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MTU 12V2000M86106, Operating Instructions Manual

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MTU 12V2000M86106 Operating Instructions Manual Download Page 89

7.6.2 Injector – Removal and installation

Preconditions

☑

Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use

Part No.

Qty.

Socket wrench

F30452389

1

Screwdriver bit T45

F30454548

1

Puller

F6790992

1

Assembly sleeve

F30454554

1

Injector alignment device

F6795554

1

Alignment mandrel

F6795777

1

HP line alignment device

F6795725

1

Torque wrench, 20–100 Nm

F30026582

1

Assembly compound (Kluthe Hakuform 30-15)

X00067620

1

Engine oil
Sealing ring

(→ Spare Parts Catalog)

O-ring

(→ Spare Parts Catalog)

O-ring

(→ 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.

Preparatory steps

1.

Close off fuel supply to engine.

2.

Remove cylinder head cover upper section (→ Page 83).

Injector – Removal

1.

Remove HP line (1) using socket wrench.

2.

Disconnect cable at control cable connec-
tion (7) of injector (3).

3.

Remove cylinder head cover lower sec-
tion (2).

4.

Release both screws (6) on flange.

5.

Remove retaining screw (4) from hold-down
clamp (5) with screwdriver bit.

MS150119/01E 2016-02

| Injector | 89

TIM-ID: 0000055245 - 006

Summary of Contents for 12V2000M86106

Page 1: ...Operating Instructions Diesel engine 12V 16V2000Mx6 12V 16V2000M96L MS150119 01E...

Page 2: ...riable low utilization Table 1 Applicability 2016 Copyright MTU Friedrichshafen GmbH This publication is protected by copyright and may not be used in any way whether in whole or in part without the p...

Page 3: ...AS 66 7 1 1 SOLAS shielding as per MTN 5233 Installation 66 7 1 2 SOLAS shielding Installation 67 7 1 3 Installation locations for SOLAS shielding 68 7 2 Engine 77 7 2 1 Barring engine manually 77 7 2...

Page 4: ...g General for Engine Gearbox Unit 138 7 20 1 Engine cabling Check 138 7 21 Fuel Treatment System 139 7 21 1 Checks prior to start up 139 7 21 2 Fuel treatment system Switching on 140 7 21 3 Differenti...

Page 5: ...l in 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 a...

Page 6: ...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 7: ...ing tackle as necessary If the engine is supplied with special aluminum foil packing Lift the engine at the lifting eyes of the bearing pedestal or use a means of transportation which is appropriate f...

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 MS150119 01E 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: ...ues MA are specified for screws of strength class 8 8 surface finish bare metal phosphatized or galvanized and 10 9 surface finish bare metal or phosphatized The values in the table are based on a fri...

Page 17: ...for studs Thread Screwed into Steel M A Nm Gray cast iron MA Nm Al alloy MA Nm M6 9 6 6 M8 11 9 10 M10 17 13 13 M12 27 23 18 M14 37 33 33 M16 55 45 MA tightening torques Tightening torques for setscr...

Page 18: ...on a friction coefficient tot 0 125 Threads and mating faces of screws and nuts must be coated with engine oil prior to assembly An assembly tolerance of 10 of the figures in the table is permitted d...

Page 19: ...hen tightening MA tightening torques Tightening torques for plug screws to MTN 5183 1 standard This standard applies to plug screws to DIN 908 DIN 910 and DIN 7604 with threaded end to DIN 3852 Form A...

Page 20: ...ightening torques for plug screws to DIN 908 DIN 910 and DIN 7604A with short threaded end Thread Screwed into Steel gray cast iron MA Nm AI alloy MA Nm M10 x 1 15 15 M12 x 1 5 25 25 M14 x 1 5 35 30 M...

Page 21: ...Steel gray cast iron M A Nm Al alloy MA Nm M8 x 1 10 10 M22 x 1 5 80 65 M26 x 1 5 105 90 M30 x 1 5 130 130 M38 x 1 5 140 120 M45 x 1 5 160 140 MA tightening torques Tightening torques for banjo screws...

