Page 1 Technical Publication Diesel Engine 12 V 2000 P62, P82 16 V 2000 P62, P82 Application group 3B Operating Instructions MS15009/00E...
Page 2 © 2006 Copyright MTU Friedrichshafen GmbH This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, microfilming and storage or processing on electronic systems including data bases and online services.
Page 3 The Commissioning Note information serves as a basis for the contractually agreed logistic support (warranty, spare parts, etc.). Veuillez séparer la carte “Signalisation de mise en service“ et la renvoyer à la MTU Friedrichshafen GmbH. Les informations contenues dans la signalisation de mise en service constituent la base pour l'assistance en exploitation contractuelle (garantie, rechanges, etc.).
Page 4 Prière de remplir en lettres capitales! ¡A rellenar en letras de imprenta! Scrivere in stampatello! Favor preencher com letras de forma! Motornr.: Auftragsnr.: Inbetriebnahme- Engine No.: MTU works order No.: meldung du moteur: N° de commande: de motor: N° de pedido: Motore N.: N. commessa: Commissioning No.
Page 8 MTU contact person/service partner ........
Page 9: Safety
Modifications or Conversions Modifications made by the customer to the engine may affect safety. MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or conversions. Spare parts Only genuine MTU spare parts must be used to replace components or assemblies. In the event of any damage caused by the use of other spare parts, no liability nor warranty claims vis-à-vis the engine manufacturer will be accepted.
Page 10: Personnel And Organizational Requirements
Depending on the kind of work, use additional protective equipment, e.g. protective goggles, gloves, helmet, apron. Work clothing must be tight fitting so that it does not catch on rotating or projecting components. Do not wear jewelry (e.g. rings, chains etc.). MS15009/00E 06-09 © MTU...
Page 11: Transport
Place the engine only on an even, firm surface. Ensure appropriate consistency and load-bearing capacity of the ground or support surface. Never place an engine on the oil pan, unless expressively authorized by MTU on a case-to-case basis to do so. MS15009/00E 06-09...
Page 12: Safety Precautions When Working On The Engine
Safety precautions when working on the engine Safety precautions when putting the equipment into operation Prior to initial operation, the product must have been installed correctly and approved according to MTU specifications. Before putting the device or the system into operation, always ensure •...
Page 13 Never route the welding lead over or near the wiring harnesses of MTU systems. The welding current may otherwise induce an interference voltage in the wiring harnesses which could conceivably damage the electrical system.
Page 14 5 mW, and in which the beam axis and surface are designed to prevent any risk to the eyes. Operation of electrical equipment When operating electrical equipment, certain components of this equipment are live. Noncompliance with the warning instructions given for this equipment may result in serious injury or damage to property. MS15009/00E 06-09 © MTU...
Page 15: Auxiliary Materials, Fire Prevention And Environmental Protection
Only fuels of the specified quality required to achieve emission limits must be used. In Germany, the VAwS (= regulations governing the use of materials that may affect water quality) is applicable, which means work must only be carried out by authorized specialist companies (MTU is such a company). Auxiliary materials Use only fluids and lubricants that have been tested and approved by MTU.
Page 16 • Do not use compressed air to clean contaminated clothing whilst it is being worn. Used oil Used oil may contain health-threatening combustion residues. Rub barrier cream into hands! Wash hands after contact with used oil. MS15009/00E 06-09 © MTU...
Page 17: Standards For Warning Notices In The Publication
ANSI Z535, which begin with one of the above signal words according to the degree of danger: Warning notices 1. Read and become acquainted with all cautions and symbols before operating or repairing this product. 2. Pass on all safety instructions to your operating, maintenance, repair and transport personnel! MS15009/00E 06-09 © MTU...
Page 19: Product Summary
• Indication of faulty operating states (display SAM (1)). Features • Electronic engine governing and control. • Monitoring of inadmissible engine operating states. • Display of fault messages and fault codes. • Connecting cable for power supply to engine governor. MS15009/00E 06-09 © MTU...
Page 20 2 CAN bus between ECS-5 interface to an external controller and MCS-5 5 External controller The design of the overall MDEC system comprising the ECS-5 and MCS-5 subsystems depends on customer requirements and the higher-level control system. MS15009/00E 06-09 © MTU...
Page 21 6 System boundary ECS-5 3 Power supply +U control systems The Engine Control System comprises the following devices: • Engine governor • Sensors on engine • Actuators on engine • Injectors on engine • Wiring harnesses on engine MS15009/00E 06-09 © MTU...
Page 22 Product Summary Basic scope of Monitoring and Control System MCS-5 1 Monitoring and Control System 2 Power supply +U 4 System boundary MCS-5 MCS-5 3 Signal connection to ECS devices 5 SAM MS15009/00E 06-09 © MTU...
Page 23 • 24 binary outputs • 3 PWM outputs • 8 display outputs • 28 channel binary input • 10 analog inputs (e.g. PT100, 4–20 mA, 0-10 V, etc.) • 4 frequency inputs • 1 dialog interface MS15009/00E 06-09 © MTU...
Page 24 • Receiving plant signals (desired speed) and commands from higher-level control systems. • Outputting all measured values/limit values for the Monitoring and Control System. • Outputting alarms for signaling and evaluation in the Monitoring and Control System. • Outputting relevant signals for engine control. MS15009/00E 06-09 © MTU...
Page 25 Electrical isolation of the mechanical and electronic components significantly increases the signal-to-noise ratio. This high signal-to-noise ratio on all electrical lines is necessary for satisfactory transmission of all data on the CAN bus and also all analog and binary sensor signals. MS15009/00E 06-09 © MTU...
Page 26: Ecs-5 - Use Of Devices
For the dialog with a PC or notebook. Automation software for open-loop control. E.g. to control injection quantity. Automation software for monitoring. E.g. for engine stop and emergency engine stop. Communication software For communication with other devices and via the CAN bus. MS15009/00E 06-09 © MTU...
Page 27 Connector X6 Connection for dialog unit Connector X4 Connection for injector wiring harness Connector X5 Connection for power supply Connector X2 Connection for sensor/actuator wiring harness Connector X3 BR 2000: Not used BR 4000: HP controller MS15009/00E 06-09 © MTU...
Page 28 = ±1.6 mm 25 Hz to 100 Hz: a= ±4 g 100 Hz to 2000 Hz: Electrical noise 1.3 g rms DIN EN 50081–2 DIN EN 50082–2 IEC 1000–4–2 IEC 1000–4–3 IEC 1000–4–4 IEC 1000–4–5 IEC 1000–4–6 MS15009/00E 06-09 © MTU...
Page 29: Mdec - Functions
Operating states which would normally lead to engine shutdown are ignored when the “Override” function is activated. The following operating states can also be configured to shut the engine down in override mode: • Coolant level • Coolant temperature MS15009/00E 06-09 © MTU...
Page 30 DBR curve. The setpoint speed is not influenced by speed droop at 100% power. The effective setpoint speed increases at lower power. This allows power to be balanced when operating a number of engines in a network. MS15009/00E 06-09 © MTU...
Page 31 Safety shutdowns are initiated by the engine protection system in case of: • Limit value violations; • Sensor faults (depending of specific configuration). This applies to the following measuring points: • Engine speed/overspeed (configurable) • Engine lube oil pressure (configurable) MS15009/00E 06-09 © MTU...
