MTU 12V2000C66 Operating Instructions Manual Download Page 81

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6.4 Injector

6.4.1 Injector – Replacement

Special tools, Material, Spare parts

Designation / Use

Part No.

Qty.

Injector

(→ Spare Parts Catalog)

Injector – Replacement

Remove injector and install new one (→ Page 82).

MS150094/02E 2015-05

| Task Description | 81

TIM-ID: 0000042329 - 002

Summary of Contents for 12V2000C66

Page 1: ...Operating Instructions Diesel engine 12V2000S56 16V2000S56 12V2000C66 16V2000C66 12V2000C66R 12V2000S96 16V2000S96 MS150094 02E...

Page 2: ...This particularly applies to its reproduction distribution editing translation micro filming and storage or processing in electronic systems including databases and online services All information in...

Page 3: ...il mist fine separator replacement 76 6 3 Valve Drive 77 6 3 1 Valve clearance Check and adjustment 77 6 3 2 Cylinder head cover Removal and installation 80 6 4 Injector 81 6 4 1 Injector Replacement...

Page 4: ...16 1 Engine governor Overview 134 6 16 2 Engine governor Removal 135 6 16 3 Engine governor Installation 136 6 16 4 Engine governor plug connections Check 137 6 17 Wiring General for Engine Gearbox Un...

Page 5: ...al as delivered configuration or in a configuration approved by the manufacturer in writing in cluding engine control parameters In compliance with all safety regulations and in adherence with all war...

Page 6: ...ation authorities The manufacturer does not accept any liability for violations of the emission regulations The maintenance schedules of the manufacturer must be observed over the entire life cycle of...

Page 7: ...ucted repeatedly Personnel requirements All work on the product shall be carried out by trained and qualified personnel only Training at the Training Center of the manufacturer Technical personnel fro...

Page 8: ...appropriate for the given weight forklift truck Install the crankshaft locking device and the locking screws for the engine mounts prior to engine transporta tion Secure the engine against tilting dur...

Page 9: ...s must not be painted They may only be installed after painting the engine or must be covered before painting work is carried out The following applies to starters with copper beryllium alloy pinions...

Page 10: ...oduct when welding in its vicinity Before starting welding work Switch off the power supply master switch Disconnect the battery Separate the electrical ground of electronic equipment from the ground...

Page 11: ...es Chafing on components Contact with hot surfaces Do not secure cables on lines carrying fluids Do not use cable straps to secure cables Always use connector pliers to tighten union nuts on connector...

Page 12: ...th its han dling Noise Noise can lead to an increased risk of accidents if acoustic signals warning shouts or sounds indicating dan ger are drowned Wear ear protectors in workplaces with a sound press...

Page 13: ...test in accordance with the specifications Painting Observe the relevant safety data sheet for all materials When carrying out painting work outside the spray stands provided with fume extraction syst...

Page 14: ...edial 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 m...

Page 15: ...tem 9 Coolant system 10 Mounting support 11 Fuel system low pressure 12 Fuel system high pressure 13 Valve gear 14 Cylinder head 15 Exhaust system 16 PTO systems driving end and free end coupling 17 S...

Page 16: ...Key to the engine model designation 6 9 Application segment 0 1 2 9 6 Design index 0 1 2 9 16 Product Summary MS150094 02E 2015 05 TIM ID 0000023527 002...

Page 17: ...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 and lette...

Page 18: ...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 18 Product Summ...

Page 19: ...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 MS150094 02E 2015 05 Product Summar...

Page 20: ...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 21: ...emperature after engine warning R C 106 105 Coolant temperature after engine shutdown L C 108 107 Coolant antifreeze content max L 50 50 Coolant pump inlet pressure max L bar 1 3 1 3 Thermostat Starts...

Page 22: ...uous max driving end up Option max operating inclinations L Degrees 15 10 Transverse inclination continuous max option max operating in clinations L Degrees 15 10 CAPACITIES Number of cylinders 12 16...

