MTU 16 V 2000 G56 S Operating Instructions Manual Download Page 1

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Operating Instructions

Diesel Engine

16 V 2000 G56 S
18 V 2000 G76 S

MS150117/01E

Summary of Contents for 16 V 2000 G56 S

Page 1: ...Operating Instructions Diesel Engine 16 V 2000 G56 S 18 V 2000 G76 S MS150117 01E...

Page 2: ...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 and storage...

Page 3: ...copic examination 43 7 2 2 Instructions and comments on endoscopic and visual examination of cylinder liners 45 7 3 Crankcase Breather 47 7 3 1 Crankcase breather Oil mist fine separator replacement 4...

Page 4: ...t Condition check 104 7 16 2 Drive belt Tension check 105 7 16 3 Drive belt Tension adjustment 108 7 16 4 Drive belt Replacement 111 7 17 Battery Charging Generator 113 7 17 1 Battery charging generat...

Page 5: ...guration approved by the manufacturer in writ ing including engine management parameters In compliance with all safety regulations and in accordance with all warning notices in this manual With mainte...

Page 6: ...rk on or around the product This personnel must be instructed repeatedly Personnel requirements All work on the product shall be carried out by trained and qualified personnel only Training at the Tra...

Page 7: ...ropriate for the given weight forklift truck Install the crankshaft locking device and the locking screws for the engine mounts prior to engine trans portation if applicable Secure the engine against...

Page 8: ...starter with compressed air Clean the interior of the flywheel housing with a class H dust extractor Observe the safety data sheet Safety requirements during maintenance and repair work Take special c...

Page 9: ...e performing necessary welding work Hydraulic installation and removal Check function and satisfactory condition of the jigs and fixtures to be used Use only the specified jigs and fixtures for hydrau...

Page 10: ...ent i e protect them against moisture in particular Pack age faulty electronic components or assemblies properly before dispatching for repair Moisture proof Shock proof Wrapped in antistatic foil if...

Page 11: ...are prohibited by emission regulations Emission control units systems may only be maintained exchanged or repaired if the components used for this purpose are approved by the manu facturer Noncomplian...

Page 12: ...be replaced Carry out leak test in accordance with the specifications Paints and varnishes Observe the relevant safety data sheet for all materials When painting in areas other than spray booths equi...

Page 13: ...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 14: ...nated in accordance with DIN ISO 1204 as viewed from driving end 4 For cylinder designation in accordance with DIN ISO 1204 the letter Ax refers to the cylinders on the left hand side of the engine 1...

Page 15: ...tem 6 Lube oil system lube oil circuit 7 Battery charging generator 8 Cooling air system 9 Coolant system 10 Mounting support 11 Fuel system low pressure 12 Fuel system high pres sure 13 Valve gear 14...

Page 16: ...uel system high pres sure 10 Starting equipment 11 PTO system driving end KS Driving end Engine model designation Explanation of engine type designation 16 18 Number of cylinders V Cylinder arrangemen...

Page 17: ...e 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 1800 Continuous power ISO 3046 10 overload capability A kW...

Page 18: ...alarm L C 105 Coolant temperature after engine shutdown L C 107 Coolant antifreeze content max L 50 Coolant pump Inlet pressure max L bar 1 5 Thermostat Starts to open R C 79 Cooling system height abo...

Page 19: ...end up option max op erating inclinations L Degrees 10 Transverse inclination continuous max Option max operating inclina tions L Degrees 10 Capacities Number of cylinders 16 Engine coolant capacity...

Page 20: ...filter DL free field sound power level Lp 1 m distance ISO 6798 2 dB A tolerance R dB A 102 Engine surface noise with attenuated intake noise filter DL sound pow er level LW ISO 6798 2 db A tolerance...

Page 21: ...er of cylinders 18 Rated engine speed A rpm 1800 Continuous power ISO 3046 10 overload capability A kW Net brake power w o fan Fuel stop power ISO 3046 A kW 1371 General conditions for maximum power N...

Page 22: ...to open R C 79 Cooling system height above engine max L m 20 Lube oil system Number of cylinders 18 Lube oil operating temperature before engine from R C 75 Lube oil operating temperature before engi...

