MTU 12 V 2000 M86 Operating Instructions Manual Download Page 131

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9 Appendix B

9.1 Special Tools

Assembly sleeve

Part No.:

F30454554

Qty.:
Used in:

1
7.7.2 Injector – Removal and installation (→ Page 81)

Barring gear

Part No.:

F6783914

Qty.:
Used in:

1
7.5.2 Valve clearance – Check and adjustment
(→ Page 77)

Centering jig

Part No.:

F6783025

Qty.:
Used in:

1
7.5.1 Cylinder head cover – Removal and installation
(→ Page 76)

MS150119/00E 2014-08

| Appendix B | 131

DCL-ID: 0000033801 - 001

Summary of Contents for 12 V 2000 M86

Page 1: ...Operating Instructions Diesel engine 12 V 2000 M86 12 V 2000 M96 12 V 2000 M96L 16 V 2000 M86 16 V 2000 M96 16 V 2000 M96L MS150119 00E...

Page 2: ...d Table 1 Applicability 2014 Copyright MTU Friedrichshafen GmbH This publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written consent...

Page 3: ...llation 61 7 1 3 Installation locations for SOLAS shielding 62 7 2 Engine 67 7 2 1 Engine Barring manually 67 7 2 2 Engine Cranking on starting system 68 7 3 Cylinder Liner 69 7 3 1 Instructions and c...

Page 4: ...mounts 112 7 20 Belt Drive 113 7 20 1 Drive belt Condition check 113 7 21 Battery Charging Generator 114 7 21 1 Battery charging generator drive Drive belt replacement 114 7 22 Wiring General for Eng...

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: ...truck Install the crankshaft locking device and the locking screws for the engine mounts prior to engine trans portation Secure the engine against tilting during transportation The engine must be addi...

Page 8: ...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 9: ...starter with compressed air Clean the interior of the flywheel housing with a class H dust extractor Observe the safety data sheet Safety requirements during maintenance and repair work Take special c...

Page 10: ...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 11: ...ent i e protect them against moisture in particular Pack age faulty electronic components or assemblies properly before dispatching for repair Moisture proof Shock proof Wrapped in antistatic foil if...

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

Page 13: ...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 14: ...medial action NOTICE In the event of a situation involving potentially adverse effects on the product Consequences Material damage Remedial action Additional product information Safety notices 1 This...

Page 15: ...tion bare phosphat ized or galvanized and 10 9 surface condition bare or phosphatized The values in the table are based on a friction coefficient tot 0 125 Coat thread and mating faces of screws and n...

Page 16: ...per MMN 209 standard and material and machining as per MMN 389 standard bright surface or phosphatized The values in the table are based on a friction coefficient tot 0 125 Coat thread and mating face...

Page 17: ...rew shaft from torsion when tightening MA Tightening torques Tightening torques for plug screws as per MTN 5183 1 standard The standard applies to plug screws as per DIN 908 DIN 910 and DIN 7604 with...

Page 18: ...s for plug screws DIN 908 DIN 910 and DIN 7604A with short screwed plug Thread inserted in Steel gray cast iron MA Nm Al alloy MA Nm M10 x 1 15 15 M12 x 1 5 30 25 M14 x 1 5 35 30 M16 x 1 5 40 35 M18 x...

Page 19: ...8 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 torque for banjo screws as per MTN 5183 2 standard The standard appl...

Page 20: ...ring 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 1 5 25 M18 x 1 5 30 M...

Page 21: ...hate coating and oiled or galvanized Coat thread and mating faces beneath heads with engine oil prior to assembly An assembly tolerance of 10 of the table values is admissible for unavoidable deviatio...

Page 22: ...ion nut firmly by hand noticeable in crease in force then tighten another 1 4 turn 90 past this point Tightening torques for threaded journals with O rings as per ISO 6149 2 Thread Torque Nm 10 M8 x 1...

