MTU Detroit Diesel 12 V 2000 P62 Technical Publication Download Page 106

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102

Task Description

6.5.2

Injection pump – Removal and installation

Preconditions

• Engine is stopped and starting disabled.

Special tools

Designation / Use

Part No.

Qty.

Barring tool

F6557929

Spider patch spanner

F30027424

Spider patch spanner

F30027425

Material

Designation / Use

Part No.

Qty.

Petroleum jelly

Spare parts

Designation / Use

Part No.

Qty.

Sealing ring
Sealing ring

DANGER

Unguarded rotating and moving engine components.

Risk of serious injury — danger to life!

• Before barring the engine, ensure that nobody is in the danger zone.

WARNING

Fuels are combustible.

Risk of fire and explosion!

• Avoid naked flames, electrical sparks and ignition sources.
• Do not smoke.

Preparatory steps

1. Shut off fuel supply line before fuel filter.
2. Remove engine control system (

3. Drain fuel (

4. Remove charge-air pipes and all seals.

MS15009/00E 06-09

Summary of Contents for Detroit Diesel 12 V 2000 P62

Page 1: ...Technical Publication Diesel Engine 12 V 2000 P62 P82 16 V 2000 P62 P82 Application group 3B Operating Instructions MS15009 00E...

Page 2: ...l entretien et de la conduite Modifications r serv es Impreso en Alemania 2006 Copyright MTU Friedrichshafen GmbH Esta publicaci n se encuentra protegida en toda su extensi n por los derechos de auto...

Page 3: ...base pour l assistance en exploitation contractuelle garantie rechanges etc Rogamos separen la tarjeta Aviso de puesta en servicio y la devuelvan rellenada a MTU Friedrichshafen GmbH Las informaciones...

Page 4: ...ta en servicio Messa in servizio il Data da coloca o em servi o Eingebaut in Installation site Lieu de montage Lugar de montaje Installato Incorporado em Schiffstyp Schiffshersteller Vessel type class...

Page 5: ...Engine side and cylinder designations 36 2 4 Final Compression Pressure 37 2 4 1 Final compression pressure 37 2 5 Technical Data 38 2 5 1 12 16V 2000 P62 82 engine data 38 2 5 2 SAM Technical data 4...

Page 6: ...clearance Check and adjustment 98 6 4 2 Cylinder head cover Removal and installation 100 6 5 Injection Pump HP Pump 101 6 5 1 Injection pump replacement 101 6 5 2 Injection pump Removal and installat...

Page 7: ...16 2 Charge air coolant filling 141 6 16 3 Charge air coolant Draining 142 6 16 4 Charge air coolant level check 143 6 17 General Cabling for Engine Gearbox Unit 144 6 17 1 Engine wiring check 144 6 1...

Page 8: ...04 Table of Contents 9 1 Manufacturer s documentation 195 9 2 MTU contact person service partner 196 9 3 Abbreviations 197 9 4 Index 201 MS15009 00E 06 09 MTU...

Page 9: ...the application specified in the contract or defined at the time of delivery Any other use is considered improper use The manufacturer will accept no liability for any resultant damage The responsibil...

Page 10: ...d in operation maintenance repair or transportation The personnel must be instructed on engine operation and repair by means of this publication and in particular the safety instructions must be expla...

Page 11: ...nt for heavy loads forklift truck Prior to transporting the engine it is imperative to install transportation locking devices for crankshaft and engine mounts Secure the engine against tilting during...

Page 12: ...s or cables Inadequate protection of electrical components can lead to electric shocks and serious injuries When the engine is running never release coolant oil fuel compressed air or hydraulic lines...

Page 13: ...ounted units Never use the engine as a ground connection This prevents the welding current passing through the engine resulting in burnt scorched bearings sliding surfaces and tooth flanks which may l...

Page 14: ...o properly support the wires For this purpose no cable binders must be used as during maintenance and or repair work the binders can be removed but not installed a second time Spare parts shall be pro...

Page 15: ...s governing the use of materials that may affect water quality is applicable which means work must only be carried out by authorized specialist companies MTU is such a company Auxiliary materials Use...

Page 16: ...set to permitted pressure must form an intermediate connection Hose coupling and connections must be securely attached Always wear protective goggles when blowing off tools or chips The snout of the...

Page 17: ...ions Consequences Slight injury or material damage Preventive measures Note This Publication contains especially emphasized safety instructions in accordance with the American standard ANSI Z535 which...

Page 18: ...14 Safety MS15009 00E 06 09 MTU...

Page 19: ...Peripheral Interface Modules can be connected for linking to higher level systems Functions Control of the engine Monitoring of operating states Closed loop control of fuel injection and engine speed...

Page 20: ...gine governor replacement Engine and interface data stored in SAM Complete automatic software download following connection of a new unprogrammed engine governor Design of the overall MDEC system 1 Mo...

Page 21: ...supply Ub 4 Signal connection to the MCS devices and the higher level control systems 5 Engine governor 6 System boundary ECS 5 The Engine Control System comprises the following devices Engine governo...

Page 22: ...duct Summary Basic scope of Monitoring and Control System MCS 5 1 Monitoring and Control System MCS 5 2 Power supply Ub 3 Signal connection to ECS devices 4 System boundary MCS 5 5 SAM MS15009 00E 06...

Page 23: ...ne governor and SAM 3 Backup function engine life data are stored every hour after every engine stop after every emergency engine stop Interface for dialog unit Diagnosis Straightforward diagnosis by...

Page 24: ...bus is a standardized automation technology field bus which allows various systems and devices to communicate with each other providing they are equipped with a CAN bus interface Tasks of the CAN bus...

