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MTU 12V 2000 G23, Use And Maintenance Manual

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MTU 12V 2000 G23 Use And Maintenance Manual Download Page 202

6 – 62

General Wiring, Engine / Gearbox / Plant

6.20

General Wiring, Engine / Gearbox / Plant

6.20.1

Engine wiring check

Preconditions

• Engine is stopped and starting disabled.

Material

Designation / Use

Part No.

Qty.

Isopropyl alcohol

Engine wiring check

1. Check securing screws of cable clamps on the engine and tighten loose screw connections.
2. Make certain that cables are securely seated in clamps and cannot move freely.
3. Check cable binders for secure seating, tighten loose cable binders.
4. Replace defective cable binders.
5. Inspect electrical components visually for damage:

• connector housings;

• contacts;
• connector sockets;

• cables and terminals;
• plug-in contacts.

6. If conductors are damaged, contact Service.
7. Clean dirty connector housings, sockets and contacts with isopropyl alcohol.

M015560

/

00E 03-05 © MTU

Summary of Contents for 12V 2000 G23

Page 1: ...Use and maintenance manual MTU Diesel Engine 12V 2000 G23 43 63 83 16V 2000 G23 43 63 83 18V 2000 G63 83 R f constructeur M015560 00E R f GPAO 33522055801...

Page 2: ...aduction l archivage sur microfiches la m morisation et ou le traitement sur des syst mes lectroniques y compris les bases de donn es et les services en ligne Le manuel devra tre observ en vue d viter...

Page 3: ...protection instructions Product Summary Engine layout technical data Operation Task descriptions Maintenance and Servicing Maintenance schedule Troubleshooting Malfunctions causes measures Task Descr...

Page 4: ......

Page 5: ...ase pour l assistance en exploitation contractuelle garantie rechanges etc Rogamos separen la tarjeta Aviso de puesta en servicio y la devuelvan rellenada a MTU Friedrichshafen GmbH Las informaciones...

Page 6: ...e o Bemerkung Remarks Remarques Observaciones Commento Observa es Motornr Engine No No du moteur No de motor Motore N No do motor Motortyp Engine model Type du moteur Tipo de motor Motore tipo Tipo do...

Page 7: ...changes in contents will be sent to you in the form of an amendment provided you complete the reverse of this receipt card and return it to us Postcard MTU Friedrichshafen GmbH Department SCT 88040 Fr...

Page 8: ...E Name Manufacturer Department Fax Telephone Street Postal box number Postal code City Country 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 No Date Name 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Please mark al...

Page 9: ...nel and organizational requirements 1 02 1 3 Transport 1 03 1 4 Safety precautions when working on the engine 1 04 1 5 Auxiliary materials fire prevention and environmental protection 1 07 1 6 Standar...

Page 10: ...1 II Table of Contents M015560 00E 03 05 MTU...

Page 11: ...application specified in the contract or defined at the time of delivery Any other use is considered improper use The manufacturer will accept no liability for any resultant damage The responsibility...

Page 12: ...ed in operation maintenance repair or transportation The personnel must be instructed on engine operation and repair by means of this publication and in particular the safety instructions must be expl...

Page 13: ...ent for heavy loads forklift truck Prior to transporting the engine it is imperative to install transportation locking devices for crankshaft and engine mounts Secure the engine against tilting during...

Page 14: ...ious injury Before starting work relieve pressure in systems and H P lines which are to be opened Never bend a fuel line and do not install bent lines Keep fuel injection lines and connections clean A...

Page 15: ...ntral expansion pressure supply screw spindle into shaft end until correct sealing is achieved During hydraulic installation and removal ensure that nobody is standing in the immediate vicinity of the...

Page 16: ...and optomechanical effects of the laser can cause damage The main danger is irreparable damage to the eyes Laser equipment must be fitted with the protective devices necessary for safe operation accor...

Page 17: ...uality is applicable which means work must only be carried out by authorized specialist companies MTU is such a company Auxiliary materials Use only fluids and lubricants that have been tested and app...

Page 18: ...ir safety precautions must be constantly observed Pay special attention to the pressure level in the compressed air network and pressure vessel Connecting devices and equipment must either be designed...

Page 19: ...equences Slight injury or material damage Note This Publication contains especially emphasized safety instructions in accordance with the American standard ANSI Z535 which begin with one of the above...

Page 20: ...1 10 Safety M015560 00E 03 05 MTU...

Page 21: ...1 2 25 2 4 6 12 16 18V 2000 Continuous operation unrestricted Application group 3B Air cooled charge air Optimized fuel consumption Optimized exhaust emission EPA 40 CFR89 Tier 1 2 29 2 4 7 12 16 18V...

Page 22: ...2 II Table of Contents M015560 00E 03 05 MTU...

Page 23: ...050 Valve gear 070 HP fuel system 080 LP fuel system 100 Exhaust turbocharger 110 Intercooler 120 Air intake air supply 140 Exhaust system 170 Starting equipment 180 Lube oil system 200 Cooling syste...

Page 24: ...designation Key to the engine model designations 812 16 18V 2000 Gxy 8 12 16 18 Number of cylinders V Cylinder configuration V engine 2000 Series G Application X Application segment 2 4 6 8 Y Design i...

Page 25: ...the driving end KS The cylinders of the left engine side are 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...

Page 26: ...e dimensions Main engine dimensions Engine model 12V 2000 Gxy 16V 2000 Gxy 18V 2000 Gxy Length A approx 2020 mm approx 2365 mm approx 2400 mm Width B approx 1580 mm approx 1580 mm approx 1580 mm Heigh...

Page 27: ...3D 3D 3D Intake air temperature C 25 25 25 25 25 Charge air coolant temperature C Raw water inlet temperature C Barometric pressure mbar 1000 1000 1000 1000 1000 Site altitude above sea level m 100 1...

Page 28: ...angle degrees 90 90 90 90 90 Bore mm 130 130 130 130 130 Stroke mm 150 150 150 150 150 Displacement cylinder liter 1 99 1 99 1 99 1 99 1 99 Displacement total liter 23 88 23 88 31 84 31 84 35 82 Comp...

