MTU 12V2000M91 Operating Instructions Manual Download Page 77

Page: 77 / 169

8.5 Injection Pump / HP Pump

8.5.1 Injection pump – Replacement

Special tools, Material, Spare parts

Designation / Use

Part No.

Qty.

Injection pump

(→ Spare Parts Catalog)

Injection pump – Replacement

Remove injection pump and install new one (→ Page 78).

MW15409/04E 2015-08

| Task Description | 77

TIM-ID: 0000000020 - 004

Summary of Contents for 12V2000M91

Page 1: ...Operating Instructions Diesel Engine 12V2000M91 16V2000M91 MW15409 04E...

Page 2: ...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 storage...

Page 3: ...ngine at the BlueLine automation system control stand 47 5 13 Emergency engine shutdown at LOP without BlueLine automation system 48 5 14 After stopping the engine 49 5 15 Plant Cleaning 50 6 Maintena...

Page 4: ...ple extraction and analysis 134 8 18 Raw Water Pump with Connections 135 8 18 1 Raw water pump Priming 135 8 18 2 Raw water pump Relief bore check 136 8 19 Belt Drive 137 8 19 1 Drive belt Condition c...

Page 5: ...nal as delivered configuration or in a configuration approved by the manufacturer in writing in cluding engine control parameters In compliance with all safety regulations and in adherence with all wa...

Page 6: ...ation authorities The manufacturer does not accept any liability for violations of the emission regulations The maintenance schedules of the manufacturer must be observed over the entire life cycle of...

Page 7: ...ucted repeatedly Personnel requirements All work on the product shall be carried out by trained and qualified personnel only Training at the Training Center of the manufacturer Technical personnel fro...

Page 8: ...nts as well as the monitoring signaling and alarm systems are working properly Smoking is prohibited in the area of the product Safety regulations during operation The operator must be familiar with t...

Page 9: ...s must not be painted They may only be installed after painting the engine or must be covered before painting work is carried out The following applies to starters with copper beryllium alloy pinions...

Page 10: ...roduct when welding in its vicinity Before starting welding work Switch off the power supply master switch Disconnect the battery Separate the electrical ground of electronic equipment from the ground...

Page 11: ...es Chafing on components Contact with hot surfaces Do not secure cables on lines carrying fluids Do not use cable straps to secure cables Always use connector pliers to tighten union nuts on connector...

Page 12: ...ith its han dling Noise Noise can lead to an increased risk of accidents if acoustic signals warning shouts or sounds indicating dan ger are drowned Wear ear protectors in workplaces with a sound pres...

Page 13: ...test in accordance with the specifications Painting Observe the relevant safety data sheet for all materials When carrying out painting work outside the spray stands provided with fume extraction syst...

Page 14: ...edial action NOTICE In the event of a situation involving potentially adverse effects on the product Consequences Material damage Remedial action Additional product information Safety notices 1 This m...

Page 15: ...o not allow hoist slings or chains to contact the engine or any of its component parts Readjust lifting gear as necessary 7 For special packaging with aluminum foil Suspend the engine by the lifting e...

Page 16: ...load Danger to life Use appropriate lifting devices and appliances Never stand beneath a suspended load Transportation without flange mounted gearbox 8V 1 Max admissible diagonal pull 10 2 Center of...

Page 17: ...Transportation without flange mounted gearbox 12V 16V 1 Max admissible diagonal pull 10 2 Center of gravity MW15409 04E 2015 08 Transport 17 TIM ID 0000064511 001...

Page 18: ...Transportation with flange mounted gearbox 8V 1 Max admissible diagonal pull 10 2 Center of gravity 18 Transport MW15409 04E 2015 08 TIM ID 0000064511 001...

Page 19: ...rbox 12V 16V 1 Max admissible diagonal pull 10 2 Center of gravity Note engine center of gravity Refer to the installation arrangement drawings for details of engine center of gravity MW15409 04E 2015...

