MTU 16 V 2000 G56 S Operating Instructions Manual
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MTU 16 V 2000 G56 S Operating Instructions Manual

MTU 16 V 2000 G56 S Operating Instructions Manual

Ms150117/01e
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Operating Instructions

Diesel Engine
16 V 2000 G56 S
18 V 2000 G76 S
MS150117/01E

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Summary of Contents for MTU 16 V 2000 G56 S

  • Page 1: Operating Instructions

    Operating Instructions Diesel Engine 16 V 2000 G56 S 18 V 2000 G76 S MS150117/01E...
  • Page 2 All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen GmbH reserves the right to change, delete or supplement the information provided as and when required.

  • Page 3: Table Of Contents

    3 Technical Data 7.5.2 Injector – Removal and installation 7.5.3 Injector functions 3.1 Engine data 16 V 2000 G56 S 7.6 Fuel System 3.2 Engine data 18 V 2000 G76 S 7.6.1 HP fuel line and pressure pipe neck ‒...
  • Page 4 8 Appendix A 7.15.2 Cooler – Cleaning cooler elements 8.1 List of abbreviations 7.16 Belt Drive 8.2 MTU contact persons/service partners 7.16.1 Drive belt – Condition check 7.16.2 Drive belt – Tension check 9 Appendix B 7.16.3 Drive belt ‒ Tension adjustment 7.16.4 Drive belt –...

  • Page 5: Safety

    • With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubri- cants Specifications of the manufacturer) • With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU contact/Service partner) •...

  • Page 6: Personnel And Organizational Requirements

    1.2 Personnel and organizational requirements Organizational measures of the operator This manual must be issued to all personnel involved in operation, maintenance, repair or transporta- tion. Keep this manual handy in the vicinity of the product such that it is accessible to operating, mainte- nance, repair and transport personnel at all times.

  • Page 7: Transport

    Only set down engine on a firm, level surface. Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate. Never set an engine down on the oil pan unless expressively authorized to do so by MTU on a case-to- case basis .

  • Page 8: Safety Requirements For Maintenance And Repair Work

    1.4 Safety requirements for maintenance and repair work Safety requirements before commencing maintenance and repair work Have maintenance or repair work carried out by qualified and authorized personnel only. Allow the product to cool down to less than 50°C (risk of explosion for oil vapors, fluids and lubricants, risk of burning).
  • Page 9 Pay particular attention to cleanliness at all times. Safety requirements after completing maintenance and repair work Ensure that all personnel is clear of danger zones before cranking. Check that all access ports/apertures which have been opened to facilitate working are closed again. Check that all safety equipment has been installed and that all tools and loose parts have been re- moved (especially the barring gear).
  • Page 10 Working on electrical/electronic assemblies Always obtain the permission of the duty supervisor before commencing maintenance or repair work or switching off any part of the electronic system required to do so. De-energize the appropriate areas prior to working on assemblies. Avoid damaging cabling during removal.

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

    The latest version can be found on the website on the "Technical Info" or "Spare Parts and Service" tabs at http://www.mtu-online.com. Consumable fluids and materials may also be hazardous or toxic. When using fluids, lubricants, consum- ables and other chemical substances, follow the safety regulations that apply to the product.

  • Page 12: Compressed Air

    Lead • Adopt suitable measures to avoid the formation of lead dust. • Switch on extraction system. • When working with lead or pastes that contain lead, avoid direct contact with the skin. Do not inhale lead vapors. • Wash hands after contact with lead or lead-containing substances. Compressed air Observe special safety precautions when working with compressed air: •...

  • Page 13: Standards For Safety Notices In The Text

    1.6 Standards for safety notices in the text DANGER In the event of immediate danger. Consequences: Death, serious or permanent injury! • Remedial action. WARNING In the event of a situation involving potential danger. Consequences: Death, serious or permanent injury! •...

  • Page 14: General Information

    2 General Information 2.1 Engine side and cylinder designations 1 Left engine side (A-side) 3 Right engine side (B-side) 2 Engine free end in accord- 4 Engine driving end in ac- ance with DIN ISO 1204 cordance with (KGS = Kupplungsgegen- DIN ISO 1204 (KS = Kup- seite) plungsseite)

  • Page 15: Engine Overview

    2.2 Engine overview 16 V 2000 G56 S 1 Exhaust turbocharger 7 Battery-charging generator 13 Valve gear 2 Air intake/air supply 8 Cooling air system 14 Cylinder head 3 EGR cooler 9 Coolant system 15 Exhaust pipework 4 Intercooler 10 Mounting/support...
  • Page 16 18 V 2000 G76 S 1 Air intake/air supply 5 Engine coolant pump 9 Fuel system (high pres- 2 Charge-air manifold 6 Fuel system (low pressure) sure) 3 Monitoring, control and 7 Fuel filter 10 Starting equipment regulation system 8 Exhaust turbocharger 11 PTO system, driving end 4 Belt drive KS Driving end...