Page 25: ...rly relevant to CE labeling as per EMC directive Ground connection The ground of the power supply battery negative and all electronic devices should not be connected to ground 8 The entire electronic...

Page 26: ...inputs 26 outputs Engine and plant related setting variables in exchangeable memory modules In case of inadmissible states and limit value violations Initiation of power reduction engine stop and emer...

Page 27: ...ata record and engine number 4 Screws 5 Connector X6 Connection for dialog unit 6 Connector X4 Connection for injector wiring harness 7 Connector X5 Connection for power supply 8 Connector X2 Connecti...

Page 28: ...on 11 VDC to 36 VDC Residual ripple Max 8 Vpp Power consumption Max 30 A Heat loss Max 35 W Operating temperature range 0 C to 75 C Storage temperature range 10 C to 75 C Relative air humidity 0 to 95...

Page 29: ...ot reached Idle speed low 11 Engine running at idling speed Restart response The response of the engine is determined by the following factors on receiving a start request when the engine is running d...

Page 30: ...uch as warning start interlock power reduction or engine shutdown by reducing the quantity of fuel injected depending on the values measured Closed loop control functions Closed loop engine control fu...

Page 31: ...ired speed is the command variable for the engine speed control loop When the engine is started it runs up to an internally programmed desired speed for 50 Hz network frequency 1500 rpm for 60 Hz netw...

Page 32: ...tical memory A counter counting up to max 10 000 is set up for each fault message number Monitoring of engine governor electronics The hardware and software of the engine governor is designed to allow...

Page 33: ...t board Basic module 1 2 with printed circuit board COB 1 0X 3 Printed Circuit Board SCB 3 Slots and terminals 1 Slot 1 2 Slot 2 Slot 1 is reserved for the microprocessor card MPU 23 and MPU 27 All ot...

Page 34: ...ssages Alarms Shutdowns Function of PIM 601 Serial interface Computer coupling 512 Procedure 3964 R RS232 or RS422 MTU SLAVE Function of PIM 602 Serial interface Computer coupling 512 Procedure 3964 R...

Page 35: ...6 LED yellow Interface 1 Receiving and transmitting line active 7 LED yellow Interface 2 Receiving and transmitting line active 8 Connector RS232 interface Features 2 interfaces as per RS422 or RS232...

Page 36: ...any one transmission channel Transmission channel 1 is equipped with a connection for a serial RS422 interface and a serial RS232 interface The RS232 interface is connected via the terminals of the P...

Page 37: ...1 Ground GND of RS422 interface n06 Channel 2 Ground GND of RS422 interface n07 Channel 1 I1 of RS422 interface n08 Channel 2 I1 of RS422 interface n09 Channel 1 I2 of RS422 interface n10 Channel 2 I2...

Page 38: ...Intercooler 4 Air intake connection 5 Crankcase ventilation 6 Crankcase ventilation 7 Cylinder head cover 8 Electronic equipment 9 Engine lifting device 10 Fuel duplex filter 11 Oil filler neck 12 Cha...

Page 39: ...coolant pump Engine model designation Key to the engine model designation 12 16V 2000 Px2 12 16 Number of cylinders V Cylinder arrangement V engine 2000 Series P Application X Application segment 6 8...

Page 40: ...end KS The cylinders of the left engine side are designated A and those of the right side B as per DIN ISO 1204 The cylinders of each bank are numbered consecutively starting with No 1 at the driving...

Page 41: ...Product Summary 37 2 4 Final Compression Pressure 2 4 1 Final compression pressure Final compression pressure Final compression pressure at 120 rpm 30 bar to 36 bar MS15009 00E 06 09 MTU...

Page 42: ...e C 25 25 25 25 Charge air coolant temperature C 45 45 45 45 Barometric pressure mbar 1000 1000 1000 1000 Site altitude above sea level m 100 100 100 100 POWER RELATED DATA power ratings are net brake...

Page 43: ...ngle degrees 90 90 90 90 Bore mm 130 130 130 130 Stroke mm 150 150 150 150 Cylinder displacement liter 1 99 1 99 1 99 1 99 Total displacement liter 23 88 23 88 31 84 31 84 Compression ratio 16 16 16 1...

Page 44: ...equipment A C 45 45 45 45 Antifreeze percentage in coolant max L 50 50 50 50 Pressure loss in off engine cooling system max L bar 0 7 0 7 0 7 0 7 LUBE OIL SYSTEM Number of cylinders 12 12 16 16 Lube o...

Page 45: ...coolant engine side without cooling system R liter 58 58 Charge air coolant engine side R liter 19 19 20 20 Engine oil capacity initial filling standard oil system Option max operating inclinations R...

Page 46: ...consumption W Under 7 0 25A at 24V without additional load Degree of protection IP 40 as per DIN 40 050 Shock Rail mounting 10g 11ms Fixed installation 30g 11ms Vibration Rail mounting Hz 2 12 8 Xpp 3...

Page 47: ...EN 61000 4 5 Surge interference immunity 1kV 2kV EN 50155 Surge interference immunity 1 8kV EN 61000 4 17 LF conducted interference 0 03 10 kHz 3Veff EN 61000 4 29 Mains fluctuation STANAG 1008 IEC 6...

Page 48: ...is 500 unless otherwise stated Mechanical design Term Unit Value Installation position Horizontal to facilitate legibility of fault display and inscriptions on SAM housing Note that space is required...

Page 49: ...ng surge voltage V 2500 Wire cross sections mm2 Up to 1 5 or AWG15 Clamping range mm2 0 08 1 5 or AWG15 Other terminals RM 5 08 are used for power supply and CAN bus connections Additional printed cir...

