MTU 12V2000M72 Operating Instructions Manual Download Page 1

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Operating Instructions

Diesel engine

12V2000M72
16V2000M72

M015650/06E

Summary of Contents for 12V2000M72

Page 1: ...Operating Instructions Diesel engine 12V2000M72 16V2000M72 M015650 06E...

Page 2: ...in any way whether in whole or in part without the prior writ ten consent of MTU Friedrichshafen GmbH This particularly applies to its reproduction distribution editing translation micro filming and s...

Page 3: ...el treatment system Switching on 54 5 8 Starting the engine 55 5 9 Re starting the engine following an automatic safety shutdown 56 5 10 Engine Shutdown 57 5 11 Emergency engine shutdown 58 5 12 After...

Page 4: ...Sample extraction and analysis 150 8 16 8 Coolant filter Replacement 151 8 17 Raw Water Pump with Connections 152 8 17 1 Raw water pump Relief bore check 152 8 18 Battery Charging Generator 153 8 18 1...

Page 5: ...are approved by the manufacturer Noncompliance with these specifications will invalidate the design type approval or certification issued by the emissions regulation authorities The manufacturer does...

Page 6: ...following when replacing components with emission labels The relevant emission labels must be affixed to the spare part Emission labels shall not be transferred from the replaced part to the spare par...

Page 7: ...ions contained in this manual in particular with regard to the specified tightening torques With the exclusive use of technical personnel trained in commissioning operation maintenance and re pair The...

Page 8: ...instructed and qualified personnel only Training at the Training Center of the manufacturer Qualified personnel from the areas mechanical engineering plant construction and electrical engineering The...

Page 9: ...ator terminals or cables against accidental contact Check that all connections have been correctly allocated e g polarity fuel line reduction agent line supply return Immediately after putting the pro...

Page 10: ...ids and lubricants immediately or soak up with a suitable binding agent Operation of electrical equipment When electrical equipment is in operation certain components of these appliances are electrica...

Page 11: ...fitted Lock circuit breakers Before starting work on CaPoS if used Switch off the charging system DC DC converter Discharge the UltraCap modules using the appropriate discharger Short circuit the Ult...

Page 12: ...ines near hot components Miscellaneous Sufficient ventilation must be guaranteed during the work Wear a breathing mask offering protection against soot dust and mineral fibers filter class P3 when wor...

Page 13: ...d the pipework at the relevant designated points For hydraulic installation screw on the jig with the piston retracted For hydraulic removal screw on the jig with the piston extended For a hydraulic i...

Page 14: ...rly prior to replacement i e protect them against moisture in particular Package faulty electronic components or assemblies properly before dispatching for repair Moisture proof Shock proof Wrapped in...

Page 15: ...fire extinguishers are always available and that staff are familiar with their correct handling A fire can result in the creation of toxic substances Always wear protective gloves when handling compo...

Page 16: ...ovided with fume extraction systems ensure that the area is well ventilated Make sure that neighboring work areas are not adversely affected Avoid open flames in the surrounding area No smoking Observ...

Page 17: ...Consequences Material damage Remedial action Additional product information Warning notices 1 This manual with all safety instructions and warning notices must be issued to all personnel involved in...

Page 18: ...en weight forklift truck Prior to transporting the engine genset system it is imperative to install the transport locking device for the crankshaft Prior to transporting the engine genset system it is...

Page 19: ...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 20: ...s The triple walled design permits low surface temperature reduced thermal load absolute gas tightness Lube oil system Wet sump forced feed lubrication system Components supplied with oil Bearings Pis...

Page 21: ...als are routed out via M threaded pins and are also integrated in the engine wiring harness Functions ECU supply EMU supply Plant signals ECU7 connector X1 Bus interface 2x MCS5 CAN CAN dialog output...

Page 22: ...unit LOP Functions Engine speed oil pressure and coolant temperature are monitored and displayed Integrated safety system Integrated Test System Redundant CAN bus interface to governor and higher leve...

Page 23: ...utside either with a copper sealing ring 1 according to DIN or an O ring ISO In case of a loose thread or a faulty sealing ring 1 the liquid first has to pass the thread The pressure is so greatly red...

Page 24: ...een distributor and HP accumulator 1 Union nut 2 O ring 3 Thrust ring 4 Thrust screw 5 O ring 6 O ring 7 Thrust ring 8 Pressure pipe 9 Jacket pipe 24 General Information M015650 06E 2018 05 TIM ID 000...

Page 25: ...st screw 7 Thrust ring 8 O ring 9 HP line 10 Pressure pipe Leak off fuel caused by leakages from the sealing cones or the HP lines is returned to the HP pump from where it is routed at atmospheric pre...

