MTU 12V2000M94 Operating Instructions Manual Download

Page: 80 / 153

8.6 Injector

8.6.1 Injector – Replacement

Special tools, Material, Spare parts

Designation / Use

Part No.

Qty.

Injector

(→ Spare Parts Catalog)

Injector – Replacement

Remove injector and install new one (→ Page 81).

80 | Injector | MS150061/06E 2016-02

TIM-ID: 0000042329 - 002

Summary of Contents for 12V2000M94

Page 1: ...Operating Instructions Diesel Engine 12V2000M94 16V2000M94 MS150061 06E ...

Page 2: ...sed in any way whether in whole or in part without the prior writ ten consent of MTU Friedrichshafen GmbH This particularly applies to its reproduction distribution editing translation micro filming and storage or processing in electronic systems including databases and online services All information in this publication was the latest information available at the time of going to print MTU Friedr...

Page 3: ... 5 11 After stopping the engine 52 5 12 Fuel treatment system Shutdown 53 5 13 Plant Cleaning 54 6 Maintenance 6 1 Maintenance task reference table QL1 55 7 Troubleshooting 7 1 Control cabinet of fuel treatment system Troubleshooting 56 7 2 Troubleshooting 57 8 Task Description 8 1 SOLAS 60 8 1 1 SOLAS shielding as per MTN 5233 Installation 60 8 1 2 SOLAS shielding Installation 61 8 1 3 Installati...

Page 4: ... Belt Drive 119 8 17 1 Drive belt Condition check 119 8 18 Battery Charging Generator 120 8 18 1 Battery charging generator drive Drive belt replacement 120 8 19 Fuel Supply System 121 8 19 1 Water drain valve Check 121 8 19 2 Differential pressure gauge Check 122 8 19 3 Water level probe 3 in 1 rod electrode Check 123 8 19 4 Pump capacity Check 124 8 19 5 Coalescer filter element Replacement 125 ...

Page 5: ...ocesses that might affect the emission characteristics of the product are prohibited by emission regulations Emission control units systems may only be maintained ex changed or repaired if the components used for this purpose are approved by the manufacturer Noncompliance with these regulations will invalidate the design type approval issued by the emissions regu lation authorities The manufacture...

Page 6: ...n 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 authorized by the manufacturer to carry out repair and overhaul The product shall not be operated in explosive atmospheres unless the necessary approval has been grant ed Any other use particularly misuse...

Page 7: ...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 personnel from the areas mechanical engineering plant construction and electrical engineering The operator must define the responsibilities of the personnel involved in operation maintenance repair as semb...

Page 8: ...e 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 during operation The operator must be familiar with the control and display elements The operator must be familiar with the consequences of any operations performed During operation the display instr...

Page 9: ...Follow the applicable warning instructions pertaining to such devices MS150061 06E 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 pinions Wear a respirator mask filter class P3 Do not blow out the interior of the flywheel housing or the starter with compressed air Clean the flywheel housing inside with a class H dust extraction d...

Page 11: ...g 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 electronic equipment from the ground of the unit No other maintenance or repair work must be carried out in the vicinity of the product while welding is going on Risk of explosion or fire due to oil vapors a...

Page 12: ...th 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 on connectors Subject the device as well as the product to a functional testing on completion of all repair work Check cor rect execution of the emergency stop function in particular Store spare parts...

Page 13: ...fully 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 pressure level in excess of 85 dB A Environmental protection and disposal Dispose of used fluids lubricants and filters in accordance with local regulations Within the EU batteries can be returned f...

Page 14: ...arrying 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 must be no naked flames in the vicinity No smoking Observe fire prevention regulations Always wear a mask providing protection against paint and solvent vapors Liquid nitrogen Observe the relevant saf...

Page 15: ...n 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 all safety instructions and safety notices must be issued to all personnel involved in opera tion maintenance repair assembly installation or transportation 2 The higher level warning notice is used ...

Page 16: ...e slowly The lifting ropes or chains must not rub against the engine or its compo nents during the lifting procedure Readjust lifting equipment as necessary 7 For special packaging with aluminum foil Attach engine to lifting eyes of bearing pedestal or transport with means of transportation device suitable for the load forklift truck 8 Secure engine against tilting during transportation Secure suc...

Page 17: ...d 1 Max admissible diagonal pull 40 2 Max admissible diagonal pull 20 3 Max admissible diagonal pull 70 4 Max admissible diagonal pull 35 5 Max admissible diagonal pull 10 6 Center of gravity Take note of the engine center of gravity See Installation Arrangement drawings for details on engine center of gravity MS150061 06E 2016 02 Transport 17 TIM ID 0000066081 001 ...

Page 18: ...shipping lock 1 Undo nuts 4 on all outer rings of resilient mount 1 then unscrew and remove locking screw 2 with washers 3 and nut 4 4 x on each mount 2 Following removal store parts 2 3 4 of the shipping lock in a safe place for future use Installing shipping lock 1 Screw in locking screw 2 together with washers 3 and nut 4 4 x on each mount until screw head with washers makes contact with mount ...

Page 19: ...gnated in accordance with DIN ISO 1204 as viewed from driving end 4 For cylinder designation in accordance with DIN ISO 1204 the letter Ax refers to the cylinders on the left hand side of the engine 1 and letter Bx refers to the cylinders on the right hand side 3 The cylinders of each bank are numbered consecutively starting with x 1 at driving end 4 The numbering of other engine components also s...

Page 20: ...s The triple walled design permits low surface temperature reduced thermal load absolute gas tightness Lube oil system Wet sump forced feed lubrication system Components supplied with oil Bearings Piston cooling Control and actuating elements of the sequential turbocharging system Cooling system Two separate circuits Engine coolant Raw water Coolant cooling by raw water cooled plate core heat exch...

Page 21: ...nals 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 MCS5 CAN ECU and EMU emergency stop Electric starter Terminal 45 starter A B engaged Pneumatic starter Starting air pressure valve Starting air pressure sensor Barring device Barring Gear 1 and 2 ...

