MTU 12 V 2000 M94 Operating Instructions Manual Download Page 136

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7.21.3 EMU – Checking plug-in connections

Preconditions

☑ Engine is stopped and starting disabled.

EMU – checking plug-in connections

Verify that all plug-in connections are securely seated.

Secure loose connectors and latch.

136 | Task Description | MS150061/04E 2012-07

TIM-ID: 0000008395 - 001

Summary of Contents for 12 V 2000 M94

Page 1: ...Operating Instructions Diesel engine 12 V 2000 M94 16 V 2000 M94 MS150061 04E...

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: ...Switching on 56 4 8 Starting the engine 57 4 9 Stopping the engine 58 4 10 Emergency stop 59 4 11 After stopping the engine 60 4 12 Fuel treatment system Shutdown 61 4 13 Plant cleaning 62 5 Maintena...

Page 4: ...ck 121 7 15 7 Engine coolant Sample extraction and analysis 122 7 15 8 Coolant filter Replacement 123 7 16 Raw Water Pump with Connections 124 7 16 1 Raw water pump Relief bore check 124 7 17 Belt Dri...

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 alon...

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: ...Transport without flange mounted gearbox A max permissible diago nal pull 70 B max permissible diago nal pull 35 Illustration is valid for 12 16V 2000 M engines MS150061 04E 2012 07 Safety 7 TIM ID 0...

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: ...ion 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 10: ...ons 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 retainers...

Page 11: ...aft 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 elec...

Page 12: ...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 13: ...r this purpose are approved by MTU or equiva lent components Noncompliance with these guidelines might represent a violation of the Clean Air Act and involves the termination of the operating license...

Page 14: ...t of containers results in a risk of explosion Forcing compressed air into thin walled containers e g containers made of tin plastic and glass for drying purposes or to check for leaks results in a ri...

Page 15: ...on 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: ...gine oil prior to assembly When tightening manually tightening specifications an assembly tolerance of 10 of the table values is permitted for unavoidable deviations of the tightening torque from the...

Page 17: ...ted with engine oil prior to assembly When tightening manually defined tightening an assembly tolerance of 10 of the table values is permitted for unavoidable deviations of the tightening torque from...

Page 18: ...lug screws as per MTN 5183 1 standard This standard applies to plug screws as per DIN 908 DIN 910 and DIN 7604 with screwed plug DIN 3852 shape A sealed by sealing ring DIN 7603 Cu 18 General Informat...

Page 19: ...cess e g resulting from inaccurate readings and overtightening during assembly Tightening torques for plug screws DIN 908 DIN 910 and DIN 7604A with short screwed plug Thread Screwed into Steel gray c...

Page 20: ...into Steel gray cast iron MA Nm Al alloy MA 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 sc...

Page 21: ...ble value during the tightening process e g resulting from inaccurate readings and overtightening during assembly Tightening torques for steel banjo screws Thread Screwed into steel gray cast iron Al...

Page 22: ...oated with engine oil prior to assembly When tightening manually defined tightening an assembly tolerance of 10 of the table values is permitted for unavoidable deviations of the tightening torque fro...

Page 23: ...tightening noticeable increase in force the union nut is further tightened by a quarter of a rotation 90 beyond this point Tightening torques for screwed plugs with O ring as per ISO 6149 2 Thread Tor...

Page 24: ...screw in valves see ISO 7789 Tightening torques for screwed plugs with O ring 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...

Page 25: ...with union nuts In contrast to the instructions for pipe unions hose fittings with sealing heads and the associated adapt ers must be installed and connected as follows these instructions do not appl...

Page 26: ...51 M20 x 1 5 12 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 T...

Page 27: ...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 i e starti...

Page 28: ...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 29: ...l 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 30: ...ay 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 Sc...

Page 31: ...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 r...

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 MS150061 04E 2012 07 TIM ID 00...

Page 33: ...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 pressu...

Page 34: ...1 Exhaust turbocharger 12 Actuating cylinder for ex haust flap 13 Carrier housing 14 Cylinder head cover 15 Engine mounting 16 Oil pan 17 Battery charging genera tor 18 Coolant filler neck 19 Raw wate...

Page 35: ...heel housing 9 Carrier housing lower section 10 Carrier housing middle section 11 Bleeder valve 12 Exhaust outlet KS engine driving end Engine model designation Key to the engine model designation 12V...

Page 36: ...ations 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 Char...

Page 37: ...essure 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 38: ...gine driving end Item Description Monitoring of 1 B1 ECU Camshaft speed 2 B13 2 optional EMU Crankshaft speed 3 B13 ECU Crankshaft speed 38 General Information MS150061 04E 2012 07 TIM ID 0000008412 0...

Page 39: ...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 40: ...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 41: ...ssure 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 A...

Page 42: ...tion max when engine is starting L bar 0 25 Fuel supply flow max R liters min 7 1 GENERAL OPERATING DATA Number of cylinders 12 Firing speed from R rpm 100 Firing speed to R rpm 120 STARTER electric N...