Page 20: ...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 21: ...be cut in out during operation Cooling system Engine cooled by split circuit cooling system with plate core heat exchanger Service block The service components are mounted at the auxiliary PTO end Th...

Page 22: ...lphanumeric monochrome LCD display for monitoring of measured values as well as alarms when limits are violated Pushbuttons for menu control and dimming unit Combined control and display elements for...

Page 23: ...MW15409 04E 2015 08 General Information 23 TIM ID 0000002178 006...

Page 24: ...Lube oil system covers 24 General Information MW15409 04E 2015 08 TIM ID 0000002178 006...

Page 25: ...MW15409 04E 2015 08 General Information 25 TIM ID 0000002178 006...

Page 26: ...pressure is greatly reduced by a faulty O ring 3 The union is confirmed as being SOLAS compliant by DNV and GL Plugs and sensors Screw in plugs 2 are sealed toward the outside either with a copper se...

Page 27: ...line 19 Ball type seal area 20 Leak fuel connection The HP fuel line is sealed by the thrust ring 8 In case of leakage around the thrust ring 8 or the HP line 5 fuel escapes into the leakage chamber L...

Page 28: ...eral spray The fluid is diverted to the catch basin whereby the pressure is greatly reduced Shielding by overlapping design The overlap 1 precludes lateral spray The fluid is diverted to the catch bas...

Page 29: ...Intercooler 120 Air intake air supply 140 Exhaust system 170 Starting system 180 Lube oil system 200 Cooling system 230 Mounting support 250 PTO systems driving end and free end 500 Monitoring contro...

Page 30: ...Site altitude above sea level m 100 100 POWER RELATED DATA power ratings are net brake power to ISO 3046 Number of cylinders 12 16 Engine rated speed A rpm 2350 2350 Fuel stop power ISO 3046 A kW 111...

Page 31: ...3 Fuel pressure at supply connection on engine max when engine is starting L bar 0 5 0 5 Fuel supply flow max R liter min 5 1 6 9 STARTING electric Number of cylinders 12 16 Rated starter voltage sta...

Page 32: ...ns R liter 98 127 Oil pan capacity dipstick mark min standard oil system Option max operating inclinations L liter 73 97 Oil pan capacity dipstick mark max standard oil system Option max operating inc...

Page 33: ...Number of cylin ders Firing order 8 V A1 B4 A4 A2 B3 A3 B2 B1 12 V A1 B2 A5 B4 A3 B1 A6 B5 A2 B3 A4 B6 16 V A1 B5 A3 A5 B2 B8 A2 A8 B3 A7 B4 B6 A4 A6 B1 B7 MW15409 04E 2015 08 Technical Data 33 TIM I...

Page 34: ...sions Engine model Overall length A Overall width B Overall height C 12V 2000 M91 approx 2470 mm approx 1400 mm approx 1460 mm 16V 2000 M91 approx 2815 mm approx 1400 mm approx 1520 mm 34 Technical Da...

Page 35: ...ite F2 3 White F3 4 White F4 5 White F5 6 White ALARM ACKNOWL Pressing the button the first time stops alarm signaliza tion Pressing the button a second time acknowledges an ac tive alarm LED spot lig...

Page 36: ...as the button is held down 15 White ENGINE SPEED DE CREASE Engine speed is decreased as long as the button is held down 16 Green READY FOR OPERA TION Pressing the button causes changeover between Not...

Page 37: ...97 Fuel prefilter pressure gauge Align adjustable pointer with position of pressure indicator Page 92 Fuel system Vent Page 88 Raw water pump if located above waterline Prime with water approx 3 4 l...

Page 38: ...olant circuit Check coolant level Page 129 Coolant circuit Preheat coolant with preheating unit Fuel prefilter Drain water Page 93 Battery charging generator drive Check condition of drive belt Page 1...

Page 39: ...5 Starting the engine from LOP Item Action Engine Start in unloaded condition System Switch on LOP Illuminated switch LOCAL OPERATION lights up brightly local control mode is active Page 35 Illuminate...

Page 40: ...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 Cranking the engine out of service period 1 month Item Act...

