MTU 12V2000M84 Operating Instructions Manual Download Page 146

Page: 146 / 151

Ratchet adapter

Part No.:

F30027340

Qty.:
Used in:

1
8.4.2 Crankcase breather – Oil separator replacement, di-
aphragm check and replacement (→ Page 74)

Qty.:
Used in:

1
8.19.5 Coalescer filter element – Replacement
(→ Page 124)

Ratchet with extension

Part No.:

F30006212

Qty.:
Used in:

1
8.2.1 Engine – Barring manually (→ Page 67)

Qty.:
Used in:

1
8.5.1 Valve clearance – Check and adjustment
(→ Page 76)

Rigid endoscope

Part No.:

Y20097353

Qty.:
Used in:

1
8.3.1 Cylinder liner – Endoscopic examination (→ Page 69)

Socket wrench

Part No.:

F30030450

Qty.:
Used in:

1
8.5.1 Valve clearance – Check and adjustment
(→ Page 76)

146 | Special Tools | MS150063/03E 2016-02

DCL-ID: 0000016266 - 003

Summary of Contents for 12V2000M84

Page 1: ...Operating Instructions Diesel engine 12V2000M84 16V2000M84 MS150063 03E...

Page 2: ...used 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...

Page 3: ...Fuel treatment system Shutdown 53 5 13 Plant Cleaning 54 6 Maintenance 6 1 Maintenance task reference table QL1 55 7 Troubleshooting 7 1 Fuel treatment system Troubleshooting 56 7 2 Troubleshooting 5...

Page 4: ...118 8 18 Battery Charging Generator 119 8 18 1 Battery charging generator drive Drive belt replacement 119 8 19 Fuel Supply System 120 8 19 1 Water drain valve Check 120 8 19 2 Differential pressure g...

Page 5: ...cesses 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 componen...

Page 6: ...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 autho...

Page 7: ...e 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 person...

Page 8: ...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...

Page 9: ...Follow the applicable warning instructions pertaining to such devices MS150063 03E 2016 02 Safety 9 TIM ID 0000040533 012...

Page 10: ...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 pi...

Page 11: ...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 electron...

Page 12: ...h 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 o...

Page 13: ...ully 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...

Page 14: ...rrying 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 m...

Page 15: ...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...

Page 16: ...slowly The lifting ropes or chains must not rub against the engine or its compo nents during the lifting procedure Readjust lifting equipment as necessary 7 For special packaging with aluminum foil A...

Page 17: ...and appliances Never stand beneath a suspended load 1 Max admissible diagonal pull 35 2 Max admissible diagonal pull 10 3 Center of gravity Take note of the engine center of gravity For details on eng...

Page 18: ...hipping lock 1 Undo nuts 4 on all outer rings of resilient mount 1 then unscrew and remove locking screw 2 with washers 3 and nut 4 4 x on each mount 2 Following removal store parts 2 3 4 of the shipp...

Page 19: ...nated in accordance with DIN ISO 1204 as viewed from driving end 4 For cylinder designation in accordance with DIN ISO 1204 the letter Ax refers to the cylinders on the left hand side of the engine 1...

Page 20: ...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 Pist...

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: ...nit 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 level...

Page 23: ...tside 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 redu...

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 MS150063 03E 2016 02 TIM ID 00...

Page 25: ...t 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 pres...

Page 26: ...pment 11 Exhaust turbocharger 12 Carrier housing 13 Actuating cylinder for ex haust flap 14 Cylinder head cover 15 Engine mounting 16 Oil pan 17 Battery charging generator 18 Coolant filler neck 19 En...

Page 27: ...ing lower sec tion 10 Carrier housing middle sec tion 11 Bleeder valve 12 Exhaust outlet KS Driving end Engine model designation Key to the engine model designations 12V 16V2000Mxyz 12 16 Number of cy...

Page 28: ...s 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 Turbo...

Page 29: ...sure 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 Cool...

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 MS150063 03E 2016 02 TIM ID 0000008412 0...

