MTU 10V2000Mx4 Operating Instructions Manual Download

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Operating Instructions

Diesel engine

8V2000Mx4x
10V2000Mx4

MS150060/04E

Summary of Contents for 10V2000Mx4

Page 1: ...Operating Instructions Diesel engine 8V2000Mx4x 10V2000Mx4 MS150060 04E...

Page 2: ...ected by copyright and may not be used 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...

Page 3: ...Starting the engine 53 5 9 Engine Shutdown 54 5 10 Emergency engine shutdown 55 5 11 After stopping the engine 56 5 12 Fuel treatment system Shutdown 57 5 13 Plant Cleaning 58 6 Maintenance 6 1 Mainte...

Page 4: ...w water pump Relief bore check 122 8 17 Belt Drive 123 8 17 1 Drive belt Condition check 123 8 18 Battery Charging Generator 124 8 18 1 Battery charging generator drive Drive belt replacement 124 8 19...

Page 5: ...cesses 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 componen...

Page 6: ...e 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 person...

Page 7: ...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 autho...

Page 8: ...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...

Page 9: ...Follow the applicable warning instructions pertaining to such devices MS150060 04E 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 pi...

Page 11: ...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 electron...

Page 12: ...h 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 o...

Page 13: ...ully 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...

Page 14: ...rrying 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 m...

Page 15: ...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...

Page 16: ...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 A...

Page 17: ...and appliances Never stand beneath a suspended load 1 Max admissible diagonal pull 35 2 Max admissible diagonal pull 10 3 Center of gravity Take note of the engine center of gravity For details on eng...

Page 18: ...A 1 On all bearing outer races of the resilient mount 1 release nut 4 and unscrew and remove locking screw 2 together with wash ers 3 and nut 4 4 x per bearing element 2 The removed parts 2 3 4 of th...

Page 19: ...2 3 4 of the transport locking device must be stored carefully for possible reuse Installing transport locking de vice version B 1 Screw in locking screw 2 together with nut 3 and nut 4 4 x per beari...

Page 20: ...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 21: ...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 Pist...

Page 22: ...als 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...

Page 23: ...nit 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...

Page 24: ...tside 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 redu...

Page 25: ...een distributor and HP accumulator 1 Union nut 2 O ring 3 Thrust ring 4 Thrust screw 5 O ring 6 O ring 7 Thrust ring 8 Pressure pipe 9 Jacket pipe MS150060 04E 2016 02 General Information 25 TIM ID 00...

Page 26: ...t 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 pres...

Page 27: ...free end Illustrations are also applicable to 10V 1 Raw water pump 2 Auxiliary PTOs 3 Coolant pump 4 HP fuel pump 5 Oil filler neck 6 Cylinder head KGS Free end MS150060 04E 2016 02 General Informati...

Page 28: ...4 Oil pan 15 Exhaust pipework 16 Battery charging generator 17 Plate core heat exchanger 18 Coolant distribution housing with integrated expansion tank KS Driving end Engine model designation Key to t...

Page 29: ...illustrations are insignificant Also valid for 8V engines No Description Monitoring of 1 B10 Charge air pressure 2 B9 Charge air temperature 3 B7 Lube oil temperature 4 B3 Intake air temperature MS150...

Page 30: ...B5 3 optional Lube oil pressure before filter 3 B5 1 Lube oil pressure 4 B5 2 optional Lube oil pressure 5 F33 Coolant level 6 B21 optional Raw water pressure 7 B6 2 optional Coolant pressure 8 B6 1 C...

Page 31: ...n Monitoring of 1 B4 21 Exhaust gas temperature A side 2 B4 22 Exhaust temperature B side 3 B1 Camshaft speed 4 B13 Crankshaft speed 5 B13 2 optional Crankshaft speed MS150060 04E 2016 02 General Info...

Page 32: ...ription Monitoring of 1 B44 Turbocharger speed 2 B33 Fuel temperature 3 B48 Fuel pressure in Common Rail 4 B16 optional Coolant pressure 5 F46 Leak fuel level 32 General Information MS150060 04E 2016...

Page 33: ...3 B54 optional Oil replenishment pump pressure System sensors The sensors are fitted on the off engine system Description Monitoring of B19 Starting air pressure B70 Water level in fuel prefilter B41...

Page 34: ...cation group 1D Intake air temperature 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 p...

Page 35: ...eas point before engine R bar 2 5 Fuel system Number of cylinders 8 Fuel pressure at engine inlet connection min when engine is starting L bar 0 3 Fuel pressure at engine inlet connection min during e...

Page 36: ...olant engine side with cooling system R Liters 100 Engine oil capacity initial filling standard oil system option max operating inclinations R Liters 73 Oil change quantity max standard oil system opt...

