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MTU 10V1600C Series, Operating Instructions Manual

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MTU 10V1600C Series Operating Instructions Manual Download Page 129

8.7.6 EGR cooler – Check

Preconditions

☑

Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use

Part No.

Qty.

Oilstone

F30454308/03

1

Crocus cloth

 

 

Engine oil
Gaskets

(→ Spare Parts Catalog)

WARNING

Hot components/surfaces.
Risk of burns!
• Allow the engine to cool down to below 50 °C before beginning work.
• Wear suitable protective equipment/thermal gloves.
• Avoid unprotected contact with hot surfaces.

WARNING

Components have sharp edges.
Risk of injury!
• Wear protective gloves.

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.
• Always wear safety goggles/face mask and ear defenders.

Checking EGR cooler

1.

Remove all covers.

2.

Remove coolant pipe after EGR cooler (3). To
do this, unscrew screws at EGR cooler (1)
and charge-air manifold (2).

3.

Visually inspect cooler grill of EGR cooler for
heavy sooting and coolant deposits indicating
a leak.

4.

Check EGR cooler for damage and coolant
leakage.

5.

Check threads for ease of movement.

6.

Replace EGR cooler in case of heavy sooting,
coolant leakage or damage (→ Page 130).

7.

Check all sealing, mating and support surfa-
ces for unevenness and damage. Smooth any
unevenness with oilstone or crocus cloth. Re-
place damaged parts.

Note:

Coat Torx screws of EGR piping after EGR
cooler with engine oil.

8.

Reinstall piping after EGR cooler (3) with new
gaskets (4).

MS150100/06E 2017-08

| Exhaust Gas Recirculation | 129

TIM-ID: 0000072939 - 002

Summary of Contents for 10V1600C Series

Page 1: ...Operating Instructions Diesel Engine 10V1600Cx0 12V1600Cx0 MS150100 06E...

Page 2: ...This publication is protected by copyright and may not be used in any way whether in whole or in part without the prior writ ten consent of MTU Friedrichshafen GmbH This particularly applies to its re...

Page 3: ...r extended out of service periods 3 months 50 5 3 Engine Starting 51 5 4 Operational checks 52 5 5 Emission label Check 53 5 6 Engine shutdown 54 5 7 After stopping the engine 55 5 8 Plant Cleaning 56...

Page 4: ...eck 152 8 12 2 Drive belt Replacement 153 8 13 Battery Charging Generator 155 8 13 1 Battery charging generator Cleaning 155 8 14 Drive Systems Driving End and Free End Coupling 156 8 14 1 Coupling Ch...

Page 5: ...purpose are approved by the manufacturer Noncompliance with these specifications will invalidate the design type approval or certification issued by the emissions regulation authorities The manufactu...

Page 6: ...ollowing when replacing components with emission labels The relevant emission labels must be affixed to the spare part Emission labels shall not be transferred from the replaced part to the spare part...

Page 7: ...om bustible gases in the surrounding area There is also a risk of the engine drawing in combustible gases thus resulting in uncontrolled operation Neither can the possibility of components being eject...

Page 8: ...instructed and qualified personnel only Training at the Training Center of the manufacturer Qualified personnel from the areas mechanical engineering plant construction and electrical engineering The...

Page 9: ...ling Protect battery terminals generator terminals or cables against accidental contact Check that all connections have been correctly allocated e g polarity fuel line urea solution line sup ply retur...

Page 10: ...iately or soak up with a suitable binding agent Operation of electrical equipment When electrical equipment is in operation certain components of these appliances are electrically live Follow the appl...

Page 11: ...s Before starting work on CaPoS if used Switch of the charging system DC DC converter Discharge the UltraCap modules using the appropriate discharger Short circuit the UltraCap modules with a suitable...

Page 12: ...neous Wear a breathing mask offering protection against soot dust and mineral fibers filter class P3 when work ing on exhaust components Wear protective gloves and goggles for protection against acidi...

Page 13: ...ith the piston extended For a hydraulic installation removal device with central expansion pressure supply screw spindle into shaft end until correct sealing is established During hydraulic installati...

Page 14: ...ic components or assemblies properly before dispatching for repair Moisture proof Shock proof Wrapped in antistatic foil as necessary Working with laser equipment Work with laser devices shall be carr...

Page 15: ...ble and that staff are familiar with their correct handling A fire can result in the creation of toxic substances Always wear protective gloves when handling compo nents and wear additional personal p...

Page 16: ...rovided with fume extraction systems ensure that the area is well ventilated Make sure that neighboring work areas are not adversely affected There must be no naked flames in the vicinity No smoking O...

Page 17: ...Consequences Material damage Remedial action Additional product information Warning notices 1 This manual with all safety instructions and warning notices must be issued to all personnel involved in o...

Page 18: ...n Secure such as to preclude slipping and tipping when driving up or down inclines and ramps Setting down an engine with standard oil pan after transportation Note The engine may only be set down on t...

