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MTU 10 V 2000 M84, Operating Instructions Manual

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MTU 10 V 2000 M84 Operating Instructions Manual Download Page 80

7.6.2 Injector – Removal and installation

Preconditions

☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use

Part No.

Qty.

Socket wrench

0005896803/00

1

Puller

F6790629

1

Double box wrench

F30011450

1

Open end wrench bit

F30025897

1

Box wrench adapter

F30451199

1

Alignment device

F6790507

1

Grease (Kluthe Hakuform 30-10/Emulgier)

X00029933

1

Engine oil

WARNING

Fuels are combustible.

Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

Preparatory steps

1.

Close fuel supply to engine.

2.

Remove cylinder head cover (→ Page 78).

Removing injector

1.

Remove HP line (5) using socket wrench.

2.

Disconnect injector cable (4).

3.

Remove screw (2).

4.

Take off hold-down clamp (3).

5.

Remove injector (1) with puller.

6.

Remove O-rings from injector.

7.

Mask all connections and bores or seal with

suitable plugs.

80 | Task Description | MS150062/01E 2012-01

TIM-ID: 0000004650 - 002

Summary of Contents for 10 V 2000 M84

Page 1: ...Operating Instructions Diesel engine 8 V 2000 M84 10 V 2000 M84 MS150062 01E...

Page 2: ...ten 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 on...

Page 3: ...ing the engine 50 4 12 Fuel treatment system Shutdown 51 4 13 Plant Cleaning 52 5 Maintenance 5 1 Maintenance task reference table QL1 53 6 Troubleshooting 6 1 Fuel treatment system Troubleshooting 54...

Page 4: ...114 7 15 8 Coolant filter Replacement 115 7 16 Raw Water Pump with Connections 116 7 16 1 Raw water pump Relief bore check 116 7 17 Belt Drive 117 7 17 1 Drive belt Condition check 117 7 18 Battery C...

Page 5: ...it on delivery Any other use is considered improper use The engine manufacturer accepts no liability whatsoever for resultant damage or injury in such case The responsibility is borne by the user alon...

Page 6: ...accessible to operating maintenance repair and transport personnel at all times Use the manual as a basis for instructing personnel on engine operation and repair In particular person nel must have r...

Page 7: ...llustration is essentially valid for 8V 2000 M engines Illustration is essentially valid for 12 16V 2000 M engines Transport with flange mounted gearbox Illustration is essentially valid for 8V 2000 M...

Page 8: ...ft the engine The eyebolts mounted at the driving end and on the gearbox must not be used for transporting plants with flange mounted gearboxes Only use transport and lifting devices approved by MTU T...

Page 9: ...rews for the engine mounts prior to engine trans portation Secure the engine against tilting during transport In particular when going down inclines or ramps the engine must be secured against moving...

Page 10: ...ing units must be permanently observed with re gard to present operating status violation of limit values and warning or alarm messages The following steps must be taken if a malfunction of the system...

Page 11: ...ons clean Always seal connections with caps or covers if a line is removed or opened Take care not to damage lines in particular fuel lines during maintenance and repair work Ensure that all retainers...

Page 12: ...aft end until correct sealing is established During hydraulic installation and removal ensure that nobody is standing in the immediate vicinity of the component to be installed removed Working on elec...

Page 13: ...used Laser devices of classes 1 2 or 3A Laser devices of class 3B which have maximum output in the visible wavelength range 400 to 700 nm a maximum output of 5 mW and in which the beam axis and surfac...

Page 14: ...emission regulations Emission control units systems may only be main tained exchanged or repaired if the components used for this purpose are approved by MTU or equiva lent components Noncompliance wi...

Page 15: ...danger class AI AII and B out of containers results in a risk of explosion Forcing compressed air into thin walled containers e g containers made of tin plastic and glass for drying purposes or to ch...

Page 16: ...on involving potentially adverse effects on the product Consequences Material damage Remedial action Additional product information Note This manual contains highlighted safety warnings in accordance...

Page 17: ...and those of the right side with B as per DIN ISO 1204 The cylinders of each bank are numbered consecutively starting with No 1 at the en gine s driving end Other components are numbered in the same...

Page 18: ...xhaust system is equipped with triple walled water cooled exhaust lines The triple walled design permits low surface temperature reduced thermal load absolute gas tightness Lube oil system Wet sump fo...