Page 22: ...unit LOP Functions Engine speed oil pressure and coolant temperature are monitored and displayed Integrated safety system Integrated Test System Redundant CAN bus interface to governor and higher level control and monitoring system 24 V DC supply SOLAS Fire safety requirements Special connections In case of leakage the connection types shown above are spray protected even without a cover and have ...

Page 23: ...utside either with a copper sealing ring 1 according to DIN or an O ring ISO In case of a loose thread or a faulty sealing ring 1 the liquid first has to pass the thread The pressure is so greatly reduced by this and the faulty sealing ring 1 that any leakage is not under pres sure HP line between injector and HP accumulator 1 Support ring 2 V ring 3 Thrust ring 4 HP line 5 Thrust screw 6 Support ...

Page 24: ...ween distributor and HP accumulator 1 Union nut 2 O ring 3 Thrust ring 4 Thrust screw 5 O ring 6 O ring 7 Thrust ring 8 Pressure pipe 9 Jacket pipe 24 General Information MS150061 06E 2016 02 TIM ID 0000002177 005 ...

Page 25: ...st screw 7 Thrust ring 8 O ring 9 HP line 10 Pressure pipe Leak off fuel caused by leakages from the sealing cones or the HP lines is returned to the HP pump from where it is routed at atmospheric pressure into a level monitored leak fuel tank MS150061 06E 2016 02 General Information 25 TIM ID 0000002177 005 ...

Page 26: ...ipment 11 Exhaust turbocharger 12 Carrier housing 13 Actuating cylinder for ex haust flap 14 Cylinder head cover 15 Engine mounting 16 Oil pan 17 Battery charging generator 18 Coolant filler neck 19 Engine Interface Module EIM 20 Raw water connection to gearbox cooling system 21 Raw water pump 22 Raw water connection from overboard 23 Protective cover belt pul ley 24 Coolant pump 25 Plate core hea...

Page 27: ...sing lower sec tion 10 Carrier housing middle sec tion 11 Bleeder valve 12 Exhaust outlet KS Driving end Engine model designation Key to the engine model designations 12V 16V2000Mxyz 12 16 Number of cylinders V Cylinder arrangement V engine 2000 Series M Application x Application segment 4 5 6 7 9 y Design status 0 1 2 z Special features MS150061 06E 2016 02 General Information 27 TIM ID 000000998...

Page 28: ...ns are insignificant Also applies similarly to 12V Item Designation Monitoring of 1 B3 Intake air temperature 2 B9 Charge air temperature 3 B7 Lube oil temperature 4 B10 Charge air pressure 5 B44 Turbocharger speed 28 General Information MS150061 06E 2016 02 TIM ID 0000008412 005 ...

Page 29: ...ssure before filter 3 B5 1 Lube oil pressure after filter 4 B5 2 optional Lube oil pressure after filter 5 F33 Engine coolant level expansion tank 6 B21 optional Raw water pressure 7 B6 2 optional Coolant temperature 8 B6 1 Coolant temperature MS150061 06E 2016 02 General Information 29 TIM ID 0000008412 005 ...

Page 30: ...ngine driving end Item Designation Monitoring of 1 B1 ECU Camshaft speed 2 B13 2 optional EMU Crankshaft speed 3 B13 ECU Crankshaft speed 30 General Information MS150061 06E 2016 02 TIM ID 0000008412 005 ...

Page 31: ...nal 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 side MS150061 06E 2016 02 General Information 31 TIM ID 0000008412 005 ...

Page 32: ... side 3 B54 optional Lube oil pressure replenishment pump System sensors These sensors are fitted outside the engine Designation Monitoring of B19 Starting air pressure B70 Fuel prefilter water level B41 Exhaust back pressure S37 Start interlock switching status 32 General Information MS150061 06E 2016 02 TIM ID 0000008412 005 ...

Page 33: ...e C 25 Raw water inlet temperature C 25 Barometric pressure mbar 1000 Site altitude above sea level m 100 Power related data power ratings are net brake power as per ISO 3046 Number of cylinders 12 Rated engine speed A rpm 2450 Fuel stop power ISO 3046 A kW 1432 General conditions for maximum power Number of cylinders 12 Intake depression new filter A mbar 15 Intake depression max L mbar 30 Model ...

Page 34: ...uel pressure at engine inlet connection min when engine is starting L bar 0 3 Fuel pressure at engine inlet connection min during engine operation L bar 0 3 Fuel pressure at engine inlet connection max when engine is starting L bar 0 25 Fuel supply flow max R liters min 7 1 General operating data Number of cylinders 12 Firing speed from R rpm 100 Firing speed to R rpm 120 Starter electric Number o...

Page 35: ...m Option max operating incli nations R Liters 113 Oil pan capacity at dipstick mark min standard oil system Option max operating inclinations L Liters 87 Oil pan capacity at dipstick mark max standard oil system Option max operating inclinations L Liters 105 Weights main dimensions Number of cylinders 12 Engine dry weight with standard accessories installed without coupling R kg 2780 Acoustics Num...

Page 36: ...r 1000 Site altitude above sea level m 100 Power related data power ratings are net brake power as per ISO 3046 Number of cylinders 16 Rated engine speed A rpm 2450 Fuel stop power ISO 3046 A kW 1939 General conditions for maximum power Number of cylinders 16 Intake depression new filter A mbar 15 Intake depression max L mbar 30 Model related data basic design Number of cylinders 16 Cylinder arran...

Page 37: ...hen engine is starting L bar 0 25 Fuel supply flow max R liters min 8 6 General operating data Number of cylinders 16 Firing speed from R rpm 100 Firing speed to R rpm 120 Starter electric Number of cylinders 16 Rated starter voltage standard design R V 24 Inclinations standard oil system reference waterline Number of cylinders 16 Longitudinal inclination continuous max driving end down Option max...