Page 23: ...ter BL free field sound pressure level Lp 1 m distance ISO 6798 2 dB A tolerance R dB A 103 104 Engine surface noise with attenuated intake noise filter BL sound power level LW ISO 6798 2 dB A toleran...

Page 24: ...brake power as per ISO 3046 Number of cylinders 12V2000C 66R Rated engine speed A rpm 1800 Fuel stop power ISO 3046 A kW 783 General conditions for maximum power Number of cylinders 12V2000C 66R Inta...

Page 25: ...at engine connection inlet from cooling equipment A C 45 Coolant antifreeze content max L 50 Pressure loss in off engine cooling system max L bar 0 8 Lube oil system Number of cylinders 12V2000C 66R...

Page 26: ...e air coolant engine side R Liters 25 Total engine oil capacity initial filling standard oil system option max operating inclinations R Liters 99 Oil change quantity max standard oil system option max...

Page 27: ...noise filter BL free field sound power level Lp 1 m distance ISO 6798 2dB A tolerance R dB A 103 Engine surface noise with attenuated intake noise filter BL sound power level LW ISO 6798 2dB A tolera...

Page 28: ...brake power as per ISO 3046 Number of cylinders 12 16 Rated engine speed A rpm 2100 2100 Fuel stop power ISO 3046 A kW 783 970 General conditions for maximum power Number of cylinders 12 16 Intake dep...

Page 29: ...loss in off engine cooling system max L bar 1 0 1 0 Lube oil system Number of cylinders 12 16 Lube oil operating temperature before engine from R C 80 80 Lube oil operating temperature before engine...

Page 30: ...ers 87 130 Oil pan capacity dipstick mark min standard oil system option max operating inclinations L Liters 73 109 Oil pan capacity dipstick mark max standard oil system option max operating inclinat...

Page 31: ...et brake power as per ISO 3046 Number of cylinders 12 16 Rated engine speed A rpm 2100 2100 Fuel stop power ISO 3046 A kW 858 1163 GENERAL CONDITIONS for maximum power Number of cylinders 12 16 Intake...

Page 32: ...cooler at engine connection in let from cooling system A C 45 45 Coolant antifreeze content max L 50 50 Pressure loss in off engine cooling system max L bar 1 0 1 0 LUBE OIL SYSTEM Number of cylinders...

Page 33: ...s 111 Oil change quantity max standard oil system Option max op erating inclinations R Liters 94 125 Oil pan capacity at dipstick mark min standard oil system Op tion max operating inclinations L Lite...

Page 34: ...Check engine oil level Page 102 Fuel system Connect appropriate equipment to fuel supply line to fill the system Fuel system Vent Page 89 Coolant circuit If engine is out of service for more than one...

Page 35: ...m Check engine oil level Page 102 Coolant circuit Check engine coolant level Page 112 check charge air coolant level Page 121 Coolant circuit Preheat engine coolant with coolant preheating unit if fit...

Page 36: ...ing the engine with starter system make sure that there are no persons in the engine s danger zone WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear prot...

Page 37: ...engine oil level Page 102 Engine operation Check engine visually for leaks and general condition Check engine for abnormal running noises exhaust color and vibrations Air filter Check service indicat...

Page 38: ...unning at full load subjects it to extreme thermal and mechanical stress es Overheating of and therefore damage to components is possible Before shutting down the engine allow it to idle until the eng...

Page 39: ...rgency engine stop Item Action Emergency stop pushbutton Press EMERGENCY STOP pushbutton Engine is stopped by disconnecting the power supply to the ECU Emergency air shutoff flaps close if applicable...

Page 40: ...eriod 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 insufficient for the engine room tem...

Page 41: ...ctly 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 environmental protec tion 2 Pri...

Page 42: ...dition and tension replace if necessary Page 127 W1005 Replace air filter Page 98 W1006 Replace fuel injectors Page 81 W1008 Replace engine oil filter when changing engine oil or when the interval yea...

