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MTU 12V2000B26F, Operating Instructions Manual

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MTU 12V2000B26F Operating Instructions Manual Download Page 129

7.16.2 Engine control system – Removal and installation

Preconditions

☑

Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use

Part No.

Qty.

Engine control system

1

Resilient mount

(→ Spare Parts Catalog)

NOTICE

Wrong engine governor installed.

Engine damage!

• When reassembling an engine, make sure that the governor with the data record for the given

engine is installed.

Removing engine control system
from engine

1.

Note or mark assignment of cables and
connectors.

2.

Release latches on connectors (1) and (3).

3.

Disconnect all connectors.

4.

Remove all screws (5).

5.

Remove engine control system (2).

Installing engine control system on engine

1.

Install in reverse order. Ensure correct assignment of connectors and sockets in so doing.

2.

Check resilient mount before installation.

Result:

Replace resilient mount if porous or defective.

MS150118/00E 2014-07

| Task Description | 129

TIM-ID: 0000053492 - 001

Summary of Contents for 12V2000B26F

Page 1: ...Instructions Diesel engine 12 V 2000 Gx6 F 16 V 2000 Gx6 F 18 V 2000 Gx6 F 12 V 2000 Bx6 F 16 V 2000 Bx6 F 18 V 2000 Bx6 F 12 V 2000 B76 switchable 16 V 2000 B76 switchable 18 V 2000 B76 switchable MS...

Page 2: ...3B continuous operation variable load ICXN 16V2000G26F 56 kW cyl 1500 3B continuous operation variable load ICXN 16V2000G36F 63 kW cyl 1500 3B continuous operation variable load ICXN 18V2000G26F 61 k...

Page 3: ...k Description 7 1 Engine 68 7 1 1 Engine Cranking manually 68 7 1 2 Engine Barring with starting system 69 7 2 Crankcase Breather 70 7 2 1 Crankcase breather Oil mist fine separator replacement 70 7 3...

Page 4: ...1 Water drain valve Check 122 7 15 2 Differential pressure gauge Check 123 7 15 3 Water level probe 3 in 1 rod electrode Check 124 7 15 4 Pump capacity Check 125 7 15 5 Coalescer filter element Replac...

Page 5: ...guration approved by the manufacturer in writ ing including engine management parameters In compliance with all safety regulations and in accordance with all warning notices in this manual With mainte...

Page 6: ...rk on or around the product This personnel must be instructed repeatedly Personnel requirements All work on the product shall be carried out by trained and qualified personnel only Training at the Tra...

Page 7: ...truck Install the crankshaft locking device and the locking screws for the engine mounts prior to engine trans portation Secure the engine against tilting during transportation The engine must be addi...

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

Page 9: ...e performing necessary welding work Hydraulic installation and removal Check function and satisfactory condition of the jigs and fixtures to be used Use only the specified jigs and fixtures for hydrau...

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

Page 11: ...are prohibited by emission regulations Emission control units systems may only be maintained exchanged or repaired if the components used for this purpose are approved by the manu facturer Noncomplian...

Page 12: ...be replaced Carry out leak test in accordance with the specifications Paints and varnishes Observe the relevant safety data sheet for all materials When painting in areas other than spray booths equi...

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

Page 14: ...nated in accordance with DIN ISO 1204 as viewed from driving end 4 For cylinder designation in accordance with DIN ISO 1204 the letter Ax refers to the cylinders on the left hand side of the engine 1...

Page 15: ...and regulation system 4 Charge air line 5 Belt drive 6 Engine coolant pump 7 Fuel system low pressure 8 Fuel filter 9 Exhaust turbocharger 10 Fuel system high pres sure 11 Charge air line 12 Starting...

Page 16: ...rol and regulation system 4 Charge air line 5 Belt drive 6 Engine coolant pump 7 Fuel system low pressure 8 Fuel filter 9 Exhaust turbocharger 10 Fuel system high pres sure 11 Charge air line 12 PTO s...