Page 19: ...Position of the wooden chocks view of driving end Position of the wooden chocks on an engine with 4 point mounting free end and side view MS150100 06E 2017 08 Transport 19 TIM ID 0000064651 003...

Page 20: ...Position of the wooden chocks on an engine with 3 point mounting free end and side view 20 Transport MS150100 06E 2017 08 TIM ID 0000064651 003...

Page 21: ...serve max admissible diagonal pull Max admissible diagonal pull in longitudinal direction is 10 degrees no transverse diagonal pull is admis sible in this case Max admissible diagonal pull in transver...

Page 22: ...nated in accordance with DIN ISO 1204 as viewed from driving end 4 For cylinder designation in accordance with DIN ISO 1204 the letter Ax refers to the cylinders on the left hand side of the engine 1...

Page 23: ...sing 4 EGR pipe with insulation 5 Cylinder head 6 Battery charging generator 7 Engine governor 8 Electric starter right side 9 Flywheel 10 Air compressor 11 Exhaust turbocharger low pressure 12 Exhaus...

Page 24: ...l dipstick 12 Fuel filter 13 Battery charging generator option 14 Belt 15 Engine coolant pump 16 Charge air coolant pump KGS Free end Engine model designation Key to the engine model designation 10V 1...

Page 25: ...oil pressure after filter 7 B9 1 Charge air temperature before exhaust gas recirculation 8 B26 Charge air coolant temperature 9 B10 Charge air pressure 10 B9 3 Charge air temperature after exhaust gas...

Page 26: ...P fuel right side 12V only 7 B93 Oil level in oil pan 8 X2 Adaption of Engine Control Unit ECU9 9 X3 Adaption of Engine Control Unit ECU9 10 XF70 Water level in fuel prefilter 11 XF33 Engine coolant l...

Page 27: ...eft side 2 M53 1 EGR shut off flap before cooler left side 3 XY39A2 Injector connection 4 XY57A Engine brake valve left side 5 XY39A1 Injector connection 6 B4 21 Exhaust temperature lambda sensor left...

Page 28: ...Item Description Description 1 B44 4 Speed of LP turbocharger right side 2 B50 Crankcase pressure 3 M52 2 HP turbine bypass flap right side 4 B13 Crankshaft speed 28 General Information MS150100 06E...

Page 29: ...Description Description 1 B7 Lube oil temperature 2 B34 2 Fuel pressure before filter 3 B34 1 Fuel pressure after filter 4 B6 3 Coolant temperature cylinder head MS150100 06E 2017 08 General Informat...

Page 30: ...1600 C60 10V1600 C70 Application group 5B 5B Charge air coolant temperature C 45 45 Barometric pressure mbar 981 981 Site altitude above sea level m 400 400 Power related data power ratings are net br...

Page 31: ...R bar abs 3 8 3 84 Exhaust gas temperature after exhaust turbocharger under stand ard conditions and at a site altitude of 400 m above sea level R C 376 422 Coolant system HT circuit Description 10V16...

Page 32: ...et connection min when engine is running L bar 0 65 0 65 Fuel pressure at engine inlet connection max when engine is starting L bar 0 0 Inclinations standard oil system reference waterline Description...

Page 33: ...p 1 m distance ISO 6798 3 dB A tolerance R dB A 111 111 Exhaust noise unsilenced BL sound power level LW ISO 6798 3 dB A tolerance R dB A 123 123 Engine surface noise with attenuated intake noise filt...

Page 34: ...ature C 45 45 Barometric pressure mbar 981 981 Site altitude above sea level m 400 400 Power related data power ratings are net brake power to ISO 3046 Description 10V1600 C60 10V1600 C70 Rated engine...

Page 35: ...22 Coolant system HT circuit Description 10V1600 C60 10V1600 C70 Coolant temperature at engine connection outlet to cooling equipment A C 95 95 Coolant temperature after engine limit 1 L C 107 107 Coo...

Page 36: ...rd oil system reference waterline Description 10V1600 C60 10V1600 C70 Longitudinal inclination continuous max driving end down L Degrees 32 32 Longitudinal inclination continuous max driving end up L...

Page 37: ...und power level LW ISO 6798 3 dB A tolerance R dB A 123 123 Engine surface noise with attenuated intake noise filter BL free field sound power level Lp 1 m distance ISO 6798 2 dB A tolerance R dB A 10...

Page 38: ...pressure mbar 981 981 981 Site altitude above sea level m 400 400 400 Power related data power ratings are net brake power to ISO 3046 Description 12V1600 C50 12V1600 C60 12V1600 C70 Rated engine spe...

Page 39: ...er engine max in DBR MCR performance map under max admissible operating conditions L C 550 550 550 Coolant system HT circuit Description 12V1600 C50 12V1600 C60 12V1600 C70 Coolant temperature at engi...

