MTU 12 V 2000 P12 Operating Instructions Manual
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MTU 12 V 2000 P12 Operating Instructions Manual

MTU 12 V 2000 P12 Operating Instructions Manual

Diesel engine
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Operating Instructions

Diesel engine
12 V 2000 P12
16 V 2000 P12
MS150025/02E

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Summary of Contents for MTU 12 V 2000 P12

  • Page 1: Operating Instructions

    Operating Instructions Diesel engine 12 V 2000 P12 16 V 2000 P12 MS150025/02E...
  • Page 2 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, micro‐ filming and storage or processing on electronic systems including data bases and online services.

  • Page 3: Table Of Contents

    Table of Contents 1 Safety 4.9 After stopping the engine – Engine remains ready for operation 1.1 Important provisions for all MTU engines or 4.10 After stopping the engine – putting the systems engine out of service 1.2 Personnel and organizational requirements 4.11 Plant cleaning...
  • Page 4 7.15.4 Engine coolant – Draining 7.15.5 Engine coolant – Filling 9.1 Abbreviations 7.15.6 Coolant pump – Relief bore check 9.2 MTU contact persons/service partners 7.16 Low-Temperature Circuit 7.16.1 Charge-air coolant – Filling 7.16.2 Charge-air coolant – Draining 10 Appendix B 7.16.3 Charge-air coolant –...

  • Page 5: Safety

    Spare parts Only genuine MTU spare parts must be used to replace components or assemblies. MTU will accept no liability or warranty claims for any damage caused by the use of other spare parts. MS150025/02E 2012-10 | Safety | 5...

  • Page 6: Personnel And Organizational Requirements

    Personnel requirements All work on the engine or plant shall be carried out by trained and qualified personnel only: • Training at the MTU Training Center • Qualified personnel specialized in mechanical and plant engineering The operator must define the responsibilities of the personnel involved in operation, maintenance, repair and transport.

  • Page 7: Transport

    Place the engine only on an even, firm surface. Ensure appropriate consistency and load-bearing capacity of the ground or support surface. Never set an engine down on the oil pan unless expressively authorized to do so by MTU on a case-to- case basis .

  • Page 8: Safety Regulations For Maintenance And Repair Work

    1.4 Safety regulations for maintenance and repair work Safety regulations prior to maintenance and repair work Have maintenance and repair work carried out by qualified and authorized personnel only. Allow the engine or plant to cool down to less than 50°C before starting maintenance work (risk of explo‐ sion of oil vapors, fluids and lubricants, risk of burning).
  • Page 9 Safety regulations after completion of maintenance and repair work Before barring the engine, make sure that nobody is standing in the danger zone of the engine or plant. Check that all guards have been reinstalled and that all tools and loose parts have been removed after working on the engine or plant (in particular, the barring tool).
  • Page 10 Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Pack de‐ fective electronic components and assemblies in a suitable manner when dispatched for repair, i.e. par‐ ticularly protected against moisture and impact and wrapped in antistatic foil if necessary. Working with laser equipment When working with laser equipment, always wear special laser-protection goggles ⇒...

  • Page 11: Fire Prevention And Environmental Protection, Auxiliary Materials, Fluids And Lubricants

    Dispose of used fluids, lubricants and filters in accordance with local regulations. Within the EU, batteries can be returned free of charge to MTU FN / MTU Onsite Energy where they are subjected to proper recycling procedures.
  • Page 12 Lead • Adopt suitable measures to avoid the formation of lead dust. • Switch on extraction system. • When working with lead or lead-containing compounds, avoid direct contact to the skin and do not inhale lead vapors. • Wash hands after contact with lead or lead-containing substances. Compressed air Observe special safety precautions when working with compressed air: •...

  • Page 13: Standards For Safety Messages In The Text

    1.6 Standards for safety messages in the text DANGER In the event of immediate danger. Consequences: Death or serious injury • Remedial action WARNING In the event of potentially dangerous situations. Consequences: Death or serious injury • Remedial action CAUTION In the event of hazardous situations.

  • Page 14: Atex Precautions (If Applicable)

    1.7 ATEX precautions (if applicable) The following additional precautions must be taken to comply with the requirements of the ATEX explosion protection directives: • Unoccupied connections for the wiring harness must be sealed with protective caps. • The entire engine wiring harness must be covered with metal guards to protect it from mechanical im‐ pact and UV radiation.

  • Page 15: General Information

    2 General Information 2.1 Engine side and cylinder designations Engine sides are always designated as viewed from the driving end (KS). The cylinders of the left engine side are designated "A" and those of the right side "B" (as per DIN ISO 1204).

  • Page 16: Engine Layout

    2.2 Engine layout Illustrations are also applicable to 16 V 1 Exhaust outlet 8 ECU 15 Oil filter 2 Exhaust turbocharger 9 Engine lifting equipment 16 Oil dipstick 3 Intercooler 10 Fuel duplex filter 17 Oil pan 4 Air intake connection 11 Oil filler neck 18 Crankcase 5 Crankcase ventilation...
  • Page 17 1 Starter 2 Charge-air 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 (1, 6, 8, 9) Design index MS150025/02E 2012-10 | General Information | 17...

  • Page 18: Use

    2.3 Use 1 Service and Automation 4 CAN bus 7 Engine monitoring (op‐ Module (SAM) 5 Engine with generator tional) 2 Peripheral Interface 6 Engine governor 8 LOP (optional) Module 601 (option) 3 Peripheral Interface Module 602 (option) Up to 8 additional Peripheral Interface Modules can be connected for linking to higher-level systems. Functions •...
  • Page 19 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. • Connecting cable for connection to a higher-level genset control system. •...
  • Page 20 Design of Engine Control System ECS-5 1 Engine with generator 3 Power supply +U 5 Engine governor 2 Engine interface 6 System boundary 4 Signal connection to the ECS-5 MCS devices and the higher-level control sys‐ tems The Engine Control System comprises the following devices: •...
  • Page 21 Basic scope of Monitoring and Control System MCS-5 1 Monitoring and Control 3 Signal connection to 5 SAM System MCS-5 ECS devices 2 Power supply +U 4 System boundary MCS-5 MS150025/02E 2012-10 | General Information | 21...
  • Page 22 Service and Automation Module (SAM) 1 Module cassette, slots 4 Control keys for minidia‐ 7 Connector with spring for additional I/O PIM design cards 5 Diagnostic lamp 2 Compact flash memory 6 Interface for dialog unit card 3 Display for fault codes and minidialog Functions SAM functions...
  • Page 23 Customer interface • 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 • Extendable with MCS 5 PIM I/O cards Data connections 1 Engine governor 3 PIM 601 (option) serial...
  • Page 24 Grounding 1 PIM 6 Generating set 11 Mounting frame 2 SAM 7 Equipotential bonding 12 GND (-) 3 Engine governor strip 13 +24 V VDC (+) 4 Battery 8 Grounding X! Inadmissible connec‐ 5 To engine sensors 9 Equipotential bonding tion! strip 10 Equipotential bonding...