Page 43: ...or faulty Charge or replace battery see manufac turer s documentation Engine wiring Faulty Check Page 137 Fuel system Air in fuel system if fault occurs after filling the system Vent fuel system Page...

Page 44: ...inated Contact Service Engine room Air intake temperature too high Check fan check air inlet outlet ducts Charge air pressure too low Component Cause Action Air supply Air filter clogged Replace air f...

Page 45: ...ocharger Cylinder head Piston rings Cylinder liner Faulty Contact Service White exhaust gas Component Cause Action Engine Not at operating temperature Run engine to reach operating tempera ture Fuel s...

Page 46: ...or leaks contamination and operation 2 Contact Service if no malfunction can be detected 10 SS T Coolant Intercooler Red alarm emergency stop Cause Corrective action Coolant temperature in intercooler...

Page 47: ...l pressure at oil filter too high Level 2 u Check oil filter replace as necessary 27 HI Leak Fuel Level Yellow alarm warning Cause Corrective action Leak fuel level too high u Contact Service 30 SS En...

Page 48: ...n can be detected 52 SS T Lube Oil Red alarm emergency stop Cause Corrective action Lube oil temperature too high Level 2 1 Check cooling system 2 Contact Service if no malfunction can be detected 53...

Page 49: ...system 2 Contact Service if no malfunction can be detected 68 SS T Coolant Red alarm emergency stop 3 min delay Cause Corrective action Coolant temperature too high Level 2 1 Check cooling system 2 Co...

Page 50: ...2 Observe additional messages 91 SS Release Speed Not Reached Yellow alarm warning Cause Corrective action Run up speed not reached start aborted 1 Restart engine Page 36 2 Observe additional messages...

Page 51: ...ce Engine Control Unit at next opportunity 118 LO ECU Supply Voltage Yellow alarm warning Cause Corrective action Supply voltage too low Level 1 u Check batteries charge as necessary check alternator...

Page 52: ...sistor installed 181 AL CAN2 Node Lost Yellow alarm warning Cause Corrective action Connection to a node on CAN bus 2 failed 1 Check devices connected to CAN 2 Check wiring termination resistor instal...

Page 53: ...circuit as necessary 2 Check shielding improve shielding as necessary 3 Contact Service 188 AL CAN2 Bus Off Yellow alarm warning Cause Corrective action CAN controller 2 is in Bus Off status 1 Check...

Page 54: ...l Yellow alarm warning Cause Corrective action Lube oil pressure sensor faulty u Check sensor B5 1 and wiring replace as necessary Page 138 215 SD P HD Yellow alarm warning Cause Corrective action Rai...

Page 55: ...er defective 1 Check sensor F57 and wiring replace as necessary Page 138 2 Fault is rectified when electronics are switched back on 227 SD P Oil before Filter Yellow alarm warning Cause Corrective act...

Page 56: ...place as necessary Page 138 240 SD P Fuel Yellow alarm warning Cause Corrective action Fuel pressure sensor before intermediate filter faulty u Check sensor B34 3 and wiring replace as necessary Page...

Page 57: ...sfiring 1 Check injector wiring 2 Rectify injector solenoid valve short circuit positive to negative e g by exchanging injectors 3 Fault is rectified when engine is restarted 323 AL Wiring Cylinder A3...

Page 58: ...uit in cylinder A7 injector wiring Result Misfiring 1 Check injector wiring 2 Rectify injector solenoid valve short circuit positive to negative e g by exchanging injectors 3 Fault is rectified when e...

Page 59: ...uit in cylinder B3 injector wiring Result Misfiring 1 Check injector wiring 2 Rectify injector solenoid valve short circuit positive to negative e g by exchanging injectors 3 Fault is rectified when e...

Page 60: ...uit positive to negative e g by exchanging injectors 3 Fault is rectified when engine is restarted 339 AL Wiring Cylinder B9 Yellow alarm warning Cause Corrective action Short circuit in cylinder B9 i...

