MTU 12V2000G series Operating Instructions Manual Download

Page: 109 / 177

7.4 Injector

7.4.1 Injector ‒ Replacement

Special tools, Material, Spare parts

Designation / Use

Part No.

Qty.

Injector

(→ Spare Parts Catalog)

Screw for hold-down clamp

(→ Spare Parts Catalog)

Replacing injector

Remove injector and install new one (→ Page 110).

MS15054/00E 2015-09

| Task Description | 109

TIM-ID: 0000053453 - 001

Summary of Contents for 12V2000G series

Page 1: ...Operating Instructions Diesel engine 12V2000Gx6x 16V2000Gx6x MS15054 00E...

Page 2: ...G76S 68 6 kW cyl 3D standby power fuel stop power IFN 3H mains backup mode special qualifications 16V2000G86S 85 7 kW cyl 3D standby power fuel stop power IFN 3H mains backup mode special qualificatio...

Page 3: ...2V 16V2000Gx6S 3F standby operation mode unlimited ICXN EPA Nonroad T2 40CFR89 and EPA Stationary EMERG T2 40CFR60 provisional 48 3 9 Engine data 12V 16V2000Gx6S 3G continuous operation time limited I...

Page 4: ...1 Charge air coolant Filling 142 7 13 2 Charge air coolant Draining 144 7 13 3 Charge air coolant Change 145 7 13 4 Charge air coolant Level check 146 7 13 5 Charge air coolant pump Relief bore check...

Page 5: ...nal 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 wa...

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: ...ting tackle as necessary If the engine is supplied with special aluminum foil packing Lift the engine at the lifting eyes of the bearing pedestal or use a means of transportation which is appropriate...

Page 9: ...nts as well as the monitoring signaling and alarm systems are working properly Smoking is prohibited in the area of the product Safety regulations during operation The operator must be familiar with t...

Page 10: ...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 11: ...roduct 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 12: ...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 13: ...ith 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 pres...

Page 14: ...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 15: ...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 16: ...gnated 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 17: ...el filter 11 Exhaust turbocharger 12 Fuel system high pressure 13 Starting equipment KS Driving end Explanation of engine model designation 12 16 Number of cylinders V Cylinder arrangement Vee engine...

Page 18: ...ew also applies to 12 V and 16 V engines Item Name Monitoring of 1 B3 Intake air temperature Table 3 Sensors and actuators Driving end Sensors and actuators A side Overview also applies to 12 V and 16...

Page 19: ...of 1 B5 1 Oil pressure after oil filter 2 B7 Oil temperature 3 B48 1 HP fuel A side 4 M8 1 Fuel pump pressure A side Table 4 Sensors and actuators A side MS15054 00E 2015 09 General Information 19 TI...

Page 20: ...sors and actuators Free end Item Name Monitoring of 1 B5 3 Oil pressure before oil filter optional Table 5 Sensors and actuators Free end 20 General Information MS15054 00E 2015 09 TIM ID 0000060374 0...

Page 21: ...B6 Coolant temperature 7 A19 EIL electronic label 8 B26 Coolant temperature 9 XF46 Leak fuel level optional 10 M8 2 Fuel pump pressure B side 11 B34 3 Fuel pressure after intermediate filter stage opt...

Page 22: ...fficiently guaranteed tolerance 10 Value not sufficiently guaranteed tolerance 5 ID Product type Application Engine speed Listed per formance 1 12V2000G16S Power generation 3B continuous opera tion va...

Page 23: ...ment V angle Degrees 90 90 90 90 Bore mm 135 135 135 135 Stroke mm 156 156 156 156 Displacement cylinder Liters 2 233 2 233 2 233 2 233 Displacement total Liters 26 8 26 8 26 8 35 7 Compression ratio...

Page 24: ...fore engine to R C 100 100 100 100 Lube oil temperature before engine limit 1 L C 103 103 103 103 Lube oil temperature before engine limit 2 L C 105 105 105 105 Lube oil operating pressure upstream of...