  • Page 25: Use Of Devices

    2.4 ECS-5 – Use of devices Engine governor Central control and monitoring device for the engine • Communication with other devices and higher-level systems via CAN bus. • Control of injection system. • Control of up to 20 injectors. • Acquisition and evaluation of engine operating states. •...
  • Page 26 Hardware structure Item. Name Meaning Cover – Housing – Rating plate Part and serial number Data record and engine number Screws – 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...
  • Page 27 Operating voltage Rated voltage: 24 VDC Continuous voltage: 16.5 VDC to 32 VDC Temporarily restricted operation: 11 VDC to 36 VDC Residual ripple: Max. 8 V Power consumption Max. 30 A Heat loss Max. 35 W Operating temperature range 0 °C to +75 °C Storage temperature range –10 °C to +75 °C Relative air humidity...

  • Page 28: Mdec - Functions

    2.5 MDEC – Functions Control functions Following engine functions are controlled: • Engine start • Engine stop • Emergency start • Restart response • Sequences with activated “Override” function (safety system bypass). • Nominal speed switching between two set values (optional operation as 50 Hz or 60 Hz genset). •...
  • Page 29 Override (safety system bypass) The “Override” feature is used to bypass safety functions tripped by limit value violations or sensor faults and to bypass start interlocks. Operating states which would normally lead to engine shutdown are ignored when the “Override” function is activated.
  • Page 30 Speed - injection control Functions of the closed-loop engine speed control integrated in the engine governor: • Maintaining the desired engine speed under changing load conditions. • Adjusting the engine speed when the setting is changed by the operator. Additional tasks with an effect on closed-loop engine speed control: •...
  • Page 31 Switching to an external speed setting takes place automatically once the nominal speed has been reached. The following speed setting variants are possible: • Desired speed setting via an analog input: The setpoint speed can be adjusted within a (configurable) range around the preset synchronous speed (depending on the set network frequency).
  • Page 32 Fault messages are stored in two memories: • Chronological memory The fault message numbers are stored in a ring memory in chronological order of their occurrence or cancellation together with the hour meter reading. The ring memory stores the last 80 setting and can‐ cellation procedures.

  • Page 33: Peripheral Interface Modules (Pims)

    2.6 Peripheral Interface Modules (PIMs) PIMs for use with processor printed circuit board MPU 23 and MPU 27 PIM design 1 Module cassette 1 2 Basic module 1 3 Printed circuit board PIM 601/602 comprises: • Module cassette 1 (1) to accommodate one MPU 23, MPU 27 and one PIM printed circuit board. •...
  • 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

    2.7 Printed circuit board SCB 3 Purpose and design Design 1 Component side 4 LED (red) “Printed circuit 7 LED (yellow) “Interface 2 Soldering side board RESET” 2: Receiving and trans‐ 3 Top view 5 LED (green) “Ready” mitting line active” 6 LED (yellow) “Interface 8 Connector RS232 inter‐...
  • Page 36 Function 1 Transmission channel 1 2 Connector 3 Module housing with SCB 3 SCB 3 is equipped with two serial transmission channels routed to the terminal strip of the PIM. The software of the relevant processor printed circuit board determines which interface is active on which transmission channel.
  • Page 37 Connection terminal Name Channel 1: O2 of RS422 interface Channel 2: O2 of RS422 interface Channel 1: Ground (GND) of RS422 interface Channel 2: Ground (GND) of RS422 interface Channel 1: I1 of RS422 interface Channel 2: I1 of RS422 interface Channel 1: I2 of RS422 interface Channel 2: I2 of RS422 interface Channel 1: TX of RS232 interface...

  • Page 38: Technical Data

    3 Technical Data 3.1 12/16 V 2000 P12 engine data Explanation: DL Ref. value: Continuous power BL Ref. value: Fuel stop power A Design value G Guaranteed value R Guideline value L Limit value up to which the engine can be operated without change, e.g. of power setting. N Not yet defined value - Not applicable X Applicable...
  • Page 39 Number of cylinders Cylinder displacement liter 1.99 1.99 Total displacement liter 23.88 31.84 Compression ratio Number of inlet valves per cylinder Number of exhaust valves per cylinder Standard flywheel housing flange (engine main PTO) COOLANT SYSTEM (HT circuit) Number of cylinders Coolant temperature (at engine outlet: to cooling equipment) °C Coolant temperature after engine, warning...
  • Page 40 GENERAL OPERATING DATA Number of cylinders Cold start capability: air temperature without starting aid, with‐ °C out preheating) - (case A) Coolant preheating: preheating temperature (min.) °C Firing speed, from Firing speed, to CAPACITIES Number of cylinders Engine coolant, engine-side (without cooling system) liter Charge-air coolant, engine side liter...

  • Page 41: Firing Order

    3.2 Firing order Firing order 12 V A1-B2-A5-B4-A3-B1-A6-B5-A2-B3-A4-B6 16 V A1-B5-A3-A5-B2-B8-A2-A8-B3-A7-B4-B6-A4-A6-B1-B7 MS150025/02E 2012-10 | Technical Data | 41...

  • Page 42: Engine - Main Dimensions

    3.3 Engine – Main dimensions Engine – Main dimensions Engine model 12 V 2000 Px2 16 V 2000 Px2 Length (A) approx. 2165 mm approx. 2505 mm Width (B) approx. 1340 mm approx. 1340 mm Height (C) approx. 1475 mm approx.

  • Page 43: Sam

    3.4 SAM Use/application • Installation in enclosed control cabinets. • Suitable for mounting on mounting rails (rail installation) or for installation with screws on the rear wall of the cabinet (fixed installation). • Suitable for connection wires or leads up to AWG16 (US) (1.5 mm Technical data Term Unit...
  • Page 44 Term Unit Value Ambient temperature: °C -40 – +70 with circulating ambient air. Storage temperature: °C -40 - +100 Relative humidity 5 – 97, no condensation. Color: Blue (RAL5015) Material: Polycarbonate, reinforced with 10 % fiberglass. Dimensions: L x W x H (295 x 151 x 75) Weight: Approx.
  • Page 45 Electrical requirements Term Unit Value Operating voltage: 24, -30 % to +30 % (+16.8 – +32) Permissible residual ripple less than 5% acc. to STA‐ NAG 1008. Note: The processor is automatically reset if the voltage falls below 7 V. Power supply: Below 7 W.
  • Page 46 Terminals Term Unit Value Terminal strip modules: WAGO spring terminals Current-carrying capacity (at 70 10 per contact °C): Rated voltage: Rated surge voltage: 2500 Wire cross-sections: Up to 1.5 or AWG15 Clamping range: 0.08 – 1.5 or AWG15 Other terminals (RM 5.08) are used for power supply and CAN bus connections. Additional printed circuit boards in slots 1 to 3 Observe the relevant technical data applicable to the printed circuit boards concerned when additional boards are used in the SAM.

