MTU 10 V 2000 M9x Operating Instructions Manual Download Page 4

Page: 4 / 157

7.10.1 Air filter – Replacement

100

7.10.2 Air filter – Removal and installation

101

7.11 Air Intake

102

7.11.1 Service indicator – Signal ring position check

(optional)

102

7.12 Starting Equipment

103

7.12.1 Starter – Condition check

103

7.13 Lube Oil System, Lube Oil Circuit

104

7.13.1 Engine oil – Level check

104

7.13.2 Engine oil – Change

105

7.14 Oil Filtration / Cooling

106

7.14.1 Engine oil filter – Replacement

106

7.14.2 Centrifugal oil filter and filter sleeve –

Cleaning and replacement

108

7.15 Coolant Circuit, General, High-Temperature

Circuit

111

7.15.1 Drain and venting points

111

7.15.2 Engine coolant – Level check

116

7.15.3 Engine coolant – Change

117

7.15.4 Engine coolant – Draining

118

7.15.5 Engine coolant – Filling

119

7.15.6 HT coolant pump – Relief bore check

120

7.15.7 Engine coolant – Sample extraction and

analysis

121

7.15.8 Coolant filter – Replacement

122

7.16 Raw Water Pump with Connections

123

7.16.1 Raw water pump – Relief bore check

123

7.17 Belt Drive

124

7.17.1 Drive belt – Condition check

124

7.18 Battery-Charging Generator

125

7.18.1 Battery-charging generator drive – Drive belt

replacement

125

7.19 Fuel Supply System

126

7.19.1 Water drain valve – Check

126

7.19.2 Differential pressure gauge – Check

127

7.19.3 Water level probe (3-in-1 rod electrode) –

Check

128

7.19.4 Pump capacity – Check

129

7.19.5 Coalescer filter element – Replacement

130

7.20 Wiring (General) for Engine/Gearbox/Unit

132

7.20.1 Engine wiring – Check

132

7.21 Accessories for (Electronic) Engine

Governor / Control System

133

7.21.1 Engine governor and connectors – Cleaning

133

7.21.2 EMU and connectors – Cleaning

134

7.21.3 Engine governor plug connections – Check

135

7.21.4 Engine Monitoring Unit EMU 7 – Plug

connection check

136

7.21.5 Interface module EIM plug connections –

Check

137

7.21.6 Engine Control Unit – Self-test

138

7.21.7 Engine Control Unit ECU 7 – Removal and

installation

139

7.21.8 Engine Monitoring Unit – Removal and

installation

140

7.21.9 Engine Interface Module EIM – Removal and

installation

141

7.21.10 Diagnostic features of EIM

142

8 Appendix A

8.1 Abbreviations

145

8.2 MTU contact persons/service partners

147

9 Appendix B

9.1 Special Tools

148

9.2 Index

155

4 | Table of Contents | M015590/06E 2014-03

DCL-ID: 0000011780 - 004

Summary of Contents for 10 V 2000 M9x

Page 1: ...Operating Instructions Diesel Engine 8 V 2000 M9x 10 V 2000 M9x M015590 06E...

Page 2: ...U Friedrichshafen GmbH This publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written consent of MTU Friedrichshafen GmbH This particul...

Page 3: ...60 4 13 Plant Cleaning 61 5 Maintenance 5 1 Maintenance task reference table QL1 62 6 Troubleshooting 6 1 Fuel treatment system Troubleshooting 63 6 2 Troubleshooting 64 7 Task Description 7 1 SOLAS...

Page 4: ...18 Battery Charging Generator 125 7 18 1 Battery charging generator drive Drive belt replacement 125 7 19 Fuel Supply System 126 7 19 1 Water drain valve Check 126 7 19 2 Differential pressure gauge C...

Page 5: ...guration approved by the manufacturer in writ ing including engine management parameters In compliance with all safety regulations and in accordance with all warning notices in this manual With mainte...

Page 6: ...rk on or around the product This personnel must be instructed repeatedly Personnel requirements All work on the product shall be carried out by trained and qualified personnel only Training at the Tra...