Page 17: ...Charge air line 12 Starting equipment 13 PTO system driving end KS Driving end Explanation of engine model designation 12 16 18 Number of cylinders V Cylinder arrangement Vee engine 2000 Series B G A...

Page 18: ...itions Power related data power ratings are net brake power as per ISO 3046 Number of cylinders 12 16 18 Rated engine speed A rpm 1500 1500 1500 Continuous power ISO 3046 10 overload capability A kW 6...

Page 19: ...X X X Combustion method direct fuel in jection X X X Number of cylinders 12 16 18 Cylinder arrangement Vee angle Degrees 90 90 90 Bore mm 135 135 135 Stroke mm 156 156 156 Displacement of a cylinder...

Page 20: ...t gauge pres sure R bar 1 0 1 0 1 0 Cooling system height above en gine max L m 20 20 20 Table 9 Coolant system HT circuit Coolant system LT circuit Number of cylinders 12 16 18 Coolant temperature be...

Page 21: ...11 Lube oil system Fuel system Number of cylinders 12 16 18 Fuel pressure at engine supply connection min during engine start L bar 0 5 0 5 0 5 Fuel pressure at engine supply connection max during eng...

Page 22: ...cooling system R Liters 63 70 73 Charge air coolant engine side R Liters Fuel engine side R Liters 6 6 7 Engine oil capacity initial filling standard oil system design max operating inclination positi...

Page 23: ...L free field sound power level Lp 1 m distance ISO 6798 2 dB A tol erance R dB A 100 101 Engine surface noise with attenu ated intake noise filter DL sound power level LW ISO 6798 2 db A tolerance R d...

Page 24: ...Reference conditions Power related data power ratings are net brake power as per ISO 3046 Number of cylinders 12 16 18 Rated engine speed A rpm 1500 1500 1500 Continuous power ISO 3046 10 overload cap...

Page 25: ...n X X X Combustion method direct fuel in jection X X X Number of cylinders 12 16 18 Cylinder arrangement Vee angle Degrees 90 90 90 Bore mm 135 135 135 Stroke mm 156 156 156 Displacement of a cylinder...

Page 26: ...t gauge pres sure R bar 1 0 1 0 1 0 Cooling system height above en gine max L m 20 20 20 Table 24 Coolant system HT circuit Coolant system LT circuit Number of cylinders 12 16 18 Coolant temperature b...

Page 27: ...26 Lube oil system Fuel system Number of cylinders 12 16 18 Fuel pressure at engine supply connection min during engine start L bar 0 5 0 5 0 5 Fuel pressure at engine supply connection max during eng...

Page 28: ...ng system R Liters 63 70 73 Charge air coolant engine side R Liters Fuel engine side R Liters 6 6 7 Engine oil capacity initial filling standard oil system design max operating inclination positions R...

Page 29: ...DL free field sound power level Lp 1 m distance ISO 6798 2 dB A tol erance R dB A 100 121 Engine surface noise with attenu ated intake noise filter DL sound power level LW ISO 6798 2 db A tolerance R...

Page 30: ...Reference conditions Power related data power ratings are net brake power as per ISO 3046 Number of cylinders 12 16 18 Rated engine speed A rpm 1800 1800 1800 Continuous power ISO 3046 10 overload cap...

Page 31: ...X X X Combustion method direct fuel in jection X X X Number of cylinders 12 16 18 Cylinder arrangement Vee angle Degrees 90 90 90 Bore mm 135 135 135 Stroke mm 156 156 156 Displacement of a cylinder...

Page 32: ...gauge pres sure R bar 1 0 1 0 1 0 Cooling system height above en gine max L m 20 20 20 Table 39 Coolant system HT circuit Coolant system LT circuit Number of cylinders 12 16 18 Coolant temperature be...

Page 33: ...41 Lube oil system Fuel system Number of cylinders 12 16 18 Fuel pressure at engine supply connection min during engine start L bar 0 5 0 5 0 5 Fuel pressure at engine supply connection max during en...

