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MTU 12V2000Gx5, Operating Instructions Manual

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MTU 12V2000Gx5 Operating Instructions Manual Download Page 101

8.5 Injection Pump / HP Pump

8.5.1 Injection pump – Replacement

Special tools, Material, Spare parts

Designation / Use

Part No.

Qty.

Injection pump

(→ Spare Parts Catalog)

Injection pump – Replacement

u

Remove injection pump and install new one (→ Page 102).

MS15019/04E 2016-02

| Injection Pump / HP Pump | 101

TIM-ID: 0000000020 - 004

Summary of Contents for 12V2000Gx5

Page 1: ...Operating Instructions Diesel engine 12V2000Gx5 Gx5 TB 16V2000Gx5 Gx5 TB 18V2000Gx5 Gx5 TB Application group 3B MS15019 04E ...

Page 2: ...ICXN 16V 2000 G65 TB 55 6 kW cyl 3B continuous operation variable load ICXN 16V2000G85 63 1 kW cyl 3B continuous operation variable load ICXN 16V2000G85 TB 63 1 kW cyl 3B continuous operation variable load ICXN 18V2000G65 55 6 kW cyl 3B continuous operation variable load ICXN 18V 2000 G65 TB 55 6 kW cyl 3B continuous operation variable load ICXN 18V2000G85 66 2 kW cyl 3B continuous operation varia...

Page 3: ...est run 55 5 7 Engine Emergency stop 56 5 8 After stopping the engine Engine remains ready for operation 57 5 9 After stopping the engine Putting the engine out of operation 58 6 Maintenance 6 1 Maintenance task reference table QL1 59 7 Troubleshooting 7 1 Fault indication on SAM display Genset applications 60 7 2 Troubleshooting 84 8 Task Description 8 1 Engine 87 8 1 1 Engine Barring manually 87...

Page 4: ... coolant Change 137 8 15 3 Engine coolant Draining 138 8 15 4 Engine coolant Filling 139 8 15 5 Coolant pump Relief bore check 141 8 16 Low Temperature Circuit 142 8 16 1 Charge air coolant Filling 142 8 16 2 Charge air coolant Draining 144 8 16 3 Charge air coolant Change 145 8 16 4 Charge air coolant Level check 146 8 17 Battery Charging Generator 147 8 17 1 Battery charging generator drive Driv...

Page 5: ...ocesses that might affect the emission characteristics of the product are prohibited by emission regulations Emission control units systems may only be maintained ex changed or repaired if the components used for this purpose are approved by the manufacturer Noncompliance with these regulations will invalidate the design type approval issued by the emissions regu lation authorities The manufacture...

Page 6: ...n particular with regard to the specified tightening torques With the exclusive use of technical personnel trained in commissioning operation maintenance and re pair By contracting only workshops authorized by the manufacturer to carry out repair and overhaul The product shall not be operated in explosive atmospheres unless the necessary approval has been grant ed Any other use particularly misuse...

Page 7: ... be instructed 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 from the areas mechanical engineering plant construction and electrical engineering The operator must define the responsibilities of the personnel involved in operation maintenance repair as sem...

Page 8: ...he product into operation make sure that all control and display instruments as well as the signaling and alarm systems work properly Smoking is prohibited in the area of the product Safety regulations during operation The operator must be familiar with the control and display elements The operator must be familiar with the consequences of any operations performed During operation the display inst...

Page 9: ...Follow the applicable warning instructions pertaining to such devices MS15019 04E 2016 02 Safety 9 TIM ID 0000040533 012 ...

Page 10: ...d V belts 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 Wear a respirator mask filter class P3 Do not blow out the interior of the flywheel housing or the starter with compressed air Clean the flywheel housing inside with a class H dust extraction ...

Page 11: ...ng in its vicinity Before starting welding work Switch off the power supply master switch Disconnect the battery cables or actuate the battery isolating switch Separate the electrical ground of electronic equipment from the ground of the unit No other maintenance or repair work must be carried out in the vicinity of the product while welding is going on Risk of explosion or fire due to oil vapors ...

Page 12: ...th sharp edges 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 connectors Subject the device as well as the product to a functional testing on completion of all repair work Check cor rect execution of the emergency stop function in particular Store spare parts...

Page 13: ...fully with its handling 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 pressure level in excess of 85 dB A Environmental protection and disposal Dispose of used fluids lubricants and filters in accordance with local regulations Within the EU batteries can be returned f...

Page 14: ...arrying out painting work outside the spray stands provided with fume extraction systems ensure that the area is well ventilated Make sure that neighboring work areas are not adversely affected There must be no naked flames in the vicinity No smoking Observe fire prevention regulations Always wear a mask providing protection against paint and solvent vapors Liquid nitrogen Observe the relevant saf...

Page 15: ...on NOTICE In the event of a situation involving potentially adverse effects on the product Consequences Material damage Remedial action Additional product information Warning notices 1 This manual with all safety instructions and safety notices must be issued to all personnel involved in opera tion maintenance repair assembly installation or transportation 2 The higher level warning notice is used...

Page 16: ... not rub against the engine or its compo nents during the lifting procedure Readjust lifting tackle as necessary 6 For special packaging with aluminum foil Attach engine to lifting eyes of bearing pedestal or transport with means of transportation device suitable for the load forklift truck 7 Secure engine against tilting during transportation Secure such as to preclude slipping and tipping when d...

Page 17: ...appropriate lifting devices and appliances Never stand beneath a suspended load 1 Lifting eye 2 Center of gravity Take note of the engine center of gravity See Installation Arrangement drawings for details on engine center of gravity MS15019 04E 2016 02 Transport 17 TIM ID 0000067354 001 ...

Page 18: ...ignated 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 and letter Bx refers to the cylinders on the right hand side 3 The cylinders of each bank are numbered consecutively starting with x 1 at driving end 4 The numbering of other engine components also ...

Page 19: ...7 Oil heat exchanger 8 Oil filter 9 Coolant pump 10 Fuel priming pump 11 Air outlet 12 Exhaust turbocharger 13 Exhaust elbow 14 Charge air manifold 15 Cylinder head 16 Flywheel housing 17 Starter 18 Storage 19 Oil pan 20 Crankcase breather Figure also applies similarly to 12V 16V 18V2000Gxy MS15019 04E 2016 02 General Information 19 TIM ID 0000009973 005 ...

Page 20: ...haust elbow 14 Charge air manifold 15 Cylinder head 16 Flywheel housing 17 Storage 18 Crankcase breather Figure also applies similarly to 12V 16V 18V2000Gxy Engine type designation Explanation of engine type designation 12V 16V 18V2000Gxy 12 16 18 Number of cylinders V Cylinder arrangement V engine 2000 Series G Application x Application segment 2 4 6 8 y Design status 0 1 2 20 General Information...

Page 21: ...e 2 B5 Lube oil pressure 3 B9 Charge air coolant temperature 4 B10 Charge air pressure 5 B1 Camshaft speed 6 B13 Crankshaft speed 7 B6 Coolant temperature 8 B33 Fuel temperature The coolant level sensor F33 is located in the coolant expansion tank at the cooler MS15019 04E 2016 02 General Information 21 TIM ID 0000022704 003 ...

Page 22: ...ssure 3 B9 Charge air coolant temperature 4 B10 Charge air pressure 5 B1 Camshaft speed 6 B13 Crankshaft speed 7 B6 Coolant temperature 8 B33 Fuel temperature The coolant level sensor F33 is located in the coolant expansion tank at the cooler 22 General Information MS15019 04E 2016 02 TIM ID 0000022704 003 ...

Page 23: ...1000 1000 1000 1000 1000 Site altitude above sea level M 100 100 100 100 100 Power related data power ratings are net brake power as per ISO 3046 Description 12V 2000 G25 12V 2000 G65 16V 2000 G25 16V 2000 G65 18V 2000 G65 Rated engine speed A rpm 1500 1500 1500 1500 1500 Continuous power ISO 3046 10 overload possible pow er range DIN 6280 ISO 8528 A kW 580 695 810 890 1000 General conditions for ...