Page 41: ...the engine plant Risk of overheating damage to components Initiate emergency stop only in emergency situations Engine emergency stop at BlueLine automation system Item Measure Engine Emergency stop a...

Page 42: ...Check exhaust color Page 52 Fuel prefilter Check if suction side pressure indicated at the fuel prefilter is within the limit Page 92 Drain water and contaminants Page 93 Air filter Check signal ring...

Page 43: ...button flashes Coupling is engaged After receiving the feedback signal from coupling the COUPLING IN but ton is illuminated brightly Engaging coupling in ahead direction with reversing gearbox FPP WJ...

Page 44: ...OUPLING OUT button flashes Coupling is disengaged After receiving the feedback signal from coupling the COUPLING OUT but ton is illuminated brightly Disengaging coupling with reversing gearbox FPP WJ...

Page 45: ...oo long Follow instructions of the waterjet manufacturer Flushing with reversing gearbox and flushing mode Item Measure LOP Press FLUSH illuminated pushbutton and keep pressed Page 35 FLUSH pushbutton...

Page 46: ...nd run the engine at idle speed for at least 10 minutes until engine temperatures have dropped and constant values are displayed Stopping the engine from LOP Item Action LOP Disengage gearbox Page 35...

Page 47: ...s 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 displayed Stopping the engine at the BlueL...

Page 48: ...opped by disconnecting the power supply to the ECU On engines with emergency air shutoff flaps flaps close Illuminated pushbutton EMERGENCY STOP flashes Horn flashing lamp etc are tripped After emerge...

Page 49: ...e 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 anti...

Page 50: ...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 51: ...efilter if fitted Page 42 W0508 Check reading on differential pressure gauge of fuel prefilter if fitted Page 42 W1001 Replace fuel filter or fuel filter element Page 90 W1002 Check valve clearance Pa...

Page 52: ...e blocked cannot be rotated by hand u Contact Service Start interlock limit switch is not installed u Check limit switch Page 146 Start interlock limit switch is defective u Check limit switch Page 14...

Page 53: ...r too big after replacement u Install suitable propeller Engine speed not steady Cause Corrective action Injector faulty u Replace Page 81 Injection pump faulty u Replace Page 77 Speed sensor is fault...

Page 54: ...uch oil in engine u Drain engine oil Page 117 Oil separator or oil preseparator of crankcase breather clogged u Replace Page 71 Exhaust turbocharger faulty u Contact Service Cylinder head is faulty u...

Page 55: ...ge 151 2 Perform LOP test procedures Page 153 3 Check ECU plug in connections Page 147 4 Check engine wiring Page 143 5 Contact Service have ECU checked and replaced if required AL Output Stage Bank 1...

Page 56: ...ower failure of control system u Check power circuit breakers and fuses AL Power Failure Monitoring Cause Corrective action Power failure u Check power circuit breakers and fuses AL Transistor Output...

Page 57: ...lt CAN bus 1 Check LOP visually Page 151 2 Perform LOP test procedures Page 153 3 Check ECU plug in connections Page 147 4 Check engine wiring Page 143 5 Contact Service Have MPU 23 of PIM No 21 X A00...

Page 58: ...age 151 2 Perform LOP test procedures Page 153 3 Check ECU plug in connections Page 147 4 Check engine wiring Page 143 5 Contact Service Have RCS checked and replaced if required DL 211 A300 A501 Caus...

Page 59: ...Cause Corrective action LCU of LOP 1 PIM No 21 X A001 A010 not detected on redundant CAN bus 1 Check LOP visually Page 151 2 Perform LOP test procedures Page 153 3 Contact Service Have MPU 23 of PIM N...

Page 60: ...laced if required RL 211 A300 A500 Cause Corrective action RCS with PIM No 21 X A300 A500 not detected on redundant CAN bus 1 Check LOP visually Page 151 2 Perform LOP test procedures Page 153 3 Conta...

