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MTU 12 V 2000 M92, Operating Instructions Manual

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MTU 12 V 2000 M92 Operating Instructions Manual Download Page 102

Free end (KGS)

1 Fuel filter vent screws

2 Engine coolant drain

plug

3 Raw water pump filling

plug

4 Measuring point, pres‐

sure before raw water

pump

5 Raw water pump drain

plug

6 Connection for oil ex‐

traction

102 | Task Description | M015700/06E 2012-06

TIM-ID: 0000006696 - 002

Summary of Contents for 12 V 2000 M92

Page 1: ...Operating Instructions Diesel engine 12 V 2000 M92 16 V 2000 M92 M015700 06E...

Page 2: ...ten permission of MTU Friedrichshafen GmbH This restriction also applies to copyright distribution translation micro filming and storage or processing on electronic systems including data bases and on...

Page 3: ...opping the engine 49 4 12 Fuel treatment system Shutdown 50 4 13 Plant cleaning 51 5 Maintenance 5 1 Maintenance task reference table QL1 52 6 Troubleshooting 6 1 Fuel treatment system Troubleshooting...

Page 4: ...ysis 111 7 15 8 Coolant filter Replacement 112 7 16 Raw Water Pump with Connections 113 7 16 1 Raw water pump Relief bore check 113 7 17 Belt Drive 114 7 17 1 Drive belt Condition check 114 7 18 Batte...

Page 5: ...it on delivery Any other use is considered improper use The engine manufacturer accepts no liability whatsoever for resultant damage or injury in such case The responsibility is borne by the user alo...

Page 6: ...to operating maintenance repair and transport personnel at all times Use the manual as a basis for instructing personnel on engine operation and repair with an emphasis on explaining safety relevant i...

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

Page 8: ...tion the display instruments and monitoring units must be permanently observed with re gard to present operating status violation of limit values and warning or alarm messages The following steps must...

Page 9: ...ions clean Always seal connections with caps or covers if a line is removed or opened Take care not to damage lines in particular fuel lines during maintenance and repair work Ensure that all retainer...

Page 10: ...haft end until correct sealing is established During hydraulic installation and removal ensure that nobody is standing in the immediate vicinity of the component to be installed removed Working on ele...

Page 11: ...used Laser devices of classes 1 2 or 3A Laser devices of class 3B which have maximum output in the visible wavelength range 400 to 700 nm a maximum output of 5 mW and in which the beam axis and surfac...

Page 12: ...dditional compo nents as well as the execution of calibration processes that might affect the emission characteristics of the engine are prohibited by emission regulations Emission control units syste...

Page 13: ...ners fittings and tools to impact or shock Compressed air Compressed air is air compressed at excess pressure and is stored in tanks from which it can be extract ed The pressure at which the air is ke...

Page 14: ...Used oil Used oil may contain harmful combustion residues Rub your hands with skin protection cream Wash your hands after contact with used oil 14 Safety M015700 06E 2012 06 TIM ID 0000002828 005...

Page 15: ...ion involving potentially adverse effects on the product Consequences Material damage Remedial action Additional product information Note This manual contains highlighted safety warnings in accordance...

Page 16: ...designated A and those of the right side B as per DIN ISO 1204 The cylinders of each bank are numbered consecutively starting with No 1 at the driving end Other components are numbered in the same way...

Page 17: ...xhaust system is equipped with triple walled water cooled exhaust lines The triple walled design permits low surface temperature reduced thermal load absolute gas tightness Lube oil system Wet sump fo...

Page 18: ...il pressure Differential oil pressure Coolant temperature Coolant level Exhaust turbocharger speed Leak fuel level Oil temperature Coolant pressure Fuel pressure after filter Monitoring in engine room...

Page 19: ...ray Only leak off along the line is possible the pressure is decreased significantly if an O ring 3 defect oc curs The connection is confirmed as compliant with SOLAS by DNV and GL Plugs and sensors S...

Page 20: ...g 2 that any leakage is not under pressure HP line between fuel injector and HP accumulator 1 Support ring 2 V ring 3 Thrust ring 4 Union nut 5 HP line 6 Thrust screw 7 Thrust ring 8 V ring 9 Support...

Page 21: ...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 M015700 06E 2012 06 General Information 21 TIM ID 000...

Page 22: ...w 6 Thrust ring 7 O ring 8 HP line 9 Pressure pipe 10 O ring Leak 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 press...