Page 23: ...tem design max operating in clinations R Liters 110 Oil pan capacity dipstick mark min standard oil system design max op erating inclinations L Liters 92 Oil pan capacity dipstick mark max standard oi...

Page 24: ...iring order Number of cylinders Firing order 16 V A1 B5 A3 A5 B2 B8 A2 A8 B3 A7 B4 B6 A4 A6 B1 B7 18 V A1 B6 A3 B4 A5 B2 A7 B1 A9 B3 A8 B5 A6 B7 A4 B9 A2 B8 24 Technical Data MS150117 01E 2014 10 TIM...

Page 25: ...gine Main dimensions 16 V 2000 G56 S Engine model Length A Width B Height C 16 V 2000 G56 S Approx 2378 mm Approx 1288 mm Approx 1490 mm Table 2 Engine model Dimensions MS150117 01E 2014 10 Technical...

Page 26: ...nsions 18 V 2000 G76 S Engine model Length A Width B Height C 18 V 2000 G76 S Approx 2569 mm Approx 1572 mm Approx 1420 mm Table 3 Engine model Dimensions 26 Technical Data MS150117 01E 2014 10 TIM ID...

Page 27: ...em Check engine oil level Page 73 Fuel system Connect appropriate equipment to fuel supply line to fill the system Fuel system Vent Page 60 Coolant circuit If engine is out of service for more than on...

Page 28: ...tem Check engine oil level Page 73 Coolant circuit Check engine coolant level Page 86 check charge air coolant level Page 96 Coolant circuit Preheat engine coolant with coolant preheating unit if fitt...

Page 29: ...ng the engine with starter system make sure that there are no persons 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 prot...

Page 30: ...speed temperature pressures Engine operation Check engine visually for leaks and general condition Check engine for abnormal running noises exhaust color and vibrations Air filter Check signal ring po...

Page 31: ...running at full load subjects it to extreme thermal and mechanical stresses Overheating of and therefore damage to components is possible Before shutting down the engine allow it to idle until the eng...

Page 32: ...rgency engine stop Item Action Emergency stop pushbutton Press EMERGENCY STOP pushbutton Engine is stopped by disconnecting the power supply to the ECU Emergency air shutoff flaps close if applicable...

Page 33: ...e the engine room is not heated the coolant is not kept at a suitable temperature the antifreeze concentration is insufficient for the engine room tem perature the antifreeze concentration is 50 and t...

Page 34: ...ressed air gun directly 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 environmenta...

Page 35: ...filter Page 30 W1001 Replace fuel filter or fuel filter element Page 62 W1003 Check belt condition and tension replace if necessary Page 104 W1006 Replace fuel injectors Page 51 W1008 Replace engine o...

Page 36: ...fuel prefilter Page 30 W0534 Carry out test run minimum duration until steady state tem perature is reached no less than 1 3 load monthly Page 42 W1001 Replace fuel filter or fuel filter element Page...

Page 37: ...ire Component Cause Action Starter Poor rotation by starter Battery low or faulty Charge or replace battery see manufac turer s documentation Engine cabling Faulty Check Page 120 Fuel system Air in fu...

Page 38: ...ake temperature too high Check fans and intake exhaust lines Charge air pressure too low Component Cause Action Air supply Air filter clogged Check signal ring position of service in dicator Page 70 L...

Page 39: ...urbocharger cylinder head piston rings cylinder liner Faulty Contact Service White exhaust gas Component Cause Action Engine Not at operating temperature Run engine to reach operating tempera ture Fue...

Page 40: ...ine make sure that all safety devices are put back in place and all tools are removed from the engine Barring the engine manually 1 Remove access cover from flywheel hous ing 2 Engage barring gear 2 i...

Page 41: ...in Before cranking the engine with starter system make sure that there are no persons in the en gine s danger zone Engine Barring with starting system 1 Press pushbutton Bar engine without starting an...

Page 42: ...no persons 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 Engine Test run 1 Start engine Page 29 2 Perform te...

Page 43: ...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 44: ...pending 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 P...

Page 45: ...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 46: ...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 47: ...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 vapo...

