MTU 12V2000M93 Operating Instructions Manual Download Page 4

Page: 4 / 163

7.10.1 Air filter – Replacement

106

7.10.2 Air filter – Removal and installation

107

7.11 Air Intake

108

7.11.1 Service indicator – Signal ring position check

108

7.12 Starting Equipment

109

7.12.1 Starter – Condition check

109

7.13 Lube Oil System, Lube Oil Circuit

110

7.13.1 Engine oil – Level check

110

7.13.2 Engine oil – Change

111

7.14 Oil Filtration / Cooling

112

7.14.1 Engine oil filter – Replacement

112

7.14.2 Centrifugal oil filter – Cleaning and filter-

sleeve replacement

114

7.15 Coolant Circuit, General, High-Temperature

Circuit

116

7.15.1 Drain and venting points

116

7.15.2 Engine coolant – Level check

121

7.15.3 Engine coolant – Change

122

7.15.4 Engine coolant – Draining

123

7.15.5 Engine coolant – Filling

124

7.15.6 HT coolant pump – Relief bore check

125

7.15.7 Engine coolant – Sample extraction and

analysis

126

7.15.8 Coolant filter – Replacement

127

7.16 Raw Water Pump with Connections

128

7.16.1 Raw water pump – Relief bore check

128

7.17 Belt Drive

129

7.17.1 Drive belt – Condition check

129

7.18 Battery-Charging Generator

130

7.18.1 Battery-charging generator drive – Drive belt

replacement

130

7.19 Fuel Supply System

131

7.19.1 Water drain valve – Check

131

7.19.2 Differential pressure gauge – Check

132

7.19.3 Water level probe (3-in-1 rod electrode) –

Check

133

7.19.4 Pump capacity – Check

134

7.19.5 Coalescer filter element – Replacement

135

7.20 Wiring (General) for Engine/Gearbox/Unit

137

7.20.1 Engine cabling – Check

137

7.21 Accessories for (Electronic) Engine

Governor / Control System

138

7.21.1 Engine governor and connector – Cleaning

138

7.21.2 EMU and connectors – Cleaning

139

7.21.3 Engine governor plug connections – Check

140

7.21.4 Engine Monitoring Unit EMU 7 – Plug

connection check

141

7.21.5 Interface module EIM plug connections –

Check

142

7.21.6 Engine Control Unit – Self-test

143

7.21.7 Engine Control Unit ECU 7 – Removal and

installation

144

7.21.8 Engine Monitoring Unit – Removal and

installation

145

7.21.9 Engine Interface Module EIM – Removal and

installation

146

7.21.10 Diagnostic features on EIM

147

8 Appendix A

8.1 Abbreviations

150

8.2 MTU contact persons/service partners

152

9 Appendix B

9.1 Special Tools

153

9.2 Index

161

4 | Table of Contents | M015655/05E 2015-06

DCL-ID: 0000014251 - 003

Summary of Contents for 12V2000M93

Page 1: ...Operating Instructions Diesel engine 12V2000M93 16V2000M93 M015655 05E...

Page 2: ...sed in any way whether in whole or in part without the prior written consent of MTU Friedrichshafen GmbH This particularly applies to its reproduction distribution editing transla tion microfilming an...

Page 3: ...Cleaning 66 5 Maintenance 5 1 Maintenance task reference table QL1 67 6 Troubleshooting 6 1 Fuel treatment system Troubleshooting 68 6 2 Troubleshooting 69 7 Task Description 7 1 SOLAS 72 7 1 1 SOLAS...

Page 4: ...tery Charging Generator 130 7 18 1 Battery charging generator drive Drive belt replacement 130 7 19 Fuel Supply System 131 7 19 1 Water drain valve Check 131 7 19 2 Differential pressure gauge Check 1...

Page 5: ...with the Spare Parts Catalog MTU contact Service partner In the original as delivered configuration or in a configuration approved by the manufacturer in writ ing including engine control parameters...

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

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

Page 8: ...ransport without flange mounted gearbox A max permissible diagonal pull 70 B max permissible diagonal pull 35 Illustration is also valid for 12V 16V2000Mxx engines 8 Safety M015655 05E 2015 06 TIM ID...