Page 43: ...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 attached standa...

Page 44: ...r 1000 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 1939...

Page 45: ...ction max when engine is starting L bar 0 25 Fuel supply flow max R liters min 8 6 GENERAL OPERATING DATA Number of cylinders 16 Firing speed from R rpm 100 Firing speed to R rpm 120 STARTER electric...

Page 46: ...iters 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 installed stand...

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 MS150061 04E 2012 07 Technical Data 47 TIM ID 0000038135 001...

Page 48: ...000 M84 approx 2094 mm approx 1295 mm approx 1350 mm 12V 2000 M94 approx 2094 mm approx 1295 mm approx 1350 mm 16V 2000 M92 approx 2486 mm approx 1295 mm approx 1390 mm 16V 2000 M93 approx 2486 mm app...

Page 49: ...e oil system Check engine oil level Page 105 Fuel prefilter Fill with fuel Page 98 Fuel prefilter pressure gauge Align adjustable pointer with position of pressure indicator Page 94 Fuel system Vent P...

Page 50: ...tem Measure Lube oil system Check engine oil level Page 105 Coolant circuit Check coolant level Page 117 Coolant circuit Heat engine coolant with coolant preheating unit Fuel prefilter Drain water and...

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: ...ne 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 delivered via the...

Page 54: ...ency 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 vi...

Page 55: ...running noises and vibration Check exhaust color Page 65 Fuel prefilter Check fuel prefilter contamination indicator for max admissible value Page 94 Drain water and contaminants Page 95 Air filter Ch...

Page 56: ...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 57: ...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 58: ...ntil 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 Op...

Page 59: ...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 60: ...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 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: ...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 Instru...

Page 63: ...95 W0508 Check reading on differential pressure gauge of fuel prefilter if fitted Page 94 W1001 Replace fuel filter or fuel filter element Page 92 W1002 Check valve clearance Page 84 W1005 Replace air...

Page 64: ...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 65: ...rter Battery low or faulty Charge or replace battery see manu facturer s documentation Engine cabling Faulty Check Page 133 Fuel system Air in fuel system Vent fuel system Page 91 ECU Faulty Contact S...

Page 66: ...ntercooler Contaminated Contact Service Exhaust turbocharger Faulty Contact Service Coolant leaks at intercooler Component Cause Action Intercooler Leaking major coolant discharge Contact Service Blac...

Page 67: ...tion Engine Not at operating temperature Run engine to reach operating temper ature Fuel system Water in fuel Drain fuel prefilter Page 95 Intercooler Leaking Contact Service MS150061 04E 2012 07 Trou...

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: ...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 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 MS150061 04E...

Page 75: ...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 76: ...e 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 Barr...

Page 77: ...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 78: ...Final steps 1 Install injector Page 89 2 Install cylinder head cover Page 87 78 Task Description MS150061 04E 2012 07 TIM ID 0000000015 013...

Page 79: ...moothened 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 p...

Page 80: ...ion 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 the...

Page 81: ...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 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: ...0 Nm F30510423 1 Measuring device Y4345888 1 Preparatory steps 1 Remove air filter Page 102 2 Remove cylinder head cover Page 87 Positioning A1 piston at TDC Note With cylinder head and valve gear ins...

Page 85: ...on Cylinder 1 2 3 4 5 6 7 8 9 Firing TDC in cylinder A1 Bank A E A A E Bank B E A E A E Overlap TDC in cylinder A1 Bank A E A E A E A Bank B A E A E A E inlet valve clearance adjustment permitted A ex...

Page 86: ...locknut 1 and unscrew adjusting screw 2 by a few threads 2 Insert feeler gauge between valve bridge and rocker arm 3 Readjust adjusting screw 2 so that the feeler gauge just passes through the gap 4 T...

Page 87: ...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 88: ...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 89 88 Task Description MS150061 04E 2...

Page 89: ...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 90: ...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 91: ...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 92: ...ponents 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 igniti...

Page 93: ...fuel system Page 91 Easy change fuel filter replacement 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 su...

Page 94: ...talling 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 differ...

Page 95: ...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 96: ...e 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 97: ...valve 6 Fuel prefilter Topping up with fuel 1 Stop engine Page 58 and disable engine start 2 Remove screws for cover and take off cover 2 3 Fill filter housing with clean fuel 4 Place new gasket in co...

Page 98: ...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 R...

Page 99: ...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 100: ...ndensate 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 bl...

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

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: ...in and max marks 4 Top up to max if required Page 106 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 106: ...d 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 u...

Page 107: ...ne WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors WARNING Hot oil Oil can contain combustion residues which are harmful to health Risk of injury and poisoning Wear pr...

Page 108: ...her oil filters in the same way 9 Switch filter to normal position 10 After each oil change and filter replace ment crank engine with starting system Page 76 11 Check oil level Page 105 Oil filter rep...

