MTU 12V 2000 C66 Operating Instructions Manual Download Page 54

Page: 54 / 136

6.5 Fuel System

6.5.1 HP fuel line and pressure pipe neck – Replacement

Preconditions

☑ Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use

Part No.

Qty.

Torque wrench, 20-100 Nm

F30026582

Ratchet adapter

F30027340

Adapter

F30006234

Socket wrench, 19 mm

F30025897

Crowfoot wrench, 19 mm

F30027424

Crowfoot wrench, 22 mm

F30027425

Double box wrench

F30011450

Grease (Kluthe Hakuform 30-10/Emulgier)

X00029933

Engine oil
Pressure pipe neck

(→ Spare Parts Catalog)

HP fuel line

(→ Spare Parts Catalog)

WARNING

Fuels are combustible.

Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.

• Do not smoke.

Preparatory steps

Shut off fuel supply line.

Drain fuel (→ Page 57).

54 | Task Description | MS150094/01E 2012-08

TIM-ID: 0000012538 - 001

Summary of Contents for 12V 2000 C66

Page 1: ...Operating Instructions Diesel engine 12V 2000 C66 16V 2000 C66 MS150094 01E...

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: ...ooting 5 1 Fuel treatment system Troubleshooting 37 5 2 Troubleshooting 38 6 Task Description 6 1 Engine 41 6 1 1 Engine Barring manually 41 6 1 2 Engine Barring with starting system 42 6 2 Crankcase...

Page 4: ...ing generator drive Drive belt replacement 98 6 16 Fuel Supply System 99 6 16 1 Water drain valve Check 99 6 16 2 Differential pressure gauge Check 100 6 16 3 Water level probe 3 in 1 rod electrode Ch...

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: ...appropriate 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 du...

Page 8: ...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 9: ...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 10: ...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 11: ...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 12: ...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 13: ...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 14: ...ube oil system lube oil circuit 7 Power supply 8 Cooling air system 9 Coolant system 10 Mounting support 11 Fuel system low pres sure 12 Fuel system high pres sure 13 Valve gear 14 Cylinder head 15 Ex...

Page 15: ...plication C charge air cooling in internal circuit with piston cooling Application S Exhaust turbocharging with supercharger 6 9 Application segment 0 1 2 9 6 Design index 0 1 2 9 MS150094 01E 2012 08...

Page 16: ...d 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 star...

Page 17: ...mension Engine model Dimension 12 V 2000 C66 S96 16 V 2000 C66 S96 Length A approx 2028 mm approx 2378 mm Width B approx 1276 5 mm approx 1287 mm Height C approx 1429 mm approx 1442 mm MS150094 01E 20...

Page 18: ...der for 12 16 V 2000 C66 S96 engines Number of cylin ders 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 18 Product Summary MS150094 01E 201...

Page 19: ...WER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 12 16 Rated engine speed A rpm 2100 2100 Effective power w o fan Fuel stop power ISO 3046 A kW 783 970 GENERAL CO...

Page 20: ...after engine shutdown L C 104 104 Coolant antifreeze content max L 50 50 Coolant pump inlet pressure max L bar 1 3 1 3 Thermostat Starts to open R C 79 79 Thermostat Fully open R C 92 92 COOLING SYSTE...

Page 21: ...oolant capacity engine side without cooling equip ment R Liters 63 70 Charge air coolant engine side R Liters 25 28 Total engine oil capacity at initial filling standard oil system Option max operatin...

Page 22: ...Check engine oil level Page 69 Fuel system Connect appropriate equipment to fuel supply line to fill the system Fuel system Vent Page 56 Coolant circuit If engine is out of service for more than one y...

Page 23: ...tem Check engine oil level Page 69 Coolant circuit Check engine coolant level Page 79 check charge air coolant level Page 88 Coolant circuit Preheat engine coolant with coolant preheating unit if fitt...

Page 24: ...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 26 2 Shut down fuel treatment system Page 34 24...