Page 50: ...5 5 from MPU 23 or MPU 27 Power consumption mA Less than 100 Power loss mW Less than 425 Data transmission Term Unit Value Bit serial As per RS422 standard Baud rate kBd 1 2 to 19 2 Electrical isolat...

Page 51: ...ps alarm signalization Pressing the button a second time acknowledges an active alarm LED spot lights up when an alarm is active 7 White DIM Holding down the button increases LCD background illuminati...

Page 52: ...17 Green LOCAL OPERATION Pressing the switch activates changeover between local and remote control mode LED spot lights up when local mode is active 18 White START Pressing the button initiates autom...

Page 53: ...age 120 Fuel prefilter pressure gauge Align adjustable pointer with position of pressure indicator Page 115 Fuel system Vent Coolant circuit If engine is out of service for more than one year change e...

Page 54: ...m Check oil level Page 129 Cooling system Check engine coolant level Page 138 Check charge air coolant level Page 143 Cooling system Preheat coolant with preheating unit Fuel prefilter Drain Page 116...

Page 55: ...t control panel etc depending on manufacturer If coolant temperature is 40 C with preheating pump or 10 C 60 Hz generator without preheating pump or 5 C 50 Hz generator without preheating pump Press s...

Page 56: ...utton for override input of ECU Switching cabinet control panel etc depending on manufacturer Press start button Automatic starting procedure is performed All safety functions are deactivated and engi...

Page 57: ...l speed Check engine plant and pipework for leaks rectify any leaks with the engine stopped Check for abnormal running noises and vibration Fuel prefilter Check whether indicated differential pressure...

Page 58: ...le speed until operating temperatures decrease and stable values are indicated Preparation Item Task Engine After the generator circuit breaker has been opened allow the engine to cool down by running...

Page 59: ...tuations Emergency stop from LOP Item Task EMERGENCY STOP button Press Engine is stopped by switching off power supply to ECU Signalization e g by horn flashing lamp is released After emergency stop f...

Page 60: ...9 After stopping the engine engine remains ready for operation After stopping the engine Item Task Engine generator control system Select operating mode e g MANUAL OPERATION AUTOMATIC OPERATION MS1500...

Page 61: ...antifreeze additive the engine room is not heated the coolant is not maintained at a suitable temperature the antifreeze concentration is insufficient for the engine room temperature antifreeze conce...

Page 62: ...58 Operation MS15009 00E 06 09 MTU...

Page 63: ...s They provide a reference to the scope of parts required and appear on the labels of the appropriate replacement parts Preventive maintenance instructions The specification of fluids and lubricants g...

Page 64: ...60 Maintenance Load factor Load factor 75 Load profile Load profile table Power 90 75 50 20 Corresponding operating time 5 40 50 5 MS15009 00E 06 09 MTU...

Page 65: ...6 000 6 500 7 000 7 500 8 000 8 500 9 000 9 500 10 000 10 500 Engine oil filter 2 Engine operation X Fuel filter 2 X X X X X X X X X X X X X X X X X X X X X Valve gear X X X X X Fuel injectors X X Co...

Page 66: ...000 11 500 12 000 Engine oil filter 2 Engine operation Fuel filter 2 X X X Valve gear X Fuel injectors X Combustion chambers X Fuel injection pump s X Component maintenance Cylinder head Extended com...

Page 67: ...njectors Replace injectors Page 105 W1006 QL1 4 000 Combustion chambers Perform endoscopic examination Page 92 W1011 QL1 6 000 Fuel injection pump s Replace fuel injection pump s Page 101 W1007 QL3 8...

Page 68: ...2 Replace conrod bearings Workshop Manual W3003 Replace crankshaft bearings Workshop Manual W3004 Replace cylinder liners Workshop Manual W3005 Replace antifriction bearing of auxiliary PTO Workshop M...

Page 69: ...ective Check Page 144 ECU Plug in connections are loose Check plug in connections Page 152 Engine Running gear blocked engine cannot be barred manually Contact Service Engine turns but does not fire C...

Page 70: ...ive Replace Page 105 Fuel injection equipment Injection pump defective Replace Page 101 Speed sensor Defective Contact Service ECU Defective Contact Service Charge air temperature too high Component P...

Page 71: ...engine oil Page 127 Engine oil Oil separator or oil preseparator of crankcase breather clogged Replace Page 96 Exhaust turbocharger Cylinder head Piston rings Cylinder liner Defective Contact Service...

Page 72: ...ve alarms B Alarm was active during the last hour C Alarm was active during the last four hours C Alarm was active during the last four to twelve hours E Alarm was active more than twelve hours ago Fa...

Page 73: ...on Error 9 I O Module Slot2 Defect 10 I O Module Slot3 Defect 11 I O Module Slot4 Defect 12 Serial Connection Lost 13 CAN Bus 3 Error Bus Defec 14 CAN Bus 3 Overrun 15 S A Bus Faulty 16 PAN 1 Defect 1...

Page 74: ...022 L2 T EXHAUST B Exhaust temperature engine B side too high 2nd limit value 1 Check cabling Engine operating instructions 2 Contact Service 023 L1 COOLANT LEVEL Coolant level too low 1st limit valu...

Page 75: ...inlet pressure too low 2nd limit value Engine operating instructions Check fuel lines for leakage Clean fuel prefilter Rinse fuel prefilter Replace fuel prefilter element Replace fuel filter 067 L1 T...

Page 76: ...120 L1 SUPPLY VOLT HIGH Supply voltage too high 1st limit value Contact Service Check engine governor supply voltage 121 L2 SUPPLY VOLT HIGH Supply voltage too high 2nd limit value automatic engine s...

Page 77: ...ernal electronics faulty automatic engine shutdown Replace engine governor Engine operating instructions 186 CAN 1 BUS OFF CAN 1 in Bus Off state Either short circuit on bus Or strong magnetic fields...