  • Page 47: Scb 3 - Technical Data

    3.5 SCB 3 – Technical data Term Unit Value Dimensions (H x W x D) 59 x 63 x 15 Weight 0.036 Input voltage +5 (±5 %) from processor printed circuit board used Power consumption < 100 Power loss < 425 Table 1: General information Term Unit...

  • Page 48: Operation

    4 Operation 4.1 LOP – Controls LOP – Controls Item Color Inscription Meaning / Function White Function keys for operating the screen. White Functions vary and are displayed on the LCD screen. White White White White ALARM AC‐ Pressing the key the first time stops alarm signalization. KNOWLEDGE Pressing the key a second time acknowledges an active alarm.
  • Page 49 Item Color Inscription Meaning / Function White DIMMER ↓ Holding down the key decreases LCD background illumina‐ tion. White LAMP TEST Pressing the key initiates lamp test. TEST OVER‐ Pressing the key initiates overspeed test. SPEED LED (spot) lights up as long as the overspeed test is run‐ ning.

  • Page 50: Putting The Engine Into Operation After Extended Out-Of-Service-Periods

    4.2 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 (→...

  • Page 51: Putting The Engine Into Operation After Scheduled Out-Of-Service-Period

    4.3 Putting the engine into operation after scheduled out-of- service-period Preconditions ☑ Engine is stopped and starting disabled. Putting the engine into operation Item Task Lube oil system Check oil level (→ Page 123); Cooling system Check engine coolant level (→ Page 131); Check charge-air coolant level (→...

  • Page 52: Start Engine In Manual Mode (Testing Mode)

    4.4 Start engine in manual mode (testing mode) Preconditions ☑ Generator (if provided) not connected to network. ☑ External start interlock is not activated. DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Before barring or starting the engine, make sure that nobody is in the danger zone. WARNING Engine noise above 85 dB (A).

  • Page 53: Safety System - Override

    4.5 Safety system – Override CAUTION Safety functions and engine shutdown alarms will be disregarded. Serious damage to plant! • Initiate emergency start only in emergency situations. CAUTION Inadmissible operational condition. Major material damage! • Use override function only in hazardous situations to ensure full capability in case of engine mal‐ functions.

  • Page 54: Operational Checks

    4.6 Operational checks DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...

  • Page 55: Stop Engine In Manual Mode (Testing Mode)

    4.7 Stop engine in manual mode (testing mode) Preconditions ☑ Generator (if provided) not connected to network. ☑ Engine is running in manual mode. CAUTION Stopping the engine when it is running at full load causes extreme stress to the engine. Risk of overheating, damage to components! •...

  • Page 56: Emergency Stop

    4.8 Emergency stop CAUTION An emergency stop causes extreme stress to the engine. Risk of overheating, damage to components! • Initiate emergency stop only in emergency situations. Emergency stop from LOP Item Task EMERGENCY STOP but‐ Press. • Engine is stopped by switching off power supply to ECU; •...

  • Page 57: After Stopping The Engine - Engine Remains Ready For Operation

    4.9 After stopping the engine – Engine remains ready for operation After stopping the engine Item Action Engine/generator/pump Select operating mode, e.g. MANUAL, AUTOMATIC OPERATION. control MS150025/02E 2012-10 | Operation | 57...

  • Page 58: 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, preserve engine (→ MTU-Preservation and Represer‐ vation Specifications A001070/..).

  • Page 59: Plant Cleaning

    4.11 Plant cleaning Preconditions ☑ Engine is stopped and starting disabled. ☑ Operating voltage is not present. Special tools, Material, Spare parts Designation / Use Part No. Qty. Steam jet cleaner Cleaner (Hakupur 312) 30390 WARNING Compressed air Risk of injury! •...

  • Page 60: Maintenance

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

  • Page 61: Troubleshooting

    6 Troubleshooting 6.1 Troubleshooting Engine does not turn when starter is actuated Component Cause Measure Battery Flat or defective Charge or replace (see manufacturer's documentation). Cable connections faulty Check if cable connections are proper‐ ly secured (see manufacturer's docu‐ mentation). Starter (electric) Engine wiring or starter faulty Check if cable connections are proper‐...
  • Page 62 Faulty Contact Service. Charge-air temperature too high Component Cause Measure Engine coolant Engine coolant treatment incorrect Check (MTU test kit). Intercooler Contaminated Contact Service. Engine room Air-intake temperature too high Check fan; check air inlet/outlet ducts. Charge-air pressure too low...
  • Page 63 Black exhaust gas Component Cause Measure Air supply Air filter clogged Check signal ring position of contami‐ nation indicator (→ Page 121). Fuel injection equip‐ Injector faulty Replace (→ Page 102). ment Injection pump defective Replace (→ Page 98). Engine Overloaded Contact Service.