Page 40: ...ssure at engine inlet connection min when engine is starting L bar 0 65 0 65 0 65 Fuel pressure at engine inlet connection min when engine is running L bar 0 65 0 65 0 65 Fuel pressure at engine inlet...

Page 41: ...g kg 2310 2334 2310 2334 2310 2334 Engine wet weight with standard accessories instal led w o coupling Engine with standard oil pan R kg 2450 2450 2450 Sound Description 12V1600 C50 12V1600 C60 12V160...

Page 42: ...etric pressure mbar 981 981 981 Site altitude above sea level m 400 400 400 Power related data power ratings are net brake power to ISO 3046 Description 12V1600 C50 12V1600 C60 12V1600 C70 Rated engin...

Page 43: ...er engine max in DBR MCR performance map under max admissible operating conditions L C 550 550 550 Coolant system HT circuit Description 12V1600 C50 12V1600 C60 12V1600 C70 Coolant temperature at engi...

Page 44: ...ssure at engine inlet connection min when engine is starting L bar 0 65 0 65 0 65 Fuel pressure at engine inlet connection min when engine is running L bar 0 65 0 65 0 65 Fuel pressure at engine inlet...

Page 45: ...g kg 2310 2334 2310 2334 2310 2334 Engine wet weight with standard accessories instal led w o coupling Engine with standard oil pan R kg 2450 2450 2450 Sound Description 12V1600 C50 12V1600 C60 12V160...

Page 46: ...s Firing order 10V A1 B4 A4 B3 A3 B2 A2 B5 A5 B1 12V A1 B2 A5 B4 A3 B1 A6 B5 A2 B3 A4 B6 Direction of rotation Direction of rotation viewed from driving end Counterclockwise non reversible 46 Technica...

Page 47: ...the engine with standard oil pan Engine model Height A Length B Width C 10V1600Cx0 Approx 1402 mm Approx 1693 mm Approx 1231 mm 12V1600Cx0 Approx 1402 mm Approx 1865 mm Approx 1231 mm MS150100 06E 20...

Page 48: ...th mid sump oil pan Engine model Height A Length B Width C 10V1600Cx0 Approx 1487 mm Approx 1693 mm Approx 1231 mm 12V1600Cx0 Approx 1487 mm Approx 1865 mm Approx 1231 mm 48 Technical Data MS150100 06...

Page 49: ...ction Lube oil system Check engine oil level Page 132 Coolant circuit Check engine coolant level Page 139 Check charge air coolant level Page 146 Coolant circuit Preheat engine coolant with coolant pr...

Page 50: ...servation Specifications A001070 Lube oil system Check engine oil level Page 132 Fuel system Vent Page 110 Coolant circuit If engine is out of service for more than one year change engine coolant Page...

Page 51: ...en it is actuated with the engine running Risk of injury through ejected parts Only actuate the starter when the engine is stationary Ensure that the starter can not be actuated accidentally Do not ex...

Page 52: ...h skin Do not inhale oil vapor Operational checks Item Action Control and display panels Check readings of operational data speed temperature pressures Engine oil Check engine oil level Page 132 Engin...

Page 53: ...emission label for intactness 3 Check that emission label is fully legible 4 Check content of emission label Does the label on the engine match the label document in the Business Portal Equipment Does...

Page 54: ...unning at full load subjects it to extreme thermal and mechanical stress es Overheating of and therefore damage to components is possible Before shutting down the engine allow it to idle until the eng...

Page 55: ...eratures are expected and the engine is to remain out of service for an extended period but engine coolant has no antifreeze addi tive the engine room is not heated the coolant is not kept at a suitab...

Page 56: ...n directly at seals or electronic components such as connectors or ECUs Cleaning the plant 1 Carry out plant cleaning only in areas where an appropriate oil separator is provided environmental protec...

Page 57: ...k for presence readability and content of emission la bel Page 53 W1001 Replace fuel filter or fuel filter element Page 113 W1003 Check belt condition and tension replace as necessary Page 152 W1008 R...

Page 58: ...ction Poor turning on starter Battery low or faulty u Charge or replace battery manufacturer s documentation Engine cabling faulty u Check Page 157 Air in fuel system u Vent fuel system Page 110 Engin...

Page 59: ...rective action Air filter clogged u Replace air filter Page 117 Charge air cooler dirty u Contact Service Exhaust turbocharger faulty u Contact Service Coolant leaks at charge air cooler Cause Correct...

Page 60: ...not at operating temperature u Run engine up to operating temperature Water in fuel u Check fuel system on fuel prefilter Drain fuel prefilter Page 115 Charge air cooler u Contact Service 60 Troubles...

Page 61: ...Contact Service 9 HI T Coolant Intercooler Cause Corrective action The charge air cooler coolant temperature measured at sensor B26 has violated limit value 1 The charge air cooler coolant temperature...

Page 62: ...if no DiaSys is available 21 HI T Exhaust B Cause Corrective action The exhaust gas temperature measured at sensor B4 22 has violated limit value 1 The exhaust gas temperature is too high u Run injec...