Page 61: ...y injector replacement 2 Fault is rectified after each working cycle 346 AL Open Load Cylinder A6 Yellow alarm warning Cause Corrective action Open circuit in cylinder A6 injector wiring Result Misfir...

Page 62: ...y injector replacement 2 Fault is rectified after each working cycle 353 AL Open Load Cylinder B3 Yellow alarm warning Cause Corrective action Open circuit in cylinder B3 injector wiring Result Misfir...

Page 63: ...t 2 Fault is rectified after each working cycle 359 AL Open Load Cylinder B9 Yellow alarm warning Cause Corrective action Open circuit in cylinder B9 injector wiring Result Misfiring 1 Check injector...

Page 64: ...ellow alarm warning Cause Corrective action Short circuit or wire break on transistor output 1 plant side TOP 1 u Check wiring Page 138 382 AL Wiring TOP 2 Yellow alarm warning Cause Corrective action...

Page 65: ...ion Line disruption at digital input 3 u Check wiring Page 138 403 AL Open Load Digital Input 4 Yellow alarm warning Cause Corrective action Line disruption at digital input 4 u Check wiring Page 138...

Page 66: ...Yellow alarm warning Cause Corrective action Injector voltage too low Level 2 u Perform Engine Control Unit self test replace as necessary 412 HI U PDU Yellow alarm warning Cause Corrective action In...

Page 67: ...wiring replace as necessary 438 LO P Fuel 2 Common Rail Yellow alarm warning Cause Corrective action Rail pressure below specified value HP fuel control block faulty or leakage in HP fuel system u Co...

Page 68: ...ective action Input signal for initial final torque faulty 1 Check signal transmitter and wiring replace as necessary 2 Restart engine Page 36 454 SS Power Reduction Active Yellow alarm warning Cause...

Page 69: ...lant Yellow alarm warning Cause Corrective action Combined alarm initiated by plant yellow u Observe any other fault messages 479 AL Comb Alarm Red Plant Yellow alarm warning Cause Corrective action C...

Page 70: ...he engine has stopped 551 SS Engine Overspeed Camshaft Red alarm emergency stop Cause Corrective action Engine overspeed camshaft u Restart engine Page 36 558 AL Wiring PWM_CM2 Yellow alarm warning Ca...

Page 71: ...or HP fuel control block replace as necessary 615 AL EIL Protection Yellow alarm emergency stop 15 min delay Cause Corrective action Alarm for Protection module as reaction to faulty or manipulated EI...

Page 72: ...not be released in the max blankshot time u Contact Service 947 AL Wrong LSI Channel Config Yellow alarm warning Cause Corrective action Data fault on allocating LSI channels u Contact Service 973 AL...

Page 73: ...Analog Output 2 Yellow alarm warning Cause Corrective action The value output at analog output 2 deviates excessively from the value read back u Check wiring MS150094 02E 2015 05 Troubleshooting 73 T...

Page 74: ...e that there are no persons in the engine s danger zone After finishing work on the engine make sure that all safety devices are put back in place and all tools are removed from the engine Barring eng...

Page 75: ...ter working on the engine check that all protective devices have been reinstalled and all tools re moved from the engine Engine Barring with starting system 1 Bar engine preventing it from firing see...

Page 76: ...ING 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 o...

Page 77: ...socket 19 mm F30038493 1 Torque wrench 20 100 Nm F30026582 1 Ratchet F30027340 1 WARNING Valve gear is moving Risk of crushing Keep hands clear of the danger zone when barring the engine Preparatory s...

Page 78: ...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 Overlap TDC in cylinder A1 Bank A E A E A E A E A Bank B A E E A E A A E E inlet valve clearance adjustment permitte...

Page 79: ...erify that the gauge just passes through the gap Result If not adjust valve clearance again Final steps 1 Install plug screw and tighten 2 Remove barring device 3 Install cylinder head cover Page 80 M...