Page 78: ...Sensor B10 faulty charge air pressure A side 1 Check cabling Engine operating instructions 2 Contact Service Check sensor 211 SD P LUBE OIL Sensor B05 faulty lube oil pressure 1 Check cabling Engine o...

Page 79: ...Sensor fault ECU operating voltage Replace engine governor Engine operating instructions 246 SD T ELECTRONIC Temperature sensor for measuring electronics temperature faulty Replace engine governor En...

Page 80: ...utomatic engine shutdown 1 Check cabling Engine operating instructions 2 Attempt to restart engine 364 STOP STAGE FAIL 2 Fault in solenoid valve cabling or in ECU automatic engine shutdown 1 Check cab...

Page 81: ...ons 2 Contact Service Check sensor 393 L2 T COOLANT RED Redundant coolant temperature 2nd limit value 1 Check cabling Engine operating instructions 2 Contact Service Check sensor 394 L1 P LUBE OIL RED...

Page 82: ...y defective sensors actuators If troubleshooting in accordance with the following table is not successful contact Service to have the sensors actuators checked and if required replaced Fault code Alar...

Page 83: ...nal temperature channel 1 Depending on the corresponding measuring point which is read via CAN bus 070 L2 T EXTERN 1 Violation of second limit for external temperature channel 1 Depending on the corre...

Page 84: ...ding on project design Check preheating pump preheating system see manufacturer s documentation 094 PREHEAT TEMP LIMIT1 Coolant preheating temperature too low during starting 1st limit Check preheatin...

Page 85: ...ctive 1 Disconnect connectors X2 and X3 from ECU If alarm does not disappear Contact Service 2 Check wiring pressure sensors 3 Contact Service 138 SENSORPOWER DEFECT Power supply for pressure sensors...

Page 86: ...2 CAN WRONG PARAMETERS Consistency error in CAN parameters Contact Service 183 CAN NO PU DATA Error during loading of CAN project design data into ECU Contact Service 184 CAN PU DATA EE FAIL Error dur...

Page 87: ...OWER SUPPLY Sensor defect ECU operating voltage Contact Service 246 SD T ELECTRONIC Sensor defect temperature in ECU Contact Service 250 SD CAN SPEED DEMAND Sensor defect CAN nominal speed demand 1 Ch...

Page 88: ...INDER A6 Injection timing fault cylinder A6 If fault occurs repeatedly Contact Service 307 TIMING CYLINDER A7 Injection timing fault cylinder A7 If fault occurs repeatedly Contact Service 308 TIMING C...

Page 89: ...Misfiring 1 Check wiring 2 Contact Service 324 WIRING CYLINDER A4 Faulty wiring to solenoid valve cylinder A4 Misfiring 1 Check wiring 2 Contact Service 325 WIRING CYLINDER A5 Faulty wiring to solenoi...

Page 90: ...NDER B8 Faulty wiring to solenoid valve cylinder B8 Misfiring 1 Check wiring 2 Contact Service 339 WIRING CYLINDER B9 Faulty wiring to solenoid valve cylinder B9 Misfiring 1 Check wiring 2 Contact Ser...

Page 91: ...52 OPEN_LOAD CYL B2 Disconnection in wiring to solenoid valve cylinder B2 Misfiring 1 Check wiring 2 Contact Service 353 OPEN_LOAD CYL B3 Disconnection in wiring to solenoid valve cylinder B3 Misfirin...

Page 92: ...automatic engine shutdown 1 Check wiring 2 Try to re start the engine Page 51 3 Contact Service 365 STOP MV WIRING Solenoid valve wiring faulty automatic engine shutdown 1 Check wiring 2 Try to re sta...

Page 93: ...ne ensure that nobody is in the danger zone After working on the engine check that all protective devices have been reinstalled and all tools removed from the engine Engine Barring manually 1 Remove c...

Page 94: ...nd all tools removed from the engine Engine Barring with starting system 1 Disengage the bayonet ring nut 4 of connector X4 with connector pliers 2 and withdraw connector 3 from ECU 2 Bar engine in un...

Page 95: ...rting the engine ensure that nobody is in the danger zone WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors Engine test run 1 Start engine Page 51 2 Perform test run at...

Page 96: ...r cooling bores Running pattern seems darker No actions required Darker areas of even or varying color intensity Beginning and end of the discoloration are not sharply defined and do not cover the ent...

Page 97: ...rature differences around the liner It appears rather darker within the honed structure in contrast to the bright metallic running surface The honing pattern is undisturbed Discolorations extend in st...

Page 98: ...n discoloration and heat discoloration are similar Thorough investigation and compliance with the above evaluation criteria allows a definite evaluation To avoid unnecessary disassembly work it is rec...

Page 99: ...manufacturer s instructions Wear protective clothing gloves and goggles safety mask Crankcase breather Wire mesh cleaning 1 Remove hose 2 Loosen clamp 5 3 Remove oil separator cover 7 4 Remove individ...

Page 100: ...bustion 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 Replacing filter eleme...

Page 101: ...iaphragm 3 for damage 4 Fit new diaphragm if used one is damaged 5 Mount diaphragm 3 on housing 1 6 Install new seal 2 and spring 5 together with cover 4 7 Tighten screws of cover 4 to specified tight...

Page 102: ...ture is max 40 C Valves are closed Special tools Designation Use Part No Qty Feeler gauge Y20010128 1 Torque wrench 20 100 Nm F30026582 1 Ratchet adapter F30027340 1 Preparatory steps 1 Remove cylinde...

Page 103: ...as per diagram 4 Use feeler gauge to determine the distance between valve bridge and rocker arm 5 If the deviation from the reference value exceeds 0 1 mm adjust valve clearance Adjusting valve clear...