Page 63: ...speed test has been tripped Emergency engine stop has been tripped 1 Restart the engine if the emergency stop was tripped by an engine overspeed test 2 Contact Service if the emergency stop was trippe...

Page 64: ...1 Reduce power 2 Contact Service 37 SS ETC2 Speed Cause Corrective action The speed of the LP turbocharger on the B side measured at sensor B44 2 has violated limit value 2 The turbocharger speed is t...

Page 65: ...ine 2 Contact Service 64 SS P Crankcase Cause Corrective action The crankcase pressure measured at sensor B50 has violated limit value 2 The crankcase pressure is too high 1 Stop engine 2 Contact Serv...

Page 66: ...Contact Service 83 LO P Fuel Common Rail Cause Corrective action The HP fuel pressure at sensor B48 1 has violated the limit value The fuel pressure is too low u Contact Service 89 SS Engine Speed too...

Page 67: ...alue 1 1 Check state of battery charge plant 2 Check plug connections to engine governor Page 159 3 Contact Service 119 LOLO ECU Supply Voltage Cause Corrective action The ECU supply voltage has viola...

Page 68: ...rective action CAN bus 1 for MTU Automation e g ECU MAU SAM disrupted or faulty 1 Check plug connections to engine governor Page 159 2 Contact Service 187 AL CAN1 Error Passive Cause Corrective action...

Page 69: ...Cause Corrective action The signal from the exhaust gas temperature sensor B4 21 in the exhaust pipe on the A side is faulty or missing 1 Check engine wiring Page 157 2 Contact Service 207 SD T Exhau...

Page 70: ...e signal from the coolant level sensor F33 is faulty or missing 1 Check engine wiring Page 157 2 Contact Service 221 SD P Diff Lube Oil Cause Corrective action The signal s from lube oil pressure sens...

Page 71: ...Corrective action The signal from the speed sensor B44 1 ETC A side is faulty or missing 1 Check engine wiring Page 157 2 Contact Service 233 SD Charger 2 Speed Cause Corrective action The signal fro...

Page 72: ...Short circuit fault in injector wiring of cylinder A3 or injector faulty 1 Check wiring of injector concerned Page 157 2 Contact Service 324 AL Wiring Cylinder A4 Cause Corrective action Short circui...

Page 73: ...B4 or injector faulty 1 Check wiring of injector concerned Page 157 2 Contact Service 335 AL Wiring Cylinder B5 Cause Corrective action Short circuit fault in injector wiring of cylinder B5 or inject...

Page 74: ...r A6 1 Check wiring of injector concerned Page 157 2 Contact Service 351 AL Open Load Cylinder B1 Cause Corrective action Disruption fault in injector cabling to cylinder B1 1 Check wiring of injector...

Page 75: ...2 system side TOP 2 1 Check wiring Page 157 2 Contact Service 383 AL Wiring TOP 3 Cause Corrective action Short circuit or line break at transistor output 3 system side TOP 3 1 Check wiring Page 157...

Page 76: ...ck engine wiring Page 157 2 Contact Service 438 LO P Fuel 2 Common Rail Cause Corrective action The HP fuel pressure measured at sensor B48 2 has violated the limit value The fuel pressure is too high...

Page 77: ...D P HD2 Cause Corrective action The signal from the rail pressure sensor B48 2 B side is faulty or missing u Contact Service 448 HI P Charge Air Cause Corrective action The charge air pressure measure...

Page 78: ...ed red alarm 1 Observe any other messages 2 Contact Service 480 AL Ext Engine Protection Cause Corrective action External engine protection function is active 1 Check plant signal 2 Contact Service 48...

Page 79: ...f the HP fuel pump cannot be activated 1 Check engine wiring Page 157 2 Contact Service 549 AL Power Cut Off detected Cause Corrective action ECU operating voltage was switched off while the engine wa...

Page 80: ...ruption or short circuit in wiring to servomotor of bypass flap B side M52 2 1 Check engine wiring Page 157 2 Contact Service 609 AL Wiring PWM_CM7 Cause Corrective action Wire break or short circuit...

Page 81: ...k engine wiring Page 157 2 Contact Service 629 AL Flap Egr A Defect Cause Corrective action The EGR shutoff flap on the A side M53 1 is faulty u Contact Service 630 AL Flap Egr B Defect Cause Correcti...

Page 82: ...157 2 Contact Service 647 SD P Exhaust Lambda Cause Corrective action The signal from the exhaust gas pressure sensor B91 3 is faulty or missing 1 Check engine wiring Page 157 2 Contact Service 693 A...

Page 83: ...796 AL HI T Charge Air B Cause Corrective action The charge air temperature on the B side measured at sensor B9 3 has violated limit value 1 The charge air temperature is too high u Contact Service 79...

Page 84: ...ion fault alarm 1 Observe any other messages 2 Contact Service 843 SD T Charge Air before EGR Cause Corrective action The signal from the charge air temperature sensor B9 1 BT9 1 is faulty or missing...