Page 25: ...stem option max operating inclina tions R Liters 80 80 80 102 Weights main dimensions ID 1 2 3 4 Engine weight dry basic engine configu ration acc to scope of delivery specifica tion R kg 2710 2710 27...

Page 26: ...iciently guaranteed tolerance 10 Value not sufficiently guaranteed tolerance 5 ID Product type Application Engine speed Listed per formance 1 12V2000G76S Power generation 3D standby current fuel stop...

Page 27: ...d direct fuel injection X X X X Cooling method conditioned water X X X X Direction of rotation c c w facing driv ing end X X X X Cylinder arrangement V angle Degrees 90 90 90 90 Bore mm 135 135 135 13...

Page 28: ...tem ID 1 2 3 4 Lube oil operating temperature before engine from R C 75 75 75 75 Lube oil operating temperature before engine to R C 100 100 100 100 Lube oil temperature before engine limit 1 L C 103...

Page 29: ...92 92 114 114 Oil change quantity max standard oil system option max operating inclina tions R Liters 80 80 102 102 Oil pan capacity at dipstick mark min standard oil system R Liters 65 65 88 88 Oil p...

Page 30: ...tual value must be lower than specified value Value not sufficiently guaranteed tolerance 10 Value not sufficiently guaranteed tolerance 5 ID Product type Application Engine speed Listed per formance...

Page 31: ...ves per cylinder 2 2 Standard housing connecting flange engine main PTO side SAE 0 0 Flywheel connection DISC 18 18 Air exhaust ID 1 2 Charge air pressure before cylinder DL R bar abs 3 0 2 8 Coolant...

Page 32: ...at ing case A R C 0 0 Coolant preheating preheating temperature min L C 32 32 Firing speed from R rpm 100 100 Firing speed to R rpm 120 120 Capacities ID 1 2 Engine coolant capacity engine side withou...

Page 33: ...ual value must be lower than specified value Value not sufficiently guaranteed tolerance 10 Value not sufficiently guaranteed tolerance 5 ID Product type Application Engine speed Listed per formance 1...

Page 34: ...ves per cylinder 2 2 Standard housing connecting flange engine main PTO side SAE 0 0 Flywheel connection DISC 18 18 Air exhaust ID 1 2 Charge air pressure before cylinder CP R bar abs 3 0 2 8 Coolant...

Page 35: ...at ing case A R C 0 0 Coolant preheating preheating temperature min L C 32 32 Firing speed from R rpm 100 100 Firing speed to R rpm 120 120 Capacities ID 1 2 Engine coolant capacity engine side withou...

Page 36: ...specified value Value not sufficiently guaranteed tolerance 10 Value not sufficiently guaranteed tolerance 5 ID Product type Application Engine speed Listed per formance 1 12V2000G76S Power generatio...

Page 37: ...t cylinder Liters 2 233 2 233 2 233 Displacement total Liters 26 8 35 7 35 7 Compression ratio 16 16 16 Cylinder heads Individual cylinder heads X X X Cylinder liners wet replaceable X X X Number of i...

Page 38: ...3 Fuel pressure at engine inlet connection min when engine is starting L bar Fuel pressure at engine inlet connection max when engine is starting absolute pressure L bar abs 1 5 1 5 1 5 General opera...

Page 39: ...ion R kg 2710 3180 3180 Sound ID 1 2 3 Exhaust noise not attenuated DL sound power lev el LW ISO 6798 3 dB A tolerance R dB A 130 X Engine surface noise with attenuated intake noise fil ter DL sound p...

Page 40: ...guaranteed tolerance 10 Value not sufficiently guaranteed tolerance 5 ID Product type Application Engine speed Listed per formance 1 12V2000G16S Power generation 3B continuous opera tion variable loa...

Page 41: ...ment V angle Degrees 90 90 90 90 Bore mm 135 135 135 135 Stroke mm 156 156 156 156 Displacement cylinder Liters 2 233 2 233 2 233 2 233 Displacement total Liters 26 8 26 8 26 8 35 7 Compression ratio...