  • Page 17: Technical Data

    3 Technical Data 3.1 Engine data 16 V 2000 G56 S 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 settings).
  • Page 18 Model-related data (basic design) Number of cylinders Number of cylinders Cylinder arrangement: V-angle Degrees (°) Bore Stroke Displacement, cylinder Liters 2.233 Displacement, total Liters 35.7 Compression ratio 16.5 Number of inlet valves per cylinder Number of exhaust valves per cylinder Combustion air / exhaust gas Number of cylinders Charge-air pressure before cylinder - DL...
  • Page 19 Number of cylinders Lube-oil temperature before engine, shutdown °C Lube oil operating pressure before engine, warning Lube oil operating pressure before engine, shutdown Fuel system Number of cylinders Fuel pressure at engine inlet connection, min. (when engine is starting) -0.5 Fuel pressure at engine inlet connection, max.
  • Page 20 Number of cylinders Engine surface noise with attenuated intake noise (filter) - DL (free-field dB(A) sound-power level Lp, 1 m distance, ISO 6798, +2 dB(A) tolerance) Engine surface noise with attenuated intake noise (filter) - DL (sound pow- dB(A) er level LW, ISO 6798 +2 db(A) tolerance) 20 | Technical Data | MS150117/01E 2014-10...

  • Page 21: Engine Data 18 V 2000 G76 S

    3.2 Engine data 18 V 2000 G76 S 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 settings). N Not yet defined value - Not applicable X Applicable...
  • Page 22 Number of cylinders Displacement, cylinder Liters 2.233 Displacement, total Liters 40.2 Compression ratio 17.5 Number of inlet valves per cylinder Number of exhaust valves per cylinder Combustion air / exhaust gas Number of cylinders Charge-air pressure before cylinder - DL bar abs Charge-air pressure before cylinder - BL bar abs...
  • Page 23 Inclinations, standard oil system (reference: waterline) Number of cylinders Longitudinal inclination, continuous max. driving end down (option: max. Degrees (°) operating inclinations) Longitudinal inclination, continuous max. driving end up (option: max. op- Degrees (°) erating inclinations) Transverse inclination continuous max. (Option: max. operating inclina- Degrees (°) tions) Capacities...

  • Page 24: Firing Order

    3.3 Firing order Firing order Number of cylinders Firing order 16 V A1-B5-A3-A5-B2-B8-A2-A8-B3-A7-B4-B6-A4-A6-B1-B7 18 V A1-B6-A3-B4-A5-B2-A7-B1-A9-B3-A8-B5-A6-B7-A4-B9-A2-B8 24 | Technical Data | MS150117/01E 2014-10...

  • Page 25: Engine - Main Dimensions

    3.4 Engine – Main dimensions Engine – Main dimensions 16 V 2000 G56 S Engine model Length (A) Width (B) Height (C) 16 V 2000 G56 S Approx. 2378 mm Approx. 1288 mm Approx. 1490 mm Table 2: Engine model / Dimensions...
  • Page 26 Engine – Main dimensions 18 V 2000 G76 S Engine model Length (A) Width (B) Height (C) 18 V 2000 G76 S Approx. 2569 mm Approx. 1572 mm Approx. 1420 mm Table 3: Engine model / Dimensions 26 | Technical Data | MS150117/01E 2014-10...

  • Page 27: Operation

    4 Operation 4.1 Putting the engine into operation after extended out-of-service periods (>3 months) Preconditions ☑Engine is stopped and starting disabled. ☑MTU Fluids and Lubricants Specifications (A001061/..) are available. Putting into operation after long out-of-service periods (>3 months) Item Action Engine Depreserve (→...

  • Page 28: Putting The Engine Into Operation After Scheduled Out-Of-Service-Period

    4.2 Putting the engine into operation after scheduled out-of- service-period Preconditions ☑Engine is stopped and starting disabled. Putting into operation Item Action Lube oil system Check engine oil level (→ Page 73). Coolant circuit Check engine coolant level (→ Page 86), check charge-air coolant level (→...

  • Page 29: Starting The Engine

    4.3 Starting the engine Preconditions ☑Engine with no load. DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Before cranking the engine with starter system, make sure that there are no persons in the en- gine's danger zone.

  • Page 30: Operational Checks

    4.4 Operational checks DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running. Risk of damage to hearing! •...

  • Page 31: Engine Shutdown

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

  • Page 32: Emergency Engine Stop

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

  • Page 33: After Stopping The Engine - Putting The Engine Out Of Operation

    4.7 After stopping the engine – Putting the engine out of operation Preconditions ☑MTU Preservation and Represervation Specifications (A001070/..) are available. NOTICE Coolant sensors may freeze if there is a risk of frost. Risk of sensor damage! • Protect sensors from frost.