Page 48: ...cylinder head and valve gear installed 1 Install dial gage 2 under preload in meas uring device 4 and clamp with screw 1 2 Install measuring device 4 in cylinder head and secure using knurled head sc...

Page 49: ...e bridge and rocker arm 5 If the deviation from the reference value exceeds 0 1 mm adjust valve clearance Valve clearance adjustment 1 Loosen locknut 1 and unscrew adjusting screw 2 by a few threads 2...

Page 50: ...lease injec tor clamps and remove spade lugs 1 Remove cylinder head cover 2 with gas ket 1 from cylinder head 2 Clean mating face 3 Check condition of gasket 1 in cylinder head cover 2 4 Replace gaske...

Page 51: ...al tools Material Spare parts Designation Use Part No Qty Injector Spare Parts Catalog Screw for hold down clamp Spare Parts Catalog Replacing injector u Remove injector and install new one Page 52 MS...

Page 52: ...011450 1 Plug in open end wrench 24 mm F30453238 1 Assembly compound Kluthe Hakuform 30 15 X00067260 1 Engine oil Sealing ring Spare Parts Catalog WARNING Fuels are combustible Risk of fire and explos...

Page 53: ...suction device 5 Disconnect terminals arrowed on injector and pull out cable lugs 6 Remove gasket 7 Remove screw 3 Note Screw 3 may be installed only once 8 Take off hold down clamp 2 9 Use the puller...

Page 54: ...nd relieve hold down clamp 2 Installation with press fitting tool 1 Place press fitting tool on hold down clamp 2 to press injector 1 carefully into the cylinder head 2 Place hold down clamp 2 in corr...

Page 55: ...bricant Value Standard Retaining screw M24 Tightening torque 50 Nm 5 Nm Installing fuel line 1 Coat thread and shoulder of union nuts on HP fuel line 1 with engine oil Note Position fuel line ensuring...

Page 56: ...the specified torque using a torque wrench Name Size Type Lubricant Value Standard Union nut M16 Tightening torque Engine oil 37 Nm 3 Nm Fitting gasket and connecting in jector cable 1 Place gasket o...

Page 57: ...id the emissions certification for the en gine Resetting drift correction parameters CDC with DiaSys 1 Dialog system DiaSys E531920 2 If no DiaSys is available contact Service Entering injector coding...

Page 58: ...Engine oil Pressure pipe neck Spare Parts Catalog HP fuel line Spare Parts Catalog WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do...

Page 59: ...ecified torque using a torque wrench a For single wall high pressure fuel system Name Size Type Lubricant Value Standard Union nut M20 Tightening torque Engine oil 37 Nm 3 Nm b For jacketed high press...

Page 60: ...cal sparks and ignition sources Do not smoke Fuel system Venting 1 Open threaded vent plug 2 on filter head and connect suitable hose 2 Provide suitable container to collect escap ing fuel 3 Actuate h...

Page 61: ...fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Fuel Draining 1 Provide a suitable container in which to collect the fuel 2 Remove fuel filter Page 62 3 Catch...

Page 62: ...sk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Fuel filter Replacement 1 Remove easy change filter 3 with filter wrench 2 Clean the sealing face on the...

Page 63: ...of dif ferential pressure gage 1 After installation of a new filter element Align adjustable pointer 2 with pressure indicating pointer 3 of pressure gage 1 2 Verify that differential pressure is with...

Page 64: ...Do not smoke Fuel prefilter Draining 1 Open vent plug 1 of the filter 2 Unlock drain cock 2 by pressing toggle and open it 3 Drain water and contaminants from the fil ter until pure fuel emerges 4 Clo...

Page 65: ...led in Only run the engine at low power Keep away from the engine s danger zone WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not...

Page 66: ...ug 5 and drain valve 6 Fuel prefilter Filling with fuel 1 Remove screws for cover and take off cover 2 2 Fill filter housing with clean fuel 3 Place new gasket in cover 2 4 Fit cover with gasket and s...

Page 67: ...ing filter element 1 Close shut off valve in fuel supply line 2 Open vent plug 1 of the filter 3 Unlock drain cock 2 by pressing toggle and open it 4 Drain water and dirt from filter 5 Close drain coc...

