MTU 12 V 1600 R50 Operating Instructions Manual Download Page 127

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8 Appendix A

8.1 Abbreviations

Abbre-
viation

Meaning

Explanation

Alternating Current

AdBlue -

Brand name of the German Association of Vehicle
Manufacturers (VDA)
Urea solution with 32.5% urea concentration

Alarm

ANSI

American National Standards Institute

Association of American standardization organiza-
tions

BDM

Backup Data Module

Data backup module

Series

Betriebsstoffvorschrift

Fluids and Lubricants Specifications, MTU publica-
tion no. A00..

CAN

Controller Area Network

Data bus system, bus standard

CaPoS Capacitor Power System

Capacitor-based starting system

CDC

Calibration Drift Compensation

Drift compensation must be reset in the engine gov-
ernor using DiaSys® to ensure optimum emissions
and consumption characteristics.

CRC

Cyclic Redundancy Control

Check sum procedure to detect data transmission
faults

Direct Current

DEF

Diesel Exhaust Fluid

Urea solution with 32.5% urea concentration
Designation used in Northern America

DIFF

Difference

DIN

Deutsches Institut für Normung e. V.

At the same time identifier of German standards
(DIN = “Deutsche Industrie-Norm”)

Default Lost

Alarm: Default CAN bus failure

DOC

Diesel Oxidation Catalyst

DPF

Diesel Particulate Filter

ECU

Engine Control Unit

Engine governor

EGR

Exhaust Gas Recirculation

ETC

Exhaust turbocharger

Frequency Output

GND

Ground

High

Alarm: Measured value exceeds 1st maximum limit

HIHI

High High

Alarm: Measured value exceeds 2nd maximum limit

High Pressure

High Temperature

Identification number

IIG

Initiale Injektorgleichstellung

The injector code must be entered in the engine gov-
ernor using DiaSys® to ensure optimum emissions
and consumption characteristics.

MS15033/02E 2015-02

| Appendix A | 127

TIM-ID: 0000009959 - 011

Summary of Contents for 12 V 1600 R50

Page 1: ...Operating Instructions Diesel engine 12 V 1600 R50 MS15033 02E...

Page 2: ...hout the prior written consent of MTU Friedrichshafen GmbH This particularly applies to its reproduction distribution editing transla tion microfilming and storage or processing in electronic systems...

Page 3: ...er 89 7 3 1 Fuel filter Replacement 89 7 3 2 Fuel prefilter Drain condensate 91 7 3 3 Fuel prefilter Filter element replacement 92 7 4 Air Filter 93 7 4 1 Air filter element Removal and installation o...

Page 4: ...s Cleaning 121 7 14 3 Engine governor Checking plug in connections 122 7 14 4 NOx sensor Replacement 123 7 14 5 Lambda sensor Replacement 125 8 Appendix A 8 1 Abbreviations 127 8 2 MTU contact persons...

Page 5: ...with the Spare Parts Catalog MTU contact Service partner In the original as delivered configuration or in a configuration approved by the manufacturer in writ ing including engine control parameters...

Page 6: ...tion authorities The manufacturer does not accept any liability for violations of the emission reg ulations The maintenance schedules of the manufacturer must be observed over the entire life cycle of...

Page 7: ...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 Training Cen...

Page 8: ...engine must only be transported in installation position max permissible diagonal pull 10 If the engine is supplied with special aluminum foil packing lift the engine at the lifting eyes of the bear...

Page 9: ...truments as well as the monitoring signaling and alarm systems are working properly Safety requirements for operation The operator must be familiar with the controls and displays The operator must be...

Page 10: ...ounts damping elements couplings and V belts must not be painted They may only be installed after painting the engine or must be covered before painting work is carried out The following applies to st...

Page 11: ...he power supply master switch Disconnect the battery Separate the electrical ground of electronic equipment from the ground of the unit No other maintenance or repair work must be carried out in the v...

Page 12: ...Always use connector pliers to tighten union nuts on connectors Subject the device as well as the product to a functional testing on completion of all repair work In particular check the function of t...

Page 13: ...lubricants and filters in accordance with local regulations Within the EU batteries can be returned free of charge to the manufacturer where they will be properly recycled Fluids and lubricants auxili...