Page 24: ...ore mm 130 130 130 130 130 Stroke mm 150 150 150 150 150 Displacement cylinder Liter 1 99 1 99 1 99 1 99 1 99 Displacement total Liter 23 88 23 88 31 84 31 84 35 82 Compression ratio 16 16 16 16 16 Cylinder heads Individual cyl inder heads x x x x x Cylinder liners wet replacea ble x x x x x Number of inlet valves per cyl inder 2 2 2 2 2 Number of exhaust valves per cylinder 2 2 2 2 2 Standard hou...

Page 25: ...g tempera ture before engine to R C 98 98 98 98 98 Lube oil temperature before engine alarm R C 100 100 100 100 100 Lube oil temperature before engine shutdown L C 105 105 105 105 105 Lube oil operating pressure before engine from R bar 6 2 6 2 5 5 5 5 6 0 Lube oil operating pressure before engine to R bar 7 5 7 5 6 5 6 5 8 0 Lube oil operating pressure before engine warning R bar 4 4 4 4 4 4 4 4 ...

Page 26: ...nitial fill ing standard oil system de sign max operating inclina tions R Liter 77 77 102 102 130 Oil change capacity max standard oil system R Liter N N N N N Oil change quantity max standard oil system design max operating inclinations R Liter 74 74 99 99 114 Oil pan capacity dipstick mark min standard oil system de sign max operating inclina tions L Liter 50 50 69 69 87 Oil pan capacity dipstic...

Page 27: ...ust noise unsilenced DL sound power level LW ISO 6798 3 dB A tolerance R dB A 124 127 126 128 128 Engine surface noise with at tenuated intake noise filter DL sound power level LW ISO 6798 2 dB A tolerance R dB A 117 118 120 121 123 MS15019 04E 2016 02 Technical Data 27 TIM ID 0000010882 002 ...

Page 28: ...Barometric pressure mbar 1000 1000 1000 1000 1000 Site altitude above sea level M 100 100 100 100 100 Power related data power ratings are net brake power as per ISO 3046 Description 12V 2000 G25 TB 12V 2000 G65 TB 16V 2000 G25 TB 16V 2000 G65 TB 18V 2000 G65 TB Rated engine speed A rpm 1500 1500 1500 1500 1500 Continuous power ISO 3046 10 overload possible pow er range DIN 6280 ISO 8528 A kW 580 ...

Page 29: ...ore mm 130 130 130 130 130 Stroke mm 150 150 150 150 150 Displacement cylinder Liter 1 99 1 99 1 99 1 99 1 99 Displacement total Liter 23 88 23 88 31 84 31 84 35 82 Compression ratio 16 16 16 16 16 Cylinder heads Individual cyl inder heads x x x x x Cylinder liners wet replacea ble x x x x x Number of inlet valves per cyl inder 2 2 2 2 2 Number of exhaust valves per cylinder 2 2 2 2 2 Standard hou...

Page 30: ...55 55 55 55 Coolant antifreeze content max L 50 50 50 50 50 Pressure loss in off engine cooling system max L bar 0 7 0 7 0 7 0 7 0 7 Lube oil system Description 12V 2000 G25 TB 12V 2000 G65 TB 16V 2000 G25 TB 16V 2000 G65 TB 18V 2000 G65 TB Lube oil operating tempera ture before engine from R C 88 88 88 88 88 Lube oil operating tempera ture before engine to R C 98 98 98 98 98 Lube oil temperature ...

Page 31: ... 120 120 120 120 Oil and coolant capacity Description 12V 2000 G25 TB 12V 2000 G65 TB 16V 2000 G25 TB 16V 2000 G65 TB 18V 2000 G65 TB Engine coolant capacity en gine side without cooling equipment R Liter 110 110 130 130 140 Charge air coolant engine side R Liter 20 20 20 20 20 Engine oil capacity initial fill ing standard oil system de sign max operating inclina tions R Liter 77 77 102 102 130 Oi...

Page 32: ...70 3180 3180 3580 Acoustics Description 12V 2000 G25 TB 12V 2000 G65 TB 16V 2000 G25 TB 16V 2000 G65 TB 18V 2000 G65 TB Exhaust noise unsilenced DL sound power level LW ISO 6798 3 dB A tolerance R dB A 124 127 126 128 128 Engine surface noise with at tenuated intake noise filter DL sound power level LW ISO 6798 2 dB A tolerance R dB A 117 118 120 121 123 32 Technical Data MS15019 04E 2016 02 TIM I...

Page 33: ...er ratings are net brake power as per ISO 3046 Description 12V 2000 G25 12V 2000 G45 12V 2000 G65 12V 2000 G85 Rated engine speed A rpm 1500 1800 1500 1800 Continuous power ISO 3046 10 over load possible power range DIN 6280 ISO 8528 A kW 580 710 695 810 General conditions for maximum power Description 12V 2000 G25 12V 2000 G45 12V 2000 G65 12V 2000 G85 Intake depression new filter A mbar 15 15 15...

Page 34: ...sing connecting flange en gine main PTO SAE 0 0 0 0 Flywheel interface DISC 18 18 18 18 Combustion air exhaust gas Description 12V 2000 G25 12V 2000 G45 12V 2000 G65 12V 2000 G85 Charge air pressure before cylinder DL R bar abs 3 6 3 2 4 0 3 35 Coolant system HT circuit Description 12V 2000 G25 12V 2000 G45 12V 2000 G65 12V 2000 G85 Coolant temperature at engine connec tion outlet to cooling equip...

Page 35: ...x when engine is starting L bar 0 5 0 5 0 5 0 5 General operating data Description 12V 2000 G25 12V 2000 G45 12V 2000 G65 12V 2000 G85 Cold start capability air temperature w o start aid w o preheating tolerance 5 case A R C 0 0 0 0 Coolant preheating preheating tempera ture min R C 32 32 32 32 Firing speed from R rpm 100 100 100 100 Firing speed to R rpm 120 120 120 120 Oil and coolant capacity D...

Page 36: ...V 2000 G25 12V 2000 G45 12V 2000 G65 12V 2000 G85 Engine weight dry basic engine configu ration acc to scope of delivery specifica tion R kg 2490 2490 2490 2490 Acoustics Description 12V 2000 G25 12V 2000 G45 12V 2000 G65 12V 2000 G85 Exhaust noise unsilenced DL sound power level LW ISO 6798 3 dB A toler ance R dB A 124 127 127 129 Engine surface noise with attenuated in take noise filter DL sound...

Page 37: ...000 Site altitude above sea level M 100 100 100 100 100 100 Power related data power ratings are net brake power as per ISO 3046 Description 16V 2000 G25 16V 2000 G45 16V 2000 G65 16V 2000 G85 18V 2000 G65 18V 2000 G85 Rated engine speed A rpm 1500 1800 1500 1800 1500 1800 Continuous power ISO 3046 10 overload possible power range DIN 6280 ISO 8528 A kW 810 915 890 1010 1000 1191 General condition...

Page 38: ... cylin ders 16 16 16 16 18 18 Cylinder arrange ment V angle degrees 90 90 90 90 90 90 Bore mm 130 130 130 130 130 130 Stroke mm 150 150 150 150 150 150 Displacement cyl inder Liter 1 99 1 99 1 99 1 99 1 99 1 99 Displacement to tal Liter 31 84 31 84 31 84 31 84 35 82 35 82 Compression ratio 16 16 16 16 16 16 Cylinder heads Individual cylinder heads x x x x x x Cylinder liners wet replaceable x x x ...