Page 7: ...for the given weight forklift truck Install the crankshaft locking device and the locking screws for the engine mounts prior to engine trans portation Secure the engine against tilting during transpor...

Page 8: ...tor must be aware of the consequences of any operations he she performs During operation the display instruments and monitoring units must be constantly observed in regard of present operating status...

Page 9: ...starter with compressed air Clean the interior of the flywheel housing with a class H dust extractor Observe the safety data sheet Safety requirements during maintenance and repair work Take special...

Page 10: ...e performing necessary welding work Hydraulic installation and removal Check function and satisfactory condition of the jigs and fixtures to be used Use only the specified jigs and fixtures for hydrau...

Page 11: ...ent i e protect them against moisture in particular Pack age faulty electronic components or assemblies properly before dispatching for repair Moisture proof Shock proof Wrapped in antistatic foil if...

Page 12: ...are prohibited by emission regulations Emission control units systems may only be maintained exchanged or repaired if the components used for this purpose are approved by the manu facturer Noncomplia...

Page 13: ...o be replaced Carry out leak test in accordance with the specifications Paints and varnishes Observe the relevant safety data sheet for all materials When painting in areas other than spray booths equ...

Page 14: ...medial action NOTICE In the event of a situation involving potentially adverse effects on the product Consequences Material damage Remedial action Additional product information Safety notices 1 This...

Page 15: ...nized and 10 9 surface finish bare metal or phosphatized The values in the table are based on a friction coefficient tot 0 125 Threads and mating faces of screws and nuts must be coated with engine oi...

Page 16: ...al and manufacture to MMN 389 standard bare metal or phosphatized The values in the table are based on a friction coefficient tot 0 125 Threads and mating faces of screws and nuts must be coated with...

Page 17: ...t from torsion when tightening MA tightening torques Tightening torques for plug screws to MTN 5183 1 standard This standard applies to plug screws to DIN 908 DIN 910 and DIN 7604 with threaded end to...

Page 18: ...ng torques for plug screws to DIN 908 DIN 910 and DIN 7604A with short threaded end Thread Screwed into Steel gray cast iron MA Nm AI alloy MA Nm M10 x 1 15 15 M12 x 1 5 30 25 M14 x 1 5 35 30 M16 x 1...

Page 19: ...Nm M8 x 1 10 10 M22 x 1 5 80 65 M26 x 1 5 105 90 M30 x 1 5 130 130 M38 x 1 5 140 120 M45 x 1 5 160 140 MA tightening torques Tightening torques for banjo screws to MTN 5183 2 standard This standard a...

Page 20: ...oidable deviations during the tightening process Tightening torques for steel banjo screws Thread Screwed into steel gray cast iron Al alloy MA Nm M8 x 1 10 M10 x 1 15 M12 x 1 5 20 M14 x 1 5 25 M16 x...

Page 21: ...iled or galvanized Threads and mating faces beneath heads must be coated with engine oil prior to assembly An assembly tolerance of 10 of the figures in the table is permitted due to unavoidable devia...

Page 22: ...t firmly by hand noticeable increase in force it should be tightened another 1 4 turn 90 past this point Tightening torques for spigot unions with O ring to ISO 6149 2 Thread Torque Nm 10 M8 x 1 10 M1...

Page 23: ...ew in valves see ISO 7789 Tightening torques for spigot unions with O ring to ISO 6149 3 Thread Torque Nm 10 M8 x 1 8 M10 x 1 15 M12 x 1 5 25 M14 x 1 5 35 M16 x 1 5 40 M18 x 1 5 45 M22 x 1 5 60 M27 x...

Page 24: ...S fittings In contrast to the instructions for pipe unions hose fittings with sealing heads and the matching adapters must be fitted and connected as follows Hose fitting forming metallic seal with un...

Page 25: ...58 M22 x 1 5 14 15 74 M24 x 1 5 16 74 M26 x 1 5 18 105 M30 x 2 20 22 135 M36 x 2 25 28 166 M42 x 2 30 240 M45 x 2 35 290 M52 x 2 38 42 330 Sealing head with BSP union nut BSPP thread Torque Nm G1 4 2...