Page 80: ...crankcase breather Loosen clamps 2 Slide rubber sleeves onto the pipe Cylinder head cover Removal and installation 1 Remove cylinder head cover 2 with gas ket 1 from cylinder head 2 Clean installation...

Page 81: ...lacement Special tools Material Spare parts Designation Use Part No Qty Injector Spare Parts Catalog Injector Replacement u Remove injector and install new one Page 82 MS150094 02E 2015 05 Task Descri...

Page 82: ...4 mm F30453238 1 Assembly compound Hakuform 30 15 X00067260 1 Engine oil Sealing ring Spare Parts Catalog WARNING Fuels are combustible and explosive Risk of fire and explosion Avoid open flames elect...

Page 83: ...e suction device 5 Loosen terminals arrow on injector and pull off terminal lugs 6 Remove gasket 7 Remove screw 3 Note Screw 3 must be used only once 8 Take off hold down clamp 2 9 Carefully remove in...

Page 84: ...e hold down clamp Assembly with installation device 1 Place installation device onto hold down clamp and carefully press injector 1 into cylinder head 2 Fit clamp 2 in correct position install screw 3...

Page 85: ...l line 1 Apply engine oil to thread and mating face of union nut of fuel line 1 Note Position fuel line ensuring that it is free of tension 2 Position fuel line 1 so that the end with the marked union...

Page 86: ...tor 1 Place gasket in correct position onto cylinder head 2 Slide terminal lugs under terminals arrow on injector and use torque wrench to tighten to the specified tightening torque Name Size Type Lub...

Page 87: ...are combustible and explosive Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Wear protective clothing protective gloves and safety glasses facial prot...

Page 88: ...rque wrench to tighten union nut 1 without marking to specified tightening torque Name Size Type Lubricant Value Standard Nut without mark ing Tightening torque 30 Nm 5 Nm 15 Observe marking on union...

Page 89: ...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 36 2 Operate the engine until it runs smoothly MS150094 02E 2015 05...

Page 90: ...hly volatile media e g fuel or ether Risk of fatal injury through swallowing risk of poisoning through inhalation irritation to eyes and skin Seek medical attention immediately do not induce vomiting...

Page 91: ...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 92: ...ssure gauge ad justment 1 When installing 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 li...

Page 93: ...Fuel prefilter Draining 1 Cut out the filter to be drained 1 Left filter cut in 2 Right filter cut in 2 Open vent plug 5 of filter to be drained 3 Unlock drain valve 6 by pressing toggle and open 4 Dr...

Page 94: ...and ignition sources Do not smoke Wear protective clothing protective gloves and safety glasses facial protection WARNING Liquid or gaseous media e g fuel are poisonous Escaping vapors of highly vola...

Page 95: ...tered side flushing the filter deposits down wards out of the filter 4 Close vent plug 5 and drain cock 6 Fuel prefilter Filling with fuel 1 Remove screws securing cover and take off cover 2 2 Fill fi...

Page 96: ...engine at low power Keep away from the engine s danger zone WARNING Fuels are combustible and explosive Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smok...

Page 97: ...4 and filter ele ment 3 8 Insert new filter element 3 and spring hous ing 4 9 Fill filter housing with clean fuel 10 Place new gasket in cover 2 11 Fit cover with gasket and secure it with screws Note...

Page 98: ...ne is stopped and starting disabled Note Component is genset manufacturer s or vehicle manufacturer s scope of supply Air filter Replacement u Perform tasks according to manufacturer s specifications...

Page 99: ...6 8 Air Intake 6 8 1 Service indicator Check See manufacturer s documentation MS150094 02E 2015 05 Task Description 99 TIM ID 0000005482 004...

Page 100: ...6 9 Exhaust Gas Recirculation 6 9 1 Exhaust gas recirculation flaps Overview 100 Task Description MS150094 02E 2015 05 TIM ID 0000024288 002...

Page 101: ...cking exhaust flap operation 1 For installation position of exhaust flaps refer to overview Page 100 2 Check operability and ease of movement of exhaust flaps and control linkage by moving the assembl...