Page 22: ...le deviations during the tightening process Tightening torques for steel banjo screws Thread inserted in steel gray cast iron aluminum alloy MA Nm M8 x 1 10 M10 x 1 15 M12 x 1 5 20 M14 x 1 5 25 M16 x...

Page 23: ...iled or galvanized Threads and mating faces beneath heads must be coated with engine oil prior to assembly An assembly tolerance of 10 of the figures in the table is permitted due to unavoidable devia...

Page 24: ...on nut firmly by hand noticeable increase in force it should be tightened another 1 4 turn 90 past this point Tightening torques for spigot unions with O ring to ISO 6149 2 Thread Torque Nm 10 M8 x 1...

Page 25: ...in valves see ISO 6149 47 and ISO 7789 Tightening torques for spigot unions with O ring to ISO 6149 3 Thread Torque Nm 10 M8 x 1 8 M10 x 1 15 M12 x 1 5 25 M14 x 1 5 35 M16 x 1 5 40 M18 x 1 5 45 M22 x...

Page 26: ...tings In contrast to the instructions for pipe unions hose fittings with sealing heads and the matching adapters must be fitted and connected as follows Hose fitting forming metallic seal with union n...

Page 27: ...2 35 290 M52 x 2 38 42 330 Sealing head with BSP union nut BSPP thread Torque Nm G1 4 20 G3 8 34 G1 2 60 G5 8 69 G3 4 115 G1 140 G1 1 4 210 G1 1 2 290 G2 400 SAE sealing cone with union nut JIC 37 UNF...

Page 28: ...Torque Nm 9 16 18 4 14 2 11 16 16 6 24 3 13 16 16 8 43 4 1 14 10 60 8 1 3 16 12 12 90 5 1 3 16 12 14 90 5 1 7 16 12 16 125 10 1 11 16 12 20 170 20 2 12 24 200 25 2 1 2 20 32 460 30 28 General Informa...

Page 29: ...cordance 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...

Page 30: ...mits low surface temperature reduced thermal load absolute gas tightness Lube oil system Wet sump forced feed lubrication system Components supplied with oil Bearings Piston cooling Control and actuat...

Page 31: ...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 1x...

Page 32: ...nd coolant temperature are monitored and displayed Integrated safety system Integrated Test System Redundant CAN bus interface to governor and higher level control and monitoring system 24 V DC supply...

Page 33: ...ording 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 reduced by this and the faulty sealing ring 1 tha...

Page 34: ...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 34 General Information MS150119 01E 2016 02 TIM ID 00...

Page 35: ...ling cones or the HP lines is returned to the HP pump from where it is routed at atmospheric pressure into a leak fuel tank To facilitate the leak search the leak fuel pipework is divided into three s...

Page 36: ...t flap 14 Actuating cylinder for air flap 15 Cylinder head cover 16 Electric starter 17 Engine mounting bracket 18 Exhaust housing 19 Oil pan 20 Oil filler neck 21 Oil dipstick 22 Engine coolant fille...

Page 37: ...on 11 Flywheel 12 Flywheel housing 13 Carrier housing lower sec tion 14 Bleeder valve a Air intake b Exhaust outlet KS Kupplungsseite driving end Engine model designation Key to the engine model desig...

Page 38: ...driving end Item Name Monitoring of 1 B4 21 Temperature before ETC A side 2 Y27 1 Flap control A side 3 B4 22 Temperature before ETC B side 4 B13 1 Crankshaft speed 5 B13 2 Crankshaft speed optional...

Page 39: ...2 Lube oil pressure after filter optional 3 B5 1 Lube oil pressure after filter 4 F33 Coolant level probe in expansion tank 5 B21 Seawater pressure optional 6 B6 2 Coolant temperature optional 7 B6 1...

Page 40: ...Sensors and actuators on left side Item Name Monitoring of 1 A18 EIM Engine Interface Module 40 General Information MS150119 01E 2016 02 TIM ID 0000055074 002...

Page 41: ...l temperature 3 Y45 1 Pressure regulating valve 4 A19 EIL electronic label 5 B16 Coolant pressure optional 6 M8 CR pump activation of HP fuel control block 7 F46 Leak off fuel level optional 8 B1 Cams...

