MTU 12 V 2000 M84 Operating Instructions Manual Download Page 87

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7.6 Injection Valve / Injector

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.

(→ Page 88)

MS150063/02E 2014-03

| Task Description | 87

TIM-ID: 0000004642 - 002

Summary of Contents for 12 V 2000 M84

Page 1: ...Operating Instructions Diesel engine 12 V 2000 M84 16 V 2000 M84 MS150063 02E...

Page 2: ...d may not be used in any way whether in whole or in part without the prior written consent of MTU Friedrichshafen GmbH This particularly applies to its reproduction distribution editing transla tion m...

Page 3: ...Cleaning 62 5 Maintenance 5 1 Maintenance task reference table QL1 63 6 Troubleshooting 6 1 Fuel treatment system Troubleshooting 64 6 2 Troubleshooting 65 7 Task Description 7 1 SOLAS 68 7 1 1 SOLAS...

Page 4: ...18 Battery Charging Generator 126 7 18 1 Battery charging generator drive Drive belt replacement 126 7 19 Fuel Supply System 127 7 19 1 Water drain valve Check 127 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: ...t Transport without flange mounted gearbox A max permissible diagonal pull 70 B max permissible diagonal pull 35 Illustration is valid for 12 16V 2000 M engines MS150063 02E 2014 03 Safety 7 TIM ID 00...

Page 8: ...the engine at the lifting eyes of the bear ing pedestal or use a means of transportation which is appropriate for the given weight forklift truck Install the crankshaft locking device and the locking...

Page 9: ...or 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 l...

Page 10: ...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 c...

Page 11: ...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 hydraul...

Page 12: ...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 13: ...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 Noncomplian...

Page 14: ...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 equi...

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: ...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 17: ...l 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 e...

Page 18: ...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 19: ...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 20: ...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 21: ...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 22: ...led 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 deviat...

Page 23: ...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 M10...

Page 24: ...w 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 2...

Page 25: ...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 uni...

Page 26: ...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 27: ...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 28: ...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 co...

Page 29: ...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 30: ...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 co...

Page 31: ...ide 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 reduce...

Page 32: ...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 32 General Information MS150063 02E 2014 03 TIM ID 00...

Page 33: ...t 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 pres...

Page 34: ...haust turbocharger 12 Actuating cylinder for ex haust flap 13 Carrier housing 14 Cylinder head cover 15 Engine mounting 16 Oil pan 17 Battery charging generator 18 Coolant filler neck 19 Engine Interf...

Page 35: ...g lower sec tion 10 Carrier housing middle section 11 Relief valve 12 Exhaust outlet KS engine driving end Engine model designation Key to the engine model designation 12V 16V 2000 Mxyz 12 16 Number o...

Page 36: ...s are insignificant Also applies similarly to 12V Item Designation Monitoring of 1 B3 Intake air temperature 2 B9 Charge air temperature 3 B7 Lube oil temperature 4 B10 Charge air pressure 5 B44 Turbo...

Page 37: ...sure before filter 3 B5 1 Lube oil pressure after filter 4 B5 2 optional Lube oil pressure after filter 5 F33 Engine coolant level expansion tank 6 B21 optional Raw water pressure 7 B6 2 optional Cool...

Page 38: ...gine driving end Item Designation Monitoring of 1 B1 ECU Camshaft speed 2 B13 2 optional EMU Crankshaft speed 3 B13 ECU Crankshaft speed 38 General Information MS150063 02E 2014 03 TIM ID 0000008412 0...

Page 39: ...al control valve 2 YB33 Fuel temperature 3 B48 Fuel pressure in rail 4 B16 optional Coolant pressure 5 F46 Leak fuel level 6 Y27 2 4 2 directional control valve B side 7 B4 22 Exhaust temperature B si...

Page 40: ...side 3 B54 optional Lube oil pressure replenishment pump System sensors These sensors are fitted outside the engine Designation Monitoring of B19 Starting air pressure B70 Fuel prefilter water level B...

Page 41: ...bar 1000 Site altitude above sea level m 100 Power related data power ratings are net brake power as per ISO 3046 Number of cylinders 12 Rated engine speed A rpm 2450 Fuel stop power ISO 3046 A kW 122...