Page 39: ...02 102 Coolant antifreeze content max L 50 50 50 50 50 50 Pressure loss in off engine cooling system max L bar 0 7 0 7 0 7 0 7 0 7 0 7 Lube oil system Description 16V 2000 G25 16V 2000 G45 16V 2000 G65 16V 2000 G85 18V 2000 G65 18V 2000 G85 Lube oil operating temperature be fore engine from R C 88 88 88 88 88 88 Lube oil operating temperature be fore engine to R C 98 98 98 98 98 98 Lube oil temper...

Page 40: ...g L bar 0 5 0 5 0 5 0 5 0 5 0 5 General operating data Description 16V 2000 G25 16V 2000 G45 16V 2000 G65 16V 2000 G85 18V 2000 G65 18V 2000 G85 Cold start capabil ity air tempera ture w o start aid w o preheat ing tolerance 5 case A R C 0 0 0 0 0 0 Coolant preheat ing preheating temperature min R C 32 32 32 32 32 32 Firing speed from R rpm 100 100 100 100 100 100 Firing speed to R rpm 120 120 120...

Page 41: ...ons R Liter 99 99 99 99 114 114 Oil pan capacity dipstick mark min standard oil system design max operating in clinations L Liter 69 69 69 69 87 87 Oil pan capacity dipstick mark max standard oil system design max operating in clinations L Liter 92 88 92 88 110 110 Weights main dimensions Description 16V 2000 G25 16V 2000 G45 16V 2000 G65 16V 2000 G85 18V 2000 G65 18V 2000 G85 Engine weight dry ba...

Page 42: ...aust noise un silenced DL sound power lev el LW ISO 6798 3 dB A toler ance R dB A 129 127 129 128 129 129 Engine surface noise with attenu ated intake noise filter DL sound power level LW ISO 6798 2 dB A toler ance R dB A 120 121 121 122 122 123 42 Technical Data MS15019 04E 2016 02 TIM ID 0000010936 002 ...

Page 43: ...C Barometric pressure mbar 1000 1000 1000 1000 1000 Site altitude above sea level M 100 100 100 100 100 Power related data power ratings are net brake power as per ISO 3046 Description 12V 2000 G45 TB 12V 2000 G85 TB 16V 2000 G45 TB 16V 2000 G85 TB 18V 2000 G85 TB Rated engine speed A rpm 1800 1800 1800 1800 1800 Continuous power ISO 3046 10 overload possible pow er range DIN 6280 ISO 8528 A kW 71...

Page 44: ...ore mm 130 130 130 130 130 Stroke mm 150 150 150 150 150 Displacement cylinder Liter 1 99 1 99 1 99 1 99 1 99 Displacement total Liter 23 88 23 88 31 84 31 84 35 82 Compression ratio 16 16 16 16 16 Cylinder heads Individual cyl inder heads x x x x x Cylinder liners wet replacea ble x x x x x Number of inlet valves per cyl inder 2 2 2 2 2 Number of exhaust valves per cylinder 2 2 2 2 2 Standard hou...

Page 45: ...em A C 45 45 45 45 45 Coolant antifreeze content max L 50 50 50 50 50 Pressure loss in off engine cooling system max L bar 0 7 0 7 0 7 0 7 0 7 Lube oil system Description 12V 2000 G45 TB 12V 2000 G85 TB 16V 2000 G45 TB 16V 2000 G85 TB 18V 2000 G85 TB Lube oil operating tempera ture before engine from R C 88 88 88 88 88 Lube oil operating tempera ture before engine to R C 98 98 98 98 98 Lube oil te...

Page 46: ... 120 120 120 120 Oil and coolant capacity Description 12V 2000 G45 TB 12V 2000 G85 TB 16V 2000 G45 TB 16V 2000 G85 TB 18V 2000 G85 TB Engine coolant capacity en gine side without cooling equipment R Liter 110 110 130 130 140 Charge air coolant engine side R Liter 20 20 20 20 20 Engine oil capacity initial fill ing standard oil system de sign max operating inclina tions R Liter 77 77 102 102 130 Oi...

Page 47: ...70 3180 3180 3500 Acoustics Description 12V 2000 G45 TB 12V 2000 G85 TB 16V 2000 G45 TB 16V 2000 G85 TB 18V 2000 G85 TB Exhaust noise unsilenced DL sound power level LW ISO 6798 3 dB A tolerance R dB A 127 129 127 128 129 Engine surface noise with at tenuated intake noise filter DL sound power level LW ISO 6798 2 dB A tolerance R dB A 117 120 121 122 123 MS15019 04E 2016 02 Technical Data 47 TIM I...

Page 48: ...r of cylinders Firing order 12V A1 B2 A5 B4 A3 B1 A6 B5 A2 B3 A4 B6 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 48 Technical Data MS15019 04E 2016 02 TIM ID 0000002793 004 ...

Page 49: ...pprox 2226 mm approx 1580 mm approx 1572 mm 18V2000Gx5 approx 2398 mm approx 1580 mm approx 1603 mm 12V2000Gx5 TB approx 1836 mm approx 1580 mm approx 1585 mm 16V2000Gx5 TB approx 2180 mm approx 1580 mm approx 1585 mm 18V2000Gx5 TB approx 2352 mm approx 1580 mm approx 1619 mm MS15019 04E 2016 02 Technical Data 49 TIM ID 0000010030 005 ...

Page 50: ...uel prefilter pressure gauge Align adjustable pointer with position of pressure indicator Page 120 Fuel system Vent Page 117 Coolant circuit If engine is out of service for more than one year change engine coolant Page 137 Change charge air coolant Page 145 Coolant circuit Check engine coolant level Page 136 Check charge air coolant level Page 146 Coolant circuit Heat engine coolant with coolant p...

Page 51: ... 133 Cooling system Check engine coolant level Page 136 Check charge air coolant level Page 146 Cooling system Preheat coolant with preheating unit Fuel prefilter Drain Page 121 Monitoring equipment Carry out lamp test see manufacturer s documentation Engine generator control system Switch ON Select operating mode e g MANUAL OPERATION AUTOMATIC OPERATION MS15019 04E 2016 02 Operation 51 TIM ID 000...

Page 52: ... if fitted Switch on Starting the engine Item Action Switchgear cabinet control panel etc depending on manufacturer If coolant temperature is 40 C with preheating system or 5 C without preheating system Press start button Automatic starting sequence is performed Engine speed display instrument indicates increasing speed After the starting sequence is completed engine is running at rated speed Conn...

Page 53: ...e when a pushbutton is provided Safety system Override Item Action Switchgear cabinet control panel etc depending on manufacturer Activate pushbutton for Override input of the ECU Certain shutdown criteria and or starting prerequisites are ignored Switchgear cabinet control panel etc depending on manufacturer Actuate start button for further starting sequence refer to engine start Page 52 Control ...

Page 54: ...k for abnormal running noises and vibration Fuel prefilter Check reading on differential pressure gage to ensure that maximum admis sible value is not exceeded Page 120 Exhaust system Check exhaust color Page 84 Intercooler Check condensate drain s for water discharge and obstruction Page 128 Air filter Check signal ring position of service indicator Page 131 Replace air filter Page 129 if the sig...

Page 55: ... After the generator breaker if provided has been opened allow the engine to cool down by running it idle for approx 5 minutes Preparing a pump drive diesel mechanical diesel electric Item Action Engine Allow the engine to cool down by running it at reduced speed for approx 5 minutes Observe the natural frequencies plant specific values of the en gine Stopping the engine Item Action Switchgear cab...

Page 56: ... from LOP Item Action Emergency stop pushbutton Press pushbutton Engine is stopped by disconnecting the power supply to the ECU Signaling e g by horn flashing lamp is tripped After emergency engine stop from LOP Item Action Control cabinet control pan el etc depending on manu facturer Press pushbutton for alarm acknowledgment Audible and visual alarm signaling stops 56 Operation MS15019 04E 2016 0...