Page 34: ...ystem R Liters 63 70 73 Charge air coolant engine side R Liters Fuel engine side R Liters 6 6 7 Engine oil capacity initial filling standard oil system design max operating inclination positions R Lit...

Page 35: ...ee field sound power level Lp 1 m distance ISO 6798 2 dB A tol erance R dB A 101 101 103 Engine surface noise with attenu ated intake noise filter DL sound power level LW ISO 6798 2 db A tolerance R d...

Page 36: ...of cylinders 12 16 Rated engine speed A rpm 1500 1500 Continuous power ISO 3046 10 overload capability A kW 665 806 Net brake power without fan fuel stop power ISO 3046 A kW 732 887 Mean effective pre...

Page 37: ...12 16 Charge air pressure before cylinder DL R bar abs 2 9 2 6 Charge air pressure before cylinder BL R bar abs 3 2 2 8 Table 53 Air exhaust gas Coolant system HT circuit Number of cylinders 12 16 Co...

Page 38: ...oil operating pressure before engine from R bar 5 8 6 2 Lube oil operating pressure before engine to R bar 8 5 8 8 Lube oil operating pressure before engine warning L bar 4 5 4 5 Lube oil operating p...

Page 39: ...e side R Liters 6 6 Engine oil capacity initial filling standard oil system design max operating inclination positions R Liters 92 114 Oil change quantity max standard oil system design max oper ating...

Page 40: ...rs 12 16 18 Rated engine speed A rpm 1500 1500 1500 Continuous power ISO 3046 10 overload capability A kW 709 890 1102 Net brake power without fan fuel stop power ISO 3046 A kW 780 979 1212 Mean effec...

Page 41: ...5 Standard housing connecting flange engine main PTO side SAE 0 0 0 Table 67 Model related data basic design Air exhaust gas Number of cylinders 12 16 18 Charge air pressure before cylin der DL R bar...

Page 42: ...air temperature after inter cooler max L C Breather valve expansion tank opening pressure at gauge pres sure R bar Cooling system height above en gine max L m Table 70 Coolant system LT circuit Lube o...

Page 43: ...eheating preheating temperature min L C 32 32 32 Starting is blocked if the engine coolant temperature is below C 20 20 20 Firing speed from R rpm 100 100 100 Firing speed to R rpm 120 120 120 Table 7...

Page 44: ...18 Fan pusher type X X X Fan drive mechanical via V belt X X X Table 76 Fan fan cooler Sound Number of cylinders 12 16 18 Exhaust noise not attenuated DL free field sound pressure level Lp 1 m distanc...

Page 45: ...ber of cylinders 12 16 18 Rated engine speed A rpm 1500 1500 1500 Continuous power ISO 3046 10 overload capability A kW Net brake power without fan fuel stop power ISO 3046 A kW 732 780 976 Mean effec...

Page 46: ...7 5 17 5 Standard housing connecting flange engine main PTO side SAE 0 0 0 Table 82 Model related data basic design Air exhaust gas Number of cylinders 12 16 18 Charge air pressure before cylin der DL...

Page 47: ...air temperature after inter cooler max L C Breather valve expansion tank opening pressure at gauge pres sure R bar Cooling system height above en gine max L m Table 85 Coolant system LT circuit Lube o...

Page 48: ...eheating preheating temperature min L C 32 32 32 Starting is blocked if the engine coolant temperature is below C 20 20 20 Firing speed from R rpm 100 100 100 Firing speed to R rpm 120 120 120 Table 8...

Page 49: ...18 Fan pusher type X X X Fan drive mechanical via V belt X X X Table 91 Fan fan cooler Sound Number of cylinders 12 16 18 Exhaust noise not attenuated DL free field sound pressure level Lp 1 m distanc...