Page 68: ...rt No Qty Air filter Spare Parts Catalog Filter insert Spare Parts Catalog Filter element Spare Parts Catalog Air filter Replacement 1 Remove air filter s and install new one s Page 69 2 Reset signal...

Page 69: ...the intake housing 3 and clean it 4 Fit air filter 1 and clamp 2 on connecting flange of intake housing 3 5 Tighten clamp 2 Variant B 1 Release latches 1 2 Take off cover 2 3 Remove filter insert 3 a...

Page 70: ...led Checking signal ring position 1 If the signal ring is completely visible in the control window 2 replace air filter Page 68 2 After installation of new filter press reset button 1 Result Engaged p...

Page 71: ...7 10 Exhaust Gas Recirculation 7 10 1 Exhaust gas recirculation flaps Overview MS150117 01E 2014 10 Task Description 71 TIM ID 0000024288 002...

Page 72: ...Unit operating voltage when performing mechanical tests Wear protective gloves Checking exhaust flap operation 1 For installation position of exhaust flaps refer to overview Page 71 2 Check operabili...

Page 73: ...1 marks 4 Top up with oil up to the max 1 mark Page 74 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 74: ...hand pump Draining oil at drain plug on oil pan 1 Provide a suitable container to collect the oil 2 Remove drain plug and drain oil 3 Install drain plug with new sealing ring 4 Replace engine oil filt...

Page 75: ...ng Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Engine oil filter Replacement 1 Remove oil filter 2 with filter wrench 2 Clean sealing face o...

Page 76: ...face mask and ear defenders Cleaning centrifugal oil filter and replacing filter sleeve 1 Slacken off nuts 4 crosswise 2 Remove housing cover 1 3 Carefully remove rotor 3 from housing lower section 5...

Page 77: ...Value Standard Nut Tightening torque 8 Nm 1 Nm 16 Fit housing cover 1 17 Screw on nuts 4 18 Tighten nuts 4 to specified torque using a torque wrench Name Size Type Lubricant Value Standard Nut Tighten...

Page 78: ...Circuit General High Temperature Circuit 7 13 1 Drain and vent points Plan view 16 V 2000 G56 S 1 Coolant vent LT circuit 2 Coolant vent HT circuit 78 Task Description MS150117 01E 2014 10 TIM ID 000...

Page 79: ...Left side 16 V 2000 G56 S 1 Coolant drain plug crank case free end 2 Coolant drain plug crank case driving end MS150117 01E 2014 10 Task Description 79 TIM ID 0000051485 002...

Page 80: ...2000 G56 S 1 Coolant drain plug crank case driving end 2 Coolant drain plug crank case free end 3 Coolant drain plug HT pump 4 Coolant drain plug LT pump 80 Task Description MS150117 01E 2014 10 TIM I...

Page 81: ...Free end 16 V 2000 G56 S 1 Coolant drain plug lube oil heat exchanger 2 Coolant filling plug 3 Coolant drain plug MS150117 01E 2014 10 Task Description 81 TIM ID 0000051485 002...

Page 82: ...Plan view 18 V 2000 G76 S 1 Coolant vent HT circuit 2 Coolant vent HT circuit 3 Coolant vent HT circuit 82 Task Description MS150117 01E 2014 10 TIM ID 0000051485 002...

Page 83: ...Left side 18 V 2000 G76 S 1 Coolant drain plug crank case driving end 2 Coolant drain plug crank case free end MS150117 01E 2014 10 Task Description 83 TIM ID 0000051485 002...

Page 84: ...ight side 18 V 2000 G76 S 1 Engine coolant drain plug 2 Coolant drain plug crank case free end 3 Coolant drain plug crank case driving end 84 Task Description MS150117 01E 2014 10 TIM ID 0000051485 00...

Page 85: ...Free end 18 V 2000 G76 S 1 Coolant drain plug lube oil heat exchanger MS150117 01E 2014 10 Task Description 85 TIM ID 0000051485 002...