Page 32 (if applicable) via the CAN bus. Overspeed test Activating this input lowers the overspeed threshold such that the engine shuts down at any speed. This makes it possible to check that the overspeed shutdown function operates correctly. MS15009/00E 06-09 © MTU...
Page 33: Peripheral Interface Modules (Pims)
Example: The "n" in "n09" stands for the slot and "09" designates the terminal. "209" means: Slot 2, terminal 9. The following information is transmitted via the optional interface modules PIM 601 and PIM 602: • Analog operational data MS15009/00E 06-09 © MTU...
Page 34 Function of PIM 601 Serial interface • Computer coupling 512 • Procedure 3964 (R) • RS232 or • RS422 • MTU (SLAVE) Function of PIM 602 Serial interface • Computer coupling 512 • Procedure 3964 (R) • RS232 or • RS422 •...
Page 35: Printed Circuit Board Scb 3
RESET" Features • 2 interfaces as per RS422 or RS232 standard • Interface are electrically isolated SCB 3 is used as an interface extension (additional serial interfaces), as an interface converter or as an amplifier. MS15009/00E 06-09 © MTU...
Page 36 When connected by the connector, the terminals of the RS232 interface are automatically switched off. • Transmission channel 2 is equipped with a connection for a serial RS422 interface and a serial RS232 interface. MPU 23 or MPU 27 processes the data and controls the interface drivers. MS15009/00E 06-09 © MTU...
Page 37 Channel 1: TX of RS232 interface Channel 2: TX of RS232 interface Channel 1: Ground (GND) of RS232 interface Channel 2: Ground (GND) of RS232 interface Channel 1: RX of RS232 interface Channel 2: RX of RS232 interface MS15009/00E 06-09 © MTU...
Page 38: Engine Overview
17 Oil pan 4 Air intake connection 11 Oil filler neck 18 Crankcase 5 Crankcase ventilation 12 Charge-air coolant pump 19 Exhaust manifold 6 Crankcase ventilation 13 Fuel pump 7 Cylinder head cover 14 Oil cooler MS15009/00E 06-09 © MTU...
Page 39 Product Summary 1 Starter 2 Engine coolant pump Engine model designation Key to the engine model designation 12/16V 2000 Px2 12/16 Number of cylinders Cylinder arrangement: V engine 2000 Series Application Application segment (6, 8) Design index MS15009/00E 06-09 © MTU...
Page 40: Engine Side And Cylinder Designations
The cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end. The numbering of engine components is also from the driving end, starting with No. 1. 1 KGS = Free end 3 KS = Driving end 2 Right side 4 Left side MS15009/00E 06-09 © MTU...
Page 41: Final Compression Pressure
Product Summary Final Compression Pressure 2.4.1 Final compression pressure Final compression pressure Final compression pressure at 120 rpm 30 bar to 36 bar MS15009/00E 06-09 © MTU...
Page 42: Technical Data
Continuous power as per ISO 3046 (10% overload capability) (rated power DIN 6280, ISO 8528) GENERAL CONDITIONS (for maximum power) Number of cylinders Intake air depression (new filter) mbar Intake air depression, max. mbar Exhaust backpressure mbar Exhaust back pressure, max. mbar MS15009/00E 06-09 © MTU...
Page 43 Number of inlet valves, per cylinder Number of exhaust valves, per cylinder Standard flywheel housing flange (engine main PTO) Flywheel connection DISC 18" 18" 18" 18" AIR / EXHAUST Number of cylinders Charge-air pressure before cylinder - DL bar abs MS15009/00E 06-09 © MTU...
Page 44 Lube-oil temperature before engine, warning °C Lube-oil temperature before engine, °C shutdown Lube oil operating pressure before engine, from Lube oil operating pressure before engine, to R Lube-oil pressure before engine, warning Lube-oil pressure before engine, shutdown MS15009/00E 06-09 © MTU...
Page 45 (standard oil system) (Option: max. operating inclinations) ACOUSTICS Number of cylinders Exhaust noise, unsilenced - DL (sound db(A) power level LW, ISO 6798) Engine surface noise with attenuated intake db(A) noise (filter) - DL - (sound-power level LW, ISO 6798) MS15009/00E 06-09 © MTU...
Page 46: Sam - Technical Data
Blue (RAL5015) Material: Polycarbonate reinforced with 10% fiberglass. Dimensions: L x W x H (295 x 151 x 75) Weight: Approx. 1.6 Note: Values stated above may be restricted when MCS 5 extension modules are used. MS15009/00E 06-09 © MTU...
Page 47 . Cable length shall not exceed 10 cm. • Twisted-conductor cables only shall be used to connect sensors and actuators. Maximum length of shall not exceed 5 m for unshielded cables and 50 m for shielded cables (providing that cable harness impedance allows). MS15009/00E 06-09 © MTU...
Page 48 Two wires may be connected to one terminal when the wires are crimped in a double-wire ferrule. For example, a Phoenix AL-TWIN 2* 0.75-10 may be used. Connector modules are plugged together. The connector modules are equipped with coding pins to preclude polarity reversal. MS15009/00E 06-09 © MTU...
Page 49 Other terminals (RM 5,08) are used for power supply and CAN bus connections. Additional printed circuit boards in slots 1 ... 3 Observe the relevant technical data applicable to the printed circuit boards concerned when additional boards are used in the SAM. MS15009/00E 06-09 © MTU...
Page 50: Scb 3 - Technical Data
Less than 425 Data transmission Term Unit Value Bit serial As per RS422 standard Baud rate 1.2 to 19.2 Electrical isolation With optocoupler. Bit serial As per RS232-Standard Baud rate 1.2 to 19.2 Electrical isolation With optocoupler. MS15009/00E 06-09 © MTU...
Page 51: Operation
Holding down the button decreases LCD background illumination. White Pressing the button initiates lamp test. LAMP TEST TEST Pressing the button initiates overspeed test. OVERSPEED LED (spot) lights up as long as the overspeed test is running. Green (none) (none) MS15009/00E 06-09 © MTU...
Page 52 LED (spot) lights up as long as the STOP signal is available (also if transmitted from RCS). EMERGENCY Pressing the button initiates immediate emergency stop. STOP LED (spot) flashes once the emergency stop has been tripped and until the alarm has been acknowledged. MS15009/00E 06-09 © MTU...
Page 53: Putting The Engine Into Operation After Extended Out-Of-Service-Periods (>3 Months)
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 the engine into operation after extended out-of-service-periods (>3 months) Item Task Engine Depreserve (→MTU Fluids and Lubricants Specifications A001061/..).
Page 54: Putting The Engine Into Operation After Scheduled Out-Of-Service-Period
Check charge-air coolant level (→ Page 143). Cooling system Preheat coolant with preheating unit. Fuel prefilter Drain (→ Page 116). Monitoring equipment Carry out lamp test (see manufacturer’s documentation). Engine/generator control system Switch ON; Select operating mode, e.g. MANUAL OPERATION, AUTOMATIC OPERATION. MS15009/00E 06-09 © MTU...