Page 61: ...is too low u Check gearbox lube oil level and top up if required see gearbox documentation SS P Gear Control Oil GCU Cause Corrective action Safety system detects that gear control oil pressure is too...

Page 62: ...n Safety system has triggered engine stop u Determine cause for shutoff and rectify SS T Coolant ECU Cause Corrective action Safety system detects that coolant temperature is too high u Reduce power S...

Page 63: ...ature sensors provide different values 1 Check LOP visually Page 151 2 Perform LOP test procedures Page 153 3 Check ECU plug in connections Page 147 4 Check engine wiring Page 143 5 Contact Service Ha...

Page 64: ...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 manually 1 Remove cover...

Page 65: ...d all tools are removed from the engine Engine Barring with starting system 1 Disengage the bayonet coupling 4 of con nector X4 with connector pliers 2 and dis connect connector 3 from engine governor...

Page 66: ...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 67: ...Final steps 1 Install injector Page 82 2 Install cylinder head cover Page 76 MW15409 04E 2015 08 Task Description 67 TIM ID 0000000015 016...

Page 68: ...und 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 m...

Page 69: ...tion 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 inspe...

Page 70: ...n WARNING Compressed air gun ejects a jet of pressurized air Risk of injury to eyes and damage to hearing risk of rupturing internal organs Never direct air jet at people Always wear safety goggles fa...

Page 71: ...f injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Replacing filter element of oil separator 1 Remove cover 2 with O ring 3...

Page 72: ...ll diaphragm 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...

Page 73: ...tools Material Spare parts Designation Use Part No Qty Torque wrench 20 100 Nm F30026582 1 Box wrench bit 17 mm F30030450 1 Feeler gauge Y4342013 1 Preparatory steps 1 Remove cover plate 2 2 Remove c...

Page 74: ...r A1 is in overlap TDC I Inlet valve X Exhaust valve 4 Use feeler gauge to determine the distance between valve bridge and rocker arm 5 If the deviation from the set value exceeds 0 1 mm adjust valve...

Page 75: ...verify that the gauge just passes through the gap Result If not adjust valve clearance Final steps 1 Remove barring device 2 For installation of removed parts follow reverse sequence of working steps...

Page 76: ...Removing and installing cylin der head cover 1 Remove screws 2 Remove cylinder head cover with gasket from cylinder head 3 Clean installation surface 4 Check condition of profile gasket in cylinder he...

Page 77: ...eplacement Special tools Material Spare parts Designation Use Part No Qty Injection pump Spare Parts Catalog Injection pump Replacement u Remove injection pump and install new one Page 78 MW15409 04E...

Page 78: ...NGER Rotating and moving engine parts Risk of crushing danger of parts of the body being caught or pulled in Before cranking the engine with starter system make sure that there are no persons in the e...

Page 79: ...njection pump securing screws 6 Remove injection pump 7 Remove sealing rings from injection pump 8 After removal seal all openings with suitable covers Installing injection pump 1 Remove all blanking...

Page 80: ...rque wrench Maximum permissible tightening torque 35 Nm Name Size Type Lubricant Value Standard Union nut Tightening torque 20 Nm 5 Nm 13 Install injection pump cabling 1 14 Tighten screws to specifie...

Page 81: ...tor Replacement Special tools Material Spare parts Designation Use Part No Qty Injector Spare Parts Catalog Replacing injector u Remove injector and install new injector Page 82 MW15409 04E 2015 08 Ta...

Page 82: ...m 30 15 X00067260 1 Sealing ring Spare Parts Catalog Sealing ring Spare Parts Catalog WARNING Fuels are combustible and explosive Risk of fire and explosion Avoid open flames electrical sparks and ign...

Page 83: ...ion 2 Clean sealing surface on cylinder head and protective sleeve 3 Coat sealing ring 1 with assembly com pound and fit onto injector 4 Coat sealing ring 2 with assembly com pound and fit onto inject...

Page 84: ...e 40 Nm 5 Nm 14 Tighten screw for clamp at injector to specified torque using a torque wrench Name Size Type Lubricant Value Standard Screw Tightening torque 50 Nm 15 Install fuel line 3 16 Tighten un...