Page 29: ...nders 12 12 16 16 18 Pressure loss in the external cooling system max permissible L bar LUBE OIL SYSTEM Number of cylinders 12 12 16 16 18 Lube oil operating temperature before engine from R C 88 88 8...

Page 30: ...0 100 Firing speed to R rpm 120 120 120 120 120 CAPACITIES Number of cylinders 12 12 16 16 18 Engine coolant capacity without cooling equipment R liter 90 90 110 110 120 Intercooler coolant capacity R...

Page 31: ...cope of supply specification R kg 2490 2490 3100 3100 3500 ACOUSTICS Number of cylinders 12 12 16 16 18 Exhaust noise unsilenced FSP sound power level LW ISO 6798 R db A 125 126 125 127 127 Engine sur...

Page 32: ...3D 3D 3D Intake air temperature C 25 25 25 25 25 Charge air coolant temperature C Raw water inlet temperature C Barometric pressure mbar 1000 1000 1000 1000 1000 Site altitude above sea level m 100 1...

Page 33: ...angle degrees 90 90 90 90 90 Bore mm 130 130 130 130 130 Stroke mm 150 150 150 150 150 Displacement cylinder liter 1 99 1 99 1 99 1 99 1 99 Displacement total liter 23 88 23 88 31 84 31 84 35 82 Comp...

Page 34: ...nders 12 12 16 16 18 Pressure loss in the external cooling system max permissible L bar LUBE OIL SYSTEM Number of cylinders 12 12 16 16 18 Lube oil operating temperature before engine from R C 88 88 8...

Page 35: ...0 100 Firing speed to R rpm 200 120 120 120 120 CAPACITIES Number of cylinders 12 12 16 16 18 Engine coolant capacity without cooling equipment R liter 90 90 110 110 120 Intercooler coolant capacity R...

Page 36: ...to scope of supply specification R kg 2490 2490 3100 3100 3500 ACOUSTICS Number of cylinders 12 12 16 16 18 Exhaust noise unsilenced FSP sound power level LW ISO 6798 R db A 129 129 128 N 130 Engine...

Page 37: ...temperature C 25 25 25 25 25 Charge air coolant temperature C Raw water inlet temperature C Barometric pressure mbar 1000 1000 1000 1000 1000 Site altitude above sea level m 100 100 100 100 100 POWER...

Page 38: ...ngle degrees 90 90 90 90 90 Bore mm 130 130 130 130 130 Stroke mm 150 150 150 150 150 Displacement cylinder liter 1 99 1 99 1 99 1 99 1 99 Displacement total liter 23 88 23 88 31 84 31 84 35 82 Compre...

Page 39: ...nders 12 12 16 16 18 Pressure loss in the external cooling system max permissible L bar LUBE OIL SYSTEM Number of cylinders 12 12 16 16 18 Lube oil operating temperature before engine from R C 88 88 8...

Page 40: ...0 100 Firing speed to R rpm 120 120 120 120 120 CAPACITIES Number of cylinders 12 12 16 16 18 Engine coolant capacity without cooling equipment R liter 90 90 110 110 120 Intercooler coolant capacity R...

Page 41: ...scope of supply specification R kg 2490 2490 3100 3100 3500 ACOUSTICS Number of cylinders 12 12 16 16 18 Exhaust noise unsilenced CP sound power level LW ISO 6798 R db A 123 125 124 125 127 Engine sur...

Page 42: ...r temperature C 25 25 25 25 25 Charge air coolant temperature C Raw water inlet temperature C Barometric pressure mbar 1000 1000 1000 1000 1000 Site altitude above sea level m 100 100 100 100 100 POWE...

Page 43: ...ngle degrees 90 90 90 90 90 Bore mm 130 130 130 130 130 Stroke mm 150 150 150 150 150 Displacement cylinder liter 1 99 1 99 1 99 1 99 1 99 Displacement total liter 23 88 23 88 31 84 31 84 35 82 Compre...

Page 44: ...nders 12 12 16 16 18 Pressure loss in the external cooling system max permissible L bar LUBE OIL SYSTEM Number of cylinders 12 12 16 16 18 Lube oil operating temperature before engine from R C 88 88 8...

Page 45: ...0 100 Firing speed to R rpm 120 120 120 120 120 CAPACITIES Number of cylinders 12 12 16 16 18 Engine coolant capacity without cooling equipment R liter 90 90 110 110 120 Intercooler coolant capacity R...

Page 46: ...scope of supply specification R kg 2490 2490 3100 3100 3500 ACOUSTICS Number of cylinders 12 12 16 16 18 Exhaust noise unsilenced CP sound power level LW ISO 6798 R db A 127 128 126 125 127 Engine sur...

Page 47: ...ion group 3B 3B 3B Intake air temperature C 25 25 25 Charge air coolant temperature C Raw water inlet temperature C Barometric pressure mbar 1000 1000 1000 Site altitude above sea level m 100 100 100...

Page 48: ...Cylinder configuration V angle degrees 90 90 90 Bore mm 130 130 130 Stroke mm 150 150 150 Displacement cylinder liter 1 99 1 99 1 99 Displacement total liter 23 88 31 84 35 82 Compression ratio 14 14...

Page 49: ...linders 12 16 18 Lube oil operating temperature before engine from R C 88 88 88 Lube oil operating temp before engine to R C 98 98 98 Lube oil temperature before engine alarm R C 103 103 103 Lube oil...

Page 50: ...uantity max standard oil system R liter N N N Oil change quantity max standard oil system Option max operating inclinations R liter 74 99 114 Oil pan capacity dipstick mark min standard oil system Opt...

Page 51: ...able Reference Conditions Engine model 12 V 2000G63 16 V 2000G63 18 V 2000G63 12 V 2000G83 16 V 2000G83 18 V 2000G83 Application group 3A 3A 3A 3A 3A 3A Intake air temperature C 25 25 25 25 25 25 Char...