  • Page 34: Plant - Cleaning

    4.8 Plant – Cleaning Preconditions ☑Engine is stopped and starting disabled. ☑Operating voltage is not applied. Special tools, Material, Spare parts Designation / Use Part No. Qty. Steam jet cleaner Cleaner (Hakupur 312) 30390 WARNING Compressed air gun ejects a jet of pressurized air. Risk of injury to eyes and damage to hearing, risk of rupturing internal organs! •...

  • Page 35: Maintenance

    5 Maintenance 5.1 Maintenance task reference table [QL1], application group 3B 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 36: Maintenance Task Reference Table [Ql1], Application Group 3D

    5.2 Maintenance task reference table [QL1], application group 3D The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Maintenance Schedule is a stand-alone publication. The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule.

  • Page 37: Troubleshooting

    6 Troubleshooting 6.1 Troubleshooting Engine does not turn when starter is actuated Component Cause Action Battery Low or faulty Charge or replace (see manufacturer's documentation). Cable connections faulty Check if cable connections are properly secured (see manufacturer's documen- tation). Starter Engine cabling or starter faulty Check if cable connections are properly secured, contact Service.
  • Page 38 Faulty Contact Service. Charge-air temperature too high Component Cause Action Engine coolant Engine coolant treatment incorrect Check (MTU test kit). Intercooler Contaminated Contact Service. Engine room Air-intake temperature too high Check fans and intake/exhaust lines. Charge-air pressure too low Component...
  • Page 39 Blue exhaust gas Component Cause Action Engine oil Too much engine oil in the engine Drain engine oil (→ Page 74). Oil separator of crankcase breather con- Replace (→ Page 47). taminated Exhaust turbocharger, Faulty Contact Service. cylinder head, piston rings, cylinder liner White exhaust gas Component...

  • Page 40: 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 gear F6792910 Ratchet with extension F30006212 DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...

  • Page 41: Engine - Barring With Starting System

    7.1.2 Engine – Barring with starting system Preconditions ☑External pushbutton “Bar engine without starting” is provided. DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Before cranking the engine with starter system, make sure that there are no persons in the en- gine's danger zone.

  • Page 42: Engine - Test Run

    7.1.3 Engine – Test run DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Before cranking the engine with starter system, make sure that there are no persons in the en- gine's danger zone.

  • Page 43: 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. Barring device F6555766 Ratchet with extension F30006212 Endoscope Y20097353 Preparatory steps Remove cylinder head cover (→ Page 50). Remove injector (→...
  • Page 44 Compile endoscopic report using the table. Use technical terms to describe the liner surface (→ Page 45). Depending on findings: • Do not take any action or • carry out a further endoscopic examination as part of maintenance work or •...

  • Page 45: 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 ex- amination report. Findings Explanations/Action Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing products, particles, broken-off burrs).
  • Page 46 Evaluation of findings and further measures The findings in the start phase of oxidation discoloration and heat discoloration are similar. A thorough investigation and compliance with the above evaluation criteria allow an unambiguous evaluation. To avoid unnecessary disassembly work, it is recommended that another inspection be carried out after further operation of the engine.

  • Page 47: Crankcase Breather

    7.3 Crankcase Breather 7.3.1 Crankcase breather – Oil mist fine separator replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil Oil mist fine separator (→ Spare Parts Catalog) O-ring (→...

  • Page 48: 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. Valve clearance gage Y4345893 Barring gear F6792910...

  • Page 49: Valve Clearance Adjustment

    Check all valve clearances at two crankshaft positions (firing TDC and overlap TDC) according to the table below. Position Cylinder 16 V Firing TDC in cylinder A1 Bank A – X – X I – – X I – – – – – Bank B I –...

  • Page 50: 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 Torque wrench, 0.5–5 Nm 0015384230 Ratchet adapter F30027340 Engine oil Gasket (→...

  • Page 51: Injection Valve / Injector

    7.5 Injection Valve / Injector 7.5.1 Injector ‒ Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Injector (→ Spare Parts Catalog) Screw for hold-down clamp (→ Spare Parts Catalog) Replacing injector Remove injector and install new one (→ Page 52). MS150117/01E 2014-10 | Task Description | 51...