Page 14: ...e spray stands provided with fume extraction systems ensure that the area is well ventilated Make sure that neighboring work areas are not adversely af fected There must be no naked flames in the vici...

Page 15: ...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 16: ...gnated 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 17: ...flap before EGR cool er 13 Lifting eye free end 14 Cylinder head 15 EGR cooler 16 Engine mount 17 Engine governor 18 Oil pan 19 Exhaust elbow 20 Flywheel housing 21 Coupling 22 Starter Engine model d...

Page 18: ...ore exhaust gas recirculation 6 B9 2 Charge air temperature after exhaust gas recirculation left side 7 B5 3 Lube oil pressure before filter option 8 B88 2 NOx sensor right side nitrogen oxide levels...

Page 19: ...91 3 Exhaust gas pressure 3 B48 2 Fuel pressure in HP system HP line right side 4 B26 Charge air coolant temperature 5 B93 Lube oil level and temperature option 6 A19 EIL Engine Ident Label 7 B1 Camsh...

Page 20: ...er high pressure speed right side 4 M52 2 Bypass flap of HP turbocharger right side 5 B50 Crankcase pressure option 6 B4 22 Exhaust temperature ritght side 7 B13 Crankshaft speed 8 B44 1 Speed of HP t...

Page 21: ...e 2 B7 Lube oil temperature 3 M53 1 EGR shut off flap before cooler left side 4 B34 1 Fuel pressure after filter 5 B34 2 Fuel pressure before filter option 6 B6 3 Engine coolant temperature in cylinde...

Page 22: ...Data 3 1 Firing order 12 V A1 B2 A5 B4 A3 B1 A6 B5 A2 B3 A4 B6 Direction of rotation Direction of rotation as viewed on driving end c c w not reversible 22 Technical Data MS15033 02E 2015 02 TIM ID 00...

Page 23: ...3 2 Engine Main dimensions Item Dimensions Length B approx 1871 mm Width C approx 1228 mm Height A approx 1327 mm MS15033 02E 2015 02 Technical Data 23 TIM ID 0000035495 003...

Page 24: ...greater than the specified value The actual value must be smaller than the specified value Not sufficiently validated value 10 tolerance Not sufficiently validated value 5 tolerance ID Produkttyp Pro...

Page 25: ...C 95 Coolant temperature after engine shutdown L C 112 Coolant pump Inlet pressure max L bar 2 5 Thermostat Starts to open R C 79 Thermostat Fully open R C 92 Coolant system low temperature circuit I...

Page 26: ...Oil pan capacity at dipstick mark max standard oil system Option max operating inclinations L Liters 65 Weights main dimensions ID 1 Dry engine weight basic configuration engine R kg 2290 Acoustics I...

Page 27: ...Action Lube oil system Check engine oil level Page 97 Coolant circuit Check engine coolant level Page 100 Check charge air coolant level Page 107 Coolant circuit Preheat engine coolant with coolant pr...

Page 28: ...reservation Specifications A001070 Lube oil system Check engine oil level Page 97 Fuel system Vent Page 87 Coolant circuit If engine is out of service for more than one year change engine coolant Page...

Page 29: ...t there are no persons 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 Starting engine Item Action Switchgear c...

Page 30: ...and display panels Check readings of operational data speed temperature pressures Engine oil Check engine oil level Page 97 Engine operation Check engine visually for leaks and general condition Check...

Page 31: ...ossible Before shutting down the engine allow it to idle until the engine temperatures decrease and constant levels are indicated Stopping engine Item Action Temperature indications Wait until engine...

Page 32: ...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 suitable temperature the antifreeze concentration is insufficie...

Page 33: ...sed 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 environmental p...

Page 34: ...011619 1 Ratchet adapter F30027340 1 DANGER Rotating and moving engine parts Risk of crushing danger of parts of the body being caught or pulled in Before cranking the engine with starter system make...

Page 35: ...ing steps Barring engine manually Var iant B Note Remove starter if necessary 1 Remove screw 2 on flywheel housing 2 Remove end cover 1 3 Engage barring device 2 in ring gear and install on flywheel h...

Page 36: ...or fuel filter element Page 89 W1005 X Replace air filter Page 95 W1008 Replace engine oil filter when changing engine oil or when the interval years is reached at the latest Page 99 W1013 Replace dr...