Page 52: ...esign Number of cylinders 12 16 18 12 16 18 Engine with exhaust turbocharging ETC and charge air cooling CAC X X X X X X Exhaust piping non cooled X X X X X X Working method four cycle diesel single a...

Page 53: ...ylinder X X X X X X Cylinder liners wet replaceable X X X X X X Number of inlet valves per cylinder 2 2 2 2 2 2 Number of exhaust valves per cylinder 2 2 2 2 2 2 Standard flywheel housing flange engin...

Page 54: ...R C 97 97 97 97 97 97 Coolant temperature after engine shutdown L C 102 102 102 102 102 102 Coolant antifreeze content max permissible L 50 50 50 50 50 50 Pressure loss in the external cooling system...

Page 55: ...f engine from R bar 6 2 5 5 6 0 6 5 6 0 6 5 Lube oil operating press bef engine to R bar 7 5 6 5 8 0 7 8 7 0 8 5 Lube oil pressure before engine alarm R bar 4 4 4 5 4 4 5 5 5 5 5 5 Lube oil pressure b...

Page 56: ...8 Cold start capability air temperature w o start aid w o preheating case A R C 0 0 0 0 0 0 Coolant preheating preheating temperature min R C 32 32 32 32 32 32 Firing speed from R rpm 100 100 100 100...

Page 57: ...r N N N N N N Oil change quantity max standard oil system Option max operating inclinations R liter 74 99 114 74 99 114 Oil pan capacity dipstick mark min standard oil system Option max operating incl...

Page 58: ...12 16 18 12 16 18 Exhaust noise unsilenced CP sound power level LW ISO 6798 R db A 123 123 125 126 126 126 Engine surface noise with attenuated CP intake noise filter sound power level LW ISO 6798 R...

Page 59: ...e air temperature C 25 25 25 25 25 Charge air coolant temperature C 55 55 55 55 55 Raw water inlet temperature C Barometric pressure mbar 1000 1000 1000 1000 1000 Site altitude above sea level m 100 1...

Page 60: ...angle degrees 90 90 90 90 90 Bore mm 130 130 130 130 130 Stroke mm 150 150 150 150 150 Displacement cylinder liter 1 99 1 99 1 99 1 99 1 99 Displacement total liter 23 88 23 88 31 84 31 84 35 82 Comp...

Page 61: ...02 Coolant antifreeze content max permissible L 50 50 50 50 50 Pressure loss in the external cooling system max permissible L bar 0 7 0 7 0 7 0 7 0 7 COOLING SYSTEM LT circuit Number of cylinders 12 1...

Page 62: ...R bar 4 4 4 4 4 5 4 5 4 4 Lube oil pressure before engine shutdown L bar 3 9 3 9 4 0 4 0 3 9 FUEL SYSTEM Number of cylinders 12 12 16 16 18 Fuel pressure at supply connection to engine when engine is...

Page 63: ...14 Oil pan capacity dipstick mark min standard oil system Option max operating inclinations L liter 50 50 69 69 87 Oil pan capacity dipstick mark max standard oil system Option max operating inclinati...

Page 64: ...Intake air temperature C 25 25 25 25 25 Charge air coolant temperature C 55 55 55 55 55 Raw water inlet temperature C Barometric pressure mbar 1000 1000 1000 1000 1000 Site altitude above sea level m...

Page 65: ...angle degrees 90 90 90 90 90 Bore mm 130 130 130 130 130 Stroke mm 150 150 150 150 150 Displacement cylinder liter 1 99 1 99 1 99 1 99 1 99 Displacement total liter 23 88 23 88 31 84 31 84 35 82 Comp...

Page 66: ...02 Coolant antifreeze content max permissible L 50 50 50 50 50 Pressure loss in the external cooling system max permissible L bar 0 7 0 7 0 7 0 7 0 7 COOLING SYSTEM LT circuit Number of cylinders 12 1...

Page 67: ...R bar 5 5 5 5 5 5 5 5 5 5 Lube oil pressure before engine shutdown L bar 5 0 5 0 5 0 5 0 5 0 FUEL SYSTEM Number of cylinders 12 12 16 16 18 Fuel pressure at supply connection to engine when engine is...

Page 68: ...99 114 Oil pan capacity dipstick mark min standard oil system Option max operating inclinations L liter 50 50 69 69 87 Oil pan capacity dipstick mark max standard oil system Option max operating incli...

Page 69: ...ature C 25 25 25 25 25 Charge air coolant temperature C 55 55 55 55 55 Raw water inlet temperature C Barometric pressure mbar 1000 1000 1000 1000 1000 Site altitude above sea level m 100 100 100 100 1...

Page 70: ...ngle degrees 90 90 90 90 90 Bore mm 130 130 130 130 130 Stroke mm 150 150 150 150 150 Displacement cylinder liter 1 99 1 99 1 99 1 99 1 99 Displacement total liter 23 88 23 88 31 84 31 84 35 82 Compre...

Page 71: ...02 Coolant antifreeze content max permissible L 50 50 50 50 50 Pressure loss in the external cooling system max permissible L bar 0 7 0 7 0 7 0 7 0 7 COOLING SYSTEM LT circuit Number of cylinders 12 1...

Page 72: ...R bar 4 4 4 4 4 5 4 5 4 4 Lube oil pressure before engine shutdown L bar 3 9 3 9 4 0 4 0 3 9 FUEL SYSTEM Number of cylinders 12 12 16 16 18 Fuel pressure at supply connection to engine when engine is...

Page 73: ...14 Oil pan capacity dipstick mark min standard oil system Option max operating inclinations L liter 50 50 69 69 87 Oil pan capacity dipstick mark max standard oil system Option max operating inclinati...

Page 74: ...erature C 25 25 25 25 25 Charge air coolant temperature C 55 55 55 55 55 Raw water inlet temperature C Barometric pressure mbar 1000 1000 1000 1000 1000 Site altitude above sea level m 100 100 100 100...

Page 75: ...ngle degrees 90 90 90 90 90 Bore mm 130 130 130 130 130 Stroke mm 150 150 150 150 150 Displacement cylinder liter 1 99 1 99 1 99 1 99 1 99 Displacement total liter 23 88 23 88 31 84 31 84 35 82 Compre...