Page 37: ...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 8 Rated engine speed A rpm 2450 Fuel stop power ISO 3046 A kW 932 Ge...

Page 38: ...when engine is starting L bar 0 25 Fuel supply flow max R liters min 5 2 General operating data Number of cylinders 8 Firing speed from R rpm 100 Firing speed to R rpm 120 Starter electric Number of...

Page 39: ...rs 54 Oil pan capacity at dipstick mark max standard oil system option max operating inclinations L Liters 62 Weights main dimensions Number of cylinders 8 Engine dry weight with attached standard acc...

Page 40: ...1000 Site altitude above sea level m 100 Power related data power ratings are net brake power as per ISO 3046 Number of cylinders 10 Rated engine speed A rpm 2450 Fuel stop power ISO 3046 A kW 1193 G...

Page 41: ...when engine is starting L bar 0 25 Fuel supply flow max R liters min 5 9 General operating data Number of cylinders 10 Firing speed from R rpm 100 Firing speed to R rpm 120 Starter electric Number of...

Page 42: ...andard oil system option max operating inclinations L Liters 70 Weights main dimensions Number of cylinders 10 Engine dry weight with attached standard accessories without coupling R kg 2230 Acoustics...

Page 43: ...4 4 Firing order Firing order 8V A1 B4 A4 A2 B3 A3 B2 B1 10 V A1 B4 A4 B3 A3 B2 A2 B5 A5 B1 MS150060 04E 2016 02 Technical Data 43 TIM ID 0000002801 004...

Page 44: ...Length A Width B Height C 8V2000M84L approx 1693 mm approx 1130 mm approx 1200 mm 8V2000M94 approx 1693 mm approx 1130 mm approx 1200 mm 10V2000M94 approx 1888 mm approx 1130 mm approx 1237 mm 44 Tec...

Page 45: ...Fuel prefilter pressure gage Align adjustable pointer with position of pressure indicator Page 91 Fuel system Vent Page 87 Raw water pump if located above waterline Prime approx 3 to 4 liters Filling...

Page 46: ...t level Page 115 Coolant circuit Heat engine coolant with coolant preheating unit Fuel prefilter Drain water and contaminants Page 92 Battery charging generator drive Check condition of drive belt Pag...

Page 47: ...eks Tasks after extended out of service periods 3 weeks Note Operate fuel treatment system for at least 5 minutes 1 Start up fuel treatment system Page 49 2 Shut down fuel treatment system Page 57 MS1...

Page 48: ...ves 4 Switch on fuel treatment system Page 52 5 Check direction of rotation of pump 6 Vent bypass and fuel lines of the system a Open ball valve for pressure tank b Open ball valve for overflow tank c...

Page 49: ...ne 3 Switch on fuel treatment system and operate it for some minutes Page 52 Result Fuel is sucked from the tank dirt particles and water are filtered and separated then the fuel is delivered via the...

Page 50: ...ncy HAT 1 Switch on fuel treatment system Page 52 2 Start engine Page 53 3 Run engine at idling speed 4 Switch off pump 21 on switch cabinet Result The engine mounted fuel delivery pump sucks fuel via...

Page 51: ...Check exhaust color Page 61 Fuel prefilter Check if suction side pressure indicated at the fuel prefilter is within the limit Page 91 Drain water and contaminants Page 92 Air filter Check signal ring...

Page 52: ...re switching on ensure that all housings are closed Before switching on ensure that no work is in progress anywhere on the entire system Fuel treatment system Switching on 1 Carry out checks prior to...

Page 53: ...rsons in the engine s danger zone WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors The engine can be started from the following points Item A...

Page 54: ...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 dis...

Page 55: ...n 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 Co...

Page 56: ...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 antif...

Page 57: ...inet until water discharge from the outlet stops 2 Switch off fuel treatment system 3 Close ball valve at the inlet to the fuel treatment system 4 Close ball valve at the outlet of the fuel treatment...

Page 58: ...ectly at seals or electronic components such as connectors or ECUs Plant Cleaning 1 Carry out plant cleaning only in areas where an appropriate oil separator is provided environmental protec tion 2 Pr...

Page 59: ...ilter Page 51 W1001 Replace fuel filter or fuel filter element Page 88 W1005 Replace air filter Page 99 W1006 Replace fuel injectors Page 84 W1008 Replace engine oil filter when changing engine oil or...

Page 60: ...e 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...

Page 61: ...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 d...

Page 62: ...ge 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 dischar...

Page 63: ...ion Engine is not at operating temperature u Run engine to reach operating temperature Water in fuel u Drain fuel prefilter Page 92 Charge air cooler leaking u Contact Service MS150060 04E 2016 02 Tro...

Page 64: ...ols Material Spare parts Designation Use Part No Qty Shield A4 735233000100 5 Shield A5 735233000101 7 Shield A7 735233000103 6 Shield A8 735233000104 2 Installing SOLAS shielding 1 Pinpoint installat...