Page 42: ...fore engine to R C 100 100 100 100 Lube oil temperature before engine limit 1 L C 103 103 103 103 Lube oil temperature before engine limit 2 L C 105 105 105 105 Lube oil operating pressure upstream of...

Page 43: ...em option max operating inclina tions R Liters 80 80 80 102 Weights main dimensions ID 1 2 3 4 Engine weight dry basic engine configu ration acc to scope of delivery specifica tion R kg 2710 2710 2710...

Page 44: ...value must be lower than specified value Value not sufficiently guaranteed tolerance 10 Value not sufficiently guaranteed tolerance 5 ID Product type Application Engine speed Listed per formance 1 12V...

Page 45: ...rge air cooling CAC X X X X Uncooled exhaust lines X X X X Operating method Four stroke cycle diesel single action X X X X Combustion method direct fuel injection X X X X Cooling method conditioned wa...

Page 46: ...oss in engine external cooling system max L bar 1 0 1 0 1 1 Lube oil system ID 1 2 3 4 Lube oil operating temperature before engine from R C 75 75 75 75 Lube oil operating temperature before engine to...

Page 47: ...s 92 92 114 114 Oil change quantity max standard oil system option max operating inclina tions R Liters 80 80 102 102 Oil pan capacity at dipstick mark min standard oil system R Liters 65 65 88 88 Oil...

Page 48: ...duct type Actual value must be higher than specified value Actual value must be lower than specified value Value not sufficiently guaranteed tolerance 10 Value not sufficiently guaranteed tolerance 5...

Page 49: ...35 7 Compression ratio 16 16 Cylinder heads Individual cylinder heads X X Cylinder liners wet replaceable X X Number of inlet valves per cylinder 2 2 Number of exhaust valves per cylinder 2 2 Standar...

Page 50: ...warning L bar 5 5 5 5 Lube oil operating pressure before engine shutdown L bar 5 0 5 0 General operating data ID 1 2 Cold start capability air temperature w o start aid w o preheat ing case A R C 0 0...

Page 51: ...d DL sound power level LW ISO 6798 3 dB A tolerance R dB A 130 Engine surface noise with attenuated intake noise filter DL sound power level LW ISO 6798 2 db A tolerance R dB A 123 MS15054 00E 2015 09...

Page 52: ...l value must be lower than specified value Value not sufficiently guaranteed tolerance 10 Value not sufficiently guaranteed tolerance 5 ID Product type Application Engine speed Listed per formance 1 1...

Page 53: ...ves per cylinder 2 2 Standard housing connecting flange engine main PTO side SAE 0 0 Flywheel connection DISC 18 18 Air exhaust ID 1 2 Charge air pressure before cylinder CP R bar abs 3 3 3 2 Coolant...

Page 54: ...ting temperature min L C 32 32 Firing speed from R rpm 100 100 Firing speed to R rpm 120 120 Capacities ID 1 2 Engine coolant capacity engine side without cooling equipment R Liters 63 70 Charge air c...

Page 55: ...ed value Actual value must be lower than specified value Value not sufficiently guaranteed tolerance 10 Value not sufficiently guaranteed tolerance 5 ID Product type Application Engine speed Listed pe...

Page 56: ...n method direct fuel injection X X X Cooling method conditioned water X X X Direction of rotation c c w facing driving end X X X Cylinder arrangement V angle Degrees 90 90 90 Bore mm 135 135 135 Strok...

Page 57: ...ture before engine limit 1 L C 103 103 103 Lube oil temperature before engine limit 2 L C 105 105 105 Lube oil operating pressure upstream of engine from R bar 6 5 6 5 6 5 Lube oil operating pressure...

Page 58: ...l pan capacity at dipstick mark max standard oil system R Liters 70 94 94 Weights main dimensions ID 1 2 3 Engine weight dry basic engine configuration acc to scope of delivery specification R kg 2710...