Page 50: ...Number of cylinders 16 Rated engine speed A rpm 1500 Continuous power ISO 3046 10 overload capability A kW 1000 Net brake power without fan fuel stop power ISO 3046 A kW 1100 Mean effective pressure p...

Page 51: ...ders 16 Charge air pressure before cylinder DL R bar abs 3 4 Charge air pressure before cylinder BL R bar abs 3 5 Table 98 Air exhaust gas Coolant system HT circuit Number of cylinders 16 Coolant temp...

Page 52: ...ngine from R bar 6 2 Lube oil operating pressure before engine to R bar 8 8 Lube oil operating pressure before engine warning L bar 4 5 Lube oil operating pressure before engine shutdown L bar 4 0 Lub...

Page 53: ...ing standard oil system design max operat ing inclination positions R Liters 114 Oil change quantity max standard oil system design max operating in clination positions R Liters 102 Table 105 Capaciti...

Page 54: ...f cylinders 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 V A1 B6 A3 B4 A5 B2 A7 B1 A9 B3 A8 B5 A6 B7 A4 B9 A2 B8 54 Technical Data MS15...

Page 55: ...1421 mm 12 V 2000 G26F approx 2044 mm approx 1522 mm approx 1470 mm 16 V 2000 G26F approx 2394 mm approx 1570 mm approx 1421 mm 18 V 2000 G26F approx 2569 mm approx 1572 mm approx 1421 mm 16 V 2000 G...

Page 56: ...ck engine oil level Page 99 Fuel system Use appropriate equipment to fill system via fuel supply line Fuel system Vent Page 85 Coolant circuit If engine is out of service for more than one year change...

Page 57: ...il system Check engine oil level Page 99 Coolant circuit Check engine coolant level Page 108 Coolant circuit Preheat engine coolant with coolant preheating unit if fitted Fuel prefilter if fitted Drai...

Page 58: ...in Before cranking the engine with starter system make sure that there are no persons in the en gine s danger zone WARNING High level of engine noise when the engine is running Risk of damage to heari...

Page 59: ...of operational data speed temperature pressures Engine oil Check engine oil level Page 99 Engine operation Check engine visually for leaks and general condition Check engine for abnormal running noise...

Page 60: ...ge to components is possible Before shutting down the engine allow it to idle until the engine temperatures decrease and constant levels are indicated Preparation Item Action Engine Allow the engine t...

Page 61: ...is 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...

Page 62: ...itive the engine room is not heated the coolant is not kept at a suitable temperature the antifreeze concentration is insufficient for the engine room tem perature the antifreeze concentration is 50 a...

Page 63: ...ressed air gun directly at seals or electronic components such as connectors or ECUs Plant Cleaning 1 Carry out plant cleaning only in areas where an appropriate oil separator is provided environmenta...

Page 64: ...essary Page 115 W1005 Replace air filter Page 93 W1006 Replace fuel injectors injectors Page 75 W1008 Replace engine oil filter when changing engine oil or when the limit value years is reached at the...

Page 65: ...re Component Probable Cause Action Starter Poor rotation by starter Battery low or faulty Charge or replace battery see manufac turer s documentation Engine cabling Faulty Check Page 131 Fuel system A...

Page 66: ...ngine room Air intake temperature too high Check fans and intake exhaust lines Charge air pressure too low Component Probable Cause Action Air supply Air filter clogged Check signal ring position of s...

Page 67: ...charger cylinder head piston rings cylinder liner Faulty Contact Service White exhaust gas Component Probable Cause Action Engine Not at operating temperature Run engine to reach operating tempera tur...

Page 68: ...ll safety devices are put back in place and all tools are removed from the engine Cranking engine manually later al installation 1 Remove starting equipment from flywheel housing Page 97 2 Engage barr...

Page 69: ...in Before cranking the engine with starter system make sure that there are no persons in the en gine s danger zone Engine Barring with starting system 1 Press pushbutton Bar engine without starting an...

Page 70: ...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 vapo...