Page 25: ...ves 4 Switch on fuel treatment system Page 29 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 26: ...ne 3 Switch on fuel treatment system and operate it for some minutes Page 29 Result Fuel is sucked from the tank dirt particles and water are filtered and separated then the fuel is delivered via the...

Page 27: ...ency HAT 1 Switch on fuel treatment system Page 29 2 Start engine Page 28 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 28: ...injury danger to life Before barring or starting the engine make sure that nobody is in the danger zone WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors Start engine F...

Page 29: ...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 30: ...operation Check engine visually for leaks and general condition Check engine for abnormal running noises exhaust color and vibra tions Air filter Check service indicator at air filter if fitted see ma...

Page 31: ...ge to components Before stopping the engine operate it at idle speed until operating temperatures decrease and stable values are indicated Preparation Item Action Engine Allow the engine to cool down...

Page 32: ...stopped by disconnecting the power supply to the ECU Emergency air shutoff flaps close if provided signalization e g by horn beacon is activated After emergency stop Item Action Switchgear cabinet con...

Page 33: ...service for an extended period but engine coolant has no antifreeze additive the engine room is not heated the coolant is not kept at a suitable temperature the antifreeze concentration is insufficie...

Page 34: ...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 35: ...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 36: ...element Page 58 W1003 Check drive belt condition and tension replace if necessary Page 94 W1005 Replace air filter Page 65 W1006 Replace fuel injectors Page 48 W1008 Replace engine oil filter when cha...

Page 37: ...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 38: ...facturer s documentation Engine wiring Faulty Check Page 108 Fuel system Air in fuel system if fault occurs after filling the system Vent fuel system Page 56 Engine governor Faulty Contact Service En...

Page 39: ...lter clogged Replace air filter see manufacturer s documentation Intercooler Contaminated Contact Service Exhaust turbocharger Faulty Contact Service Coolant leaks at intercooler Component Cause Actio...

Page 40: ...operating temperature Run engine to reach operating temper ature Fuel system Water in fuel Check fuel system at fuel prefilter Drain fuel prefilter Page 60 Intercooler Leaking Contact Service 40 Trou...

Page 41: ...e 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 Engine Barring manually 1 Fit ratchet with...

Page 42: ...ter working on the engine check that all protective devices have been reinstalled and all tools removed from the engine Engine Barring with starting system 1 Bar engine preventing it from firing see d...

Page 43: ...Hot oil Oil can contain combustion residues which are harmful to health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil...

Page 44: ...g socket 19 mm F30038493 1 Torque wrench 10 60 Nm F30510423 1 WARNING Valve gear is moving Risk of crushing Keep hands clear of the danger zone when barring the engine Preparatory steps u Remove cylin...

Page 45: ...e clearance adjustment permitted A exhaust valve clearance adjustment permitted 16 V 2000 Position Cylinder 1 2 3 4 5 6 7 8 Firing TDC in cylinder A1 Bank A E A A E A E A E Bank B E A E A E E A A Over...

Page 46: ...lue Standard Locknut Tightening torque 50 Nm 5 Nm 5 Insert feeler gauge between valve bridge and rocker arm to verify that the gauge just passes through the gap Result If not adjust valve clearance ag...

Page 47: ...overs with crankcase breather Loosen clamps 2 Slide rubber sleeves onto the pipe Cylinder head cover Removal and installation 1 Remove cylinder head cover with gasket from cylinder head 2 Clean instal...

Page 48: ...tor Replacement Special tools Material Spare parts Designation Use Part No Qty Injector Spare Parts Catalog Replacing injector u Remove injector and install new injector Page 49 48 Task Description MS...

Page 49: ...oot wrench 22 mm F30027425 1 Double head box wrench F30011450 1 Open end socket wrench 24 mm F30453238 1 Grease Kluthe Hakuform 30 10 Emulgier X00029933 1 Engine oil Sealing ring Spare Parts Catalog W...