Page 9: ...lift the engine at the lifting eyes of the bear ing pedestal or use a means of transportation which is appropriate for the given weight forklift truck Install the crankshaft locking device and the loc...

Page 10: ...instruments 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 famili...

Page 11: ...Observe the warning information applicable to the devices M015655 05E 2015 06 Safety 11 TIM ID 0000040533 010...

Page 12: ...e mounts damping elements couplings and 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...

Page 13: ...cable straps Welding work Welding operations on the product or mounted units are not permitted Cover the product when welding in its vicinity Before starting welding work Switch off the power supply m...

Page 14: ...hat cabling cannot be dam aged during operation by Contact with sharp edges Chafing on components Contact with hot surfaces Do not secure cables on lines carrying fluids Do not use cable straps to sec...

Page 15: ...with its handling Noise Noise can lead to an increased risk of accidents if acoustic signals warning shouts or sounds indicating danger are drowned Wear ear protectors in workplaces with a sound pres...

Page 16: ...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 17: ...medial 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...

Page 18: ...ues MA are specified for screws of strength class 8 8 surface finish bare metal phosph atized or galvanized and 10 9 surface finish bare metal or phosphatized The values in the table are based on a fr...

Page 19: ...s Tightening torques 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 Tightenin...

Page 20: ...rial and manufacture to MMN 389 standard bare metal or phosphatized The values in the table are based on a friction coefficient tot 0 125 Threads and mating faces of screws and nuts must be coated wit...

Page 21: ...1230 M30 1250 1575 Protect screw shaft from torsion when tightening MA tightening torques Tightening torques for plug screws to MTN 5183 1 standard This standard applies to plug screws to DIN 908 DIN...

Page 22: ...Tightening 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...

Page 23: ...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 screw...

Page 24: ...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 25: ...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 26: ...ion 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 27: ...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 28: ...ttings 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...

Page 29: ...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 30: ...e 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 30 General Inform...

Page 31: ...ccordance 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 32: ...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 Piston c...

Page 33: ...ignals are routed out via M threaded pins and are also integrated in the engine wiring har ness Functions ECU supply EMU supply Plant signals ECU7 connector X1 Bus interface 2x MCS5 CAN CAN dialog out...

Page 34: ...t 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 c...

Page 35: ...side 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 reduc...

Page 36: ...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 36 General Information M015655 05E 2015 06 TIM ID 000...

Page 37: ...st screw 7 Thrust ring 8 O ring 9 HP line 10 Pressure pipe Leak off fuel caused by leakages from the sealing cones or the HP lines is returned to the HP pump from where it is routed at atmospheric pre...

Page 38: ...st turbocharger left secondary turbocharger 16 Exhaust outlet horizontal 17 Actuating cylinder for ex haust flap 18 Actuating cylinder for air flap 19 Control valve for flap con trol 20 Cylinder head...

Page 39: ...t housing 15 Exhaust system housing 16 Coolant pump 17 Crankcase breather 18 HP fuel pump 19 Fuel delivery pump 20 Oil filler neck 21 Oil dipstick 22 Drive flange 23 Flywheel housing 24 Engine mountin...

Page 40: ...ns are insignificant Also applies similarly to 12V Item Designation Monitoring of 1 B3 Intake air temperature 2 B9 Charge air temperature 3 B7 Lube oil temperature 4 B10 Charge air pressure 5 B44 Turb...

Page 41: ...ssure before filter 3 B5 1 Lube oil pressure after filter 4 B5 2 optional Lube oil pressure after filter 5 F33 Engine coolant level expansion tank 6 B21 optional Raw water pressure 7 B6 2 optional Coo...

Page 42: ...gine driving end Item Designation Monitoring of 1 B1 ECU Camshaft speed 2 B13 2 optional EMU Crankshaft speed 3 B13 ECU Crankshaft speed 42 General Information M015655 05E 2015 06 TIM ID 0000008412 00...

Page 43: ...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 44: ...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 45: ...bar 1000 Site altitude above sea level M 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 12 Rated engine speed A rpm 2450 Fuel stop power ISO 3046 A kW 134...

Page 46: ...when engine is starting L bar 0 25 Fuel supply flow max R Liter min 6 0 GENERAL OPERATING DATA Number of cylinders 12 Firing speed from R rpm 100 Firing speed to R rpm 120 STARTER electric Number of c...