Page 59: ...of cylinders Firing order 12V A1 B5 A5 B3 A3 B6 A6 B2 A2 B4 A4 B1 16V A1 B5 A3 A5 B2 B8 A2 A8 B3 A7 B4 B6 A4 A6 B1 B7 18V A1 B6 A3 B4 A5 B2 A7 B1 A9 B3 A8 B5 A6 B7 A4 B9 A2 B8 MS15054 00E 2015 09 Tec...

Page 60: ...1885 2 mm Length A for 16V approx 2235 2 mm Width B for 12V approx 1588 3 mm Width B for 16V approx 1568 4 mm Height C for 12V approx 1420 2 mm Height C for 16V approx 1420 2 mm Table 7 Main engine di...

Page 61: ...Check engine oil level Page 130 Fuel system Connect appropriate equipment to fuel supply line to fill the system Fuel system Vent Page 117 Coolant circuit If engine is out of service for more than on...

Page 62: ...em Check engine oil level Page 130 Coolant circuit Check engine coolant level Page 135 check charge air coolant level Page 146 Coolant circuit Preheat engine coolant with coolant preheating unit if fi...

Page 63: ...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 64: ...ssures Engine operation Visually inspect engine for leaks and general condition Check engine for abnormal running noises exhaust color and vibrations Air filter Check signal ring position of maintenan...

Page 65: ...the label on the engine match the label document in the Business Portal Equipment 3 Check emission label for intactness 4 Check content of emission label for complete readability 5 Does the engine nu...

Page 66: ...running 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 en...

Page 67: ...ngine is stopped by disconnecting the power supply to the ECU Emergency air shutoff flaps close if applicable Signalization e g by horn beacon is activated After emergency engine stop Item Action Swit...

Page 68: ...f service for longer than 1 week seal the engine on the air and exhaust side If the engine is to be taken out of service for longer than 1 month it has to be preserved MTU Preservation and Represervat...

Page 69: ...ectly 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 Pr...

Page 70: ...r element Page 119 W1003 X Check belt condition and tension replace if necessary Page 149 W1005 Replace air filter Page 124 W1006 Replace fuel injectors Page 109 W1008 Replace engine oil filter when c...

Page 71: ...Component 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 162 Fuel system Air in fuel...

Page 72: ...ake temperature too high Check fans and intake exhaust lines Charge air pressure too low Component Cause Action Air supply Air filter clogged Check signal ring position of service in dicator Page 126...

Page 73: ...turbocharger 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 Fu...

Page 74: ...for 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 intercoole...

Page 75: ...il 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 E...

Page 76: ...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 77: ...ing 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...

Page 78: ...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 63 2 Observe additional messages...

Page 79: ...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 80: ...esistor 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 insta...

Page 81: ...t 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 82: ...il Yellow alarm warning Cause Corrective action Lube oil pressure sensor faulty u Check sensor B5 1 and wiring replace as necessary Page 162 215 SD P HD Yellow alarm warning Cause Corrective action Ra...

Page 83: ...er defective 1 Check sensor F57 and wiring replace as necessary Page 162 2 Fault is rectified when electronics are switched back on 227 SD P Oil before Filter Yellow alarm warning Cause Corrective act...

Page 84: ...eplace as necessary Page 162 240 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 85: ...isfiring 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 A...

Page 86: ...cuit 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...

Page 87: ...cuit 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...

Page 88: ...cuit 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...

Page 89: ...by 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 Misfi...

Page 90: ...by 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 Misfi...

Page 91: ...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 92: ...ellow alarm warning Cause Corrective action Short circuit or wire break on transistor output 1 plant side TOP 1 u Check wiring Page 162 382 AL Wiring TOP 2 Yellow alarm warning Cause Corrective action...

Page 93: ...tion Line disruption at digital input 3 u Check wiring Page 162 403 AL Open Load Digital Input 4 Yellow alarm warning Cause Corrective action Line disruption at digital input 4 u Check wiring Page 162...

Page 94: ...U 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 I...

Page 95: ...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 96: ...rective action Input signal for initial final torque faulty 1 Check signal transmitter and wiring replace as necessary 2 Restart engine Page 63 454 SS Power Reduction Active Yellow alarm warning Cause...