Page 26: ...left hand side of the engine and the letter B 3 to refer to the cylinders on the right hand side The cylinders of each bank are numbered consecutively starting with No 1 at the driving end The number...

Page 27: ...triple walled design permits low surface temperature reduced thermal load absolute gas tightness Lube oil system Wet sump forced feed lubrication system Components supplied with oil Bearings Piston c...

Page 28: ...ignals are routed out via M threaded pins and are also integrated in the engine wiring har ness Functions ECU supply EMU supply Plant signals ECU7 connector X1 Bus interface 2x MCS5 CAN CAN dialog out...

Page 29: ...t LOP Functions Engine speed oil pressure and coolant temperature are monitored and displayed Integrated safety system Integrated Test System Redundant CAN bus interface to governor and higher level c...

Page 30: ...side either with a copper sealing ring 1 according to DIN or an O ring ISO In case of a loose thread or a faulty sealing ring 1 the liquid first has to pass the thread The pressure is so greatly reduc...

Page 31: ...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 M015590 06E 2014 03 General Information 31 TIM ID 000...

Page 32: ...st screw 7 Thrust ring 8 O ring 9 HP line 10 Pressure pipe Leak off 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 pre...

Page 33: ...secondary turbocharger 16 Actuating cylinder for ex haust flap 17 Actuating cylinder for air flap 18 Control valve for flap con trol 19 Cylinder head cover 20 Exhaust system housing 21 Engine mounting...

Page 34: ...ng middle section 12 Carrier housing lower sec tion 13 Wastegate 14 Carrier housing upper sec tion KS engine driving end Engine model designation Key to the engine model designation 8V 10V 2000 Mxyz 8...

Page 35: ...illustrations are insignificant Also valid for 8V engines No Description Monitoring of 1 B10 Charge air pressure 2 B9 Charge air temperature 3 B7 Lube oil temperature 4 B3 Intake air temperature M0155...

Page 36: ...B5 3 optional 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...

Page 37: ...n Monitoring of 1 B4 21 Exhaust gas temperature A side 2 B4 22 Exhaust temperature B side 3 B1 Camshaft speed 4 B13 Crankshaft speed 5 B13 2 optional Crankshaft speed M015590 06E 2014 03 General Infor...

Page 38: ...cription 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 38 General Information M015590 06E 2014...

Page 39: ...3 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 40: ...0 1000 Site altitude above sea level m 100 100 Power related data power ratings are net brake power as per ISO 3046 Number of cylinders 8 8 Rated engine speed A rpm 2450 2450 Fuel stop power ISO 3046...

Page 41: ...bar 0 3 0 3 Fuel pressure at engine inlet connection max when engine is starting L bar 0 25 0 25 Fuel supply flow max R Liter min 4 5 4 5 General operating data Number of cylinders 8 8 Firing speed fr...

Page 42: ...ng inclinations L Liters 54 54 Oil pan capacity dipstick mark max standard oil system design max operating inclinations L Liters 62 62 Weights main dimensions Number of cylinders 8 8 Engine dry weight...

Page 43: ...altitude above sea level m 100 100 Power related data power ratings are net brake power as per ISO 3046 Number of cylinders 10 10 Rated engine speed A rpm 2450 2450 Fuel stop power ISO 3046 A kW 1015...

Page 44: ...o engine min when engine is running L bar 0 3 0 3 Fuel pressure at engine inlet connection max when engine is starting L bar 0 25 0 25 Fuel supply flow max R Liter min 5 0 5 0 General operating data N...

Page 45: ...r ating inclinations R Liters 75 75 Oil pan capacity dipstick mark min standard oil system design max operating inclinations L Liters 64 64 Oil pan capacity dipstick mark max standard oil system desig...

Page 46: ...3 3 Firing order Firing order 8V A1 B4 A4 A2 B3 A3 B2 B1 10 V A1 B4 A4 B3 A3 B2 A2 B5 A5 B1 46 Technical Data M015590 06E 2014 03 TIM ID 0000002801 004...