Page 23: ...valves see ISO 7789 Tightening torques for threaded journals with O rings as per 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 M2...

Page 24: ...ions do not apply to ORFS valves and fittings When connecting hose fittings with sealing heads and the associated adapters proceed as follows contrary to the instructions for pipe unions Hose fitting...

Page 25: ...8 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 20...

Page 26: ...cordance 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 and letter...

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

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

Page 29: ...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 30: ...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 31: ...een distributor and HP accumulator 1 Union nut 2 O ring 3 Thrust ring 4 Thrust screw 5 O ring 6 O ring 7 Thrust ring 8 Pressure pipe 9 Jacket pipe MS150119 00E 2014 08 General Information 31 TIM ID 00...

Page 32: ...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 33: ...ex haust flap 14 Actuating cylinder for air flap 15 Cylinder head cover 16 Electric starter 17 Engine mounting 18 Exhaust housing 19 Oil filler neck 20 Oil dipstick 21 Engine coolant filler neck 22 C...

Page 34: ...wheel housing 11 Fuel filter 12 Carrier housing lower sec tion 13 Bleeder valve a Air intake b Exhaust outlet KS Kupplungsseite driving end Engine model designation Key to the engine model designation...

Page 35: ...erview Sensors and actuators on engine driving end Item Name Monitoring of 1 B4 21 ETC temperature A side 2 B4 22 ETC temperature B side 3 B13 1 Crankshaft speed MS150119 00E 2014 08 General Informati...

Page 36: ...er 2 B5 2 Lube oil pressure after filter 3 B5 1 Lube oil pressure after filter 4 F33 Coolant level probe in expansion tank 5 B21 Raw water pressure 6 B6 2 Coolant temperature 7 B6 1 Coolant temperatur...

Page 37: ...on left side Item Name Monitoring of 1 Y27 1 4 2 directional control valve A side 2 B54 Oil replenishment pump pressure 3 A18 EIM Engine Interface Module MS150119 00E 2014 08 General Information 37 T...

Page 38: ...2 B48 HP fuel pressure 3 Y45 1 Pressure regulating valve 4 A19 EIL electronic label 5 B16 Coolant pressure 6 M8 CR pump 7 F46 Leak fuel level 8 B1 Camshaft speed B side 9 B13 2 Crankshaft speed 10 Y27...

Page 39: ...tercooler 3 Y56 4 2 directional control valve recirculation 4 A77 EMU Engine Monitoring Unit 5 B7 Lube oil temperature 6 B33 Fuel temperature 7 Y45 2 Pressure regulating valve 8 B9 Charge air temperat...

Page 40: ...1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Power related data Unit Value Number of cylinders 12 Rated engine speed A rpm 2450 Fuel st...

Page 41: ...g L bar 0 3 Fuel pressure at supply connection to engine min when engine is running L bar 0 3 Fuel pressure at engine inlet connection max when engine is starting L bar 0 25 Fuel supply flow max R Lit...

Page 42: ...n max operating inclina tions R Liters Oil pan capacity dipstick mark min standard oil system design max operat ing inclinations L Liters Oil pan capacity dipstick mark max standard oil system design...

Page 43: ...RELATED DATA power ratings are net brake power as per ISO 3046 Power related data Unit Value Number of cylinders 16 Rated engine speed A rpm 2450 Fuel stop power ISO 3046 16V 2000 M86 A kW 1630 16V 20...

Page 44: ...ine is starting L bar 0 25 Fuel supply flow max A Liter min GENERAL OPERATING DATA Engine speed Unit Value Firing speed from R rpm 100 Firing speed to R rpm 120 STARTER electric Starter Unit Value Rat...

Page 45: ...rat ing inclinations L Liters 106 Oil pan capacity dipstick mark max standard oil system design max oper ating inclinations L Liters 134 WEIGHT Weight Unit Value Engine dry weight with mounted standar...