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: ...up 1D Intake air temperature C 25 Raw water inlet temperature 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 304...

Page 34: ...l operating pressure before engine from R bar 7 5 Lube oil operating pressure before engine to R bar 8 5 Lube oil operating pressure low idle meas point before engine R bar 3 Fuel system 12V2000 M84 F...

Page 35: ...e side with cooling system R Liters 125 Engine oil capacity initial filling standard oil system Option max operating inclinations R Liters 123 Oil change quantity max standard oil system Option max op...

Page 36: ...r inlet temperature 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 16V2000 M84 Rated engine speed A rpm 245...

Page 37: ...from R bar 6 0 Lube oil operating pressure before engine to R bar 7 5 Lube oil operating pressure low idle meas point before engine R bar 2 5 Fuel system 16V2000 M84 Fuel pressure at engine inlet con...

Page 38: ...e side with cooling system R Liters 135 Engine oil capacity initial filling standard oil system Option max operating inclinations R Liters 168 Oil change quantity max standard oil system Option max op...

Page 39: ...4 3 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 MS150063 03E 2016 02 Technical Data 39 TIM ID 0000038135 002...

Page 40: ...in dimensions Engine model Length A Width B Height C 12V 2000 M84 approx 2094 mm approx 1295 mm approx 1350 mm 16V 2000 M84 approx 2511 mm approx 1295 mm approx 1390 mm 40 Technical Data MS150063 03E...

Page 41: ...Fuel prefilter pressure gage Align adjustable pointer with position of pressure indicator Page 86 Fuel system Vent Page 83 Raw water pump if located above waterline Prime approx 3 to 4 liters Filling...

Page 42: ...t level Page 110 Coolant circuit Heat engine coolant with coolant preheating unit Fuel prefilter Drain water and contaminants Page 87 Battery charging generator drive Check condition of drive belt Pag...

Page 43: ...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 45 2 Shut down fuel treatment system Page 53 MS1...

Page 44: ...ves 4 Switch on fuel treatment system Page 48 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 45: ...ne 3 Switch on fuel treatment system and operate it for some minutes Page 48 Result Fuel is sucked from the tank dirt particles and water are filtered and separated then the fuel is delivered via the...

Page 46: ...ncy HAT 1 Switch on fuel treatment system Page 48 2 Start engine Page 49 3 Run engine at idling speed 4 Switch off pump 21 on switch cabinet Result The engine mounted fuel delivery pump sucks fuel via...

Page 47: ...n Check exhaust color Page 57 Fuel prefilter Check if suction side pressure indicated at the fuel prefilter is within the limit Page 86 Drain water and contaminants Page 87 Air filter Check signal rin...

Page 48: ...re 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 49: ...rsons 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 The engine can be started from the following points Item A...

Page 50: ...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 dis...

Page 51: ...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 52: ...coolant has no antifreeze addi tive 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 antif...

Page 53: ...inet 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 54: ...ectly at seals or electronic components such as connectors or ECUs Plant Cleaning 1 Carry out plant cleaning only in areas where an appropriate oil separator is provided environmental protec tion 2 Pr...

Page 55: ...ter Page 47 W1001 Replace fuel filter or fuel filter element Page 84 W1005 Replace air filter Page 94 W1006 Replace fuel injectors Page 80 W1008 Replace engine oil filter when changing engine oil or w...

Page 56: ...ped 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 off u R...

Page 57: ...be barred manually u Contact Service Engine turns on starting but does not fire Cause Corrective action Poor rotation by starter Battery low or faulty u Charge or replace battery see manufacturer s d...

Page 58: ...rge air cooler contaminated u Contact Service Exhaust turbocharger defective u Contact Service Coolant leaks at charge air cooler Cause Corrective action Charge air cooler leaking major coolant discha...

Page 59: ...ion Engine is not at operating temperature u Run engine to reach operating temperature Water in fuel u Drain fuel prefilter Page 87 Charge air cooler leaking u Contact Service MS150063 03E 2016 02 Tro...

Page 60: ...s 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 install...