Page 85: ...he HP accumulator at sensors B48 1 A side and or B48 2 B side exceeds the limit value u Contact Service 852 AL Max Blank Shot time expired Cause Corrective action The alarm is generated when the engin...

Page 86: ...action Faulty rapid reference movement of the EGR shutoff flap on the B side M53 2 always executed after restarting the ECU 1 Check state of battery charge plant 2 Contact Service 877 AL Bypass FlpA W...

Page 87: ...lue invalid Cause Corrective action Status information of the lambda sensor B89 generated in case of temporarily implausible measured values or lambda sensor defect 1 Acknowledge alarm 2 Replace lambd...

Page 88: ...ective action The first Engine CAN CAN 3 connected to the engine sensors actuators is faulty 1 Check engine wiring Page 157 2 Contact Service 976 AL CAN4 Bus Off Cause Corrective action The second Eng...

Page 89: ...60 2 Contact Service 1097 AL Flap Egr A Communication Lost Cause Corrective action The ECU can no longer detect the EGR shutoff flap on the A side M53 1 MA53 1 on the bus 1 Check engine wiring Page 15...

Page 90: ...too high Cause Corrective action The internal electronics of the servomotor for the bypass flap on the A side M52 1 MA52 1 signal excessively high temperature u Contact Service 1105 AL Flap Bypass A T...

Page 91: ...the ECU has violated limit value 2 The intake air differential pressure is too high 1 Check air filter for dirt plant 2 Contact Service 1120 AL Flap Egr A Calibration Drive Err Cause Corrective actio...

Page 92: ...ation movement is not plausible The teach in angle does not lie between the minimum and maximum range u Contact Service 1130 AL Short Circuit Analog Out 1 Cause Corrective action Incorrect plant value...

Page 93: ...2 u Contact Service 1178 AL J1939 Heartbeat1 Lost Cause Corrective action No message via J1939 plant bus CAN2 u Contact Service 1179 AL J1939 Heartbeat2 Lost Cause Corrective action No message via J19...

Page 94: ...d after restarting the ECU Limit value 2 1 Check state of battery charge plant 2 Contact Service 1189 AL Bypass FlpB Wear Limit2 Cause Corrective action Faulty rapid reference movement of the bypass f...

Page 95: ...plant 2 Check plug connections to engine governor Page 159 3 Contact Service 1380 AL Act Byp A Ref Drv EngStop Cause Corrective action This alarm is set in the fault memory if homing the bypass flap A...

Page 96: ...ine governor Page 159 3 Check engine wiring Page 157 4 Contact Service 1390 AL Flap Egr A Wear Limit 1 Cause Corrective action The range of rotation on homing the EGR shutoff flap A side M53 1 has vio...

Page 97: ...flap mechanism is significantly worn u Contact Service 1398 AL Flap Byp A Wear Limit 2 Cause Corrective action The range of rotation on homing the bypass flap A side M52 1 has violated limit value 2 T...

Page 98: ...Check exhaust flap for damage Page 120 2 Contact Service on detecting any other damage at the exhaust flap 1408 AL Flap Egr A restricted Limit 1 Cause Corrective action The range of rotation on homing...

Page 99: ...act Service 1416 AL Flap Byp A restricted Limit 2 Cause Corrective action The range of rotation on homing the bypass flap A side M52 1 has violated limit value 2 Flap travel is restricted 1 Check smoo...

Page 100: ...f the servomotor e g resulting from faulty insulation defective seals signs of sooting Page 119 2 Contact Service 1432 AL Act Byp A Temperature Alert Cause Corrective action The internal servomotor el...

Page 101: ...ly voltage for the bypass flap A side M52 1 is below 9 V or above 32 V The servomotor assumes a safe position 1 Check state of battery charge plant 2 Check plug connections to engine governor Page 159...

Page 102: ...nger 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 Remove guard plate from flywhee...

Page 103: ...e are no persons in the engine s danger zone WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Engine Test run 1 Start engine Page 51 2 Perfor...

Page 104: ...10128 1 Torque wrench 20 100 Nm F30026582 1 Box wrench 14 mm F30028346 1 Allen keys 2 10 mm F30453050 1 Barring tool F6790714 1 Preparatory steps 1 Remove cylinder head cover Page 107 2 Install barrin...

Page 105: ...n firing TDC 2 Cylinder A1 is in overlap TDC I Inlet valve X Exhaust valve 4 Use feeler gage to determine the distance between valve bridge and rocker arm 5 Adjust valve clearance if the deviation fro...

Page 106: ...llen key 5 mm Name Size Type Lubricant Value Standard Nut M10x1 Tightening torque 43 4 Nm 6 Check valve clearance readjust as necessary Final steps 1 Remove barring tool Page 102 2 Install cylinder he...

Page 107: ...1 Torque screwdriver 1 0 5 0 Nm F30452774 1 Engine oil Gasket Spare Parts Catalog NOTICE Contamination of components Damage to component Observe manufacturer s instructions Check components for specia...