Page 47: ...000 M92 Approx 1683 mm Approx 1147 mm Approx 1200 mm 8V 2000 M93 Approx 1683 mm Approx 1147 mm Approx 1200 mm 10V 2000 M92 Approx 1860 mm Approx 1147 mm Approx 1320 mm 10V 2000 M93 Approx 1860 mm Appr...

Page 48: ...7 Fuel prefilter pressure gage Align adjustable pointer with position of pressure indicator Page 92 Fuel system Vent Page 89 Raw water pump if located above waterline Prime approx 3 to 4 liters Fillin...

Page 49: ...nt level Page 116 Coolant circuit Heat engine coolant with coolant preheating unit Fuel prefilter Drain water and contaminants Page 93 Battery charging generator drive Check condition of drive belt Pa...

Page 50: ...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 52 2 Shut down fuel treatment system Page 60 50...

Page 51: ...ves 4 Switch on fuel treatment system Page 55 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 52: ...ne 3 Switch on fuel treatment system and operate it for some minutes Page 55 Result Fuel is sucked from the tank dirt particles and water are filtered and separated then the fuel is deliv ered via the...

Page 53: ...ncy HAT 1 Switch on fuel treatment system Page 55 2 Start engine Page 56 3 Run engine at idling speed 4 Switch off pump 21 on switch cabinet Result The engine mounted fuel delivery pump sucks fuel via...

Page 54: ...Check exhaust color Page 64 Fuel prefilter Check if suction side pressure indicated at the fuel prefilter is within the limit Page 92 Drain water and contaminants Page 93 Air filter Check signal ring...

Page 55: ...ore switching on ensure that all housings are closed Before switching on ensure that no work is in progress anywhere on the entire system Fuel treatment system Switching on 1 Carry out checks prior to...

Page 56: ...rsons in the en gine s danger zone WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors The engine can be started from the following points Item...

Page 57: ...d for at least 10 minutes until engine temperatures have dropped and constant values are displayed The engine can be stopped from the following points Item Action Control stand Operating instructions...

Page 58: ...An emergency engine stop can be initiated from the following points Item Action Control stand Operating instructions for electronic system Local Operating Panel LOP Operating instructions for electro...

Page 59: ...itable temperature the antifreeze concentration is insufficient for the engine room tem perature antifreeze concentration is 50 and engine room temperature is be low 40 C Raw water Drain if freezing t...

Page 60: ...binet 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 61: ...pressed air gun directly at seals or electronic components such as connectors or ECUs Plant Cleaning 1 Carry out plant cleaning only in areas where an appropriate oil separator is provided environment...

Page 62: ...ge 54 W1001 Replace fuel filter or fuel filter element Page 90 W1002 Check valve clearance Page 83 W1003 Check condition and tension of drive belt replace belt if re quired Page 124 W1005 Replace air...

Page 63: ...uipped with an overload protection If the maximum permissible current consumption is exceeded e g in case of a blockage or dry running the motor protection relay triggers and the pump is switched off...

Page 64: ...not be barred manually u Contact Service Engine turns on starting but does not fire Cause Corrective action Poor rotation by starter Battery low or faulty u Charge or replace battery see manufacturer...

Page 65: ...r Page 102 Intercooler dirty u Contact Service Exhaust turbocharger defective u Contact Service Coolant leaks at intercooler Cause Corrective action Intercooler leak ng major coolant discharge u Conta...

Page 66: ...action Engine is not at operating temperature u Run engine to reach operating temperature Water in fuel u Drain fuel prefilter Page 93 Intercooler leaking u Contact Service 66 Troubleshooting M015590...

Page 67: ...ools 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 installa...

Page 68: ...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 fil ter and fuel filter 1 Pinpoint...

Page 69: ...ielding as per MTN 5233 Page 67 On crankcase Item Type of shielding Remarks 1 Shield A4 On brazed on union 2 Shield A5 On crankcase Free end B side Item Type of shielding Remarks 1 Free end B side Shi...