Page 86: ...nterclockwise to the first stop and allow pressure to escape 2 Continue to turn breather valve counter clockwise and remove 3 Check coolant level coolant must be visi ble at the lower edge of the cast...

Page 87: ...nge Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 88 2 Fill with engine coolant Page 90 MS150117 01E 2014 10 Task Description...

Page 88: ...ontinue to turn breather valve counter clockwise and remove 3 Draw off precipitated corrosion inhibitor oil from the coolant expansion tank through filler neck 4 Open drain valves and or drain plugs a...

Page 89: ...rom the coolant expansion tank through filler neck 4 Open drain valves and or drain plugs and drain coolant at the following points At the preheating unit At the HT coolant pump 1 At the crankcase 1 a...

Page 90: ...Cold coolant in hot engine can cause thermal stress Possible formation of cracks in the engine Fill top up coolant only into cold engine Preparatory steps 1 Turn breather valve 1 on coolant expan sio...

Page 91: ...inal steps 1 Start the engine and operate it at idle speed for some minutes 2 Check coolant level Page 86 top up with coolant if required MS150117 01E 2014 10 Task Description 91 TIM ID 0000000034 008...

Page 92: ...is running Risk of damage to hearing Wear ear protectors Engine coolant pump Relief bore check 1 Check relief bore for oil and coolant dis charge Permissible coolant discharge up to 10 drops per hour...

Page 93: ...is 1 Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to escape 2 Continue to turn breather valve counterclockwise and remove 3 Draw off precipitated...

Page 94: ...t 7 14 1 Intercooler Vent and drain points Intercooler Vent and drain points 1 LT circuit vent connection 2 HT circuit vent connection 3 Coolant drain plug LT pump 94 Task Description MS150117 01E 201...

Page 95: ...king intercooler condensate drain for coolant discharge and obstructions 1 Remove plug screw s from charge air manifold 2 Check drain bore s for air discharge If no air escapes 3 Clean drain bore s an...

Page 96: ...llow pressure to escape 2 Continue to turn cap counterclockwise and remove Note Charge air coolant must be visible at mark er plate 3 Check charge air coolant level 4 Top up charge air coolant as nece...

Page 97: ...pecial tools Material Spare parts Designation Use Part No Qty Coolant Charge air coolant Change 1 Drain charge air coolant Page 100 2 Fill with charge air coolant Page 98 MS150117 01E 2014 10 Task Des...

Page 98: ...al stress Possible formation of cracks in the engine Fill top up coolant only into cold engine Preparatory steps 1 Turn breather valve 1 on coolant expan sion tank counterclockwise to the first stop a...

Page 99: ...Final steps 1 Start the engine and operate it at idle speed for some minutes 2 Check coolant level Page 96 MS150117 01E 2014 10 Task Description 99 TIM ID 0000000039 006...

Page 100: ...coolant 1 Provide a suitable container to catch the coolant 2 Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to escape 3 Continue to turn breather...

Page 101: ...is running Risk of damage to hearing Wear ear protectors Charge air coolant pump Relief bore check 1 Check relief bore for oil and coolant dis charge Permissible coolant discharge up to 10 drops per h...

Page 102: ...lly for dirt Preconditions Engine is stopped and starting disabled Checking cooler elements externally for dirt 1 Visually inspect cooler elements for dirt 2 Clean badly soiled cooler elements Page 10...

Page 103: ...ns for use NOTICE Inappropriate cleaning tool Risk of damage to component Observe manufacturer s instructions Use appropriate cleaning tool NOTICE Cleaning agents should not be left to take effect for...

Page 104: ...ed 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 113 Drive belt C Chunking Drive belt Belt...

Page 105: ...ting disabled Special tools Material Spare parts Designation Use Part No Qty Tester Y4345711 1 Belt tension tester 150 600 N Y20097429 1 Checking belt tension Fan drive 16V Checking belt tension Fan d...

Page 106: ...23 mm fan Depression depth 6 mm Test force 188 N Depression depth 5 mm Test force 188 N Drive belt 1665 mm fan Depression depth 6 mm Test force 188 N Depression depth 5 mm Test force 188 N Drive belt...