Page 37: ...tion by starter Battery low or faulty u Charge or replace battery manufacturer s documentation Engine wiring defective u Check Page 119 Air in fuel system u Vent fuel system Page 87 Engine governor de...

Page 38: ...w Cause Corrective action Air filter clogged u Replace air filter Page 95 Intercooler clogged u Contact Service Exhaust turbocharger defective u Contact Service Coolant leaks at intercooler Cause Corr...

Page 39: ...not at operating temperature u Run engine to reach operating temperature Water in fuel u Check fuel system on fuel prefilter Drain fuel prefilter Page 91 Intercooler leaky u Contact Service MS15033 0...

Page 40: ...ive action Charge air temperature too high 1 Reduce power 2 If fault code number 9 is signaled at the same time then it has priority 6 SS T Charge Air Limit 2 ZKP Number 2 0121 932 Yellow alarm power...

Page 41: ...100 922 Red alarm engine stop Cause Corrective action Lube oil pressure too low 1 Check oil level top up as necessary Page 97 2 Acknowledge alarm 3 Restart engine Page 29 4 Request towing locomotive i...

Page 42: ...P Diff Lube Oil ZKP Number 2 0154 931 Yellow alarm warning Cause Corrective action Differential pressure at oil filter too high u Replace oil filter Page 99 26 SS P Diff Lube Oil ZKP Number 2 0154 93...

Page 43: ...otive if required 33 Hi P Diff Fuel ZKP Number 2 0114 931 Yellow alarm warning Cause Corrective action Differential pressure on fuel filter too high u Check fuel filter replace if necessary 34 SS P Di...

Page 44: ...en it has priority 52 SS T Lube Oil Limit 2 ZKP Number 2 0125 932 Red alarm power reduction 20 Cause Corrective action Lube oil temperature too high 1 Reduce power 2 If fault code number 67 is signale...

Page 45: ...engine stop Cause Corrective action Crankcase pressure too high 1 Contact Service 2 Request towing locomotive if required 65 LO P Fuel ZKP Number 2 0102 921 Yellow alarm warning Cause Corrective acti...

Page 46: ...Corrective action Rail pressure set value DBR fuel limitation start of injection readjusted retarded HP fuel control block jamming or wiring faulty u Contact Service 83 LO P Fuel Common Rail Limit 1...

Page 47: ...ached ZKP Number 2 1090 923 Yellow alarm warning Cause Corrective action Starter speed not reached termination of starting sequence starter does not turn or turns slowly 1 Initiate new starting attemp...

Page 48: ...meter faulty u Replace consumption meter 104 AL Eng Hours Counter Defect ZKP Number 1 8004 623 Yellow alarm warning Cause Corrective action Hour meter faulty u Replace hour meter 118 LO ECU Power Sup...

Page 49: ...rm warning Cause Corrective action Electronic unit temperature too high 1 Reduce power 2 Observe subsequent fault messages e g intercooler 180 AL CAN1 Node Lost ZKP Number 2 0500 680 Yellow alarm warn...

Page 50: ...arning Cause Corrective action A programming error occurred when attempting to copy a received PU data module into the Flash module u Contact Electroncs Service 186 AL CAN1 Bus Off ZKP Number 2 0500 6...

Page 51: ...e shielding as necessary 201 SD T Coolant ZKP Number 1 8004 570 Yellow alarm power limitation 20 Cause Corrective action Coolant temperature sensor faulty short circuit or wire break u Check sensors B...

Page 52: ...77 Yellow alarm warning Cause Corrective action Exhaust temperature sensor on B side faulty short circuit or wire break u Check sensor B4 22 and wiring replace as necessary Page 119 208 SD P Charge Ai...

Page 53: ...Lube Oil ZKP Number 1 8004 575 Yellow alarm warning Cause Corrective action Lube oil temperature sensor faulty short circuit or wire break u Check sensor B7 and wiring replace as necessary Page 119 21...

Page 54: ...stop Cause Corrective action Engine stop due to camshaft sensor fault and a previous crankshaft sensor fault in the same operating cycle 1 Check sensor and wiring to connectors B1 and B13 replace as...

Page 55: ...w alarm warning Cause Corrective action Pressure sensors for differential fuel pressure faulty short circuit or wire break Fault only occurs in connection u Check sensors B34 1 B34 2 and cabling repla...