Page 97: ...Plant 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...

Page 98: ...he engine has stopped 551 SS Engine Overspeed Camshaft Red alarm emergency stop Cause Corrective action Engine overspeed camshaft u Restart engine Page 63 558 AL Wiring PWM_CM2 Yellow alarm warning Ca...

Page 99: ...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 100: ...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 101: ...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 MS15054 00E 2015 09 Troubleshooting 101 T...

Page 102: ...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 128 2 Engage barri...

Page 103: ...fore cranking the engine with starter system make sure that there are no persons in the engine s danger zone Barring engine with starting system 1 If fitted press pushbutton Bar engine without startin...

Page 104: ...stion 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 vapor Replacing oil mist fine...

Page 105: ...position without marking on flywheel Note With cylinder head and valve gear installed 1 Insert preloaded measuring gauge 2 into measuring device 4 and secure using screw 1 2 Install measuring device 4...

Page 106: ...nce Diagram for 12V 16V engines two crankshaft positions Position Cylinder 1 2 3 4 5 6 7 8 9 10 12V Firing TDC in cylinder A1 Side A I X I X I X Side B I X I I X X Overlap TDC in cylinder A1 Side A X...

Page 107: ...e Type Lubricant Value Standard Locknut M12x1 Tightening torque 50 Nm 5 Nm 5 Insert feeler gauge between valve bridge and rocker arm to verify that the gauge just passes through the gap Result If not...

Page 108: ...injector 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...

Page 109: ...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 110 MS15054 0...

Page 110: ...d safety glasses facial protection WARNING Residual pressure in HP fuel system Risk of injury due to fuel escaping at high pressure Energize the Engine Control Unit for around 30 s after emergency sto...

Page 111: ...enders Preparatory steps 1 Shut off fuel supply line 2 Drain fuel Page 118 3 Remove cylinder head cover Page 108 Removing injector 1 Remove HP fuel line 1 2 Unscrew union nut 2 3 Pull off pressure pip...

Page 112: ...or 1 into the cylinder head 4 Align faces on injector 1 for mounting in the hold down clamp 2 and insert injector by hand in a straight line into the cylinder head 5 Fit hold down clamp 2 in correct p...

Page 113: ...3 up to contact point on sealing ring in cylinder head 6 Press pressure pipe neck 3 in completely by hand 7 Align HP connection of injector with pressure pipe neck 3 8 Coat thread and shoulder of unio...

Page 114: ...HP fuel system Name Size Type Lubricant Value Standard Union nut M20 Tightening torque Engine oil 37 Nm 3 Nm b In case of double wall jacketed HP fuel system Name Size Type Lubricant Value Standard Un...

Page 115: ...ine oil 37 Nm 3 Nm 2 Push cable lugs under the terminals arrowed on the injector and tighten to specified torque using a torque wrench Name Size Type Lubricant Value Standard Nut M4 Tightening torque...

Page 116: ...er successful installation of DiaSys document can be found here C DiaSys Doku auf ihrem Service PC 1 Dialog system DiaSys E531920 2 If no DiaSys is available contact Service Entering injector coding I...

Page 117: ...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 Do not inhale vapors or mist We...

Page 118: ...ly 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 D...

Page 119: ...pors of highly 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 induc...

Page 120: ...quid or gaseous media e g fuel are poisonous Escaping vapors of highly volatile media e g fuel or ether Risk of fatal injury through swallowing risk of poisoning through inhalation irritation to eyes...

Page 121: ...sparks 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 high...

Page 122: ...h fuel 6 Insert new filter element 3 into filter hous ing 4 7 Screw filter cover 1 into filter housing 8 Tighten filter cover 1 with torque wrench to the specified tightening torque Name Size Type Lub...

Page 123: ...on to eyes and skin Seek medical attention immediately do not induce vomiting Do not inhale vapors or mist Wear protective clothing protective gloves and safety glasses If contact is made with skin wa...

Page 124: ...t 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 125 2 Reset signal...