Page 19: ...l pressure Differential oil pressure Coolant temperature Coolant level Exhaust turbocharger speed Leak fuel level Oil temperature Coolant pressure Fuel pressure after filter Monitoring in engine room...

Page 20: ...ay Only leak off along the line is possible the pressure is decreased significantly if an O ring 3 defect oc curs The connection is confirmed as compliant with SOLAS by DNV and GL Plugs and sensors Sc...

Page 21: ...2 that any leakage is not under pressure HP line between fuel injector and HP accumulator 1 Support ring 2 V ring 3 Thrust ring 4 Union nut 5 HP line 6 Thrust screw 7 Thrust ring 8 V ring 9 Support r...

Page 22: ...een distributor and HP accumulator 1 Union nut 2 O ring 3 Thrust ring 4 Thrust screw 5 O ring 6 O ring 7 Thrust ring 8 Pressure pipe 9 Jacket pipe 22 General Information MS150062 01E 2012 01 TIM ID 00...

Page 23: ...6 Thrust ring 7 O ring 8 HP line 9 Pressure pipe 10 O ring Leak fuel caused by leakages from the sealing cones or the HP lines is returned to the HP pump from where it is routed at atmospheric pressu...

Page 24: ...il separator 9 Actuating cylinder 10 2 2 way solenoid 11 4 2 way solenoid valve 12 Starter 13 Battery charging genera tor 14 Raw water connection to gearbox cooling system 15 Raw water pump 16 Raw wat...

Page 25: ...Flywheel 13 Flywheel housing 14 Auxiliary PTO 15 Carrier housing lower section 16 Carrier housing middle section 17 Relief valve 18 Exhaust outlet KS engine driving end Engine model designation Key t...

Page 26: ...jectors Overview Top view No Description Monitoring of 1 B10 Charge air pressure 2 B9 Charge air temperature 3 B7 Lube oil temperature 4 B3 Intake air temperature 26 General Information MS150062 01E 2...

Page 27: ...3 option Lube oil pressure before filter 3 B5 1 Lube oil pressure 4 B5 2 optional Lube oil pressure 5 F33 Coolant level 6 B21 optional Raw water pressure 7 B6 2 optional Coolant pressure 8 B6 1 Coola...

Page 28: ...onitoring of 1 B4 22 Exhaust temperature B side 2 B1 Camshaft speed 3 B13 Crankshaft speed 4 B13 2 option Crankshaft speed 5 B4 21 Exhaust gas temperature A side 28 General Information MS150062 01E 20...

Page 29: ...ription Monitoring of 1 B44 Turbocharger speed 2 B33 Fuel temperature 3 B48 Fuel pressure in Common Rail 4 B16 optional Coolant pressure 5 F46 Leak fuel level MS150062 01E 2012 01 General Information...

Page 30: ...7 B54 optional Oil replenishment pump pressure System sensors The sensors are fitted on the off engine system Description Monitoring of B19 Starting air pressure B70 Water level in fuel prefilter B41...

Page 31: ...1000 Site altitude above sea level m 100 Power related data power ratings are net brake power as per ISO 3046 Number of cylinders 8 Rated engine speed A rpm 2450 Fuel stop power ISO 3046 A kW 810 Gene...

Page 32: ...en engine is starting L bar 0 25 Fuel supply flow max A Liters min 5 2 General operating data Number of cylinders 8 Firing speed from R rpm 100 Firing speed to R rpm 120 Starter electric Number of cyl...

Page 33: ...Liters 54 Oil pan capacity at dipstick mark max standard oil system Option max operating inclinations L Liters 62 Weights main dimensions Number of cylinders 8 Engine dry weight with standard accesso...

Page 34: ...te altitude above sea level m 100 POWER RELATED DATA performance refers to net brake power as per ISO 3046 Number of cylinders 10 Engine rated speed A rpm 2450 Fuel stop power ISO 3046 A kW 1015 GENER...

Page 35: ...hen engine is starting L bar 0 25 Fuel supply flow max R Liter min 5 9 GENERAL OPERATING DATA Number of cylinders 10 Firing speed from R rpm 100 Firing speed to R rpm 120 STARTER electric Number of cy...

Page 36: ...ax standard oil system Option max operating inclinations L liters 70 WEIGHTS MAIN DIMENSIONS Number of cylinders 10 Engine dry weight with attached standard accessories without coupling R kg 2230 ACOU...