Page 26: ...turbocharger left secondary turbocharger 16 Exhaust outlet horizontal 17 Actuating cylinder for ex haust flap 18 Actuating cylinder for air flap 19 Control valve for flap con trol 20 Cylinder head co...

Page 27: ...housing 15 Exhaust system housing 16 Coolant pump 17 Crankcase breather 18 HP fuel pump 19 Fuel delivery pump 20 Oil filler neck 21 Oil dipstick 22 Drive flange 23 Flywheel housing 24 Engine mounting...

Page 28: ...ns are insignificant Also applies similarly to 12V Item Designation Monitoring of 1 B3 Intake air temperature 2 B9 Charge air temperature 3 B7 Lube oil temperature 4 B10 Charge air pressure 5 B44 Turb...

Page 29: ...ssure before filter 3 B5 1 Lube oil pressure after filter 4 B5 2 optional Lube oil pressure after filter 5 F33 Engine coolant level expansion tank 6 B21 optional Raw water pressure 7 B6 2 optional Coo...

Page 30: ...gine driving end Item Designation Monitoring of 1 B1 ECU Camshaft speed 2 B13 2 optional EMU Crankshaft speed 3 B13 ECU Crankshaft speed 30 General Information M015650 06E 2018 05 TIM ID 0000008412 00...

Page 31: ...al control valve 2 YB33 Fuel temperature 3 B48 Fuel pressure in rail 4 B16 optional Coolant pressure 5 F46 Leak fuel level 6 Y27 2 4 2 directional control valve B side 7 B4 22 Exhaust temperature B si...

Page 32: ...side 3 B54 optional Lube oil pressure replenishment pump System sensors These sensors are fitted outside the engine Designation Monitoring of B19 Starting air pressure B70 Fuel prefilter water level B...

Page 33: ...ure C 25 Barometric pressure mbar 1000 Site altitude above sea level m 100 Power related data power ratings are net brake power as per ISO 3046 Number of cylinders 12 Rated engine speed A rpm 2250 Fue...

Page 34: ...ar 0 3 Fuel pressure at engine supply connection max when engine is started L bar 0 25 Fuel supply flow max R Liters mi n 4 6 General operating data Number of cylinders 12 Firing speed from R rpm 100...

Page 35: ...linations L Liters 87 Oil pan capacity at dipstick mark max standard oil system option max operating inclinations L Liters 105 Weights main dimensions Number of cylinders 12 Engine dry weight with sta...

Page 36: ...ometric pressure mbar 1000 Site altitude above sea level m 100 Power related data power ratings are net brake power as per ISO 3046 Number of cylinders 12 Rated engine speed A rpm 2250 Fuel stop power...

Page 37: ...rpm 200 Starting electric Number of cylinders 12 Starter rated voltage standard design R V 24 Inclinations standard oil system reference waterline Number of cylinders 12 Longitudinal inclination conti...

Page 38: ...s main dimensions Number of cylinders 12 Engine dry weight with standard accessories installed without coupling R kg 2770 Acoustics Number of cylinders 12 Exhaust noise unsilenced BL free field sound...

Page 39: ...Barometric pressure mbar 1000 Site altitude above sea level m 100 Power related data power ratings are net brake power as per ISO 3046 Number of cylinders 16 Rated engine speed A rpm 2250 Fuel stop p...

Page 40: ...ar 0 3 Fuel pressure at engine supply connection max when engine is started L bar 0 25 Fuel supply flow max R Liters mi n 6 2 General operating data Number of cylinders 16 Firing speed from R rpm 100...

Page 41: ...inations L Liters 115 Oil pan capacity at dipstick mark max standard oil system option max operating inclinations L Liters 138 Weights main dimensions Number of cylinders 16 Engine dry weight with sta...

Page 42: ...ometric pressure mbar 1000 Site altitude above sea level m 100 Power related data power ratings are net brake power as per ISO 3046 Number of cylinders 16 Rated engine speed A rpm 2250 Fuel stop power...

Page 43: ...rpm 120 Starting electric Number of cylinders 16 Starter rated voltage standard design R V 24 Inclinations standard oil system reference waterline Number of cylinders 16 Longitudinal inclination conti...

Page 44: ...s main dimensions Number of cylinders 16 Engine dry weight with standard accessories installed without coupling R kg 3337 Acoustics Number of cylinders 16 Exhaust noise unsilenced BL free field sound...

Page 45: ...4 5 Firing order 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 M015650 06E 2018 05 Technical Data 45 TIM ID 0000038135 002...