Page 70: ...m Type of shielding Remarks 1 Free end B side Shield A7 On HP fuel pump Free end Item Type of shielding Remarks 1 Free end Shield A7 Above fuel priming pump 70 Task Description M015590 06E 2014 03 TIM...

Page 71: ...ype 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 M015590 06E 2014 03 Task Description 71 TIM ID...

Page 72: ...de Item Type of shielding Remarks 1 Driving end Shield A5 On air flap control 2 Driving end Shield A4 On brazed on union 3 Driving end Shield A5 On exhaust turbocharger flap control 4 Driving end Shie...

Page 73: ...end Shield A4 Exhaust turbocharger lubrication 2 Driving end Shield A4 On brazed on union Driving end Item Type of shielding Remarks 1 Driving end Shield A4 Exhaust turbocharger lubrication M015590 0...

Page 74: ...no persons in the engine s danger zone After finishing work on the engine make sure that all safety devices are put back in place and all tools are removed from the engine Barring engine manually 1 F...

Page 75: ...in Before barring the engine make sure that there are no persons in the engine s danger zone After finishing work on the engine make sure that all safety devices are put back in place and all tools ar...

Page 76: ...pattern First signs of marks left by lower cooling bores Running pattern seems darker No action required Darker areas of even or varying color intensity Beginning and end of the discoloration are not...

Page 77: ...Final steps 1 Install injector Page 87 2 Install cylinder head cover Page 85 M015590 06E 2014 03 Task Description 77 TIM ID 0000000015 016...

Page 78: ...und the liner It appears rather darker within the honed struc ture in contrast to the bright metallic running surface The honing pattern is undis turbed Discolorations extend in stroke direction and m...

Page 79: ...ation 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 inspec...

Page 80: ...Always wear safety goggles face mask and ear defenders Crankcase breather Cleaning oil pre separator element 1 Undo clamp 2 2 Remove hose 1 and clamp 2 from cov er 3 3 Slacken screws 4 4 Remove screw...

Page 81: ...ich are 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 oil separator element 1 Remove...

Page 82: ...aphragm 3 on housing 1 5 Install new seal 2 and spring 5 together with cover 4 6 Use torque wrench to tighten the screws of cover 4 to the specified torque Name Size Type Lubricant Value Standard Scre...

Page 83: ...Note With cylinder head and valve gear installed 1 Install dial gage 2 under preload in meas uring device 4 and clamp with screw 1 2 Install measuring device 4 in cylinder head and secure using knurle...

Page 84: ...alve bridge and rocker arm 5 If the deviation from the reference value exceeds 0 1 mm adjust valve clearance Adjusting valve clearance 1 Loosen locknut 1 and unscrew adjusting screw 2 by a few threads...

Page 85: ...installing cylin der head cover 1 Remove screws 1 2 Remove cylinder head cover 2 with gas ket from cylinder head 3 Clean installation surface 4 Check condition of gasket of cylinder head cover Result...

Page 86: ...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 87 86 Task Description M015590 06E 20...

Page 87: ...0059351 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 off fuel supply to engine...

Page 88: ...ne 5 and injector 1 with engine oil 9 Align injector 1 and HP line 5 with alignment jig 10 Connect HP line 5 to HP accumulator and tighten by hand 11 Connect HP line 5 to injector 1 and tighten by han...

Page 89: ...ump 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...

Page 90: ...l damage For filter replacement with the engine running operate the engine at low engine load The filter which is to be replaced must be cut out for a brief period only Replacing easy change fuel filt...

Page 91: ...four threaded vent plugs 3 Close threaded vent plugs 4 Remove cut out easy change filter using the oil filter wrench 5 Clean sealing surface on filter head 6 Check sealing ring of the new easy change...

Page 92: ...if ferential pressure gauge 1 After installation of a new filter element align adjustable pointer 2 with pressure indicating pointer 3 of pressure gauge 1 2 Verify that differential pressure is within...