Page 50: ...suction device 5 Disconnect terminals arrow on injector and pull out cable lugs 6 Remove gasket 7 Remove screw 3 Note Screw 3 may be installed only once 8 Take off hold down clamp 2 9 Use the puller t...

Page 51: ...e hold down clamp Installation with installation device 1 Place installation tool on hold down clamp to press injector 1 carefully into the cylinder head 2 Place clamping piece 2 in correct position s...

Page 52: ...line 1 Coat thread and shoulder of union nuts on fuel line 1 with engine oil Note Position fuel line ensuring it is free of tension 2 Position fuel line 1 so that the union nut with the torque specifi...

Page 53: ...1 Place gasket on cylinder head ensuring correct installation position 2 Push cable lugs under the terminals arrow on the injector and tighten with torque wrench to the speci fied tightening torque Na...

Page 54: ...25897 1 Crowfoot wrench 19 mm F30027424 1 Crowfoot wrench 22 mm F30027425 1 Double box wrench F30011450 1 Grease Kluthe Hakuform 30 10 Emulgier X00029933 1 Engine oil Pressure pipe neck Spare Parts Ca...

Page 55: ...between union nut and HP fuel line ball seal and thread on both ends of the new HP fuel line 2 with engine oil 11 Install new HP fuel line 2 12 Observe marking on union nut 1 Use torque wrench to tig...

Page 56: ...ine is not connected to load Fuel system Venting Note The fuel system can only be vented with the engine running 1 Start engine Page 28 2 Operate the engine until it runs smoothly 56 Task Description...

Page 57: ...fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Fuel Draining 1 Provide a suitable container in which to collect the fuel 2 Remove fuel filter Page 58 3 Catch...

Page 58: ...oid open flames electrical sparks and ignition sources Do not smoke Fuel filter Replacement 1 Remove easy change filter using the filter wrench 2 Clean sealing surface on filter head 3 Check sealing r...

Page 59: ...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 60: ...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 61: ...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 62: ...valve 6 Fuel prefilter Topping up with fuel 1 Stop engine Page 31 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 63: ...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 64: ...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 65: ...Preconditions Engine is stopped and starting disabled For air filter replacement carry out operations as specified by the manufacturer filter is plant vehicle manufacturer s supply MS150094 01E 2012 0...

Page 66: ...6 8 Air Intake 6 8 1 Service indicator Check See manufacturer s documentation 66 Task Description MS150094 01E 2012 08 TIM ID 0000005482 003...

Page 67: ...6 9 Exhaust Gas Recirculation 6 9 1 Exhaust gas recirculation flaps Overview MS150094 01E 2012 08 Task Description 67 TIM ID 0000024288 001...

Page 68: ...ecking exhaust flap operation 1 For installation position of exhaust flaps refer to overview Page 67 2 Check operability and ease of movement of exhaust flaps and control linkage by moving the assembl...

Page 69: ...min and max marks 4 Top up to max if required Page 70 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 70: ...hand pump Draining oil at drain plug on oil pan 1 Provide a suitable container to collect the oil 2 Remove drain plug and drain oil 3 Install drain plug with new sealing ring 4 Replace engine oil filt...

Page 71: ...g Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Engine oil filter Replacement 1 Remove oil filter with filter wrench 2 Clean the sealing surfa...

Page 72: ...talog Sealing ring Spare Parts Catalog Sealing ring Spare Parts Catalog WARNING Hot oil Oil can contain combustion residues which are harmful to health Risk of injury and poisoning Wear protective clo...

Page 73: ...r base 10 with sealing ring 9 14 Insert new filter sleeve 6 in rotor tube 7 with the smooth paper surface facing the outer wall 15 Check sealing ring 5 fit new one if neces sary 16 Mount rotor cover 4...