Page 61: ...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 62: ...information Install SOLAS shielding as per MTN 5233 as a matter of priority Page 60 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 63: ...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 ex...

Page 64: ...lve 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 S...

Page 65: ...ger 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 Shiel...

Page 66: ...ng 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 66 SOLAS MS150063 03E 2016 02 TIM ID 0000010064...

Page 67: ...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 68: ...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 69: ...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...

Page 70: ...Final steps 1 Install injector Page 81 2 Install cylinder head cover Page 79 70 Cylinder Liner MS150063 03E 2016 02 TIM ID 0000000015 016...

Page 71: ...ound 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...

Page 72: ...ation 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 insp...

Page 73: ...ays wear safety goggles face mask and ear defenders Crankcase breather cleaning oil pre separator element 1 Undo clamp 2 2 Remove hose 1 and clamp 2 from cov er 3 3 Slacken screws 4 4 Remove screws 4...

Page 74: ...re 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 Remo...

Page 75: ...hragm 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 Scre...

Page 76: ...h 20 100 Nm F30026582 1 Measuring instrument Y4345888 1 Engine oil Preparatory steps 1 Remove air filter Page 95 2 Remove cylinder head cover Page 79 Positioning piston of cylinder A1 at TDC Note With...

Page 77: ...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 78: ...Final steps 1 Remove barring device 2 Install cylinder head cover Page 79 3 Install air filter Page 95 78 Valve Drive MS150063 03E 2016 02 TIM ID 0000050016 003...

Page 79: ...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 80: ...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 81 80 Injector MS150063 03E 201...

Page 81: ...talog Injector 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...

Page 82: ...ing cone 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...

Page 83: ...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 84: ...E 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 period...

Page 85: ...aded vent plugs 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...

Page 86: ...dif ferential pressure gauge 1 After installation of a new filter element align adjustable pointer 2 with pressure indicat ing pointer 3 of pressure gauge 1 2 Verify that differential pressure is with...

Page 87: ...e 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 and soap WARNING Fuels are combustible and explos...

Page 88: ...ing connection 1 on the intake side of the filter 7 Open vent valve 2 and fill with fuel until fuel emerges from the vent pipe 3 8 Close vent valve 2 9 Open rotary slide valve 4 a little by approx 30...

Page 89: ...nd 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 with...

Page 90: ...pump to filling connection 1 on the intake side of the filter 3 Open vent valve 2 and fill with fuel until fuel emerges from the vent pipe 3 4 Close vent valve 2 5 Open rotary slide valve 4 a little...

Page 91: ...tion 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 contact is made...

Page 92: ...Remove spring cartridge 3 and filter ele ment 4 8 Insert new filter element 4 and spring car tridge 3 9 Fill filter housing with clean fuel 10 Place new seal in cover 11 Fit cover with gasket and secu...

Page 93: ...wear safety goggles face mask and ear defenders Charge air cooler checking con densate drain line for coolant discharge and obstruction 1 Check drain line for water discharge and ob struction when the...

Page 94: ...Spare parts Designation Use Part No Qty Air filter Spare Parts Catalog Replacing the air filter 1 Remove old air filter and install new air filter Page 95 2 Reset signal ring of contamination indicat...

Page 95: ...p 2 2 Remove air filter 1 and clamp 2 from con necting flange of intake housing 3 3 Verify that there are no objects in the con necting flange of the intake housing 3 and clean it 4 Place new air filt...

Page 96: ...isabled Checking signal ring position 1 If the signal ring is completely visible in the control window 2 replace air filter Page 94 2 After installation of new filter press reset button 1 Result Engag...

Page 97: ...eck Preconditions Engine is stopped and starting disabled Checking starter condition 1 Check securing screws of starter for secure seating and tighten if required 2 Check wiring Page 126 MS150063 03E...

Page 98: ...4 Top up with oil up to the max 1 mark Page 99 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 remov...

Page 99: ...tact with skin Do not inhale oil vapor Version with extraction equipment Engine oil extraction 1 Position a suitable container to drain the engine oil into 2 Extract all engine oil from oil pan using...