Page 46: ...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 46 Technical Data MS150119 00E 2014 08 TIM ID 0000038135 001...

Page 47: ...ensions Engine model Length A Width B Height C 16V 2000 M86 16V 2000 M96 16V 2000 M96L 2495 mm 1318 mm 1455 mm 12V 2000 M86 12V 2000 M96 12V 2000 M96L 2082 mm 1292 mm 1440 mm MS150119 00E 2014 08 Tech...

Page 48: ...Fuel prefilter pressure gage Align adjustable pointer with position of pressure indicator Page 85 Fuel system Vent Page 83 Raw water pump if located above waterline Prime approx 3 to 4 liters Filling...

Page 49: ...t level Page 103 Coolant circuit Heat engine coolant with coolant preheating unit Fuel prefilter Drain water and contaminants Page 86 Battery charging generator drive Check condition of drive belt Pag...

Page 50: ...n Check exhaust color Page 57 Fuel prefilter Check if suction side pressure indicated at the fuel prefilter is within the limit Page 85 Drain water and contaminants Page 86 Air filter Check signal rin...

Page 51: ...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 52: ...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 53: ...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 54: ...table 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 te...

Page 55: ...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 56: ...Drain water and contaminants from fuel prefilter Page 86 W0508 X Check reading on differential pressure gage of fuel prefilter Page 85 W1001 Replace fuel filter or fuel filter element Page 84 W1002 Ch...

Page 57: ...s documentation Engine wiring faulty u Check Page 115 Air in fuel system u Vent fuel system Page 83 Engine governor ECU is defective u Contact Service Engine fires unevenly Cause Corrective action In...

Page 58: ...ts Charge air pressure too low Cause Corrective action Air filter clogged u Check signal ring position of contamination indicator Page 95 Charge air cooler is contaminated u Contact Service Exhaust tu...

Page 59: ...ead is faulty u Contact Service Piston rings are defective u Contact Service Cylinder liner defective u Contact Service White exhaust gas Cause Corrective action Engine is not at operating temperature...

Page 60: ...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 61: ...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 62: ...Primarily fit SOLAS shielding as per MTN 5233 Page 60 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 63: ...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 64: ...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 65: ...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 66: ...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 66 Task Description MS150119 00E...

Page 67: ...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 68: ...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 69: ...ences around 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 direct...

Page 70: ...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 71: ...rst 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 sharply de...

Page 72: ...Final steps 1 Install injector Page 81 2 Install cylinder head cover Page 76 72 Task Description MS150119 00E 2014 08 TIM ID 0000000015 016...

Page 73: ...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 74: ...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 75: ...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 76: ...ng and installing cylin der head cover 1 Remove screws 1 2 Remove cylinder head cover 2 with gas ket from cylinder head 3 Clean installation surface 4 Check condition of gasket of cylinder head cover...

Page 77: ...0423 1 Measuring instrument Y4345888 1 Preparatory steps 1 Remove air filter Page 94 2 Remove cylinder head cover Page 76 Positioning A1 piston at TDC Note With cylinder head and valve gear installed...

Page 78: ...ition Cylin der 1 2 3 4 5 6 7 8 Firing TDC in cylinder A1 Bank A E A A A E A E Bank B E A E E A E E A A Overlap TDC in cylinder A1 Bank A E E A E A E A E A Bank B A E E A A A E 1 Loosen locknut 1 and...

Page 79: ...RNING Oils oil vapors are combustible explosive Risk of fire and explosion Avoid open flames electric sparks and ignition sources Do not smoke NOTICE HP fuel pump not filled with engine oil Damage to...

Page 80: ...lacement Special tools Material Spare parts Designation Use Part No Qty Injector Spare Parts Catalog Injector Replacement u Remove injector and install new one Page 81 80 Task Description MS150119 00E...

Page 81: ...re and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Preparatory steps 1 Close off fuel supply to engine 2 Remove upper part of cylinder head cover Page 76 Removing i...