Page 42: ...for charge air cooler seawater 3 Y56 4 2 directional control valve for blowing off only 16 V 4 A77 EMU Engine Monitoring Unit optional 5 B7 Lube oil temperature 6 B48 High pressure fuel 7 B9 Charge a...

Page 43: ...ation only conditionally suitable for design L Limit Value that must not be undershot lower limit value min value or exceeded upper limit value max value not suitable for design N Not yet defined valu...

Page 44: ...A Marine T3 40CFR1042 RECREA TION EU Marine Directive 2013 53 EU Recrea tional Craft 3 12V2000M96L Marine ship s main propulsion 1 DS continuous vari able operation low uti lization 2450 1 min 1432 kW...

Page 45: ...water system max L bar 4 0 4 0 4 0 Raw water pump Inlet pressure min L bar 0 4 0 4 0 4 Lube oil system ID 1 2 3 Lube oil operating temperature before engine from R C 75 75 75 Lube oil operating temper...

Page 46: ...cities ID 1 2 3 Engine coolant capacity engine side with cooling equipment R Liters 125 125 125 Engine oil capacity initial filling standard oil system option max operating inclinations R Liters 123 1...

Page 47: ...ly conditionally suitable for design L Limit Value that must not be undershot lower limit value min value or exceeded upper limit value max value not suitable for design N Not yet defined value Value...

Page 48: ...A Marine T3 40CFR1042 RECREA TION EU Marine Directive 2013 53 EU Recrea tional Craft 3 16V2000M96L Marine ship s main propulsion 1 DS continuous vari able operation low uti lization 2450 1 min 1939 kW...

Page 49: ...water system max L bar 4 0 4 0 4 0 Raw water pump Inlet pressure min L bar 0 4 0 4 0 4 Lube oil system ID 1 2 3 Lube oil operating temperature before engine from R C 75 75 75 Lube oil operating temper...

Page 50: ...ID 1 2 3 Engine coolant capacity engine side with cooling equipment R Liters 135 135 135 Engine oil capacity initial filling standard oil system option max operating inclinations R Liters 145 145 145...

Page 51: ...3 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 MS150119 01E 2016 02 Technical Data 51 TIM ID 0000038135 002...

Page 52: ...in dimensions Engine model Length A Width B Height C 16V2000M86 16V2000M96 16V2000M96L 2495 mm 1292 mm 1452 mm 12V2000M86 12V2000M96 12V2000M96L 2082 mm 1292 mm 1414 mm 52 Technical Data MS150119 01E...

Page 53: ...Fuel prefilter pressure gage Align adjustable pointer with position of pressure indicator Page 100 Fuel system Vent Page 94 Raw water pump if located above waterline Prime approx 3 to 4 liters Fillin...

Page 54: ...t level Page 126 Coolant circuit Heat engine coolant with coolant preheating unit Fuel prefilter Drain water and contaminants Page 102 Battery charging generator drive Check condition of drive belt Pa...

Page 55: ...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 56: ...heck exhaust color Page 63 Fuel prefilter Check if suction side pressure indicated at the fuel prefilter is within the limit Page 100 Drain water and contaminants Page 102 Air filter Check signal ring...

Page 57: ...the label on the engine match the label document in the Business Portal Equipment 3 Check emission label for intactness 4 Check content of emission label for complete readability 5 Does the engine num...

Page 58: ...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 59: ...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 Con...

Page 60: ...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 61: ...ctly at seals or electronic components such as connectors or ECUs Plant Cleaning 1 Carry out plant cleaning only in areas where an appropriate oil separator is provided environmental protec tion 2 Pri...

Page 62: ...eck for presence readability and content of emission la bel Page 57 W1001 Replace fuel filter or fuel filter element Page 97 W1002 Check valve clearance and adjust as necessary Page 84 W1005 Replace a...

Page 63: ...s documentation Engine wiring faulty u Check Page 138 Air in fuel system u Vent fuel system Page 94 Engine governor ECU is defective u Contact Service Engine fires unevenly Cause Corrective action Inj...

Page 64: ...arge air cooler is contaminated u Contact Service Exhaust turbocharger faulty u Contact Service Coolant leaks at charge air cooler Cause Corrective action Major coolant discharge at drain valve of the...