Page 56: ...mitter 3 Contact Service 321 AL Wiring Cylinder A1 ZKP Number 1 8004 520 Yellow alarm warning Cause Corrective action Short circuit in cylinder injector wiring Result Misfiring u Check solenoid valve...

Page 57: ...t in cylinder injector wiring Result Misfiring u Check solenoid valve 331 AL Wiring Cylinder B1 ZKP Number 1 8004 530 Yellow alarm warning Cause Corrective action Short circuit in cylinder injector wi...

Page 58: ...n cylinder injector wiring Result Misfiring u Check solenoid valve 341 AL Open Load Cylinder A1 ZKP Number 1 8004 540 Yellow alarm warning Cause Corrective action Open circuit in cylinder injector wir...

Page 59: ...t in cylinder injector wiring Result Misfiring u Check solenoid valve 351 AL Open Load Cylinder B1 ZKP Number 1 8004 550 Yellow alarm warning Cause Corrective action Open circuit in cylinder injector...

Page 60: ...id valve 361 AL Power Stage Low Internal Electronic Failure ZKP Number 1 8004 496 Red alarm engine stop Cause Corrective action Internal electronic fault electronics possibly faulty 1 Observe any othe...

Page 61: ...st towing locomotive if required 381 AL Wiring TOP 1 ZKP Number 2 8006 638 Yellow alarm warning Cause Corrective action Short circuit or wire break on transistor output 1 plant side 1 TOP 1 u Check wi...

Page 62: ...U PDU Low Injector Voltage Limit 1 ZKP Number 2 0141 921 Yellow alarm warning Cause Corrective action Injector voltage too low 1 Check wiring Page 119 2 Check supply 411 LOLO U PDU Injector Voltage L...

Page 63: ...Yellow alarm warning Cause Corrective action Water level sensor of fuel prefilter faulty short circuit or wire break u Check sensor and wiring replace as necessary 422 SD T Charge Air B ZKP Number 2 0...

Page 64: ...low alarm warning Cause Corrective action Injector power stage sensor defect internal fault in engine governor u Replace engine governor 446 SD P HD2 ZKP Number 1 8004 599 Yellow alarm power limitatio...

Page 65: ...required 470 SD T ECU ZKP Number 1 8004 587 Yellow alarm warning Cause Corrective action Temperature sensor for engine governor faulty short circuit or wire break u Check sensor and wiring replace as...

Page 66: ...ated by plant u Observe any other messages 500 AL Wiring POM Starter 1 ZKP Number 1 4500 900 Yellow alarm warning Cause Corrective action A cabling fault in connection of starter 1 to POM has been det...

Page 67: ...Node Lost ZKP Number 1 4500 904 Yellow alarm warning Cause Corrective action POM missing on CAN bus u Check connection and POM 506 AL Low Starter Voltage ZKP Number 1 4500 906 Yellow alarm warning Cau...

Page 68: ...ation value into flash or SD of level sensor u Check sensor and wiring replace as necessary Page 119 536 AL Wiring PWM_CM1 ZKP Number 1 1041 921 Yellow alarm warning Cause Corrective action Wire break...

Page 69: ...orrective action T Lube Oil Pan has violated the limit value too cold significantly increased engine wear Engine start might be inhibited by the locomotive control system 1 Extend preheating period 2...

Page 70: ...ered Cause Corrective action Pressure relief valve of second rail faulty u Check pressure relief valve replace as necessary 600 SD T Exhaust A B ZKP Number 1 8004 646 Red alarm power reduction 20 Caus...

Page 71: ...1041 927 Yellow alarm warning Cause Corrective action Wire break or short circuit on channel PWM_CM7 u Check wiring to connected device or check connected device actuator sensor replace if necessary...

Page 72: ...AL AGR Throttle B Defect ZKP Number 1 0700 031 Yellow alarm warning Cause Corrective action Actuator at EGR shutoff flap B or flap mechanism faulty u Replace actuator or flap 631 AL Bypass Throttle D...

Page 73: ...0700 105 Yellow alarm warning Cause Corrective action CAN lube oil level sensor faulty short circuit or wire break u Check sensor and wiring replace as necessary 637 SD T Lube Oil Pan J1939 ZKP Numbe...