Page 38: ... 115 Oil pan capacity at dipstick mark max standard oil system Option max operating inclinations L Liters 138 Weights main dimensions Number of cylinders 16 Engine dry weight with standard accessories installed without coupling R kg 3337 Acoustics Number of cylinders 16 Exhaust noise unsilenced BL free field sound pressure level Lp 1 m dis tance ISO 6798 3 dB A tolerance R dB A 110 Engine surface ...

Page 39: ...4 3 Firing order Firing order 12V A1 B5 A5 B3 A3 B6 A6 B2 A2 B4 A4 B1 16V A1 B5 A3 A5 B2 B8 A2 A8 B3 A7 B4 B6 A4 A6 B1 B7 MS150061 06E 2016 02 Technical Data 39 TIM ID 0000038135 002 ...

Page 40: ...ain dimensions Engine model Length A Width B Height C 12V2000M94 Approx 2137 mm Approx 1292 6 mm Approx 1376 mm 16V2000M94 Approx 2554 mm Approx 1292 6 mm Approx 1416 mm 40 Technical Data MS150061 06E 2016 02 TIM ID 0000050221 002 ...

Page 41: ...2 Fuel prefilter pressure gage Align adjustable pointer with position of pressure indicator Page 87 Fuel system Vent Page 83 Raw water pump if located above waterline Prime approx 3 to 4 liters Filling point Page 106 Coolant circuit If engine is out of service for more than one year change engine coolant Page 112 Coolant circuit Check coolant level Page 111 Coolant circuit Heat engine coolant with...

Page 42: ...nt level Page 111 Coolant circuit Heat engine coolant with coolant preheating unit Fuel prefilter Drain water and contaminants Page 88 Battery charging generator drive Check condition of drive belt Page 119 Engine Control Unit ECU Check plug connections Page 130 Engine Interface Module EIM Check plug connections Page 132 Engine Monitoring Unit EMU Check plug connections Page 131 42 Operation MS150...

Page 43: ...eeks Tasks after extended out of service periods 3 weeks Note Operate fuel treatment system for at least 5 minutes 1 Start up fuel treatment system Page 45 2 Shut down fuel treatment system Page 53 MS150061 06E 2016 02 Operation 43 TIM ID 0000007730 005 ...

Page 44: ...lves 4 Switch on fuel treatment system Page 48 5 Check direction of rotation of pump 6 Vent bypass and fuel lines of the system a Open ball valve for pressure tank b Open ball valve for overflow tank c Close ball valve at the inlet to the fuel treatment system Result Bypass line is vented via the overflow tank d Open ball valve at the inlet to the fuel treatment system 7 Check the fuel treatment s...

Page 45: ...ine 3 Switch on fuel treatment system and operate it for some minutes Page 48 Result Fuel is sucked from the tank dirt particles and water are filtered and separated then the fuel is delivered via the overflow tank back to the tank Water which has settled in the tank is separated 4 Start engine Page 49 5 Run engine at idling speed 6 Check suction pressure see technical data of the engine at the en...

Page 46: ...ency HAT 1 Switch on fuel treatment system Page 48 2 Start engine Page 49 3 Run engine at idling speed 4 Switch off pump 21 on switch cabinet Result The engine mounted fuel delivery pump sucks fuel via bypass 2 directly from the tank 5 Check suction pressure at the engine mounted fuel delivery pump Note If the suction pressure is within the permissible limits and engine operation is satisfactory 6...

Page 47: ...on Check exhaust color Page 57 Fuel prefilter Check if suction side pressure indicated at the fuel prefilter is within the limit Page 87 Drain water and contaminants Page 88 Air filter Check signal ring position of contamination indicator Page 97 Replace air filter Page 95 if the signal ring is completely visible in the service indicator observation window HT coolant pump Check relief bore for oil...

Page 48: ...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 start up Page 44 2 Switch on master switch on switchgear cabinet Result Signal lamp Control voltage present lights up 3 Switch on switch for pump Result Signal lamp Pump running lights up 48 Operatio...

Page 49: ...ersons 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 Action Control stand Operating instructions for electronic system Local Operating Panel LOP Operating instructions for electronic system Local Operation Station LOS Operating instructions for electron...

Page 50: ... Risk of overheating damage to components Before shutting down disengage gear and run the engine at idle speed for at least 10 minutes until engine temperatures have dropped and constant values are displayed The engine can be stopped from the following points Item Action Control stand Operating instructions for electronic system Local Operating Panel LOP Operating instructions for electronic syste...

Page 51: ...an 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 Control stand Operating instructions for electronic system Local Operating Panel LOP Operating instructions for electronic system Local Operation Station LOS Operating instructions for electronic syste...

Page 52: ...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 antifreeze concentration is 50 and engine room temperature is below 40 C Raw water Drain if freezing temperatures are to be expected and the engine is to remain out of service for an extended period Engin...

Page 53: ...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 system 5 Open drain valve until pressure has escaped from fuel treatment system MS150061 06E 2016 02 Operation 53 TIM ID 0000007732 005 ...

Page 54: ...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 protec tion 2 Prior to putting the cleaning unit into operation read the operating instructions of the high pressure cleaning units carefully and observe the safety precautions 3 The following requirements apply for...

Page 55: ...filter Page 47 W1001 Replace fuel filter or fuel filter element Page 84 W1005 Replace air filter Page 95 W1006 Replace fuel injectors Page 80 W1008 Replace engine oil filter when changing engine oil or when the interval years is reached at the latest Page 101 W1009 X Check layer thickness of oil residue clean and replace filter sleeve at every oil change at the latest Page 103 W1011 Perform endosc...

Page 56: ...ve motor is equipped with an overload protection If the maximum permissible current consumption is exceeded e g in case of a blockage or dry running the motor protection relay triggers and the pump is switched off u Reset motor protection relay Pre alarm Cause Corrective action The differential pressure exceeded 1 3 bar u Replace coalescer filter element Page 125 Replace filter element Cause Corre...