Page 55: Starting The Engine In Manual Mode
Close the generator circuit breaker. (depending on manufacturer) Engine Run engine at 10 to 15 % of rated power to reach operating temperature. Apply full load only after engine has reached operating temperature (coolant temperature approx. 75 °C). MS15009/00E 06-09 © MTU...
Page 56: Emergency Start (Override Mode)
• After the starting procedure is completed, engine is running at rated speed. Connecting the generator to network Item Task Switching cabinet, control panel etc. If generator is not connected to network: Close the generator circuit (depending on manufacturer) breaker. Engine Run at rated power. MS15009/00E 06-09 © MTU...
Page 57: Operational Checks
Coolant pump Check relief bore (→ Page 139). Compressed-air system (if Check operating pressure on pressure gauge; installed) Always fill compressed-air tank to max. pressure; Drain condensate from compressed-air tank, pressure drop must not exceed 1 bar. MS15009/00E 06-09 © MTU...
Page 58: Stopping The Engine In Manual Mode
Switching cabinet, control panel etc. Press stop button. (depending on manufacturer) • Automatic stopping procedure is performed; • Engine is stopped. After stopping the engine Item Task Cooling pump Operate for approx. 5 minutes after engine stop. MS15009/00E 06-09 © MTU...
Page 59: Emergency Stop
• Engine is stopped by switching off power supply to ECU; • Signalization (e.g. by horn, flashing lamp) is released. After emergency stop from LOP Item Task Switching cabinet, control panel etc. Press button for alarm acknowledgement. (depending on manufacturer) • Audible and visual signalization stops. MS15009/00E 06-09 © MTU...
Page 60: After Stopping The Engine - Engine Remains Ready For Operation
Operation After stopping the engine – engine remains ready for operation After stopping the engine Item Task Engine/generator control system Select operating mode, e.g. MANUAL OPERATION, AUTOMATIC OPERATION. MS15009/00E 06-09 © MTU...
Page 61: After Stopping The Engine - Putting The Engine Out Of Service
If the engine is to remain out of service for more than 1 week, seal the engine’s air and exhaust sides. If the engine is to remain out of service for more than 1 month, carry out preservation (→MTU Fluids and Lubricants Specification A001061/..).
Page 63: Maintenance
The specification of fluids and lubricants, guidelines for maintenance and change intervals as well as a list of approved fluids and lubricants are provided in the MTU Fluids and Lubricants Specifications A001061 and the component manufacturers’ fluids and lubricants specifications. They are therefore not listed in the maintenance schedule (exception: deviations from the Fluids and Lubricants Specifications).
Page 64 Maintenance Load factor Load factor <75% Load profile Load-profile table Power Corresponding operating time MS15009/00E 06-09 © MTU...
Page 65: Maintenance Schedule Matrix
X X X X X X X X X X X X X X X X X X X X X Valve gear Fuel injectors Combustion chambers Fuel injection pump(s) Component maintenance Cylinder head Extended component maintenance Fuel pressure maintaining valve MS15009/00E 06-09 © MTU...
Page 66 11,000-12,000 operating hours Item Operating hours [h] Engine oil filter Engine operation Fuel filter X X X Valve gear Fuel injectors Combustion chambers Fuel injection pump(s) Component maintenance Cylinder head Extended component maintenance Fuel pressure maintaining valve MS15009/00E 06-09 © MTU...
Page 67: Maintenance Tasks
Overhaul exhaust turbochargers (→Workshop Manual). W2075 Replace seals of all disassembled components (→Workshop Manual). W2062 Overhaul engine coolant pump. W2110 8,000 Cylinder head Overhaul cylinder heads, inspect piston crowns and running pattern W1063 of cylinder liners (→Workshop Manual). MS15009/00E 06-09 © MTU...
Page 68 Replace oil separator of crankcase breather (→Workshop Manual). W3009 Replace fuel delivery pump (→Workshop Manual). W3010 Overhaul starter (→Workshop Manual). W3041 Overhaul battery-charging generator (→Workshop Manual). W3042 12,000 Fuel pressure maintaining Replace fuel pressure maintaining valve (→Operating Instructions) W1056 valve (→ Page 109) MS15009/00E 06-09 © MTU...
Page 69: Troubleshooting
Defective Contact Service. Engine fires unevenly Component Probable Cause Task Fuel injection Injector defective Replace (→ Page 105). equipment Injection pump defective Replace (→ Page 102). Engine wiring Defective Check (→ Page 144). Defective Contact Service. MS15009/00E 06-09 © MTU...
Page 70 Defective Contact Service. Charge-air temperature too high Component Probable Cause Task Engine coolant Incorrect coolant concentration Check (MTU test kit) Intercooler Contaminated Contact Service. Engine room Air-intake temperature too high Check fans; Check air supply / ventilation ducts. Charge-air pressure too low...
Page 71 Task Component Probable Cause Engine Not at operating temperature Run engine to reach operating temperature. Fuel system Water in fuel Check fuel system on fuel prefilter; Drain fuel prefilter (→ Page 116). Intercooler Leaking Contact Service. MS15009/00E 06-09 © MTU...
Page 72: Fault Indication On Printed Circuit Board Sam
• Fault type (e.g. SE03). • Node number at which the fault occurred (e.g. nd11). • Second line • Running text, providing more information about the fault currently displayed Proceed to the next alarm by pressing key (↓ ↑). MS15009/00E 06-09 © MTU...
Page 73 PAN 2 Defect PAN 3 Defect PAN 4 Defect PAN 5 Defect PAN 6 Defect I/O-Module Slot1 Defect I/O-Module Slot5 Defect I/O-Module Slot6 Defect I/O-Module Slot7 Defect I/O-Module Slot8 Defect Download Server Collision not projected node MS15009/00E 06-09 © MTU...
Page 74 • Engine management system OVERSPEED2 (2nd limit value) automatically reduces power. • Check air filter (→ Engine operating instructions). L1 LEVEL Charge air coolant level Check coolant level (→ Engine INTERCOOLER too high/low (1st limit value operating instructions). violated). MS15009/00E 06-09 © MTU...
Page 75 Checksum error in Interface Redundant design of EDM allows Data Module IDM/EEPROM 2. engine management system to remain operational. INVALID FUEL CONS. Invalid fuel consumption Contact Service. display, checksum error in EDM/EEPROM 1 (redundant data record 1). MS15009/00E 06-09 © MTU...
Page 76 • Check sensors; • replace engine governor. BANK1 ECU DEFECT Power output stage for control Replace engine governor (→ Engine of solenoid valves on bank 1 operating instructions). is faulty; engine does not start. MS15009/00E 06-09 © MTU...
Page 77 CAN node . node is present. Check cabling as necessary. • Check shielding, improve shielding as necessary. SD T-COOLANT Sensor B06 faulty (coolant 1. Check cabling (→ Engine temperature). operating instructions); 2. Contact Service • Check sensor. MS15009/00E 06-09 © MTU...
Page 78 2. check fault message; 3. check cabling (→ Engine operating instructions); 4. Contact Service • Check sensor. SD LEVEL LEAKAGE Sensor fault (leak fuel). 1. Check cabling (→ Engine FUEL operating instructions); 2. Contact Service • Check sensor. MS15009/00E 06-09 © MTU...