Page 71: ...0 Nm F30510423 1 Measuring device Y4348409 1 Preparatory steps 1 Install barring tool Page 68 2 Remove cylinder head cover Page 74 Positioning A1 cylinder piston at TDC Note With cylinder head and val...

Page 72: ...X I X I X X Bank B X X I X I X I I X I Overlap TDC in cylinder A1 Bank A X I X I I X I I X I X Bank B I I I X I X X X I Inlet Inlet valve adjustment permitted X exhaust Exhaust valve adjustment permi...

Page 73: ...Final steps 1 Remove barring tool 2 Install cylinder head cover Page 74 MS150118 00E 2014 07 Task Description 73 TIM ID 0000053450 001...

Page 74: ...c tor clamps and remove spade lugs 1 Remove cylinder head cover 2 with gas ket 1 from cylinder head 2 Clean mating face 3 Check condition of gasket 1 in cylinder head cover 2 4 Replace gasket 1 if dam...

Page 75: ...al tools Material Spare parts Designation Use Part No Qty Injector Spare Parts Catalog Screw for hold down clamp Spare Parts Catalog Replacing injector u Remove injector and install new one Page 76 MS...

Page 76: ...50 1 Open end socket wrench 24 mm F30453238 1 Assembly compound Kluthe Hakuform 30 15 X00067260 1 Engine oil Sealing ring Spare Parts Catalog WARNING Fuels are combustible Risk of fire and explosion A...

Page 77: ...uel suction device 5 Disconnect terminals arrow on injector and pull out spade lugs 6 Remove gasket 7 Remove screw 3 Note Screw 3 may be used only once 8 Take off hold down clamp 2 9 Use the puller to...

Page 78: ...nstallation with press in tool 1 Place press in tool on hold down clamp 2 and press injector 1 carefully into the cylinder head 2 Place hold down clamp 2 in correct position screw in screw 3 and tight...

Page 79: ...me Size Type Lubricant Value Standard Retaining screw M25 Tightening torque 50 Nm 5 Nm Installing fuel line 1 Coat thread and shoulder of union nuts on HP fuel line 1 with engine oil Note Position fue...

Page 80: ...n 3 to the specified tightening torque using a torque wrench Name Size Type Lubricant Value Standard Union nut M16 Tightening torque Engine oil 37 Nm 3 Nm Fitting gasket and connecting in jector cable...

Page 81: ...id the emissions certification for the en gine Resetting drift correction parameters CDC with DiaSys 1 Dialog system DiaSys E531920 2 If no DiaSys is available contact Service Entering injector coding...

Page 82: ...1 Assembly compound Kluthe Hakuform 30 15 X00067260 1 Engine oil Pressure pipe connection Spare Parts Catalog HP fuel line Spare Parts Catalog Gasket Spare Parts Catalog WARNING Fuels are combustible...

Page 83: ...ecified tightening torque Name Size Type Lubricant Value Standard Union nut M24 Preload torque Engine oil 15 Nm 5 Nm Union nut M24 Tightening torque 50 Nm 5 Nm 11 Coat mating face with engine oil betw...

Page 84: ...teps 1 Clean mating faces on cylinder head and charge air pipe 2 Check gaskets for damage and replace them if required 3 Coat gaskets with assembly compound and place on cylinder head 4 Install leak o...

Page 85: ...cal sparks and ignition sources Do not smoke Fuel system Venting 1 Open threaded vent plug 2 on filter head and connect suitable hose 2 Provide suitable container to collect escap ing fuel 3 Actuate h...

Page 86: ...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 87 3 Catch...

Page 87: ...sk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Fuel filter Replacement 1 Remove easy change filter 3 with filter wrench 2 Clean the sealing face on the...

Page 88: ...of dif ferential pressure gage 1 After installation of a new filter element Align adjustable pointer 2 with pressure indicating pointer 3 of pressure gage 1 2 Verify that differential pressure is with...