Page 47: ...at ing inclinations L Liters 87 Oil pan capacity dipstick mark max standard oil system option max operat ing inclinations L Liters 105 WEIGHTS MAIN DIMENSIONS Number of cylinders 12 Engine dry weight...

Page 48: ...Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 16 Rated engine speed A rpm 2450 Fuel stop power ISO 3046 A kW 1790 GENERA...

Page 49: ...when engine is starting L bar 0 25 Fuel supply flow max R Liter min 8 0 GENERAL OPERATING DATA Number of cylinders 16 Firing speed from R rpm 100 Firing speed to R rpm 120 STARTER electric Number of...

Page 50: ...at ing inclinations L Liters 115 Oil pan capacity dipstick mark max standard oil system option max operat ing inclinations L Liters 138 WEIGHTS MAIN DIMENSIONS Number of cylinders 16 Engine dry weight...

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 M015655 05E 2015 06 Technical Data 51 TIM ID 0000038135 002...

Page 52: ...Main dimensions Engine model Length A Width B Height C 12V2000M93 approx 2069 mm approx 1295 mm approx 1350 mm 16V2000M93 approx 2486 mm approx 1295 mm approx 1390 mm 52 Technical Data M015655 05E 201...

Page 53: ...3 Fuel prefilter pressure gage Align adjustable pointer with position of pressure indicator Page 98 Fuel system Vent Page 95 Raw water pump if located above waterline Prime approx 3 to 4 liters Fillin...

Page 54: ...nt level Page 121 Coolant circuit Heat engine coolant with coolant preheating unit Fuel prefilter Drain water and contaminants Page 99 Battery charging generator drive Check condition of drive belt Pa...

Page 55: ...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 57 2 Shut down fuel treatment system Page 65 M01...

Page 56: ...ves 4 Switch on fuel treatment system Page 60 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 57: ...ne 3 Switch on fuel treatment system and operate it for some minutes Page 60 Result Fuel is sucked from the tank dirt particles and water are filtered and separated then the fuel is deliv ered via the...

Page 58: ...ncy HAT 1 Switch on fuel treatment system Page 60 2 Start engine Page 61 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 59: ...Check exhaust color Page 69 Fuel prefilter Check if suction side pressure indicated at the fuel prefilter is within the limit Page 98 Drain water and contaminants Page 99 Air filter Check signal ring...

Page 60: ...ore switching on ensure that all housings are closed Before switching on ensure that no work is in progress anywhere on the entire system Fuel treatment system Switching on 1 Carry out checks prior to...

Page 61: ...rsons in the en gine 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...

Page 62: ...d for at least 10 minutes until engine temperatures have dropped and constant values are displayed The engine can be stopped from the following points Item Action Control stand Operating instructions...

Page 63: ...An emergency engine stop can be initiated from the following points Item Action Control stand Operating instructions for electronic system Local Operating Panel LOP Operating instructions for electro...

Page 64: ...suitable temperature the antifreeze concentration is insufficient for the engine room tempera ture antifreeze concentration is 50 and engine room temperature is below 40 C Raw water Drain if freezing...

Page 65: ...binet until water discharge from the outlet stops 2 Switch off fuel treatment system 3 Close ball valve at the inlet to the fuel treatment system 4 Close ball valve at the outlet of the fuel treatment...

Page 66: ...rectly 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 protection 2 Pr...

Page 67: ...ed Page 59 W1001 Replace fuel filter or fuel filter element Page 96 W1002 Check valve clearance Page 88 W1003 Check condition and tension of drive belt replace belt if re quired Page 129 W1005 Replace...

Page 68: ...pped 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...

Page 69: ...not 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...

Page 70: ...r Page 108 Intercooler dirty u Contact Service Exhaust turbocharger defective u Contact Service Coolant leaks at intercooler Cause Corrective action Intercooler leak ng major coolant discharge u Conta...

Page 71: ...action Engine is not at operating temperature u Run engine to reach operating temperature Water in fuel u Drain fuel prefilter Page 99 Intercooler leaking u Contact Service M015655 05E 2015 06 Troubl...

Page 72: ...ls Material Spare parts Designation Use Part No Qty Shield A4 735233000100 10 Shield A5 735233000101 14 Shield A7 735233000103 6 Shield A8 735233000104 2 SOLAS shielding Installation 1 Pinpoint instal...