Page 82: ...stall lower part of cylinder head cover 6 9 Coat thread and sealing cone of HP line 1 and injector 2 with engine oil 10 Align injector 2 and HP line 1 with alignment device 11 Connect HP line 1 to HP...

Page 83: ...ctrical sparks and ignition sources Do not smoke Fuel system Venting 1 Unlock fuel priming pump unscrew handle 2 Open threaded vent plug 1 on filter head 3 Operate the pump 2 with the handle until bub...

Page 84: ...flames electrical sparks and ignition sources Do not smoke Replacing easy change fuel filter with the engine stopped 1 Stop engine and disable engine start 2 Unscrew easy change filter 2 from filter b...

Page 85: ...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 86: ...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 87: ...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 88: ...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 89: ...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 90: ...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 91: ...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 92: ...y goggles face mask and ear defenders Intercooler Checking conden sate drain line for coolant dis charge and obstruction 1 With the engine running check the conden sate drain line 1 on engine driving...

Page 93: ...are parts Designation Use Part No Qty Air filter Spare Parts Catalog Replacing the air filter 1 Remove old air filter and install new air filter Page 94 2 Reset signal ring of contamination indicator...

Page 94: ...p 2 2 Remove air filter 3 and clamp 2 from connecting flange of intake housing 1 3 Clean connecting flange 1 of intake hous ing and check for obstruction 4 Place new air filter 3 with clamp 2 onto int...

Page 95: ...bled Checking signal ring position 1 If the signal ring is completely visible in the control window 2 replace air filter Page 93 2 After installation of new filter press reset button 1 Result Engaged...

Page 96: ...heck Preconditions Engine is stopped and starting disabled Checking starter condition 1 Check securing screws of starter for secure seating and tighten if required 2 Check wiring Page 115 96 Task Desc...

Page 97: ...1 marks 4 Top up with oil up to the max 1 mark Page 98 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 98: ...ety mask Avoid 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 f...

Page 99: ...tive clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor NOTICE Damage to component Severe material damage For filter replacement with the engine running operate th...

Page 100: ...gh Temperature Circuit 7 16 1 Engine coolant drain and venting points 16V 2000 M96L 1 Engine coolant drain screw 2 Filling screw on seawater pump 3 Seawater pump drain 100 Task Description MS150119 00...

Page 101: ...screw 2 Engine coolant drain screw Preheating line inlet con nection 1 Engine coolant overflow line 2 Engine coolant filler neck 3 Engine coolant drain screw MS150119 00E 2014 08 Task Description 101...

Page 102: ...1 Engine coolant drain screw 102 Task Description MS150119 00E 2014 08 TIM ID 0000055251 001...

Page 103: ...low pressure to escape 2 Continue to turn breather valve counterclockwise and remove 3 Check coolant level coolant must be visible at the bottom edge of the cast in eye of the filler neck Checking coo...

Page 104: ...e Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 105 2 Fill with engine coolant Page 106 104 Task Description MS150119 00E 201...

Page 105: ...3 Switch off preheating unit Draining engine coolant 1 Turn breather valve of filler neck on coolant expansion tank Page 100 counterclockwise to first stop and allow pressure to escape 2 Continue to...

Page 106: ...cracks in the engine Fill top up coolant only into cold engine Filling with engine coolant 1 Turn breather valve of coolant expansion tank Page 33 counterclockwise until the first stop and al low pre...

Page 107: ...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 108: ...expansion tank Page 100 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 109: ...oves and goggles safety mask Charge air coolant Draining 1 Provide a suitable container to collect the raw water 2 Open union nut on drain line 2 on driving end and free end Result It may take a littl...

Page 110: ...e engine s danger zone WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Raw water pump Relief bore check 1 Check relief bore 1 for oil and co...