Page 104: ...cylinder head covers with crankcase breather Loosen clamps 2 Slide rubber sleeves onto the pipe Cylinder head cover Removal and installation 1 Remove screws 2 Remove cylinder head cover with gasket fr...

Page 105: ...Description 101 6 5 Injection Pump HP Pump 6 5 1 Injection pump replacement Spare parts Designation Use Part No Qty Injection pump Remove injection pump and install new one Page 102 MS15009 00E 06 09...

Page 106: ...ation Use Part No Qty Sealing ring Sealing ring DANGER Unguarded rotating and moving engine components Risk of serious injury danger to life Before barring the engine ensure that nobody is in the dang...

Page 107: ...recess in the injection pump head 5 Remove injection pump securing screws 6 Remove injection pump 7 Remove sealing rigs from injection pump 8 Seal all openings with appropriate covers after removal In...

Page 108: ...ion nut on pressure pipe neck to specified torque 20 Nm 5 Nm Maximum permissible tightening torque 35 Nm 13 Install injection pump wiring 1 14 Tighten screws to specified torque 1 0 Nm 0 2 Nm using to...

Page 109: ...Task Description 105 6 6 Injector 6 6 1 Injector replacement Spare parts Designation Use Part No Qty Injector Remove injector and install new one Page 106 MS15009 00E 06 09 MTU...

Page 110: ...ouble box wrench F30011450 1 Ratchet adapter F30027340 1 Material Designation Use Part No Qty Petroleum jelly Spare parts Designation Use Part No Qty Sealing ring Sealing ring WARNING Fuels are combus...

Page 111: ...l off pressure pipe neck 1 5 Extract fuel from the exposed bores using the suction device 6 Remove screw 2 7 Take off clamp 1 8 Screw extractor into injector 9 Remove injector using the extractor 10 R...

Page 112: ...still rotatable 8 Blow out fuel line 3 and pressure pipe neck 1 with compressed air 9 Coat sealing ring with petroleum jelly and fit onto pressure pipe neck 1 10 Coat sealing cone of pressure pipe ne...

Page 113: ...explosion Avoid naked flames electrical sparks and ignition sources Do not smoke Fuel pressure relief valve Replacement variant A 1 Close fuel supply 2 Remove fuel line 1 3 Remove adapter 2 4 Remove s...

Page 114: ...upply 2 Remove fuel line 7 3 Remove banjo screw 4 4 Remove sealing rings 5 5 Remove screws 2 with washer 3 6 Remove screws 6 and take off bracket 7 Install new pressure relief valve 1 with new sealing...

Page 115: ...e and explosion Avoid naked flames electrical sparks and ignition sources Do not smoke Fuel Draining 1 Release threaded vent plugs on filter head 2 Open nipple on fuel line and drain fuel into appropr...

Page 116: ...rious injury danger to life Take special care when working on a running engine WARNING Fuels are combustible Risk of fire and explosion Avoid naked flames electrical sparks and ignition sources Do not...

Page 117: ...ck to operating position both filters cut in 8 Replace further fuel filters in the same way 9 Vent fuel system Fuel filter replacement with the engine running 1 Cut out the filter to be replaced 2 Ope...

Page 118: ...l prefilter cleaning 1 Shut off fuel supply 2 Remove nuts from filter head 3 Take off filter housing and drain fuel into appropriate container 4 Remove filter element securing nut and remove filter el...

Page 119: ...erential 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 the...

Page 120: ...stopped and starting disabled Material Designation Use Part No Qty Diesel fuel Spare parts Designation Use Part No Qty Gasket WARNING Fuels are combustible Risk of fire and explosion Avoid naked flame...

Page 121: ...ssing toggle and open it 4 Drain water and contaminants from the filter until pure fuel emerges 5 Close drain cock 6 6 Remove screws securing the cover and take off cover 2 7 Fill filter housing with...

Page 122: ...ed rotating and moving engine components Risk of serious injury danger to life Take special care when working on a running engine WARNING Fuels are combustible Risk of fire and explosion Avoid naked f...

Page 123: ...the filter deposits downwards out of the filter 4 Close vent plug 5 and drain cock 6 Fuel prefilter filling fuel 1 Stop engine Page 54 and disable engine start 2 Remove screws securing the cover and...

Page 124: ...stopped and starting disabled Material Designation Use Part No Qty Diesel fuel Spare parts Designation Use Part No Qty Filter element Gasket WARNING Fuels are combustible Risk of fire and explosion A...

Page 125: ...ilter 5 Close drain cock 6 6 Remove screws securing the cover and take off cover 2 7 Remove spring 4 and filter element 3 8 Insert new filter element 3 and spring 4 9 Fill filter housing with clean fu...

Page 126: ...sate drains 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 emerges 3 Clean drain bore s and blow out with compre...

Page 127: ...6 10 1 Air filter Replacement Preconditions Engine is stopped and starting disabled Replace air filter carry out work in accordance with the instructions of the manufacturer scope of supply of the uni...

Page 128: ...d starting disabled Checking signal ring position of service indicator if fitted 1 If the signal ring is completely visible in the control window 2 replace air filter Page 123 2 After installation of...

Page 129: ...o life Before barring or starting the engine ensure that nobody is in the danger zone WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors Air starter manual operation 1 Pr...

Page 130: ...arter Condition check Preconditions Engine is stopped and starting disabled Starter Condition check 1 Check starter securing screws for secure seating 2 Tighten loose screw connections 3 Check wiring...

Page 131: ...alth Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Oil change without semirotary hand pump Draining oil at drain...