Page 93: ...nition sources Do not smoke Draining fuel prefilter 1 Switch off filter which is to be drained A or B 1 Filter A switched off 2 Filter B switched off 2 Open threaded vent plug 1 of the filter to be dr...

Page 94: ...ll with fuel until it emerges from the vent pipe 3 8 Close vent valve 2 9 Turn slide 4 a little approx 30 and open vent valve s 2 until fuel emerges from the vent pipe 3 10 Close vent valve s 2 11 Tur...

Page 95: ...power Keep away from the engine s danger zone WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke WARNING High level of engi...

Page 96: ...mp to filling connec tion 1 on the intake side of the filter 3 Open vent valve 2 and fill with fuel until fuel emerges from the vent pipe 3 4 Close vent valve 2 5 Open rotary slide valve 4 a little by...

Page 97: ...Filter element Spare Parts Catalog Sealing Spare Parts Catalog WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Replacing...

Page 98: ...spring cartridge 3 and filter ele ment 4 8 Insert new filter element 4 and spring car tridge 3 9 Fill filter housing with clean fuel 10 Place new seal in cover 11 Fit cover with gasket and secure it...

Page 99: ...lways wear safety goggles face mask and ear defenders Intercooler Checking conden sate drain line for coolant dis charge and obstruction 1 Check drain line for water discharge and obstruction when the...

Page 100: ...re 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 101 2 Reset signal ring of contamination indicator...

Page 101: ...2 Remove air filter 1 and clamp 2 from connecting flange of intake housing 3 3 Verify that there are no objects in the con necting flange of the intake housing 3 and clean it 4 Place new air filter 1...

Page 102: ...disabled Checking signal ring position 1 If the signal ring is completely visible in the control window 2 replace air filter Page 100 2 After installation of new filter press reset button 1 Result Eng...

Page 103: ...heck Preconditions Engine is stopped and starting disabled Checking starter condition 1 Check securing screws of starter for secure seating and tighten if required 2 Check wiring Page 132 M015590 06E...

Page 104: ...1 marks 4 Top up with oil up to the max 1 mark Page 105 if required 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 engi...

Page 105: ...oid contact with skin Do not inhale oil vapor Version with extraction equipment Engine oil extraction 1 Position a suitable container to drain the engine oil into 2 Extract all engine oil from oil pan...

Page 106: ...tectors WARNING Hot oil Oil can contain combustion residues which are harmful to health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do...

Page 107: ...ment crank engine with starting system Page 75 11 Check oil level Page 104 Replacing oil filter with the engine running 1 Reduce engine speed to 1100 rpm 2 Unscrew cut out oil filter with oil filter w...

Page 108: ...Parts Catalog O ring Spare Parts Catalog O 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 o...

Page 109: ...4 Measure 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...

Page 110: ...10 Nm 13 Hold rotor old design with oil filter wrench and tighten nut 1 to specified torque using a torque wrench Name Size Type Lubricant Value Standard Nut M16 x 1 5 Tightening torque 40 Nm to 50 N...

Page 111: ...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 M015590 06E 2014 03 Task Description 111 TIM ID 0000006696 00...

Page 112: ...ews 2 Engine coolant drain plug 3 Raw water pump filling plug 4 Measuring point pressure before raw water pump 5 Raw water pump drain plug 6 Connection for oil extrac tion 112 Task Description M015590...

Page 113: ...Left side 1 Engine coolant drain plug 2 Engine coolant drain plug M14x1 5 M015590 06E 2014 03 Task Description 113 TIM ID 0000006696 002...

Page 114: ...drain plug M14x1 5 2 Oil filler neck connection on left or right engine se lectable 3 Oil dipstick connection on left or right engine selecta ble 4 Leak fuel tank 114 Task Description M015590 06E 201...

Page 115: ...Driving end KS 1 Engine coolant drain plug 2 Connection for oil extrac tion M015590 06E 2014 03 Task Description 115 TIM ID 0000006696 002...

Page 116: ...ather valve on coolant expansion tank Page 33 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 117: ...ge Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 118 2 Fill with engine coolant Page 119 M015590 06E 2014 03 Task Description...