Page 23: ...ry turbocharger 15 Exhaust turbocharger left secondary turbo charger 16 Exhaust outlet horizon tal 17 Actuating cylinder for ex haust flap 18 Actuating cylinder for air flap 19 Control valve for flap...

Page 24: ...distribution housing with integral ex pansion tank 14 Thermostat housing 15 Exhaust manifold 16 Coolant pump 17 HP fuel pump 18 Fuel delivery pump 19 Oil filler neck 20 Oil dipstick 21 Drive flange 22...

Page 25: ...rations are insignificant Also applies similarly to 12V Item Description Monitoring of 1 B7 Lube oil temperature 2 B10 Charge air pressure 3 B44 Turbocharger speed 4 B3 Intake air temperature 5 B9 Cha...

Page 26: ...ressure before filter 3 B5 1 Lube oil pressure after filter 4 B5 2 option Lube oil pressure after filter 5 F33 Engine coolant level expansion tank 6 B21 option Raw water pressure 7 B6 2 option Coolant...

Page 27: ...gine driving end Item Description Monitoring of 1 B1 ECU Camshaft speed 2 B13 2 optional EMU Crankshaft speed 3 B13 ECU Crankshaft speed M015700 06E 2012 06 General Information 27 TIM ID 0000008412 00...

Page 28: ...ature 2 B48 Fuel pressure in rail 3 B16 option Coolant pressure 4 F46 Leak fuel level 5 Y27 2 4 2 directional control valve B side 6 B4 22 Exhaust temperature B side 7 F41 2 2 directional control valv...

Page 29: ...side 3 B54 option Lube oil pressure replenishment pump System sensors These sensors are fitted outside the engine Description Monitoring of B19 Starting air pressure B70 Fuel prefilter water level B4...

Page 30: ...ressure mbar 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...

Page 31: ...engine is starting L bar 0 25 Fuel supply flow max A Liters min 5 5 General operating data Number of cylinders 12 Firing speed from R rpm 100 Firing speed to R rpm 120 Starter electric Number of cylin...

Page 32: ...Liters 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 standard access...

Page 33: ...Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power to ISO 3046 Number of cylinders 16 Engine rated speed A rpm 2450 Fuel stop power ISO 3046 A kW 1630 GENERAL CO...

Page 34: ...ax when engine is starting L bar 0 25 Fuel supply flow max R liter min 7 3 GENERAL OPERATING DATA Number of cylinders 16 Firing speed from R rpm 100 Firing speed to R rpm 120 STARTING electric Number...

Page 35: ...ations L liter 115 Oil pan capacity dipstick mark max standard oil system Option max op erating inclinations L liter 138 WEIGHTS MAIN DIMENSIONS Number of cylinders 16 Engine dry weight with attached...

Page 36: ...3 3 Firing order Firing order 8V A1 B4 A4 A2 B3 A3 B2 B1 10 V A1 B4 A4 B3 A3 B2 A2 B5 A5 B1 36 Technical Data M015700 06E 2012 06 TIM ID 0000002801 004...

Page 37: ...00 M84 approx 1683 mm approx 1147 mm approx 1200 mm 8V 2000 M94 approx 1683 mm approx 1147 mm approx 1200 mm 10V 2000 M72 approx 1860 mm approx 1147 mm approx 1320 mm 10V 2000 M92 approx 1860 mm appro...

Page 38: ...be oil system Check engine oil level Page 94 Fuel prefilter Fill with fuel Page 87 Fuel prefilter pressure gauge Align adjustable pointer with position of pressure indicator Page 83 Fuel system Vent P...

Page 39: ...Item Measure Lube oil system Check engine oil level Page 94 Coolant circuit Check coolant level Page 106 Coolant circuit Heat engine coolant with coolant preheating unit Fuel prefilter Drain water and...

Page 40: ...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 42 2 Shut down fuel treatment system Page 50 40...

Page 41: ...ves 4 Switch on fuel treatment system Page 45 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 42: ...ne 3 Switch on fuel treatment system and operate it for some minutes Page 45 Result Fuel is sucked from the tank dirt particles and water are filtered and separated then the fuel is delivered via the...

Page 43: ...ency HAT 1 Switch on fuel treatment system Page 45 2 Start engine Page 46 3 Run engine at idling speed 4 Switch off pump 21 on switch cabinet Result The engine mounted fuel delivery pump sucks fuel vi...