  • Page 64: Fault Indication On Printed Circuit Board Sam

    6.2 Fault indication on printed circuit board SAM The structure of the display (1) is as follows: • First line • Fault indication • # (2) = Alarm is no longer active, does not appear on next power-up, • A = Currently active alarms, •...
  • Page 65 SE No. Fault message text I/O-Module Slot4 Defect Serial Connection Lost CAN Bus- 3 Error/Bus Defec CAN Bus- 3 Overrun S/A Bus Faulty PAN 1 Defect 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...
  • Page 66 Fault code Fault message Meaning Action L1 COOLANT LEVEL Coolant level too low Check coolant level in expansion (1st limit value) tank (→ Engine operating instruc‐ tions). L2 COOLANT LEVEL Coolant level too low Check coolant level in expansion (2nd limit value) tank (→...
  • Page 67 Fault code Fault message Meaning Action L1 T-COOLANT Coolant temperature too Reduce power. high (1st limit value); L2 T-COOLANT Coolant temperature too 1. Allow engine to cool down. high (2nd limit value); 2. Contact Service • Check engine coolant cooler, automatic engine shutdown clean if dirty (→...
  • Page 68 Fault code Fault message Meaning Action L1 T-ELECTRONIC Temperature in ECU hous‐ 1. Improve engine room ventila‐ ing too high (1st limit value) tion. 2. Reduce engine power. 15V POS ECU DE‐ Internal voltage (-15 VDC) Replace engine governor (→ En‐ FECT faulty;...
  • Page 69 Fault code Fault message Meaning Action CAN 1 ERROR PAS‐ CAN 1 in Error-Passive Contact Service. SIVE state, minor bus disruption • Check that at least one CAN or missing CAN node . node is present. Check cabling as necessary. •...
  • Page 70 Fault code Fault message Meaning Action SD T-LUBE OIL Sensor B07 faulty (lube oil 1. Check cabling (→ Engine oper‐ temperature). ating instructions); 2. Contact Service • Check sensor. SD T-INTAKE AIR Sensor B03 faulty (intake 1. Check cabling (→ Engine oper‐ air temperature).
  • Page 71 Fault code Fault message Meaning Action SD SP. DEM. TEST External test bench speed Check potentiometer and cabling BENCH setting faulty. (→ Engine operating instructions). SD SPEED DE‐ Sensor fault frequency set‐ 1. Check cabling (→ Engine oper‐ MAND ting. ating instructions);...
  • Page 72 Fault code Fault message Meaning Action TRAN.OUT3 EN‐ Binary transistor output en‐ GINE DEF gine 3 faulty. TRAN.OUT4 EN‐ Binary transistor output en‐ GINE DEF gine 4 faulty. TRAN.OUT1 PLANT Binary transistor output Check cabling to plant. TAA 1 faulty. TRAN.OUT2 PLANT Binary transistor output Check cabling to plant.

  • Page 73: Ecu Alarms

    6.3 ECU alarms The ECU generates alarms which are indicated in different ways depending on the equipment configura‐ tion: • as four-digit code on a PIM • as alarm text on a display • as four-digit code on a dialog PC The four-digit code consists of one letter and three figures: •...
  • Page 74 Fault Alarm text Meaning Task code L2 P-LUBE OIL Lube-oil pressure too low (2nd 1. Check engine-oil level and top up, if limit) required (→ Page 123); 2. Try to re-start the engine automatic engine shutdown (→ Page 52). 3. Contact Service. L1 COOLANT Engine coolant level too low Check coolant level and top up, if re‐...
  • Page 75 Fault Alarm text Meaning Task code LIM INTER‐ Alarm from external charge-air (Depending on the corresponding meas‐ COOLER LEV. coolant level monitoring uring point, which is read via CAN bus) L Bin-EXTERN 3 Alarm from external binary (Depending on the corresponding meas‐ channel 3 uring point, which is read via CAN bus) L Bin-EXTERN 4...
  • Page 76 Fault Alarm text Meaning Task code ERR REC1 NOT Check sum error of fault mem‐ If fault occurs repeatedly: Contact Serv‐ VALID ory in EDM (redundant data ice. record 1) ERR REC2 NOT Check sum error of fault mem‐ If fault occurs repeatedly: Contact Serv‐ VALID ory in EDM (redundant data ice.
  • Page 77 Fault Alarm text Meaning Task code L1 AD-TEST1 A/D-converter supply voltage Contact Service. SUPPLY too low AD-TEST1 ECU Electronic equipment defec‐ Contact Service. DEFECT tive; automatic engine shutdown L1 AD-TEST2 A/D-converter supply voltage Contact Service. SUPPLY too low AD-TEST2 ECU Electronic equipment defec‐...
  • Page 78 Fault Alarm text Meaning Task code SD T-COOLANT Sensor defect (coolant tem‐ 1. Check wiring. perature) 2. Contact Service. SD T-FUEL Sensor defect (Fuel tempera‐ 1. Check wiring. ture) 2. Contact Service. SD T-CHARGE Sensor defect (charge-air 1. Check wiring. temperature) 2.
  • Page 79 Fault Alarm text Meaning Task code SD P-EXTERN 2 External device defective Contact Service. (CAN P-EXTERN 2) SD EXT.COOL‐ External coolant-level monitor‐ Contact Service. ANT LEVEL ing defective (CAN) SD INTERCOOL‐ External charge-air coolant- Contact Service. ER LEVEL level monitoring defective (CAN) SD BIN-EXTERN External device defective...
  • Page 80 Fault Alarm text Meaning Task code TIMING CYLIN‐ Injection timing fault cylinder If fault occurs repeatedly: Contact Serv‐ DER B9 ice. TIMING CYLIN‐ Injection timing fault cylinder If fault occurs repeatedly: Contact Serv‐ DER B10 ice. WIRING CYLIN‐ Faulty wiring to solenoid valve 1.
  • Page 81 Fault Alarm text Meaning Task code WIRING CYLIN‐ Faulty wiring to solenoid valve 1. Check wiring. DER B4 cylinder B4; 2. Contact Service. Misfiring WIRING CYLIN‐ Faulty wiring to solenoid valve 1. Check wiring. DER B5 cylinder B5; 2. Contact Service. Misfiring WIRING CYLIN‐...
  • Page 82 Fault Alarm text Meaning Task code OPEN_LOAD Disconnection in wiring to sol‐ 1. Check wiring. CYL. A8 enoid valve cylinder A8; 2. Contact Service. Misfiring OPEN_LOAD Disconnection in wiring to sol‐ 1. Check wiring. CYL. A9 enoid valve cylinder A9; 2.
  • Page 83 Fault Alarm text Meaning Task code STOP POWER Solenoid valve or wiring or 1. Check wiring. STAGE 1 ECU defective 2. Try to re-start the engine (→ Page 52). automatic engine shutdown 3. Contact Service. STOP POWER Solenoid valve or wiring or 1.

  • Page 84: Task Description

    7 Task Description 7.1 Engine 7.1.1 Engine – Barring manually Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring tool for 12V engines F6558556 Barring tool for 16V engines F6558557 DANGER Unguarded rotating and moving engine components.

  • Page 85: Engine - Barring With Starting System

    7.1.2 Engine – Barring with starting system Special tools, Material, Spare parts Designation / Use Part No. Qty. Connector pliers 0135315483 DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Before barring or starting the engine, ensure that nobody is in the danger zone. •...

  • Page 86: Engine - Test Run

    7.1.3 Engine – Test run DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Before barring or starting the engine, make sure that nobody is in the danger zone. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...