Page 76: ...02 Coolant antifreeze content max permissible L 50 50 50 50 50 Pressure loss in the external cooling system max permissible L bar 0 7 0 7 0 7 0 7 0 7 COOLING SYSTEM LT circuit Number of cylinders 12 1...

Page 77: ...R bar 4 4 4 4 4 5 4 5 4 4 Lube oil pressure before engine shutdown L bar 3 9 3 9 4 0 4 0 3 9 FUEL SYSTEM Number of cylinders 12 12 16 16 18 Fuel pressure at supply connection to engine when engine is...

Page 78: ...114 Oil pan capacity dipstick mark min standard oil system Option max operating inclinations L liter 50 50 69 69 87 Oil pan capacity dipstick mark max standard oil system Option max operating inclinat...

Page 79: ...group 3B 3B 3B Intake air temperature C 25 25 25 Charge air coolant temperature C 55 55 55 Raw water inlet temperature C Barometric pressure mbar 1000 1000 1000 Site altitude above sea level m 100 10...

Page 80: ...Cylinder configuration V angle degrees 90 90 90 Bore mm 130 130 130 Stroke mm 150 150 150 Displacement cylinder liter 1 99 1 99 1 99 Displacement total liter 23 88 31 84 35 82 Compression ratio 14 14...

Page 81: ...cooling system max permissible L bar 0 7 0 7 0 7 LUBE OIL SYSTEM Number of cylinders 12 16 18 Lube oil operating temperature before engine from R C 88 88 88 Lube oil operating temp before engine to R...

Page 82: ...e quantity max standard oil system R liter N N N Oil change quantity max standard oil system Option max operating inclinations R liter 74 99 114 Oil pan capacity dipstick mark min standard oil system...

Page 83: ...ference Conditions Engine model 12 V 2000G63 16 V 2000G63 18 V 2000G63 12 V 2000G83 16 V 2000G83 18 V 2000G83 Application group 3A 3A 3A 3A 3A 3A Intake air temperature C 25 25 25 25 25 25 Charge air...

Page 84: ...esign Number of cylinders 12 16 18 12 16 18 Engine with exhaust turbocharging ETC and charge air cooling CAC X X X X X X Exhaust piping non cooled X X X X X X Working method four cycle diesel single a...

Page 85: ...ylinder X X X X X X Cylinder liners wet replaceable X X X X X X Number of inlet valves per cylinder 2 2 2 2 2 2 Number of exhaust valves per cylinder 2 2 2 2 2 2 Standard flywheel housing flange engin...

Page 86: ...oolant antifreeze content max permissible L 50 50 50 50 50 50 Pressure loss in the external cooling system max permissible L bar 0 7 0 7 0 7 0 7 0 7 0 7 COOLING SYSTEM LT circuit Number of cylinders 1...

Page 87: ...f engine from R bar 6 2 5 5 6 0 6 5 6 0 6 5 Lube oil operating press bef engine to R bar 7 5 6 5 8 0 7 8 7 0 8 5 Lube oil pressure before engine alarm R bar 4 4 4 5 4 4 5 5 5 5 5 5 Lube oil pressure b...

Page 88: ...8 Cold start capability air temperature w o start aid w o preheating case A R C 0 0 0 0 0 0 Coolant preheating preheating temperature min R C 32 32 32 32 32 32 Firing speed from R rpm 100 100 100 100...

Page 89: ...tem R liter N N N N N N Oil change quantity max standard oil system Option max operating inclinations R liter 74 99 114 74 99 114 Oil pan capacity dipstick mark min standard oil system Option max oper...

Page 90: ...12 16 18 12 16 18 Exhaust noise unsilenced CP sound power level LW ISO 6798 R db A 123 123 125 126 126 126 Engine surface noise with attenuated CP intake noise filter sound power level LW ISO 6798 R d...

Page 91: ...2 69 2 4 13 Firing order Firing order 12 V A1 B2 A5 B4 A3 B1 A6 B5 A2 B3 A4 B6 16 V A1 B5 A3 A5 B2 B8 A2 A8 B3 A7 B4 B6 A4 A6 B1 B7 18 V A1 B6 A3 B4 A5 B2 A7 B1 A9 B3 A8 B5 A6 B7 A4 B9 A2 B8 M015560 0...

Page 92: ...2 70 Engine Data 2 4 14 Final compression pressure Final compression pressure Final compression pressure at 120 rpm 30 bar to 36 bar M015560 00E 03 05 MTU...

Page 93: ...duled out of service period 3 02 3 3 Starting the engine in manual mode 3 03 3 4 Emergency start override mode 3 04 3 5 Operational checks 3 05 3 6 Stopping the engine in manual mode 3 06 3 7 Emergenc...

Page 94: ...3 II Table of Contents M015560 00E 03 05 MTU...

Page 95: ...uel prefilter pressure gauge Align adjustable pointer with position of pressure indicator Page 6 27 Fuel system Vent Page 6 23 Cooling system If engine is out of service for more than one year change...

Page 96: ...Check oil level Page 6 41 Cooling system Check engine coolant level Page 6 46 Check charge air coolant level Page 6 52 Cooling system Preheat coolant with preheating unit Fuel prefilter Drain Page 6...

Page 97: ...et control panel etc depending on manufacturer If coolant temperature is 40 C with preheating pump or 10 C 60 Hz generator without preheating pump or 5 C 50 Hz generator without preheating pump Press...

Page 98: ...button for override input of ECU Switching cabinet control panel etc depending on manufacturer Press start button Automatic starting procedure is performed All safety functions are deactivated and eng...

Page 99: ...stopped Check for abnormal running noises and vibrations Fuel prefilter Check if indicated differential pressure is within the limit Page 6 27 Exhaust system Check exhaust color Page 5 01 Intercooler...

Page 100: ...dle speed until operating temperatures decrease and stable values are indicated Preparation Item Task Engine After the generator circuit breaker has been opened allow the engine to cool down by runnin...