Page 89: ...Do not smoke Fuel prefilter Draining 1 Open vent plug 1 of the filter 2 Unlock drain cock 2 by pressing toggle and open it 3 Drain water and contaminants from the fil ter until pure fuel emerges 4 Clo...

Page 90: ...at low power Keep away from the engine s danger zone WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke WARNING High level...

Page 91: ...k 6 Fuel prefilter Filling with fuel 1 Stop engine Page 60 and disable engine start 2 Remove screws securing the cover and take off cover 2 3 Fill filter housing with clean fuel 4 Place new seal in co...

Page 92: ...ing filter element 1 Close shut off valve in fuel supply line 2 Open vent plug 1 of the filter 3 Unlock drain cock 2 by pressing toggle and open it 4 Drain water and dirt from filter 5 Close drain coc...

Page 93: ...rt No Qty Air filter Spare Parts Catalog Filter insert Spare Parts Catalog Filter element Spare Parts Catalog Air filter Replacement 1 Remove air filter s and install new one s Page 94 2 Reset signal...

Page 94: ...1 Release clamp 2 2 Remove air filter 1 and clamp 2 from connecting flange of intake housing 3 3 Clean the connecting flange of the intake housing 3 and check it for free passage 4 Fit air filter 1 a...

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

Page 96: ...7 9 Starting Equipment 7 9 1 Electric starter Overview 1 Starter 2 Gasket 3 Flange 4 Gasket 5 Stud screw 6 Washer 7 Nut 96 Task Description MS150118 00E 2014 07 TIM ID 0000029152 002...

Page 97: ...NING The component is very heavy and may fall or tip over if unstable Risk of crushing injuries to persons or limbs Use appropriate lifting gear and equipment Wear safety footwear Disconnecting and re...

Page 98: ...ricating grease 2 Install starter as shown in overview drawing Page 96 Starter electrical connection 1 Connect cables in accordance with the marking 2 Screw on nuts of connections and use torque wrenc...

Page 99: ...1 marks 4 Top up with oil up to the max 1 mark Page 100 if required 5 Insert oil dipstick into guide tube up to the stop Oil level check after the engine is stopped 1 5 minutes after stopping the engi...

Page 100: ...and 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 filte...

Page 101: ...ng 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 2 with filter wrench 2 Clean sealing face o...

Page 102: ...les face mask and ear defenders Centrifugal oil filter Cleaning and filter sleeve replacement 1 Undo nuts 4 crosswise 2 Remove housing cover 1 3 Carefully remove rotor 3 from lower part of housing 5 4...

Page 103: ...alue Standard Nut Tightening torque 8 Nm 1 Nm 16 Fit housing cover 1 17 Screw on nuts 4 18 Use torque wrench to tighten nuts 4 to specified tightening torque Name Size Type Lubricant Value Standard Nu...

Page 104: ...rcuit 7 12 1 Drain and vent points Plan view 1 HT circuit coolant ventila tion 2 HT circuit coolant ventila tion 3 HT circuit coolant ventila tion Also applies to 12 V and 16 V engines 104 Task Descri...

Page 105: ...Left side 1 Coolant drain plug crank case driving end 2 Coolant drain plug crank case free end Also applies to 12 V and 16 V engines MS150118 00E 2014 07 Task Description 105 TIM ID 0000053457 001...

Page 106: ...ant drain plug engine coolant 2 Coolant drain plug crank case free end 3 Coolant drain plug crank case driving end Also applies to 12 V and 16 V engines 106 Task Description MS150118 00E 2014 07 TIM I...

Page 107: ...Free end KGS 1 Coolant drain plug lube oil heat exchanger Also applies to 12 V and 16 V engines MS150118 00E 2014 07 Task Description 107 TIM ID 0000053457 001...

Page 108: ...terclockwise 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 visi ble at the lower edge of the cast...

Page 109: ...e Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 110 2 Fill with engine coolant Page 111 MS150118 00E 2014 07 Task Description...