Page 57: ...t be barred manually u Contact Service Engine turns on starting but does not fire Cause Corrective action Poor rotation by starter Battery low or faulty u Charge or replace battery see manufacturer s documentation Engine cabling defective u Check Page 127 Air in fuel system u Vent fuel system Page 83 Engine Control Unit defective u Contact Service Engine fires unevenly Cause Corrective action Inje...

Page 58: ...rge air cooler contaminated u Contact Service Exhaust turbocharger defective u Contact Service Coolant leaks at charge air cooler Cause Corrective action Charge air cooler leaking major coolant discharge u Contact Service Black exhaust gas Cause Corrective action Air supply Air filter clogged u Check signal ring position of service indicator Page 97 Fuel injection Injector defective u Replace Page...

Page 59: ...tion Engine is not at operating temperature u Run engine to reach operating temperature Water in fuel u Drain fuel prefilter Page 88 Charge air cooler leaking u Contact Service MS150061 06E 2016 02 Troubleshooting 59 TIM ID 0000044001 002 ...

Page 60: ...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 installation location Page 62 2 Install suitable shielding 3 Press shielding until locked 60 Task Description MS150061 06E 2016 02 TIM ID 0000010550 003 ...

Page 61: ...ambient 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 installation location Page 62 2 Install suitable shielding MS150061 06E 2016 02 SOLAS 61 TIM ID 0000010702 005 ...

Page 62: ...l information Install SOLAS shielding as per MTN 5233 as a matter of priority Page 60 Free end B side Item Type of shielding Comments 1 Shield A7 On fuel delivery pump 2 Shield A7 On HP fuel pump Free end 62 SOLAS MS150061 06E 2016 02 TIM ID 0000010064 007 ...

Page 63: ... 3 Shield A7 Below fuel priming pump Driving end A side Item Type of shielding Comments 1 Shield A5 On air flap 2 Shield A4 On brazed on union 3 Shield A5 On exhaust turbocharger flap 4 Shield A5 On exhaust turbocharger flap Driving end A side MS150061 06E 2016 02 SOLAS 63 TIM ID 0000010064 007 ...

Page 64: ...alve plate Driving end Item Type of shielding Comments 1 Shield A4 Turbocharger lubrication left side 2 Shield A4 Exhaust turbocharger lubrication center Driving end Item Type of shielding Comments 1 Shield A4 Turbocharger lubrication right side 64 SOLAS MS150061 06E 2016 02 TIM ID 0000010064 007 ...

Page 65: ...rger flap 2 Shield A5 Turbocharger flap 3 Shield A4 On brazed on union 4 Shield A5 On air flap 5 Shield A4 To exhaust turbocharger lubrication Driving end B side Item Type of shielding Comments 1 Shield A5 On valve plate MS150061 06E 2016 02 SOLAS 65 TIM ID 0000010064 007 ...

Page 66: ...ing end A side Item Type of shielding Comments 1 Shield A5 To flap control Driving end B side Item Type of shielding Comments 1 Shield A5 To flap control 66 SOLAS MS150061 06E 2016 02 TIM ID 0000010064 007 ...

Page 67: ...at 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 manually 1 Fit ratchet with barring device on barring device connection at the vibration damper on engine free end 2 Rotate crankshaft in engine direction of rotation Apart from the normal compression...

Page 68: ...t or pulled 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 are removed from the engine Barring 1 Press and hold the Turn button on the LMB motherboard of the LOP Result Engine is barred by starter for max 20 sec onds 2 Release Turn button 68 Engine ...

Page 69: ...en 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 lower cooling bores Running pattern seems darker No actions required Dark areas with even or varying degrees of discoloration Beginning and end of the discoloration are not sharply defined and do not co...

Page 70: ...Depending 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 81 2 Install cylinder head cover Page 79 70 Cylinder Liner MS150061 06E 2016 02 TIM ID 0000003304 006 ...

Page 71: ...round 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 may be interrupted Findings not critical Corrosion fields spots Corrosion fields spots result from water condensed water with the valves in the overlap open position They are clearly visible due to t...

Page 72: ...ration 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 inspection be carried out after further operation of the engine 72 Cylinder Liner MS150061 06E 2016 02 TIM ID 0000000014 015 ...

Page 73: ...ways wear safety goggles face mask and ear defenders Crankcase breather cleaning oil pre separator element 1 Undo clamp 2 2 Remove hose 1 and clamp 2 from cov er 3 3 Slacken screws 4 4 Remove screws 4 and washers 5 5 Remove cover 3 gasket 6 oil pre separa tor 7 and gasket 8 6 Wash oil pre separator element 7 and cov er 3 in fuel and blow out with compressed air 7 Moisten oil pre separator element ...

Page 74: ...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 Replacing oil separator filter el ement 1 Remove cover 2 with O ring 3 2 Remove filter element 1 from housing 4 3 Insert new filter element in housing 4 4 Install cover 2 with new O ring 5 Use torque wrench to tighten the screws of cover 2 to th...

Page 75: ...phragm 3 on housing 1 5 Install new gasket 2 and spring 5 together with cover 4 6 Use torque wrench to tighten the screws of cover 4 to the specified torque Name Size Type Lubricant Value Standard Screw Tightening torque Engine oil 10 Nm 2 Nm 7 Check diaphragm in other oil separators in the same manner MS150061 06E 2016 02 Crankcase Breather 75 TIM ID 0000000017 010 ...

Page 76: ...ch 20 100 Nm F30026582 1 Measuring instrument Y4345888 1 Engine oil Preparatory steps 1 Remove air filter Page 96 2 Remove cylinder head cover Page 79 Positioning piston of cylinder A1 at TDC Note With cylinder head and valve gear installed 1 Insert preloaded dial gage 2 into measuring device 4 and secure using screw 1 2 Install measuring device 4 in cylinder head and secure using knurled screw 3 ...