Page 46: ...Main dimensions Engine model Length A Width B Height C 12V2000M72 approx 2078 mm approx 1295 mm approx 1390 mm 16V2000M72 approx 2486 mm approx 1295 mm approx 1390 mm 46 Technical Data M015650 06E 201...

Page 47: ...Fuel prefilter pressure gage Align adjustable pointer with position of pressure indicator Page 118 Fuel system Vent Page 115 Raw water pump if located above waterline Prime approx 3 to 4 liters Filli...

Page 48: ...l Page 145 Coolant circuit If necessary heat up coolant with coolant preheating unit if T 5 C Fuel prefilter Drain water and contaminants Page 119 Battery charging generator drive Check condition of d...

Page 49: ...eks Tasks after extended out of service periods 3 weeks Note Operate fuel treatment system for at least 5 minutes 1 Start up fuel treatment system Page 51 2 Shut down fuel treatment system Page 60 M01...

Page 50: ...ves 4 Switch on fuel treatment system Page 54 5 Check direction of rotation of pump 6 Vent bypass and fuel lines of the system a Open ball valve for pressure tank b Open ball valve for overflow tank c...

Page 51: ...ine 3 Switch on fuel treatment system and operate it for some minutes Page 54 Result Fuel is sucked from the tank dirt particles and water are filtered and separated then the fuel is delivered via the...

Page 52: ...ency HAT 1 Switch on fuel treatment system Page 54 2 Start engine Page 55 3 Run engine at idling speed 4 Switch off pump 21 on switch cabinet Result The engine mounted fuel delivery pump sucks fuel vi...

Page 53: ...ally inspect engine for leaks and general condition Check for abnormal running noises and vibration Check exhaust color Page 63 Fuel prefilter Check if suction side pressure indicated at the fuel pref...

Page 54: ...ore switching on ensure that all housings are closed Before switching on ensure that no work is in progress anywhere on the entire system Fuel treatment system Switching on 1 Carry out checks prior to...

Page 55: ...ear protectors NOTICE Re starting the engine following an automatic safety shutdown Risk of severe engine damage Before starting the engine make sure the root cause of the safety shutdown was eliminat...

Page 56: ...ified or eliminated contact Service Note If an engine has been shutdown by a fault red alarm the engine may only be re started when the fault has been identified and eliminated Procedure following an...

Page 57: ...Risk of overheating damage to components Before shutting down disengage gear and run the engine at idle speed for at least 10 minutes until engine temperatures have dropped and constant values are di...

Page 58: ...n extremely high load Risk of overheating damage to components Trigger an emergency stop only in emergency situations The engine can be stopped from the following points in an emergency Item Action Co...

Page 59: ...and if no antifreeze has been added 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 tem...

Page 60: ...binet until water discharge from the outlet stops 2 Switch off fuel treatment system 3 Close ball valve at the inlet to the fuel treatment system 4 Close ball valve at the outlet of the fuel treatment...

Page 61: ...un directly at seals or electronic components such as connectors or ECUs Cleaning the plant 1 Carry out plant cleaning only in areas where an appropriate oil separator is provided environmental protec...

Page 62: ...tion and tension replace if necessary Page 107 W1005 Replace air filter Page 130 W1006 Replace fuel injectors Page 112 W1008 Replace engine oil filter when changing engine oil or when the interval yea...

Page 63: ...g harness defective fuse lamp on EIM flashes with relevant flashing code u Check fuse replace if required and re start the system by actuating the key switch Running gear blocked engine cannot be barr...

Page 64: ...Corrective action Incorrect coolant concentration u Check MTU test kit Charge air cooler clogged u Contact Service Engine room Air intake temperature too high u Check fans and air supply ventilation...

Page 65: ...lace oil separator element Page 105 Exhaust turbocharger cylinder head piston rings cylinder liner defective u Contact Service White exhaust gas Cause Corrective action Engine is not at operating temp...

Page 66: ...eck fuel cooling system visually 6 Contact Service 4 SS T Fuel PV Number Cause Corrective action The fuel temperature at sensor B33 has violated limit value 2 Fuel temperature is too high An emergency...

Page 67: ...Cause Corrective action The lube oil pressure at sensor B5 1 has violated lower limit value 2 Lube oil pressure is too low An emergency engine shutdown has been initiated 1 Observe any other messages...

Page 68: ...test as per DiaSys description if DiaSys is available 6 Check injectors of conspicuous cylinders on bank B 7 Replace defective injectors Page 112 8 Check and adjust valve clearance Page 108 9 Contact...

