noise when the engine is running.
Page 182: Intercooler - Checking Condensate Drain For Coolant Discharge And Obstructions
8.15.6 Intercooler – Checking condensate drain for coolant discharge and obstructions Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Sealing ring (→ Spare Parts Catalog) WARNING Compressed air gun ejects a jet of pressurized air. Risk of injury to eyes and damage to hearing, risk of rupturing internal organs! •...
Page 183: Battery-Charging Generator
8.16 Battery-Charging Generator 8.16.1 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 184: Drive Belt - Tension Check
8.16.2 Drive belt – Tension check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Test device Y4345711 Preload measuring device Preparatory steps Remove safety equipment (if applicable). Remove screws of protective cover (engine free end). Take off protective cover.
Page 185 Belt length ‒ Application Measured value Measured value Initial installation (new belt, (used belt, runtime 500 h) runtime 0.5-2 h) 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 15: Specified values ‒...
Page 186: Drive Belt - Tension Adjustment
8.16.3 Drive belt ‒ Tension adjustment Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 8–40 Nm F30453004/21 Ratchet bit F30027340 Engine oil Preparatory steps Remove safety equipment (if applicable). Remove screws of protective cover (engine free end).
Page 187: Drive Belt - Replacement
8.16.4 Drive belt – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 8–40 Nm F30453004/21 Ratchet bit F30027340 Engine oil Drive belt (→ Spare Parts Catalog) Preparatory steps Remove safety equipment (if fitted).
Page 188: Preheater
8.17 Preheater 8.17.1 Preheater – Overhaul Preconditions ☑ Engine is stopped and starting disabled. ☑ All preheater power sources are disconnected. Replacing solenoid switch Preheater 3 kW, 230 V, 50 Hz (→ Page 201) Preheater 3 kW, 240 V, 60 Hz (→...
Page 189: Preheater - Function And Leak Check
8.17.2 Preheater – Function and leak check Preconditions ☑ Preheater is switched on. WARNING Coolant is hot and highly pressurized. Risk of injury! Risk of scalding! • Allow engine to cool down. • Wear protective clothing, protective gloves, and safety glasses / facial protection. Function check Note: The preheater operates properly if the measured value of the coolant temperature is within the control range...
Page 190: Preheater - Heating Element And Housing Check
8.17.3 Preheater – Heating element and housing check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Screw locking compound (Loctite 586) 40033 O-ring (→ Spare Parts Catalog) DANGER Electric voltage supply for operation. Danger of burns and fatal electric shock! •...
Page 191 Open drain plug at coolant inlet (arrow) and drain coolant. Undo clamps on both lines on preheater side. Checking heating element and housing for contamination Undo screws (1) between electrical part (2) and housing. Pull electrical part (2) with heating element out of housing.
Page 192 Final steps Connect preheater power sources. Switch on preheater. 192 | Preheater | MS15054/03E 2018-07...
Page 193: Preheater - Heating Element And Housing Check
8.17.4 Preheater – Heating element and housing check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Screw locking compound (Loctite 586) 40033 O-ring (→ Spare Parts Catalog) DANGER Electric voltage supply for operation. Danger of burns and fatal electric shock! •...
Page 194 Open drain plug at coolant inlet (arrowed) and drain coolant. Undo clamps on both lines on preheater side. Checking heating element and housing for contamination Undo screws (1) between electrical part (2) and housing. Pull electrical part (2) with heating element out of housing.
Page 195 Final steps Connect preheater power sources. Switch on preheater. MS15054/03E 2018-07 | Preheater | 195...
Page 196: Preheater - Heating Element And Housing Check