Page 77: ... X I I X X X I I Inlet Inlet valve adjustment admissible X Exhaust Exhaust valve adjustment admissible Valve adjustment inadmissible 4 Check gap between valve bridge and rocker arm with valve clearance gage 5 If the deviation from the specified value exceeds 0 1 mm adjust valve clearance Adjusting valve clearance 1 Undo locknut 1 and unscrew adjusting screw 2 by a few turns 2 Insert valve clearanc...

Page 78: ...Final steps 1 Remove barring device 2 Install cylinder head cover Page 79 3 Install air filter Page 96 78 Valve Drive MS150061 06E 2016 02 TIM ID 0000050016 003 ...

Page 79: ...Remove air guide housing Removing and installing cylin der head cover 1 Remove screws 1 2 Remove cylinder head cover 2 with gasket from cylinder head 3 Clean installation surface 4 Check condition of gasket of cylinder head cover Result Replace damaged seals 5 Align cylinder head cover 2 with centering device 6 Insert and tighten screws 1 Final steps 1 Install air filter Page 96 2 Install air guid...

Page 80: ...r Replacement Special tools Material Spare parts Designation Use Part No Qty Injector Spare Parts Catalog Injector Replacement u Remove injector and install new one Page 81 80 Injector MS150061 06E 2016 02 TIM ID 0000042329 002 ...

Page 81: ...atalog Injector Spare Parts Catalog WARNING Fuels are combustible and explosive Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Wear protective clothing protective gloves and safety glasses facial protection Preparatory steps 1 Close off fuel supply to engine 2 Remove cylinder head cover Page 79 Remove injector 1 Remove HP line 5 using socket wrench...

Page 82: ...ling cone of HP line 5 and injector 1 with engine oil 9 Align injector 1 and HP line 5 with align ment device 10 Connect HP line 5 to HP accumulator and tighten by hand 11 Connect HP line 5 to injector 1 and tighten by hand 12 Tighten screw of hold down clamp 3 with a box wrench adapter and a torque wrench to specified tightening torque Name Size Type Lubricant Value Standard Screw M10 x 85 Tighte...

Page 83: ... and ignition sources Do not smoke Wear protective clothing protective gloves and safety glasses facial protection Venting fuel system 1 Unscrew handle 3 at fuel priming pump 2 2 Open vent plug 1 3 Operate the pump with the handle 3 until bubble free fuel emerges from the vent plug 1 4 Close vent plug 1 5 Unscrew handle 3 at fuel priming pump 2 MS150061 06E 2016 02 Fuel System 83 TIM ID 0000004716...

Page 84: ...ombustible 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 NOTICE Damage to component Severe material damage For filter replacement with the engine running operate the engine at low engine load The filter which is to be replaced must be cut out for a brief ...

Page 85: ...y change filter 2 with oil filter wrench 7 Clean sealing surface on filter head 8 Lightly oil sealing ring of new easy change fil ter 9 Screw on easy change filter 2 by hand until seal makes contact then tighten by hand Note Cut the fuel filter back in slowly following re placement to return both filters to operation The engine may shut down if the filter is cut back in too quickly 10 Turn three w...

Page 86: ... Clean sealing surface on filter head 6 Lightly oil sealing ring of new easy change fil ter 7 Screw on easy change filter 1 by hand until gasket makes contact then tighten by hand 8 Turn three way cock to position A so both filters are in use standard position 9 Replace other fuel filters in the same way 10 Vent fuel system Page 83 86 Fuel Filter MS150061 06E 2016 02 TIM ID 0000043257 003 ...

Page 87: ... dif ferential pressure gauge 1 After installation of a new filter element align adjustable pointer 2 with pressure indicat ing pointer 3 of pressure gauge 1 2 Verify that differential pressure is within the limit Fuel prefilter checking differential pressure 1 With the engine running at full load or rated power read off pressure at gauge 1 2 If differential pressure as indicated between position ...

Page 88: ...ce 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 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 Draining fuel pref...

Page 89: ...ling 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 and open vent valve s 2 until fuel emerges from the vent pipe 3 10 Close vent valve s 2 11 Turn rotary slide valve 4 back to locked po sition MS150061 06E 2016 02 Fuel Filter 89 TIM ID 0000045553 004...

Page 90: ...and skin Seek medical attention immediately do not induce vomiting Do not inhale vapors or mist Wear protective clothing protective gloves and safety glasses If contact is made with skin wash off 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 smoke Wear protective clothing protective gloves ...

Page 91: ...g pump to filling connection 1 on the intake side of the filter 3 Open vent valve 2 and fill with fuel until fuel emerges from the vent pipe 3 4 Close vent valve 2 5 Open rotary slide valve 4 a little by approx 30 and open vent valve s 2 until fuel emerges from the vent pipe 3 6 Close vent valve s 2 7 Turn rotary slide valve 4 back to locked po sition 8 Check differential pressure Page 87 Result I...

Page 92: ...ation 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 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 smoke Wear protective cl...

Page 93: ... Remove spring cartridge 3 and filter ele ment 4 8 Insert new filter element 4 and spring car tridge 3 9 Fill filter housing with clean fuel 10 Place new seal in cover 11 Fit cover with gasket and secure it with screws 2 12 Cut in the cut out filter again 13 Close threaded vent plug 1 when fuel emerges 14 Set differential pressure display instrument Page 87 MS150061 06E 2016 02 Fuel Filter 93 TIM ...

Page 94: ... wear safety goggles face mask and ear defenders Charge air cooler checking con densate drain line for coolant discharge and obstruction 1 Check drain line for water discharge and ob struction when the engine is running idle 2 If no air emerges remove condensate drain line and blow out with compressed air 3 Replace obstructed drain line by new one 4 Install condensate drain line 5 If a large amoun...

Page 95: ...l 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 96 2 Reset signal ring of contamination indicator Page 97 MS150061 06E 2016 02 Air Filter 95 TIM ID 0000005447 009 ...