Page 69: ...own has been initiated 1 Observe any other messages 2 Restart the engine if the emergency stop was tripped by the engine overspeed test 3 Contact Service if the emergency stop was tripped by the engin...

Page 70: ...t PV Number Cause Corrective action Coolant pressure at sensor B16 has violated lower limit value 1 Coolant pressure is too low 1 Reduce power 2 Observe any other messages 3 Check engine coolant level...

Page 71: ...ges 3 Check engine coolant level Page 145 4 Check coolant and raw water pressure at the LOP 5 Visually check cooling system for leaks 6 Check operation of cooler and fan plant 7 Check relief bore of e...

Page 72: ...83 LO P Fuel Common Rail PV Number Cause Corrective action The HP fuel pressure at sensor B48 1 went below the limit value Fuel pressure is too low 1 Observe any other messages 2 Contact Service 89 SS...

Page 73: ...er limit value 2 1 Check condition of batteries plant 2 Check engine cabling Page 160 3 Check plug connections for engine governor ECU Page 163 4 Check automatic circuit breakers of UPS Technical Desc...

Page 74: ...Lost PV Number Cause Corrective action Connection or communication with a node on CAN bus 2 has failed 1 Observe any other messages 2 Check engine wiring Page 160 3 Disconnect power supply then reconn...

Page 75: ...ber Cause Corrective action CAN bus 1 to MTU automation system e g ECU MAU SAM disrupted or defective 1 Observe any other messages 2 Check engine wiring Page 160 3 Check plug connections for engine go...

Page 76: ...missing 1 Check engine wiring Page 160 2 Contact Service 206 SD T Exhaust A PV Number Cause Corrective action The signal from the exhaust temperature sensor B4 21 in the A side exhaust pipe is faulty...

Page 77: ...ring Page 160 2 Contact Service 220 SD Level Coolant Water PV Number Cause Corrective action The signal from the coolant level sensor F33 is faulty or missing 1 Check engine wiring Page 160 2 Contact...

Page 78: ...160 2 Contact Service 245 SD ECU Power Supply Voltage PV Number Cause Corrective action The signal from the voltage sensor in the ECU is faulty or missing 1 Check engine wiring Page 160 2 Check plug c...

Page 79: ...tion Short circuit fault in the injector wiring for cylinder A4 or injector defective 1 Check wiring of affected injector Page 160 2 Check injector 3 Replace injector Page 112 4 Contact Service 325 AL...

Page 80: ...tion Short circuit fault in the injector wiring for cylinder B1 or injector defective 1 Check wiring of affected injector Page 160 2 Check injector 3 Replace injector Page 112 4 Contact Service 332 AL...

Page 81: ...tion Short circuit fault in the injector wiring for cylinder B6 or injector defective 1 Check wiring of affected injector Page 160 2 Check injector 3 Replace injector Page 112 4 Contact Service 336 AL...

Page 82: ...se Corrective action Disruption fault in injector wiring for cylinder A3 1 Check wiring of affected injector Page 160 2 Check injector 3 Replace injector Page 112 4 Contact Service 344 AL Open Load Cy...

Page 83: ...use Corrective action Disruption fault in injector wiring for cylinder A8 1 Check wiring of affected injector Page 160 2 Check injector 3 Replace injector Page 112 4 Contact Service 351 AL Open Load C...

Page 84: ...use Corrective action Disruption fault in injector wiring to cylinder B5 1 Check wiring of affected injector Page 160 2 Check injector 3 Replace injector Page 112 4 Contact Service 356 AL Open Load Cy...

Page 85: ...Service 363 AL Stop Power Stage PV Number Cause Corrective action Engine emergency stop because the output stage voltage to control the injectors is too low 1 Check power supply plant 2 Check engine w...

Page 86: ...1 Check engine wiring Page 160 2 Contact Service 381 AL Wiring TOP 1 PV Number Cause Corrective action Short circuit or wire break at transistor output 1 plant side TOP 1 1 Check engine wiring Page 1...

Page 87: ...3 3 Contact Service 401 AL Open Load Digital Input 2 PV Number Cause Corrective action Open load detected at digital input 2 of the ECU 1 Check engine wiring Page 160 2 Check plug connections for engi...

Page 88: ...160 2 Check plug connections for engine governor ECU Page 163 3 Contact Service 407 AL Open Load Digital Input 8 PV Number Cause Corrective action Open load detected at digital input 8 of the ECU 1 C...

Page 89: ...engine wiring Page 160 3 Check plug connections for engine governor ECU Page 163 4 Contact Service 413 HIHI U PDU PV Number Cause Corrective action The ECU voltage to control the injectors has violate...