Page 108: ...f gasket and replace as necessary 3 Wet the sealing lip along the trapezoidal edges with engine oil on the side of the gas ket facing the cylinder head 4 Fit gasket 5 Screw wiring onto injectors 1 Nam...

Page 109: ...cutive tightening sequence starting at position 1 1 to 18 on 12V engines The same tightening specifications apply to 10V engines making allowance for the smaller number of screws on the long sides 7 T...

Page 110: ...enting fuel system with external fuel pump Note Do not open the high pressure system when putting into operation and servicing 1 Open the unpressurized return to the tank 1 and connect to the tank or...

Page 111: ...threaded vent plug 3 and tighten by hand Venting fuel filter with cooler 1 Unlock fuel priming pump at fuel prefilter screw out handle see above Step 1 2 Provide a suitable container in which to colle...

Page 112: ...handle until bub ble free fuel emerges from the threaded vent plug arrowed 5 Screw in threaded vent plug arrowed and tighten to specified torque using a torque wrench Name Size Type Lubricant Value St...

Page 113: ...ridge before installing Fill the filter cartridge after installing to prevent contami nated fuel ingressing the HP fuel system Variant A Replacing fuel filter with cooler 1 Provide a suitable containe...

Page 114: ...ed torque using a torque wrench Name Size Type Lubricant Value Standard Drain screw A F 10 Tightening torque Engine oil 6 5 1 3 Nm 12 Vent fuel system Page 110 Variant B Replacing fuel filter without...

Page 115: ...ire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Wear protective clothing protective gloves and safety glasses facial protection Draining fuel prefilter 1 Provid...

Page 116: ...es facial protection Preparatory step u Provide a suitable container in which to collect the fuel Replacing fuel prefilter 1 Close fuel supply 2 Unscrew filter cover 1 3 Remove filter cover 1 with fil...

Page 117: ...t air filters Note Component is genset manufacturer s or vehicle manufacturer s scope of supply Replacing air filter Note The engine must not be operated without an air filter After removing the air f...

Page 118: ...8 6 Air Intake 8 6 1 Service indicator Check See manufacturer s documentation 118 Air Intake MS150100 06E 2017 08 TIM ID 0000005482 004...

Page 119: ...t Gas Recirculation 8 7 1 Exhaust flaps Overview 1 EGR shutoff flap right 2 Bypass flap right 3 Bypass flap left 4 EGR shutoff flap left MS150100 06E 2017 08 Exhaust Gas Recirculation 119 TIM ID 00000...

Page 120: ...quipment thermal gloves Avoid unprotected contact with hot surfaces Checking coupling rod mechanical Note For installation positions of EGR shutoff flaps refer to overview drawing Page 119 1 Remove gu...

Page 121: ...ly Risk of crushing hands To carry out the teach in routine keep clear of the safety zone of the actuation mechanism in the intake and exhaust area Switch off the operating voltage of the engine gover...

Page 122: ...Name Size Type Lubricant Value Standard Locknut Tightening torque Assembly compound Molykote P 37 16 Nm 2 Nm 3 Fit nut 4 with washer 5 and tighten to specified torque using a torque wrench 4 Mount gu...

Page 123: ...torque Name Size Type Lubricant Value Standard Countersunk head screw Tightening torque Assembly compound Molykote P 37 5 Nm 1 Nm 7 Use DiaSys to carry out an actuator test learning run Dialog system...

Page 124: ...rfaces Risk of burns Allow the engine to cool down to below 50 C before beginning work Wear suitable protective equipment thermal gloves Avoid unprotected contact with hot surfaces Checking coupling r...

Page 125: ...f movement and make sure that there is no ex cessive play Result Replace coupling rod 1 if it is jamming slug gish or features excessive play Page 126 6 Install actuator with holder on turbine hous in...

Page 126: ...sk of crushing hands To carry out the teach in routine keep clear of the safety zone of the actuation mechanism in the intake and exhaust area Switch off the operating voltage of the engine governor b...

Page 127: ...ers 1 4 Remove actuator 3 with holder 6 and cou pling rod 4 from turbine housing 5 Remove lockwasher 2 and coupling rod 1 Installing coupling rod 1 Install coupling rod 1 and lockwasher 2 MS150100 06E...

Page 128: ...upling rod 4 must be connected under tensile stress with the lever 4 Connect coupling rod 4 with lever of flap and install lockwasher 5 5 Install screw 2 with washer 1 and tighten to specified tighten...

Page 129: ...ct air jet at people Always wear safety goggles face mask and ear defenders Checking EGR cooler 1 Remove all covers 2 Remove coolant pipe after EGR cooler 3 To do this unscrew screws at EGR cooler 1 a...

Page 130: ...own to below 50 C before beginning work Wear suitable protective equipment thermal gloves Avoid unprotected contact with hot surfaces WARNING Components have sharp edges Risk of injury Wear protective...