Page 44: ...l running noises and vibration Check exhaust color Page 54 Fuel prefilter Check fuel prefilter contamination indicator for max admissible value Page 83 Drain water and contaminants Page 84 Air filter...

Page 45: ...hing on ensure that all housings are closed Before switching on ensure that no work is in progress anywhere on the entire system Switching on fuel treatment system 1 Carry out checks prior to start up...

Page 46: ...y is in the danger zone WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors The engine can be started from the following points Item Action Control stand Operating instruc...

Page 47: ...until engine temperatures have dropped and constant values are displayed The engine can be stopped from the following points 1 Operating instructions for electronic system 2 Commanding control stand O...

Page 48: ...be initiated from the following points 1 Operating instructions for electronic system 2 Commanding control stand Operating instructions for electronic system 3 Local operating panel LOP Operating inst...

Page 49: ...at a suitable temperature the antifreeze concentration is insufficient for the engine room tempera ture antifreeze concentration is 50 and engine room temperature is below 40 C Raw water Drain If free...

Page 50: ...binet until water discharge from the outlet stops 2 Switch off fuel treatment system 3 Close ball valve at the inlet to the fuel treatment system 4 Close ball valve at the outlet of the fuel treatment...

Page 51: ...cleaning 1 Carry out plant cleaning only in areas where an appropriate oil separator is provided environmental pro tection 2 Prior to putting the cleaning unit into operation read the Operating Instr...

Page 52: ...eplace fuel filter or fuel filter element Page 81 W1002 Check valve clearance Page 73 W1003 Check drive belt condition and tension replace if necessary Page 114 W1005 Replace air filter Page 90 W1006...

Page 53: ...d with an overload protection If the maximum permissible current consumption is exceeded e g in case of a blockage or dry run ning the motor protection relay triggers and the pump is switch ed off u R...

Page 54: ...tarter Battery low or defective Charge or replace battery see manu facturer s documentation Engine wiring Defective Check Page 122 Fuel system Not vented Vent fuel system Page 80 ECU Defective Contact...

Page 55: ...Contaminated Contact Service Exhaust turbocharger Defective Contact Service Coolant leaks on intercooler Component Probable Cause Task Intercooler Leaking major coolant discharge Contact Service Exha...

Page 56: ...use Task Engine Not at operating temperature Run engine to reach operating temper ature Fuel system Water in fuel Drain fuel prefilter Page 84 Intercooler Leaking Contact Service 56 Troubleshooting M0...

Page 57: ...ls 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 instal...

Page 58: ...t temperature Special tools Material Spare parts Designation Use Part No Qty Oil filter shield X00009628 Fuel filter shield X00009654 Installing SOLAS shield on oil filter and fuel filter 1 Pinpoint i...

Page 59: ...Primarily fit SOLAS shielding as per MTN 5233 Page 57 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 60: ...l 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 turboch...

Page 61: ...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 62: ...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 63: ...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 M015700 06E 2012 06 Task Descript...

Page 64: ...body is in the danger zone After working on the engine check that all protective devices have been reinstalled and all tools removed from the engine Engine Barring manually 1 Fit ratchet with barring...

Page 65: ...re barring or starting the engine ensure that nobody is in the danger zone After working on the engine check that all protective devices have been reinstalled and all tools removed from the engine Bar...

Page 66: ...ns First signs of marks left by lower cooling bores Running pattern seems darker No action required Dark areas with even or varying degrees of discoloration Beginning and end of the discoloration are...

Page 67: ...Final steps 1 Install injector Page 78 2 Install cylinder head cover Page 76 M015700 06E 2012 06 Task Description 67 TIM ID 0000000015 013...

Page 68: ...Smoothened areas appear brighter and more brilliant than the surrounding running surface Findings not critical Bright area Bright areas are on the running surface and show local removal of the honing...

Page 69: ...tion starting in TDC ring 1 have to be replaced Seizure marks scuff ing Irregular circumference lengths and depths Can be caused either by the pis ton skirt or the piston crown Material deposits on th...

Page 70: ...ve goggles safety mask and ear protectors Crankcase breather Cleaning oil pre separator element 1 Remove cover 5 from housing 4 2 Take off oil pre separator element 1 gas ket 3 and O ring 2 3 Wash oil...

Page 71: ...alth Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Replacing filter element of oil separator 1 Remove cover 2 wit...

Page 72: ...ged 5 Mount diaphragm 3 on housing 1 6 Install new seal 2 and spring 5 together with cover 4 7 Tighten screws of cover 4 to specified tightening torque Name Size Type Lubricant Value Standard Screw Ti...