Page 85: ...ngine oil Pressure pipe neck 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 prote...

Page 86: ...hten thrust screw 2 to specified torque using a torque wrench Name Size Type Lubricant Value Standard Thrust screw Tightening torque 40 Nm 5 Nm 10 Install fuel line 3 11 Tighten union nut on injection...

Page 87: ...urces Do not smoke Wear protective clothing protective gloves and safety glasses facial protection Draining fuel 1 Release threaded vent plugs on filter head 2 Open nipple on fuel line and drain fuel...

Page 88: ...urces Do not smoke Wear protective clothing protective gloves and safety glasses facial protection Venting fuel system 1 Unlock fuel priming pump unscrew handle 2 Open threaded vent plugs on filter he...

Page 89: ...erges at the nipple 7 Close nipple at fuel heat exchanger 8 Open nipple at fuel line 9 Operate the pump with the handle until bub ble free fuel emerges at the nipple 10 Close nipple on fuel line 11 Lo...

Page 90: ...the engine s danger zone WARNING Fuels are combustible and explosive Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Wear protective clothing protecti...

Page 91: ...ters in the same way 9 Vent fuel system Page 88 Easy change fuel filter replace ment with the engine running 1 Cut out the filter to be replaced 2 Open the threaded vent plugs at the filter head of th...

Page 92: ...f 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 within...

Page 93: ...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 explosiv...

Page 94: ...g 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 an...

Page 95: ...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 wa...

Page 96: ...ump 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 by...

Page 97: ...on 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 w...

Page 98: ...move 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 secure...

Page 99: ...1 B03 intake air temperature 2 B10 charge air pressure 3 B09 charge air tempera ture 4 B5 2 lube oil pressure 5 F25 lube oil pressure differ ence over filter 6 B34 fuel pressure after fil ter 7 B07 l...

Page 100: ...Left engine side 12V 2000 M 1 F33 coolant level 2 Y27 turbocharger control valve 3 B21 raw water pressure 100 Task Description MW15409 04E 2015 08 TIM ID 0000012937 004...

Page 101: ...Engine free end 12V 2000 M 1 B06 coolant temperature 2 B6 2 coolant temperature MW15409 04E 2015 08 Task Description 101 TIM ID 0000012937 004...

Page 102: ...Right engine side 12V 2000 M 1 B44 turbocharger speed 2 B16 coolant pressure 3 F46 leak off fuel level 4 B33 fuel temperature 102 Task Description MW15409 04E 2015 08 TIM ID 0000012937 004...

Page 103: ...00 M 1 B01 camshaft speed 2 B4 22 exhaust bulk tem perature B side 3 B13 crankshaft speed 4 B13 2 crankshaft speed 5 B4 21 exhaust bulk tem perature A side MW15409 04E 2015 08 Task Description 103 TIM...

Page 104: ...ir pressure 3 B09 charge air tempera ture 4 B5 2 lube oil pressure 5 F25 lube oil pressure differ ence over filter 6 B34 fuel pressure after fil ter 7 B07 lube oil temperature 8 B05 lube oil pressure...

Page 105: ...Left engine side 16V 2000 M 1 F33 coolant level 2 Y27 turbocharger control valve 3 B21 raw water pressure MW15409 04E 2015 08 Task Description 105 TIM ID 0000012937 004...

Page 106: ...Free end 16V 2000 M 1 B06 coolant temperature 2 B6 2 coolant temperature 106 Task Description MW15409 04E 2015 08 TIM ID 0000012937 004...

Page 107: ...Right engine side 16V 2000 M 1 B44 turbocharger speed 2 B16 coolant pressure 3 F46 leak off fuel level 4 B33 fuel temperature MW15409 04E 2015 08 Task Description 107 TIM ID 0000012937 004...