  • Page 52: Injector - Removal And Installation

    7.5.2 Injector – Removal and installation Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Press-fitting tool F6790085 Puller F6790636 Fuel suction device F30378207 Torque wrench, 20-100 Nm F30026582 Torque wrench, 0.5–5 Nm 0015384230 Ratchet adapter F30027340...
  • Page 53 Removing injector Remove HP fuel line (1). Unscrew union nut (2). Pull off pressure pipe neck (3). Extract fuel from the exposed bores using the suction device. Disconnect terminals (arrowed) on injector and pull out cable lugs. Remove gasket. Remove screw (3). Note: Screw (3) may be installed only once.
  • Page 54 Installing injector Remove all covers before installation. Clean sealing surface on cylinder head and protective sleeve. Coat sealing ring on injector (1) with as- sembly compound. Note: Use either the press-fitting tool or the hold- down clamp (2) to press injector (1) into the cylinder head.
  • Page 55 Tighten screw (3) for hold-down clamp (2) to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Screw Tightening torque (Engine oil) 40 Nm +4 Nm Tighten union nut (2) on pressure pipe neck (3) to specified torque using a torque wrench. Name Size Type...
  • Page 56 Tighten union nut of HP fuel line (1) on rail to specified torque using a torque wrench. a) For single-wall high-pressure fuel system Name Size Type Lubricant Value/Standard Union nut Tightening torque (Engine oil) 37 Nm +3 Nm b) For jacketed high-pressure fuel system Name Size Type...

  • Page 57: Injector Functions

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

  • Page 58: Fuel System

    7.6 Fuel System 7.6.1 HP fuel line and pressure pipe neck ‒ Replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 20-100 Nm F30026582 Ratchet adapter F30027340 Plug-in open-end wrench, 19 mm F30025897 Crowfoot wrench, 19 mm F30027424...
  • Page 59 Coat sealing ring of new pressure pipe neck (5) with assembly compound. Coat sealing cone of pressure pipe neck (5) with engine oil. Insert pressure pipe neck (5) into cylinder head until the sealing ring is in contact with cylinder head. Fully press in pressure pipe neck (5) by hand.

  • Page 60: Fuel System - Venting

    7.6.2 Fuel system – Venting Preconditions ☑Engine is stopped. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 6-50 Nm F30027336 Ring socket, 22 mm F30038494 WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. •...

  • Page 61: Fuel - Draining

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

  • Page 62: Fuel Filter

    7.7 Fuel Filter 7.7.1 Fuel filter – Replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Easy-change filter (→ Spare Parts Catalog) WARNING Fuels are combustible. Risk of fire and explosion! •...

  • Page 63: Fuel Prefilter - Differential Pressure Gage Check And Adjustment Of Gage

    7.7.2 Fuel prefilter – Differential pressure gage check and adjustment of gage DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running.

  • Page 64: Fuel Prefilter - Draining

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

  • Page 65: Fuel Prefilter - Flushing

    7.7.4 Fuel prefilter – Flushing Preconditions ☑Engine is stopped and starting disabled (only in the case of single fuel prefilter). Special tools, Material, Spare parts Designation / Use Part No. Qty. Fuel Gasket (→ Spare Parts Catalog) DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...

  • Page 66: Fuel Prefilter – Filling With Fuel

    Open vent plug (5) of the filter to be flush- Unlock drain valve (6) by pressing toggle, open it and drain fuel. Result: Fuel flows from filtered side back to the un- filtered side, flushing the filter deposits downwards out of the filter. Close vent plug (5) and drain valve (6).

  • Page 67: Fuel Prefilter - Filter Element Replacement

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

  • Page 68: Air Filter

    7.8 Air Filter 7.8.1 Air filter – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Air filter (→ Spare Parts Catalog) Filter insert (→ Spare Parts Catalog) Filter element (→ Spare Parts Catalog) Air filter – Replacement Remove air filter(s) and install new one(s) (→...

  • Page 69: Air Filter - Removal And Installation

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

  • Page 70: Air Intake

    7.9 Air Intake 7.9.1 Service indicator – Signal ring position check Preconditions ☑Engine is stopped and starting disabled. Checking signal ring position If the signal ring is completely visible in the control window (2), replace air filter (→ Page 68). After installation of new filter, press reset button (1).

  • Page 71: Exhaust Gas Recirculation

    7.10 Exhaust Gas Recirculation 7.10.1 Exhaust gas recirculation flaps – Overview MS150117/01E 2014-10 | Task Description | 71...

  • Page 72: Exhaust Gas Recirculation - Checking Flap Operation

    7.10.2 Exhaust gas recirculation ‒ Checking flap operation Preconditions ☑Engine is stopped and starting disabled. WARNING Component is hot. Risk of burning! • Wear protective gloves. WARNING Exhaust flaps close automatically. Danger of crushing hands! • Keep clear of the danger zone around the exhaust flaps when calibrating. •...