Page 101: ...ituations Emergency stop from LOP Item Task EMERGENCY STOP button Press Engine is stopped by switching off power supply to ECU Signalization e g by horn flashing lamp is released After emergency stop...

Page 102: ...8 After stopping the engine engine remains ready for operation After stopping the engine Item Task Engine generator control system Select operating mode e g MANUAL OPERATION AUTOMATIC OPERATION M0155...

Page 103: ...no antifreeze additive the engine room is not heated the coolant is not maintained at a suitable temperature the antifreeze concentration is insufficient for the engine room temperature antifreeze con...

Page 104: ...3 10 Operation M015560 00E 03 05 MTU...

Page 105: ...Application Group 3D 4 02 4 2 1 Maintenance schedule 4 02 4 3 Maintenance Schedule Application Group 3B 4 05 4 3 1 Maintenance schedule 4 05 4 4 Maintenance Schedule Application Group 3B TAL 4 08 4 4...

Page 106: ...4 II Table of Contents M015560 00E 03 05 MTU...

Page 107: ...e The time intervals at which the maintenance work is to be carried out and the relevant checks and tasks involved are average results based on operational experience and therefore represent guideline...

Page 108: ...cation Group 3D 4 2 Maintenance Schedule Application Group 3D 4 2 1 Maintenance schedule Application group 3D Standby operation load factor 85 Load profile Load factor 100 85 Corresponding operating t...

Page 109: ...ear Air filter Fuel injectors Fuel injection pumps Combustion chambers Maintenance level W2 W2 W3 W3 W3 W4 W4 W4 W4 Time limit years 2 2 1 2 3 4 Operating hours Daily 500 X X X 1000 X X X 1500 X X X 2...

Page 110: ...enerator drive Page 6 56 Ventilator drive Page 6 57 W3 500 Valve gear Check valve clearance Page 6 10 W3 500 1 Coolant cooler Check cooler elements for external contamination see manufacturer s docume...

Page 111: ...5 4 3 Maintenance Schedule Application Group 3B 4 3 1 Maintenance schedule Application group 3B Continuous operation with variable load load factor 75 Load profile Load factor 110 100 70 Corresponding...

Page 112: ...ear Air filter Fuel injectors Fuel injection pumps Combustion chambers Maintenance level W2 W2 W3 W3 W3 W4 W4 W4 W4 Time limit years 2 2 1 2 3 4 Operating hours Daily 500 X X X 1000 X X X 1500 X X X 2...

Page 113: ...enerator drive Page 6 56 Ventilator drive Page 6 57 W3 500 Valve gear Check valve clearance Page 6 10 W3 500 1 Coolant cooler Check cooler elements for external contamination see manufacturer s docume...

Page 114: ...ctor 110 100 70 Corresponding operating time 1 9 90 Maintenance schedule matrix Engine oil filter Engine oil Belt drive Coolant cooler Fuel filter Valve gear Air filter Fuel injectors Fuel injection p...

Page 115: ...cooler Fuel filter Valve gear Air filter Fuel injectors Fuel injection pumps Combustion chambers 2250 X 2500 X X X X 2750 X 3000 X X X X X X X X 3250 X 3500 X X X X 3750 X 4000 X X X X 4250 X 4500 X...

Page 116: ...essary Battery charging generator drive Page 6 56 Ventilator drive Page 6 57 W3 500 Valve gear Check valve clearance Page 6 10 W3 500 1 Coolant cooler Check cooler elements for external contamination...

Page 117: ...A 4 11 4 5 Maintenance Schedule Application Group 3A 4 5 1 Maintenance schedule Application group 3A Continuous operation unrestricted load factor 100 Load profile Load factor 110 100 Corresponding op...

Page 118: ...lter Valve gear Air filter Fuel injectors Fuel injection pumps Combustion chambers Maintenance level W2 W2 W3 W3 W3 W4 W4 W4 W4 Time limit years 2 2 1 2 3 4 Operating hours Daily 500 X 1000 X X X 1500...

Page 119: ...nerator drive Page 6 56 Ventilator drive Page 6 57 W3 500 2 Fuel filter Replace fuel filter or fuel filter element Page 6 32 W3 1000 Valve gear Check valve clearance Page 6 10 W3 1000 1 Coolant cooler...

Page 120: ...4 14 Maintenance Schedule Application Group 3A M015560 00E 03 05 MTU...

Page 121: ...Table of Contents 5 I 5 Troubleshooting 5 1 Troubleshooting 5 01 5 2 ECU alarms 5 04 M015560 00E 03 05 MTU...

Page 122: ...5 II Table of Contents M015560 00E 03 05 MTU...

Page 123: ...ufacturer s documentation ECU Plug in connections are loose Check plug in connections Page 6 65 Engine Running gear blocked engine cannot be barred manually Contact Service Engine turns but does not f...

Page 124: ...ive Replace Page 6 18 Fuel injection equipment Injection pump defective Replace Page 6 15 Speed sensor Defective Contact Service Fuel system Not vented Vent fuel system Page 6 23 ECU Defective Contact...

Page 125: ...15 Engine Overloaded Contact Service Exhaust gas blue Component Probable Cause Task Too much oil in engine Drain engine oil Page 6 39 Engine oil Oil separator of crankcase breather contaminated Replac...

Page 126: ...low Alarms can also be caused by defective sensors actuators If troubleshooting in accordance with the following table is not successful contact Service to have the sensors actuators checked and if re...

Page 127: ...epeatedly Contact Service 065 L1 P FUEL Fuel supply pressure too low 1st limit 1 Check fuel lines for leaks repair defective lines 2 Clean fuel prefilter Page 6 26 3 Flush fuel prefilter Page 6 30 4 R...

Page 128: ...read via CAN bus 075 L1 P EXTERN 2 Violation of first limit for external pressure channel 2 Depending on the corresponding measuring point which is read via CAN bus 076 L2 P EXTERN 2 Violation of sec...