Page 108: ...00 M 1 B01 camshaft speed 2 B4 22 exhaust bulk tem perature B side 3 B13 crankshaft speed 4 B13 2 crankshaft speed 5 B4 21 exhaust bulk tem perature A side 108 Task Description MW15409 04E 2015 08 TIM...

Page 109: ...s wear safety goggles face mask and ear defenders Intercooler Checking conden sate drain line for coolant dis charge and obstruction 1 With the engine running check the conden sate drain line on engin...

Page 110: ...re 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 111 2 Reset signal ring of contamination indicator...

Page 111: ...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 filter 1...

Page 112: ...led Checking signal ring position 1 If the signal ring is completely visible in the control window 2 replace air filter Page 110 2 After installation of new filter press reset button 1 Result Engaged...

Page 113: ...d and starting disabled Checking air flap for ease of movement 1 Repeatedly shift lever between A and B positions by hand and check ease of move ment 2 Contact Service if the mechanism does not move e...

Page 114: ...opped and starting disabled Checking exhaust flap for ease of movement 1 Repeatedly shift linkage and actuating cylin der between A and B positions by hand and check ease of movement 2 Contact Service...

Page 115: ...heck 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 143 MW15409 04E...

Page 116: ...ck Page 118 4 If necessary top up to max mark Page 117 5 Insert oil dipstick into guide tube up to the stop Checking oil level after the engine is stopped 1 5 minutes after stopping the engine remove...

Page 117: ...aining oil at drain plug on oil pan 1 Provide a suitable container to collect the oil 2 Unscrew the bleed screw and drain the oil 3 Screw bleed screw back in with new sealing ring 4 Replace engine oil...

Page 118: ...les safety mask Avoid contact with skin Do not inhale oil vapor Note In the case of new engines and spare parts oil dipsticks are delivered without marks Oil dipstick Marking 1 Extract or drain off al...

Page 119: ...s 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 in...

Page 120: ...acement crank engine on starting system Page 65 11 Check oil level Page 116 Changing oil filter with engine running 1 Reduce engine speed to 1100 rpm 2 Remove cut out oil filter using the oil filter w...

Page 121: ...Parts 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 o...

Page 122: ...4 Measure 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...

Page 123: ...10 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 N...

Page 124: ...erature Circuit 8 17 1 Drain and venting points Top side 1 Engine coolant vent 2 Intercooler 3 Overflow line 4 Engine coolant expansion tank 5 Fuel filter 6 Engine oil filter 124 Task Description MW15...

Page 125: ...Left side 1 Engine coolant drain plug 2 Engine coolant drain plug 3 Raw water pump drain plug MW15409 04E 2015 08 Task Description 125 TIM ID 0000006697 003...

Page 126: ...lling plug 5 Raw water pump drain plug 6 Connection for oil extrac tion 7 Oil dipstick connection left or right engine side option al 8 Oil filler neck connection left or right engine side op tional 9...

Page 127: ...ine oil filter 4 Fuel priming pump 5 Raw water pump filling plug 6 Oil filler neck connection left or right engine side op tional 7 Oil dipstick connection left or right engine side option al 4 Leak f...

Page 128: ...tional 3 Oil dipstick connection left or right engine side option al 4 Oil dipstick connection left or right engine side option al 5 Oil filler neck connection left or right engine side op tional 6 E...

Page 129: ...rn breather valve counterclock wise and remove 3 Check coolant level coolant must be visible at the lower edge of the cast in eye Checking coolant level at re mote cooler 1 Check coolant level coolant...

Page 130: ...ge Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 131 2 Fill with engine coolant Page 132 130 Task Description MW15409 04E 201...

Page 131: ...lve of coolant expansion tank counterclockwise until the first stop and al low pressure to escape 2 Continue to turn breather valve counterclock wise and remove 3 Draw off separated corrosion inhibito...

Page 132: ...l top up coolant only into cold engine Engine coolant Filling 1 Turn breather valve of filler neck on coolant expansion tank counterclockwise to first stop and allow pressure to escape 2 Continue to t...