8.17.5 Preheater – Heating element and housing check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Screw locking compound (Loctite 586) 40033 O-ring (→ Spare Parts Catalog) DANGER Electric voltage supply for operation. Danger of burns and fatal electric shock! •...
Page 197 Open drain plug at coolant inlet (arrowed) and drain coolant. Undo clamps on both lines on preheater side. Checking heating element and housing for contamination Undo screws (1) between electrical part (2) and housing. Pull electrical part (2) with heating element out of housing.
Page 198 Final steps Connect preheater power sources. Switch on preheater. 198 | Preheater | MS15054/03E 2018-07...
Page 199: Preheater - Solenoid Switch Replacement
8.17.6 Preheater – Solenoid switch replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Solenoid switch (→ Spare Parts Catalog) DANGER Electric voltage supply for operation. Danger of burns and fatal electric shock! •...
Page 200 Mark all cables (4) prior to disconnection. Disconnect all cables (4) from solenoid switch (1). Note: The solenoid switch is secured to the rail (2) by a spring clip (3). Pull out the spring clip with a screwdriver and slide the solenoid switch off the rail. Fit a new solenoid switch on the rail and fully engage the spring clip.
Page 201: Preheater - Solenoid Switch Replacement
8.17.7 Preheater – Solenoid switch replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Solenoid switch (→ Spare Parts Catalog) DANGER Electric voltage supply for operation. Danger of burns and fatal electric shock! •...
Page 202 Mark all cables (1) prior to disconnection. Disconnect all cables (1) from solenoid switch (2). Undo screws (3) on solenoid switch (2) and remove solenoid switch (2). Install new solenoid switch (2) and tighten screws (3). Connect up all wires as marked previously. Close the control box and tighten the screws.
Page 203: Preheater - Solenoid Switch Replacement
8.17.8 Preheater – Solenoid switch replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Solenoid switch (→ Spare Parts Catalog) DANGER Electric voltage supply for operation. Danger of burns and fatal electric shock! •...
Page 204 Mark all cables (1) prior to disconnection. Disconnect all cables (1) from solenoid switch (2). Undo screws (3) on solenoid switch (2) and remove solenoid switch (2). Install new solenoid switch (2) and tighten screws (3). Connect up all wires as marked previously. Close the control box and tighten the screws.
Page 205: Preheater Thermostats - Replacement
8.17.9 Preheater thermostats – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Thermostat (→ Spare Parts Catalog) DANGER Electric voltage supply for operation. Danger of burns and fatal electric shock! •...
Page 206 Mark cables prior to disconnection. Disconnect terminals from blade terminals of measuring unit (2). Undo thermostat clip (1) and remove safety thermostat. Insert new safety thermostat in recess. Secure thermostat clip. Connect cable. Fit cover and tighten screws. Replacing control thermostat Undo screws (1) on housing cover (2) of con- trol thermostat and remove cover.
Page 207 Final steps Connect preheater to power supply. Switch on preheater. MS15054/03E 2018-07 | Preheater | 207...
Page 208: Preheater Thermostats - Replacement
8.17.10 Preheater thermostats – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Thermostat (→ Spare Parts Catalog) DANGER Electric voltage supply for operation. Danger of burns and fatal electric shock! •...
Page 209 Mark cables prior to disconnection. Disconnect terminals from blade terminals of measuring unit (2). Undo thermostat clip (1) and remove safety thermostat. Insert new safety thermostat in recess. Secure thermostat clip. Connect cable. Fit cover and tighten screws. Replacing control thermostat Undo screws (1) on housing cover (2) of con- trol thermostat and remove cover.
Page 210 Final steps Connect preheater to power supply. Switch on preheater. 210 | Preheater | MS15054/03E 2018-07...
Page 211: Preheater Thermostats - Replacement
8.17.11 Preheater thermostats – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Thermostat (→ Spare Parts Catalog) DANGER Electric voltage supply for operation. Danger of burns and fatal electric shock! •...