Page 90: ...is equipped with an overload protection If the maximum permissible current consumption is exceeded e g in case of a blockage or dry running the motor protection relay triggers and the pump is switched...

Page 91: ...ls Material Spare parts Designation Use Part No Qty Shield A4 735233000100 10 Shield A5 735233000101 14 Shield A7 735233000103 6 Shield A8 735233000104 2 SOLAS shielding Installation 1 Pinpoint instal...

Page 92: ...mbient temperature Special tools Material Spare parts Designation Use Part No Qty Oil filter shield X00009628 Fuel filter shield X00009654 Installing SOLAS shield on oil fil ter and fuel filter 1 Pinp...

Page 93: ...l information Install SOLAS shielding as per MTN 5233 as a matter of priority Page 91 Free end B side Item Type of shielding Comments 1 Shield A7 On fuel delivery pump 2 Shield A7 On HP fuel pump Free...

Page 94: ...3 Shield A7 Below fuel priming pump Driving end A side Item Type of shielding Comments 1 Shield A5 On air flap 2 Shield A4 On brazed on union 3 Shield A5 On exhaust turbocharger flap 4 Shield A5 On e...

Page 95: ...alve plate Driving end Item Type of shielding Comments 1 Shield A4 Turbocharger lubrication left side 2 Shield A4 Exhaust turbocharger lubrication center Driving end Item Type of shielding Comments 1...

Page 96: ...rger flap 2 Shield A5 Turbocharger flap 3 Shield A4 On brazed on union 4 Shield A5 On air flap 5 Shield A4 To exhaust turbocharger lubrication Driving end B side Item Type of shielding Comments 1 Shie...

Page 97: ...ing end A side Item Type of shielding Comments 1 Shield A5 To flap control Driving end B side Item Type of shielding Comments 1 Shield A5 To flap control M015650 06E 2018 05 SOLAS 97 TIM ID 0000010064...

Page 98: ...t there are no persons in the engine s danger zone After finishing work on the engine make sure that all safety devices are put back in place and all tools are removed from the engine Barring engine m...

Page 99: ...led in Before barring the engine make sure that there are no persons in the engine s danger zone After finishing work on the engine make sure that all safety devices are put back in place and all tool...

Page 100: ...top piston ring and bottom edge of carbon scraper ring First signs of marks left by top piston ring Bright mark on entire circumference Faultless even honing pattern First signs of marks left by lowe...

Page 101: ...epending on findings Do not take any action or carry out a further endoscopic examination as part of maintenance work or contact Service cylinder liner must be replaced Final steps 1 Install injector...

Page 102: ...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 interrup...

Page 103: ...ks are similar A thorough investigation and compliance with the above evaluation criteria allow an unambiguous evaluation To avoid unnecessary disassembly work it is recommended that another inspectio...

Page 104: ...to hearing risk of rupturing internal organs Never direct air jet at people Always wear safety goggles face mask and ear defenders Crankcase breather Cleaning oil pre separator element 1 Remove cover...

Page 105: ...poisoning Allow the product to cool to below 50 C before beginning work Wear protective clothing protective gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Replacing oil...

Page 106: ...hragm 3 on housing 1 5 Install new seal 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...

Page 107: ...nents Never operate the engine without protective covers or safety guards which meet applicable accident prevention regulations Ensure that the safety guards can prevent body parts from being drawn in...

Page 108: ...20 100 Nm F30026582 1 Measuring instrument Y4345888 1 Engine oil Preparatory steps 1 Remove air filter Page 131 2 Remove cylinder head cover Page 111 Positioning piston of cylinder A1 at TDC Note Wit...

Page 109: ...X I I X X X I I Inlet Inlet valve adjustment admissible X Exhaust Exhaust valve adjustment admissible Valve adjustment inadmissible 4 Check gap between valve bridge and rocker arm with valve clearance...

Page 110: ...Final steps 1 Remove barring device 2 Install cylinder head cover Page 111 3 Install air filter Page 131 110 Valve Drive M015650 06E 2018 05 TIM ID 0000050016 003...

Page 111: ...emove air guide housing Removing and installing cylin der head cover 1 Remove screws 1 2 Remove cylinder head cover 2 with gasket from cylinder head 3 Clean installation surface 4 Check condition of g...

Page 112: ...Replacement Special tools Material Spare parts Designation Use Part No Qty Injector Spare Parts Catalog Injector Replacement u Remove injector and install new one Page 113 112 Injection Valve Injecto...

Page 113: ...ector 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 protecti...

Page 114: ...of HP line 5 and injector 1 with engine oil 9 Align injector 1 and HP line 5 with align ment device 10 Connect HP line 5 to HP accumulator and tighten by hand 11 Connect HP line 5 to injector 1 and t...