  • Page 87: Cylinder Liner

    7.2 Cylinder Liner 7.2.1 Cylinder liner – Endoscopic examination Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Rigid endoscope Y20097353 Preparatory steps Remove cylinder head cover (→ Page 97). Remove injector (→...
  • Page 88 Final steps Install injector (→ Page 103). Install cylinder head cover (→ Page 97). 88 | Task Description | MS150025/02E 2012-10...

  • Page 89: Instructions And Comments On Endoscopic And Visual Examination Of Cylinder Liners

    7.2.2 Instructions and comments on endoscopic and visual examination of cylinder liners Terms used for endoscopic examination Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic exami‐ nation report. Findings Action Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing prod‐...
  • Page 90 Findings Action Burn mark This is caused by a malfunction in the liner / ring tribosystem. Usually they run over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring and be‐ coming more visible from the second TDC-ring 2 onwards and less pronounced from TDC-ring 1.

  • Page 91: Crankcase Breather

    7.3 Crankcase Breather 7.3.1 Crankcase breather – Wire mesh cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Cleaner Diesel fuel Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 Sealing ring (→ Spare Parts Catalog) Screw (→...
  • Page 92 Crankcase breather – Wire mesh cleaning Remove hose from oil separator hous‐ ing (1). Remove cylinder head cover (5). Release screws (4), remove deflector plate (6) and retainer (7). Take off oil separator housing (1). Remove sealing ring (8) from oil separator housing (1).

  • Page 93: Crankcase Breather - Oil Separator Element Replacement, Diaphragm Check And Replacement

    7.3.2 Crankcase breather – Oil separator element replacement, diaphragm check and replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 6-50 Nm F30027336 Ratchet adapter F30027340 Engine oil Filter element (→...
  • Page 94 Checking diaphragm Remove cover (4). Remove spring (5), gasket (2) and dia‐ phragm (3). Check diaphragm (3) for damage, fit new diaphragm if used one is damaged. Install diaphragm (3) on housing (1). Install new seal (2) and spring (5) together with cover (4).

  • Page 95: Valve Drive

    7.4 Valve Drive 7.4.1 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 96: Adjusting Valve Clearance

    Checking valve clearance at two crankshaft positions 1 Cylinder A1 is in firing TDC 2 Cylinder A1 is in overlap TDC I Inlet valve X Exhaust valve Check TDC position of piston in cylinder A1: • The piston is at firing TDC when the rockers are unloaded at cylinder A1. •...

  • Page 97: Cylinder Head Cover - Removal And Installation

    7.4.2 Cylinder head cover – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 8-40 Nm F30043446 Ratchet F30027340 Gasket (→ Spare Parts Catalog) Preparatory steps On cylinder head covers with crankcase breather: Loosen clamps.

  • Page 98: Injection Pump / Hp Pump

    7.5 Injection Pump / HP Pump 7.5.1 Injection pump – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Injection pump (→ Spare Parts Catalog) Injection pump – Replacement Remove injection pump and install new one (→ Page 99). 98 | Task Description | MS150025/02E 2012-10...

  • Page 99: Injection Pump - Removal And Installation

    7.5.2 Injection pump – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Crowfoot wrench, 19 mm F30027424 Crowfoot wrench, 22 mm F30027425 Torque wrench, 20–100 Nm F30026582 Ratchet adapter F30027340...
  • Page 100 Removing injection pump Mark installation position of injection pump. Disconnect wiring (1) from injection pump. Remove fuel line (2). Unscrew securing screws of injection pump by approx. 6 mm. • The pretensioned compression spring will press the injection pump out of the crankcase, if this does not happen: a) Turn crankshaft with engine barring tool (→...
  • Page 101 Install injection pump, observing marked in‐ stallation position. Install securing screws of injection pump and tighten with torque wrench to specified torque 60 Nm + 12 Nm. Install fuel line (2). Use torque wrench to tighten union nut at injection pump to specified torque 20 Nm + 5 Nm.

  • Page 102: Injection Valve / Injector

    7.6 Injection Valve / Injector 7.6.1 Injector – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Injector (→ Spare Parts Catalog) Replacing injector Remove injector and install new injector (→ Page 103). 102 | Task Description | MS150025/02E 2012-10...

  • Page 103: Injector - Removal And Installation

    7.6.2 Injector – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Extractor F30377999 Fuel suction device F30378207 Torque wrench, 20-100 Nm F30026582 Socket wrench F30025897 Crowfoot wrench, 19 mm F30027424 Crowfoot wrench, 22 mm F30027425...
  • Page 104 Removing fuel injector Remove leak-off-fuel lines. Remove fuel line (3). Remove thrust screw (2). Pull off pressure pipe neck (1). Extract fuel from the exposed bores using the suction device. Remove screw (2). Take off clamp (1). Screw extractor into injector. Remove injector using the extractor.
  • Page 105 Installing fuel injector Remove all covers before installation. Clean sealing surface on cylinder head and protective sleeve. Coat sealing ring (1) with grease and fit on‐ to injector. Coat sealing ring (2) with grease and fit on‐ to injector. Press injector into cylinder head by hand. Result: •...

  • Page 106: Fuel System

    7.7 Fuel System 7.7.1 Fuel pressure relief valve – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Pressure relief valve (→ Spare Parts Catalog) Sealing ring (→ Spare Parts Catalog) WARNING Fuels are combustible.
  • Page 107 Fuel pressure relief valve – Replacement, variant B Close fuel supply. Remove fuel line (7). Remove banjo screw (4). Remove sealing rings (5). Remove screws (2) with washer (3). Remove screws (6) and take off bracket. Install new pressure relief valve (1) with new sealing rings (5) in reverse sequence of operations.

  • Page 108: Fuel - Draining

    7.7.2 Fuel – Draining Preconditions ☑ Engine is stopped and starting disabled. WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Fuel – Draining Provide a suitable container in which to collect the fuel. Remove fuel filter (→...

  • Page 109: Fuel System – Venting

    7.7.3 Fuel system – Venting Fuel system – Venting Bar engine with starting system (→ Page 85). Repeat procedure 2 to 3 times, the fuel system is automatically vented. MS150025/02E 2012-10 | Task Description | 109...

  • Page 110: Fuel Filter

    7.8 Fuel Filter 7.8.1 Fuel filter – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Diesel fuel Easy-change filter (→ Spare Parts Catalog) Synthetic ring (→ Spare Parts Catalog) DANGER Unguarded rotating and moving engine components. Risk of serious injury –...

  • Page 111: Engine Running

    Stop engine (→ Page 55) and disable engine start. Cut out the filter to be replaced. Remove cut-out easy-change filter using the filter wrench. Clean the sealing surface of the filter head. Check sealing ring of the new easy-change filter and coat it with fuel. Install and tighten new filter by hand.