Page 132: ...Open cover of filler neck 2 Pour oil in at filler neck up to max mark at oil dipstick 3 Close cover of filler neck 4 Check oil level Page 129 5 After oil change and oil filter replacement bar engine w...

Page 133: ...st be between min and max marks 4 Top up to max if required Page 127 5 Insert dipstick into guide tube up to the stop Oil level check after the engine is stopped 1 5 minutes after stopping the engine...

Page 134: ...e 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 Engine oil filter Replacement 1 Remove oil filt...

Page 135: ...Task Description 131 6 15 Cooling Circuit General HT Circuit 6 15 1 Drain and venting points Top view 1 Engine coolant vent 2 Engine coolant vent MS15009 00E 06 09 MTU...

Page 136: ...132 Task Description Left side 1 Engine coolant drain plug 2 Engine coolant drain plug MS15009 00E 06 09 MTU...

Page 137: ...Task Description 133 Right side 1 Engine oil drain plug heat exchanger 2 Engine coolant drain plug MS15009 00E 06 09 MTU...

Page 138: ...134 Task Description Driving end KS 1 Engine coolant drain plug 2 Intercooler drain 3 Engine oil drain plug MS15009 00E 06 09 MTU...

Page 139: ...p coolant only into cold engine Preparatory steps 1 Turn breather valve on coolant expansion tank counterclockwise to first stop and allow pressure to escape 2 Continue to turn breather valve counterc...

Page 140: ...ing engine coolant 1 Turn valve cover on coolant expansion tank counterclockwise to the first detent and allow pressure to escape 2 Continue to turn breather valve counterclockwise and remove 3 Draw o...

Page 141: ...Task Description 137 6 15 4 Engine coolant Change Material Designation Use Part No Qty Engine coolant Drain engine coolant Page 136 Fill engine coolant system Page 135 MS15009 00E 06 09 MTU...

Page 142: ...terclockwise to first stop and allow pressure to escape 2 Continue to turn breather valve counterclockwise and remove 3 Check coolant level coolant must be visible at the lower edge of the cast in eye...

Page 143: ...oise above 85 dB A Risk of damage to hearing Wear ear protectors Coolant pump Relief bore check 1 Check relief bore for oil and water discharge 2 Stop engine Page 54 and disable engine start 3 Clean t...

Page 144: ...Description 6 16 LT Circuit 6 16 1 Charge air coolant change Material Designation Use Part No Qty Coolant Drain charge air coolant system Page 142 Fill charge air coolant system Page 141 MS15009 00E 0...

Page 145: ...ther valve on coolant expansion tank counterclockwise to first stop and allow pressure to escape 2 Continue to turn breather valve counterclockwise and remove 3 Remove plug screw from filling point on...

Page 146: ...e coolant into 2 Turn breather valve of filler neck on coolant expansion tank counterclockwise to first stop and allow pressure to escape 3 Continue to turn breather valve counterclockwise and remove...

Page 147: ...nsion tank counterclockwise to first stop and allow pressure to escape 2 Continue to turn breather valve counterclockwise and remove 3 Check coolant level coolant must be visible at marking plate 4 If...

Page 148: ...loose screw connections 2 Make certain that cables are securely seated in clamps and cannot move freely 3 Check cable binders for secure seating tighten loose cable binders 4 Replace defective cable...

Page 149: ...Task Description 145 6 17 2 Sensors and actuators No Designation Monitoring of 1 B10 Charge air pressure MS15009 00E 06 09 MTU...

Page 150: ...Designation Monitoring of 1 B9 Charge air temperature 2 B34 Fuel pressure after filter 3 B33 Fuel temperature 4 B6 2 Coolant temperature 5 F25 Lube oil differential pressure 6 B44 1 Turbocharger spee...

Page 151: ...ency air shutoff flaps 2 Y12 Solenoid valve emergency air shut off flaps 3 F46 Leak off fuel level 4 B6 Coolant temperature 5 B5 2 Lube oil pressure 6 B5 Lube oil pressure 7 B7 Lube oil temperature 8...

Page 152: ...Task Description No Designation Monitoring of 1 2 B1 Camshaft speed 3 B4 22 Exhaust gas temperature 4 B13 Crankshaft speed 5 B13 2 Crankshaft speed 6 B4 21 Exhaust gas temperature MS15009 00E 06 09 M...

Page 153: ...nector pliers 0135315483 1 Material Designation Use Part No Qty Isopropyl alcohol ECU and connectors Cleaning 1 Remove coarse dirt from housing surface using a cloth moistened with isopropyl alcohol 2...

Page 154: ...2 to disengage bayonet union nut 4 and withdraw connector 3 2 Clean connector housings connector socket housings 1 and all contacts with isopropyl alcohol 3 When connectors sockets and all contacts a...

Page 155: ...Remove dirt from surface of connectors 1 connector sockets and shrink sleeves 2 using a cloth moistened with isopropyl alcohol 3 Check legibility of cable labels Clean or replace illegible labels Clea...

Page 156: ...Checking plug in connections 1 Use connector pliers 3 to make certain that all plug in connections of ECU are securely seated 2 Tighten loose bayonet union nuts 2 with connector pliers 3 by turning t...

Page 157: ...U Checking plug in connections 1 Use connector pliers 3 to make certain that all EMU plug in connections are securely seated 2 Tighten loose bayonet union nuts 2 with connector pliers 3 by turning the...

Page 158: ...35315483 1 Material Designation Use Part No Qty Covering caps for Cannon sockets ECU Removal 1 Note or mark assignment of cables to connector sockets 2 Use connector pliers 2 to disengage the bayonet...

Page 159: ...m engine 7 If the screws 4 are not easily accessible 7 1 Remove screws 1 7 2 Take off ECU housing 3 together with mounting brackets 2 7 3 Unscrew cable shock absorbers 5 and further securing parts 6 a...