Page 111: ...ws for firm seating Preconditions Engine is stopped and starting disabled Engine mounting checking securing screws for firm seating 1 Check securing screws for firm seating 2 Tighten loose threaded co...

Page 112: ...hecking the condition of resilient mounts 1 Wipe rubber surface with dry cloth do not use organic detergents 2 Visually inspect resilient mounts for cracking and deformation 3 Check rubber surfaces fo...

Page 113: ...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 114 Drive belt C Chunking Drive belt Belt...

Page 114: ...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 115: ...re 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 component...

Page 116: ...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 117: ...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 118: ...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 119: ...tarting disabled Checking EMU plug connections 1 Check both connectors on EMU 2 for firm seating Ensure that the clips 1 are engag ed 2 Check screws 3 of cable clamps on EMU 2 for firm seating Ensure...

Page 120: ...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 121: ...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 122: ...e governor from engine 1 Note or mark assignment of cables and connectors 2 Remove all screws 2 3 Undo clips 3 on connectors 4 Remove all male connectors 5 Remove screws 1 6 Take off engine governor I...

Page 123: ...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 124: ...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 125: ...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 126: ...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 127: ...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 128: ...he same time identifier of German standards Deutsche In dustrie Norm DIS Display Unit Display panel DL Default Lost Alarm CAN bus missing DOC Diesel Oxidation Catalyst DPF Diesel Particulate Filter EC...

Page 129: ...oint xyz specifies the measur ing point designation PAN Panel Control panel PAU Power Automation Unit Module for monitoring control and plant related sys tem integration of peripheral components PCU P...

Page 130: ...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 131: ...r Removal and installation Page 81 Barring gear Part No F6783914 Qty Used in 1 7 5 2 Valve clearance Check and adjustment Page 77 Centering jig Part No F6783025 Qty Used in 1 7 5 1 Cylinder head cover...

Page 132: ...o F6783914 Qty Used in 1 7 2 1 Engine Barring manually Page 67 Feeler gage Part No Y4345893 Qty Used in 1 7 5 2 Valve clearance Check and adjustment Page 77 Mandrel Part No 8205892861 08 Qty Used in 1...

Page 133: ...ngine coolant Sample extraction and analysis Page 108 Offset screwdriver Part No F30002816 Qty Used in 1 7 5 2 Valve clearance Check and adjustment Page 77 Oil filter wrench Part No F30379104 Qty Used...

Page 134: ...F6790991 Qty Used in 1 7 7 2 Injector Removal and installation Page 81 Puller Part No F6790992 Qty Used in 1 7 7 2 Injector Removal and installation Page 81 Puller Part No F6795777 Qty Used in 1 7 7 2...

Page 135: ...ty Used in 1 7 4 2 Crankcase breather Oil separator element re placement diaphragm check and replacement Page 74 Rigid endoscope Part No Y20097353 Qty Used in 1 7 3 2 Cylinder liner Endoscopic examina...

Page 136: ...Part No Qty Used in 1 4 8 Plant Cleaning Page 55 Torque wrench 10 60 Nm Part No F30510423 Qty Used in 1 7 5 2 Valve clearance Check and adjustment Page 77 Torque wrench 10 60 Nm Part No F30452769 Qty...

Page 137: ...wrench 6 50 Nm Part No F30027336 Qty Used in 1 7 4 2 Crankcase breather Oil separator element re placement diaphragm check and replacement Page 74 MS150119 00E 2014 08 Appendix B 137 DCL ID 000003380...

Page 138: ...dimensions 47 Shutdown 52 Start 51 Engine Control Unit Self test 121 Engine coolant Change 104 Draining 105 Filling 106 Level check 103 Engine coolant Sample extraction and analysis 108 Engine data 12...

Page 139: ...afety notices standards 14 Safety regulations Auxiliary materials 12 Environmental protection 12 Fire prevention 12 Fluids and lubricants 12 Organizational requirements 6 Personnel requirements 6 Safe...

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