  • Page 112: Fuel Prefilter Cleaning

    7.8.2 Fuel prefilter cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel Sealing ring (→ Spare Parts Catalog) WARNING Fuels are combustible. Risk of fire and explosion! •...
  • Page 113 7.8.3 Fuel prefilter – Differential pressure gauge check and adjustment DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...

  • Page 114: Fuel Prefilter – Draining

    7.8.4 Fuel prefilter – Draining Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel Gasket (→ Spare Parts Catalog) WARNING Fuels are combustible. Risk of fire and explosion! •...

  • Page 115: Fuel Prefilter – Flushing

    7.8.5 Fuel prefilter – Flushing Special tools, Material, Spare parts Designation / Use Part No. Qty. Fuel Gasket (→ Spare Parts Catalog) DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Fuels are combustible.
  • Page 116 Open threaded vent plug (5) of filter to be flushed. Unlock drain valve (6) by pressing valve toggle, open it and drain fuel. Result: Fuel flows from filtered side back to the un‐ filtered side, flushing the filter deposits downwards out of the filter. Close threaded vent plug (5) and drain valve (6).

  • Page 117: Fuel Prefilter – Filter Element Replacement

    7.8.6 Fuel prefilter – Filter element replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel Filter element (→ Spare Parts Catalog) Gasket (→ Spare Parts Catalog) WARNING Fuels are combustible.
  • Page 118 Open threaded vent plug (5) of contaminat‐ ed filter. Unlock drain valve (6) by pressing toggle and open it. Drain water and dirt from filter. Close drain valve (6). Remove screws securing the cover and take off cover (2). Remove spring housing (4) and filter ele‐ ment (3).

  • Page 119: Charge-Air Cooling General, Left-Hand Side

    7.9 Charge-Air Cooling General, Left-Hand Side 7.9.1 Intercooler – Checking condensate drains 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 Risk of injury!

  • Page 120: Air Filter

    7.10 Air Filter 7.10.1 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. 120 | Task Description | MS150025/02E 2012-10...

  • Page 121: Air Intake

    7.11 Air Intake 7.11.1 Service indicator – Signal ring position check Preconditions ☑ Engine is stopped and starting disabled. Checking signal ring position of service indicator (if fitted) If the signal ring is completely visible in the control window (2), replace air filter (→...

  • Page 122: Starting Equipment

    7.12 Starting Equipment 7.12.1 Starter – Condition check Preconditions ☑ Engine is stopped and starting disabled. Checking starter condition Check securing screws of starter for secure seating and tighten if required. Check wiring (→ Page 144). 122 | Task Description | MS150025/02E 2012-10...

  • Page 123: Lube Oil System, Lube Oil Circuit

    7.13 Lube Oil System, Lube Oil Circuit 7.13.1 Engine oil – Level check Preconditions ☑ Engine is stopped and starting disabled. Oil level check prior to engine start Withdraw oil dipstick from guide tube and wipe it. Insert oil dipstick into guide tube up to the stop, withdraw after approx.

  • Page 124: Engine Oil – Change

    7.13.2 Engine oil – Change Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine is at operating temperature. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil Sealing ring (→...

  • Page 125: Oil Filtration / Cooling

    7.14 Oil Filtration / Cooling 7.14.1 Engine oil filter – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Engine oil Oil filter (→ Spare Parts Catalog) DANGER Unguarded rotating and moving engine components. Risk of serious injury –...
  • Page 126 Oil filter replacement with the engine running A Filter in operation (normal position) B Filter switched off Note: When changing filters during engine operation only 1 filter may ever be cut out. Cut out the filter to be replaced: Turn switching lever to position B. Remove oil filter using the filter wrench.

  • Page 127: Coolant Circuit, General, High Temperature Circuit

    7.15 Coolant Circuit, General, High-Temperature Circuit 7.15.1 Drain and venting points Top view 1 Engine coolant vent 2 Engine coolant vent MS150025/02E 2012-10 | Task Description | 127...
  • Page 128 Left side 1 Engine coolant drain 2 Engine coolant drain plug plug 128 | Task Description | MS150025/02E 2012-10...
  • Page 129 Right side 1 Engine oil drain 2 Engine coolant drain plug (heat exchanger) plug MS150025/02E 2012-10 | Task Description | 129...
  • Page 130 Driving end (KS) 1 Engine coolant drain 2 Intercooler drain 3 Engine oil drain plug plug 130 | Task Description | MS150025/02E 2012-10...

  • Page 131: Engine Coolant – Level Check

    7.15.2 Engine coolant – Level check Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down.

  • Page 132: Engine Coolant – Change

    7.15.3 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant – Change Drain engine coolant (→ Page 133). Fill with engine coolant (→ Page 134). 132 | Task Description | MS150025/02E 2012-10...

  • Page 133: Engine Coolant – Draining

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

  • Page 134: Engine Coolant – Filling

    7.15.5 Engine coolant – Filling Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant WARNING Coolant is hot and under pressure.
  • Page 135 Final steps Start the engine and operate it at idle speed for some minutes. Check coolant level (→ Page 131), top up with coolant if required. MS150025/02E 2012-10 | Task Description | 135...

  • Page 136: Coolant Pump – Relief Bore Check

    7.15.6 Coolant pump – Relief bore check DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...

  • Page 137: Low-Temperature Circuit

    7.16 Low-Temperature Circuit 7.16.1 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 138 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, clean sealing faces if required. Fit breather valve and close it.

  • Page 139: Charge-Air Coolant – Draining

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

  • Page 140: Charge-Air Coolant – Change

    7.16.3 Charge-air coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Charge-air coolant – Change Drain charge-air coolant (→ Page 139). Fill with charge-air coolant (→ Page 137). 140 | Task Description | MS150025/02E 2012-10...

  • Page 141: Charge-Air Coolant – Level Check

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

  • Page 142: Belt Drive

    7.17 Belt Drive 7.17.1 Drive belt – Condition check Preconditions ☑ Engine is stopped and starting disabled. ☑ Guard is removed. Item Findings Task Drive belt A Breaks in a few individual places None Drive belt Belt is oily, shows signs of over‐ Replace heating Drive belt B...

  • Page 143: Engine Mounting / Support

    7.18 Engine Mounting / Support 7.18.1 Engine mounts – Resilient elements check Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine is filled with coolant and engine oil. Engine mounts – Resilient elements check Wipe rubber surface with dry cloth, do not use organic detergents.