Page 57: ...the engine Engine remains ready for operation After stopping the engine Item Action Engine generator pump control Select operating mode e g MANUAL AUTOMATIC OPERATION MS15019 04E 2016 02 Operation 57 TIM ID 0000000983 003 ...

Page 58: ...to the coolant the engine room is not heated the coolant is not kept at a suitable temperature the antifreeze concentration is insufficient for the engine room tempera ture antifreeze concentration is 50 and engine room temperature is below 40 C Engine generator pump control Switch off Air intake and exhaust sys tem If the engine is to remain out of service for more than 1 week seal the en gine s ...

Page 59: ...r Page 121 W0508 X Check reading on differential pressure gage of fuel prefilter Page 120 W0534 Carry out test run minimum duration until steady state tem perature is reached no less than 1 3 load monthly Page 89 W1001 Replace fuel filter or fuel filter element Page 119 W1002 Check valve clearance Page 97 W1003 Check belt condition and tension replace belt if necessary Page 147 W1005 Replace air f...

Page 60: ...urred e g nd11 Second line option Running text providing more information about the fault currently displayed Time indicator for alarms Meaning Alarm is no longer active does not appear on next power up A Alarm is active B Alarm was active during the last hour C Alarm was active during the last four hours D Alarm was active during the last four to twelve hours E Alarm was active more than twelve h...

Page 61: ... Module Slot5 Defect 24 I O Module Slot6 Defect 25 I O Module Slot7 Defect 26 I O Module Slot8 Defect 27 Download Server Collision 28 not projected node Engine governor messages Recommended action in case of alarm Yellow alarm The engine can still be operated providing that automatic engine shutdown to protect the engine has not been configured or is not tripped Contact Service immediately start f...

Page 62: ...le below lists possible fault codes Fault code no Full designation Meaning Action Setting parame ter no 003 HI T Fuel Prewarning Fuel tempera ture too high limit value 1 alarm configuration parame ter see PR 2 8008 100 for explanation Check tank temper ature contact Serv ice if no fault detect ed 2 0122931 004 SS T Fuel Main warning Fuel tempera ture too high limit value 2 alarm configuration para...

Page 63: ... 8008 100 for explanation Automatic en gine shutdown Check oil level con tact Service 2 0100 922 024 SS Coolant Level Coolant level too low limit value 2 alarm configuration parameter see PR 2 8008 100 for explanation Automatic engine shutdown Check coolant level in expansion tank check for leakage and seal any leaks as necessary 2 0152 912 030 SS Engine Overspeed Engine overspeed limit value 2 al...

Page 64: ... leaking alarm configuration parame ter see PR 2 8008 100 for explanation On stopping Seal off system contact Service On starting Check engine for leakage if none found attempt re starting as per oper ating instructions air in system 1 8004 046 082 HI P Fuel Common Rail Rail pressure is greater than set value alarm configura tion parameter see PR 2 8008 100 for explanation Warning Check HP fuel co...

Page 65: ...parameter see PR 2 8008 100 for explanation Engine start inter lock is active as coolant temperature is too low for engine start preheating necessary 2 1090 921 095 AL Prelubrication Fault Oil priming pressure not reached alarm configuration parameter see PR 2 8008 100 for explanation Contact Service 2 1090 920 102 AL Fuel Cons Counter Defect Electronic fault Consump tion counter faulty alarm conf...

Page 66: ... or CAN bus to backup system is dis rupted alarm configuration parameter see PR 2 8008 100 for explanation Contact Service 2 4000 004 177 AL LifeData restore in complete This fault message is gener ated when a CRC is faulty stated for each module or upload is incomplete during a restore data upload process into ADEC alarm configura tion parameter see PR 2 8008 100 for explanation Contact Service 2...

Page 67: ...a warning Causes are e g missing associate nodes mi nor disruptions and tempora ry bus overload alarm con figuration parameter see PR 2 8008 100 for explanation Contact Service 2 0500 687 188 AL CAN2 Bus Off CAN controller 2 is in Bus Off state automatic switch ing to CAN1 results Causes are e g short circuit massive disruptions or baud rate in compatibility alarm configu ration parameter see PR 2...

Page 68: ...l pressure sensor faulty HP controller in emergency mode short circuit or wire break Check sensor and wiring B48 replace as necessary 1 8004 567 216 SD T Lube Oil SD alarm configuration lube oil temperature sensor faulty short circuit or wire break Check sensor and wiring B7 replace as necessary 1 8004 575 219 SD T Intake Air SD alarm configuration in take air temperature sensor faulty short circu...

Page 69: ...uration cam shaft sensor faulty short cir cuit or wiring damage engine remains operational Check sensor and wiring B1 attempt restart fault may be rectified when en gine is restarted Contact Service if this is not the case 1 8004 499 240 SD P Fuel SD alarm configuration en gine remains operational fuel pressure sensor faulty short circuit or wiring dam age Check sensor and wiring B34 replace as ne...

Page 70: ...ump if this occurs frequently 1 8004 502 304 AL Timing Cylinder A4 Time of flight measuring fault injector cylinder A4 Time of flight value measured ex tremely small or large alarm configuration parameter see PR 2 8008 100 for explana tion Replace plug in pump if this occurs frequently 1 8004 503 305 AL Timing Cylinder A5 Time of flight measuring fault injector cylinder A5 Time of flight value mea...

Page 71: ... B1 Time of flight measuring fault injector cylinder B1 Time of flight value measured ex tremely small or large alarm configuration parameter see PR 2 8008 100 for explana tion Replace plug in pump if this occurs frequently 1 8004 510 312 AL Timing Cylinder B2 Time of flight measuring fault injector cylinder B2 Time of flight value measured ex tremely small or large alarm configuration parameter s...

Page 72: ...ector cylinder B8 Time of flight value measured ex tremely small or large alarm configuration parameter see PR 2 8008 100 for explana tion Replace plug in pump if this occurs frequently 1 8004 517 319 AL Timing Cylinder B9 Time of flight measuring fault injector cylinder B9 Time of flight value measured ex tremely small or large alarm configuration parameter see PR 2 8008 100 for explana tion Repl...

Page 73: ...sitive to negative e g by exchanging injec tors Fault rectifica tion When engine is restarted 1 8004 523 325 AL Wiring Cylinder A5 Wiring fault in injector wiring cylinder A5 Result Misfiring alarm configuration parame ter see PR 2 8008 100 for explanation Check injector wir ing rectify injector solenoid valve short circuit positive to negative e g by exchanging injec tors Fault rectifica tion Whe...

Page 74: ...ositive to negative e g by exchanging injec tors Fault rectifica tion When engine is restarted 1 8004 529 331 AL Wiring Cylinder B1 Wiring fault in injector wiring cylinder B1 Result Misfiring alarm configuration parame ter see PR 2 8008 100 for explanation Check injector wir ing rectify injector solenoid valve short circuit positive to negative e g by exchanging injec tors Fault rectifica tion Wh...

Page 75: ...sitive to negative e g by exchanging injec tors Fault rectifica tion When engine is restarted 1 8004535 337 AL Wiring Cylinder B7 Wiring fault in injector wiring cylinder B7 Result Misfiring alarm configuration parame ter see PR 2 8008 100 for explanation Check injector wir ing rectify injector solenoid valve short circuit positive to negative e g by exchanging injec tors Fault rectifica tion When...

Page 76: ...ude disrup tion in solenoid valve e g by injec tor replacement Fault rectification After each working cycle 1 8004 541 343 AL Open Load Cylinder A3 Disruption fault in injector wiring cylinder A3 Result Misfiring alarm configuration parameter see PR 2 8008 100 for explanation Check injector wir ing exclude disrup tion in solenoid valve e g by injec tor replacement Fault rectification After each wo...