Page 37: ...order 8V A1 B4 A4 A2 B3 A3 B2 B1 10 V A1 B4 A4 B3 A3 B2 A2 B5 A5 B1 12 V A1 B5 A5 B3 A3 B6 A6 B2 A2 B4 A4 B1 16 V A1 B5 A3 A5 B2 B8 A2 A8 B3 A7 B4 B6 A4 A6 B1 B7 MS150062 01E 2012 01 Technical Data 3...

Page 38: ...M93 approx 1860 mm approx 1147 mm approx 1320 mm 10V 2000 M84 approx 1860 mm approx 1147 mm approx 1320 mm 10V 2000 M94 approx 1860 mm approx 1147 mm approx 1320 mm 12V 2000 M92 approx 2069 mm approx...

Page 39: ...e oil system Check engine oil level Page 96 Fuel prefilter Fill with fuel Page 89 Fuel prefilter pressure gauge Align adjustable pointer with position of pressure indicator Page 85 Fuel system Vent Pa...

Page 40: ...Item Measure Lube oil system Check engine oil level Page 96 Coolant circuit Check coolant level Page 109 Coolant circuit Heat engine coolant with coolant preheating unit Fuel prefilter Drain water and...

Page 41: ...eks Tasks after extended out of service periods 3 weeks Note Operate fuel treatment system for at least 5 minutes 1 Start up fuel treatment system Page 43 2 Shut down fuel treatment system Page 51 MS1...

Page 42: ...ves 4 Switch on fuel treatment system Page 46 5 Check direction of rotation of pump 6 Vent bypass and fuel lines of the system a Open ball valve for pressure tank b Open ball valve for overflow tank c...

Page 43: ...ne 3 Switch on fuel treatment system and operate it for some minutes Page 46 Result Fuel is sucked from the tank dirt particles and water are filtered and separated then the fuel is delivered via the...

Page 44: ...ency HAT 1 Switch on fuel treatment system Page 46 2 Start engine Page 47 3 Run engine at idling speed 4 Switch off pump 21 on switch cabinet Result The engine mounted fuel delivery pump sucks fuel vi...

Page 45: ...l running noises and vibration Check exhaust color Page 55 Fuel prefilter Check fuel prefilter contamination indicator for max admissible value Page 85 Drain water and contaminants Page 86 Air filter...

Page 46: ...hing on ensure that all housings are closed Before switching on ensure that no work is in progress anywhere on the entire system Switching on fuel treatment system 1 Carry out checks prior to start up...

Page 47: ...y is in the danger zone WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors The engine can be started from the following points Item Action Control stand Operating instruc...

Page 48: ...ntil engine temperatures have dropped and constant values are displayed The engine can be stopped from the following points 1 Operating instructions for electronic system 2 Commanding control stand Op...

Page 49: ...be initiated from the following points 1 Operating instructions for electronic system 2 Commanding control stand Operating instructions for electronic system 3 Local operating panel LOP Operating inst...

Page 50: ...at a suitable temperature the antifreeze concentration is insufficient for the engine room tempera ture antifreeze concentration is 50 and engine room temperature is below 40 C Raw water Drain If free...

Page 51: ...inet until water discharge from the outlet stops 2 Switch off fuel treatment system 3 Close ball valve at the inlet to the fuel treatment system 4 Close ball valve at the outlet of the fuel treatment...

Page 52: ...sensors with compressed air Plant Cleaning 1 Carry out plant cleaning only in areas where an appropriate oil separator is provided environmental pro tection 2 Prior to putting the cleaning unit into...

Page 53: ...86 W0508 Check reading on differential pressure gauge of fuel prefilter if fitted Page 85 W1001 Replace fuel filter or fuel filter element Page 83 W1002 Check valve clearance Page 75 W1005 Replace air...

Page 54: ...d with an overload protection If the maximum permissible current consumption is exceeded e g in case of a blockage or dry run ning the motor protection relay triggers and the pump is switch ed off u R...

Page 55: ...arter Battery low or defective Charge or replace battery see manu facturer s documentation Engine wiring Defective Check Page 125 Fuel system Not vented Vent fuel system Page 82 ECU Defective Contact...

Page 56: ...Contaminated Contact Service Exhaust turbocharger Defective Contact Service Coolant leaks on intercooler Component Probable Cause Task Intercooler Leaking major coolant discharge Contact Service Exhau...

Page 57: ...se Task Engine Not at operating temperature Run engine to reach operating temper ature Fuel system Water in fuel Drain fuel prefilter Page 86 Intercooler Leaking Contact Service MS150062 01E 2012 01 T...