  • Page 73: Lube Oil System, Lube Oil Circuit

    7.11 Lube Oil System, Lube Oil Circuit 7.11.1 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 74: Engine Oil - Change

    7.11.2 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 75: Oil Filtration / Cooling

    7.12 Oil Filtration / Cooling 7.12.1 Engine oil filter – Replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Engine oil Oil filter (→ Spare Parts Catalog) WARNING Hot oil.

  • Page 76: Centrifugal Oil Filter - Cleaning And Filter-Sleeve Replacement

    7.12.2 Centrifugal oil filter – Cleaning and filter-sleeve replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 8-40 Nm F30043446 Cold cleaner (Hakutex 60) X00056750 Filter sleeve (→ Spare Parts Catalog) Sealing ring (→...
  • Page 77 Tighten nut (2) to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Tightening torque 8 Nm + 1 Nm Fit housing cover (1). Screw on nuts (4). Tighten nuts (4) to specified torque using a torque wrench. Name Size Type...

  • Page 78: Coolant Circuit, General, High-Temperature Circuit

    7.13 Coolant Circuit, General, High-Temperature Circuit 7.13.1 Drain and vent points Plan view 16 V 2000 G56 S 1 Coolant vent LT circuit 2 Coolant vent HT circuit 78 | Task Description | MS150117/01E 2014-10...
  • Page 79 Left side 16 V 2000 G56 S 1 Coolant drain plug, crank- 2 Coolant drain plug, crank- case free end case driving end MS150117/01E 2014-10 | Task Description | 79...
  • Page 80 Right side 16 V 2000 G56 S 1 Coolant drain plug, crank- 3 Coolant drain plug HT case driving end pump 2 Coolant drain plug, crank- 4 Coolant drain plug LT case free end pump 80 | Task Description | MS150117/01E 2014-10...
  • Page 81 Free end 16 V 2000 G56 S 1 Coolant drain plug, lube-oil 2 Coolant filling plug 3 Coolant drain plug heat exchanger MS150117/01E 2014-10 | Task Description | 81...
  • Page 82 Plan view 18 V 2000 G76 S 1 Coolant vent HT circuit 2 Coolant vent HT circuit 3 Coolant vent HT circuit 82 | Task Description | MS150117/01E 2014-10...
  • Page 83 Left side 18 V 2000 G76 S 1 Coolant drain plug, crank- 2 Coolant drain plug, crank- case driving end case free end MS150117/01E 2014-10 | Task Description | 83...
  • Page 84 Right side 18 V 2000 G76 S 1 Engine coolant drain plug 2 Coolant drain plug, crank- 3 Coolant drain plug, crank- case free end case driving end 84 | Task Description | MS150117/01E 2014-10...
  • Page 85 Free end 18 V 2000 G76 S 1 Coolant drain plug, lube-oil heat exchanger MS150117/01E 2014-10 | Task Description | 85...

  • Page 86: Engine Coolant – Level Check

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

  • Page 87: Engine Coolant – Change

    7.13.3 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change Drain engine coolant (→ Page 88). Fill with engine coolant (→ Page 90). MS150117/01E 2014-10 | Task Description | 87...

  • Page 88: Engine Coolant ‒ Draining

    7.13.4 Engine coolant ‒ Draining Preconditions ☑Engine is stopped and starting disabled. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask. Preparatory steps Provide a suitable container to catch the coolant.
  • Page 89 Draining engine coolant 18V Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to escape. Continue to turn breather valve counter- clockwise and remove. Draw off precipitated corrosion inhibitor oil from the coolant expansion tank through filler neck.

  • Page 90: Engine Coolant – Filling

    7.13.5 Engine coolant – Filling Preconditions ☑Engine is stopped and starting disabled. ☑MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...
  • Page 91 Final steps Start the engine and operate it at idle speed for some minutes. Check coolant level (→ Page 86), top up with coolant if required. MS150117/01E 2014-10 | Task Description | 91...

  • Page 92: Engine Coolant Pump – Relief Bore Check

    7.13.6 Engine coolant pump – Relief bore check DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running.

  • Page 93: Engine Coolant – Sample Extraction And Analysis

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

  • Page 94: Low-Temperature Circuit

    7.14 Low-Temperature Circuit 7.14.1 Intercooler – Vent and drain points Intercooler – Vent and drain points 1 LT circuit vent connection 2 HT circuit vent connection 3 Coolant drain plug LT pump 94 | Task Description | MS150117/01E 2014-10...

  • Page 95: Intercooler – Checking Condensate Drain For Coolant Discharge And Obstructions

    7.14.2 Intercooler – Checking condensate drain for coolant discharge and obstructions Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Sealing ring (→ Spare Parts Catalog) WARNING Compressed air gun ejects a jet of pressurized air. Risk of injury to eyes and damage to hearing, risk of rupturing internal organs! •...