Page 65: ...mbient 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 Pinp...

Page 66: ...AS shielding as per MTN 5233 Page 64 On crankcase Item Type of shielding Remarks 1 Shield A4 On brazed on union 2 Shield A5 On crankcase Free end B side Item Type of shielding Remarks 1 Free end B sid...

Page 67: ...e Item Type of shielding Remarks 1 Free end B side Shield A7 On HP fuel pump Free end Item Type of shielding Remarks 1 Free end Shield A7 Above fuel priming pump MS150060 04E 2016 02 SOLAS 67 TIM ID 0...

Page 68: ...tem Type of shielding Remarks 1 Free end Shield A7 Below fuel priming pump Free end Item Type of shielding Remarks 1 Free end Shield A8 On fuel filter housing 68 SOLAS MS150060 04E 2016 02 TIM ID 0000...

Page 69: ...A side Item Type of shielding Remarks 1 Driving end Shield A5 On air flap control 2 Driving end Shield A4 On brazed on union 3 Driving end Shield A5 On exhaust turbocharger flap control 4 Driving end...

Page 70: ...iving end Shield A4 Exhaust turbocharger lubrication 2 Driving end Shield A4 On brazed on union Driving end Item Type of shielding Remarks 1 Driving end Shield A4 Exhaust turbocharger lubrication 70 S...

Page 71: ...t 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 m...

Page 72: ...led 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 tool...

Page 73: ...n 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 low...

Page 74: ...epending on findings Do not take any action or carry out a further endoscopic examination as part of maintenance work or contact Service cylinder liner must be replaced Final steps 1 Install injector...

Page 75: ...ound 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...

Page 76: ...ation 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 insp...

Page 77: ...ays 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...

Page 78: ...re 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 Remo...

Page 79: ...hragm 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 Scre...

Page 80: ...ench 20 100 Nm F30026582 1 Measuring device Y4345888 1 Engine oil Preparatory steps 1 Remove air filter Page 100 2 Remove cylinder head cover Page 83 Positioning A1 piston at TDC Note With cylinder he...

Page 81: ...inder A1 Bank A I X I X I X Bank B X I X I X I Inlet Inlet valve adjustment admissible X Exhaust Exhaust valve adjustment admissible Valve adjustment inadmissible 4 Use valve clearance gauge to determ...

Page 82: ...ses through between valve bridge and rocker arm Result If not adjust valve clearance Final steps 1 Remove barring device 2 Install cylinder head cover Page 83 3 Install air filter Page 100 82 Valve Dr...

Page 83: ...emove 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 g...

Page 84: ...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 85 84 Injector MS150060 04E 201...

Page 85: ...talog 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...

Page 86: ...ing 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...

Page 87: ...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 Ope...

Page 88: ...mbustible 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...

Page 89: ...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 th...

Page 90: ...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...

Page 91: ...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 with...

Page 92: ...e 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 explos...

Page 93: ...ing 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...

Page 94: ...nd 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...

Page 95: ...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...

Page 96: ...tion 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...

Page 97: ...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 secu...

Page 98: ...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...

Page 99: ...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 100 2 Reset signal ring of contamination indicat...

Page 100: ...p 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 filt...

Page 101: ...sabled Checking signal ring position 1 If the signal ring is completely visible in the control window 2 replace air filter Page 99 2 After installation of new filter press reset button 1 Result Engage...

Page 102: ...ck 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 131 102 Starting E...

Page 103: ...4 Top up with oil up to the max 1 mark Page 104 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 remov...

Page 104: ...act 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 t...

Page 105: ...tors 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...

Page 106: ...crank engine with starting system Page 72 11 Check oil level Page 103 Replacing oil filter with the engine running 1 Reduce engine speed to 1100 rpm 2 Unscrew cut out oil filter with oil filter wrenc...

Page 107: ...s 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 organ...

Page 108: ...easure 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 noz...

Page 109: ...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...

Page 110: ...erature Circuit 8 15 1 Drain and venting points Illustrations are also applicable to 8V Top view 1 Overflow line expansion tank 2 Filler neck 110 Coolant Circuit General High Temperature Circuit MS150...

Page 111: ...oolant 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 MS150060 04E 2016 02 Coolant Circuit General Hi...

Page 112: ...Left side 1 Engine coolant drain plug 2 Engine coolant drain plug M14x1 5 112 Coolant Circuit General High Temperature Circuit MS150060 04E 2016 02 TIM ID 0000006696 003...

Page 113: ...1 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 MS150060 04E 2016 02 Coolant Circuit General High Te...

Page 114: ...Driving end KS 1 Engine coolant drain plug 2 Oil extraction connection 114 Coolant Circuit General High Temperature Circuit MS150060 04E 2016 02 TIM ID 0000006696 003...