Page 107: ...Drive belt 1623 mm fan Frequency 113 1 Hz Frequency 103 1 Hz Drive belt 1665 mm fan Frequency 113 1 Hz Frequency 103 1 Hz Drive belt 1707 mm fan Frequency 113 1 Hz Frequency 103 1 Hz Drive belt 1800 m...

Page 108: ...30027340 1 Torque wrench 40 200 Nm F30027337 1 Engine oil Drive belt Tension adjustment 16V 1 Remove protective cover 2 Loosen screws 1 a little 3 Set distance A to 100 mm with screw 2 4 Tighten screw...

Page 109: ...pe Lubricant Value Standard Screw M12 x 240 Tightening torque Engine oil 30 Nm 3 Nm 12 Tighten screw 5 to specified torque using a torque wrench Name Size Type Lubricant Value Standard Screw M12 x 240...

Page 110: ...7 Install protective grill on fan 8 Install protective cover on cooler 110 Task Description MS150117 01E 2014 10 TIM ID 0000051490 002...

Page 111: ...ive belt removal 6 Check belt pulley on radiator bearing mount and crankshaft for contamination and clean if necessary 7 Release screws 3 and 4 a little 8 Slide tensioning roller over screws 3 and 4 i...

Page 112: ...e belt removal 6 Check belt pulley on radiator bearing mount and crankshaft for contamination and clean if necessary Note When placing the drive belt in the grooves no force must be applied 7 Fit new...

Page 113: ...protective cover Drive belt replacement 16V 1 Hold adjusting lever in place at square 2 2 Rotate adjusting lever until drive belt is re leased 3 Secure adjusting lever with a pin punch or screwdriver...

Page 114: ...Size Type Lubricant Value Standard Clamping bolt Preload torque 8 Nm Belt application Specification Initial installation new belt Specification Operating tension used belt Battery charging generator...

Page 115: ...Engine governor Overview Engine governor 16V Overview 1 Screw 2 Damper 3 Washer 4 Engine governor 5 Connector X3 6 Screw 7 Connector X2 8 Screw for grounding strap MS150117 01E 2014 10 Task Descriptio...

Page 116: ...Engine governor 18V Overview 1 Connector X2 2 Engine governor 3 Connector X3 4 Washer 5 Screw 6 Damper 116 Task Description MS150117 01E 2014 10 TIM ID 0000057019 001...

Page 117: ...given engine is installed Removing engine governor from engine 16V 1 Note or mark assignment of cables and connectors 2 Release latches on connectors 5 and 7 3 Disconnect all connectors 4 Remove screw...

Page 118: ...18V 1 Note or mark assignment of cables and connectors 2 Release latches on connectors 1 and 3 3 Disconnect all connectors 4 Remove all screws 5 5 Remove engine governor 2 118 Task Description MS1501...

Page 119: ...table 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 plu...

Page 120: ...ips are closed and intact 4 Replace faulty cable clips 5 Check that cable clamps are firm tighten loose cable clamps 6 Replace faulty cable clamps 7 Visually inspect the following electrical line comp...

Page 121: ...7 19 2 Lambda NOx and humidity sensors Overview 1 Humidity sensor 2 Lambda sensor 3 NOx sensor MS150117 01E 2014 10 Task Description 121 TIM ID 0000051492 002...

Page 122: ...t Risk of burning Wear protective gloves NOTICE Ceramic cell breakage due to shock or impact Risk of damage to components Avoid shocks and impacts Exercise extreme care when handling sensors NOTICE Hi...

Page 123: ...off the thread lubricant applied by the manufacturer 2 Coat sensor thread with specified assembly compound as required 3 Screw in sensor by hand 4 Tighten nut 2 to specified torque using a torque wre...

Page 124: ...r protective gloves NOTICE High voltage Risk of damage to components Switch off ignition before replacing components NOTICE Ceramic cell breakage due to shock or impact Risk of damage to components Av...

Page 125: ...nly just before installation Note Do not wipe off the thread lubricant applied by the manufacturer 3 Coat sensor thread with specified assembly compound as required 4 Screw in sensor by hand 5 Tighten...