Page 79 (→ Engine operating (A1- A10) (solenoid valve 10) instructions). 311...320 TIMING CYLINDER Timing bank 2 (solenoid Replace injector if fault message valve 1) ... Timing bank 2 occurs frequently (→ Engine operating (B1- B10) (solenoid valve 10) instructions). MS15009/00E 06-09 © MTU...
Page 80 TRAN.OUT1 PLANT Binary transistor output TAA 1 Check cabling to plant. faulty. TRAN.OUT2 PLANT Binary transistor output TAA 2 Check cabling to plant. faulty. TRAN.OUT3 PLANT Binary transistor output TAA 3 Check cabling to plant. faulty. MS15009/00E 06-09 © MTU...
Page 81 Transmitter deviation coolant 1. Check cabling (→ Engine temperature. operating instructions). 2. Contact Service • Check sensor. TD OIL PRESSURE Transmitter deviation engine 1. Check cabling (→ Engine oil pressure. operating instructions). 2. Contact Service • Check sensor. MS15009/00E 06-09 © MTU...
Page 82: Ecu Alarms
L2 P-LUBE OIL Lube-oil pressure too low (2nd 1. Check engine-oil level and top up, if limit) required (→ Page 129); 2. Try to re-start the engine (→ Page 51). automatic engine shutdown 3. Contact Service. MS15009/00E 06-09 © MTU...
Page 83 (Depending on the corresponding measuring external pressure channel 2 point, which is read via CAN bus) Alarm from external coolant level (Depending on the corresponding measuring EXT.COOLANT monitoring point, which is read via CAN bus) LEV. MS15009/00E 06-09 © MTU...
Page 84 Check sum error of fault memory If fault occurs repeatedly: Contact Service. VALID in EDM (redundant data record 1) ERR REC2 NOT Check sum error of fault memory If fault occurs repeatedly: Contact Service. VALID in EDM (redundant data record 2) MS15009/00E 06-09 © MTU...
Page 85 Electronic equipment defective; Contact Service. DEFECT automatic engine shutdown L1 AD-TEST1 A/D-converter supply voltage too Contact Service. SUPPLY AD-TEST1 ECU Electronic equipment defective; Contact Service. DEFECT automatic engine shutdown L1 AD-TEST2 A/D-converter supply voltage too Contact Service. SUPPLY MS15009/00E 06-09 © MTU...
Page 86 SD T-COOLANT Sensor defect (coolant 1. Check wiring. temperature) 2. Contact Service. SD T-FUEL Sensor defect (Fuel temperature) 1. Check wiring. 2. Contact Service. SD T-CHARGE Sensor defect (charge-air 1. Check wiring. temperature) 2. Contact Service. MS15009/00E 06-09 © MTU...
Page 87 Contact Service. T-EXTERN 1) SD T-EXTERN 2 External device defective (CAN Contact Service. T-EXTERN 2) SD P-EXTERN 1 External device defective (CAN Contact Service. P-EXTERN 1) SD P-EXTERN 2 External device defective (CAN Contact Service. P-EXTERN 2) MS15009/00E 06-09 © MTU...
Page 88 If fault occurs repeatedly: Contact Service. CYLINDER B4 TIMING Injection timing fault cylinder B5 If fault occurs repeatedly: Contact Service. CYLINDER B5 TIMING Injection timing fault cylinder B6 If fault occurs repeatedly: Contact Service. CYLINDER B6 MS15009/00E 06-09 © MTU...
Page 89 2. Contact Service. Misfiring WIRING Faulty wiring to solenoid valve 1. Check wiring. CYLINDER A10 cylinder A10; 2. Contact Service. Misfiring WIRING Faulty wiring to solenoid valve 1. Check wiring. CYLINDER B1 cylinder B1; 2. Contact Service. Misfiring MS15009/00E 06-09 © MTU...
Page 90 2. Contact Service. Misfiring OPEN_LOAD CYL. Disconnection in wiring to 1. Check wiring. solenoid valve cylinder A4; 2. Contact Service. Misfiring OPEN_LOAD CYL. Disconnection in wiring to 1. Check wiring. solenoid valve cylinder A5; 2. Contact Service. Misfiring MS15009/00E 06-09 © MTU...
Page 91 2. Contact Service. Misfiring OPEN_LOAD CYL. Disconnection in wiring to 1. Check wiring. solenoid valve cylinder B8; 2. Contact Service. Misfiring OPEN_LOAD CYL. Disconnection in wiring to 1. Check wiring. solenoid valve cylinder B9; 2. Contact Service. Misfiring MS15009/00E 06-09 © MTU...
Page 92 PLANT DEF defective Binary transistor output plant 4 TRAN.OUT4 Contact Service. defective PLANT DEF TRAN.OUT5 Binary transistor output plant 5 Contact Service. defective PLANT DEF TRAN.OUT6 Binary transistor output plant 6 Contact Service. defective PLANT DEF MS15009/00E 06-09 © MTU...
Page 93: Task Description
3. Rotate crankshaft in engine direction of rotation. Apart from the normal compression resistance, there should be no abnormal resistance. Result: If the resistance exceeds the normal compression resistance, contact Service. 4. For barring-tool removal follow reverse sequence of working steps. MS15009/00E 06-09 © MTU...
Page 94: Engine - Barring With Starting System
If necessary, re-start the engine after approx. 20 seconds. 5. Plug connector X4 (3) and use connector pliers (2) to secure the bayonet ring (4) by turning it clockwise until it latches into place. MS15009/00E 06-09 © MTU...
Page 95: Engine Test Run
1. Start engine (→ Page 51). 2. Perform test run at not below 1/3 load and at least until steady-state temperature is reached. 3. Carry out operational checks (→ Page 53). 4. Stop engine (→ Page 54). MS15009/00E 06-09 © MTU...
Page 96: Cylinder Liner
• Do not take any action or • carry out further endoscopic examination as part of maintenance work or • contact Service: cylinder liner must be replaced. Final steps 1. Install injector (→ Page 106). 2. Install cylinder-head cover (→ Page 100). MS15009/00E 06-09 © MTU...
Page 97: Instructions And Comments On Endoscopic And Visual Examination Of Cylinder Liners
Liners with heat discoloration starting in the TDC-ring 1 have to be replaced. Seizures, Seizure marks Irregular circumference lengths and depths. Can be caused by either the piston skirt or the piston crown. Material deposits on the liner (smear), heavy discoloration. Severe, visible scoring. Replace liner. MS15009/00E 06-09 © MTU...
Page 98 The findings in the start phase of oxidation discoloration and heat discoloration are similar. Thorough investigation and compliance with the above evaluation criteria allows a definite evaluation. To avoid unnecessary disassembly work, it is recommended that another inspection be carried out after further operation of the engine. MS15009/00E 06-09 © MTU...
Page 99: Crankcase Ventilation
(3) into the oil separator cover (7), ensuring correct installation sequence. 11. Install oil separator cover (7) with clamp (5) on cylinder head cover (1). 12. Install hose, ensuring that it is not subjected to tension. MS15009/00E 06-09 © MTU...
Page 100: Crankcase Breather - Oil Separator Replacement, Diaphragm Check And Replacement
(2) with new O-ring. 4. Tighten screws of cover (2) to specified tightening torque of 6 Nm + 2 Nm. 5. Replace filter elements of further oil separators in the same way. MS15009/00E 06-09 © MTU...