Page 58: ...ols Material Spare parts Designation Use Part No Qty Shield A4 735233000100 5 Shield A5 735233000101 7 Shield A7 735233000103 6 Shield A8 735233000104 2 Installing SOLAS shielding 1 Pinpoint installat...

Page 59: ...t temperature Special tools Material Spare parts Designation Use Part No Qty Oil filter shield X00009628 Fuel filter shield X00009654 Installing SOLAS shield on oil filter and fuel filter 1 Pinpoint i...

Page 60: ...neral information Primarily fit SOLAS shielding as per MTN 5233 Page 58 On crankcase Item Type of shielding Remarks 1 Shield A4 On brazed on union 2 Shield A5 On crankcase Free end B side 60 Task Desc...

Page 61: ...Remarks 1 Free end B side Shield A7 On fuel delivery pump Free end B side Item Type of shielding Remarks 1 Free end B side Shield A7 On HP fuel pump Free end MS150062 01E 2012 01 Task Description 61...

Page 62: ...ove fuel priming pump Free end Item Type of shielding Remarks 1 Free end Shield A7 Below fuel priming pump Free end Item Type of shielding Remarks 1 Free end Shield A8 On fuel filter housing 62 Task D...

Page 63: ...Driving end A side Item Type of shielding Remarks 1 Driving end Shield A5 On valve plate Driving end A side MS150062 01E 2012 01 Task Description 63 TIM ID 0000010065 006...

Page 64: ...ving end Shield A5 On exhaust turbocharger flap control 4 Driving end Shield A5 On exhaust turbocharger flap control Driving end Item Type of shielding Remarks 1 Driving end Shield A4 Exhaust turbocha...

Page 65: ...Driving end Item Type of shielding Remarks 1 Driving end Shield A4 Exhaust turbocharger lubrication MS150062 01E 2012 01 Task Description 65 TIM ID 0000010065 006...

Page 66: ...body is in the danger zone After working on the engine check that all protective devices have been reinstalled and all tools removed from the engine Engine Barring manually 1 Fit ratchet with barring...

Page 67: ...e barring or starting the engine ensure that nobody is in the danger zone After working on the engine check that all protective devices have been reinstalled and all tools removed from the engine Barr...

Page 68: ...ns First signs of marks left by lower cooling bores Running pattern seems darker No action required Dark areas with even or varying degrees of discoloration Beginning and end of the discoloration are...

Page 69: ...Final steps 1 Install injector Page 80 2 Install cylinder head cover Page 78 MS150062 01E 2012 01 Task Description 69 TIM ID 0000000015 013...

Page 70: ...moothened areas appear brighter and more brilliant than the surrounding running surface Findings not critical Bright area Bright areas are on the running surface and show local removal of the honing p...

Page 71: ...ion starting in TDC ring 1 have to be replaced Seizure marks scuff ing Irregular circumference lengths and depths Can be caused either by the pis ton skirt or the piston crown Material deposits on the...

Page 72: ...ARNING Compressed air Risk of injury Do not direct compressed air jet at persons Wear protective goggles safety mask and ear protectors Crankcase breather Cleaning oil separator element 1 Remove cover...

Page 73: ...e harmful to health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Replacing filter element of oil separator 1 Rem...

Page 74: ...nstall diaphragm 3 on housing 1 6 Install new gasket 2 and spring 5 togeth er with cover 4 7 Tighten screws of cover 4 to specified tightening torque Name Size Type Lubricant Value Standard Screw Tigh...

Page 75: ...gine direction of rotation until the marking on the flywheel is aligned with the center of the sensor seat Checking valve clearance at two crankshaft positions 1 Check TDC position of piston in cylind...

Page 76: ...7 8 9 Firing TDC in cylinder A1 Bank A E A A A E A E Bank B E A E E A E E A A Overlap TDC in cylinder A1 Bank A E E A E A E A E A Bank B A E E A A A E E inlet valve clearance adjustment permitted A e...

Page 77: ...rench to the prescribed tightening torque of 50 Nm while holding the adjusting screw 2 with screwdriver 5 Insert feeler gauge between valve bridge and rocker arm to verify that the gauge just passes t...

Page 78: ...d cover Removal and installation 1 Remove screws 1 2 Remove cylinder head cover 2 with gas ket from cylinder head 3 Clean mating faces 4 Check condition of gasket of cylinder head cover Result Replace...