Page 115: ...and ignition sources Do not smoke Wear protective clothing protective gloves and safety glasses facial protection Venting fuel system 1 Unscrew handle 3 at fuel priming pump 2 2 Open vent plug 1 3 Ope...

Page 116: ...OTICE Damage to component Severe material damage For filter replacement with the engine running operate the engine at low engine load The filter which is to be replaced must be cut out for a brief per...

Page 117: ...ded vent plug old version has two threaded vent plugs 3 Close vent plug 4 Unscrew switched off easy change filter 2 with oil filter wrench 5 Clean sealing surface on filter head 6 Check sealing ring o...

Page 118: ...urn rotary valve 4 into the upright position until it en gages Note The adjustment procedure should be per formed under normal load conditions 2 Align adjustable pointer 3 with pressure in dicating po...

Page 119: ...es 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 wash off w...

Page 120: ...lugs 2 Fuel prefilter with reversible du plex filter Draining 1 Switch off filter which is to be drained A or B 1 Filter A switched off 2 Filter B switched off 2 Loosen threaded vent plug 1 of filter...

Page 121: ...uel until fuel emerges from vent pipe 3 8 Close vent valve 2 9 Open rotary slide valve 4 a little by approx 30 and open vent valve s 2 until fuel emerges from vent pipe 3 10 Close vent valve s 2 11 Tu...

Page 122: ...n 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 wash off with water...

Page 123: ...2 Fuel prefilter with single stage filter Filling 1 Stop engine Page 57 and disable engine start 2 Connect filling pump to filling connection 1 on intake side of filter 3 Loosen threaded vent plug 2 a...

Page 124: ...er to be flushed 3 Remove drain valve 2 and drain fuel Result Fuel flows from filtered side back to unfil tered side flushing filter deposits downwards out of the filter 4 Close threaded vent plug 1 a...

Page 125: ...otary slide valve 4 a little by approx 30 and open vent valve s 2 until fuel emerges from the vent pipe 3 6 Close vent valve s 2 7 Turn rotary slide valve 4 back to locked po sition 8 Check differenti...

Page 126: ...gh inhalation irritation 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 contac...

Page 127: ...er cartridge 4 8 Insert new level monitor 3 and new filter cartridge 4 9 Place new gasket in filter cartridge housing 10 Close filter cartridge housing and tighten screws 2 11 Open fuel shutoff valve...

Page 128: ...cover 7 Remove spring housing 3 and filter element 4 8 Insert new filter element 4 and spring hous ing 3 9 Fill filter housing with clean fuel 10 Place new gasket in cover 11 Fit cover with gasket and...

Page 129: ...Always wear safety goggles face mask and ear defenders Intercooler Checking conden sate drain line for coolant dis charge and obstruction 1 Check drain line for water discharge and ob struction when...

Page 130: ...l Spare parts Designation Use Part No Qty Air filter Spare Parts Catalog Replacing air filter 1 Remove old air filter and install new air filter Page 131 2 Reset signal ring of contamination indicator...

Page 131: ...otective gloves safety goggles respiratory protection etc is to be used NOTICE Stepping or climbing on the genset to perform installation tasks is to be avoided Otherwise there is a risk of component...

Page 132: ...r if opening of the entrance door can be prevented Only operate the engine with installed air filters Never open air carrying components during operation Ensure that the engine room is well ventilated...

Page 133: ...ions Engine is stopped and starting disabled Starter Condition check 1 Check securing screws of starter and nut on cable connection for secure seating and tighten if required 2 Check cabling Page 160...

Page 134: ...Top up with oil up to the max 1 mark Page 135 if required 5 Insert oil dipstick into guide tube up to the stop Checking engine oil level after engine has stopped 1 5 minutes after stopping the engine...

Page 135: ...rotective gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Version with extraction equipment Engine oil extraction 1 Position a suitable container to drain engine oil int...

Page 136: ...ngine noise when the engine is running Risk of damage to hearing Wear ear protectors WARNING Oil is hot Oil can contain residue substances which are harmful to health Risk of injury and poisoning Allo...

Page 137: ...er oil filters in the same way 9 Switch filter to normal position 10 After each oil change and filter replacement crank engine with starting system Page 99 11 Check oil level Page 134 Oil filter repla...

Page 138: ...ct air jet at people Always wear safety goggles face mask and ear defenders Centrifugal oil filter Cleaning and filter sleeve replacement 1 Loosen nuts 4 crosswise 2 Remove housing cover 1 3 Carefully...