Page 126: ...ompound Kluthe Hakuform 30 15 X00067260 Humidity sensor Spare Parts Catalog 1 NOTICE Contamination of components Damage to component Observe manufacturer s instructions Check components for special cl...

Page 127: ...rrect installation position Note Observe air flow direction 2 Screw in screws 1 3 Tighten screws 1 to specified torque using a torque wrench Name Size Type Lubricant Value Standard Sensor M6 Tightenin...

Page 128: ...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 cable labels Cle...

Page 129: ...table 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 plu...

Page 130: ...y module for engine data EMU Engine Monitoring Unit ETC Exhaust turbocharger GCU Gear Control Unit GMU Gear Monitoring Unit HAT Harbor Acceptance Test HI High Range violation alarm 1st upper limit val...

Page 131: ...e PPC Priming Pump Control RCS Remote Control System RL Redundancy Lost Alarm Redundant CAN bus failure SAT Sea Acceptance Test SD Sensor Defect Alarm Sensor failure SDAF Shut Down Air Flap s Emergenc...

Page 132: ...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 133: ...Used in 1 7 1 1 Engine Barring manually Page 40 Qty Used in 1 7 4 1 Valve clearance Check and adjustment Page 48 Belt tension tester 150 600 N Part No Y20097429 Qty Used in 1 7 16 2 Drive belt Tensio...

Page 134: ...o F30002800 Qty Used in 1 7 4 1 Valve clearance Check and adjustment Page 48 Double box wrench Part No F30011450 Qty Used in 1 7 5 2 Injector Removal and installation Page 52 Qty Used in 1 7 6 1 HP fu...

Page 135: ...device Part No F30378207 Qty Used in 1 7 5 2 Injector Removal and installation Page 52 Measuring device Part No Y4348409 Qty Used in 1 7 4 1 Valve clearance Check and adjustment Page 48 MTU test kit...

Page 136: ...y Used in 1 7 5 2 Injector Removal and installation Page 52 Plug in open end wrench 19 mm Part No F30025897 Qty Used in 1 7 6 1 HP fuel line and pressure pipe neck Replace ment Page 58 Plug in open en...

Page 137: ...Removal and installation Page 50 Qty Used in 1 7 5 2 Injector Removal and installation Page 52 Qty Used in 1 7 6 1 HP fuel line and pressure pipe neck Replace ment Page 58 Qty Used in 1 7 16 3 Drive...

Page 138: ...e 48 Ring socket 22 mm Part No F30038494 Qty Used in 1 7 5 2 Injector Removal and installation Page 52 Qty Used in 1 7 6 2 Fuel system Venting Page 60 Ring socket 24 mm Part No F30501562 Qty Used in 1...

Page 139: ...enerator drive Drive belt re placement Page 113 Torque wrench 0 5 5 Nm Part No 0015384230 Qty Used in 1 7 4 2 Cylinder head cover Removal and installation Page 50 Torque wrench 10 60 Nm Part No F30510...

Page 140: ...r Removal and installation Page 52 Qty Used in 1 7 6 1 HP fuel line and pressure pipe neck Replace ment Page 58 Qty Used in 1 7 16 3 Drive belt Tension adjustment Page 108 Torque wrench 40 200 Nm Part...

Page 141: ...art No F30043446 Qty Used in 1 7 4 2 Cylinder head cover Removal and installation Page 50 Torque wrench 0 5 5 Nm Part No 0015384230 Qty Used in 1 7 5 2 Injector Removal and installation Page 52 Valve...

Page 142: ...elements 103 Cooler elements Checking Externally for dirt 102 Cleaning 103 Crankcase breather Oil mist fine separator Replacement 47 Cylinder Designation 14 Cylinder head cover Installation 50 Remova...

Page 143: ...tial pressure gage 63 Check Differential pressure gage 63 Draining 64 Filter element replacement 67 Flushing 65 Fuel system Installation Injector 52 Removal Injector 52 Venting 60 H Hotline 132 HP fue...

Page 144: ...ety regulations Auxiliary materials 11 Environmental protection 11 Fire prevention 11 Fluids and lubricants 11 Organizational requirements 6 Personnel requirements 6 Safety requirements Important requ...

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