  • Page 96: Charge-Air Coolant – Level Check

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

  • Page 97: Charge-Air Coolant – Change

    7.14.4 Charge-air coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Charge-air coolant – Change Drain charge-air coolant (→ Page 100). Fill with charge-air coolant (→ Page 98). MS150117/01E 2014-10 | Task Description | 97...

  • Page 98: Charge-Air Coolant – Filling

    7.14.5 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 99 Final steps Start the engine and operate it at idle speed for some minutes. Check coolant level (→ Page 96). MS150117/01E 2014-10 | Task Description | 99...

  • Page 100: Charge-Air Coolant ‒ Draining

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

  • Page 101: Charge-Air Coolant Pump – Relief Bore Check

    7.14.7 Charge-air coolant pump – Relief bore check DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running.

  • Page 102: Coolant System

    7.15 Coolant System 7.15.1 Cooler – Checking cooler elements externally for dirt Preconditions ☑Engine is stopped and starting disabled. Checking cooler elements externally for dirt Visually inspect cooler elements for dirt. Clean badly soiled cooler elements (→ Page 103). 102 | Task Description | MS150117/01E 2014-10...

  • Page 103: Cooler – Cleaning Cooler Elements

    7.15.2 Cooler – Cleaning cooler elements Preconditions ☑Engine is stopped and starting disabled. WARNING Compressed air gun ejects a jet of pressurized air. Risk of injury to eyes and damage to hearing, risk of rupturing internal organs! • Never direct air jet at people. •...

  • Page 104: Belt Drive

    7.16 Belt Drive 7.16.1 Drive belt – Condition check Preconditions ☑Engine is stopped and starting disabled. ☑Guard is removed. Drive belt – Condition check Item Findings Action Drive belt A Singular cracks None Drive belt B Cracks on entire circumference Replace (→...

  • Page 105: Drive Belt – Tension Check

    7.16.2 Drive belt – Tension check Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Tester Y4345711 Belt tension tester, 150-600 N Y20097429 Checking belt tension – Fan drive 16V Checking belt tension – Fan drive 18V MS150117/01E 2014-10 | Task Description | 105...
  • Page 106 Measuring depression depth with belt tension tester Note: The frequency measurement procedure is the preferred one because it provides more exact results. Remove protective cover. Set belt tension tester onto the drive belt in the middle between the belt pulleys (arrowed). Using pushbutton, press vertically on top side of drive belt exerting even pressure until spring engages noticeably.
  • Page 107 Measuring belt tension with frequency meter Remove protective cover. Tap against the belt with the handle of a hammer or with a wrench to initiate belt vibration. Hold measuring tip of the frequency meter over belt drive. The measured frequency value appears in the display of the frequency meter. Compare measured value with value in the table.

  • Page 108: Drive Belt ‒ Tension Adjustment

    7.16.3 Drive belt ‒ Tension adjustment Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 20-100 Nm F30026582 Ratchet adapter F30027340 Torque wrench, 40-200 Nm F30027337 Engine oil Drive belt ‒ Tension adjustment Remove protective cover.
  • Page 109 Tighten screw (2) to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Screw M16 x Tightening torque (Engine oil) 50 Nm +5 Nm Release screws (3) and (4) a little. Adjust belt tension acc. to specifications with screw (5) (→ Page 105). Turn crankshaft through two revolutions with barring gear.
  • Page 110 Install protective grill on fan. Install protective cover on cooler. 110 | Task Description | MS150117/01E 2014-10...

  • Page 111: Drive Belt – Replacement

    7.16.4 Drive belt – Replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Drive belt (→ Spare Parts Catalog) Fan drive – Drive belt replace- ment 16V Remove protective cover from cooler. Remove protective grill from fan.
  • Page 112 Fan drive – Drive belt replace- ment 18V Remove protective cover from cooler. Remove protective grill from fan. Remove fan. Slacken off securing screws (1). Screw out screw (2) as far as necessary to allow drive belt removal. Check belt pulley on radiator bearing mount and crankshaft for contamination and clean if necessary.

  • Page 113: Battery-Charging Generator

    7.17 Battery-Charging Generator 7.17.1 Battery-charging generator drive – Drive belt replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Tester Y4345711 Belt tension tester, 150-600 N Y20097429 Engine oil Drive belt (→...
  • Page 114 Drive belt replacement 18V When fitting for the first time: Wet running surfaces of generator mount (2) with oil. When retensioning: Undo screws (1) and drip oil into the gap between gearcase (3) and generator mount (2). Remove drive belt. Check cleanness of belt pulleys.