Page 133: ...s running Risk of damage to hearing Wear ear protectors HT coolant pump Relief bore check 1 Check relief bore arrow for oil and coolant discharge 2 Stop engine Page 46 and disable engine start 3 Clean...

Page 134: ...coolant expansion tank counterclockwise to first stop and allow pressure to escape 2 Continue to turn breather valve counterclock wise and remove 3 Draw off precipitated corrosion inhibitor oil from...

Page 135: ...ke performance the pump must be filled with 3 to 4 liters of water in the following cas es Before initial operation Following repair maintenance work or pump exchange After extended out of service per...

Page 136: ...ARNING 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 arrow for oil and coolant discharge 2 Cl...

Page 137: ...led 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 140 Drive belt C Chunking Drive belt Bel...

Page 138: ...embly device F6559691 1 Preparatory steps 1 Remove limit switch 4 2 Remove indicator 1 3 Remove screws 3 of protective cover 2 4 Remove protective cover 5 Check drive belt condition Page 137 Belt driv...

Page 139: ...4 Use assembly device to adjust distance A by turning adjustment lever 2 5 Tighten screws 1 and 3 6 Measure distance A with assembly device Final steps 1 Install protective cover 2 2 Install securing...

Page 140: ...e end 3 Remove protective cover Replacing drive belt 1 Hold adjusting lever at square 2 Rotate adjusting lever until drive belt is released 3 Use mandrel to lock adjusting lever in position 4 Remove d...

Page 141: ...nts 1 Measure height setting b with feeler gauge 2 Measure dimension a with calipers 3 Calculate permissible value of dimension a considering the measured value of height ad justment b Reference value...

Page 142: ...Damage to component Severe material damage Do not press in grease at high pressure or with hard strokes Permissible lubrication pressure max 15 bar Universal shaft Greasing 1 Remove guard from univers...

Page 143: ...closed and intact 4 Replace faulty cable clips 5 Check cable clamps for secure fit tighten loose clamps 6 Replace faulty cable clamps 7 Visually inspect the following electrical components for damage...

Page 144: ...dirt from surface of connectors 1 connector sockets and shrink sleeves 2 us ing a cloth moistened with isopropyl alcohol 3 Check legibility of cable labels Clean or re place illegible labels Cleaning...

Page 145: ...onnectors 1 connector sockets and shrink sleeves 2 us ing a cloth moistened with isopropyl alcohol 3 Check legibility of cable labels Clean or re place illegible labels Cleaning severely contaminated...

Page 146: ...ng 1 and or cover plate 3 is are not mounted Secure cover plate 3 with screws Then install switch housing 1 with screws ensuring that the switch 2 is ac tuated by the cover plate 3 3 If switch housing...

Page 147: ...g connections 1 Use connector pliers 3 to make certain that all plug connections on the Engine Control Unit are securely seated 2 Tighten loose bayonet union nuts 2 with connector pliers 3 by turning...

Page 148: ...ine Monitoring Unit 1 Use connector pliers 3 to make certain that all Engine Monitoring Unit plug connections are securely seated 2 Tighten loose bayonet union nuts 2 with connector pliers 3 by turnin...

Page 149: ...m grounding stud 7 6 If the screws 4 are easily accessible 1 Unscrew screws 4 2 Remove engine control system hous ing 3 from mounting brackets 2 3 Unscrew mounting brackets 2 cable shock absorbers 5 a...

Page 150: ...1 Cleaning LOP 1 Wipe LCD display with dry cloth without applying excessive pressure 2 Remove dirt from keys using isopropyl alcohol 3 Remove heavy soiling from housing surface with isopropyl alcohol...

Page 151: ...nt door 2 Check securing screws 1 4 5 7 for firm seating Tighten loose threaded connections 3 Check internal assemblies for firm seating this applies in particular to printed circuit board 2 and PIMs...

Page 152: ...r damage Pushbuttons move easily Pushbutton housing is seated securely Seals 2 between PAN operating panels and LOP housing are not damaged 2 Display Ensure that Front glass is not damaged or pressed...