Page 77: ... in solenoid valve e g by injec tor replacement Fault rectification After each working cycle 1 8004 547 349 AL Open Load Cylinder A9 Disruption fault in injector wiring cylinder A9 Result Misfiring alarm configuration parameter see PR 2 8008 100 for explanation Check injector wir ing exclude disrup tion in solenoid valve e g by injec tor replacement Fault rectification After each working cycle 1 8...

Page 78: ...n in solenoid valve e g by injec tor replacement Fault rectification After each working cycle 1 8004 553 355 AL Open Load Cylinder B5 Disruption fault in injector wiring cylinder B5 Result Misfiring alarm configuration parameter see PR 2 8008 100 for explanation Check injector wir ing exclude disrup tion in solenoid valve e g by injec tor replacement Fault rectification After each working cycle 1 ...

Page 79: ...ive If parameter 1 1020 021 Pow er Stage Failure Stop En gine is set engine is stop ped here additionally alarm configuration parameter see PR 2 8008 100 for explana tion Start engine gover nor self test Re place engine gover nor in case of fault if self test diagnoses Electronics OK check for additional fault messages e g wiring fault 1 8004 496 362 AL Power Stage high Internal electronic fault e...

Page 80: ...iring TOP 3 Short circuit or wire break at transistor output 3 plant side TOP 3 alarm configuration parameter see PR 2 8008 100 for explanation Check wiring 2 8006 640 384 AL Wiring TOP 4 Short circuit or wire break at transistor output 4 plant side TOP 4 alarm configuration parameter see PR 2 8008 100 for explanation Check wiring 2 8006 641 390 AL MCR exceeded DBR MCR function MCR maximum continu...

Page 81: ...lty or no re sistance via switch alarm configuration parameter see PR 2 8008 100 for explana tion Check wiring 2 8006 631 407 AL Open Load Digital Input 8 Line disruption at digital in put 8 wiring faulty or no re sistance via switch alarm configuration parameter see PR 2 8008 100 for explana tion Check wiring 2 8006 632 408 AL Open Load Emerg Stop Input ESI Line disruption at input for emergency ...

Page 82: ...ture Alarm con figuration parameter see PR 2 8008 100 for explanation None 2 7000 011 463 SD AUX 2 SD alarm configuration ana log input signal for Aux 2 faulty short circuit or wiring damage Check signal trans mitter and wiring replace as necessa ry 1 8004 591 464 SD P AUX 1 SD alarm configuration ana log input signal for pressure Aux 1 faulty short circuit or wiring damage Check pressure transmit...

Page 83: ...error of crash re corder Contact Service 1 8010 007 478 AL Comb Alarm Yel Plant YELLOW combined alarm from plant alarm configura tion parameter see PR 2 8008 100 for explanation Contact Service 2 8006 001 479 AL Comb Alarm Red Plant RED combined alarm from plant alarm configuration pa rameter see PR 2 8008 100 for explanation Contact Service 2 8006 002 480 AL Ext Engine Protec tion External engine...

Page 84: ...r rotation by starter Battery flat or faulty u Charge or replace battery see manufacturer s documentation Engine wiring is faulty u Check Page 154 Air in fuel system u Vent fuel system Page 117 Engine governor is faulty u Contact Service Engine fires unevenly Cause Corrective action Injector is faulty u Replace Page 105 Injection pump is faulty u Replace Page 102 Engine wiring is faulty u Check Pa...

Page 85: ...r supply ventilation ducts Charge air pressure too low Cause Corrective action Air filter clogged u Check signal ring position of contamination indicator Page 131 Charge air cooler is contaminated u Contact Service Exhaust turbocharger is faulty u Contact Service Coolant leaks at intercooler Cause Corrective action Major coolant discharge at charge air cooler Charge air cooler leaky u Contact Serv...

Page 86: ... is faulty u Contact Service Piston rings are faulty u Contact Service Cylinder liner is faulty u Contact Service White exhaust gas Cause Corrective action Engine is not at operating temperature u Run engine to reach operating temperature Water in fuel u Check fuel system at fuel prefilter Drain water from fuel prefilter Page 121 Charge air cooler leaky u Contact Service 86 Troubleshooting MS15019...

Page 87: ...ersons 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 Engine Barring manually 1 Remove access cover from flywheel housing 2 Install barring device arrow on flywheel housing 3 Rotate crankshaft in engine direction of rota tion Apart from the normal compression re sistance there should b...

Page 88: ...ulled in Before cranking the engine with starter system make sure that there are no persons in the engine s danger zone Engine Barring with starting system 1 Press pushbutton Bar engine without starting and keep depressed 2 Let the crankshaft rotate until oil pressure is indicated but not longer than 10 seconds 3 Repeat procedure after approx 20 seconds if necessary 88 Engine MS15019 04E 2016 02 T...

Page 89: ...ere 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 protectors Engine Test run 1 Start engine Page 52 2 Perform test run not below 1 3 load and at least until steady state temperature is reached 3 Carry out operational checks Page 54 4 Stop engine Page 55 MS15019 04E 2016 02 Engine 89 TIM ID 0000000870 008 ...

Page 90: ...ng pattern First signs of marks left by lower cooling bores Running pattern seems darker No action required Darker areas of even or varying color intensity Beginning and end of the discoloration are not sharply defined and do not cover the entire stroke area Dark areas in the upper section of the cooling bore remaining circum ference cannot be faulted Piston rings faultless Further endoscopic exam...

Page 91: ...Final steps 1 Install injector Page 106 2 Install cylinder head cover Page 100 MS15019 04E 2016 02 Cylinder Liner 91 TIM ID 0000000015 016 ...

Page 92: ...round the liner It appears rather darker within the honed struc ture in contrast to the bright metallic running surface The honing pattern is undis turbed Discolorations extend in stroke direction and may be interrupted Findings not critical Corrosion fields spots Corrosion fields spots result from water condensed water with the valves in the overlap open position They are clearly visible due to t...

Page 93: ...ration are similar A thorough inves tigation and compliance with the above evaluation criteria allow an unambiguous evaluation To avoid unnec essary disassembly work it is recommended that another inspection be carried out after further operation of the engine MS15019 04E 2016 02 Cylinder Liner 93 TIM ID 0000000014 015 ...

Page 94: ...idues 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 separator filter el ement 1 Remove cover 2 with O ring 3 2 Remove filter element 1 from housing 4 3 Insert new filter element in housing 4 4 Install cover 2 with new O ring 5 Use torque wrench to tighten the screws of c...

Page 95: ...phragm 3 on housing 1 5 Install new gasket 2 and spring 5 together with cover 4 6 Use torque wrench to tighten the screws of cover 4 to the specified torque Name Size Type Lubricant Value Standard Screw Tightening torque Engine oil 10 Nm 2 Nm 7 Check diaphragm in other oil separators in the same manner MS15019 04E 2016 02 Crankcase Breather 95 TIM ID 0000000017 010 ...

Page 96: ...s NOTICE Cleaning agents should not be left to take effect for too long Damage to components is possible Observe manufacturer s instructions Crankcase breather Wire mesh cleaning 1 Remove hose 2 Loosen clamp 5 3 Remove oil separator cover 7 4 Remove individual parts from cover 7 5 Wash filter element wire mesh 3 with die sel fuel 6 Blow out filter element wire mesh 3 with compressed air 7 Clean re...

Page 97: ...linder head cover Page 100 2 Install barring tool Page 87 3 Bar crankshaft with barring tool in engine di rection of rotation until TDC pointer and TDC mark on the flywheel are aligned Checking valve clearance at two crankshaft positions 1 Check TDC position of piston in cylinder A1 The piston is at firing TDC when the rocker arms at cylinder A1 are unloaded The piston is at overlap TDC when the r...

Page 98: ...I Inlet Inlet valve adjustment admissible X Exhaust Exhaust valve adjustment admissible Valve adjustment not admissible Table 3 Valve clearance settings 4 Use feeler gage to determine the distance between valve bridge and rocker arm 5 Adjust valve clearance if the deviation from the desired value exceeds 0 1 mm Adjusting valve clearance 1 Loosen locknut 1 and unscrew adjusting screw 2 by a few thr...