Page 74: ...r Element ZKP Number 1 0700 141 Yellow alarm warning Cause Corrective action SD Smart NOx heating element faulty short circuit or wire break u Check sensors B88 1 B88 2 and cabling replace if necessar...

Page 75: ...800 990 Yellow alarm warning Cause Corrective action Bosch LSU lambda sensor faulty u Check sensor and wiring replace as necessary 757 AL Lim T Coolant NT Fan ZKP Number 2 2800 900 Yellow alarm warnin...

Page 76: ...place as necessary Page 119 807 SD Charger 4 Speed ZKP Number 1 3010 903 Yellow alarm warning Cause Corrective action Speed sensor of secondary turbocharger faulty short circuit or wire break u Check...

Page 77: ...Corrective action Charge air temperature sensor faulty short circuit or wire break u Check sensor B9 1 and wiring replace as necessary Page 119 844 AL HI T Charge Air before AGR ZKP Number 2 0147 931...

Page 78: ...or flap 872 AL EGR A Fast learn failed ZKP Number 1 0700 021 Yellow alarm warning Cause Corrective action Actuator at bypass flap or flap mechanism faulty u Replace actuator or flap 876 AL EGR B Fast...

Page 79: ...emperature too high 1 Check belt drive 2 Check coolant pump 903 AL SD T Coolant at cylinder head ZKP Number 1 0054 007 Yellow alarm warning Cause Corrective action Cylinder head coolant temperature se...

Page 80: ...ck engine in steady state condition for black exhaust color 5 Check if fault code 961 is active 6 Check engine for idle speed hunting Verify with DiaSys that the engine speed signal does not vary 7 Co...

Page 81: ...warning Cause Corrective action Internal engine fault u Contact Service 961 AL NOx p5 max BOI min active ZKP Number 1 1600 919 Yellow alarm warning Cause Corrective action Internal engine fault u Con...

Page 82: ...e 91 3 Replace filter element of fuel prefilter Page 92 4 Replace fuel filter Page 89 1025 LOLO P Fuel Common RailB ZKP Number 2 0115 911 Yellow alarm warning Cause Corrective action Fuel pressure in...

Page 83: ...y 5 mm F30002815 1 Barring device F6790714 1 Preparatory steps u Remove cylinder head cover Page 86 Diagram for 12V engines two crankshaft positions 1 Cylinder A1 is in firing TDC 2 Cylinder A1 is in...

Page 84: ...B side Page 34 A Cylinder A1 is in firing TDC B Cylinder A1 is in overlap TDC 2 Bar engine manually in direction of rotation of the engine until the straight surface arrow points up wards and the ang...

Page 85: ...locknut 1 with torque wrench to specified torque holding adjusting screw 2 firm with Allen screw Name Size Type Lubricant Value Standard Nut M10 x 1 Tightening torque 43 Nm 4 Nm 5 Check if the feeler...

Page 86: ...and re place if required 5 Position cylinder head cover and screws at positions 1 to 4 and tighten to specified initial tightening torque using a torque wrench Name Size Type Lubricant Value Standard...

Page 87: ...1 Unlock fuel priming pump screw out han dle 1 Note Catch emerging fuel with a suitable cloth 2 Loosen threaded vent plug 2 and screw out by approx 3 to 4 turns 3 Operate the pump with the handle 1 un...

Page 88: ...fuel Note Do not remove threaded vent plug 3 Open threaded vent plug arrow 4 Screw in threaded vent plug arrowed and tighten to specified torque using a torque wrench Name Size Type Lubricant Value S...

Page 89: ...crew it approx 3 to 4 turns 3 Wait 10 minutes until fuel has drained from filter housing 2 4 Remove threaded cover 1 5 Remove fuel filter element 6 Check condition of the sealing ring on the threaded...

Page 90: ...12 Vent fuel system Page 87 90 Task Description MS15033 02E 2015 02 TIM ID 0000035537 004...

Page 91: ...f fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Draining condensate from fuel prefilter 1 Provide a suitable container to collect the water 2 Open drain scre...

Page 92: ...r in which to collect the fuel Replacing fuel prefilter 1 Close fuel supply 2 Unscrew filter cover 1 3 Remove filter cover 1 with filter ele ment 3 from filter housing 4 Remove filter element 3 from f...