Page 131: ...care to avoid damaging the coiled spring pin when installing the EGR flaps 4 Tighten diagonally opposing new screws 1 to specified initial tightening torque using a torque wrench then tighten to final...

Page 132: ...tive clothing protective gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear...

Page 133: ...d back to the oil pan 3 Remove oil dipstick 1 from guide tube and wipe it 4 Insert oil dipstick 1 into guide tube up to the stop pull out after approx 10 seconds 5 Read off the oil level on the side o...

Page 134: ...after approx 10 seconds 4 Read off the oil level on the side of the oil dipstick inscribed ENGINE IDLING 5 The oil level must be in the cross hatched area between the lines marking the upper 1 and low...

Page 135: ...h Risk of injury and poisoning Allow the product to cool to below 50 C before beginning work Wear protective clothing protective gloves and goggles safety mask Avoid contact with skin Do not inhale oi...

Page 136: ...specified torque using a torque wrench Name Size Type Lubricant Value Standard Drain screw M27x2 Tightening torque Engine oil 57 5 Nm 7 Replace engine oil filter Page 137 Fill with new engine oil Note...

Page 137: ...ing ring Spare Parts Catalog Oil filter element Spare Parts Catalog WARNING Oil is hot Oil can contain residue substances which are harmful to health Risk of injury and poisoning Allow the product to...

Page 138: ...sealing ring 2 if damaged 8 Coat sealing ring 2 with oil 9 Insert new oil filter element 3 in cover 1 and press in until it locks in place 10 Screw on cover 1 with oil filter element 3 and tighten to...

Page 139: ...kwise to the first stop and allow pressure to escape 2 Continue to turn breather valve counterclock wise and remove 3 Check coolant level coolant must be visible at the lower edge of the cast in eye o...

Page 140: ...Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 141 2 Fill with engine coolant Page 143 140 Coolant Circuit General High Temperature Circuit...

Page 141: ...vide an appropriate container to drain the coolant into 2 Switch off preheater if installed Engine coolant Draining 1 Turn breather valve of filler neck on coolant expansion tank counterclockwise to f...

Page 142: ...ng ring on engine coolant pump and use torque wrench to tighten to specified tightening torque Name Size Type Lubricant Value Standard Screw M14x1 5 Tightening torque 35 3 Nm 2 Install drain plugs wit...

Page 143: ...e Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask WARNING High level of engine noise when the engine is running Risk of damage to hearing W...

Page 144: ...r marking plate 2 Check proper condition of valve cover 1 clean sealing faces if required 3 Fit valve cover 1 and close it Final steps 1 Start engine and run at idle speed for some minutes 2 Check coo...

Page 145: ...ing Wear ear protectors Engine coolant pump Relief bore check 1 Check relief bore 1 for coolant discharge Result In case of continuous discharge of large vol umes of coolant 0 1ml h contact Serv ice N...

Page 146: ...counterclockwise to the first stop and allow pressure to escape 2 Continue to turn breather valve counterclock wise and remove 3 Check coolant level coolant must be visible at marker plate 4 Top up c...

Page 147: ...al tools Material Spare parts Designation Use Part No Qty Coolant Charge air coolant Change 1 Drain charge air coolant Page 148 2 Fill with charge air coolant Page 149 MS150100 06E 2017 08 Low Tempera...

Page 148: ...coolant expansion tank counterclockwise to the first stop and allow pressure to escape 3 Continue to turn breather valve counterclock wise and remove 4 Draw off precipitated corrosion inhibitor oil fr...

Page 149: ...of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear...

Page 150: ...plate 2 Install plug screws of filling points with new sealing rings 3 Check proper condition of valve cover 1 clean sealing faces if required 4 Fit valve cover 1 and close it Final steps 1 Start engi...

Page 151: ...ge to hearing Wear ear protectors Charge air coolant pump check ing relief bore 1 Check relief bore 1 for coolant discharge Result In case of continuous discharge of large vol umes of coolant 0 1ml h...

Page 152: ...ine without protective covers or safety guards which meet applicable accident prevention regulations Ensure that the safety guards can prevent body parts from being drawn in by rotating components Dri...

Page 153: ...components WARNING Belt tensioner spring is pretensioned Risk of hands being crushed Lock belt tensioner in position Only use specified tools and devices Belt drive version A Drive belt replacement 1...

Page 154: ...e against the spring force almost up to the stop to remove the 8 mm steel pin 8 Remove 8 mm steel pin 9 Relieve belt tensioner and remove square of socket wrench extension 10 Make sure that drive belt...

Page 155: ...oggles face mask and ear defenders NOTICE Cleaning agents should not be left to take effect for too long Damage to components is possible Observe manufacturer s instructions Cleaning the battery charg...

Page 156: ...ystems Driving End and Free End Coupling 8 14 1 Coupling Checking radial axial play See manufacturer s documentation 156 Drive Systems Driving End and Free End Coupling MS150100 06E 2017 08 TIM ID 000...