Page 212 Mark cables prior to disconnection. Disconnect terminals from blade terminals of measuring unit (2). Undo thermostat clip (1) and remove safety thermostat. Insert new safety thermostat in recess. Secure thermostat clip. Connect cable. Fit cover and tighten screws. Replacing control thermostat Undo screws (1) on housing cover (2) of con- trol thermostat and remove cover.
Page 213 Final steps Connect preheater to power supply. Switch on preheater. MS15054/03E 2018-07 | Preheater | 213...
Page 214: Engine Mounting / Support
8.18 Engine Mounting / Support 8.18.1 Engine mounting – Checking securing screws for firm seating Preconditions ☑ Engine is stopped and starting disabled. Engine mounting, checking securing screws for firm seating Check securing screws for firm seating. Tighten loose threaded connections. 214 | Engine Mounting / Support | MS15054/03E 2018-07...
Page 215: Engine Mounting - Checking Condition Of Resilient Mounts
8.18.2 Engine mounting – Checking condition of resilient mounts Preconditions ☑ Engine is stopped and starting disabled. Engine mounting – Checking the condition of resilient mounts Wipe rubber surface with dry cloth, do not use organic detergents. Visually inspect resilient mounts for cracking and deformation. Check rubber surfaces for swelling.
Page 216: Generator
8.19 Generator 8.19.1 Generator mounting – Checking condition of resilient mounts Preconditions ☑ Engine is stopped and starting disabled. Generator mounting – Checking condition of resilient mounts Wipe rubber surface with dry cloth, do not use organic detergents. Visually inspect resilient mounts for cracks and deformation. Check rubber surfaces for swelling.
Page 217: Generator Mounting - Checking Firm Seating Of Securing Screws
8.19.2 Generator mounting – Checking firm seating of securing screws Preconditions ☑ Engine is stopped and starting disabled. Generator mounting – Checking firm seating of securing screws Check securing screws for firm seating. Tighten loose screw connections. MS15054/03E 2018-07 | Generator | 217...
Page 218: Engine Governor
8.20 Engine Governor 8.20.1 Engine Control Unit – Overview 1 Connector X2 3 Connector X3 5 Screw 2 Connector X1 (customer 4 Washer 6 Damping element connection) 218 | Engine Governor | MS15054/03E 2018-07...
Page 219: Engine Control Unit - Removal And Installation
8.20.2 Engine Control Unit – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine Control Unit (→ Spare Parts Catalog) Rubber mount (→ Spare Parts Catalog) NOTICE Wrong engine governor installed.
Page 220: Engine Governor Plug Connections - Check
8.20.3 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 221: Wiring (General) For Engine/Gearbox/Unit
8.21 Wiring (General) for Engine/Gearbox/Unit 8.21.1 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 222: Accessories For (Electronic) Engine Governor / Control System
8.22 Accessories for (Electronic) Engine Governor / Control System 8.22.1 Engine governor and connector – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Solvent (isopropyl alcohol) X00058037 NOTICE Insertion of unsuitable test probe, e.g.
Page 223: 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 224 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 225: Mtu Contact/Service Partners
Local Support Experienced and qualified specialists place their knowledge and expertise at your disposal. For locally available support, go to the MTU Internet site: http://www.mtu-online.com 24h Hotline With our 24h hotline and high flexibility, we're your contact around the clock: during each operating phase, preventive maintenance and corrective operations in case of a malfunction, for information on changes in conditions of use and for supplying spare parts.
Page 226: Special Tools
10 Appendix B 10.1 Special Tools Angular screw driver Part No.: F30453001 Qty.: Used in: 8.5.1 Valve clearance – Check and adjustment (→ Page 121) Barring device Part No.: F6792910 Qty.: Used in: 8.5.1 Valve clearance – Check and adjustment (→...