Page 129: ...ing procedure Note further alarms 093 PREHEAT TEMP LIMIT2 Coolant preheating temperature too low during starting 2nd limit Termination of starting procedure depending on project design Check preheatin...

Page 130: ...ject design Check ECU supply voltage If engine was stopped Start engine Page 3 03 122 L1 T ELECTRONIC Temperature in ECU housing too high 1st limit 1 Improve engine room ventilation 2 Reduce engine po...

Page 131: ...Contact Service 170 MI MODULE FAIL Module in maintenance predictor either defective or missing Contact Service 171 MI NOT ACTIVE Maintenance predictor no more activated Contact Service 173 MODULE WRI...

Page 132: ...OIL Sensor defect lube oil pressure 1 Check wiring 2 Contact Service 215 SD P RAIL FUEL Sensor defect common rail pressure HP controller in emergency mode 1 Check wiring 2 Contact Service 216 SD T LUB...

Page 133: ...N 2 External device defective CAN P EXTERN 2 Contact Service 275 SD EXT COOLANT LEVEL External coolant level monitoring defective CAN Contact Service 276 SD INTERCOOLER LEVEL External charge air coola...

Page 134: ...If fault occurs repeatedly Contact Service 316 TIMING CYLINDER B6 Injection timing fault cylinder B6 If fault occurs repeatedly Contact Service 317 TIMING CYLINDER B7 Injection timing fault cylinder...

Page 135: ...Service 332 WIRING CYLINDER B2 Faulty wiring to solenoid valve cylinder B2 Misfiring 1 Check wiring 2 Contact Service 333 WIRING CYLINDER B3 Faulty wiring to solenoid valve cylinder B3 Misfiring 1 Che...

Page 136: ...PEN_LOAD CYL A6 Disconnection in wiring to solenoid valve cylinder A6 Misfiring 1 Check wiring 2 Contact Service 347 OPEN_LOAD CYL A7 Disconnection in wiring to solenoid valve cylinder A7 Misfiring 1...

Page 137: ...r B10 Misfiring 1 Check wiring 2 Contact Service 361 POWER STAGE FAIL 1 Defect in ECU solenoid valve power stage Contact Service 362 POWER STAGE FAIL 2 Defect in ECU solenoid valve power stage Contact...

Page 138: ...ault code Alarm text Meaning Task 385 TRAN OUT5 PLANT DEF Binary transistor output plant 5 defective Contact Service 386 TRAN OUT6 PLANT DEF Binary transistor output plant 6 defective Contact Service...

Page 139: ...6 18 6 6 2 Injector removal and installation 6 19 6 7 Fuel System Low Pressure 6 22 6 7 1 Fuel Draining 6 22 6 7 2 Fuel system Venting 6 23 6 8 Fuel Filter 6 25 6 8 1 Fuel filter Replacement 6 25 6 8...

Page 140: ...y Charging Generator 6 53 6 17 1 Battery charging generator drive Drive belt check and adjustment 6 53 6 17 2 Battery charging generator drive drive belt condition check 6 55 6 17 3 Battery charging g...

Page 141: ...s 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 Remove cover from flywheel hous...

Page 142: ...ls removed from the engine Barring engine with starting system 1 Disengage the bayonet ring nut 4 of connector X4 with connector pliers 2 and withdraw connector 3 from ECU 2 Bar engine in unloaded con...

Page 143: ...he engine ensure that nobody is in the danger zone WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors Engine test run 1 Start engine Page 3 03 2 Perform test run at not b...

Page 144: ...ing oil bores Wear pattern appears to be darker No measures necessary Oxidation discoloration of even or uneven intensity Start and end of discolored areas have no clear edges and do not extend over t...

Page 145: ...Cylinder Liner 6 05 Final steps 1 Install injector Page 6 19 2 Install cylinder head cover Page 6 13 M015560 00E 03 05 MTU...

Page 146: ...r fuel and temperature differences around the liner It appears rather darker within the honed structure in contrast to the bright metallic running surface The honing pattern is undisturbed Discolorati...

Page 147: ...on discoloration and heat discoloration are similar A definite opinion can first be made after a careful inspection and reference to the above criteria To avoid unnecessary disassembly work it is reco...

Page 148: ...ch Spare parts Designation Use Part No Qty Filter element Diaphragm O ring Oil separator replacement 1 Remove cover 2 with O ring 3 2 Remove filter element 1 from housing 4 3 Insert new filter element...

Page 149: ...diaphragm 3 3 Check diaphragm 3 for damage 4 Replace diaphragm if damaged 5 Mount diaphragm 3 on housing 2 6 Install new seal 4 and spring 6 together with cover 5 7 Tighten screws of cover 5 to 6 Nm...

Page 150: ...g disabled Engine coolant temperature is max 40 C Valves are closed Special tools Designation Use Part No Qty Feeler gauge Preparatory steps 1 Remove cylinder head cover Page 6 13 2 Use barring tool t...

Page 151: ...ankshaft positions firing and overlap TDC for cylinder A1 as per diagram 4 Use feeler gauge to determine the distance between valve bridge and rocker arm 5 If the deviation from the reference value ex...

Page 152: ...6 12 Valve Gear Final steps 1 Remove barring tool 2 Install cylinder head cover Page 6 13 3 Install cover M015560 00E 03 05 MTU...

Page 153: ...crankcase breather Loosen clamps 2 Slide rubber sleeves onto the pipe Cylinder head cover Removal and installation 1 Remove screws 2 Remove cylinder head cover with gasket from cylinder head 3 Clean m...

Page 154: ...ection Pump HP Pump 6 5 Injection Pump HP Pump 6 5 1 Injection pump replacement Spare parts Designation Use Part No Qty Injection pump Remove injection pump and install new one Page 6 15 M015560 00E 0...

Page 155: ...ling ring DANGER Unguarded rotating and moving engine components Risk of serious injury danger to life Before barring the engine ensure that nobody is in the danger zone WARNING Fuels are combustible...

Page 156: ...ll blanking plugs and covers 2 Clean mating face of injection pump and roller Note Sealing rings are identified by different item numbers pay attention to correct installation position 3 Coat new seal...