Page 100: ...tors WARNING Hot oil Oil can contain combustion residues which are harmful to health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not...

Page 101: ...t crank engine with starting system Page 68 11 Check oil level Page 98 Replacing oil filter with the engine running 1 Reduce engine speed to 1100 rpm 2 Unscrew cut out oil filter with oil filter wrenc...

Page 102: ...s Catalog O ring Spare Parts Catalog O ring Spare Parts Catalog WARNING Compressed air gun ejects a jet of pressurized air Risk of injury to eyes and damage to hearing risk of rupturing internal organ...

Page 103: ...easure the layer thickness of the oil resi due 5 If maximum layer thickness 25 mm is ex ceeded shorten maintenance interval 6 Clean rotor components and remove strain ers 2 7 Wash standpipes 3 and noz...

Page 104: ...Nm 13 Hold rotor old design with oil filter wrench and tighten nut 1 to specified torque using a torque wrench Name Size Type Lubricant Value Standard Nut M16 x 1 5 Tightening torque 40 Nm to 50 Nm 14...

Page 105: ...ure Circuit 8 15 1 Draining and venting points Figures also apply similarly to 12V and 16V Plan view 1 Overflow line expansion tank 2 Filler neck MS150063 03E 2016 02 Coolant Circuit General High Temp...

Page 106: ...oolant drain plug 3 Raw water pump filling plug 4 Measuring point pressure before raw water pump 5 Raw water pump drain plug 6 Oil extraction connection 106 Coolant Circuit General High Temperature Ci...

Page 107: ...Left side 1 Engine coolant drain plug 2 Engine coolant drain plug M14x1 5 MS150063 03E 2016 02 Coolant Circuit General High Temperature Circuit 107 TIM ID 0000038198 002...

Page 108: ...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 108 Coolant Circuit General High Temperature Circuit...

Page 109: ...Driving end KS 1 Engine coolant drain plug 2 Oil extraction connection MS150063 03E 2016 02 Coolant Circuit General High Temperature Circuit 109 TIM ID 0000038198 002...

Page 110: ...expansion tank Page 26 counterclockwise until 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...

Page 111: ...Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 112 2 Fill with engine coolant Page 113 MS150063 03E 2016 02 Coolant Circuit General High Tem...

Page 112: ...eheating unit Draining engine coolant 1 Turn breather valve of filler neck on coolant expansion tank Page 105 counterclockwise to first stop and allow pressure to escape 2 Continue to turn breather va...

Page 113: ...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 114: ...ank Page 105 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 expan...

Page 115: ...o hearing Wear ear protectors HT coolant pump Relief bore check 1 Check relief bore for oil and coolant dis charge 2 Stop engine Operating Instructions for Electronic System and disable engine start 3...

Page 116: ...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 wis...

Page 117: ...hen the engine is running Risk of damage to hearing Wear ear protectors Raw water pump Relief bore check 1 Check relief bore for oil and coolant dis charge 2 Stop engine Page 50 and disable engine sta...

Page 118: ...abled Guard is removed Drive belt Condition check Item Findings Action Drive belt A Singular cracks None Drive belt B Cracks on entire circumference Replace Page 119 Drive belt C Chunking Drive belt B...

Page 119: ...Replacing drive belt 1 Counterhold adjusting lever at square 2 2 Rotate adjusting lever until drive belt is re leased 3 Secure adjusting lever with screwdriver 1 4 Remove drive belt 5 Check cleanness...

Page 120: ...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 120 Fuel Supply System MS150063 03E 2016 02 TIM I...

Page 121: ...otective clothing protective gloves and safety glasses facial protection Checking differential pressure gauge 1 Switch on fuel treatment system Page 48 2 Set the alarm points at the differential press...

Page 122: ...probe 2 Unscrew water level probe 3 Disconnect connector from water level probe 4 Immerse water level probe into a tank filled with water until water level reaches the thread 5 Switch on the system R...