Page 96: ...mp 2 2 Remove air filter 1 and clamp 2 from con necting flange of intake housing 3 3 Verify that there are no objects in the con necting flange of the intake housing 3 and clean it 4 Place new air filter 1 with clamp 2 onto in take housing 3 5 Tighten screw on clamp 2 with torque wrench to the specified tightening torque Name Size Type Lubricant Value Standard Screw Tightening torque 5 Nm 96 Air F...

Page 97: ...disabled Checking signal ring position 1 If the signal ring is completely visible in the control window 2 replace air filter Page 95 2 After installation of new filter press reset button 1 Result Engaged piston with signal ring moves back to initial position MS150061 06E 2016 02 Air Intake 97 TIM ID 0000005484 009 ...

Page 98: ...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 127 98 Starting Equipment MS150061 06E 2016 02 TIM ID 0000000905 017 ...

Page 99: ... 4 Top up with oil up to the max 1 mark Page 100 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 remove oil dipstick from the guide tube and wipe it 2 Insert oil dipstick into guide tube up to the stop withdraw after approx 10 seconds and check oil level 3 Oil level must be between min and max marks ...

Page 100: ...tact with skin Do not inhale oil vapor Version with extraction equipment Engine oil extraction 1 Position a suitable container to drain the engine oil into 2 Extract all engine oil from oil pan using the extraction equipment Filling with new engine oil 1 Determine amount of engine oil required for oil change Product Summary Technical Data 2 Open cover on filler neck 3 Pour engine oil in at filler ...

Page 101: ...ctors 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 inhale oil vapor NOTICE Damage to component Severe material damage For filter replacement with the engine running operate the engine at low engine load The filter which is to be replaced must be cut...

Page 102: ...nt crank engine with starting system Page 68 11 Check oil level Page 99 Replacing oil filter with the engine running 1 Reduce engine speed to 1100 rpm 2 Unscrew cut out oil filter with oil filter wrench 3 Clean sealing surface on connecting piece 4 Check condition of new oil filter sealing ring and coat it with oil 5 Fit SOLAS shield Page 60 6 Screw on and tighten new oil filter by hand 7 Replace ...

Page 103: ...ts 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 organs Never direct air jet at people Always wear safety goggles face mask and ear defenders Removing rotor of centrifugal oil filter 1 Release nuts 3 2 Remove housing cover 1 3 Remove complete rotor 2 fr...

Page 104: ...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 nozzles 4 with cleaner blow out with compressed air 8 Insert the new filter sleeve with the smooth surface facing the rotor cap 104 Oil Filtration Cooling MS150061 06E 2016 02 TIM ID 0000006418 005 ...

Page 105: ... Nm 13 Hold rotor old design with oil filter wrench and tighten nut 1 to specified torque using a torque wrench Name Size Type Lubricant Value Standard Nut M16 x 1 5 Tightening torque 40 Nm to 50 Nm 14 Insert complete rotor 2 into the housing and check for ease of movement 15 Set housing cover 1 with new O ring onto lower section observe marks 16 Tighten nuts 3 crosswise and evenly MS150061 06E 20...

Page 106: ...ture Circuit 8 15 1 Draining and venting points Figures also apply similarly to 12V and 16V Plan view 1 Overflow line expansion tank 2 Filler neck 106 Coolant Circuit General High Temperature Circuit MS150061 06E 2016 02 TIM ID 0000038198 002 ...

Page 107: ...coolant drain plug 3 Raw water pump filling plug 4 Measuring point pressure before raw water pump 5 Raw water pump drain plug 6 Oil extraction connection MS150061 06E 2016 02 Coolant Circuit General High Temperature Circuit 107 TIM ID 0000038198 002 ...

Page 108: ...Left side 1 Engine coolant drain plug 2 Engine coolant drain plug M14x1 5 108 Coolant Circuit General High Temperature Circuit MS150061 06E 2016 02 TIM ID 0000038198 002 ...

Page 109: ...x1 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 MS150061 06E 2016 02 Coolant Circuit General High Temperature Circuit 109 TIM ID 0000038198 002 ...

Page 110: ...Driving end KS 1 Engine coolant drain plug 2 Oil extraction connection 110 Coolant Circuit General High Temperature Circuit MS150061 06E 2016 02 TIM ID 0000038198 002 ...

Page 111: ...t expansion tank Page 26 counterclockwise until the first stop and allow pressure to escape 2 Continue to turn breather valve counterclock wise and remove 3 Check coolant level coolant must be visible at the lower edge of the cast in eye of the fill er neck Coolant level check by means of level sensor 1 Switch engine control system on and check display coolant level is automatically monitored by t...

Page 112: ... Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 113 2 Fill with engine coolant Page 114 112 Coolant Circuit General High Temperature Circuit MS150061 06E 2016 02 TIM ID 0000000036 031 ...

Page 113: ...reheating unit Draining engine coolant 1 Turn breather valve of filler neck on coolant expansion tank Page 106 counterclockwise to first stop and allow pressure to escape 2 Continue to turn breather valve counterclockwise and remove 3 Draw off separated corrosion inhibitor oil in expansion tank through the filler neck 4 Open drain valves plugs Page 106 and drain or pump out engine coolant 5 Close ...

Page 114: ... engine Fill top up coolant only into cold engine Filling with engine coolant 1 Turn breather valve of coolant expansion tank Page 26 counterclockwise until the first stop and allow pressure to escape 2 Continue to turn breather valve counterclockwise and remove 3 Pour coolant into engine until coolant level reaches bottom edge of cast in eye of filler neck 4 Check satisfactory condition of breath...

Page 115: ...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 for Electronic System and disable engine start 3 Clean relief bore with a wire if dirty Admissible engine coolant discharge up to 10 drops per hour Admissible oil discharge up to 5 drops per hour 4 Contact Service if discharge exceeds the specifie...