Page 153: ...button 2 is illumi nated brightly gearbox disengaged Switching between local and re mote control mode 1 Press LOCAL OPERATION illuminated push button 1 Result LOCAL OPERATION button 1 flashes Set ting...

Page 154: ...nated pushbutton 1 again Result Power supply to engine governor is re estab lished 4 On engines with emergency air shutoff flaps open flaps Emergency stop simulation with the engine at standstill 1 Op...

Page 155: ...hes Institut f r Normung e V At the same time identifier of German standards DIN Deutsche Industrie Norm DIS Display unit DL Default Lost Alarm CAN bus missing ECS Engine Control System ECS UNI Engine...

Page 156: ...Main Reduction Gear OT Oberer Totpunkt Top Dead Center TDC P xyz Pressure xyz Pressure measuring point xyz PAN Panel Control panel PCU Propeller Control Unit PIM Peripheral Interface Module PT Power...

Page 157: ...lanation WZK Werkzeugkatalog Tool Catalog TC ZKP Zugeh rigkeit Kategorie Parameter Assignment category parameter number scheme for signals from the ADEC engine governor MW15409 04E 2015 08 Appendix A...

Page 158: ...e work in case of malfunction or changed oper ating conditions or for spare parts supply Your contact person in our Customer Assistance Center E mail info mtu online com Tel 49 7541 9077777 Fax 49 754...

Page 159: ...ator drive Drive belt check and adjustment Page 138 Box wrench Part No F30038493 Qty Used in 1 8 5 2 Injection pump Removal and installation Page 78 Box wrench bit 17 mm Part No F30030450 Qty Used in...

Page 160: ...e monitoring unit and connectors Cleaning Page 145 Qty Used in 1 8 24 5 Engine Monitoring Unit Plug connection check Page 148 Qty Used in 1 8 24 6 Engine control system Removal and installation Page 1...

Page 161: ...h Part No F30379104 Qty Used in 1 8 8 1 Fuel filter Replacement Page 90 Fuel suction device Part No F30378207 Qty Used in 1 8 6 2 Injector Removal and installation Page 82 High pressure cleaning unit...

Page 162: ...134 Oil filter wrench Part No F30379104 Qty Used in 1 8 16 2 Engine oil filter Replacement Page 119 Qty Used in 1 8 16 3 Centrifugal oil filter and filter sleeve Cleaning and replacement Page 121 Open...

Page 163: ...ator replacement di aphragm check and replacement Page 71 Qty Used in 1 8 4 2 Cylinder head cover Removal and installation Page 76 Qty Used in 1 8 5 2 Injection pump Removal and installation Page 78 Q...

Page 164: ...and installation Page 78 Qty Used in 1 8 6 2 Injector Removal and installation Page 82 Qty Used in 1 8 7 1 HP fuel line Pressure pipe neck replacement Page 85 Spider patch spanner Part No F30027425 Q...

Page 165: ...Page 78 Qty Used in 1 8 6 2 Injector Removal and installation Page 82 Qty Used in 1 8 7 1 HP fuel line Pressure pipe neck replacement Page 85 Torque wrench 20 100 Nm Part No F30026582 Qty Used in 1 8...

Page 166: ...and replacement Page 71 Torque wrench 6 50 Nm Part No F30027336 Qty Used in 1 8 4 2 Cylinder head cover Removal and installation Page 76 Vernier caliper 300 mm Part No Y20000275 Qty Used in 1 8 21 1...

Page 167: ...check 137 E Emergency engine shutdown At LOP without BlueLine automation system 48 Engine Barring manually 64 Shutdown At LOP without BlueLine automation system 46 Start At BlueLine automation system...

Page 168: ...t persons 158 O Oil dipstick Marking 118 Operational checks 42 P Plant Cleaning 50 Product description 21 Putting into operation Preparations after extended out of service periods 3 months 37 R Raw wa...

Page 169: ...W Waterjet Flushing From LOP option 45 MW15409 04E 2015 08 Appendix B 169 DCL ID 0000039398 002...

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