Page 123: ...the 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 pr...

Page 124: ...ial cleanliness 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 insta...

Page 125: ...htening torque Engine oil 30 Nm 3 Nm 17 Fit gasket 10 18 Install cover 19 Install screws 1 washers 2 and nuts 9 20 Tighten nuts 9 21 Open ball valve at the inlet and outlet of the fuel treatment syste...

Page 126: ...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 h...

Page 127: ...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 128: ...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 129: ...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 seatin...

Page 130: ...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 131: ...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 no...

Page 132: ...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 133: ...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 134: ...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 Engine...

Page 135: ...e correct assignment between cables and plugs 2 Check seal before installing Result Replace seal if porous or defective Downloading software 1 The new EIM still does not have appropriate FSW and param...

Page 136: ...ation loader active 5 External RAM faulty 6 External FLASH faulty 7 No firmware 8 Application crashed Fuse lamp SILA A second indicator is the fuse lamp This is also integrated in the housing of the E...

Page 137: ...rgency 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 current pat...

Page 138: ...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 138 Accessories...

Page 139: ...Engine management system ECU Engine Control Unit Engine governor EDM Engine Data Module Memory module for engine data EIM Engine Interface Module Interface to engine monitoring system EMU Engine Moni...

Page 140: ...nel PCU Propeller Control Unit PIM Peripheral Interface Module RCS Remote Control System RL Redundancy Lost Alarm Redundant CAN bus failure SAE Society of Automotive Engineers U S standardization orga...

Page 141: ...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 142: ...ctor Removal and installation Page 81 Angular screw driver Part No F30453001 Qty Used in 1 8 5 1 Valve clearance Check and adjustment Page 76 Box wrench Part No F30451199 Qty Used in 1 8 6 2 Injector...

Page 143: ...Crossbeam Part No T80091731 Qty Used in 1 2 1 Transportation Page 16 Crossbeam Part No T80092210 Qty Used in 1 2 1 Transportation Page 16 Double head box wrench Part No F30002800 Qty Used in 1 8 5 1...

Page 144: ...in 1 8 2 1 Engine Barring manually Page 67 Qty Used in 1 8 5 1 Valve clearance Check and adjustment Page 76 High pressure cleaning unit Part No Qty Used in 1 5 13 Plant Cleaning Page 54 Measuring ins...

Page 145: ...l filter Replacement Page 100 Qty Used in 1 8 14 2 Centrifugal oil filter and filter sleeve Cleaning and replacement Page 102 Qty Used in 1 8 15 8 Coolant filter Replacement Page 116 Open end wrench b...

Page 146: ...het with extension Part No F30006212 Qty Used in 1 8 2 1 Engine Barring manually Page 67 Qty Used in 1 8 5 1 Valve clearance Check and adjustment Page 76 Rigid endoscope Part No Y20097353 Qty Used in...

Page 147: ...art No F30026582 Qty Used in 1 8 5 1 Valve clearance Check and adjustment Page 76 Torque wrench 8 40 Nm Part No F30043446 Qty Used in 1 8 4 2 Crankcase breather Oil separator replacement di aphragm ch...

Page 148: ...Valve clearance gage Part No Y4345893 Qty Used in 1 8 5 1 Valve clearance Check and adjustment Page 76 148 Special Tools MS150063 03E 2016 02 DCL ID 0000016266 003...

Page 149: ...acement 74 Cylinder Designation 19 Cylinder head cover Installation 79 Removal 79 Cylinder liner Endoscopic examination 69 Instructions and comments on endoscopic and visual examination 71 D Diagnosti...

Page 150: ...ing on 48 Fuse lamp SILA On EIM 136 H Hotline 141 HT coolant pump Check Relief bore 115 I Injector Installation 81 Removal 81 Replacement 80 Installation locations SOLAS shielding 62 Interface module...

Page 151: ...arter Condition check 97 Startup After extended out of service periods 3 months 41 Putting into operation after scheduled out of service pe riod 42 T Tasks After extended out of service periods 43 Tas...

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