Page 42: ...n engine is starting L bar 0 25 Fuel supply flow max R liters min 6 3 General operating data Number of cylinders 12 Firing speed from R rpm 100 Firing speed to R rpm 120 Starter electric Number of cyl...

Page 43: ...ers 87 Oil pan capacity at dipstick mark max standard oil system Option max operating inclinations L Liters 105 Weights main dimensions Number of cylinders 12 Engine dry weight with attached standard...

Page 44: ...Site altitude above sea level m 100 Power related data power ratings are net brake power as per ISO 3046 Number of cylinders 16 Rated engine speed A rpm 2450 Fuel stop power ISO 3046 A kW 1630 Genera...

Page 45: ...en engine is starting L bar 0 25 Fuel supply flow max R liters min 7 3 General operating data Number of cylinders 16 Firing speed from R rpm 100 Firing speed to R rpm 120 Starter electric Number of cy...

Page 46: ...ers 115 Oil pan capacity at dipstick mark max standard oil system Option max operating inclinations L Liters 138 Weights main dimensions Number of cylinders 16 Engine dry weight with attached standard...

Page 47: ...3 3 Firing order Firing order 12 V A1 B5 A5 B3 A3 B6 A6 B2 A2 B4 A4 B1 16 V A1 B5 A3 A5 B2 B8 A2 A8 B3 A7 B4 B6 A4 A6 B1 B7 MS150063 02E 2014 03 Technical Data 47 TIM ID 0000038135 001...

Page 48: ...in dimensions Engine model Length A Width B Height C 12V 2000 M84 approx 2094 mm approx 1295 mm approx 1350 mm 16V 2000 M84 approx 2511 mm approx 1295 mm approx 1390 mm 48 Technical Data MS150063 02E...

Page 49: ...Fuel prefilter pressure gage Align adjustable pointer with position of pressure indicator Page 93 Fuel system Vent Page 90 Raw water pump if located above waterline Prime approx 3 to 4 liters Filling...

Page 50: ...t level Page 117 Coolant circuit Heat engine coolant with coolant preheating unit Fuel prefilter Drain water and contaminants Page 94 Battery charging generator drive Check condition of drive belt Pag...

Page 51: ...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 53 2 Shut down fuel treatment system Page 61 MS1...

Page 52: ...ves 4 Switch on fuel treatment system Page 56 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 53: ...e 3 Switch on fuel treatment system and operate it for some minutes Page 56 Result Fuel is sucked from the tank dirt particles and water are filtered and separated then the fuel is deliv ered via the...

Page 54: ...ncy HAT 1 Switch on fuel treatment system Page 56 2 Start engine Page 57 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 55: ...heck exhaust color Page 65 Fuel prefilter Check if suction side pressure indicated at the fuel prefilter is within the limit Page 93 Drain water and contaminants Page 94 Air filter Check signal ring p...

Page 56: ...re 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 57: ...sons 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 A...

Page 58: ...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 f...

Page 59: ...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 electron...

Page 60: ...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 61: ...inet until water discharge from the outlet stops 2 Switch off fuel treatment system 3 Close ball valve at the inlet to the fuel treatment system 4 Close ball valve at the outlet of the fuel treatment...

Page 62: ...ressed 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 environmenta...

Page 63: ...inants from fuel prefilter Page 55 W0508 Check reading on differential pressure gage of fuel prefilter Page 55 W1001 Replace fuel filter or fuel filter element Page 91 W1002 Check valve clearance Page...

Page 64: ...ped 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 u R...

Page 65: ...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 66: ...r Page 103 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 67: ...action Engine is not at operating temperature u Run engine to reach operating temperature Water in fuel u Drain fuel prefilter Page 94 Intercooler leaking u Contact Service MS150063 02E 2014 03 Troubl...

Page 68: ...s Material Spare parts Designation Use Part No Qty Shield A4 735233000100 10 Shield A5 735233000101 14 Shield A7 735233000103 6 Shield A8 735233000104 2 SOLAS shielding Installation 1 Pinpoint install...

Page 69: ...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 i...

Page 70: ...Primarily fit SOLAS shielding as per MTN 5233 Page 68 Free end B side Item Type of shielding Comments 1 free end B side Shield A7 On fuel delivery pump 2 free end B side Shield A7 On HP fuel pump Fre...