Page 93: ...lement Removal and installation 1 Release latches 9 2 Remove dust bowl 8 and partition 7 3 Remove collar nut 6 4 Screw off air filter element 4 5 Clean housing 3 and dust bowl 8 6 Check seal 5 for dam...

Page 94: ...Note Clean paper filter element dry only 1 Open air filter and remove filter element Page 93 2 Check seal for damage and cleanness re place if necessary 3 Clean all mating and sealing surfaces Note De...

Page 95: ...isabled Special tools Material Spare parts Designation Use Part No Qty Air filter Spare Parts Catalog Replacing air filter 1 Remove air filter and install new one Page 93 2 Reset signal ring of servic...

Page 96: ...led Checking signal ring position 1 Replace air filter if the signal ring 2 is completely visible in the red area of the ob servation window 3 Page 95 2 After installation of new filter press reset bu...

Page 97: ...and max 1 marks 4 If necessary top up to the max 2 mark Page 98 5 Insert oil dipstick 1 in guide tube up to the stop Checking oil level after the engine is stopped 1 5 minutes after stopping the engin...

Page 98: ...Avoid contact with skin Do not inhale oil vapor Draining oil via drain plug on oil pan 1 Provide a suitable container to collect the oil 2 Remove drain plug 2 and drain oil 3 Insert drain plug 2 and u...

Page 99: ...ilter covers 1 approx 3 to 4 revolutions 2 Wait 10 minutes until the oil has drained from the filter housings 3 Take off threaded cover 1 with oil filter el ement 3 4 Pull oil filter element 3 to deta...

Page 100: ...ank counterclockwise to the first stop and allow pressure to escape 2 Continue to turn breather valve counter clockwise and remove 3 Check coolant level coolant must be visi ble at the lower edge of t...

Page 101: ...e Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 102 2 Fill with engine coolant Page 104 MS15033 02E 2015 02 Task Description...

Page 102: ...Preparatory steps 1 Provide a suitable container to catch the coolant 2 Switch off preheater if installed Engine coolant Draining 1 Turn breather valve of filler neck on coolant expansion tank counter...

Page 103: ...nkcase right side 1 2 6 Open drain plugs and drain coolant at crankcase left side 1 2 7 Install drain plug with new sealing ring 8 Position breather valve on filler neck and close MS15033 02E 2015 02...

Page 104: ...ICE Cold coolant in hot engine can cause thermal stress Possible formation of cracks in the engine Fill top up coolant only into cold engine Preparatory steps 1 Turn breather valve 1 of coolant expan...

Page 105: ...inal steps 1 Start the engine and operate it at idle speed for some minutes 2 Check coolant level Page 100 top up with coolant if required MS15033 02E 2015 02 Task Description 105 TIM ID 0000000909 00...

Page 106: ...f engine noise when the engine is running Risk of damage to hearing Wear ear protectors Engine coolant pump Relief bore check 1 Check relief bore 1 for coolant discharge Permissible coolant discharge...

Page 107: ...ank counterclockwise to the first stop and allow pressure to escape 2 Continue to turn breather valve counter clockwise and remove 3 Check coolant level coolant must be visi ble at marker plate 4 Top...

Page 108: ...ecial tools Material Spare parts Designation Use Part No Qty Coolant Charge air coolant Change 1 Drain charge air coolant Page 109 2 Fill with charge air coolant Page 110 108 Task Description MS15033...

Page 109: ...ate container to drain the coolant into 2 Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to escape 3 Continue to turn breather valve counter clockw...

Page 110: ...thermal stress Possible formation of cracks in the engine Fill top up coolant only into cold engine Preparatory steps 1 Turn breather valve 1 on coolant expan sion tank counterclockwise to the first s...

Page 111: ...Final steps 1 Start the engine and operate it at idle speed for some minutes 2 Check coolant level Page 107 MS15033 02E 2015 02 Task Description 111 TIM ID 0000031875 006...

Page 112: ...ine is running Risk of damage to hearing Wear ear protectors Charge air coolant pump Re lief bore check 1 Check relief bore 1 for coolant discharge Permissible coolant discharge Up to 0 1 ml per hour...

Page 113: ...engine make sure that all safety devices are put back in place and all tools are removed from the engine Preparatory step 1 Install barring gear Page 34 2 Cut poly vee belt 2 on charge air coolant pum...