Page 101 6. Install new seal (2) and spring (5) together with cover (4). 7. Tighten screws of cover (4) to specified tightening torque of 6 Nm + 2 Nm. 8. Check diaphragms in further oil separators in the same way. MS15009/00E 06-09 © MTU...
Page 102: Valve Drive
Torque wrench 20-100 Nm F30026582 Ratchet adapter F30027340 Preparatory steps 1. Remove cylinder-head cover (→ Page 100). 2. Using the barring tool, bar engine manually in engine direction of rotation (→ Page 89) until cylinders are at TDC. MS15009/00E 06-09 © MTU...
Page 103 5. Check whether the feeler gauge just passes through between valve bridge and rocker arm. Result: If not, adjust valve clearance. Final steps 1. Remove barring tool. 2. Follow reverse sequence of working steps for installation. MS15009/00E 06-09 © MTU...
Page 104: Cylinder-Head Cover - Removal And Installation
4. Check condition of gasket in cylinder-head cover. 5. Replace damaged gasket(s). 6. Place cylinder-head covers onto crankcase and tighten screws to 20 Nm. Final steps 1. Slide rubber sleeves onto the relevant pipe connection. 2. Tighten all clamps. MS15009/00E 06-09 © MTU...
Page 105: Injection Pump/ Hp Pump
Task Description Injection Pump/ HP Pump 6.5.1 Injection pump replacement Spare parts Designation / Use Part No. Qty. Injection pump Remove injection pump and install new one (→ Page 102). MS15009/00E 06-09 © MTU...
Page 106: Injection Pump - Removal And Installation
• Do not smoke. Preparatory steps 1. Shut off fuel supply line before fuel filter. 2. Remove engine control system (→ Page 154). 3. Drain fuel (→ Page 111). 4. Remove charge-air pipes and all seals. MS15009/00E 06-09 © MTU...
Page 107 4. Coat sealing ring (2) with petroleum jelly and fit onto injection pump. 5. Coat roller (arrowed) with engine oil. 6. Clean sealing face and fuel bores in crankcase. 7. Use barring tool (→ Page 89) to align camshaft pump cams with base circle. MS15009/00E 06-09 © MTU...
Page 108 3. Check gaskets for damage and replace them, if required. 4. Coat gaskets with petroleum jelly and place onto cylinder head. 5. Install charge-air pipes. 6. Install engine control system (→ Page 154). 7. Open fuel supply line before fuel filter. 8. Vent fuel system. MS15009/00E 06-09 © MTU...
Page 109: Injector
Task Description Injector 6.6.1 Injector replacement Spare parts Designation / Use Part No. Qty. Injector Remove injector and install new one (→ Page 106). MS15009/00E 06-09 © MTU...
Page 110: Injector - Removal And Installation
Risk of injury! WARNING • Do not direct compressed-air jet at persons. • Wear protective goggles / safety mask and ear protectors. Preparatory steps 1. Remove cylinder-head cover (→ Page 100). 2. Drain fuel (→ Page 111). MS15009/00E 06-09 © MTU...
Page 111 6. Remove screw (2). 7. Take off clamp (1). 8. Screw extractor into injector. 9. Remove injector using the extractor. 10. Remove sealing ring using a self-made hook. 11. Seal all openings with appropriate covers after removal. MS15009/00E 06-09 © MTU...
Page 112 20 Nm + 5 Nm. 17. Use torque wrench to tighten screw for clamp at injector to specified torque 50 Nm. 18. Install leak-off-fuel lines. Final steps 1. Install cylinder-head cover (→ Page 100). 2. Vent fuel system. MS15009/00E 06-09 © MTU...
Page 113: Fuel System
5. Remove fuel pressure relief valve (4) from connecting piece (5). 6. Insert new fuel pressure relief valve (4) into connecting piece (5). 7. Screw in adapter (2) with sealing ring (3) and tighten. 8. Install fuel line (1). 9. Open fuel supply. MS15009/00E 06-09 © MTU...
Page 114 5. Remove screws (2) with washer (3). 6. Remove screws (6) and take off bracket. 7. Install new pressure relief valve (1) with new sealing rings (5) in reverse sequence of operations. 8. Open fuel supply. MS15009/00E 06-09 © MTU...
Page 115: Fuel - Draining
1. Release threaded vent plugs on filter head. 2. Open nipple on fuel line and drain fuel into appropriate container. 3. When fuel stops emerging from system, close nipple on fuel line. 4. Close vent plugs on filter head. MS15009/00E 06-09 © MTU...
Page 116: Fuel Filter
Serious damage to plant! CAUTION • For filter replacement with the engine running, operate the engine at low engine load. • The filter which is to be exchanged must be cut out for a brief period only. MS15009/00E 06-09 © MTU...
Page 117 6. Check sealing ring of the new easy-change filter and coat it with fuel. 7. Install and tighten new filter by hand. 8. Set three-way cock to operating position (both filters cut in). 9. Replace further fuel filters in the same way. MS15009/00E 06-09 © MTU...
Page 118: Fuel Prefilter Cleaning
7. Insert filter element into filter housing and secure with nut. 8. Place new sealing ring into groove in filter head. 9. Fit cover with seal and secure it with nuts crosswise. 10. Open fuel supply. MS15009/00E 06-09 © MTU...
Page 119: Fuel Prefilter - Differential Pressure Check And Adjustment Of Gauge
1. With the engine running at full load or rated power, read off pressure at gauge (1). 2. If differential pressure as indicated between position of adjustable pointer (2) and pressure-indicating pointer (3) of pressure gauge is ≥ 0.3 bar, flush filter element of the cut-in filter (→ Page 118). MS15009/00E 06-09 © MTU...
Page 120: Fuel Prefilter - Draining
Part No. Qty. Diesel fuel Spare parts Designation / Use Part No. Qty. Gasket Fuels are combustible. Risk of fire and explosion! WARNING • Avoid naked flames, electrical sparks and ignition sources. • Do not smoke. MS15009/00E 06-09 © MTU...
Page 121 7. Fill filter housing with clean fuel. 8. Place new gasket in cover (2). 9. Fit cover with gasket and secure it with screws. 10. Cut the cut-out filter in again. 11. When fuel emerges from system, close vent plug (5). MS15009/00E 06-09 © MTU...
Page 122: Fuel Prefilter - Flushing
Fuels are combustible. Risk of fire and explosion! WARNING • Avoid naked flames, electrical sparks and ignition sources. • Do not smoke. Engine noise above 85 dB (A). Risk of damage to hearing! WARNING • Wear ear protectors. MS15009/00E 06-09 © MTU...
Page 123 5. Fit cover with gasket and secure it with screws. 6. Check differential pressure (→ Page 115). Result: If flushing did not lead to an improvement of the differential pressure, replace filter element (→ Page 120). MS15009/00E 06-09 © MTU...
Page 124: Fuel Prefilter - Filter Element Replacement
Qty. Diesel fuel Spare parts Designation / Use Part No. Qty. Filter element Gasket Fuels are combustible. Risk of fire and explosion! WARNING • Avoid naked flames, electrical sparks and ignition sources. • Do not smoke. MS15009/00E 06-09 © MTU...