Page 71: ...priming pump Driving end A side Item Type of shielding Comments 1 Driving end A side Shield A5 On air flap 2 driving end A side Shield A4 On brazed on union 3 driving end A side Shield A5 On turbocha...

Page 72: ...plate Driving end Item Type of shielding Comments 1 driving end Shield A4 Turbocharger lubrication left side 2 driving end Shield A4 Turbocharger lubrication center Driving end Item Type of shielding...

Page 73: ...Turbocharger flap 3 driving end B side Shield A4 On brazed on union 4 driving end B side Shield A5 On air flap 5 driving end B side Shield A4 To turbocharger lubrication Driving end B side Item Type...

Page 74: ...of shielding Comments 1 Driving end A side Shield A5 To flap control Driving end B side Item Type of shielding Comments 1 driving end B side Shield A5 To flap control 74 Task Description MS150063 02E...

Page 75: ...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 Fi...

Page 76: ...n 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 are...

Page 77: ...attern 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 s...

Page 78: ...Final steps 1 Install injector Page 88 2 Install cylinder head cover Page 86 78 Task Description MS150063 02E 2014 03 TIM ID 0000000015 016...

Page 79: ...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 80: ...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 81: ...Never direct air jet at people Always wear safety goggles face mask and ear defenders Crankcase breather Cleaning oil pre separator element 1 Remove cover 5 from housing 4 2 Take off oil pre separator...

Page 82: ...ch 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 c...

Page 83: ...phragm 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 Screw...

Page 84: ...F30510423 1 Measuring instrument Y4345888 1 Preparatory steps 1 Remove air filter Page 102 2 Remove cylinder head cover Page 86 Positioning piston of cylinder A1 at TDC Note With cylinder head and val...

Page 85: ...I X X I I Inlet Inlet valve adjustment admissible X eXhaust Exhaust valve adjustment admissible Valve adjustment inadmissible 4 Use feeler gage to determine the distance between valve bridge and rocke...

Page 86: ...nstalling 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 R...

Page 87: ...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 88 MS150063 02E 2014 03 Task Descript...

Page 88: ...059351 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 2...

Page 89: ...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 90: ...mp unscrew handle 2 Open vent plugs on filter head Note New version has two threaded vent plugs old version has four threaded vent plugs 3 Operate the pump with the handle until fuel without bubbles c...

Page 91: ...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 filte...

Page 92: ...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 93: ...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 94: ...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 95: ...l 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 Turn...

Page 96: ...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 engin...

Page 97: ...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 98: ...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 99: ...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 w...

Page 100: ...ways 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 101: ...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 102 2 Reset signal ring of contamination indicator...

Page 102: ...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 103: ...isabled Checking signal ring position 1 If the signal ring is completely visible in the control window 2 replace air filter Page 101 2 After installation of new filter press reset button 1 Result Enga...

Page 104: ...eck 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 133 104 Task Desc...

Page 105: ...1 marks 4 Top up with oil up to the max 1 mark Page 106 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 106: ...id 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 107: ...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 108: ...ment crank engine with starting system Page 76 11 Check oil level Page 105 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 109: ...arts 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 or...

Page 110: ...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 111: ...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 Nm...

Page 112: ...15 Coolant Circuit General High Temperature Circuit 7 15 1 Drain and venting points 12 V 16 V 1 Overflow line expansion tank 2 Filler neck 112 Task Description MS150063 02E 2014 03 TIM ID 0000038198 0...

Page 113: ...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 MS150063 02E 2014 03 Task De...

Page 114: ...Left side 1 Engine coolant drain plug 2 Engine coolant drain plug M14x1 5 114 Task Description MS150063 02E 2014 03 TIM ID 0000038198 001...

Page 115: ...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 MS150063 02E 2014 03 Task Descriptio...

Page 116: ...Driving end KS 1 Engine coolant drain plug 2 Connection for oil extrac tion 116 Task Description MS150063 02E 2014 03 TIM ID 0000038198 001...

Page 117: ...ather valve on coolant expansion tank Page 34 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 118: ...e Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 119 2 Fill with engine coolant Page 120 118 Task Description MS150063 02E 201...