Page 116: ...tank Page 106 counterclockwise until the first stop and allow pressure to escape 2 Continue to turn breather valve counterclockwise and remove 3 Draw off precipitated corrosion inhibitor oil from expansion tank and dispose of oil 4 Draw off approx 1 liter coolant and drain into a clean container 5 Using the equipment and chemicals from the MTU test kit examine coolant for antifreeze concentration ...

Page 117: ... mask Replacing coolant filter 1 Turn breather valve of coolant expansion tank counterclockwise Page 26 to the first stop and allow pressure to escape 2 Continue to turn breather valve counterclock wise and remove 3 Remove coolant filter using the oil filter wrench 4 Clean the sealing face on the adapter 5 Coat sealing ring of the new coolant filter with engine oil 6 Install and tighten coolant fi...

Page 118: ...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 50 and disable engine start 3 Clean the relief bore with a wire if it is dirty Permissible coolant discharge up to 10 drops per hour Permissible oil discharge up to 5 drops per hour 4 If discharge exceeds the specified limit...

Page 119: ...sabled 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 120 Drive belt C Chunking Drive belt Belt is oily shows signs of over heating MS150061 06E 2016 02 Belt Drive 119 TIM ID 0000000920 011 ...

Page 120: ... Replacing drive belt 1 Counterhold adjusting lever at square 2 2 Rotate adjusting lever until drive belt is re leased 3 Secure adjusting lever with screwdriver 1 4 Remove drive belt 5 Check cleanness of belt pulleys 6 Fit new drive belt 7 Release securing element at adjusting lever 8 Mount adjusting lever with square 2 slowly on drive belt Final steps 1 Install protective cover 2 Install screws o...

Page 121: ... System 8 19 1 Water drain valve Check Water drain valve Check 1 Open water drain valve 2 Check water outlet for obstructions 3 Close water drain valve MS150061 06E 2016 02 Fuel Supply System 121 TIM ID 0000007733 007 ...

Page 122: ...rotective clothing protective gloves and safety glasses facial protection Checking differential pressure gauge 1 Switch on fuel treatment system Page 48 2 Set the alarm points at the differential pressure gauge to zero Result Alarm is issued after preset time 3 Reset alarm points at pressure gauge for differential pressure 122 Fuel Supply System MS150061 06E 2016 02 TIM ID 0000007737 006 ...

Page 123: ...l 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 Result Water drain valve opens 6 Leave water level probe in tank Result Alarm must be issued after the preset time 7 Switch off the system 8 Disconnect connector from water level probe 9 Remove water ...

Page 124: ... 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 pressure of pump to 0 8 bar with the shut off valve at the pump intake side b Check pressure at the pressure gauge in the inlet to the fuel treatment system and note down c Open ball valve at inlet and...

Page 125: ...cial 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 installation position of components Replacing coalescer filter ele ment 1 Close ball valve at the inlet and outlet of the fuel treatment system 2 Open drain ball valve 3 Drain fuel 4 Close drain ball valv...

Page 126: ...ghtening torque Engine oil 30 Nm 3 Nm 17 Fit gasket 10 18 Install cover 19 Install screws 1 washers 2 and nuts 9 20 Tighten nuts 9 21 Open ball valve at the inlet and outlet of the fuel treatment system Result The fuel treatment system is ready for operation 126 Fuel Supply System MS150061 06E 2016 02 TIM ID 0000007735 011 ...

Page 127: ... 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 housings Contacts Plug connectors Cables and terminals Plug in contacts Result If cable conductors are damaged contact Service Note Close connectors that are not plugged in with the protective cap sup...

Page 128: ...opropyl alcohol to remove coarse dirt from housing surface 2 Use isopropyl alcohol to remove dirt from the connector and cable surfaces 3 Check legibility of cable labels Clean or replace illegible labels Heavily contaminated connectors on engine governor Cleaning Note Close connectors that are not plugged in with the protective cap supplied 1 Release latches of connectors and withdraw connectors ...

Page 129: ...e coarse dirt from housing surface using a cloth moistened with isopropyl alcohol 2 Remove dirt from the connector and cable surfaces with isopropyl alcohol 3 Check legibility of cable labels Clean or replace illegible labels Cleaning severely contaminated connectors on EMU 1 Release the latch and pull off connector 2 Clean connector housings connector socket housings and all contacts with isoprop...

Page 130: ... 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 seating 2 Lock loose connectors 3 Check dust cap on ECU and EXU connectors for damage and correct seating 130 Accessories for Electronic Engine Governor Control System MS150061 06E 2016 02 TIM ID 000000004...

Page 131: ...cking 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 not faulty MS150061 06E 2016 02 Accessories for Electronic Engine Governor Control System 131 TIM ID 0000035355 002 ...

Page 132: ... 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 not faulty 132 Accessories for Electronic Engine Governor Control System MS150061 06E 2016 02 TIM ID 0000017034 004 ...

Page 133: ...ectors 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 switched on If the diagnostic lamp 1 flashes after 30 seconds replace Engine Control Unit and contact Service Check the power supply if the diagnostic lamp remains dark 4 Switch off power supply 5 Refit ...

Page 134: ...gine governor from engine 1 Note or mark assignment of cables and plugs 2 Remove all screws 3 3 Undo clips 2 on connectors 4 Remove all male connectors 5 Remove screws 1 6 Take off engine governor Installing engine governor on engine 1 Install in reverse order Ensure correct assignment of plugs and sockets 2 Check resilient mount before installing Result If resilient mount is porous or defective t...

Page 135: ... 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 Monitoring Unit 1 Place Engine Monitoring Unit 4 in position on Engine Control Unit 1 2 Screw in and tighten screws on base of Engine Monitoring Unit 4 Installing Engine Control Unit with Engine Mon...

Page 136: ...ve 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 parameter descriptor module the diagnostic lamp DI LA indicates flashing code 4 when the power supply is connected Page 137 2 The FSW and the parameter descriptor module must first be downloaded from the ...

Page 137: ...cation 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 Engine Interface Module It indicates the status of the fuses An orange LED is provided to allow diagnosis of a tripped fuse fault directly at the unit as it is often difficult to pinpoint a fault in t...