Page 74: ...6 12 Coolant Circuit General High Temperature Circuit 6 12 1 Drain and vent points 12 V 16 V 1 Engine coolant vent 74 Task Description MS150094 01E 2012 08 TIM ID 0000025286 001...

Page 75: ...Left side 1 Engine coolant drain plug 2 Oil drain plug 3 Engine coolant drain plug MS150094 01E 2012 08 Task Description 75 TIM ID 0000025286 001...

Page 76: ...Right side 1 Engine coolant drain plug 2 Engine coolant drain plug 3 Oil drain plug 4 Engine coolant drain plug 76 Task Description MS150094 01E 2012 08 TIM ID 0000025286 001...

Page 77: ...Driving end KS 1 Oil drain plug MS150094 01E 2012 08 Task Description 77 TIM ID 0000025286 001...

Page 78: ...Free end KGS 1 Oil drain plug 2 Engine coolant filling plug 3 Oil drain plug 4 Engine coolant drain plug 78 Task Description MS150094 01E 2012 08 TIM ID 0000025286 001...

Page 79: ...unterclockwise to the first stop and allow pressure to escape 2 Continue to turn breather valve counter clockwise and remove 3 Check coolant level coolant must be visible at the lower edge of the cast...

Page 80: ...nge Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant Change 1 Drain engine coolant Page 81 2 Fill with engine coolant Page 82 80 Task Description MS150094 01E 2012...

Page 81: ...olant expansion tank counterclockwise to first stop and allow pressure to escape 4 Continue to turn breather valve counter clockwise and remove 5 Draw off precipitated corrosion inhibitor oil from the...

Page 82: ...d coolant in hot engine can cause thermal stress Formation of cracks in components Fill top up coolant only into cold engine Preparatory steps 1 Turn breather valve on coolant expansion tank countercl...

Page 83: ...inal steps 1 Start the engine and operate it at idle speed for some minutes 2 Check coolant level Page 79 top up with coolant if required MS150094 01E 2012 08 Task Description 83 TIM ID 0000000034 005...

Page 84: ...ing Wear ear protectors Engine coolant pump Relief bore check 1 Check relief bore for oil and coolant dis charge Permissible coolant discharge up to 10 drops per hour Permissible oil discharge up to 5...

Page 85: ...is 1 Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to escape 2 Continue to turn breather valve counterclockwise and remove 3 Draw off precipitated...

Page 86: ...goggles safety mask Coolant filter Replacement 1 Turn breather valve of coolant expansion tank counterclockwise Page 14 to the first stop and allow pressure to escape 2 Continue to turn breather valv...

Page 87: ...6 13 Low Temperature Circuit 6 13 1 Intercooler Vent and drain points 12 V 16 V 1 Intercooler vent plugs MS150094 01E 2012 08 Task Description 87 TIM ID 0000025297 002...

Page 88: ...rclockwise to the first stop and allow pressure to escape 2 Continue to turn breather valve counter clockwise and remove 3 Check coolant level coolant must be visible at marking plate 4 Top up coolant...

Page 89: ...Special tools Material Spare parts Designation Use Part No Qty Coolant Charge air coolant Change 1 Drain charge air coolant Page 92 2 Fill with charge air coolant Page 90 MS150094 01E 2012 08 Task Des...

Page 90: ...gloves and goggles safety mask WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors CAUTION Cold coolant in hot engine can cause thermal stress Formation of cracks in comp...

Page 91: ...ing plate 2 Install plug screws of filling points with new sealing rings 3 Check proper condition of breather valve clean sealing faces if required 4 Fit breather valve and close it Final steps 1 Star...

Page 92: ...priate container to drain the coolant into 2 Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to escape 3 Continue to turn breather valve counter clo...

Page 93: ...ing Wear ear protectors Charge air coolant pump Relief bore check 1 Check relief bore for oil and coolant dis charge Permissible coolant discharge up to 10 drops per hour Permissible oil discharge up...

Page 94: ...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 98 Drive belt B Cracks on entire...