Page 110: ...rclockwise to the first stop and re lease pressure 2 Continue to turn valve cover counterclock wise and remove 3 Draw off precipitated corrosion inhibitor oil from the coolant expansion tank through f...

Page 111: ...Cold coolant in hot engine can cause thermal stress Possible formation of cracks in the engine Fill top up coolant only into cold engine Preparatory steps 1 Turn breather valve 1 on coolant expan sio...

Page 112: ...nal steps 1 Start the engine and operate it at idle speed for some minutes 2 Check coolant level Page 108 top up with coolant if required 112 Task Description MS150118 00E 2014 07 TIM ID 0000000034 00...

Page 113: ...is running Risk of damage to hearing 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...

Page 114: ...s 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 115: ...ed Guard is removed Drive belt Condition check Item Findings Action Drive belt A Singular cracks None Drive belt B Cracks on entire circumference Replace Page 120 Drive belt C Chunking Drive belt Belt...

Page 116: ...4 Do not exert any more pressure as displayed value will otherwise be falsified 5 Remove preload measuring device without changing the position of the display arm 6 Read off measured value at the int...

Page 117: ...easured value with value in the table 6 If the measured values deviate from the specified values adjust drive belt tension Page 118 7 Install protective cover Belt length Application Measured value In...

Page 118: ...fan 3 Loosen screws 1 slightly 4 Adjust belt tension acc to specifications with screw 2 Page 116 5 Use torque wrench 1 to tighten screws to specified tightening torque Name Size Type Lubricant Value S...

Page 119: ...move fan 4 Undo securing screws 1 5 Unscrew screw 2 as far as necessary to allow drive belt removal 6 Check belt pulley on fan bearing mount and crankshaft for contamination and clean if necessary Not...

Page 120: ...ndo screws 1 and trickle oil into the gap between gear case 3 and battery charger carrier 2 3 Remove drive belt 4 Check cleanness of belt pulleys 5 Fit new drive belt on belt pulleys without tension 6...

Page 121: ...ssion depth 8 9 mm Test force 60 N Table 116 Set point values Measurement with preload measuring device 8 Tighten screws 1 9 Use nut 5 to fasten the clamping bolt 4 Final steps 1 Install protective co...

Page 122: ...System 7 15 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 122 Task Description MS150118 00E 2014 07 TIM ID...

Page 123: ...rces Do not smoke Differential pressure gauge Check 1 Switch on fuel treatment system optional 2 Set the alarm points at the differential pressure gauge to zero Result Alarm is issued after preset del...

Page 124: ...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 125: ...Check pressure at the pressure gauge in the inlet to the fuel treatment system and note down 3 Checking pump pressure in throttled condition a Reduce suction pressure of pump to 0 8 bar with the shut...

Page 126: ...mponents 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 filter ele...

Page 127: ...htening torque Engine oil 30 Nm 3 Nm 17 Fit gasket 10 18 Install cover 19 Install screws 1 washers 2 and nuts 9 20 Tighten nuts 9 21 Open ball valve at the inlet and outlet of the fuel treatment syste...

Page 128: ...16 Engine Governor 7 16 1 Engine control system Overview 1 Connector X2 2 Engine control system 3 Connector X3 4 Washer 5 Screw 6 Damper 128 Task Description MS150118 00E 2014 07 TIM ID 0000053491 00...

Page 129: ...record for the given engine is installed Removing engine control system from engine 1 Note or mark assignment of cables and connectors 2 Release latches on connectors 1 and 3 3 Disconnect all connecto...

Page 130: ...table test probe e g test prod The contacts in the plug connection can be bent Carry out check of plug connection only with test connectors Checking plug connections at engine governor 1 Check all plu...

Page 131: ...re closed and intact 4 Replace faulty cable clips 5 Check that cable clamps are firm tighten loose cable clamps 6 Replace faulty cable clamps 7 Visually inspect the following electrical line component...