Page 79: ...7 6 1 Injector Replacement Special tools Material Spare parts Designation Use Part No Qty Injector Spare Parts Catalog Remove injector and install new one u Page 80 MS150062 01E 2012 01 Task Descript...

Page 80: ...gier X00029933 1 Engine oil WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Preparatory steps 1 Close fuel supply to engi...

Page 81: ...and injector 1 with engine oil 9 Align injector 1 and HP line 5 with alignment device 10 Connect HP line 5 to HP accumulator and tighten by hand 11 Connect HP line 5 to injector 1 and tighten by hand...

Page 82: ...mp unscrew handle 2 Open vent plugs on filter head Note New version has two threaded vent plugs old version has four threaded vent plugs 3 Operate the pump with the handle until fuel without bubbles c...

Page 83: ...ponents Risk of serious injury danger to life Take special care when working on a running engine WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and igniti...

Page 84: ...fuel system Page 82 Easy change fuel filter replacement with the engine running 1 Cut out the filter to be replaced 2 Open the threaded vent plugs at the filter head of the cut out filter and make su...

Page 85: ...talling the new filter element align adjustable pointer 2 with pressure indicat ing pointer 3 of pressure gauge 1 2 Verify that differential pressure is within the limit Fuel prefilter Checking differ...

Page 86: ...eft filter cut in II Right filter cut in 2 Open threaded vent plug 5 of the filter to be drained 3 Unlock drain valve 6 by pressing toggle and open it 4 Drain water and contaminants from the filter un...

Page 87: ...e Take special care when working on a running engine WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke WARNING Engine noise...

Page 88: ...valve 6 Fuel prefilter Topping up with fuel 1 Stop engine Page 48 and disable engine start 2 Remove screws for cover and take off cover 2 3 Fill filter housing with clean fuel 4 Place new gasket in co...

Page 89: ...Diesel fuel Filter element Spare Parts Catalog Seal Spare Parts Catalog WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke R...

Page 90: ...2 7 Remove spring housing 4 and filter ele ment 3 8 Insert new filter element 3 and spring housing 4 9 Fill filter housing with clean fuel 10 Place new seal in cover 2 11 Fit cover with gasket and sec...

Page 91: ...ondensate drain line for coolant discharge and obstruction 1 Check drain line for water discharge and obstruction when the engine is running idle 2 If no air emerges remove condensate drain line and b...

Page 92: ...are parts Designation Use Part No Qty Air filter Spare Parts Catalog Replacing the air filter 1 Remove old air filter and install new air filter Page 93 2 Reset signal ring of contamination indicator...

Page 93: ...stallation 1 Release clamp 2 2 Remove air filter 3 and clamp 2 from flange of intake housing 1 3 Verify that there are no objects in the flange of the intake housing 1 and clean it 4 Place new air fil...

Page 94: ...isabled Checking signal ring position 1 If the signal ring is completely visible in the control window 2 replace air filter Page 92 2 After installation of new filter press reset button 1 Result Engag...

Page 95: ...check Preconditions Engine is stopped and starting disabled Starter Condition check 1 Check securing screws of starter for secure seating and tighten if required 2 Check wiring Page 125 MS150062 01E 2...

Page 96: ...min and max marks 4 Top up to max if required Page 97 5 Insert oil dipstick into guide tube up to the stop Oil level check after the engine is stopped 1 5 minutes after stopping the engine remove oil...

Page 97: ...id contact with skin Do not inhale oil vapor Version with extraction equipment Extracting engine oil 1 Position a suitable container to drain the engine oil into 2 Extract all engine oil from oil pan...

Page 98: ...ine WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors WARNING Hot oil Oil can contain combustion residues which are harmful to health Risk of injury and poisoning Wear p...

Page 99: ...ther oil filters in the same way 9 Switch filter to normal position 10 After each oil change and filter replace ment crank engine with starting system Page 67 11 Check oil level Page 96 Oil filter rep...

Page 100: ...utex 50 50622 1 Filter sleeve Spare Parts Catalog O ring Spare Parts Catalog O ring Spare Parts Catalog WARNING Compressed air Risk of injury Do not direct compressed air jet at persons Wear protectiv...

Page 101: ...asure the layer thickness of the oil resi due 5 If maximum layer thickness 25 mm is ex ceeded shorten maintenance interval 6 Clean rotor components and remove strain ers 2 7 Wash standpipes 3 and nozz...