Page 157: ...ure fit tighten loose clamps 6 Replace faulty cable clamps 7 Visually inspect the following electrical components for damage Connector housings Contacts Insulation of contacts on battery charging gene...

Page 158: ...propyl alcohol to remove coarse dirt from housing surface 2 Use isopropyl alcohol to remove dirt from the connector and cable surfaces 3 Check legibility of cable labels Clean or replace illegible lab...

Page 159: ...n engine governor 1 Check firm seating of all connectors on the engine governor Ensure that the clips 1 are engaged 2 Check firm seating of all screws 2 on engine governor cable clamps Make sure that...

Page 160: ...fore beginning work Wear suitable protective equipment thermal gloves Avoid unprotected contact with hot surfaces NOTICE High voltage Risk of damage to components Switch off ignition before replacing...

Page 161: ...en sor 3 only just before installation Note Do not wipe off thread grease of manufactur er 3 Coat sensor 3 thread with specified assem bly compound as required 4 Screw in sensor 3 by hand 5 Use torque...

Page 162: ...elow 50 C before beginning work Wear suitable protective equipment thermal gloves Avoid unprotected contact with hot surfaces NOTICE Ceramic cell breakage due to shock or impact Risk of damage to comp...

Page 163: ...ompound to sen sor thread if required 3 Screw in sensor by hand 4 Tighten nut 2 to specified torque using a torque wrench Name Size Type Lubricant Value Standard Nut M18 x 1 5 Tightening torque Assemb...

Page 164: ...ture Sensor DDEC Detroit Diesel Electronic Controls Engine control system made by Detroit Diesel DDL Diagnostic Data Link Diagnostic lines DDR Diagnostic Data Reader Diagnostic unit DIN Deutsches Inst...

Page 165: ...value lower than 1st mini mum limit value LOLO Low Low Alarm Measured value lower than 2nd mini mum limit value LSG Limiting Speed Governor Maximum speed governor N A Not applicable not available ND N...

Page 166: ...Alarm Sensor comparison fault TPS Throttle Position Sensor TRS Timing Reference Sensor T xyz Temperature xyz Temperature measuring point xyz UT Unterer Totpunkt Bottom Dead Center BDC VNT Variable No...

Page 167: ...of a malfunction for information on changes in conditions of use and for supplying spare parts Your contact person in our Customer Assistance Center E mail info mtu online com Tel 49 7541 9077777 Fax...

Page 168: ...Engine Barring manually Page 102 Allen keys 2 10 mm Part No F30453050 Qty Used in 1 8 2 1 Valve clearance Check and adjustment Page 104 Assembly device Part No F6794712 Qty Used in 1 8 12 2 Drive belt...

Page 169: ...F6790714 Qty Used in 1 8 2 1 Valve clearance Check and adjustment Page 104 Box wrench 14 mm Part No F30028346 Qty Used in 1 8 2 1 Valve clearance Check and adjustment Page 104 Crocus cloth Part No Qt...

Page 170: ...in 1 8 7 6 EGR cooler Check Page 129 Ratchet adapter Part No F30027340 Qty Used in 1 8 1 1 Engine Barring manually Page 102 Qty Used in 1 8 2 2 Cylinder head cover Removal and installation Page 107 Qt...

Page 171: ...7 EGR cooler Replacement Page 130 Socket 32 mm Part No F30006120 Qty Used in 1 8 4 1 Fuel filter Replacement Page 113 Qty Used in 1 8 9 1 Engine oil filter Replacement Page 137 Torque screwdriver 1 0...

Page 172: ...placement Page 121 Qty Used in 1 8 7 7 EGR cooler Replacement Page 130 Qty Used in 1 8 16 3 NOx sensor Replacement Page 160 Torque wrench 8 40 Nm Part No F30043446 Qty Used in 1 8 2 2 Cylinder head co...

Page 173: ...1 8 4 1 Fuel filter Replacement Page 113 Qty Used in 1 8 9 1 Engine oil filter Replacement Page 137 Torque wrench 4 20 Nm Part No F30044239 Qty Used in 1 8 4 1 Fuel filter Replacement Page 113 MS15010...

Page 174: ...Check Bypass flap 124 EGR shutoff flap 120 Coupling rods Replacement Bypass flaps 126 EGR shutoff flaps 121 Cylinder Designation 22 Cylinder head cover Installation 107 Removal 107 D Direction of rota...

Page 175: ...efilter Draining 115 Filter element replacement 116 Fuel system Venting 110 H Hotline 167 L Lambda sensor Replacement 162 Lifting requirements 21 M Main dimensions Engine 47 Maintenance Schedule Maint...

Page 176: ...periods 3 months 50 After scheduled out of service period 49 T Transportation Description 18 Lifting requirements 21 Troubleshooting 58 V Valve clearance Adjustment 104 Check 104 W Warning notices sta...

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