Page 73: ...t 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 Pinpoint...

Page 74: ...Primarily fit SOLAS shielding as per MTN 5233 Page 72 Free end B side Item Type of shielding Comments 1 free end B side Shield A7 On fuel delivery pump 2 free end B side Shield A7 On HP fuel pump Fre...

Page 75: ...l priming pump Driving end A side Item Type of shielding Comments 1 Driving end A side Shield A5 On air flap 2 driving end A side Shield A4 On brazed on union 3 driving end A side Shield A5 On turboch...

Page 76: ...plate Driving end Item Type of shielding Comments 1 driving end Shield A4 Turbocharger lubrication left side 2 driving end Shield A4 Turbocharger lubrication center Driving end Item Type of shielding...

Page 77: ...Turbocharger flap 3 driving end B side Shield A4 On brazed on union 4 driving end B side Shield A5 On air flap 5 driving end B side Shield A4 To turbocharger lubrication Driving end B side Item Type...

Page 78: ...of shielding Comments 1 Driving end A side Shield A5 To flap control Driving end B side Item Type of shielding Comments 1 driving end B side Shield A5 To flap control 78 Task Description M015655 05E 2...

Page 79: ...ere 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 manua...

Page 80: ...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 tools ar...

Page 81: ...top piston ring and bottom edge of carbon scraper ring First signs of marks left by top piston ring Bright mark on entire circumference Faultless even honing pattern First signs of marks left by lowe...

Page 82: ...epending on findings Do not take any action or carry out a further endoscopic examination as part of maintenance work or contact Service cylinder liner must be replaced Final steps 1 Install injector...

Page 83: ...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 84: ...ation are similar A thorough investigation and compliance with the above evaluation criteria allow an unambiguous evaluation To avoid unnecessary disassembly work it is recommended that another inspec...

Page 85: ...to hearing risk of rupturing internal organs Never direct air jet at people Always wear safety goggles face mask and ear defenders Crankcase breather Cleaning oil pre separator element 1 Remove cover...

Page 86: ...are harmful to health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Replace oil separator filter ele ment 1 Remo...

Page 87: ...aphragm 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 Scre...

Page 88: ...60 Nm F30510423 1 Measuring instrument Y4345888 1 Engine oil Preparatory steps 1 Remove air filter Page 107 2 Remove cylinder head cover Page 91 Positioning A1 piston at TDC Note With cylinder head a...

Page 89: ...rlap TDC in cylinder A1 Bank A I I X I X I X I X Bank B X I I X X X I I Inlet Inlet valve adjustment admissible X Exhaust Exhaust valve adjustment admissible Valve adjustment inadmissible 4 Use feeler...

Page 90: ...hrough between valve bridge and rocker arm Result If not adjust valve clearance Final steps 1 Remove barring device 2 Install cylinder head cover Page 91 3 Install air filter Page 107 90 Task Descript...

Page 91: ...installing cylin der head cover 1 Remove screws 1 2 Remove cylinder head cover 2 with gas ket from cylinder head 3 Clean installation surface 4 Check condition of gasket of cylinder head cover Result...

Page 92: ...ector 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 93 92 Task Description M01...

Page 93: ...ustible 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 P...

Page 94: ...cone of HP line 5 and injector 1 with engine oil 9 Align injector 1 and HP line 5 with alignment device 10 Connect HP line 5 to HP accumulator and tighten by hand 11 Connect HP line 5 to injector 1 an...

Page 95: ...d 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 Opera...

Page 96: ...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 pro...

Page 97: ...5 Easy change fuel filter replace ment with the engine running 1 Cut out filter to be replaced e g turn three way cock to position B to switch off the filter 2 to be replaced 2 Open threaded vent plug...

Page 98: ...if ferential pressure gauge 1 After installation of a new filter element align adjustable pointer 2 with pressure indicating pointer 3 of pressure gauge 1 2 Verify that differential pressure is within...

Page 99: ...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 100: ...g connec tion 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 ap prox 30...

Page 101: ...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 wat...

Page 102: ...p to filling connec tion 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 103: ...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 104: ...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 105: ...lways wear safety goggles face mask and ear defenders Intercooler Checking conden sate drain line for coolant dis charge and obstruction 1 Check drain line for water discharge and obstruction when the...