Page 125 11. Fit cover with gasket and secure it with screws. 12. Cut the cut-out filter in again. 13. Close vent plug (5) when fuel emerges. 14. Align adjustable pointer of differential pressure gauge with pressure-indicating pointer. (→ Page 115). MS15009/00E 06-09 © MTU...
Page 126: Charge-Air Cooling, General, Left Side
Emergency measures prior to engine start with a leaking intercooler 1. Remove injectors (→ Page 106). 2. Bar engine manually (→ Page 89). 3. Bar engine with starting system to blow out combustion chambers (→ Page 90). 4. Install injectors (→ Page 106). MS15009/00E 06-09 © MTU...
Page 127: Air Filter
Air Filter 6.10.1 Air filter – Replacement Preconditions • Engine is stopped and starting disabled. Replace air filter, carry out work in accordance with the instructions of the manufacturer – scope of supply of the unit manufacturer. MS15009/00E 06-09 © MTU...
Page 128: Air Intake
1. If the signal ring is completely visible in the control window (2), replace air filter (→ Page 123). 2. After installation of new filter, press reset button (1). Result: Engaged piston with signal ring moves back to initial position. MS15009/00E 06-09 © MTU...
Page 129: Starting System
WARNING • Wear ear protectors. Air starter – manual operation 1. Press pushbutton for manual start and hold it. 2. Allow compressed air to enter the air starter until the engine fires evenly. 3. Release pushbutton. MS15009/00E 06-09 © MTU...
Page 130: Starter - Condition Check
6.12.2 Starter – Condition check Preconditions • Engine is stopped and starting disabled. Starter – Condition check 1. Check starter securing screws for secure seating. 2. Tighten loose screw connections. 3. Check wiring (→ Page 144). MS15009/00E 06-09 © MTU...
Page 131: Lube Oil System / Lube Oil Circuit
Lube Oil System / Lube Oil Circuit 6.13.1 Engine oil change Preconditions • Engine is stopped and starting disabled. • Engine is at operating temperature. • MTU Fluids and Lubricants Specification (A001061/..) is available. Material Designation / Use Part No. Qty. Engine oil...
Page 132 2. Pour oil in at filler neck up to "max." mark at oil dipstick. 3. Close cover of filler neck. 4. Check oil level (→ Page 129). 5. After oil change and oil filter replacement, bar engine with starting system (→ Page 90). MS15009/00E 06-09 © MTU...
Page 133: Engine Oil - Level Check
2. Insert dipstick into guide tube up to the stop, withdraw after approx. 10 seconds and check oil level. 3. Oil level must be between "min." and "max." marks. 4. Top up to "max." if required (→ Page 127). 5. Insert dipstick into guide tube up to the stop. MS15009/00E 06-09 © MTU...
Page 134: Oil Filtration / Cooling
4. Install and tighten new oil filter by hand. 5. Replace further oil filters in the same way. 6. After each oil change and filter replacement, bar the engine with starting system (→ Page 90). 7. Check oil level (→ Page 129). MS15009/00E 06-09 © MTU...
Page 135: Cooling Circuit, General, Ht Circuit
Task Description 6.15 Cooling Circuit, General, HT Circuit 6.15.1 Drain and venting points Top view 1 Engine coolant vent 2 Engine coolant vent MS15009/00E 06-09 © MTU...
Page 137 Task Description Right side 1 Engine oil drain plug (heat exchanger) 2 Engine coolant drain plug MS15009/00E 06-09 © MTU...
Page 138 Task Description Driving end (KS) 1 Engine coolant drain plug 2 Intercooler drain 3 Engine oil drain plug MS15009/00E 06-09 © MTU...
Page 139: Engine Coolant Filling
Task Description 6.15.2 Engine coolant filling Preconditions • Engine is stopped and starting disabled. • MTU Fluids and Lubricants Specification (A001061/..) is available. Material Designation / Use Part No. Qty. Engine coolant Coolant is hot and under pressure. Risk of injury and scalding! WARNING •...
Page 140: Engine Coolant Draining
• Drain plug (4) • Crankcase (1) • Intercooler (6) • Exhaust-pipe elbow (5) • Heating connection (3) • Engine-oil heat exchanger (2) 5. Close all open drain points. 6. Fit breather valve on filler neck and close it. MS15009/00E 06-09 © MTU...
Page 141: Engine Coolant - Change
Task Description 6.15.4 Engine coolant – Change Material Designation / Use Part No. Qty. Engine coolant Drain engine coolant (→ Page 136). Fill engine coolant system (→ Page 135). MS15009/00E 06-09 © MTU...
Page 142: Engine Coolant Level - Check
6.15.5 Engine coolant level – Check Preconditions • Engine is stopped and starting disabled. • MTU Fluids and Lubricants Specification (A001061/..) is available. Coolant is hot and under pressure. Risk of injury and scalding! WARNING • Let the engine cool down.
Page 143: Coolant Pump - Relief Bore Check
3. Clean the relief bore with a wire if it is dirty. • Permissible coolant discharge: Up to 10 drops/hour; • Permissible oil discharge: Up to 5 drops/hour; 4. If discharge exceeds the specified limits, contact Service. MS15009/00E 06-09 © MTU...
Page 144: Circuit
Task Description 6.16 LT Circuit 6.16.1 Charge-air coolant change Material Designation / Use Part No. Qty. Coolant Drain charge-air coolant system (→ Page 142). Fill charge-air coolant system (→ Page 141). MS15009/00E 06-09 © MTU...
Page 145: Charge-Air Coolant Filling
Task Description 6.16.2 Charge-air coolant filling Preconditions • Engine is stopped and starting disabled. • MTU Fluids and Lubricants Specification (A001061/..) is available. Material Designation / Use Part No. Qty. Coolant Spare parts Designation / Use Part No. Qty. Sealing ring Engine noise above 85 dB (A).
Page 146: Charge-Air Coolant - Draining
• at the LT cooling pump; • at the coolant line (customer’s equipment). 6. Draining of residual coolant: • at charge-air cooler. 7. Screw in drain plugs with new sealing rings. 8. Fit breather valve onto filler neck and close it. MS15009/00E 06-09 © MTU...
Page 147: Charge-Air Coolant Level Check
6.16.4 Charge-air coolant level check Preconditions • Engine is stopped and starting disabled. • MTU Fluids and Lubricants Specification (A001061/..) is available. Coolant is hot and under pressure. Risk of injury and scalding! WARNING • Let the engine cool down.
Page 148: General Cabling For Engine / Gearbox / Unit
5. Inspect electrical components visually for damage: • connector housings; • contacts; • connector sockets; • cables and terminals; • plug-in contacts. 6. If conductors are damaged, contact Service. 7. Clean dirty connector housings, sockets and contacts with isopropyl alcohol. MS15009/00E 06-09 © MTU...
Page 149: Sensors And Actuators
Task Description 6.17.2 Sensors and actuators Designation Monitoring of Charge-air pressure MS15009/00E 06-09 © MTU...
Page 150 Task Description Designation Monitoring of Charge-air temperature Fuel pressure after filter Fuel temperature B6.2 Coolant temperature Lube oil differential pressure B44.1 Turbocharger speed MS15009/00E 06-09 © MTU...