  • Page 144: Wiring (General) For Engine/Gearbox/Unit

    7.19 Wiring (General) for Engine/Gearbox/Unit 7.19.1 Engine wiring – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol X00058037 Engine wiring – Check Check securing screws of cable clamps on engine and tighten loose threaded connections. Ensure that cables are fixed in their clamps and cannot swing freely.

  • Page 145: Governor / Control System

    7.20 Accessories for (Electronic) Engine Governor / Control System 7.20.1 Engine governor and connectors – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Connector pliers 0135315483 Isopropyl alcohol X00058037 Engine governor and connectors - Cleaning...
  • Page 146 7.20.2 Engine monitoring unit and connectors – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Connector pliers 0135315483 Isopropyl alcohol X00058037 Engine monitoring unit and connectors – Cleaning Remove coarse dirt from housing surface with isopropyl alcohol.

  • Page 147: Checking Engine Control Unit Plug Connections

    7.20.3 Checking engine control unit plug connections Preconditions ☑ Engine shut down and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Connector pliers 0135315483 Checking engine control unit plug connections Use connector pliers (3) to make certain that all plug-in connections on engine con‐...
  • Page 148 7.20.4 Engine monitoring unit – Plug connection check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Connector pliers 0135315483 Checking engine monitoring unit plug connections Use connector pliers (3) to make certain that all engine monitoring unit plug connec‐...

  • Page 149: Engine Control Unit – Removal And Installation

    7.20.5 Engine control unit – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Connector pliers 0135315483 Covering caps for Cannon sockets Removing control unit from engine Note or mark assignment of cables to con‐...
  • Page 150 Disconnect ground strap from engine con‐ trol unit grounding stud (7). If the screws (4) are easily accessible: 1. Remove screws (4). 2. Remove engine control unit housing (3) from mounting plates (2). 3. Unscrew mounting plates (2), cable shock absorbers (5) and further fasten‐ ing parts (6) as one unit from engine.

  • Page 151: Emergency Instrumentation (Local Operating Panel)

    7.21 Emergency Instrumentation (Local Operating Panel) 7.21.1 LOP – Visual inspection Preconditions ☑ Engine is stopped and starting disabled. Preparatory steps If READY FOR OPERATION pushbutton is illuminated brightly, press switch briefly. Result: READY FOR OPERATION pushbutton returns to basic brightness. Switch master power switch to OFF.

  • Page 152: Checking Threaded Connections

    Checking threaded connections Check all connected cables to verify that the two securing elements (1) are engaged on the lugs (2) so that the respective male connector (3) is held firmly in place in the socket. If this is not the case, press the securing el‐ ements (1) concerned in the direction of the arrow until they engage noticeably.
  • Page 153 Performing lamp test Connect battery in accordance with battery manufacturer's instructions. Switch master power switch to ON. Switch on engine control system. Hold down LAMP TEST pushbutton: Result: Indicators and controls light up. Have damaged lamps immediately replaced by Service. MS150025/02E 2012-10 | Task Description | 153...

  • Page 154: Lop – Test Procedures

    7.21.2 LOP – Test procedures Preconditions ☑ Engine is stopped and starting disabled. Preparatory steps Connect battery in accordance with battery manufacturer's instructions. Switch master power switch to ON. Switch on engine management system ECS-5. Result: • LOCAL OPERATION pushbutton (1) is il‐ luminated brightly (local control mode is active);.
  • Page 155 Overspeed test with the engine at standstill Note: Overspeed test with the engine at standstill can only be carried out if the engine is equipped with Engine Monitoring Unit. Press OVERSPEED TEST illuminated pushbutton (3). Observe speed limit and speed simulated by Engine Monitoring Unit on display.

  • Page 156: Engine Governor Assignment And Circuitry 8.1 Engine Governor

    8 Engine Governor Assignment and Circuitry 8.1 Engine Governor 8.1.1 Engine governor channel circuitry Engine governor channel circuitry Binary inputs BE1 to BE9 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.
  • Page 157 Current input IUE 1 1 Current source, voltage source 2 Engine Control Unit ECU 4 Function Function Source Acquisition of a current signal (4 to 20 mA). Measuring channel specification Measuring range = 4 to 20 mA; Load: At 20 mA approx. 4 V; iso‐ lated.
  • Page 158 Pulse measuring inputs KW 1 and NW 1 1 Inductive sensor 2 Engine Control Unit ECU 4 Channel Function Sensor Measuring of crankshaft angle Inductive sensor and crankshaft speed. Measuring of camshaft angle and Inductive sensor camshaft speed. Speed measuring input DME 1, DME 2 1 Inductive sensor 2 Engine Control Unit ECU 4 Function...
  • Page 159 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). Pressure inputs DE 1 to DE 7 1 Pressure sensor 2 Engine Control Unit ECU 4 Function Function Sensor...
  • Page 160 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 Function Function Sensor Pressure measuring Relative pressure sensor Measuring channel specification...
  • Page 161 Transistor outputs TAA 1 to TAA 6 1 Engine Control Unit ECU 4 Function 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.
  • Page 162 Function Function Sensor Output voltage 0 to 10 V, e.g. for display instru‐ Plant ments Channel specification Output voltage = 0 to 10 V Output current = 5 mA max. Transistor outputs TAM 1 to TAM 4 1 Engine Control Unit ECU 4 Function Sensor Switching output...
  • Page 163 Function Sensor Switching output Engine Solenoid valve outputs MVA 1 to MVA 20 1 Engine Control Unit ECU 4 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...
  • Page 164 Channel specification Physical level ISO 11 898 CAN specification Version 2.0 A Data format MTU-specific Terminator In connector (no bus disruption when connector disconnected) Baud rate 125 kbaud Electrical isolation ± 50 V The CAN bus interfaces operate independently of each other.

  • Page 165: 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 166 TAA3 Combined alarm All warning messages (Limit1) are indicated here as a combined alarm. TAA4 n > 300 Indication of engine speed > 300 rpm. TAA5 SS T-coolant Shutdown, coolant temperature too high. TAA6 SS P-lube oil Shutdown, lube oil pressure too low. Analog MDEC inputs IEU1 = 0 to 10 V or 4 to 20 mA It is possible to activate different analog desired...