Page 102: ...1 marks 4 Top up with oil up to the max 1 mark Page 103 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 103: ...nd 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 filter...

Page 104: ...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 surfac...

Page 105: ...goggles face mask and ear defenders Centrifugal oil filter Cleaning and filter sleeve replacement 1 Slacken off nuts 4 crosswise 2 Remove housing cover 1 3 Carefully remove rotor 3 from lower part of...

Page 106: ...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 crosswise to specified tightening torque Name Size Type Lubricant Value Standa...

Page 107: ...6 12 Coolant Circuit General High Temperature Circuit 6 12 1 Drain and vent points 12 V 16 V 1 Engine coolant vent MS150094 02E 2015 05 Task Description 107 TIM ID 0000025286 001...

Page 108: ...Left side 1 Engine coolant drain plug 2 Oil drain plug 3 Engine coolant drain plug 108 Task Description MS150094 02E 2015 05 TIM ID 0000025286 001...

Page 109: ...Right side 1 Engine coolant drain plug 2 Engine coolant drain plug 3 Oil drain plug 4 Engine coolant drain plug MS150094 02E 2015 05 Task Description 109 TIM ID 0000025286 001...

Page 110: ...Driving end KS 1 Oil drain plug 110 Task Description MS150094 02E 2015 05 TIM ID 0000025286 001...

Page 111: ...Free end KGS 1 Oil drain plug 2 Engine coolant filling plug 3 Oil drain plug 4 Engine coolant drain plug MS150094 02E 2015 05 Task Description 111 TIM ID 0000025286 001...

Page 112: ...terclockwise to the first stop and allow pressure to escape 2 Continue to turn breather valve counterclock wise and remove 3 Check coolant level coolant must be visible at the lower edge of the cast i...

Page 113: ...e Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 114 2 Fill with engine coolant Page 115 MS150094 02E 2015 05 Task Description...

Page 114: ...tank counterclockwise until the first stop and al low pressure to escape 4 Continue to turn breather valve counterclock wise and remove 5 Draw off separated corrosion inhibitor oil in expansion tank...

Page 115: ...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 expansion...

Page 116: ...nal steps 1 Start the engine and operate it at idle speed for some minutes 2 Check coolant level Page 112 top up with coolant if required 116 Task Description MS150094 02E 2015 05 TIM ID 0000000034 00...

Page 117: ...Allow the engine to cool down to below 50 C before beginning work Wear suitable protective equipment thermal gloves Avoid unprotected contact with hot surfaces Engine coolant pump Relief bore check 1...

Page 118: ...s 1 Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to es cape 2 Continue to turn breather valve counterclockwise and remove 3 Draw off precipitated...

Page 119: ...goggles safety mask Coolant filter Replacement 1 Turn breather valve of coolant expansion tank counterclockwise Page 15 to the first stop and allow pressure to escape 2 Continue to turn breather valve...

Page 120: ...6 13 Low Temperature Circuit 6 13 1 Intercooler Vent and drain points 12 V 16 V 1 Intercooler vent plugs 120 Task Description MS150094 02E 2015 05 TIM ID 0000025297 002...

Page 121: ...low pressure to escape 2 Continue to turn cap counterclockwise and remove Note Charge air coolant must be visible at marker plate 3 Check charge air coolant level 4 Top up charge air coolant as necess...

Page 122: ...ecial tools Material Spare parts Designation Use Part No Qty Coolant Charge air coolant Change 1 Drain charge air coolant Page 125 2 Fill with charge air coolant Page 123 122 Task Description MS150094...

Page 123: ...l 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 expansion tank counterclockwise to the first stop and...

Page 124: ...Final steps 1 Start the engine and operate it at idle speed for some minutes 2 Check coolant level Page 121 124 Task Description MS150094 02E 2015 05 TIM ID 0000000039 006...

Page 125: ...riate 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 counterclock...

Page 126: ...s running Risk of damage to hearing Wear ear protectors Charge air coolant pump Re lief bore check 1 Check relief bore for oil and coolant dis charge Permissible coolant discharge up to 10 drops per h...