Page 65: ...at operating temperature u Run engine to reach operating temperature Water in fuel u Check fuel system at fuel prefilter Drain fuel prefilter Page 102 Charge air cooler leaky u Contact Service MS1501...

Page 66: ...nation Use Part No Qty Shield A4 735233000100 15 Shield A5 12V 735233000101 31 Shield A5 16V 735233000101 33 Shield A6 735233000102 1 Shield A7 735233000103 8 Shield B2 735233000200 2 Installing SOLAS...

Page 67: ...s cooled down to ambient temperature Special tools Material Spare parts Designation Use Part No Qty Oil filter shield X00009628 2 pcs Installing SOLAS shielding for oil filter 1 Pinpoint installation...

Page 68: ...66 Free end B side Item Type of shielding Comments 1 Shield A7 For fuel priming pump 2 Shield A7 For HP fuel pump Item Type of shielding Comments 1 Shield A7 For fuel priming pump 2 Shield A7 For HP...

Page 69: ...mp outlet 2 Shield A6 Lubrication of HP fuel pump 3 Shield A7 HP fuel pump supply line Item Type of shielding Comments 1 Shield A7 Fuel priming pump supply line 2 Shield A7 Fuel priming pump return li...

Page 70: ...em Type of shielding Comments 1 Shield A5 Oil sampling point on crankcase B side Item Type of shielding Comments 1 Shield A5 Oil sampling point on crankcase 70 SOLAS MS150119 01E 2016 02 TIM ID 000006...

Page 71: ...rom valve 2 Shield B2 Oil supply line 3 Shield A4 Oil supply to seawater valve cylin der 4 Shield A4 Oil supply to seawater valve cylin der 5 Shield A4 Remove shield from bleeder valve 6 Shield A4 Rem...

Page 72: ...supply to seawater valve cylin der 7 Shield A4 Connection to bleeder valve 8 Shield A4 Connection to bleeder valve Free end A side Item Type of shielding Comments 1 Shield A4 Oil supply to cylinder se...

Page 73: ...f hydraulic cylinder B side Item Type of shielding Comments 1 Shield A5 Exhaust turbocharger flaps 2 Shield A5 Exhaust turbocharger flaps 3 Shield A5 Oil supply for air flap 4 Shield A5 Oil supply for...

Page 74: ...supply for air flap 2 Shield A5 Oil supply for exhaust turbocharg er 3 Shield A4 Oil return line in crankcase 4 Shield A5 Oil supply for air flap 5 Shield A4 Oil supply for air flap 6 Shield A5 Exhau...

Page 75: ...ield A4 Exhaust turbocharger lubrication center 3 Shield A5 Turbocharger lubrication left side 4 Shield A5 Turbocharger lubrication left side 5 Shield A5 Oil supply for exhaust turbocharg er 6 Shield...

Page 76: ...ments 1 Shield A4 Turbocharger lubrication right side 2 Shield A5 Oil supply 3 Shield A5 Turbocharger lubrication right side 4 Shield A5 Oil supply for exhaust turbocharg er 76 SOLAS MS150119 01E 2016...

Page 77: ...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 78: ...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 79: ...rences around 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 direc...

Page 80: ...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 81: ...ven honing pattern First signs of marks left by lower cooling bores Running pattern seems darker No actions required Dark areas with even or varying degrees of discoloration Beginning and end of the d...

Page 82: ...Final steps 1 Install injector Page 89 2 Install cylinder head cover Page 83 82 Cylinder Liner MS150119 01E 2016 02 TIM ID 0000067215 001...

Page 83: ...Cylinder head cover removal and installation 1 Unscrew screws 5 and take off with wash ers 4 2 Remove cylinder head cover 3 with gas ket 2 from cylinder head 3 Clean mounting surface 1 4 Check conditi...

Page 84: ...adapter F30027340 1 Measuring instrument Y4348409 1 Preparatory steps 1 Remove air filter Page 115 2 Remove cylinder head cover Page 83 3 Remove HP line and injector Page 89 Positioning A1 piston at...