Page 125: ...1 Release clamp 2 2 Remove air filter 1 and clamp 2 from con necting 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 126: ...ed Checking signal ring position 1 If the signal ring is completely visible in the control window 2 replace air filter Page 124 2 After installation of new filter press reset button 1 Result Engaged p...

Page 127: ...7 9 Starting Equipment 7 9 1 Electric starter Overview 1 Starter 2 Gasket 3 Flange 4 Gasket 5 Stud 6 Washer 7 Nut MS15054 00E 2015 09 Task Description 127 TIM ID 0000029152 003...

Page 128: ...onent 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 removing starte...

Page 129: ...starter pinion with lubricating grease 2 Install starter as per overview drawing Page 127 Starter electrical connection 1 Connect cables in accordance with the marking 2 Screw on nuts of connections...

Page 130: ...1 marks 4 Top up with oil up to the max 1 mark Page 131 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 131: ...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 132: ...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 133: ...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 134: ...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 Stand...

Page 135: ...coolant expansion tank counterclockwise 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...

Page 136: ...ge Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 137 2 Fill with engine coolant Page 138 136 Task Description MS15054 00E 201...

Page 137: ...n breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to escape 2 Continue to turn breather valve counterclock wise and remove 3 Draw off precipitated corros...

Page 138: ...k of damage to hearing Wear ear protectors NOTICE 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 s...

Page 139: ...Final steps 1 Start the engine and operate it at idle speed for some minutes 2 Check coolant level top up coolant if necessary Page 135 MS15054 00E 2015 09 Task Description 139 TIM ID 0000061049 001...

Page 140: ...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 141: ...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 142: ...s and goggles safety mask WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors NOTICE Cold coolant in hot engine can cause thermal stress Possibl...

Page 143: ...g plate 2 Install plug screws of filling points with new sealing rings 3 Check proper condition of breather valve 1 clean sealing faces if required 4 Fit breather valve 1 and close it Final steps 1 St...

Page 144: ...g charge air coolant 1 Provide a suitable container to catch the coolant 2 Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to escape 3 Continue to t...

Page 145: ...pecial tools Material Spare parts Designation Use Part No Qty Coolant Charge air coolant Change 1 Drain charge air coolant Page 144 2 Fill with charge air coolant Page 142 MS15054 00E 2015 09 Task Des...

Page 146: ...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 147: ...ne is 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 p...

Page 148: ...g intercooler condensate drain for coolant discharge and obstruc tions 1 Remove plug screw s from charge air manifold 2 Check drain bore s for air discharge If no air escapes 3 Clean drain bore s and...

Page 149: ...uard is removed Drive belt Condition check Item Findings Action Drive belt A Singular cracks None Drive belt B Cracks on entire circumference Replace Page 153 Page 154 Drive belt C Chunking Drive belt...

Page 150: ...below for set point value 7 If the measured values deviate from the specified values adjust drive belt tension Page 152 8 Install protective cover Belt length Application Measured value Initial insta...

Page 151: ...d value Operating tension used belt Drive belt 1800 mm Fan Frequency 88 1 Hz Frequency 77 1 Hz Drive belt 1520 mm Fan Frequency 104 1 Hz Frequency 92 1 Hz Table 11 Set point values Measurement with fr...

Page 152: ...otective grill from fan 3 Loosen screws 2 slightly 4 Adjust belt tension acc to specifications with screw 1 Page 150 5 Use torque wrench to tighten screws 2 to specified tightening torque Name Size Ty...

Page 153: ...from fan 3 Remove fan 4 Slacken off securing screws 2 5 Screw out screw 1 until drive belt can be re moved 6 Check belt pulley on cooler bearing mount and crankshaft for contamination and clean if nec...

Page 154: ...ndo screws 1 and trickle oil into the gap between gearcase 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 ten sion 6...

Page 155: ...ession depth 8 9 mm Test force 60 N Table 13 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 156: ...ective clothing protective gloves and safety glasses facial protection Checking differential pressure gage 1 Switch on fuel treatment system optional 2 Set both alarm points at the differential pressu...