Page 127: ...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 133 Drive belt C Chunking Drive belt Belt...

Page 128: ...ency 113 1 Hz Frequency 103 1 Hz Drive belt 1558 mm fan with supplementary mass Frequency 113 1 Hz Frequency 103 1 Hz Drive belt 1522 mm fan Frequency 113 1 Hz Frequency 103 1 Hz Drive belt 1707 mm fa...

Page 129: ...Depression depth 6 mm Test force 188 N Depression depth 5 mm Test force 188 N Drive belt 1936 mm fan Depression depth 6 mm Test force 188 N Depression depth 6 mm Test force 188 N Table 3 Measuring dep...

Page 130: ...ent 1 Loosen screws 1 2 Set distance A to 100 mm with screw 2 3 Use torque wrench to tighten screws 1 to specified tightening torque Name Size Type Lubricant Value Standard Screw M16 Tightening torque...

Page 131: ...wrench to tighten screw 4 to specified tightening torque Name Size Type Lubricant Value Standard Screw M18 Tightening torque Engine oil 30 Nm 3 Nm MS150094 02E 2015 05 Task Description 131 TIM ID 000...

Page 132: ...ecuring screws 1 4 Screw out screw 2 as far as necessary to al low drive belt removal 5 Check belt pulley on radiator bearing mount and crankshaft for contamination and clean if necessary Note When pl...

Page 133: ...over engine free end 3 Remove protective cover Replacing drive belt 1 Hold adjusting lever at square 2 Rotate adjusting lever until drive belt is released 3 Use mandrel to lock adjusting lever in posi...

Page 134: ...overnor 6 16 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 134 Task Description MS150094 02E 2015 05 TIM ID 0...

Page 135: ...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 136: ...g element Spare Parts Catalog 8 Engine governor Installation 1 Install engine governor as per overview drawing Page 134 Name Size Type Lubricant Value Standard Screw for grounding strap M6 Tightening...

Page 137: ...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 plug connecti...

Page 138: ...closed and intact 4 Replace faulty cable clips 5 Check cable clamps for secure fit tighten loose clamps 6 Replace faulty cable clamps 7 Visually inspect the following electrical components for damage...

Page 139: ...6 17 2 Lambda NOx and humidity sensors Overview 1 Humidity sensor 2 NOx sensor 3 Lambda sensor MS150094 02E 2015 05 Task Description 139 TIM ID 0000025179 001...

Page 140: ...ol down to below 50 C before beginning work Wear suitable protective equipment thermal gloves Avoid unprotected contact with hot surfaces NOTICE Ceramic cell breakage due to shock or impact Risk of da...

Page 141: ...nsor thread with specified assembly compound as required 3 Screw in sensor by hand 4 Tighten nut 2 to specified torque using a torque wrench Name Size Type Lubricant Value Standard Nut M18 x 1 5 Tight...

Page 142: ...beginning work Wear suitable protective equipment thermal gloves Avoid unprotected contact with hot surfaces NOTICE High voltage Risk of damage to components Switch off ignition before replacing compo...

Page 143: ...M6 Tightening torque max 12 Nm 2 Remove protective cap on thread of sensor 3 only just before installation Note Do not wipe off the thread lubricant applied by the manufacturer 3 Coat sensor 3 thread...

Page 144: ...compound Kluthe Hakuform 30 15 X00067260 Humidity sensor Spare Parts Catalog 1 NOTICE Contamination of components Damage to component Observe manufacturer s instructions Check components for special...

Page 145: ...in stallation position Note Observe air flow direction 2 Screw in screws 1 3 Use torque wrench 1 to tighten screws to specified tightening torque Name Size Type Lubricant Value Standard Sensor M6 Tig...

Page 146: ...set the emission certification becomes invalid Resetting parameters for drift correction CDC with DiaSys 1 Use DiaSys to reset the CDC parameters Dialog system DiaSys E531920 2 If no DiaSys is availab...