Page 109: ...utex 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 protectiv...

Page 110: ...asure 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 nozz...

Page 111: ...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 112: ...5 Coolant Circuit General High Temperature Circuit 7 15 1 Drain and venting points 12 V 16 V 1 Overflow line expan sion tank 2 Filler neck 112 Task Description MS150061 04E 2012 07 TIM ID 0000038198 0...

Page 113: ...ws 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 MS150061 04E 2012 07 Task De...

Page 114: ...Left side 1 Engine coolant drain plug 2 Engine coolant drain plug M14x1 5 114 Task Description MS150061 04E 2012 07 TIM ID 0000038198 001...

Page 115: ...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 MS150061 04E 2012 07 Task Descriptio...

Page 116: ...Driving end KS 1 Engine coolant drain plug 2 Connection for oil ex traction 116 Task Description MS150061 04E 2012 07 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 MS150061 04E 201...

Page 119: ...vice 3 Switch off preheating unit Engine coolant Draining 1 Turn breather valve on coolant expansion tank Page 112 counterclockwise to the first stop and re lease pressure 2 Continue to turn breather...

Page 120: ...of cracks in components Fill top up coolant only into cold engine Filling engine coolant 1 Page 34 Turn breather valve of coolant expansion tank counterclockwise until the first stop and allow pressu...

Page 121: ...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 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: ...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 gine start 3 Clean the relief bor...

Page 125: ...ed 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 126 Drive belt B Cracks on entire...

Page 126: ...ver 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 pos...

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 MS150061 04E 2012 07 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: ...sure at the pressure gauge in the inlet to the fuel treatment system and note down 3 Checking pump pressure with reduced suction a Reduce suction pressure of pump to 0 8 bar with the shut off valve at...

Page 131: ...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 132: ...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 133: ...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 134: ...leaning 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 ille...

Page 135: ...ays 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 connectio...

Page 136: ...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 136 Task Description...

Page 137: ...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 138: ...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 139: ...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 140: ...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 141: ...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 142: ...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 143: ...kt 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 144: ...u 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 o...

Page 145: ...Page 89 Angular screw driver Part No F30002816 Qty Used in 1 7 5 1 Valve clearance Check and adjustment Page 84 Barring tool Part No F6783914 Qty Used in 1 7 2 1 Engine Barring manually Page 75 Qty U...

Page 146: ...5 Qty Used in 1 7 5 2 Cylinder head cover Removal and installation Page 87 Double box wrench Part No F30002800 Qty Used in 1 7 5 1 Valve clearance Check and adjustment Page 84 Double box wrench Part N...

Page 147: ...18 1 Battery charging generator drive Drive belt re placement Page 126 Measuring device Part No Y4345888 Qty Used in 1 7 5 1 Valve clearance Check and adjustment Page 84 MTU test kit Part No 56058920...

Page 148: ...Page 123 Open end wrench bit Part No F30025897 Qty Used in 1 7 6 2 Injector Removal and installation Page 89 Puller Part No F6790629 Qty Used in 1 7 6 2 Injector Removal and installation Page 89 Ratch...

Page 149: ...adapter 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...

Page 150: ...art No F30379104 Qty Used in 1 7 14 2 Centrifugal oil filter Cleaning and filter sleeve replacement Page 109 Torque wrench 10 60 Nm Part No F30510423 Qty Used in 1 7 5 1 Valve clearance Check and adju...

Page 151: ...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 82 MS150061 04E 2012 07 Appendix B 151 DCL ID 000001070...

Page 152: ...in 7 8 5 Fuel prefilter Filter element replacement Page 98 Qty Used in 7 19 5 Coalescer filter element Replacement Page 131 Engine coolant Part No Qty Used in 7 15 5 Engine coolant Filling Page 120 E...

Page 153: ...d connectors Cleaning Page 134 Oil filter shield Part No X00009628 Qty Used in 7 1 2 SOLAS shielding Installation Page 69 Shield A4 Part No 735233000100 Qty Used in 10 7 1 1 SOLAS shielding as per MTN...

Page 154: ...separator element replacement diaphragm check and replacement Page 82 Easy change filter Part No Qty Used in 7 8 1 Fuel filter Replacement Page 92 Filter element Part No Qty Used in 7 4 2 Crankcase b...

Page 155: ...placement Page 88 O ring Part No Qty Used in 7 14 2 Centrifugal oil filter Cleaning and filter sleeve replacement Page 109 Qty Used in 7 14 2 Centrifugal oil filter Cleaning and filter sleeve replacem...

Page 156: ...tion check 125 E ECU 7 engine governor Removal and installation 139 Emergency stop 59 EMU and connectors Cleaning 138 EMU Checking plug in connections 136 Engine Barring manually 75 Main dimensions 48...

Page 157: ...into operation Preparation after extended out of service periods 3 months 49 Putting into operation Fuel treatment system 53 Preparation after scheduled out of service period 50 R Raw water pump Relie...

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