Page 118: ...3 Switch off preheating unit Draining engine coolant 1 Turn breather valve of filler neck on coolant expansion tank Page 111 counterclockwise to first stop and allow pressure to escape 2 Continue to...

Page 119: ...f cracks in the engine Fill top up coolant only into cold engine Filling with engine coolant 1 Turn breather valve of coolant expansion tank Page 33 counterclockwise until the first stop and al low pr...

Page 120: ...of damage to hearing Wear ear protectors 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 engin...

Page 121: ...t expansion tank Page 111 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 f...

Page 122: ...goggles safety mask Coolant filter Replacement 1 Turn breather valve of coolant expansion tank counterclockwise Page 33 to the first stop and allow pressure to escape 2 Continue to turn breather valv...

Page 123: ...noise when the engine is running 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 57 and disable en...

Page 124: ...led 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 125 Drive belt C Chunking Drive belt Bel...

Page 125: ...cover engine free end 3 Remove protective cover Replacing drive belt 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 126: ...y System 7 19 1 Water drain valve Check Water drain valve Check 1 Open water drain valve 2 Check water outlet for obstructions 3 Close water drain valve 126 Task Description M015590 06E 2014 03 TIM ID...

Page 127: ...es Do not smoke Checking differential pressure gauge 1 Switch on fuel treatment system Page 55 2 Set the alarm points at the differential pressure gauge to zero Result Alarm is initiated with preset d...

Page 128: ...ect connector from water level probe 4 Immerse water level probe into a tank filled with water until water level reaches the thread 5 Switch system on Result Water drain valve opens 6 Leave water leve...

Page 129: ...ck pressure at the pressure gauge in the inlet to the fuel treatment system and note down 3 Check pump pressure with reduced suction a Reduce suction pressure of pump to 0 8 bar with the shutoff valve...

Page 130: ...omponents 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 Coalescer filter el...

Page 131: ...htening torque Engine oil 30 Nm 3 Nm 17 Fit gasket 10 18 Install cover 19 Install screws 1 washers 2 and nuts 9 20 Tighten nuts 9 21 Open ball valve at the inlet and outlet of the fuel treatment syste...

Page 132: ...sed and in proper condition 4 Replace cable clips if defective 5 Check that cable clamps are firm tighten loose cable clamps 6 Replace faulty cable clamps 7 Visually inspect the following electrical l...

Page 133: ...ove coarse dirt from housing surface using a cloth moistened with isopropyl alcohol 2 Remove dirt from the connector and cable surfaces with isopropyl alcohol 3 Check legibility of cable labels Clean...

Page 134: ...opropyl alcohol 2 Remove dirt from the connector and cable surfaces with isopropyl alcohol 3 Check legibility of cable labels Clean or replace illegible labels Cleaning severely contaminated connector...

Page 135: ...itable 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 1 Check all pl...

Page 136: ...tarting disabled Checking EMU plug connections 1 Check both connectors on EMU 2 for firm seating Ensure that the clips 1 are engag ed 2 Check screws 3 of cable clamps on EMU 2 for firm seating Ensure...

Page 137: ...ing disabled Checking EIM plug connections 1 Check both Tyco plugs 62 pole 2 on EIM for firm seating Ensure that clips 3 are engaged 2 Check screws 1 of cable clamps on EIM for firm seating Ensure tha...

Page 138: ...ease lock 3 of connectors 2 b Unplug connector 2 3 Switch on power supply Result The Engine Control Unit is operable if the diagnostic lamp 1 changes to con tinuous illumination within 30 seconds afte...

Page 139: ...ontrol Unit from engine 1 Note or mark assignment of cables and connectors 2 Remove all screws 3 3 Undo clips 2 on connectors 4 Remove all male connectors 5 Remove screws 1 6 Take off Engine Control U...

Page 140: ...move Engine Control Unit 1 with En gine Monitoring Unit 4 Removing Engine Monitoring Unit 1 Unscrew screws on base of Engine Monitoring Unit 4 2 Remove Engine Monitoring Unit 4 with Engine Control Uni...