Page 132: ...ve coarse dirt from housing surface using a cloth moistened with isopropyl alcohol 2 Remove dirt from the connector and cable surfaces with isopropyl alcohol 3 Check legibility of cable labels Clean o...

Page 133: ...table test probe e g test prod The contacts in the plug connection can be bent Carry out check of plug connection only with test connectors Checking plug connections at engine governor 1 Check all plu...

Page 134: ...y module for engine data EMU Engine Monitoring Unit ETC Exhaust turbocharger GCU Gear Control Unit GMU Gear Monitoring Unit HAT Harbor Acceptance Test HI High Range violation alarm 1st upper limit val...

Page 135: ...e PPC Priming Pump Control RCS Remote Control System RL Redundancy Lost Alarm Redundant CAN bus failure SAT Sea Acceptance Test SD Sensor Defect Alarm Sensor failure SDAF Shut Down Air Flap s Emergenc...

Page 136: ...e work in case of malfunction or changed operating conditions or for spare parts supply Your contact person in our Customer Assistance Center E mail info mtu online com Tel 49 7541 9077777 Fax 49 7541...

Page 137: ...ustment Page 71 Crowfoot wrench 19 mm Part No F30027424 Qty Used in 1 7 4 2 Injector Removal and installation Page 76 Qty Used in 1 7 5 1 HP fuel line and pressure pipe connection Re placement Page 82...

Page 138: ...rench Part No F30379104 Qty Used in 1 7 6 1 Fuel filter Replacement Page 87 Qty Used in 1 7 11 1 Engine oil filter Replacement Page 101 Fuel suction device Part No F30378207 Qty Used in 1 7 4 2 Inject...

Page 139: ...01 Qty Used in 1 7 3 1 Valve clearance Check and adjustment Page 71 Open end socket wrench 24 mm Part No F30453238 Qty Used in 1 7 4 2 Injector Removal and installation Page 76 Plug in open end wrench...

Page 140: ...20097429 Qty Used in 1 7 13 2 Drive belt Tension check Page 116 Qty Used in 1 7 14 1 Battery charger drive Drive belt replacement Page 120 Press in tool Part No F6790085 Qty Used in 1 7 4 2 Injector R...

Page 141: ...Removal and installation Page 76 Qty Used in 1 7 5 1 HP fuel line and pressure pipe connection Re placement Page 82 Qty Used in 1 7 13 3 Drive belt Tension adjustment Page 118 Ratchet Part No F3002733...

Page 142: ...450 Qty Used in 1 7 3 1 Valve clearance Check and adjustment Page 71 Steam jet cleaner Part No Qty Used in 1 4 8 Plant Cleaning Page 63 Tester Part No Y4345711 Qty Used in 1 7 13 2 Drive belt Tension...

Page 143: ...uel line and pressure pipe connection Re placement Page 82 Qty Used in 1 7 13 3 Drive belt Tension adjustment Page 118 Torque wrench 40 200 Nm Part No F30027337 Qty Used in 1 7 13 3 Drive belt Tension...

Page 144: ...lter sleeve replacement Page 102 Torque wrench 0 5 5 Nm Part No 0015384230 Qty Used in 1 7 3 2 Cylinder head cover Removal and installation Page 74 Qty Used in 1 7 4 2 Injector Removal and installatio...

Page 145: ...ressure gauge Check 123 Differential pressure gage Adjustment Fuel prefilter 88 Check Fuel prefilter 88 Drain and vent points 104 Drift correction parameters Reset 81 Drive Replacement Drive 119 Drive...

Page 146: ...131 F Filter Coalescer element Replacement 126 Filter sleeve Replacement 102 Firing order 54 Fuel Draining 86 Fuel filter Replacement 87 Fuel prefilter Adjustment Differential pressure gage 88 Check D...

Page 147: ...standards 13 Service indicator Signal ring position check 95 Service partners 136 Spare parts service 136 Starter Electric Installation 98 Removal 97 Startup after long out of service periods 3 month...

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