Page 95: ...For specifi cations refer to table below Application Specification Initial installation new belt Specification Operating tension used belt Fan drive belt Frequency 99 1 Hz Frequency 86 1 Hz Table 2 Me...

Page 96: ...rd Screw M16x50 Tightening torque Engine oil 180 Nm 18 Nm 4 Tighten screw 2 to specified torque using a torque wrench Name Size Type Lubricant Value Standard Screw M16x280 Tightening torque Engine oil...

Page 97: ...securing screws 1 4 Screw out screw 2 as far as necessary to allow drive belt removal 5 Check belt pulley on radiator bearing mount and crankshaft for contamination and clean if necessary Note When pl...

Page 98: ...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 99: ...y System 6 16 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 MS150094 01E 2012 08 Task Description 99 TIM ID...

Page 100: ...ces Do not smoke Differential pressure gauge Check 1 Switch on fuel treatment system Page 26 2 Set the alarm points at the differential pressure gauge to zero Result Alarm is initiated with preset del...

Page 101: ...water level probe 3 Disconnect plug from 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...

Page 102: ...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 103: ...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 104: ...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 105: ...overnor 6 17 1 Engine governor Overview 1 Screw 2 Washer 3 Damper 4 Engine governor 5 Connector X3 6 Screw 7 Connector X1 8 Screw for grounding strap MS150094 01E 2012 08 Task Description 105 TIM ID 0...

Page 106: ...sabled Preparatory steps 1 Observe safety instructions 2 Switch off operating voltage 3 Note or mark assignment of cables and plugs Engine governor Removal u Remove engine governor as per overview dra...

Page 107: ...ngine governor Installation 1 Install engine governor as per overview drawing Page 105 Name Size Type Lubricant Value Standard Screw for ground ing strap M6x12 Tightening torque Engine oil Max 8 Nm 2...

Page 108: ...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 109: ...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 110: ...6 18 2 Lambda NOx and humidity sensors Overview 1 Humidity sensor 2 NOx sensor 3 Lambda sensor 110 Task Description MS150094 01E 2012 08 TIM ID 0000025179 001...

Page 111: ...ing Wear protective gloves CAUTION Overvoltage Damage to component Switch off ignition voltage before exchanging component s CAUTION Fracture of ceramic cell due to shock load or impact Damage to comp...

Page 112: ...applied on the thread 2 Manually screw sensor into bore 3 Tighten nut 2 to specified tightening torque using a torque wrench Name Size Type Lubricant Value Standard Sensor M18 x 1 5 Tightening torque...

Page 113: ...g Wear protective gloves CAUTION Overvoltage Damage to component Switch off ignition voltage before exchanging component s CAUTION Fracture of ceramic cell due to shock load or impact Damage to compon...

Page 114: ...applied on the thread 2 Manually screw sensor into bore 3 Tighten nut 2 to specified tightening torque using a torque wrench Name Size Type Lubricant Value Standard Sensor M20 x 1 5 Tightening torque...

Page 115: ...Ratchet adapter F30027340 1 Engine 1 NOx sensor 1 CAUTION Contamination of components Damage to component Observe manufacturer s instructions Check components for special cleanness NOx sensor Removal...

Page 116: ...n position Note Take direction of air flow into account 2 Screw in screws 1 3 Use torque wrench to tighten screws 1 to the specified tightening torque Name Size Type Lubricant Value Standard Sensor M6...

Page 117: ...parameters must be reset otherwise the emission certification of the engine is no longer appli cable u Reset the CDC parameters with DiaSys Manufacturer s documentation Resetting CDC parameters DiaSy...

Page 118: ...om 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 illegible labels Cleaning severely...

Page 119: ...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 120: ...me identifier of German standards Deutsche In dustrie Norm DIS Display Unit Display panel DL Default Lost Alarm CAN bus missing DPF Diesel Particulate Filter ECS Engine Control System ECU Engine Contr...