Page 151 Task Description Designation Monitoring of Emergency air-shutoff flaps Solenoid valve, emergency air shut-off flaps Leak-off fuel level Coolant temperature B5.2 Lube-oil pressure Lube-oil pressure Lube oil temperature Coolant temperature, coolant cooler MS15009/00E 06-09 © MTU...
Page 152 Task Description Designation Monitoring of — — Camshaft speed B4.22 Exhaust gas temperature Crankshaft speed B13.2 Crankshaft speed B4.21 Exhaust gas temperature MS15009/00E 06-09 © MTU...
Page 153: Accessories For Engine Governor (Electronic) / Control System
2. Remove dirt from surface of connectors (1), connector sockets and shrink sleeves (2) using a cloth moistened with isopropyl alcohol. 3. Check legibility of cable labels. Clean or replace illegible labels. MS15009/00E 06-09 © MTU...
Page 154 (4) and withdraw connector (3). 2. Clean connector housings, connector socket housings (1) and all contacts with isopropyl alcohol. 3. When connectors, sockets and all contacts are dry: Install connectors and check plug-in connection on ECU (→ Page 152). MS15009/00E 06-09 © MTU...
Page 155: Emu And Connectors - Cleaning
(4) and withdraw connector (3). 2. Clean connector housings, connector socket housings (1) and all contacts with isopropyl alcohol. 3. When connectors, sockets and all contacts are dry: Install connectors and check plug-in connection on EMU (→ Page 153). MS15009/00E 06-09 © MTU...
Page 156: Ecu - Checking Plug-In Connections
2. Tighten loose bayonet union nuts (2) with connector pliers (3) by turning them clockwise until they lock into place. 3. Ensure that unassigned connector sockets are protected with covering caps. 4. If bayonet union nut is defective, contact Service. MS15009/00E 06-09 © MTU...
Page 157: Emu - Checking Plug-In Connections
2. Tighten loose bayonet union nuts (2) with connector pliers (3) by turning them clockwise until they lock into place. 3. Ensure that unassigned connector sockets are protected with covering caps. 4. Contact Service if bayonet union nut is defective. MS15009/00E 06-09 © MTU...
Page 158: Ecu - Removal And Installation
1. Note or mark assignment of cables to connector sockets. 2. Use connector pliers (2) to disengage the bayonet union nuts (4) of the connectors (3) by turning them counterclockwise. 3. Withdraw all connectors. 4. Close connector sockets with appropriate covering caps (1). MS15009/00E 06-09 © MTU...
Page 159 1. For installation follow reverse sequence of working steps. Ensure that connectors are plugged in the correct socket. 2. Use connector pliers to turn the bayonet union nuts of the connectors clockwise until they lock into place. MS15009/00E 06-09 © MTU...
Page 160: Emergency Instrumentation (Lop)
(3) is held firmly in place in the base. 2. If this is not the case, press the securing elements (1) concerned in the direction of the arrows until they are felt to engage. MS15009/00E 06-09 © MTU...
Page 161 2. Display: Make certain that • Front glass is not damaged or crushed; • Gasket (1) between display housing and LOP housing is not damaged. 3. Have damaged components immediately replaced by Service. MS15009/00E 06-09 © MTU...
Page 162 2. Switch master power switch to ON. 3. Switch on engine control system. 4. Keep LAMP TEST button pressed: Result: Control and indication fields light up. 5. Have damaged lamps immediately replaced by Service. MS15009/00E 06-09 © MTU...
Page 163: Lop Test Procedures
2. Press ALARM ACKNOWLEDGE button (1). Result: Audible and visual signalization stops. 3. Press ALARM ACKNOWLEDGE button (1) again. Result: Power supply to ECU is provided. 4. Engines with emergency air-shut-off flaps: Flaps open. MS15009/00E 06-09 © MTU...
Page 164 3. Press ALARM ACKNOWLEDGE button (1). Result: Audible and visual signalization stops. 4. Press ALARM ACKNOWLEDGE button (1) again. Result: Power supply to ECU is provided. 5. Engines with emergency air-shut-off flaps: Flaps open. MS15009/00E 06-09 © MTU...
Page 165: Engine Governor Assignment And Circuitry
1 Engine Control Unit ECU 4 Function Function Source Acquisition of binary signals. Switches, pushbuttons, monitors, contacts. Channel specification Type Isolated binary input, external supply. Input signal (high) = 24 V (min. 8 V). (low) = 0 V (max. 4 V). MS15009/00E 06-09 © MTU...
Page 166 Measuring range = 4 to 20 mA; Load: At 20 mA approx. 4 V; isolated. Or: UIn = 0 to 10 V Binary sensor input NSE 1 1 Monitor contact 2 Engine Control Unit ECU 4 MS15009/00E 06-09 © MTU...
Page 167 Pulse measuring inputs KW 1 and NW 1 1 Inductive sensor 2 Engine Control Unit ECU 4 Channel Function Sensor Measuring of crankshaft angle and Inductive sensor crankshaft speed. Measuring of camshaft angle and Inductive sensor camshaft speed. MS15009/00E 06-09 © MTU...
Page 168 Function Sensor Measuring of speeds (e.g. ETC). Inductive sensor Temperature inputs TE 1 to TE 9 1 Engine Control Unit ECU 4 Function Sensor Temperature measuring Temperature-dependent resistor Pt100/Pt1000 (exhaust gas temperatures are measured with Pt100). MS15009/00E 06-09 © MTU...
Page 169 Measuring channel specification Measuring range Sensor-dependent Output signal U 0.5 to 4.5 VDC Sensor supply 5 V ± 250 mV Pressure measuring input HP pump DEH (rail pressure) 1 Pressure sensor 2 Engine Control Unit ECU 4 MS15009/00E 06-09 © MTU...
Page 170 Function Sensor Switching output Plant Channel specification Channel TAA1 to TAA6 positive-switching 24 VDC. Output current TAA1 to TAA4: l = 150 mA max. TAA5: l = 300 mA max. TAA6: l = 1 A max. MS15009/00E 06-09 © MTU...
Page 171 Voltage outputs UA 1 to UA 4 1 Engine Control Unit ECU 4 Function Function Sensor Output voltage 0 to 10 V, e.g. for display instruments Plant Channel specification Output voltage = 0 to 10 V Output current = 5 mA max. MS15009/00E 06-09 © MTU...
Page 172 Engine Governor Assignment and Circuitry Transistor outputs TAM 1 to TAM 4 1 Engine Control Unit ECU 4 Function Sensor Switching output Engine PWM output PDM 2 1 Engine Control Unit ECU 4 Function Sensor Switching output Engine MS15009/00E 06-09 © MTU...
Page 173 Function Sensor Injector control Injection solenoid valve CAN bus interface 1 CAN bus 2 Terminator 3 Electrical isolation 4 Engine Control Unit ECU 4 Function Channel Function Target CAN1 / CAN2 Bus connection to external systems. MS15009/00E 06-09 © MTU...
Page 174 The CAN bus interfaces operate independently of each other. Serial interface RS232 1 Dialog unit 2 Connector XC6 3 Engine Control Unit ECU 4 4 Dialog cable Channel Function Target RS232 Serial interface for data transmission Dialog unit between dialog unit and engine governor. MS15009/00E 06-09 © MTU...