Page 99: ... to verify that the gage just passes through the gap Result Adjust valve clearance if this is not the case Final steps 1 Remove barring tool Page 87 2 Install cylinder head cover Page 100 3 Install cap MS15019 04E 2016 02 Valve Drive 99 TIM ID 0000000018 006 ...

Page 100: ...rs with 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 surface 3 Check condition of gasket 1 in cylinder head cover 1 4 Replace damaged gasket s 1 5 Install cylinder head cover 2 with screws 4 and washers 3 Final steps 1 Slide rubber sleeves onto...

Page 101: ...acement Special tools Material Spare parts Designation Use Part No Qty Injection pump Spare Parts Catalog Injection pump Replacement u Remove injection pump and install new one Page 102 MS15019 04E 2016 02 Injection Pump HP Pump 101 TIM ID 0000000020 004 ...

Page 102: ...nd moving engine parts Risk of crushing danger of parts of the body being caught or pulled in Before cranking the engine with starter system make sure that there are no persons in 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 smoke Wear protective clothing protective gloves and safety ...

Page 103: ...6 Remove injection pump 7 Remove sealing rings from injection pump 8 After removal seal all openings with suitable covers Installing injection pump 1 Remove all blanking plugs and covers 2 Clean mating face of injection pump and roll er Note Sealing ring 1 Ø47 mm 3 Coat sealing ring 1 with assembly com pound and fit onto injection pump Note Sealing ring 2 Ø45 mm 4 Coat sealing ring 2 with assembly...

Page 104: ...3 Tighten union nuts 2 and 4 marked with 30 3 Nm see arrow to specified torque using a torque wrench Name Size Type Lubricant Value Standard Union nut M14 Tightening torque Engine oil 30 Nm 3 Nm 14 Install injection pump cabling 1 15 Tighten screws to specified torque using a torque wrench Name Size Type Lubricant Value Standard Screw Tightening torque Engine oil 1 5 Nm 0 2 Nm Final steps 1 Remove...

Page 105: ...Replacement Special tools Material Spare parts Designation Use Part No Qty Injector Spare Parts Catalog Replacing injector u Remove injector and install new injector Page 106 MS15019 04E 2016 02 Injection Valve Injector 105 TIM ID 0000000022 016 ...

Page 106: ... Spare Parts Catalog WARNING Fuels 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 protection WARNING Compressed air gun ejects a jet of pressurized air Risk of injury to eyes and damage to hearing risk of rupturing internal organs Never direct air jet...

Page 107: ...ew 2 4 Pull off pressure pipe neck 3 5 Extract fuel from the exposed bores using the suction device 6 Remove sealing ring from pressure pipe neck 3 7 Remove screw 1 8 Take off clamp 2 9 Screw puller into injector 10 Remove injector with puller MS15019 04E 2016 02 Injection Valve Injector 107 TIM ID 0000000023 005 ...

Page 108: ...from cylinder head with screwdriver 14 Remove sealing ring Installing injector 1 Remove all covers before installation 2 Clean sealing surface on cylinder head and protective sleeve 3 Coat sealing ring with grease and insert in groove of sealing cap 4 Insert sealing cap in bore 108 Injection Valve Injector MS15019 04E 2016 02 TIM ID 0000000023 005 ...

Page 109: ...on the injector is engaged in the groove of the clamp 2 Forked clamp end 2 is engaged in the cover recess 10 Tighten screw 3 of the clamp by hand Result Injector can still be turned 11 Blow out fuel line 2 and pressure pipe neck 5 with compressed air 12 Coat sealing ring with assembly compound and fit onto pressure pipe neck 5 13 Coat the taper of the pressure pipe neck 5 with engine oil 14 Insert...

Page 110: ...tion pump hand tight 22 Tighten union nut 3 on pressure pipe neck 5 hand tight Note Observe the lettering on the union nuts 1 and 3 23 Tighten union nuts 1 and 3 marked with 35 3 Nm see arrows to specified torque using a torque wrench Name Size Type Lubricant Value Standard Union nut M14 Tightening torque Engine oil 35 Nm 3 Nm 24 Tighten union nuts 1 and 3 marked with 30 3 Nm see arrows to specifi...

Page 111: ...Catalog WARNING Fuels 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 protection WARNING Compressed air gun ejects a jet of pressurized air Risk of injury to eyes and damage to hearing risk of rupturing internal organs Never direct air jet at people Al...

Page 112: ...ne oil 12 Connect fuel line 2 to injection pump and pressure pipe neck 5 13 Tighten union nut 1 on injection pump hand tight 14 Tighten union nut 3 on pressure pipe neck 5 hand tight Note Observe the tightening torque according to the lettering on the union nuts 1 and 3 15 Tighten union nuts 1 marked with 35 3 Nm see arrows with torque wrench to the specified tightening torque Name Size Type Lubri...

Page 113: ...eck gaskets for damage and replace them if required 3 Coat gaskets with grease and place onto cylinder head 4 Install charge air pipes 5 Install engine governor Page 157 6 Open fuel supply line 7 Vent fuel system Page 117 MS15019 04E 2016 02 Fuel System 113 TIM ID 0000000024 005 ...

Page 114: ...e 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 protection Draining fuel 1 Loosen nut arrowed on banjo union 2 Disconnect fuel line on non return valve ar rowed 3 Remove non return valve and collect emerg ing fuel in a suitable container 114 Fuel System ...

Page 115: ...and tighten to specified torque using a torque wrench Name Size Type Lubricant Value Standard Non return valve Tightening torque Engine oil 10 Nm 1 Nm 5 Install fuel line 6 Tighten nut on banjo union MS15019 04E 2016 02 Fuel System 115 TIM ID 0000000025 004 ...

Page 116: ...nd explosion Avoid open flames electrical sparks and ignition sources Do not smoke Wear protective clothing protective gloves and safety glasses facial protection Removing and installing pres sure relief valve 1 Close fuel supply 2 Remove fuel line 6 3 Remove banjo screws 1 and 4 4 Remove sealing rings 2 and 5 5 Remove screws 9 with washer 8 6 Remove screws 7 and take off holder 7 Install new pres...

Page 117: ...nd explosion Avoid open flames electrical sparks and ignition sources Do not smoke Wear protective clothing protective gloves and safety glasses facial protection Venting fuel system 1 Unlock fuel priming pump unscrew handle 2 Loosen nut arrowed on banjo union 3 Operate the pump with the handle until bub ble free fuel emerges 4 Tighten nut on banjo union MS15019 04E 2016 02 Fuel System 117 TIM ID ...

Page 118: ... arrowed 10 Operate the pump with the handle until bub ble free fuel emerges 11 Tighten non return valve to specified torque using a torque wrench Name Size Type Lubricant Value Standard Non return valve Tightening torque Engine oil 10 Nm 1 Nm 12 Tighten union nut of fuel return line 13 Lock fuel priming pump screw in handle 118 Fuel System MS15019 04E 2016 02 TIM ID 0000000026 003 ...

Page 119: ...ive 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 protection Replacing fuel filter 1 Remove easy change filter using the filter wrench 2 Clean the sealing surface on the bracket 3 Fill the new easy change filter with clean fuel 4 Install and tighten easy change filter by hand 5 V...

Page 120: ...r of dif ferential pressure gage 1 After installation of a new filter element Align adjustable pointer 2 with pressure indicat ing pointer 3 of pressure gage 1 2 Verify that differential pressure is within the limit Fuel prefilter Checking differential pressure 1 With the engine running at full load or rated power read off pressure at gage 1 2 If differential pressure as indicated between position...

Page 121: ...eep 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 smoke Wear protective clothing protective gloves and safety glasses facial protection WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Fuel prefilter Draining Note Onl...