Page 157: ...osion Avoid open flames electrical sparks and ignition sources Do not smoke Wear protective clothing protective gloves and safety glasses facial protection Checking coolant level sensor 1 Drain coolan...

Page 158: ...ll valve at the outlet of the fuel treatment system c Check pressure at the pressure gage in the inlet to the fuel treatment system and note down 3 Checking pump pressure in throttled condition a Redu...

Page 159: ...17 Engine Governor 7 17 1 Engine control system Overview 1 Connector X2 2 Engine control system 3 Connector X3 4 Washer 5 Screw 6 Damper MS15054 00E 2015 09 Task Description 159 TIM ID 0000053491 001...

Page 160: ...ith the data record for the given engine is installed Removing engine governor from engine 1 Note or mark assignment of cables and con nectors 2 Release latches on connectors 1 and 3 3 Disconnect all...

Page 161: ...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 162: ...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 163: ...or Cleaning 1 Use isopropyl alcohol 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...

Page 164: ...ry 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 va...

Page 165: ...le 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 Emergen...

Page 166: ...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 167: ...1 Valve clearance Check and adjustment Page 105 Barring device Part No F6792910 Qty Used in 1 7 3 1 Valve clearance Check and adjustment Page 105 Barring tool Part No F6792910 Qty Used in 1 7 1 1 Eng...

Page 168: ...154 Crowfoot wrench 19 mm Part No F30027424 Qty Used in 1 7 4 2 Injector Removal and installation Page 110 Double head box wrench Part No F30002800 Qty Used in 1 7 3 1 Valve clearance Check and adjust...

Page 169: ...32 Fuel suction device Part No F30378207 Qty Used in 1 7 4 2 Injector Removal and installation Page 110 High pressure cleaning unit Part No Qty Used in 1 4 9 Plant Cleaning Page 69 Measuring instrumen...

Page 170: ...ch 19 mm Part No F30453236 Qty Used in 1 7 4 2 Injector Removal and installation Page 110 Press fitting tool Part No F6790085 Qty Used in 1 7 4 2 Injector Removal and installation Page 110 Puller Part...

Page 171: ...No F30027340 Qty Used in 1 7 3 2 Cylinder head cover Removal and installation Page 108 Qty Used in 1 7 4 2 Injector Removal and installation Page 110 Qty Used in 1 7 6 3 Fuel prefilter Filter element...

Page 172: ...0 Qty Used in 1 7 3 1 Valve clearance Check and adjustment Page 105 Socket wrench 24 mm Part No F30453238 Qty Used in 1 7 4 2 Injector Removal and installation Page 110 Tester Part No Y4345711 Qty Use...

Page 173: ...art No F30026582 Qty Used in 1 7 14 3 Drive belt Tension adjustment Page 152 Torque wrench 40 200 Nm Part No F30027337 Qty Used in 1 7 14 3 Drive belt Tension adjustment Page 152 Torque wrench 6 50 Nm...

Page 174: ...ter sleeve re placement Page 133 Torque wrench 0 5 5 Nm Part No 0015384230 Qty Used in 1 7 3 2 Cylinder head cover Removal and installation Page 108 Qty Used in 1 7 4 2 Injector Removal and installati...

Page 175: ...oolant level Check 135 Coolant level sensor Check 157 Crankcase breather Oil mist fine separator Replacement 104 Cylinder Designation 16 Cylinder head cover Installation 108 Removal 108 D Differential...

Page 176: ...operation time limited ICXN 33 3H standby operation mode special qualifications 36 Engine data 16V2000Gx6S EPA Nonroad T2 40CFR89 3G continuous operation time limited ICXN 52 55 Engine driving end Def...

Page 177: ...operation after scheduled out of service period 62 S Safety notices standards 15 Safety regulations Auxiliary materials 13 Environmental protection 13 Fire prevention 13 Fluids and lubricants 13 Impo...

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MTU 12V2000G series, Operating Instructions Manual

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