Page 102: ...10 Nm 13 Hold rotor old design with strap wrench and tighten nut 1 with torque wrench to the specified torque Name Size Type Lubricant Value Standard Nut M16 x 1 5 Tightening torque 40 Nm to 50 Nm 14...

Page 103: ...15 Coolant Circuit General High Temperature Circuit 7 15 1 Drain and venting points 8 V 10 V 1 Overflow line expansion tank 2 Filler neck MS150062 01E 2012 01 Task Description 103 TIM ID 0000006696 00...

Page 104: ...12 V 16 V 1 Overflow line expansion tank 2 Filler neck 104 Task Description MS150062 01E 2012 01 TIM ID 0000006696 001...

Page 105: ...ws 2 Engine coolant drain plug 3 Raw water pump filling plug 4 Measuring point pres sure before raw water pump 5 Raw water pump drain plug 6 Connection for oil extrac tion MS150062 01E 2012 01 Task De...

Page 106: ...Left side 1 Engine coolant drain plug 2 Engine coolant drain plug M14x1 5 106 Task Description MS150062 01E 2012 01 TIM ID 0000006696 001...

Page 107: ...drain plug M14x1 5 2 Oil filler neck connection left or right engine side optional 3 Oil dipstick connection left or right engine side optional 4 Leak off fuel tank MS150062 01E 2012 01 Task Descripti...

Page 108: ...Driving end KS 1 Engine coolant drain plug 2 Connection for oil extrac tion 108 Task Description MS150062 01E 2012 01 TIM ID 0000006696 001...

Page 109: ...ather valve on coolant expansion tank Page 24 counterclockwise until first stop and allow pressure to escape 2 Continue to turn breather valve counter clockwise and remove 3 Check coolant level coolan...

Page 110: ...ecial tools Material Spare parts Designation Use Part No Qty Engine coolant Changing engine coolant 1 Drain engine coolant Page 111 2 Fill with engine coolant Page 112 110 Task Description MS150062 01...

Page 111: ...vice 3 Switch off preheating unit Engine coolant Draining 1 Turn breather valve on coolant expansion tank Page 103 counterclockwise to the first stop and re lease pressure 2 Continue to turn breather...

Page 112: ...of cracks in components Fill top up coolant only into cold engine Filling engine coolant 1 Page 24 Turn breather valve of coolant expansion tank counterclockwise until the first stop and allow pressu...

Page 113: ...tectors HT coolant pump Relief bore check 1 Check relief bore for oil and coolant dis charge 2 Stop engine Operating instructions elec tronic system and disable engine start 3 Clean the relief bore wi...

Page 114: ...expansion tank Page 103 counterclockwise until first stop and allow pressure to escape 2 Continue to turn breather valve counterclockwise and remove 3 Draw off precipitated corrosion inhibitor oil fr...

Page 115: ...goggles safety mask Coolant filter Replacement 1 Turn breather valve of coolant expansion tank counterclockwise Page 24 to the first stop and allow pressure to escape 2 Continue to turn breather valve...

Page 116: ...Risk of damage to hearing Wear ear protectors Raw water pump Relief bore check 1 Check relief bore for oil and coolant dis charge 2 Stop engine Page 48 and disable en gine start 3 Clean the relief bor...

Page 117: ...ed Guard is removed Drive belt Condition check Item Findings Action Drive belt A Singular cracks None Drive belt Belt is oily shows signs of over heating Replace Page 118 Drive belt B Cracks on entire...

Page 118: ...ver engine free end 3 Remove protective cover Drive belt Replacement 1 Hold adjusting lever at square 2 Rotate adjusting lever until drive belt is released 3 Use mandrel to lock adjusting lever in pos...

Page 119: ...System 7 19 1 Water drain valve Check Checking water drain valve 1 Open water drain valve 2 Check water outlet for obstructions 3 Close water drain valve MS150062 01E 2012 01 Task Description 119 TIM...

Page 120: ...es Do not smoke Checking differential pressure gauge 1 Switch on fuel treatment system Page 46 2 Set the alarm points at the differential pressure gauge to zero Result Alarm is initiated with preset d...

Page 121: ...water level probe 3 Disconnect plug from water level probe 4 Immerse water level probe into a tank filled with water until water level reaches the thread Result Water drain valve opens 5 Leave water...