  • Page 115: Engine Governor

    7.18 Engine Governor 7.18.1 Engine governor – Overview Engine governor 16V – Overview 1 Screw 4 Engine governor 7 Connector X2 2 Damper 5 Connector X3 8 Screw for grounding strap 3 Washer 6 Screw MS150117/01E 2014-10 | Task Description | 115...
  • Page 116 Engine governor 18V – Overview 1 Connector X2 3 Connector X3 5 Screw 2 Engine governor 4 Washer 6 Damper 116 | Task Description | MS150117/01E 2014-10...

  • Page 117: Engine Governor – Removal And Installation

    7.18.2 Engine governor – Removal and installation Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine governor Resilient mount (→ Spare Parts Catalog) NOTICE Wrong engine governor installed. Engine damage! •...
  • Page 118 Removing engine governor from engine 18V Note or mark assignment of cables and connectors. Release latches on connectors (1) and (3). Disconnect all connectors. Remove all screws (5). Remove engine governor (2). 118 | Task Description | MS150117/01E 2014-10...

  • Page 119: Engine Governor Plug Connections – Check

    7.18.3 Engine governor plug connections – Check Preconditions ☑Engine stopped and starting disabled. NOTICE Insertion of unsuitable test probe, e.g. test prod. The contacts in the plug connection can be bent! • Carry out check of plug connection only with test connectors. Checking plug connections at engine governor Check all plug connections for secure seating.

  • Page 120: Wiring (General) For Engine/Gearbox/Unit

    7.19 Wiring (General) for Engine/Gearbox/Unit 7.19.1 Еngine cabling ‒ Check Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Solvent (isopropyl alcohol) X00058037 Еngine cabling ‒ 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 121: Lambda, Nox And Humidity Sensors Overview

    7.19.2 Lambda, NOx and humidity sensors – Overview 1 Humidity sensor 2 Lambda sensor 3 NOx sensor MS150117/01E 2014-10 | Task Description | 121...

  • Page 122: Lambda Sensor – Replacement

    7.19.3 Lambda sensor – Replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10-60 Nm F30452769 Ratchet adapter F30027340 Assembly compound (Molykote P 37) 50564 Lambda sensor (→ Spare Parts Catalog) WARNING Component is hot.
  • Page 123 Installing Lambda sensor Note: If the sensor was subjected to shock or im- pact load, it is considered to be defective and may not be used. Remove protective cap on thread only just before installation. Note: Do not wipe off the thread lubricant applied by the manufacturer.

  • Page 124: Nox Sensor – Replacement

    7.19.4 NOx sensor – Replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10-60 Nm F30452769 Ratchet adapter F30027340 Assembly compound (Molykote P 37) 50564 NOx sensor (→ Spare Parts Catalog) WARNING Component is hot.
  • Page 125 Note: Always only replace NOx sensor together with control unit. Installing NOx sensor Note: Install control unit. Note: If the sensor was subjected to shock or im- pact load, it is considered to be defective and may not be used. Remove protective cap on thread only just before installation.

  • Page 126: Humidity Sensor – Replacement

    7.19.5 Humidity sensor – Replacement Preconditions ☑Engine is stopped and starting disabled. ☑Preparatory steps completed. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10-60 Nm F30510423 Ratchet adapter F30027340 Assembly compound (Kluthe Hakuform 30-15) X00067260 Humidity sensor (→...
  • Page 127 Installing humidity sensor Note: Apply assembly compound for O-ring spar- ingly. Insert sensor (2) in bore, ensuring correct installation position. Note: Observe air flow direction. Screw in screws (1). Tighten screws (1) to specified torque using a torque wrench. Name Size Type Lubricant...

  • Page 128: Accessories For (Electronic) Engine 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. Solvent (isopropyl alcohol) X00058037 Note: Always use test connectors to enter the connectors. Never use test leads for this purpose. Otherwise the contacts could be bent.

  • Page 129: Engine Governor Plug Connections – Check

    7.20.2 Engine governor plug connections – Check Preconditions ☑Engine stopped and starting disabled. NOTICE Insertion of unsuitable test probe, e.g. test prod. The contacts in the plug connection can be bent! • Carry out check of plug connection only with test connectors. Checking plug connections at engine governor Check all plug connections for secure seating.

  • Page 130: List Of Abbreviations

    Abgasturbolader Exhaust turbocharger (ETC) Backup Data Module Baureihe Series Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Publication No. A01061/.. Controller Area Network Data bus system, bus standard Controllable Pitch Propeller Deutsches Institut für Normung e. V. At the same time identifier of German standards (DIN = “Deutsche Industrie-Norm”)
  • Page 131 Abbrevia- Meaning Explanation tion Monitoring and Control System Message Microprocessor Unit, Microprocessing Unit Oberer Totpunkt Top dead center (TDC) Panel Control panel PCU/PMU Propeller Control Unit Propeller controller Peripheral Interface Module Priming Pump Control Remote Control System Redundancy Lost Alarm: Redundant CAN bus failure Sea Acceptance Test Sensor Defect Alarm: Sensor failure...