Page 227 Crossbeam Part No.: T80091731 Qty.: Used in: 2.1 Transport (→ Page 19) Crowfoot wrench, 19 mm Part No.: F30027424 Qty.: Used in: 8.6.2 Injector – Removal and installation (→ Page 127) Qty.: Used in: 8.7.1 HP fuel line and pressure pipe neck – Replacement (→...
Page 228 Endoscope Part No.: Y20097353 Qty.: Used in: 8.2.2 Cylinder liner – Endoscopic examination (→ Page 113) Extraction device Part No.: F6790636 Qty.: Used in: 8.6.2 Injector – Removal and installation (→ Page 127) Filter wrench Part No.: F30379104 Qty.: Used in: 8.8.1 Fuel filter –...
Page 229 Measuring instrument Part No.: Y4348409 Qty.: Used in: 8.5.1 Valve clearance – Check and adjustment (→ Page 121) MTU test kit Part No.: 5605892099/00 Qty.: Used in: 8.14.6 Engine coolant – Sample extraction and analysis (→ Page 175) Plug-in open-end wrench, 19 mm Part No.:...
Page 230 Plug-in open-end wrench, 19 mm Part No.: F30025897 Qty.: Used in: 8.7.1 HP fuel line and pressure pipe neck – Replacement (→ Page 133) Preload gauge, 150–600 N Part No.: Y20097429 Qty.: Used in: 8.4.2 Drive belt – Tension check (→ Page 117) Preload measuring device Part No.: Qty.:...
Page 231 Ratchet Part No.: F30006212 Qty.: Used in: 8.1.2 Engine – Barring manually (→ Page 109) Qty.: Used in: 8.5.1 Valve clearance – Check and adjustment (→ Page 121) Ratchet bit Part No.: F30027340 Qty.: Used in: 8.4.3 Drive belt ‒ Tension adjustment (→ Page 119) Qty.: Used in: 8.5.2 Cylinder head cover –...
Page 232 Ring socket, 22 mm Part No.: F30038494 Qty.: Used in: 8.6.2 Injector – Removal and installation (→ Page 127) Qty.: Used in: 8.7.2 Fuel system – Venting (→ Page 136) Ring socket, 24 mm Part No.: F30501562 Qty.: Used in: 8.4.3 Drive belt ‒...
Page 233 Test device Part No.: Y4345711 Qty.: Used in: 8.4.2 Drive belt – Tension check (→ Page 117) Qty.: Used in: 8.16.2 Drive belt – Tension check (→ Page 184) Torque screwdriver, 1–5 Nm Part No.: F30452774 Qty.: Used in: 8.9.2 Air filter – Removal and installation (→ Page 158) Torque wrench, 20-100 Nm Part No.: F30026582...
Page 234 Torque wrench, 40–200 Nm Part No.: F30027337 Qty.: Used in: 8.4.3 Drive belt ‒ Tension adjustment (→ Page 119) Torque wrench, 8–40 Nm Part No.: F30043446 Qty.: Used in: 8.5.2 Cylinder head cover – Cylinder head cover (→ Page 124) Qty.: Used in: 8.7.2 Fuel system –...
Page 235 Valve clearance gauge Part No.: Y4345893 Qty.: Used in: 8.5.1 Valve clearance – Check and adjustment (→ Page 121) MS15054/03E 2018-07 | Special Tools | 235...
Page 236: Index
10.2 Index Coolant – Change 170, 179 Actuators – Charge air – Overview 22 – Filling 176 After stopping the engine 73 – Filling 172 Air filter – Intercooler – Installation 158 – Draining 178 – Removal 158 – Sample –...
Page 237 Engine Fuel filter – After stopping 73 – Replacement 141 – Barring Fuel prefilter – Manually 109 – Draining 142 – Barring with starting system 110 – Non-switchable 143 – Emergency shutdown 72 – Switchable 145 – Main dimensions 64 –...
Page 238 – 3D, standby power, fuel stop power, IFN 48 regions 75 – 3F, mains backup mode, unlimited, ICXN 52 MTU contact persons 225 – 3H, mains backup mode, special qualification 59 – EPA Stationary EMERG T2 (40CFR60) – 3F, mains backup mode, unlimited, ICXN 52...
Page 239 Starter – Electric – Installation 162 – Removal 161 – Pneumatic – Installation 165 – Overview 163 – Removal 164 Thermostat – Replacement – Preheater 205, 208, 211 Transport – Description 19 Troubleshooting 77 Valve clearance – Adjustment 121 –...

This manual is also suitable for:

16v2000gx6 series

MTU 12V2000Gx6 series Operating Instructions Manual

1 Safety

2 Transport

3 General Information

4 Technical Data

5 Operation

6 Maintenance

7 Troubleshooting

8 Task Description

9 Appendix A

Quick Links

Operating Instructions

Need help?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for MTU 12V2000Gx6 series

Summary of Contents for MTU 12V2000Gx6 series

This manual is also suitable for:

Table of Contents