Page 160: ...for secure seating 1 Open LOP front door 2 Check securing screws 1 3 4 7 for secure seating Tighten loose screw connections 3 Check internal assemblies for secure seating this applies in particular t...

Page 161: ...ng elements 1 concerned in the direction of the arrows until they are felt to engage Keys and display check 1 Keys Make certain that Button caps are not damaged cracks or similar damage Keys move easi...

Page 162: ...with battery manufacturer s instructions 2 Switch master power switch to ON 3 Switch on engine control system 4 Keep LAMP TEST button pressed Result Control and indication fields light up 5 Have damag...

Page 163: ...ON button 1 again Result LOCAL OPERATION button 1 is illuminated brightly local control mode is active Overspeed test with the engine at standstill Note Overspeed test with the engine at standstill ca...

Page 164: ...Engines with emergency air shut off flaps Flaps close EMERGENCY STOP button 2 flashes Signalization by horn flash lamp etc is released ALARM ACKNOWLEDGE button 1 is illuminated brightly 3 Press ALARM...

Page 165: ...el circuitry Engine governor channel circuitry Binary inputs BE1 to BE9 1 Engine Control Unit ECU 4 Function Function Source Acquisition of binary signals Switches pushbuttons monitors contacts Channe...

Page 166: ...ngine Control Unit ECU 4 Function Function Source Acquisition of a current signal 4 to 20 mA Measuring channel specification Measuring range IIn 4 to 20 mA Load At 20 mA approx 4 V isolated Or UIn 0 t...

Page 167: ...g Lube oil differential pressure monitor Pulse measuring inputs KW 1 and NW 1 1 Inductive sensor 2 Engine Control Unit ECU 4 Channel Function Sensor KW1 Measuring of crankshaft angle and crankshaft sp...

Page 168: ...Engine Control Unit ECU 4 Function Sensor Measuring of speeds e g ETC Inductive sensor Temperature inputs TE 1 to TE 9 1 Engine Control Unit ECU 4 Function Sensor Temperature measuring Temperature dep...

Page 169: ...range measuring Relative pressure sensors exception The charge air pressure sensor is an absolute pressure sensor Measuring channel specification Measuring range Sensor dependent Output signal UO 0 5...

Page 170: ...ange Sensor dependent Output signal UO 0 5 to 4 5 VDC Sensor supply 5 V 250 mV Transistor outputs TAA 1 to TAA 6 1 Engine Control Unit ECU 4 Function Function Sensor Switching output Plant Channel spe...

Page 171: ...67 Voltage outputs UA 1 to UA 4 1 Engine Control Unit ECU 4 Function Function Sensor Output voltage 0 to 10 V e g for display instruments Plant Channel specification Output voltage UO 0 to 10 V Output...

Page 172: ...ent and Circuitry Transistor outputs TAM 1 to TAM 4 1 Engine Control Unit ECU 4 Function Sensor Switching output Engine PWM output PDM 2 1 Engine Control Unit ECU 4 Function Sensor Switching output En...

Page 173: ...1 Engine Control Unit ECU 4 Function Sensor Injector control Injection solenoid valve CAN bus interface 1 CAN bus 2 Terminator 3 Electrical isolation 4 Engine Control Unit ECU 4 Function Channel Func...

Page 174: ...isruption when connector disconnected Baud rate 125 kbaud Electrical isolation 50 V The CAN bus interfaces operate independently of each other Serial interface RS232 1 Dialog unit 2 Connector XC6 3 En...

Page 175: ...e last PIM module Terminal resistors for the MDEC governor are already fitted in cable W004 connector X1 Digital MDEC inputs outputs Inputs Observe input polarity BE1 Stop input This input is inverted...

Page 176: ...A4 n 300 Indication of engine speed 300 rpm TAA5 SS T coolant Shutdown coolant temperature too high TAA6 SS P lube oil Shutdown lube oil pressure too low Analog MDEC inputs IEU1 0 to 10 V or 4 to 20 m...

Page 177: ...22 55 P Target Plant wiring harness Pin assignment Channel Signal Pin Comments IUE1 5V_ISO BB 5 V 20 mA electrically isolated IUE1 U_IN AA 0 V to 10 V IUE1 I_IN X 0 V to 23 7 mA IUE1 GND_ISO q IUE2 5V...

Page 178: ...3 IN P Electrically isolated BE4 IN j U 4 V low U 8 V high BE4 IN i Electrically isolated BE5 IN FF U 4 V low U 8 V high BE5 IN EE Electrically isolated BE6 IN v U 4 V low U 8 V high BE6 IN u Electric...

Page 179: ...600 mA TAA4 GND y TAA5 OUT m 24 V 600 mA TAA5 GND k TAA6 OUT L 24 V 2 A TAA6 GND K Plant supply coil instruments FZ CAN1 HIGH G Electrically isolated CAN1 LOW F CAN1 GND E CAN2 HIGH C Electrically is...

Page 180: ...GND FF TE7 IN w 0 V to 5 V internal 2 k0 pullup to 5 V_TE_BUF TE7 GND x TE8 IN t 0 V to 5 V internal 2 k0 pullup to 5 V_TE_BUF TE8 GND a TE9 IN E 0 V to 5 V internal 2 k0 pullup to 5 V_TE_BUF TE9 GND...

Page 181: ...down DE7 GND b NSE1 24 V_NSE1 X Sensor supply max 300 mA NSE1 IN C 0 V to 5 V internal 47k5 pullup to 5 V_TE_BUF NSE1 GND B NSE2 24 V_NSE2 W Sensor supply max 300 mA NSE2 IN q 0 V to 5 V internal 47k5...