Page 157: ...n cylinder head and charge air manifold 3 Check gaskets for damage and replace them if required 4 Set gasket onto cylinder head 5 Install charge air manifold 6 Install engine control system Page 6 63...

Page 158: ...6 18 Fuel Injector 6 6 Fuel Injector 6 6 1 Injector replacement Spare parts Designation Use Part No Qty Injector Remove injector and install new one Page 6 19 M015560 00E 03 05 MTU...

Page 159: ...roleum jelly Spare parts Designation Use Part No Qty Sealing ring Sealing ring WARNING Fuels are combustible Risk of fire and explosion Avoid naked flames electrical sparks and ignition sources Do not...

Page 160: ...off pressure pipe neck 1 5 Extract fuel from the exposed bores using the suction device 6 Seal all connections with appropriate plugs 7 Remove screw 2 8 Take off clamp 1 9 Screw extractor into inject...

Page 161: ...correct seating 8 Tighten clamp screw 5 to 50 Nm 9 Blow out fuel line 3 and pressure pipe neck 1 with compressed air 10 Coat new O ring with petroleum jelly and fit on pressure pipe neck 1 11 Coat se...

Page 162: ...d flames electrical sparks and ignition sources Do not smoke Fuel Draining 1 Loosen nut arrow on banjo union 2 Remove fuel line from non return valve 3 Unscrew non return valve on end piece arrow and...

Page 163: ...le Risk of fire and explosion Avoid naked flames electrical sparks and ignition sources Do not smoke Fuel system Venting 1 Unlock fuel priming pump unscrew handle 2 Loosen nut arrow on banjo union 3 O...

Page 164: ...of the nipple 7 Tighten banjo screw 8 Loosen union nut of fuel return line 9 Loosen non return valve arrow 10 Operate the pump with the handle until fuel without bubbles comes out of the nipple 11 Ti...

Page 165: ...esignation Use Part No Qty Easy change filter WARNING Fuels are combustible Risk of fire and explosion Avoid naked flames electrical sparks and ignition sources Do not smoke Fuel filter Replacement 1...

Page 166: ...prefilter cleaning 1 Shut off fuel supply 2 Remove nuts from filter head 3 Take off filter housing and drain fuel into appropriate container 4 Remove filter element securing nut and remove filter elem...

Page 167: ...ential pressure gauge 1 After installation of a new filter element align adjustable pointer 2 with pressure indicating pointer 3 of pressure gauge 1 2 Verify that differential pressure is within the l...

Page 168: ...Part No Qty Diesel fuel Spare parts Designation Use Part No Qty Gasket WARNING Fuels are combustible Risk of fire and explosion Avoid naked flames electrical sparks and ignition sources Do not smoke...

Page 169: ...ts from the filter until pure fuel emerges 5 Close drain cock 6 6 Remove screws securing the cover and take off cover 2 7 Fill filter housing with clean fuel 8 Place new gasket in cover 2 9 Fit cover...

Page 170: ...ous injury danger to life Take special care when working on a running engine WARNING Fuels are combustible Risk of fire and explosion Avoid naked flames electrical sparks and ignition sources Do not s...

Page 171: ...e vent plug 5 and drain cock 6 Fuel prefilter filling fuel 1 Stop engine Page 3 06 and disable engine start 2 Remove screws securing the cover and take off cover 2 3 Fill filter housing with clean fue...

Page 172: ...o Qty Diesel fuel Spare parts Designation Use Part No Qty Filter element Gasket WARNING Fuels are combustible Risk of fire and explosion Avoid naked flames electrical sparks and ignition sources Do no...

Page 173: ...nd take off cover 2 7 Remove spring 4 and filter element 3 8 Insert new filter element 3 and spring 4 9 Fill filter housing with clean fuel 10 Place new gasket in cover 2 11 Fit cover with gasket and...

Page 174: ...condensate drains for coolant discharge and obstructions 1 Remove plug screw s from charge air manifold 2 Check drain bore s for air discharge If no air emerges 3 Clean drain bore s and blow out with...

Page 175: ...6 10 Air Filter 6 10 1 Air filter replacement Spare parts Designation Use Part No Qty Air filter Remove air filter and install new one Page 6 36 Reset signal ring of service indicator Page 6 37 M01556...

Page 176: ...led Air filter removal and installation 1 Loosen clamp 2 2 Remove air filter 3 and clamp 2 from flange of intake housing 1 3 Verify that there are no objects in the flange of the intake housing 1 and...

Page 177: ...is stopped and starting disabled Signal ring position check 1 If the signal ring is completely visible in the control window 2 replace air filter Page 6 35 2 After installation of new filter press re...

Page 178: ...o life Before barring or starting the engine ensure that nobody is in the danger zone WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors Air starter manual operation 1 Pr...

Page 179: ...th Risk of injury and scalding Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Oil change without semirotary hand pump Draining oil at drain plu...

Page 180: ...l change Product Summary Technical Data 2 Open cover of filler neck 3 Pour oil in at filler neck up to max mark at oil dipstick 4 Close cover of filler neck 5 Check oil level Page 6 41 6 After oil cha...

Page 181: ...st be between min and max marks 4 If necessary top up to max mark Page 6 39 5 Insert dipstick into guide tube to stop Oil level check after the engine is stopped 1 5 minutes after stopping the engine...

Page 182: ...re harmful to health Risk of injury and scalding Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Engine oil filter Replacement 1 Remove oil filt...

Page 183: ...cks in components Fill top up coolant only into cold engine Preparatory steps 1 Turn breather valve on coolant expansion tank counterclockwise to first stop and allow pressure to escape 2 Continue to...

Page 184: ...1 Turn breather valve of filler neck on coolant expansion tank counterclockwise to first stop and allow pressure to escape 2 Continue to turn breather valve counterclockwise and remove 3 Draw off pre...

Page 185: ...ooling System General HT Circuit 6 45 6 15 3 Engine coolant change Material Designation Use Part No Qty Coolant Drain engine coolant Page 6 44 Fill engine coolant system Page 6 43 M015560 00E 03 05 MT...