Page 119: ...3 Switch off preheating unit Draining engine coolant 1 Turn breather valve of filler neck on coolant expansion tank Page 112 counterclockwise to first stop and allow pressure to escape 2 Continue to...

Page 120: ...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 34 counterclockwise until the first stop and al low pre...

Page 121: ...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 engine...

Page 122: ...expansion tank Page 112 counterclockwise until first stop and allow pressure to escape 2 Continue to turn breather valve counterclockwise and remove 3 Draw off precipitated corrosion inhibitor oil fr...

Page 123: ...goggles safety mask Coolant filter Replacement 1 Turn breather valve of coolant expansion tank counterclockwise Page 34 to the first stop and allow pressure to escape 2 Continue to turn breather valve...

Page 124: ...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 58 and disable en...

Page 125: ...ed 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 126 Drive belt C Chunking Drive belt Belt...

Page 126: ...over 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 posi...

Page 127: ...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 MS150063 02E 2014 03 Task Description 127 TIM ID...

Page 128: ...es Do not smoke Checking differential pressure gauge 1 Switch on fuel treatment system Page 56 2 Set the alarm points at the differential pressure gauge to zero Result Alarm is initiated with preset d...

Page 129: ...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 130: ...k 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 131: ...mponents 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 ele...

Page 132: ...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 133: ...ed 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 li...

Page 134: ...ve 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 o...

Page 135: ...propyl 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 connectors...

Page 136: ...table 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 plu...

Page 137: ...arting 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 t...

Page 138: ...ng 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 that...

Page 139: ...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 140: ...ntrol 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 Un...

Page 141: ...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 142: ...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 appro...

Page 143: ...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 144: ...oring 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 145: ...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 146: ...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 147: ...nel 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 orga...

Page 148: ...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 149: ...tor Removal and installation Page 88 Box wrench Part No F30451199 Qty Used in 1 7 6 2 Injector Removal and installation Page 88 Centering jig Part No F6783025 Qty Used in 1 7 5 2 Cylinder head cover R...

Page 150: ...n 1 7 6 2 Injector Removal and installation Page 88 Engine barring gear Part No F6783914 Qty Used in 1 7 2 1 Engine Barring manually Page 75 Qty Used in 1 7 5 1 Valve clearance Check and adjustment Pa...

Page 151: ...Y4345888 Qty Used in 1 7 5 1 Valve clearance Check and adjustment Page 84 MTU test kit Part No 5605892099 00 Qty Used in 1 7 15 7 Engine coolant Sample extraction and analysis Page 122 Offset screwdr...

Page 152: ...Qty Used in 1 7 15 8 Coolant filter Replacement Page 123 Open end wrench bit Part No F30025897 Qty Used in 1 7 6 2 Injector Removal and installation Page 88 Puller Part No F6790629 Qty Used in 1 7 6 2...

Page 153: ...het Part No F30027339 Qty Used in 1 7 19 5 Coalescer filter element Replacement Page 131 Rigid endoscope Part No Y20097353 Qty Used in 1 7 3 1 Cylinder liner Endoscopic examination Page 77 Socket wren...

Page 154: ...rt No Qty Used in 1 4 13 Plant Cleaning Page 62 Torque wrench 10 60 Nm Part No F30510423 Qty Used in 1 7 5 1 Valve clearance Check and adjustment Page 84 Torque wrench 4 20 Nm Part No F30044239 Qty Us...

Page 155: ...Qty Used in 1 7 4 2 Crankcase breather Oil separator element re placement diaphragm check and replacement Page 82 Qty Used in 1 7 19 5 Coalescer filter element Replacement Page 131 MS150063 02E 2014...

Page 156: ...9 D Designations Engine sides and cylinders 27 Differential pressure gauge Check 128 Drain and venting points 112 Drive belt Condition check 125 E ECU 7 Installation 140 Removal 140 EMU Cleaning 135 E...

Page 157: ...ion 28 Pump capacity Check 130 Putting into operation Fuel treatment system 53 R Raw water pump Relief bore Check 124 S Safety notices standards 15 Safety regulations Auxiliary materials 13 Environmen...

Page 158: ...W Water drain valve Check 127 Water level probe 3 in 1 rod electrode Check 129 158 Appendix B MS150063 02E 2014 03 DCL ID 0000016266 002...

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