Page 85: ...rmine the distance between valve bridge and rocker arm 5 If the deviation from the reference value exceeds 0 1 mm adjust valve clearance Valve clearance Adjustment Position Cylinder 1 2 3 4 5 6 7 8 9...

Page 86: ...e adjusting screw 2 with Allen key to prevent it from turning Name Size Type Lubricant Value Standard Locknut M12x1 Tightening torque 50 Nm 5 Nm 5 Insert feeler gauge between valve bridge and rocker a...

Page 87: ...ses facial protection WARNING Oils oil vapors are combustible explosive Risk of fire and explosion Avoid open flames electric sparks and ignition sources Do not smoke NOTICE HP fuel pump not filled wi...

Page 88: ...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 89 88 Injector MS150119 01E 201...

Page 89: ...ng Spare Parts Catalog O ring 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 prot...

Page 90: ...le plugs Injector Installation 1 Remove all covers and plugs prior to installation Note Lubrication is not required if a sliding varnish coated O ring is used 2 Fit new O ring on injector with assembl...

Page 91: ...fied tightening torque Name Size Type Lubricant Value Standard Retaining screw M8 Preload torque Engine oil 40 4 Nm Note Check and clean surface of bottom side of cylinder head cover lower section 9 A...

Page 92: ...socket wrench and torque wrench to specified tightening torque Name Size Type Lubricant Value Standard HP line Tightening torque Engine oil 37 Nm 3 Nm Note Ensure they run centrally A Do not pinch the...

Page 93: ...t reset the emission certification of the engine becomes void 20 Reset drift correction CDC with DiaSys and enter injector coding IIG Page 144 Final steps 1 Install cylinder head cover upper section P...

Page 94: ...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 not inhale vapo...

Page 95: ...pump with the handle 2 until bubble free fuel emerges from the threaded vent plug 1 4 Tighten vent screw 1 to specified torque Name Size Type Lubricant Value Standard Threaded vent plug M8 Tightening...

Page 96: ...bubble free fuel emerges from the threaded vent plugs 1 and 3 4 Tighten threaded vent plugs 1 and 3 to specified torque Name Size Type Lubricant Value Standard Threaded vent plug M8 Tightening torque...

Page 97: ...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 contact i...

Page 98: ...change filter and moisten with fuel 6 Install and tighten easy change filter by hand 7 Vent fuel system Page 94 Fuel filter change with reversi ble filters and running engine 1 Cut out the filter to...

Page 99: ...ighten threaded vent plugs 1 and 2 to specified torque Name Size Type Lubricant Value Standard Threaded vent plug M8 Tightening torque 6 Nm 2 Nm MS150119 01E 2016 02 Fuel Filter 99 TIM ID 0000064785 0...

Page 100: ...ointer 3 of pressure gauge 1 2 Verify that differential pressure is within the limit Fuel prefilter checking differential pressure with single stage filter 1 With the engine running at full load or ra...

Page 101: ...ll load or rated power read off pressure at gauge 1 2 If differential pressure as indicated between position of adjustable pointer 2 and pressure indicating point er 3 of pressure gauge is 0 3 bar flu...

Page 102: ...l 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 and soap WARN...

Page 103: ...vent plugs 2 Draining fuel prefilter with re versible duplex filter 1 Switch off filter which is to be drained A or B 1 Filter A cut out 2 Filter B cut out 2 Open threaded vent plug 1 of the filter to...

Page 104: ...uel until fuel emerges from the 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 the vent pipe 3 10 Close vent valve s...

Page 105: ...ses If contact is made with skin wash off with water and soap WARNING Fuels are combustible and explosive Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smo...

Page 106: ...tial pres sure replace fuel prefilter element Page 108 Flushing fuel prefilter with re versible duplex filter 1 Cut out contaminated filter A or B 1 Filter A cut out 2 Filter B cut out 2 Open threaded...

Page 107: ...rges from the vent pipe 3 4 Close vent valve 2 5 Open rotary 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 sl...

Page 108: ...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 not inhale vapo...

Page 109: ...ilter 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 val...

Page 110: ...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 secure...

Page 111: ...RNING 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 Always wear safety goggles face m...