Page 122: ...sure at the pressure gauge in the inlet to the fuel treatment system and note down 3 Checking pump pressure with reduced suction a Reduce suction pressure of pump to 0 8 bar with the shut off valve at...

Page 123: ...tion of components and lines Damage to component Ensure that components lines are installed so that they are never under tension or strain Ensure correct installation position of components Replacing...

Page 124: ...ightening torque Engine oil 30 Nm 3 Nm 17 Fit gasket 10 18 Install cover 19 Install screw 1 washer 2 and nut 9 20 Tighten nut 9 21 Open ball valve at the inlet and outlet of the fuel treatment system...

Page 125: ...nnot swing freely 3 Check that cable ties are firm tighten loose cable ties 4 Replace faulty cable ties 5 Visually inspect the following electrical line components for damage connector housings contac...

Page 126: ...leaning 1 Remove coarse dirt from housing surface with isopropyl alcohol 2 Remove dirt from connector and cable surfaces with isopropyl alcohol 3 Check legibility of cable labels Clean or replace ille...

Page 127: ...ays use test connectors to enter the connectors Never use test leads for this purpose Otherwise the contacts could be bent Checking plug in connections on engine governor 1 Check all plug in connectio...

Page 128: ...econditions Engine is stopped and starting disabled EMU checking plug in connections 1 Verify that all plug in connections are securely seated 2 Secure loose connectors and latch 128 Task Description...

Page 129: ...overnor a Release lock 3 of connectors 2 b Unplug connector 2 3 Switch on power supply Result The engine governor is operable if the di agnostic lamp 1 changes to continuous illumination within 30 sec...

Page 130: ...l 2 Remove dirt from connector and cable surfaces with isopropyl alcohol 3 Check legibility of cable labels Clean or replace illegible labels Cleaning severely contaminated EMU connectors 1 Release la...

Page 131: ...overnor from engine 1 Note or mark assignment of cables and connectors 2 Remove all screws 2 3 Undo latches 3 of the connectors 4 Remove all connectors 5 Remove screws 1 6 Take off engine governor Ins...

Page 132: ...Remove all connectors 5 Remove screws 1 6 Remove engine governor 1 with engine monitoring unit 4 Removing engine monitoring unit 1 Unscrew screws on base of EMU 4 2 Remove EMU 4 with engine governor...

Page 133: ...bine DE Diesel Engine DIN Deutsches Institut f r Normung e V At the same time identifier of German standards DIN Deutsche Industrie Norm DIS Display unit DL Default Lost Alarm CAN bus missing ECS Engi...

Page 134: ...OS Local Operating Station MCS Monitoring and Control System MG Message MPU Microprocessor Unit Microprocessing Unit MRG Main Reduction Gear OT Oberer Totpunkt Top Dead Center TDC P xyz Pressure xyz P...

Page 135: ...kt Bottom Dead Center BDC VS Voith Schneider Voith Schneider drive WJ Water jet Water jet drive WZK Werkzeugkatalog Tool Catalog TC ZKP Zugeh rigkeit Kategorie Parameter Assignment category parameter...

Page 136: ...during operation for preventive maintenance corrective work in case of malfunction or changed operating conditions or for spare parts supply Your contact at Headquarters Service support mtu online co...

Page 137: ...t Page 75 Box wrench adapter Part No F30451199 Qty Used in 1 7 6 2 Injector Removal and installation Page 80 Centering device Part No F6783025 Qty Used in 1 7 5 2 Cylinder head cover Removal and insta...

Page 138: ...n end wrench bit Part No F30025897 Qty Used in 1 7 6 2 Injector Removal and installation Page 80 Puller Part No F6790629 Qty Used in 1 7 6 2 Injector Removal and installation Page 80 Ratchet Part No F...

Page 139: ...13 Plant Cleaning Page 52 Strap wrench Part No F30379104 Qty Used in 1 7 14 2 Centrifugal oil filter Cleaning and filter sleeve replacement Page 100 Torque wrench 10 60 Nm Part No F30510423 Qty Used...

Page 140: ...s on endoscopic and visual examination 70 Cylinder head cover Removal and installation 78 D Differential pressure gauge Check 120 Drain and venting points 103 Drive belt Condition check 117 E ECU 7 en...

Page 141: ...10 Operational checks 45 P Personnel and organizational requirements 6 Plant Cleaning 52 Product description 18 Pump capacity Check 122 Putting engine into operation Preparation after extended out of...

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