Page 106: ...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 107 2 Reset signal ring of contamination indicator...

Page 107: ...2 Remove air filter 1 and clamp 2 from connecting 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 108: ...led Checking signal ring position 1 If the signal ring is completely visible in the control window 2 replace air filter Page 106 2 After installation of new filter press reset button 1 Result Engaged...

Page 109: ...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 137 M015655 05E...

Page 110: ...1 marks 4 Top up with oil up to the max 1 mark Page 111 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 engi...

Page 111: ...oid contact 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...

Page 112: ...tectors 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...

Page 113: ...ment crank engine with starting system Page 80 11 Check oil level Page 110 Replacing oil filter with the engine running 1 Reduce engine speed to 1100 rpm 2 Unscrew cut out oil filter with oil filter w...

Page 114: ...g Spare Parts Catalog 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...

Page 115: ...or bottom with cold cleaner 10 Blow out with compressed air 11 Check sealing ring fit new one if necessa ry 12 Insert new filter sleeve into rotor cap with the smooth paper surface facing the outer wa...

Page 116: ...15 Coolant Circuit General High Temperature Circuit 7 15 1 Drain and venting points 12 V 16 V 1 Overflow line expansion tank 2 Filler neck 116 Task Description M015655 05E 2015 06 TIM ID 0000038198 00...

Page 117: ...ews 2 Engine coolant drain plug 3 Raw water pump filling plug 4 Measuring point pressure before raw water pump 5 Raw water pump drain plug 6 Connection for oil extrac tion M015655 05E 2015 06 Task Des...

Page 118: ...Left side 1 Engine coolant drain plug 2 Engine coolant drain plug M14x1 5 118 Task Description M015655 05E 2015 06 TIM ID 0000038198 001...

Page 119: ...drain plug M14x1 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 M015655 05E 2015 06 Task Description...

Page 120: ...Driving end KS 1 Engine coolant drain plug 2 Connection for oil extrac tion 120 Task Description M015655 05E 2015 06 TIM ID 0000038198 001...

Page 121: ...ather valve on coolant expansion tank Page 38 counterclockwise until first stop and allow pressure to escape 2 Continue to turn breather valve counter clockwise and remove 3 Check coolant level coolan...

Page 122: ...ge Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 123 2 Fill with engine coolant Page 124 122 Task Description M015655 05E 201...

Page 123: ...3 Switch off preheating unit Draining engine coolant 1 Turn breather valve of filler neck on coolant expansion tank Page 116 counterclockwise to first stop and allow pressure to escape 2 Continue to...

Page 124: ...f cracks in the engine Fill top up coolant only into cold engine Filling with engine coolant 1 Turn breather valve of coolant expansion tank Page 38 counterclockwise until the first stop and al low pr...

Page 125: ...of damage to 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 elec tronic system and disable engin...

Page 126: ...t expansion tank Page 116 counterclockwise until first stop and allow pressure to escape 2 Continue to turn breather valve counterclockwise and remove 3 Draw off precipitated corrosion inhibitor oil f...

Page 127: ...goggles safety mask Coolant filter Replacement 1 Turn breather valve of coolant expansion tank counterclockwise Page 38 to the first stop and allow pressure to escape 2 Continue to turn breather valv...

Page 128: ...noise when 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 62 and disable en...

Page 129: ...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 130 Drive belt C Chunking Drive belt Bel...

Page 130: ...cover engine free 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 pos...

Page 131: ...y System 7 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 M015655 05E 2015 06 Task Description 131 TIM ID...

Page 132: ...rotective clothing protective gloves and safety glasses facial protection Checking differential pressure gauge 1 Switch on fuel treatment system Page 60 2 Set the alarm points at the differential pres...

Page 133: ...el 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...

Page 134: ...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 135: ...r special 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...

Page 136: ...6 Tightening torque Engine oil 30 Nm 3 Nm 17 Fit seal 10 18 Install cover 19 Install screws 1 washers 2 and nuts 9 20 Tighten nuts 9 21 Open ball valve at the inlet and outlet of the fuel treatment sy...

Page 137: ...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 138: ...or Cleaning 1 Use isopropyl 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...

Page 139: ...d connectors 1 Remove 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 c...