Page 186: ...o escape 2 Continue to turn breather valve counterclockwise and remove 3 Check coolant level coolant must be visible at the lower edge of the cast in eye Coolant level check at external cooler 1 Check...

Page 187: ...noise above 85 dB A Risk of damage to hearing Wear ear protectors Cooling pump Relief bore check 1 Check relief bore for oil and water discharge 2 Stop engine Page 3 06 and disable engine start 3 Cle...

Page 188: ...nts Fill top up coolant only into cold engine Preparatory steps 1 Turn breather valve on coolant expansion tank counterclockwise to first stop and allow pressure to escape 2 Continue to turn breather...

Page 189: ...Cooling System LT Circuit 6 49 Final steps 1 Start the engine and operate it at idle speed for some minutes 2 Check coolant level Page 6 52 M015560 00E 03 05 MTU...

Page 190: ...in the coolant into 2 Turn breather valve of filler neck on coolant expansion tank counterclockwise to first stop and allow pressure to escape 3 Continue to turn breather valve counterclockwise and re...

Page 191: ...System LT Circuit 6 51 6 16 3 Charge air coolant change Material Designation Use Part No Qty Coolant Drain charge air coolant system Page 6 50 Fill charge air coolant system Page 6 48 M015560 00E 03...

Page 192: ...expansion tank counterclockwise to first stop and allow pressure to escape 2 Continue to turn breather valve counterclockwise and remove 3 Check coolant level coolant must be visible at marking plate...

Page 193: ...material is broken off in some places B Page 6 56 4 Install guard cover Belt tension check 1 Remove guard cover 2 Place belt tension tester onto drive belt midway between the belt pulleys 3 Press butt...

Page 194: ...Loosen securing screws 2 and 3 2 Tension ribbed drive belt with tensioning nut 1 and check belt tension 3 Tighten securing screw 2 Tightening torque 40 Nm 4 Nm 4 Tighten securing screw 3 5 Check drive...

Page 195: ...k 1 Remove guard cover 2 Check belt for contamination by oil cracks wear and signs of overheating 3 Replace drive belt If belt is oily If belt shows signs of overheating If ribs are broken around the...

Page 196: ...ventilator drive belt applicable only to TD cooling Page 6 60 3 Loosen securing screws 2 and 3 4 Release tensioning screw 1 until the ribbed belt can be removed 5 Check belt pulleys for cleanliness r...

Page 197: ...ws signs of overheating If belt shows cracks If belt is worn If belt is chunked Page 6 60 Belt tension check on 12 16V engines 1 Place belt tension tester onto V belt midway between the belt pulleys a...

Page 198: ...ured value deviates from the specified belt tension readjust belt tension Belt tension adjustment on 12 16V engines 1 Loosen securing screws 3 2 Release locknut 2 3 Screw in tensioning screw 1 to set...

Page 199: ...Ventilator Drive 6 59 Final steps 1 Install guard cover 2 Fit screws and tighten M015560 00E 03 05 MTU...

Page 200: ...ut applying any force 5 Fit new set of drive belts 6 To check V belt tension the ventilator bearing pedestal must rest against the gearcase 7 Adjust and check V belt tension Page 6 57 Drive belt repla...

Page 201: ...lient elements check 1 Wipe rubber surface with dry cloth do not use organic detergents 2 Check resilient elements for crack formation and deformation by visual inspection 3 Have cracked elements repl...

Page 202: ...tighten loose screw connections 2 Make certain that cables are securely seated in clamps and cannot move freely 3 Check cable binders for secure seating tighten loose cable binders 4 Replace defectiv...

Page 203: ...nector pliers 2 to disengage the bayonet union nuts 4 of the connectors 3 by turning them counterclockwise 3 Withdraw all connectors 4 Close connector sockets with appropriate covering caps 1 5 Discon...

Page 204: ...l 2 Remove dirt from surface of connectors 1 connector sockets and shrink sleeves 2 using a cloth moistened with isopropyl alcohol 3 Check legibility of cable labels Clean or replace illegible labels...

Page 205: ...Part No Qty Connector pliers ECU checking plug in connections 1 Use connector pliers 3 to make certain that all plug in connections of ECU are securely seated 2 Tighten loose bayonet union nuts 2 with...

Page 206: ...6 66 Engine Governor Electronic Control System M015560 00E 03 05 MTU...

Page 207: ...Table of Contents 7 I 7 Annex 7 1 Abbreviations 7 01 7 2 Index 7 03 M015560 00E 03 05 MTU...

Page 208: ...7 II Table of Contents M015560 00E 03 05 MTU...

Page 209: ...exceeds 1st maximum limit HIHI High High Alarm Measured value exceeds 2nd maximum limit HT High Temperature IDM Interface Data Module ISO International Organization for Standardization KGS Kraftgegens...

Page 210: ...evia tion Meaning Explanation SPC Spare Parts Catalog T xyz Temperature xyz Temperature measuring point xyz TC Tools Catalog TD Transmitter Deviation UT Unterer Totpunkt Bottom dead center BDC M015560...

Page 211: ...ater cooled charge air Optimized exhaust emission TA Luft 2 52 A Abbreviations 7 01 After stopping the engine engine remains ready for operation 3 08 After stopping the engine putting the engine out o...

Page 212: ...40 CFR89 Tier 1 2 10 12 16 18V 2000 Standby operation Application Group 3D Air cooled charge air Optimized fuel consumption 2 05 12 16 18V 2000 Standby operation Application Group 3D Water cooled cha...

Page 213: ...nsate drains for coolant discharge and obstructions 6 34 L Lube Oil System 6 39 Engine oil change 6 39 Engine oil level check 6 41 M Main engine dimensions 2 04 Main Engine Dimensions 2 04 Main engine...

Page 214: ...ve clearance Check and adjustment 6 10 Ventilator Drive 6 57 Ventilator drive Drive belt replacement 6 60 Ventilator drive Drive belt check and adjustment 6 57 Ventilator drive Drive belt replacement...

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