Page 141: ...When doing so observe correct assignment between cables and plugs 2 Check seal before installing Result Replace seal if porous or defective Downloading software 1 The new EIM still does not have appr...

Page 142: ...or operation 4 Application loader active 5 External RAM faulty 6 External FLASH faulty 7 No firmware 8 Application crashed Fuse lamp SILA A second indicator is the fuse lamp This is also integrated in...

Page 143: ...toring current path failed S8 10 Emergency stop current path failed 24V internal S9 11 ES pushbutton current path failed 24V external S10 12 Key switch current path failed S11 13 SDAF 1 2 current path...

Page 144: ...fuse S4 fail ure 1 2 second steps Note These bit sequences are transmitted constantly Information about the status of the current paths of the EIM is also provided in the CAN message Sta tus internal...

Page 145: ...Engine management system ECU Engine Control Unit Engine governor EDM Engine Data Module Memory module for engine data EIM Engine Interface Module Interface to engine monitoring system EMU Engine Moni...

Page 146: ...anel PCU Propeller Control Unit PIM Peripheral Interface Module RCS Remote Control System RL Redundancy Lost Alarm Redundant CAN bus failure SAE Society of Automotive Engineers U S standardization org...

Page 147: ...e work in case of malfunction or changed operating conditions or for spare parts supply Your contact person in our Customer Assistance Center E mail info mtu online com Tel 49 7541 9077777 Fax 49 7541...

Page 148: ...ctor Removal and installation Page 87 Box wrench Part No F30451199 Qty Used in 1 7 6 2 Injector Removal and installation Page 87 Centering jig Part No F6783025 Qty Used in 1 7 5 2 Cylinder head cover...

Page 149: ...n 1 7 6 2 Injector Removal and installation Page 87 Engine barring gear Part No F6783914 Qty Used in 1 7 2 1 Engine Barring manually Page 74 Qty Used in 1 7 5 1 Valve clearance Check and adjustment Pa...

Page 150: ...4345888 Qty Used in 1 7 5 1 Valve clearance Check and adjustment Page 83 MTU test kit Part No 5605892099 00 Qty Used in 1 7 15 7 Engine coolant Sample extraction and analysis Page 121 Offset screwdriv...

Page 151: ...Qty Used in 1 7 15 8 Coolant filter Replacement Page 122 Open end wrench bit Part No F30025897 Qty Used in 1 7 6 2 Injector Removal and installation Page 87 Puller Part No F6790629 Qty Used in 1 7 6...

Page 152: ...chet Part No F30027339 Qty Used in 1 7 19 5 Coalescer filter element Replacement Page 130 Rigid endoscope Part No Y20097353 Qty Used in 1 7 3 1 Cylinder liner Endoscopic examination Page 76 Socket wre...

Page 153: ...art No Qty Used in 1 4 13 Plant Cleaning Page 61 Torque wrench 10 60 Nm Part No F30510423 Qty Used in 1 7 5 1 Valve clearance Check and adjustment Page 83 Torque wrench 4 20 Nm Part No F30044239 Qty U...

Page 154: ...Qty Used in 1 7 4 2 Crankcase breather Oil separator element re placement diaphragm check and replacement Page 81 Qty Used in 1 7 19 5 Coalescer filter element Replacement Page 130 154 Appendix B M01...

Page 155: ...ination 78 D Designations Engine sides and cylinders 26 Differential pressure gauge Check 127 Drain and venting points 111 Drive belt Condition check 124 E ECU 7 Installation 139 Removal 139 EMU Clean...

Page 156: ...ng into operation Fuel treatment system 52 R Raw water pump Relief bore Check 123 S Safety notices standards 14 Safety regulations Auxiliary materials 12 Environmental protection 12 Fire prevention 12...

Page 157: ...W Water drain valve Check 126 Water level probe 3 in 1 rod electrode Check 128 M015590 06E 2014 03 Appendix B 157 DCL ID 0000011780 004...

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MTU 10 V 2000 M9x, Operating Instructions Manual

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