  • Page 132: 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 133: Special Tools

    9 Appendix B 9.1 Special Tools Barring device Part No.: F6555766 Qty.: Used in: 7.2.1 Cylinder liner – Endoscopic examination (→ Page 43) Barring gear Part No.: F6792910 Qty.: Used in: 7.1.1 Engine – Barring manually (→ Page 40) Qty.: Used in: 7.4.1 Valve clearance –...
  • Page 134 Crowfoot wrench, 19 mm Part No.: F30027424 Qty.: Used in: 7.5.2 Injector – Removal and installation (→ Page 52) Qty.: Used in: 7.6.1 HP fuel line and pressure pipe neck ‒ Replace- ment (→ Page 58) Double box wrench Part No.: F30002800 Qty.: Used in:...
  • Page 135 Measuring device Part No.: Y4348409 Qty.: Used in: 7.4.1 Valve clearance – Check and adjustment (→ Page 48) MTU test kit Part No.: 5605892099/00 Qty.: Used in: 7.13.7 Engine coolant – Sample extraction and analysis (→ Page 93) MS150117/01E 2014-10 | Appendix B | 135...
  • Page 136 Offset screwdriver Part No.: F30453001 Qty.: Used in: 7.4.1 Valve clearance – Check and adjustment (→ Page 48) Plug-in open-end wrench, 19 mm Part No.: F30453236 Qty.: Used in: 7.5.2 Injector – Removal and installation (→ Page 52) Plug-in open-end wrench, 19 mm Part No.: F30025897 Qty.:...
  • Page 137 Press-fitting tool Part No.: F6790085 Qty.: Used in: 7.5.2 Injector – Removal and installation (→ Page 52) Puller Part No.: F6790636 Qty.: Used in: 7.5.2 Injector – Removal and installation (→ Page 52) Ratchet adapter Part No.: F30027340 Qty.: Used in: 7.4.2 Cylinder head cover –...
  • Page 138 Ratchet with extension Part No.: F30006212 Qty.: Used in: 7.1.1 Engine – Barring manually (→ Page 40) Qty.: Used in: 7.2.1 Cylinder liner – Endoscopic examination (→ Page 43) Qty.: Used in: 7.4.1 Valve clearance – Check and adjustment (→ Page 48) Ring socket, 22 mm Part No.: F30038494...
  • Page 139 Steam jet cleaner Part No.: Qty.: Used in: 4.8 Plant – Cleaning (→ Page 34) Tester Part No.: Y4345711 Qty.: Used in: 7.16.2 Drive belt – Tension check (→ Page 105) Qty.: Used in: 7.17.1 Battery-charging generator drive – Drive belt re- placement (→...
  • Page 140 Torque wrench, 10-60 Nm Part No.: F30452769 Qty.: Used in: 7.19.3 Lambda sensor – Replacement (→ Page 122) Qty.: Used in: 7.19.4 NOx sensor – Replacement (→ Page 124) Torque wrench, 20-100 Nm Part No.: F30026582 Qty.: Used in: 7.5.2 Injector – Removal and installation (→ Page 52) Qty.: Used in: 7.6.1 HP fuel line and pressure pipe neck ‒...
  • Page 141 Torque wrench, 8-40 Nm Part No.: F30043446 Qty.: Used in: 7.12.2 Centrifugal oil filter – Cleaning and filter-sleeve replacement (→ Page 76) Torque wrench, 8–40 Nm Part No.: F30043446 Qty.: Used in: 7.4.2 Cylinder head cover – Removal and installation (→...

  • Page 142: Index

    – Drive   – Replacement  111 Data  Belt drive  – Engine   – Tension adjustment  108 – 16 V 2000 G56 S  17 – Tension check  105 – 18 V 2000 G76 S  21 Differential pressure gage  – Adjustment  ...
  • Page 143 – Maintenance task reference table [QL1]   – Function check  72 – Application group 3B  35 – Overview  71 – Application group 3D  36 Fuel  MTU contact persons 132 – Draining  61 Fuel filter  – Replacement  62 NOx sensor  Fuel prefilter  – Overview  121...
  • Page 144 Plant  – Cleaning  34 Pressure pipe neck  – Replacement  58 Pump  – Charge-air coolant   – Relief bore check  101 – Engine coolant   – Relief bore check  92 Putting into operation  – After scheduled out-of-service period   – Preparation  28 Putting the engine into operation after extended out-of- service periods (>3...

This manual is also suitable for:

18 v 2000 g76 s

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