Page 140: ...itable test probe e g test prod 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 pl...

Page 141: ...tarting disabled Checking 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...

Page 142: ...ing disabled Checking EIM plug connections 1 Check both Tyco plugs 62 pole 2 on EIM for firm seating Ensure that clips 3 are engaged 2 Check screws 1 of cable clamps on EIM for firm seating Ensure tha...

Page 143: ...ease lock 3 of connectors 2 b Unplug connector 2 3 Switch on power supply Result The Engine Control Unit is operable if the diagnostic lamp 1 changes to con tinuous illumination within 30 seconds afte...

Page 144: ...ontrol Unit from engine 1 Note or mark assignment of cables and connectors 2 Remove all screws 3 3 Undo clips 2 on connectors 4 Remove all male connectors 5 Remove screws 1 6 Take off Engine Control U...

Page 145: ...move Engine Control Unit 1 with En gine 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 Uni...

Page 146: ...When doing so observe 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 appr...

Page 147: ...or operation 4 Application 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...

Page 148: ...path failed S8 10 Emergency stop current path failed 24 V internal S9 11 ES pushbutton current path failed 24 V external S10 12 Key switch current path failed S11 13 SDAF 1 and 2 current path failed S...

Page 149: ...S1 and fuse S4 fail ure 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 th...

Page 150: ...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 151: ...anel 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 org...

Page 152: ...e work in case of malfunction or changed operating 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 7541...

Page 153: ...Removal and installation Page 93 Angular screw driver Part No F30002816 Qty Used in 1 7 5 1 Valve clearance Check and adjustment Page 88 Barring device Part No F6555766 Qty Used in 1 7 3 1 Cylinder l...

Page 154: ...in 1 7 5 2 Cylinder head cover Removal and installation Page 91 Double head box wrench Part No F30002800 Qty Used in 1 7 5 1 Valve clearance Check and adjustment Page 88 Double head box wrench Part N...

Page 155: ...t No F6783914 Qty Used in 1 7 5 1 Valve clearance Check and adjustment Page 88 Engine barring gear Part No F6783914 Qty Used in 1 7 2 1 Engine Barring manually Page 79 Feeler gauge Part No Y4345893 Qt...

Page 156: ...ery charging generator drive Drive belt re placement Page 130 Measuring instrument Part No Y4345888 Qty Used in 1 7 5 1 Valve clearance Check and adjustment Page 88 MTU test kit Part No 5605892099 00...

Page 157: ...Replacement Page 127 Open end wrench bit Part No F30025897 Qty Used in 1 7 6 2 Injector Removal and installation Page 93 Puller Part No F6790629 Qty Used in 1 7 6 2 Injector Removal and installation...

Page 158: ...r element Replacement Page 135 Ratchet with extension Part No F30006212 Qty Used in 1 7 2 1 Engine Barring manually Page 79 Qty Used in 1 7 3 1 Cylinder liner Endoscopic examination Page 81 Qty Used i...

Page 159: ...stment Page 88 Torque wrench 4 20 Nm Part No F30044239 Qty Used in 1 7 10 2 Air filter Removal and installation Page 107 Torque wrench 6 50 Nm Part No F30027336 Qty Used in 1 7 4 2 Crankcase breather...

Page 160: ...Torque wrench 8 40 Nm Part No F30043446 Qty Used in 1 7 14 2 Centrifugal oil filter Cleaning and filter sleeve replacement Page 114 160 Appendix B M015655 05E 2015 06 DCL ID 0000014251 003...

Page 161: ...s On EIM 147 Diagnostic lamp DILA On EIM 147 Differential pressure gauge Check 132 Drain and venting points 116 Drive belt Condition check 129 E ECU 7 Installation 144 Removal 144 EMU Cleaning 139 EMU...

Page 162: ...AS shielding 74 Intercooler Condensate drain line Checking for coolant discharge 105 Checking for obstruction 105 Interface module EIM Check 142 M Main dimensions Engine 52 Maintenance schedule Mainte...

Page 163: ...service pe riod 54 T Tasks After extended out of service periods 55 Tasks after extended out of service periods 3 weeks 55 Tightening specifications Nuts 18 Screws and bolts 18 Screws nuts and bolts...

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MTU 12V2000M93, Operating Instructions Manual

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