Page 138: ...ergency 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 path failed S13 15 Spare current path failed S14 only for EIM with ECU 7 The failed current paths are signaled consecutively following the preamble 1 LED on for 4 seconds There is a pause lasting 4 seco...

Page 139: ...re 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 MS150061 06E 2016 02 Accessories for Electronic Engine Governor Control System 139 TIM ID 0000038009 004 ...

Page 140: ...hes Institut für 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 Control System UNIversal ECU Engine Control Unit Engine governor EDM Engine Data Module EMU Engine Monitoring Unit ETK Ersatzteilkatalog Spare Parts Catalog SPC FPP Fixed Pitch Propeller GCU Gear Con...

Page 141: ... 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 Turbine RCS Remote Control System RL Redundancy Lost Alarm Redundant CAN bus missing SAE Society of Automotive Engineers U S standardization organization SAT Sea Acceptance Test SD Sensor Defect Alarm...

Page 142: ...lanation WZK Werkzeugkatalog Tool Catalog TC ZKP Zugehörigkeit Kategorie Parameter Assignment category parameter number scheme for signals from the ADEC engine governor 142 Appendix A MS150061 06E 2016 02 TIM ID 0000002049 005 ...

Page 143: ... 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 49 7541 9077778 Asia Pacific 65 6100 2688 North and Latin America 1 248 560 8000 Spare Parts Service Fast simple and correct identification of spare parts for your drive system or vehicle fleet The r...

Page 144: ...or Removal and installation Page 81 Angular screw driver Part No F30453001 Qty Used in 1 8 5 1 Valve clearance Check and adjustment Page 76 Barring device Part No F6555766 Qty Used in 1 8 3 1 Cylinder liner Endoscopic examination Page 69 144 Appendix B MS150061 06E 2016 02 DCL ID 0000010704 006 ...

Page 145: ...ing device Part No F6783025 Qty Used in 1 8 5 2 Cylinder head cover Removal and installation Page 79 Crossbeam Part No T80091731 Qty Used in 1 2 1 Transportation Page 16 Crossbeam Part No T80092210 Qty Used in 1 2 1 Transportation Page 16 MS150061 06E 2016 02 Special Tools 145 DCL ID 0000010704 006 ...

Page 146: ...1 8 6 2 Injector Removal and installation Page 81 Endoscope Part No Y20097353 Qty Used in 1 8 3 1 Cylinder liner Endoscopic examination Page 69 Engine barring device Part No F6783914 Qty Used in 1 8 2 1 Engine Barring manually Page 67 Qty Used in 1 8 5 1 Valve clearance Check and adjustment Page 76 146 Special Tools MS150061 06E 2016 02 DCL ID 0000010704 006 ...

Page 147: ...n 1 8 15 7 Engine coolant sample extraction and analysis Page 116 Oil filter wrench Part No F30379104 Qty Used in 1 8 8 1 Fuel filter Replacement Page 84 Qty Used in 1 8 14 1 Engine oil filter Replacement Page 101 Qty Used in 1 8 14 2 Centrifugal oil filter and filter sleeve Cleaning and replacement Page 103 Qty Used in 1 8 15 8 Coolant filter Replacement Page 117 MS150061 06E 2016 02 Special Tool...

Page 148: ...2 Crankcase breather Oil separator replacement di aphragm check and replacement Page 74 Qty Used in 1 8 19 5 Coalescer filter element Replacement Page 125 Ratchet with extension Part No F30006212 Qty Used in 1 8 2 1 Engine Barring manually Page 67 Qty Used in 1 8 3 1 Cylinder liner Endoscopic examination Page 69 Qty Used in 1 8 5 1 Valve clearance Check and adjustment Page 76 148 Special Tools MS1...

Page 149: ...Used in 1 8 6 2 Injector Removal and installation Page 81 Torque screwdriver 1 5 Nm Part No F30452774 Qty Used in 1 8 10 2 Air filter Removal and installation Page 96 Torque wrench 20 100 Nm Part No F30026582 Qty Used in 1 8 5 1 Valve clearance Check and adjustment Page 76 MS150061 06E 2016 02 Special Tools 149 DCL ID 0000010704 006 ...

Page 150: ...d replacement Page 74 Qty Used in 1 8 5 2 Cylinder head cover Removal and installation Page 79 Qty Used in 1 8 19 5 Coalescer filter element Replacement Page 125 Valve clearance gage Part No Y4345893 Qty Used in 1 8 5 1 Valve clearance Check and adjustment Page 76 150 Special Tools MS150061 06E 2016 02 DCL ID 0000010704 006 ...

Page 151: ... Cylinder Designation 19 Cylinder head cover Installation 79 Removal 79 Cylinder liner Endoscopic examination 69 Instructions and comments on endoscopic and visual examination 71 D Diagnostic features On EIM 137 Diagnostic lamp DILA On EIM 137 Differential pressure gauge Check 122 Dimensions Engine 40 Draining points 106 Drive belt Condition check 119 Replacement Battery charging generator drive 1...

Page 152: ...acement 92 Flushing 90 Fuel system Venting 83 Fuel treatment system Putting into operation 45 Shutdown 53 Switching on 48 Fuse lamp SILA On EIM 137 H Hotline 143 HT coolant pump Check Relief bore 115 I Injector Installation 81 Removal 81 Replacement 80 Installation locations SOLAS shielding 62 Interface module EIM Check 132 L Lifting requirements 17 M Main dimensions Engine 40 Maintenance schedule...

Page 153: ... shielding Installation 61 Installation locations 62 SOLAS shielding as per MTN 5233 Installation 60 Spare parts service 143 Starter Condition check 98 Startup After extended out of service periods 3 months 41 Putting into operation after scheduled out of service pe riod 42 T Tasks After extended out of service periods 43 Tasks after extended out of service periods 3 weeks 43 Transportation Descri...

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