Page 182: ...rnor Assignment and Circuitry Channel Signal Pin Comments TAM2 OUT h 24 V 1 5A TAM2 GND i Connector X3 view to socket Connector X3 Connector type VPT 06 GSE 16 26 P Target Engine wiring harness MS1500...

Page 183: ...E8 5 V_BUF4 J 5 V 20 mA DE8 IN Y 0 V to 5 V internal 47k5 pulldown DE8 GND K DEH 5 V_BUF5 B 5 V 20 mA DEH IN T 0 V to 5 V internal 47k5 pulldown TP2 20 Hz DEH GND C NSE3 24 V_NSE3 A Sensor supply max...

Page 184: ...nt Channel Signal Pin Comments MV1 HIGH n 24 V 20 A MV1 LOW m Bank 1 MV2 HIGH D 24 V 20 A MV2 LOW C Bank 1 MV3 HIGH F 24 V 20 A MV3 LOW E Bank 1 MV4 HIGH a 24 V 20 A MV4 LOW Z Bank 1 MV5 HIGH H 24 V 2...

Page 185: ...IGH P 24 V 20 A MV12 LOW N Bank 2 MV13 HIGH i 24 V 20 A MV13 LOW h Bank 2 MV14 HIGH g 24 V 20 A MV14 LOW f Bank 2 MV15 HIGH U 24 V 20 A MV15 LOW T Bank 2 MV16 HIGH K 24 V 20 A MV16 LOW J Bank 2 MV17 H...

Page 186: ...tor X5 view to socket Connector X5 Connector type CIR 06 G2 18 11 S Target Plant wiring harness power supply Pin assignment Channel Signal Pin Comments POWER 24 V A Usupp 24 V 30 A POWER 24 V D POWER...

Page 187: ...183 Connector X6 view to socket Connector X6 Connector type VPT 06 GSE 12 10 P Target Dialog unit Pin assignment Channel Signal Pin Comments POWER 24 V A Usupp 24 V 30 A POWER 24 V D POWER GND B POWER...

Page 188: ...184 Engine Governor Assignment and Circuitry MS15009 00E 06 09 MTU...

Page 189: ...Special Tools 185 8 Special Tools 8 1 Special tools Part No Designation Use Qty F6558556 Barring tool for 12V engines 1 F6558557 Barring tool for 16V engines 1 MS15009 00E 06 09 MTU...

Page 190: ...186 Special Tools Part No Designation Use Qty 0135315483 Connector pliers 1 Y20097353 Rigid endoscope 1 MS15009 00E 06 09 MTU...

Page 191: ...Special Tools 187 Part No Designation Use Qty F30027336 Torque wrench 6 50 Nm 1 F30027340 Ratchet adapter 1 MS15009 00E 06 09 MTU...

Page 192: ...188 Special Tools Part No Designation Use Qty Y20010128 Feeler gauge 1 F30026582 Torque wrench 20 100 Nm 1 MS15009 00E 06 09 MTU...

Page 193: ...Special Tools 189 Part No Designation Use Qty F30043446 Torque wrench 8 40 Nm 1 F6557929 Barring tool 1 MS15009 00E 06 09 MTU...

Page 194: ...190 Special Tools Part No Designation Use Qty F30027424 Spider patch spanner 1 F30027425 Spider patch spanner 1 MS15009 00E 06 09 MTU...

Page 195: ...Special Tools 191 Part No Designation Use Qty F30377999 Extractor 1 F30378207 Fuel suction device 1 MS15009 00E 06 09 MTU...

Page 196: ...192 Special Tools Part No Designation Use Qty F30025897 Socket wrench 1 MS15009 00E 06 09 MTU...

Page 197: ...Special Tools 193 Part No Designation Use Qty F30011450 Double box wrench 1 F30379104 Filter wrench 1 MS15009 00E 06 09 MTU...

Page 198: ...194 Special Tools MS15009 00E 06 09 MTU...

Page 199: ...Annex 195 9 Annex 9 1 Manufacturer s documentation See Manufacturer s documentation MS15009 00E 06 09 MTU...

Page 200: ...Annex 9 2 MTU contact person service partner You will find the MTU contact person service partner for your region at www mtu online com worldwide in the left hand navigation margin MS15009 00E 06 09...

Page 201: ...ant temperature DDEC Detroit Diesel Electronic Controls Engine control system made by Detroit Diesel DDL Diagnostic Data Link DDR Diagnostic Data Reader DIN Deutsches Institut f r Normung e V German S...

Page 202: ...ght Emitting Diode LO LOW Alarm Measured value lower than 1st minimum limit LOLO Low Low Alarm Measured value lower than 2nd minimum limit LSG Limiting Speed Governor N A Not Applicable OEM Original E...

Page 203: ...m is initiated by the safety system TBS Turbocharger Boost Sensor Monitors charge air pressure TC Tools Catalog TCI Turbo Compressor Inlet TCO Turbo Compressor Outlet TD Transmitter Deviation Alarm Se...

Page 204: ...200 Annex MS15009 00E 06 09 MTU...

Page 205: ...ine coolant level Check 138 Crankcase breather Oil separator replacement diaphragm check and replacement 96 Crankcase breather Wire mesh cleaning 95 Crankcase Ventilation 95 Crankcase breather Oil sep...

Page 206: ...ump replacement 101 Injection Pump HP Pump 101 Injection pump Removal and installation 102 Injection pump replacement 101 Injector 105 Injector Removal and installation 106 Injector replacement 105 In...

Page 207: ...e publication 13 Starter Condition check 126 Starting System 125 Air starter manual operation 125 Starter Condition check 126 Starting the engine in manual mode 51 Stopping the engine in manual mode 5...

Page 208: ......

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