Page 73: ...ngine direction of rotation until the marking on the flywheel is aligned with the center of the sensor seat Checking valve clearance at two crankshaft positions 1 Check TDC position of piston in cylin...

Page 74: ...6 7 8 9 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 E inlet valve clearance adjustment permitted A...

Page 75: ...rench to the prescribed tightening torque of 50 Nm while holding the adjusting screw 2 with screwdriver 5 Insert feeler gauge between valve bridge and rocker arm to verify that the gauge just passes t...

Page 76: ...d cover Removal and installation 1 Remove screws 1 2 Remove cylinder head cover 2 with gas ket from cylinder head 3 Clean mating faces 4 Check condition of gasket of cylinder head cover Result Replace...

Page 77: ...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 78 M015700 06E 2012 06 Task Descripti...

Page 78: ...gier X00029933 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 fuel supply to engi...

Page 79: ...and injector 1 with engine oil 9 Align injector 1 and HP line 5 with alignment device 10 Connect HP line 5 to HP accumulator and tighten by hand 11 Connect HP line 5 to injector 1 and tighten by hand...

Page 80: ...ump unscrew handle 2 Open vent plugs on filter head Note New version has two threaded vent plugs old version has four threaded vent plugs 3 Operate the pump with the handle until fuel without bubbles...

Page 81: ...mponents Risk of serious injury danger to life Take special care when working on a running engine WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignit...

Page 82: ...Vent fuel system Page 80 Replacing fuel filter with the engine running 1 Cut out the filter to be replaced 2 Open the threaded vent plugs at the filter head of the cut out filter and make sure that th...

Page 83: ...stalling the new filter element align adjustable pointer 2 with pressure indicat ing pointer 3 of pressure gauge 1 2 Verify that differential pressure is within the limit Fuel prefilter Checking diffe...

Page 84: ...eft filter cut in II Right filter cut in 2 Open threaded vent plug 5 of the filter to be drained 3 Unlock drain valve 6 by pressing toggle and open it 4 Drain water and contaminants from the filter un...

Page 85: ...Take special care when working on a running engine WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke WARNING Engine noise...

Page 86: ...el prefilter Filling with fuel 1 Stop engine Operating Instructions for electronic system and disable engine start 2 Remove screws securing the cover and take off cover 2 3 Fill filter housing with cl...

Page 87: ...Diesel fuel Filter element Spare Parts Catalog Seal Spare Parts Catalog WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke...

Page 88: ...2 7 Remove spring housing 4 and filter ele ment 3 8 Insert new filter element 3 and spring housing 4 9 Fill filter housing with clean fuel 10 Place new seal in cover 2 11 Fit cover with gasket and sec...

Page 89: ...ondensate drain line for coolant discharge and obstruction 1 Check drain line for water discharge and obstruction when the engine is running idle 2 If no air emerges remove condensate drain line and b...

Page 90: ...pare 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 91 2 Reset signal ring of contamination indicator...

Page 91: ...1 Release clamp 2 2 Remove air filter 3 and clamp 2 from connecting flange of intake housing 1 3 Verify that there are no objects in the con necting flange of the intake housing 1 and clean it 4 Place...

Page 92: ...g disabled Checking signal ring position 1 If the signal ring is completely visible in the observation window 2 replace air filter Page 90 2 After installation of new filter press reset button 1 Resul...

Page 93: ...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 122 M015700 06E...

Page 94: ...min and max marks 4 Top up to max if required Page 95 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 engine remove oil...

Page 95: ...id contact with skin Do not inhale oil vapor Version with extraction equipment Extracting engine oil 1 Position a suitable container to drain the engine oil into 2 Extract all engine oil from oil pan...

Page 96: ...ombustion residues which 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 CAUTION Damage to co...

Page 97: ...ment bar engine with starting system Page 65 10 Check oil level Page 94 Oil filter replacement with the engine running 1 Cut out the filter to be replaced 2 Remove cut out oil filter using the oil fi...

Page 98: ...kutex 50 50622 1 Filter sleeve Spare Parts Catalog O ring Spare Parts Catalog O ring Spare Parts Catalog WARNING Compressed air Risk of injury Do not direct compressed air jet at persons Wear protecti...

Page 99: ...easure 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 noz...