Page 112: ...With the engine shut down check leak line 1 on B side driving end for liquid dis charge 2 Check line for free passage 3 With the engine stationary blow through clogged line with compressed air 112 Ch...

Page 113: ...t Wait until the first coolant emerges from the drain line of the intercooler 3 Completely drain coolant from the intercool er 4 Blow through line with compressed air 5 Close union nut on drain line 2...

Page 114: ...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 115 2 Reset signal ring of contamination indicat...

Page 115: ...mps 2 and 3 2 Remove air filter 4 and clamps from con necting flange 1 of intake neck 3 Clean connecting flange 1 of intake neck and check for free passage 4 Attach air filter 4 with clamps 2 and 3 on...

Page 116: ...arting disabled Checking signal ring position 1 When the yellow piston has reached the red shaded Service lettering 2 replace air filter Page 114 2 After installation of new filter press reset button...

Page 117: ...ck 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 138 MS150119 01E 2...

Page 118: ...4 Top up with oil up to the max 1 mark Page 119 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 119: ...ective gloves and safety glasses facial protection Avoid contact with skin Do not inhale oil vapor Version with extraction equipment Engine oil extraction 1 Position a suitable container to drain the...

Page 120: ...he engine is running Risk of damage to hearing Wear ear protectors WARNING Engine oil is hot Engine oil can contain combustion residues which are harmful to health Risk of injury and poisoning Allow t...

Page 121: ...vel Page 118 Oil filter change with reversible filters and stationary engine 1 Stop engine Page 58 and disable engine start 2 Cut out the filter to be replaced A Right filter cut out B Both filters cu...

Page 122: ...th oil filter wrench 4 Clean the sealing face on the adapter 5 Check condition of the new sealing ring and coat it with oil 6 Fit SOLAS shield Page 66 7 Screw on and tighten new engine oil filter by h...

Page 123: ...olant drain and venting points Drain points free end 1 Engine coolant drain screw 2 Filling screw on seawater pump 3 Seawater pump drain 4 Preheating line outlet con nection MS150119 01E 2016 02 Coola...

Page 124: ...points driving end 1 Engine coolant drain screw 2 Engine coolant drain screw Preheating line inlet con nection 124 Coolant Circuit General High Temperature Circuit MS150119 01E 2016 02 TIM ID 00000552...

Page 125: ...e coolant overflow line 2 Engine coolant filler neck 3 Engine coolant drain screw Drain points right side 1 Engine coolant drain screw MS150119 01E 2016 02 Coolant Circuit General High Temperature Cir...

Page 126: ...es cape 2 Continue to turn breather valve counterclockwise and remove 3 Check coolant level coolant must be visible at the bottom edge of the cast in eye of the filler neck Checking coolant level at e...

Page 127: ...Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 128 2 Fill with engine coolant Page 129 MS150119 01E 2016 02 Coolant Circuit General High Tem...

Page 128: ...eheating unit Draining engine coolant 1 Turn breather valve of filler neck on coolant expansion tank Page 123 counterclockwise to first stop and allow pressure to escape 2 Continue to turn breather va...

Page 129: ...engine Fill top up coolant only into cold engine Filling with engine coolant 1 Turn breather valve of coolant expansion tank Page 36 counterclockwise until the first stop and allow pressure to escape...

Page 130: ...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 fluid s...

Page 131: ...ank Page 123 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 132: ...thing gloves and goggles safety mask Preparatory steps u Switch off preheating unit Breather valve Replacement 1 Turn breather valve 1 on coolant expansion tank counterclockwise to the first stop and...

Page 133: ...s danger zone 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 coolant di...

Page 134: ...for firm seating Preconditions Engine is stopped and starting disabled Engine mounting checking securing screws for firm seating 1 Check securing screws for firm seating 2 Tighten loose threaded conne...

Page 135: ...king the condition of resilient mounts 1 Wipe rubber surface with dry cloth do not use organic detergents 2 Visually inspect resilient mounts for cracking and deformation 3 Check rubber surfaces for s...

Page 136: ...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 137 Drive belt C Chunking Drive belt B...

Page 137: ...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 138: ...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 139: ...arge valves 4 Switch on fuel treatment system Page 140 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 overfl...

Page 140: ...itching 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 start...