  • Page 167: Connector Assignment

    8.2 Connector Assignment 8.2.1 Connector pin assignment Connector pin assignment Connector X1, view to socket Connector X1 Connector type VPT 06 GSE 22–55 P Target Plant wiring harness Pin assignment Channel Signal Comments IUE1 5V_ISO 5 V / 20 mA electrically isolated IUE1 U_IN...
  • Page 168 Channel Signal Comments 0 V to 10 V/ 8 mA U < 4 V = low / U > 8 V = high Electrically isolated U < 4 V = low / U > 8 V = high Electrically isolated U <...
  • Page 169 Channel Signal Comments TAA6 (Plant supply, coil instru‐ ments 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 Pin assignment Channel Signal...
  • Page 170 Channel Signal Comments 0 V to 5 V/ internal 2 k0 pullup to 5 V_TE_BUF 0 V to 5 V/ internal 2 k0 pullup to 5 V_TE_BUF 0 V to 5 V/ internal 2 k0 pullup to 5 V_TE_BUF 5 V_BUF1 5 V / 20 mA 0 V to 5 V / inter‐...
  • Page 171 Channel Signal Comments NSE2 0 V to 5 V/ internal 47k5 pullup to 5 V_TE_BUF NSE2 U < 0 V = low / U > 400 mV = high U < 0 V = low / U > 400 mV = high DME1 U <...
  • Page 172 Channel Signal Comments 0 V to 5 V/ internal 2 k0 pullup to 5 V_TE_BUF 0 V to 5 V/ internal 2 k0 pullup to 5 V_TE_BUF TE10 0 V to 5 V/ internal 2 k0 pullup to 5 V_TE_BUF TE10 5 V_BUF4 5 V / 20 mA...
  • Page 173 Connector X4, view to socket Connector X4 Connector type VPT 06 GSE 21–41 PW Target Engine wiring harness (solenoid valves) Pin assignment Channel Signal Comments HIGH 24 V / 20 A Bank 1 HIGH 24 V / 20 A Bank 1 HIGH 24 V / 20 A Bank 1...
  • Page 174 Channel Signal Comments MV11 Bank 2 MV12 HIGH 24 V / 20 A MV12 Bank 2 MV13 HIGH 24 V / 20 A MV13 Bank 2 MV14 HIGH 24 V / 20 A MV14 Bank 2 MV15 HIGH 24 V / 20 A MV15 Bank 2 MV16...
  • Page 175 Channel Signal Comments POWER +24 V = 24 V / 30 A supp POWER +24 V POWER POWER POWER 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...

  • Page 176: Appendix A 9.1 Abbreviations

    Abgasturbolader Exhust turbocharger (ETC) Air Temperature Sensor Baureihe Series Betriebsstoffvorschrift MTU Fluids and Lubricants Specifications, publica‐ tion No. A01061/.. Controller Area Network Data bus system, bus standard Calibration Drift Compensation Setting of drift compensation in engine governor with DiaSys...
  • Page 177 Abbre‐ Meaning Explanation viation Engine Monitoring Unit Ersatzteilkatalog Spare Parts Catalog (SPC) Electronic Unit Injector Fuel Pressure Sensor Fuel Differential Pressure Sensor Fuel Temperature Sensor FWCP Fire Water Control Panel Ground High pressure High Alarm: Measured value exceeds 1st maximum limit HIHI High High Alarm: Measured value exceeds 2nd maximum...
  • Page 178 Abbre‐ Meaning Explanation viation Stop engine light 1st function: Warning lamp (stop engine and rectify fault) 2nd function: Read out fault codes System Identifier Synchronous Reference Sensor TDC cylinder 1 Safety System Safety system alarm Turbocharger Boost Sensor Monitors charge-air pressure Turbo Compressor Inlet Turbo Compressor Outlet Transmitter Deviation...

  • Page 179: Mtu Contact Persons/Service Partners

    Local support Experienced and qualified specialists place their knowledge and expertise at your disposal. For locally available support, go to the MTU Internet site: http://www.mtu-online.com 24h hotline With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist you –...

  • Page 180: Appendix B 10.1 Special Tools

    10 Appendix B 10.1 Special Tools Barring tool for 12V engines Part No.: F6558556 Qty.: Used in: 7.1.1 Engine – Barring manually (→ Page 84) Barring tool for 16V engines Part No.: F6558557 Qty.: Used in: 7.1.1 Engine – Barring manually (→ Page 84) Connector pliers Part No.: 0135315483...
  • Page 181 Crowfoot wrench, 19 mm Part No.: F30027424 Qty.: Used in: 7.5.2 Injection pump – Removal and installation (→ Page 99) Qty.: Used in: 7.6.2 Injector – Removal and installation (→ Page 103) Crowfoot wrench, 22 mm Part No.: F30027425 Qty.: Used in: 7.5.2 Injection pump –...
  • Page 182 Feeler gauge Part No.: Y20010128 Qty.: Used in: 7.4.1 Valve clearance – Check and adjustment (→ Page Filter wrench Part No.: F30379104 Qty.: Used in: 7.8.1 Fuel filter – Replacement (→ Page 110) Qty.: Used in: 7.14.1 Engine oil filter – Replacement (→ Page 125) Fuel suction device Part No.: F30378207...
  • Page 183 Ratchet Part No.: F30027340 Qty.: Used in: 7.4.2 Cylinder head cover – Removal and installation (→ Page 97) Ratchet adapter Part No.: F30027340 Qty.: Used in: 7.3.2 Crankcase breather – Oil separator element re‐ placement, diaphragm check and replacement (→ Page Qty.: Used in: 7.4.1 Valve clearance –...
  • Page 184 Steam jet cleaner Part No.: Qty.: Used in: 4.11 Plant cleaning (→ Page 59) Torque wrench, 0.5–5 Nm Part No.: 0015384230 Qty.: Used in: 7.5.2 Injection pump – Removal and installation (→ Page 99) Torque wrench, 20-100 Nm Part No.: F30026582 Qty.: Used in:...
  • Page 185 Torque wrench, 6-50 Nm Part No.: F30027336 Qty.: Used in: 7.3.2 Crankcase breather – Oil separator element re‐ placement, diaphragm check and replacement (→ Page Torque wrench, 8-40 Nm Part No.: F30043446 Qty.: Used in: 7.4.2 Cylinder head cover – Removal and installation (→ Page 97) Transition piece Part No.:...

  • Page 186: Index

    10.2 Index 12/16 V 2000 P12 engine data  38 Engine control unit – Removal and installation  149 Engine coolant Abbreviations 176 – Change  132 After stopping the engine – Engine remains ready for op‐ – Filling  134 eration 57 – Level check  131 After stopping the engine –...
  • Page 187 Wiring - engine – Maintenance task reference table [QL1]  60 – Check  144 Maintenance work – Safety regulations  8 MDEC governor assignment 165 MDEC – Functions 28 MTU contact persons 179 Operational checks 54 Organizational requirements 6 Peripheral Interface Modules (PIMs) 33 Personnel requirements 6 Plant – Cleaning  59...

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