Page 122: ...ose drain valve 6 6 Remove screws securing the cover and take off cover 2 7 Fill filter housing with clean fuel 8 Place new seal in cover 2 9 Fit cover with seal and secure it with screws Note Only in the case of double fuel prefilter 10 Cut in the cut out filter again 11 When fuel emerges from system close threaded vent plug 5 122 Fuel Filter MS15019 04E 2016 02 TIM ID 0000004929 008 ...

Page 123: ...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 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 induce vomiting Do...

Page 124: ...tered side flushing the filter deposits down wards out of the filter 4 Close threaded vent plug 5 and drain valve 6 Fuel prefilter Filling with fuel 1 Remove screws securing cover and take off cover 2 2 Fill filter housing with clean fuel 3 Place new seal in cover 2 4 Fit cover with seal and secure it with screws 5 Check differential pressure Page 120 Result If flushing did not lead to an improvem...

Page 125: ... safety glasses facial protection Cleaning fuel prefilter 1 Close fuel supply 2 Remove nuts from filter head 3 Unscrew filter bowl and drain fuel into a suit able container 4 Remove securing nut for filter element and pull off filter element downwards 5 Use a soft brush to wash filter element in clean fuel 6 Wash filter bowl with clean fuel 7 Insert filter element in filter head and secure with nu...

Page 126: ...og Gasket Spare Parts Catalog WARNING Fuels 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 protection Replacing filter element 1 Switch off filter to be drained 1 Left filter cut in 2 Right filter cut in 126 Fuel Filter MS15019 04E 2016 02 TIM ID 0000...

Page 127: ...ove spring housing 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 12 Cut in the cut out filter again 13 Close threaded vent plug 5 when fuel emerges 14 Set adjustable pointer of differential pressure display instrument Page 120 MS15019 04E 2016 02 Fue...

Page 128: ...s Checking 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 blow out with compressed air 4 More significant coolant leakage indicates a leaking charge air cooler Contact Service 5 Install plug screw s with new sealing ring and tighten Emergency measur...

Page 129: ...e Part 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 130 2 Reset signal ring of service indicator Page 131 MS15019 04E 2016 02 Air Filter 129 TIM ID 0000013385 002 ...

Page 130: ...ge of the intake housing 3 and clean it 4 Fit air filter 1 and clamp 2 on connecting flange of intake housing 3 5 Tighten clamp 2 Variant B 1 Release latches 1 2 Take off cover 2 3 Remove filter insert 3 and filter element 4 4 Wipe out filter housing 5 and cover 2 with moist cloth 5 Insert new filter element 4 and filter in sert 3 6 For installation follow reverse sequence of working steps 130 Air...

Page 131: ...isabled Checking signal ring position 1 Replace air filter if the signal ring 2 is com pletely visible in the red area of the observa tion window 3 Page 129 2 After installation of new filter press reset button 1 Result Signal ring returns to initial position MS15019 04E 2016 02 Air Intake 131 TIM ID 0000000985 004 ...

Page 132: ...tem 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 protectors Air starter Manual operation 1 Press pushbutton for manual start arrow and hold 2 Allow compressed air to enter the starter un til the engine fires evenly 3 Release pushbutton 132 Starting Equipment MS15019 04E 2016 02 TIM I...

Page 133: ... 4 Top up with oil up to the max 1 mark Page 134 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 engine remove oil dipstick from the guide tube and wipe it 2 Insert oil dipstick into guide tube up to the stop withdraw after approx 10 seconds and check oil level 3 Oil level must be between min and max marks ...

Page 134: ...p 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 135 Oil change with semirotary hand pump Oil extraction 1 Provide a suitable container to collect the oil 2 Extract all oil from oil pan using the semirotary hand pump 3 Replace engine oil filter Page...

Page 135: ...ear 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 face on the adapter 3 Check condition of the new sealing ring and coat it with oil 4 Screw on and tighten new engine oil filter by hand 5 Replace other engine oil filters in the same way 6 After each oil chan...

Page 136: ...ion 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 the lower edge of the cast in eye or at the marking plate 4 Top up with treated coolant as necessary Page 139 5 Check and clean breather valve 6 Place breather valve on filler neck and close Coolant level check by m...

Page 137: ...s Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 138 2 Fill with engine coolant Page 139 MS15019 04E 2016 02 Coolant Circuit General High Temperature Circuit 137 TIM ID 0000000036 031 ...

Page 138: ...ting unit Engine coolant Draining 1 Turn 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 corrosion inhibitor oil from the expansion tank through filler neck 4 Open drain valves and or drain plugs and drain coolant at the following points At the preheating ...

Page 139: ...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 tank counterclockwise to the first stop and allow pressure to escape 2 Continue to turn breather valve 1 counter clockwise and remove Engine coolant Filling 1 Fill coolant through filler neck on expansion tank or ...

Page 140: ...art the engine and operate it at idle speed for some minutes 2 Check coolant level Page 136 top up with coolant if required 140 Coolant Circuit General High Temperature Circuit MS15019 04E 2016 02 TIM ID 0000000034 008 ...

Page 141: ...Relief bore check 1 Check relief bore for oil and coolant dis charge 2 Permissible discharge Up to 10 drops of coolant per hour Up to 5 drops of oil per hour 3 If discharge exceeds the specified limits con tact Service 4 If relief bore is dirty a Stop engine Page 55 and disable en gine start b Clean relief bore with a wire c Start engine Page 52 and operate it at idle speed for some minutes d Chec...

Page 142: ...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 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 allow pressure to...

Page 143: ...late 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 Start the engine and operate it at idle speed for some minutes 2 Check coolant level Page 146 MS15019 04E 2016 02 Low Temperature Circuit 143 TIM ID 0000000039 006 ...

Page 144: ...ate 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 wise and remove 4 Draw off precipitated corrosion inhibitor oil from the expansion tank through filler neck 5 Open drain plugs and drain coolant at the fol lowing points At the charge air coolant pump ...

Page 145: ...ial 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 MS15019 04E 2016 02 Low Temperature Circuit 145 TIM ID 0000000041 011 ...

Page 146: ...w 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 necessary Page 142 5 Check that cap is in serviceable condition 6 Clean sealing surfaces as necessary 7 Fit cap and close tight Checking charge air coolant level by means of level sensor Note Coolant level is...

Page 147: ...7429 1 Torque wrench 20 100 Nm F30026582 1 Ratchet adapter F30027340 1 Engine oil Preparatory steps u Remove protective cover Drive belt Condition check u Visually inspect condition of drive belt Item Findings Action Drive belt A Singular cracks None Drive belt B Cracks on entire circumference Replace Page 149 Drive belt C Chunking Drive belt Belt is oily shows signs of over heating MS15019 04E 20...

Page 148: ...e below Application Specified value new drive belt Specified value used drive belt Battery charging generator drive belt 450 N 50 N 350 N 50 N 6 If the measured value does not correspond to the specified measured value adjust the drive belt tension Adjusting drive belt tension 1 Release screws 2 3 2 Tension drive belt with tensioning nut 1 and check belt tension 3 Tighten screw 2 to specified torq...

Page 149: ...an drive Page 153 3 Undo securing screws 2 and 3 4 Release tensioning nut 1 until the drive belt can be removed 5 Check belt pulleys for cleanliness remove dirt if any 6 Fit new drive belt 7 Tension drive belt with tensioning nut 1 and check belt tension Page 147 8 Tighten securing screw 2 to specified torque using a torque wrench Name Size Type Lubricant Value Standard Screw M18 Tightening torque...

Page 150: ... check var iant A 1 Place belt tension tester onto drive midway between the belt pulleys arrowed 2 Actuate pushbutton to press the tester uni formly on the drive belt surface until the spring disengages 3 Do not press any further otherwise the dis play value will be falsified 4 Take off belt tension tester without changing the position of the indication arm 5 Read off measured value at the interse...