Page 141: ...ective clothing protective gloves and safety glasses facial protection Checking differential pressure gauge 1 Switch on fuel treatment system Page 140 2 Set the alarm points at the differential pressu...

Page 142: ...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 143: ...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 Re...

Page 144: ...tification becomes invalid Resetting parameters for drift correction CDC with DiaSys 1 Use DiaSys to reset the CDC parameters Dialog system DiaSys E531920 2 If no DiaSys is available contact Service E...

Page 145: ...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 connect...

Page 146: ...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 147: ...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 148: ...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 149: ...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 150: ...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 151: ...e 1 Note or mark assignment of cables and con nectors 2 Remove all screws 2 3 Undo clips 3 on connectors 4 Remove all male connectors 5 Remove screws 1 6 Take off engine governor Installing engine gov...

Page 152: ...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 153: ...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 154: ...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 155: ...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 156: ...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 156 Accessories...

Page 157: ...cpsi cells per square inch CR Common Rail CSMF Coated Sintered Metal Filter DIN Deutsches Institut f r Normung e V German Standardization Organization at the same time identifier of German standards D...

Page 158: ...ntrol MCS Monitoring and Control System MG Message MPU Microprocessor Unit Microprocessing Unit OT Oberer Totpunkt Top Dead Center TDC P xyz Pressure xyz Pressure measuring point xyz PAN Panel Control...

Page 159: ...Abbre viation Meaning Explanation VS Voith Schneider Voith Schneider drive WJ Water jet Water jet drive WZK Werkzeugkatalog Tool catalog TC MS150119 01E 2016 02 Appendix A 159 TIM ID 0000002045 020...

Page 160: ...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 161: ...r Removal and installation Page 89 Angular screw driver Part No F30453001 Qty Used in 1 7 4 2 Valve clearance Check and adjustment Page 84 Assembly sleeve Part No F30454554 Qty Used in 1 7 6 2 Injecto...

Page 162: ...ge 84 Double head box wrench Part No F30002800 Qty Used in 1 7 4 2 Valve clearance Check and adjustment Page 84 Endoscope Part No Y20097353 Qty Used in 1 7 3 2 Cylinder liner Endoscopic examination Pa...

Page 163: ...t Part No Qty Used in 1 4 9 Plant Cleaning Page 61 HP line alignment device Part No F6795725 Qty Used in 1 7 6 2 Injector Removal and installation Page 89 Injector alignment device Part No F6795554 Qt...

Page 164: ...Part No F30038494 Qty Used in 1 7 7 1 Fuel system Venting Page 94 Measuring instrument Part No Y4348409 Qty Used in 1 7 4 2 Valve clearance Check and adjustment Page 84 MTU test kit Part No 560589209...

Page 165: ...and installation Page 89 Ratchet adapter Part No F30027340 Qty Used in 1 7 4 2 Valve clearance Check and adjustment Page 84 Ratchet with extension Part No F30006212 Qty Used in 1 7 2 1 Barring engine...

Page 166: ...wrench 20 100 Nm Part No F30026582 Qty Used in 1 7 4 2 Valve clearance Check and adjustment Page 84 Qty Used in 1 7 6 2 Injector Removal and installation Page 89 Torque wrench 8 40 Nm Part No F3004344...

Page 167: ...Torque wrench 8 40 Nm Part No F30453004 21 Qty Used in 1 7 7 1 Fuel system Venting Page 94 MS150119 01E 2016 02 Special Tools 167 DCL ID 0000033801 003...

Page 168: ...emoval and installation 83 D Diagnostic features On EIM 154 Diagnostic lamp DILA On EIM 154 Differential pressure gauge Check 141 Drive belt Condition check 136 Replacement Battery charging generator...

Page 169: ...LA On EIM 154 H Hotline 160 HP fuel pump Filling with engine oil 87 I IIG Input 144 Injector Installation 89 Removal 89 Replacement 88 Injector coding IIG Input 144 Intercooler Check Coolant discharge...

Page 170: ...160 Starter Condition check 117 Startup After extended out of service periods 3 months 53 Putting into operation after scheduled out of service pe riod 54 T Tightening specifications Nuts 16 Screws an...

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