Page 139: ...andard 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 Standard...

Page 140: ...ture Circuit 8 16 1 Draining and venting points Figures also apply similarly to 12V and 16V Plan view 1 Overflow line expansion tank 2 Filler neck 140 Coolant Circuit General High Temperature Circuit...

Page 141: ...coolant drain plug 3 Raw water pump filling plug 4 Measuring point pressure before raw water pump 5 Raw water pump drain plug 6 Connection Oil extraction M015650 06E 2018 05 Coolant Circuit General Hi...

Page 142: ...Left side 1 Engine coolant drain plug 2 Engine coolant drain plug M14x1 5 142 Coolant Circuit General High Temperature Circuit M015650 06E 2018 05 TIM ID 0000038198 003...

Page 143: ...1 5 2 Oil filler neck connection on left or right engine se lectable 3 Oil dipstick connection on left or right engine selecta ble 4 Leak fuel tank M015650 06E 2018 05 Coolant Circuit General High Tem...

Page 144: ...Driving end KS 1 Engine coolant drain plug 2 Connection Oil extraction 144 Coolant Circuit General High Temperature Circuit M015650 06E 2018 05 TIM ID 0000038198 003...

Page 145: ...terclockwise until the first stop and allow pressure to escape 2 Continue to turn breather valve counterclock wise and remove Note Coolant must be visible at the lower edge of the cast in eye of the f...

Page 146: ...Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 147 2 Fill with engine coolant Page 148 146 Coolant Circuit General High Temperature Circuit...

Page 147: ...eheating unit Draining engine coolant 1 Turn breather valve of filler neck on coolant expansion tank Page 140 counterclockwise to first stop and allow pressure to escape 2 Continue to turn breather va...

Page 148: ...engine Fill top up coolant only into cold engine Filling with engine coolant 1 Turn breather valve of coolant expansion tank Page 26 counterclockwise until the first stop and allow pressure to escape...

Page 149: ...High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors HT coolant pump Relief bore check 1 Check relief bore 1 for oil and coolant dis charge Result No flu...

Page 150: ...Page 140 counterclockwise until the first stop and allow pressure to escape 2 Continue to turn breather valve counterclockwise and remove 3 Draw off precipitated corrosion inhibitor oil from expansion...

Page 151: ...mask Replacing coolant filter 1 Turn breather valve of coolant expansion tank counterclockwise Page 26 to the first stop and allow pressure to escape 2 Continue to turn breather valve counterclock wi...

Page 152: ...zone of the engine WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Raw water pump Relief bore check 1 Check relief bore 1 for oil and coolan...

Page 153: ...rive belt Replacement 1 Counterhold adjusting lever at square 1 2 Rotate adjusting lever until drive belt is re leased 3 Secure adjusting lever with screwdriver 2 4 Remove drive belt 5 Check cleanness...

Page 154: ...System 8 19 1 Water drain valve Check Water drain valve Check 1 Open water drain valve 2 Check water outlet for obstructions 3 Close water drain valve 154 Fuel Supply System M015650 06E 2018 05 TIM I...

Page 155: ...Wear protective clothing protective gloves and safety glasses facial protection Checking differential pressure gage alarm function 1 Switch on fuel treatment system Page 54 2 Set the alarm points at...

Page 156: ...om water level probe 2 Unscrew water level probe 3 Disconnect plug from water level probe 4 Immerse water level probe into a tank filled with water until water level reaches the thread 5 Switch on pla...

Page 157: ...he outlet of the fuel treatment system c Check pressure at the pressure gauge in the inlet to the fuel treatment system and note down 3 Checking pump pressure with reduced suction a Reduce suction pre...

Page 158: ...leanliness NOTICE Incorrect installation of components and lines Damage to component Ensure that components lines are installed so that they are never under tension or strain Ensure correct installati...

Page 159: ...ng torque Engine oil 30 Nm 3 Nm 17 Fit seal 10 18 Install cover 19 Install screws 1 washers 2 and nuts 9 20 Tighten nuts 9 21 Open ball valve at the inlet and outlet of the fuel treatment system Resul...

Page 160: ...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...

Page 161: ...propyl 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 lab...

Page 162: ...e coarse dirt from housing surface using a cloth moistened with isopropyl alcohol 2 Remove dirt from the connector and cable surfaces with isopropyl alcohol 3 Check legibility of cable labels Clean or...

Page 163: ...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 seati...

Page 164: ...king EMU plug connections 1 Check both connectors on EMU 2 for firm seating Ensure that the clips 1 are engag ed 2 Check screws 3 of cable clamps on EMU 2 for firm seating Ensure that cable clamps are...