Page 151: ...ale The speci fied values are listed in the table below Application Specified value new drive belt Specified value used drive belt Drive belt of fan drive 670 N 50 N 570 N 50 N 6 If the measured value does not correspond to the specified measured value adjust the drive belt tension Drive belt Tension adjustment variant A 1 Release screws 3 2 Release locknut 2 3 Screw in screw 1 to tension drive be...

Page 152: ...z 2 Screw in screw 2 to tension drive belt 3 Check drive belt tension 4 Tighten screws 1 and 4 to specified torque using a torque wrench Name Size Type Lubricant Value Standard Screw M18 Tightening torque Engine oil 69 Nm 5 Check drive belt tension Final steps u Install protective cover 152 Fan Drive MS15019 04E 2016 02 TIM ID 0000000045 006 ...

Page 153: ...without applying any force 5 Fit new set of drive belts 6 To check drive tension the fan bearing ped estal must rest against the gearcase 7 Adjust and check drive belt tension Page 150 Drive belt replacement variant B 1 Release securing screws 1 4 2 Unscrew tensioning screw 2 with bolt 3 until the drive belts can be removed 3 Check belt pulley on fan bearing pedestal and crankshaft for contaminati...

Page 154: ...d 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 Connector housings Contacts Plug connectors Cables and terminals Plug in contacts Result If cable conductors are damaged contact Service Note Close connectors that are not plugged in with the protective cap su...

Page 155: ...opropyl 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 replace illegible labels Heavily contaminated connectors on engine governor Cleaning Note Close connectors that are not plugged in with the protective cap supplied 1 Release latches of connectors and withdraw connectors ...

Page 156: ...d 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 connections for secure seating 2 Lock loose connectors 3 Check dust cap on ECU and EXU connectors for damage and correct seating 156 Accessories for Electronic Engine Governor Control System MS15019 04E 2016 02 TIM ID 000000004...

Page 157: ...gine governor from engine 1 Note or mark assignment of cables and plugs 2 Remove all screws 3 3 Undo clips 2 on connectors 4 Remove all male connectors 5 Remove screws 1 6 Take off engine governor Installing engine governor on engine 1 Install in reverse order Ensure correct assignment of plugs and sockets 2 Check resilient mount before installing Result If resilient mount is porous or defective t...

Page 158: ...ches Institut für Normung e V At the same time identifier of German standards DIN Deutsche Industrie Norm DIS Display unit DL Default Lost Alarm CAN bus missing ECS Engine Control System ECS UNI Engine Control System UNIversal ECU Engine Control Unit Engine governor EDM Engine Data Module EMU Engine Monitoring Unit ETK Ersatzteilkatalog Spare Parts Catalog SPC FPP Fixed Pitch Propeller GCU Gear Co...

Page 159: ...G Main Reduction Gear OT Oberer Totpunkt Top Dead Center TDC P xyz Pressure xyz Pressure measuring point xyz PAN Panel Control panel PCU Propeller Control Unit PIM Peripheral Interface Module PT Power Turbine RCS Remote Control System RL Redundancy Lost Alarm Redundant CAN bus missing SAE Society of Automotive Engineers U S standardization organization SAT Sea Acceptance Test SD Sensor Defect Alar...

Page 160: ...planation WZK Werkzeugkatalog Tool Catalog TC ZKP Zugehörigkeit Kategorie Parameter Assignment category parameter number scheme for signals from the ADEC engine governor 160 Appendix A MS15019 04E 2016 02 TIM ID 0000002049 005 ...

Page 161: ...e of a malfunction for information on changes in conditions of use and for supplying spare parts Your contact person in our Customer Assistance Center E mail info mtu online com Tel 49 7541 9077777 Fax 49 7541 9077778 Asia Pacific 65 6100 2688 North and Latin America 1 248 560 8000 Spare Parts Service Fast simple and correct identification of spare parts for your drive system or vehicle fleet The ...

Page 162: ...and installation Page 106 Qty Used in 1 8 7 1 Fuel injection line Pressure pipe neck replacement Page 111 Barring device for 12V engines Part No F6558556 Qty Used in 1 8 1 1 Engine Barring manually Page 87 Barring device for 16V 18V engines Part No F6558557 Qty Used in 1 8 1 1 Engine Barring manually Page 87 162 Appendix B MS15019 04E 2016 02 DCL ID 0000014859 005 ...

Page 163: ... Used in 1 8 18 1 Fan drive Drive belt check and adjustment Page 150 Belt tension tester 150 600 N Part No Y20097429 Qty Used in 1 8 17 1 Battery charging generator drive Drive belt check and adjustment Page 147 Crossbeam Part No T80092210 Qty Used in 1 2 1 Transportation Page 16 MS15019 04E 2016 02 Special Tools 163 DCL ID 0000014859 005 ...

Page 164: ...ion pump Removal and installation Page 102 Qty Used in 1 8 6 2 Injector Removal and installation Page 106 Qty Used in 1 8 7 1 Fuel injection line Pressure pipe neck replacement Page 111 Double head box wrench Part No F30011450 Qty Used in 1 8 6 2 Injector Removal and installation Page 106 Qty Used in 1 8 7 1 Fuel injection line Pressure pipe neck replacement Page 111 Feeler gage Part No Y4342013 Q...

Page 165: ...in 1 8 6 2 Injector Removal and installation Page 106 Open end socket wrench 19 mm Part No F30025897 Qty Used in 1 8 6 2 Injector Removal and installation Page 106 Qty Used in 1 8 7 1 Fuel injection line Pressure pipe neck replacement Page 111 Plug in open end wrench 17 mm Part No F30028341 Qty Used in 1 8 7 2 Fuel Draining Page 114 MS15019 04E 2016 02 Special Tools 165 DCL ID 0000014859 005 ...

Page 166: ...d installation Page 100 Qty Used in 1 8 5 2 Injection pump Removal and installation Page 102 Qty Used in 1 8 6 2 Injector Removal and installation Page 106 Qty Used in 1 8 7 1 Fuel injection line Pressure pipe neck replacement Page 111 Qty Used in 1 8 17 1 Battery charging generator drive Drive belt check and adjustment Page 147 Qty Used in 1 8 17 2 Battery charging generator drive Drive belt re p...

Page 167: ... Used in 1 8 5 2 Injection pump Removal and installation Page 102 Qty Used in 1 8 6 2 Injector Removal and installation Page 106 Qty Used in 1 8 7 1 Fuel injection line Pressure pipe neck replacement Page 111 Qty Used in 1 8 17 1 Battery charging generator drive Drive belt check and adjustment Page 147 Qty Used in 1 8 17 2 Battery charging generator drive Drive belt re placement Page 149 Qty Used ...

Page 168: ...Crankcase breather Oil separator replacement di aphragm check and replacement Page 94 Qty Used in 1 8 4 2 Cylinder head cover Removal and installation Page 100 Qty Used in 1 8 7 2 Fuel Draining Page 114 168 Special Tools MS15019 04E 2016 02 DCL ID 0000014859 005 ...

Page 169: ...ination 92 D Differential pressure gage Adjustment Fuel prefilter 120 Check Fuel prefilter 120 Drive belt Condition check 147 150 Replacement 149 Tension adjustment 147 150 Tension check 147 150 E ECU 7 Installation 157 Removal 157 Engine Barring With starting system 88 Barring manually 87 Emergency stop 56 Main dimensions 49 Overview 19 Starting in manual mode test run 52 Stopping in manual mode ...

Page 170: ...ructions Check 128 L Lifting requirements 17 M Maintenance schedule Maintenance task reference table QL1 59 MTU contact persons 161 O Operational checks 54 Overview Engine 19 P Putting the engine into operation after extended out of service periods 3 months 50 Putting the engine into operation after scheduled out of service period 51 S Safety notices standards 15 Safety regulations Auxiliary mater...

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