Page 100: ...10 Nm 13 Hold rotor old design with strap wrench and tighten nut 1 with torque wrench to the specified torque Name Size Type Lubricant Value Standard Nut M16 x 1 5 Tightening torque 40 Nm to 50 Nm 14...

Page 101: ...15 Coolant Circuit General High Temperature Circuit 7 15 1 Drain and venting points 8 V 10 V 1 Overflow line expan sion tank 2 Filler neck M015700 06E 2012 06 Task Description 101 TIM ID 0000006696 00...

Page 102: ...ews 2 Engine coolant drain plug 3 Raw water pump filling plug 4 Measuring point pres sure before raw water pump 5 Raw water pump drain plug 6 Connection for oil ex traction 102 Task Description M01570...

Page 103: ...Left side 1 Engine coolant drain plug 2 Engine coolant drain plug M14x1 5 M015700 06E 2012 06 Task Description 103 TIM ID 0000006696 002...

Page 104: ...drain plug M14x1 5 2 Oil filler neck connec tion on left or right en gine selectable 3 Oil dipstick connection on left or right engine se lectable 4 Leak fuel tank 104 Task Description M015700 06E 20...

Page 105: ...Driving end KS 1 Engine coolant drain plug 2 Connection for oil ex traction M015700 06E 2012 06 Task Description 105 TIM ID 0000006696 002...

Page 106: ...eather valve on coolant expansion tank Page 23 counterclockwise until first stop and allow pressure to escape 2 Continue to turn breather valve counter clockwise and remove 3 Check coolant level coola...

Page 107: ...ge Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant Change 1 Drain engine coolant Page 108 2 Fill with engine coolant Page 109 M015700 06E 2012 06 Task Description...

Page 108: ...vice 3 Switch off preheating unit Engine coolant Draining 1 Turn breather valve on coolant expansion tank Page 101 counterclockwise to the first stop and re lease pressure 2 Continue to turn breather...

Page 109: ...of cracks in components Fill top up coolant only into cold engine Filling engine coolant 1 Page 23 Turn breather valve of coolant expansion tank counterclockwise until the first stop and allow pressu...

Page 110: ...tectors 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 start 3 Clean the relief bore wi...

Page 111: ...t expansion tank Page 101 counterclockwise until first stop and allow pressure to escape 2 Continue to turn breather valve counterclockwise and remove 3 Draw off precipitated corrosion inhibitor oil f...

Page 112: ...goggles safety mask Coolant filter Replacement 1 Turn breather valve of coolant expansion tank counterclockwise Page 23 to the first stop and allow pressure to escape 2 Continue to turn breather valv...

Page 113: ...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 47 and disable en gine start 3 Clean the relief bo...

Page 114: ...led Guard is removed Drive belt Condition check Item Findings Action Drive belt A Singular cracks None Drive belt Belt is oily shows signs of over heating Replace Page 115 Drive belt B Cracks on entir...

Page 115: ...over engine free end 3 Remove protective cover Drive belt Replacement 1 Hold adjusting lever at square 2 Rotate adjusting lever until drive belt is released 3 Use mandrel to lock adjusting lever in po...

Page 116: ...y System 7 19 1 Water drain valve Check Water drain valve Check 1 Open water drain valve 2 Check water outlet for obstructions 3 Close water drain valve 116 Task Description M015700 06E 2012 06 TIM ID...

Page 117: ...es Do not smoke Checking differential pressure gauge 1 Switch on fuel treatment system Page 45 2 Set the alarm points at the differential pressure gauge to zero Result Alarm is initiated with preset d...

Page 118: ...rew water level probe 3 Connect plug to water level probe 4 Immerse water level probe into a tank filled with water until water level reaches the thread Result Water drain valve opens 5 Leave water le...

Page 119: ...heck pressure at the pressure gauge in the inlet to the fuel treatment system and note it 3 Check pump pressure with reduced suction a Reduce suction pressure of pump to 0 8 bar with the shutoff valve...

Page 120: ...ion of components 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 f...

Page 121: ...ightening torque Engine oil 30 Nm 3 Nm 17 Fit gasket 10 18 Install cover 19 Install screw 1 washer 2 and nut 9 20 Tighten nut 9 21 Open ball valve at the inlet and outlet of the fuel treatment system...

Page 122: ...nnot swing freely 3 Check that cable ties are firm tighten loose cable ties 4 Replace faulty cable ties 5 Visually inspect the following electrical line components for damage connector housings contac...