Page 121: ...dead center TDC P xyz Pressure xyz Pressure measuring point xyz PAN Panel Control panel PAU Power Automation Unit Module for monitoring control and plant related system integration of peripheral comp...

Page 122: ...Abbrevia tion Meaning Explanation WJ Water Jet Water jet drive WZK Werkzeugkatalog Tool Catalog TC 122 Appendix A MS150094 01E 2012 08 TIM ID 0000002045 013...

Page 123: ...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 124: ...49 Qty Used in 1 6 5 1 HP fuel line and pressure pipe neck Replace ment Page 54 Barring device Part No F6783914 Qty Used in 1 6 3 1 Valve clearance Check and adjustment Page 44 Barring tool Part No F6...

Page 125: ...1 6 5 1 HP fuel line and pressure pipe neck Replace ment Page 54 Crowfoot wrench 22 mm Part No F30027425 Qty Used in 1 6 4 2 Injector Removal and installation Page 49 Qty Used in 1 6 5 1 HP fuel line...

Page 126: ...sed in 1 6 4 2 Injector Removal and installation Page 49 Feeler gauge Part No Y4345893 Qty Used in 1 6 3 1 Valve clearance Check and adjustment Page 44 Filter wrench Part No F30379104 Qty Used in 1 6...

Page 127: ...Used in 1 6 4 2 Injector Removal and installation Page 49 Mandrel Part No 8205892861 08 Qty Used in 1 6 15 1 Battery charging generator drive Drive belt re placement Page 98 MTU test kit Part No 56058...

Page 128: ...o F30453236 Qty Used in 1 6 4 2 Injector Removal and installation Page 49 Open end socket wrench 24 mm Part No F30453238 Qty Used in 1 6 4 2 Injector Removal and installation Page 49 Puller Part No F6...

Page 129: ...2 Cylinder head cover Removal and installation Page 47 Qty Used in 1 6 4 2 Injector Removal and installation Page 49 Ratchet adapter Part No F30027340 Qty Used in 1 6 5 1 HP fuel line and pressure pip...

Page 130: ...ty Used in 1 6 18 4 NOx sensor Replacement Page 113 Qty Used in 1 6 18 5 Humidity sensor Replacement Page 115 Ring socket 19 mm Part No F30038493 Qty Used in 1 6 3 1 Valve clearance Check and adjustme...

Page 131: ...14 2 Drive belt Tension check Page 95 Torque wrench 0 5 5 Nm Part No 0015384230 Qty Used in 1 6 4 2 Injector Removal and installation Page 49 Torque wrench 10 60 Nm Part No F30510423 Qty Used in 1 6...

Page 132: ...100 Nm Part No F30026582 Qty Used in 1 6 4 2 Injector Removal and installation Page 49 Qty Used in 1 6 5 1 HP fuel line and pressure pipe neck Replace ment Page 54 Torque wrench 20 100 Nm Part No F30...

Page 133: ...03 Torque wrench 6 50 Nm Part No F30027336 Qty Used in 1 6 11 2 Centrifugal oil filter Cleaning and filter sleeve replacement Page 72 Torque wrench 8 40 Nm Part No F30043446 Qty Used in 1 6 3 2 Cylind...

Page 134: ...Coolant level Check 79 Crankcase breather Oil mist fine separator replacement 43 Cylinder Designation 16 Cylinder head cover Removal and installation 47 D Data Engine 19 Differential pressure Pressure...

Page 135: ...g on 29 Fuel filter Replacement 58 Fuel prefilter Differential pressure gauge Check and adjustment 59 Draining 60 Filter element Replacement 63 Flushing 61 Fuel system Venting 56 Fuel treatment system...

Page 136: ...iod 23 R Repair work Safety regulations 8 S Safety instructions 13 Safety regulations 8 Sensor Humidity Replacement 115 Sensors Lambda Replacement 111 NOx Replacement 113 Service indicator Check 66 Se...

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