Page 175: Mdec Governor Assignment
The MDEC governor is protected by a 20 A automatic cutout via cable W003 connector X5. The PIM modules are wired to a separate 10 A fuse (see MTU wiring diagram). All control, display and communication signals are in interface cable W004 MDEC connector X1.
Page 176 Default setting: • Characteristic curve 71 (50 Hz) in MDEC governor 0 to 10 V activated. Parameterized desired speed setting 4 to 20 mA must be changed if desired. Same applies to characteristic curve 72 (60 Hz). MS15009/00E 06-09 © MTU...
Page 177: Connector Assignment
5 V / 20 mA electrically isolated IUE2 U_IN 0 V to 10 V IUE2 I_IN 0 V to 23.7 mA IUE2 GND_ISO 0 V to 10 V/ 8 mA 0 V to 10 V/ 8 mA MS15009/00E 06-09 © MTU...
Page 178 U < 4 V = low / U > 8 V = high Electrically isolated U < 1.5 V = low / U > 3.5 V = high Frequency input TAA1 24 V / 600 mA TAA1 MS15009/00E 06-09 © MTU...
Page 179 TAA6 (Plant supply, coil instruments FZ) CAN1 HIGH Electrically isolated CAN1 CAN1 CAN2 HIGH Electrically isolated CAN2 CAN2 Connector X2, view to socket Connector X2 Connector type VPT 06 GSE 22–55 PW Target Engine wiring harness MS15009/00E 06-09 © MTU...
Page 180 0 V to 5 V / internal 47k5 pulldown 5 V_BUF2 5 V / 20 mA 0 V to 5 V / internal 47k5 pulldown 5 V_BUF2 5 V / 20 mA 0 V to 5 V / internal 47k5 pulldown MS15009/00E 06-09 © MTU...
Page 181 U > 400 mV = high DME1 DME2 U < -400 mV = low / U > 400 mV = high DME2 PDM1 24 V / 3 A PDM1 TAM1 24 V / 1.5 A TAM1 MS15009/00E 06-09 © MTU...
Page 182 Engine Governor Assignment and Circuitry Channel Signal Comments TAM2 24 V / 1.5A TAM2 Connector X3, view to socket Connector X3 Connector type VPT 06 GSE 16–26 P Target Engine wiring harness MS15009/00E 06-09 © MTU...
Page 183 5 V_TE_BUF NSE3 PDM2 24 V / 3 A PDM2 TAM3 24 V / 1.5 A TAM3 TAM4 24 V / 1.5 A TAM4 RS232 RS232 RS232 TA_EDM 24 V_OUT EDM - supply / 2 A TA_EDM MS15009/00E 06-09 © MTU...
Page 184 24 V / 20 A Bank 1 HIGH 24 V / 20 A Bank 1 HIGH 24 V / 20 A Bank 1 HIGH 24 V / 20 A Bank 1 HIGH 24 V / 20 A MS15009/00E 06-09 © MTU...
Page 185 24 V / 20 A MV17 Bank 2 MV18 HIGH 24 V / 20 A MV18 Bank 2 MV19 HIGH 24 V / 20 A MV19 Bank 2 MV20 HIGH 24 V / 20 A MV20 Bank 2 MS15009/00E 06-09 © MTU...
Page 186 Connector type CIR 06 G2 – 18 – 11 S Target Plant wiring harness (power supply) Pin assignment Channel Signal Comments POWER +24 V = 24 V / 30 A supp POWER +24 V POWER POWER POWER MS15009/00E 06-09 © MTU...
Page 187 Connector X6, view to socket Connector X6 Connector type VPT 06 GSE 12-10 P Target Dialog unit Pin assignment Channel Signal Comments POWER +24 V = 24 V / 30 A supp +24 V POWER POWER POWER POWER MS15009/00E 06-09 © MTU...
Page 189: Special Tools
Special Tools Special Tools Special tools Part No. Designation / Use Qty. F6558556 Barring tool for 12V engines F6558557 Barring tool for 16V engines MS15009/00E 06-09 © MTU...
Page 190 Special Tools Part No. Designation / Use Qty. 0135315483 Connector pliers Y20097353 Rigid endoscope MS15009/00E 06-09 © MTU...
Page 191 Special Tools Part No. Designation / Use Qty. F30027336 Torque wrench 6-50 Nm F30027340 Ratchet adapter MS15009/00E 06-09 © MTU...
Page 192 Special Tools Part No. Designation / Use Qty. Y20010128 Feeler gauge F30026582 Torque wrench 20-100 Nm MS15009/00E 06-09 © MTU...
Page 193 Special Tools Part No. Designation / Use Qty. F30043446 Torque wrench 8-40 Nm F6557929 Barring tool MS15009/00E 06-09 © MTU...
Page 194 Special Tools Part No. Designation / Use Qty. F30027424 Spider patch spanner F30027425 Spider patch spanner MS15009/00E 06-09 © MTU...
Page 195 Special Tools Part No. Designation / Use Qty. F30377999 Extractor F30378207 Fuel suction device MS15009/00E 06-09 © MTU...
Page 197 Special Tools Part No. Designation / Use Qty. F30011450 Double box wrench F30379104 Filter wrench MS15009/00E 06-09 © MTU...
Page 200 Annex MTU contact person/service partner You will find the MTU contact person/service partner for your region at www.mtu-online.com, worldwide, in the left-hand navigation margin. MS15009/00E 06-09 © MTU...
Page 201 Engine Data Module EEPROM Electrically Erasable Programmable Read Only Memory EFPA Electronic Foot Pedal Assembly Exhaust Gas Recirculation Engine Monitoring Unit Electronic Unit Injector Fluids and Lubricants Specification MTU Publication No. A01061/.. Fuel Pressure Sensor Monitors fuel pressure MS15009/00E 06-09 © MTU...
Page 202 Oberer Totpunkt Top dead center (TDC) Panel Peripheral Interface Module Pulsewidth modulated P-xyz Pressure-xyz Pressure measuring point xyz Redundancy Lost Alarm: Redundant CAN bus failure Society of Automotive Engineers U.S. standardization organization Sensor Defect Alarm: Sensor failure MS15009/00E 06-09 © MTU...
Page 203 Turbo Compressor Inlet Turbo Compressor Outlet Transmitter Deviation Alarm: Sensor-comparison failure Throttle Position Sensor Timing Reference Sensor T-xyz Temperature-xyz Temperature measuring point xyz Unterer Totpunkt Bottom dead center (BDC) Variable nozzle turbine Variable Speed Governor Vehicle Speed Sensor MS15009/00E 06-09 © MTU...
Page 206 Fuel prefilter – flushing ....MTU contact person/service partner ..Fuel prefilter cleaning ....

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Detroit diesel 12 v 2000 p82 Detroit diesel 16 v 2000 p62 Detroit diesel 16 v 2000 p82

MTU Detroit Diesel 12 V 2000 P62 Technical Publication

1 Safety

2 Product Summary

3 Operation

4 Maintenance

5 Troubleshooting

6 Task Description

7 Engine Governor Assignment and Circuitry

8 Special Tools

9 Annex

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