Page 114: ...kshaft 2 Fit poly vee belt 2 on front three grooves of belt pulley 3 to crankshaft and preload with assembly jig 4 3 Bar engine with barring gear until poly vee belt 2 lies completely on belt pulley 3...

Page 115: ...are Parts Catalog Diverter pulley Spare Parts Catalog WARNING Belt tensioner spring is pretensioned Risk of hands being crushed Lock belt tensioner in position Only use specified tools and devices Pre...

Page 116: ...with screw 2 5 Tighten screw 2 to specified torque using a torque wrench Name Size Type Lubricant Value Standard Screw Tightening torque Engine oil 60 Nm 10 Nm Final steps Note Remove pin before relea...

Page 117: ...to the stop to re move the 8 mm steel pin 6 Remove 8 mm steel pin 7 Release belt tensioner and remove square wrench with extension Install battery charging genera tor drive belt 1 Fit square wrench w...

Page 118: ...auge 7 Carry out this measuring procedure two times with the measuring points arranged 90 degrees from each other 8 Bearing bushing wear is equal to the half of the measured value If the measured valu...

Page 119: ...lips are closed and intact 4 Replace faulty cable clips 5 Check that cable clamps are firm tighten loose cable clamps 6 Replace faulty cable clamps 7 Visually inspect the following electrical line com...

Page 120: ...pensation parameters CDC will void the emissions certification for the en gine Resetting drift correction parameters CDC with DiaSys 1 Dialog system DiaSys E531920 2 If no DiaSys is available contact...

Page 121: ...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 or replace illegible labels...

Page 122: ...plug in connections on 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 en gine governor cable...

Page 123: ...ar suitable protective equipment thermal gloves Avoid unprotected contact with hot surfaces NOTICE High voltage Risk of damage to components Switch off ignition before replacing components NOTICE Cera...

Page 124: ...Tightening torque max 12 Nm 2 Remove protective cap on thread of sensor 3 only just before installation Note Do not wipe off the thread lubricant applied by the manufacturer 3 Coat sensor 3 thread wi...

Page 125: ...ore 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 components Avoid...

Page 126: ...the manufacturer 2 Coat sensor thread with specified assembly compound as required 3 Screw in sensor by hand 4 Tighten nut 2 to specified torque using a torque wrench Name Size Type Lubricant Value S...

Page 127: ...y Control Check sum procedure to detect data transmission faults DC Direct Current DEF Diesel Exhaust Fluid Urea solution with 32 5 urea concentration Designation used in Northern America DIFF Differe...

Page 128: ...integration of peripheral components PDU Process Data Unit POM Power Output Module Module to control starter and battery charging gen erator PU Projektierungsumgebung Project engineering environment P...

Page 129: ...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 130: ...ne Barring manually Page 34 Allen key 5 mm Part No F30002815 Qty Used in 1 7 1 1 Valve clearance Check and adjustment Page 83 Assembly jig Part No F6794712 Qty Used in 1 7 10 1 Coolant pump Drive belt...

Page 131: ...ge 83 Barring device Part No F6797426 Qty Used in 1 4 8 Engine Barring manually Page 34 Box wrench 14 mm Part No F30028346 Qty Used in 1 7 1 1 Valve clearance Check and adjustment Page 83 Feeler gauge...

Page 132: ...lacement Page 99 Qty Used in 1 7 11 1 Battery charging generator Belt tensioner and diverter pulley replacement Page 115 Qty Used in 1 7 14 4 NOx sensor Replacement Page 123 Qty Used in 1 7 14 5 Lambd...

Page 133: ...sed in 1 7 14 4 NOx sensor Replacement Page 123 Qty Used in 1 7 14 5 Lambda sensor Replacement Page 125 Torque wrench 4 20 Nm Part No F30044239 Qty Used in 1 7 2 1 Fuel system Venting Page 87 Qty Used...

Page 134: ...on 86 Removal 86 D Diverter pulley Replacement On battery charging generator 115 Drift correction parameters Reset 120 Drive belt Charge air coolant pump Replacement 113 Engine coolant pump Replacemen...

Page 135: ...duct data 12V1600R50 24 R Relief bore Engine coolant pump Check 106 S Safety notices standards 15 Safety regulations Auxiliary materials 13 Environmental protection 13 Fire prevention 13 Fluids and lu...

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