Page 165: ...EIM plug connections 1 Check both Tyco plugs 62 pole 2 on EIM for firm seating Ensure that clips 3 are en gaged 2 Check screws 1 of cable clamps on EIM for firm seating Ensure that cable clamps are n...

Page 166: ...ctors 2 b Unplug connector 2 3 Switch on power supply Result The Engine Control Unit is operable if the diagnostic lamp 1 changes to continuous illumination within 30 seconds after power has been swit...

Page 167: ...ine 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 Inst...

Page 168: ...Unit 1 with Engine Monitoring Unit 4 Removing Engine Monitoring Unit 1 Unscrew screws on base of Engine Monitoring Unit 4 2 Remove Engine Monitoring Unit 4 with Engine Control Unit 1 Installing Engin...

Page 169: ...so observe correct assignment between cables and connectors 2 Check seal before installing Result Replace seal if porous or defective Downloading software 1 The new EIM 2 still does not have appropri...

Page 170: ...ion 4 Application loader active 5 External RAM defective 6 External FLASH defective 7 No firmware 8 Application crashed Fuse lamp SILA A second indicator is the fuse lamp This is also integrated in th...

Page 171: ...10 Emergency stop current path failed 24 V internal S9 11 ES pushbutton current path failed 24 V external S10 12 Key switch current path failed S11 13 SDAF 1 and 2 current path failed S12 14 PIM curr...

Page 172: ...e 1 2 second steps Note These bit patterns are continuously transmitted The CAN message Status of internal power supply also contains information on the current path states of the EIM 2 172 Accessorie...

Page 173: ...panel DL Default Lost Alarm Default CAN bus failure ECS Engine Control System Engine management system ECU Engine Control Unit Engine governor EDM Engine Data Module Memory module for engine data EIM...

Page 174: ...OT Oberer Totpunkt Top Dead Center P xyz Pressure xyz Pressure measuring point xyz PAN Panel Control panel PCU Propeller Control Unit Propeller controller PIM Peripheral Interface Module RCS Remote C...

Page 175: ...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...

Page 176: ...r Removal and installation Page 113 Angular screw driver Part No F30453001 Qty Used in 1 8 6 1 Valve clearance Check and adjustment Page 108 Barring tool Part No F6555766 Qty Used in 1 8 3 1 Cylinder...

Page 177: ...in 1 8 6 2 Cylinder head cover Removal and installation Page 111 Double head box wrench Part No F30002800 Qty Used in 1 8 6 1 Valve clearance Check and adjustment Page 108 Double head box wrench Part...

Page 178: ...n 1 8 2 1 Engine Barring manually Page 98 Qty Used in 1 8 6 1 Valve clearance Check and adjustment Page 108 High pressure cleaner Part No Qty Used in 1 5 14 Plant Cleaning Page 61 Measuring instrument...

Page 179: ...ement Page 116 Qty Used in 1 8 15 1 Engine oil filter Replacement Page 136 Qty Used in 1 8 16 8 Coolant filter Replacement Page 151 Open end wrench bit Part No F30025897 Qty Used in 1 8 7 2 Injector R...

Page 180: ...105 Qty Used in 1 8 19 5 Coalescer filter element Replacement Page 158 Ratchet with extension Part No F30006212 Qty Used in 1 8 2 1 Engine Barring manually Page 98 Qty Used in 1 8 3 1 Cylinder liner...

Page 181: ...Qty Used in 1 8 6 2 Cylinder head cover Removal and installation Page 111 Torque wrench 8 40 Nm Part No F30043446 Qty Used in 1 8 4 2 Crankcase breather Oil separator replacement di aphragm check and...

Page 182: ...Valve clearance gage Part No Y4345893 Qty Used in 1 8 6 1 Valve clearance Check and adjustment Page 108 182 Special Tools M015650 06E 2018 05 DCL ID 0000014355 005...

Page 183: ...Replacement 151 Coolant pump Check Relief bore 149 Crankcase breather Diaphragm check 105 Oil pre separator element Cleaning 104 Oil separator element replacement 105 Cylinder Designation 19 Cylinder...

Page 184: ...119 Filter element Replacement 126 Flushing 122 Fuel prefilter with water separator Differential pressure gage Adjustment 118 Check 118 Fuel system Venting 115 Fuel treatment system Putting into oper...

Page 185: ...tion 92 Installation locations 93 SOLAS shielding as per MTN 5233 Installation 91 Spare parts service 175 Starter Condition check 133 Startup After extended out of service periods 3 months 47 Putting...

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MTU 12V2000M72, Operating Instructions Manual

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