Page 123: ...Cleaning 1 Remove coarse dirt from housing surface with isopropyl alcohol 2 Remove dirt from connector and cable surfaces with isopropyl alcohol 3 Check legibility of cable labels Clean or replace ill...

Page 124: ...ways use test connectors to enter the connectors Never use test leads for this purpose Otherwise the contacts could be bent Checking plug in connections on engine governor 1 Check all plug in connecti...

Page 125: ...econditions Engine is stopped and starting disabled EMU checking plug in connections 1 Verify that all plug in connections are securely seated 2 Secure loose connectors and latch M015700 06E 2012 06 T...

Page 126: ...overnor a Release lock 3 of connectors 2 b Unplug connector 2 3 Switch on power supply Result The engine governor is operable if the di agnostic lamp 1 changes to continuous illumination within 30 sec...

Page 127: ...l 2 Remove dirt from connector and cable surfaces with isopropyl alcohol 3 Check legibility of cable labels Clean or replace illegible labels Cleaning severely contaminated EMU connectors 1 Release la...

Page 128: ...overnor from engine 1 Note or mark assignment of cables and connectors 2 Remove all screws 2 3 Undo latches 3 of the connectors 4 Remove all connectors 5 Remove screws 1 6 Take off engine governor Ins...

Page 129: ...Remove all connectors 5 Remove screws 1 6 Remove engine governor 1 with engine monitoring unit 4 Removing engine monitoring unit 1 Unscrew screws on base of EMU 4 2 Remove EMU 4 with engine governor...

Page 130: ...bine DE Diesel Engine DIN Deutsches Institut f r Normung e V At the same time identifier of German standards DIN Deutsche Industrie Norm DIS Display unit DL Default Lost Alarm CAN bus missing ECS Engi...

Page 131: ...OS Local Operating Station MCS Monitoring and Control System MG Message MPU Microprocessor Unit Microprocessing Unit MRG Main Reduction Gear OT Oberer Totpunkt Top Dead Center TDC P xyz Pressure xyz P...

Page 132: ...nkt Bottom Dead Center BDC VS Voith Schneider Voith Schneider drive WJ Water jet Water jet drive WZK Werkzeugkatalog Tool Catalog TC ZKP Zugeh rigkeit Kategorie Parameter Assignment category parameter...

Page 133: ...you either during operation for preventive maintenance corrective work in case of malfunction or changed operating conditions or for spare parts supply Your contact at Headquarters Service support mtu...

Page 134: ...n Page 78 Angular screw driver Part No F30002816 Qty Used in 1 7 5 1 Valve clearance Check and adjustment Page 73 Barring tool Part No F6783914 Qty Used in 1 7 2 1 Engine Barring manually Page 64 Qty...

Page 135: ...5 Qty Used in 1 7 5 2 Cylinder head cover Removal and installation Page 76 Double box wrench Part No F30002800 Qty Used in 1 7 5 1 Valve clearance Check and adjustment Page 73 Double box wrench Part N...

Page 136: ...placement Page 115 MTU test kit Part No 5605892099 00 Qty Used in 1 7 15 7 Engine coolant Sample extraction and analysis Page 111 Oil filter wrench Part No F30379104 Qty Used in 1 7 8 1 Fuel filter R...

Page 137: ...nd installation Page 78 Ratchet Part No F30006212 Qty Used in 1 7 2 1 Engine Barring manually Page 64 Qty Used in 1 7 5 1 Valve clearance Check and adjustment Page 73 Ratchet adapter Part No F30027340...

Page 138: ...der liner Endoscopic examination Page 66 Socket wrench Part No F30030450 Qty Used in 1 7 5 1 Valve clearance Check and adjustment Page 73 Socket wrench Part No 0005896803 00 Qty Used in 1 7 6 2 Inject...

Page 139: ...t No F30510423 Qty Used in 1 7 5 1 Valve clearance Check and adjustment Page 73 Torque wrench 6 50 Nm Part No F30027336 Qty Used in 1 7 4 2 Crankcase breather Oil separator replacement diaphragm check...

Page 140: ...points 101 Drive belt Condition check 114 E ECU 7 engine governor Removal and installation 128 Emergency stop 48 EMU and connectors Cleaning 127 EMU Checking plug in connections 125 Engine Barring man...

Page 141: ...capacity Check 119 Putting engine into operation Preparation after extended out of service periods 3 months 38 Putting into operation Fuel treatment system 42 Preparation after scheduled out of servic...

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