Page 147: ...hol to remove coarse dirt from housing surface 2 Use isopropyl alcohol to remove dirt from the connector and cable surfaces 3 Check legibility of cable labels Clean or replace illegible labels Heavily...

Page 148: ...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 plug connecti...

Page 149: ...AN bus failure DOC Diesel Oxidation Catalyst DPF Diesel Particulate Filter ECS Engine Control System Engine management system ECU Engine Control Unit Engine governor EDM Engine Data Module Memory modu...

Page 150: ...panel PAU Power Automation Unit Module for monitoring control and plant related sys tem integration of peripheral components PCU Propeller Control Unit PIM Peripheral Interface Module UPS Unit Pump S...

Page 151: ...e work in case of malfunction or changed oper ating 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 49 754...

Page 152: ...Qty Used in 1 6 5 1 HP fuel line and pressure pipe neck Replacement Page 87 Adapter Part No F30452771 Qty Used in 1 6 4 2 Injector Removal and installation Page 82 Barring device Part No F6783914 Qty...

Page 153: ...No F30027425 Qty Used in 1 6 5 1 HP fuel line and pressure pipe neck Replacement Page 87 Crowfoot wrench 19 mm Part No F30027424 Qty Used in 1 6 4 2 Injector Removal and installation Page 82 Crowfoot...

Page 154: ...4 2 Injector Removal and installation Page 82 Qty Used in 1 6 5 1 HP fuel line and pressure pipe neck Replacement Page 87 Engine barring gear Part No F6783914 Qty Used in 1 6 1 1 Engine Barring manual...

Page 155: ...104 Fuel suction device Part No F30378207 Qty Used in 1 6 4 2 Injector Removal and installation Page 82 High pressure cleaning unit Part No Qty Used in 1 3 8 Plant Cleaning Page 41 Installation devic...

Page 156: ...Qty Used in 1 6 12 7 Engine coolant Sample extraction and analysis Page 118 Oil filter wrench Part No F30379104 Qty Used in 1 6 12 8 Coolant filter Replacement Page 119 Plug in open end wrench 19 mm...

Page 157: ...1 2 Centrifugal oil filter Cleaning and filter sleeve re placement Page 105 Qty Used in 1 6 16 3 Engine governor Installation Page 136 Ratchet adapter Part No F30027340 Qty Used in 1 6 5 1 HP fuel lin...

Page 158: ...Engine Barring manually Page 74 Qty Used in 1 6 3 1 Valve clearance Check and adjustment Page 77 Ring socket 19 mm Part No F30038493 Qty Used in 1 6 3 1 Valve clearance Check and adjustment Page 77 So...

Page 159: ...moval and installation Page 82 Tester Part No Y4345711 Qty Used in 1 6 14 2 Drive belt Tension check Page 128 Torque wrench 1 5 Nm Part No F30452774 Qty Used in 1 6 4 2 Injector Removal and installati...

Page 160: ...6 17 4 NOx sensor Replacement Page 142 Torque wrench 60 320 Nm Part No F30047446 Qty Used in 1 6 14 3 Drive belt Tension adjustment Page 130 Torque wrench 8 40 Nm Part No F30043446 Qty Used in 1 6 3 2...

Page 161: ...cement 119 Coolant level Check 112 Crankcase breather Oil mist fine separator Replacement 76 Cylinder Designation 17 Cylinder head cover Removal and installation 80 D Data Engine 20 Dimensions Engine...

Page 162: ...ilter Differential pressure gauge checking and adjust ing 92 Draining 93 Fuel filter Replacement 91 Fuel prefilter Differential pressure gauge Checking and adjusting 92 Draining 93 Flushing 94 Replace...

Page 163: ...s 14 Safety regulations Auxiliary materials 12 Environmental protection 12 Fire prevention 12 Fluids and lubricants 12 Important provisions 5 Maintenance work 9 Organizational requirements 7 Personnel...

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