Page 115: ...expansion tank Page 27 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...

Page 116: ...Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 117 2 Fill with engine coolant Page 118 116 Coolant Circuit General High Temperature Circuit...

Page 117: ...eheating unit Draining engine coolant 1 Turn breather valve of filler neck on coolant expansion tank Page 110 counterclockwise to first stop and allow pressure to escape 2 Continue to turn breather va...

Page 118: ...engine Fill top up coolant only into cold engine Filling with engine coolant 1 Turn breather valve of coolant expansion tank Page 27 counterclockwise until the first stop and allow pressure to escape...

Page 119: ...o 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...

Page 120: ...ank Page 110 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 expan...

Page 121: ...mask Replacing coolant filter 1 Turn breather valve of coolant expansion tank counterclockwise Page 27 to the first stop and allow pressure to escape 2 Continue to turn breather valve counterclock wis...

Page 122: ...hen 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 54 and disable engine sta...

Page 123: ...abled 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 124 Drive belt C Chunking Drive belt B...

Page 124: ...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...

Page 125: ...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 MS150060 04E 2016 02 Fuel Supply System 125 TIM I...

Page 126: ...otective clothing protective gloves and safety glasses facial protection Checking differential pressure gauge 1 Switch on fuel treatment system Page 52 2 Set the alarm points at the differential press...

Page 127: ...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 R...

Page 128: ...the outlet of the fuel treatment system c Check pressure at the pressure gauge in the inlet to the fuel treatment system and note down 3 Checking pump pressure with reduced suction a Reduce suction pr...

Page 129: ...ial 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 insta...

Page 130: ...htening 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 syste...

Page 131: ...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 h...

Page 132: ...propyl 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 lab...

Page 133: ...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...

Page 134: ...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 seatin...

Page 135: ...king 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...

Page 136: ...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 no...

Page 137: ...ctors 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 swit...

Page 138: ...ine 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 Inst...

Page 139: ...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...

Page 140: ...e 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 param...

Page 141: ...ation 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 E...

Page 142: ...rgency 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 pat...

Page 143: ...e 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 MS150060 04E 201...

Page 144: ...Engine management system ECU Engine Control Unit Engine governor EDM Engine Data Module Memory module for engine data EIM Engine Interface Module Interface to engine monitoring system EMU Engine Moni...

Page 145: ...nel PCU Propeller Control Unit PIM Peripheral Interface Module RCS Remote Control System RL Redundancy Lost Alarm Redundant CAN bus failure SAE Society of Automotive Engineers U S standardization orga...

Page 146: ...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...

Page 147: ...njector Removal and installation Page 85 Barring device Part No F6555766 Qty Used in 1 8 3 1 Cylinder liner Endoscopic examination Page 73 Box wrench Part No F30451199 Qty Used in 1 8 6 2 Injector Rem...

Page 148: ...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 Double head box wrench Part No F30002800 Qty Used in 1 8 5 1...

Page 149: ...3 1 Cylinder liner Endoscopic examination Page 73 Engine barring device Part No F6783914 Qty Used in 1 8 2 1 Engine Barring manually Page 71 Qty Used in 1 8 5 1 Valve clearance Check and adjustment P...

Page 150: ...F30453001 Qty Used in 1 8 5 1 Valve clearance Check and adjustment Page 80 Oil filter wrench Part No F30379104 Qty Used in 1 8 8 1 Fuel filter Replacement Page 88 Qty Used in 1 8 14 1 Engine oil filte...

Page 151: ...Crankcase breather Oil separator replacement di aphragm check and replacement Page 78 Qty Used in 1 8 19 5 Coalescer filter element Replacement Page 129 Ratchet with extension Part No F30006212 Qty U...

Page 152: ...sed in 1 8 6 2 Injector Removal and installation Page 85 Torque screwdriver 1 5 Nm Part No F30452774 Qty Used in 1 8 10 2 Air filter Removal and installation Page 100 Torque wrench 20 100 Nm Part No F...

Page 153: ...replacement Page 78 Qty Used in 1 8 5 2 Cylinder head cover Removal and installation Page 83 Qty Used in 1 8 19 5 Coalescer filter element Replacement Page 129 Valve clearance gauge Part No Y4345893...

Page 154: ...rator element replacement 78 Cylinder Designation 20 Cylinder head cover Installation 83 Removal 83 Cylinder liner Endoscopic examination 73 Instructions and comments on endoscopic and visual examinat...

Page 155: ...gauge Adjustment 91 Check 91 Draining 92 Filter element Replacement 96 Flushing 94 Fuel system Venting 87 Fuel treatment system Putting into operation 49 Shutdown 57 Switching on 52 Fuse lamp SILA On...

Page 156: ...ocations 66 Spare parts service 146 Starter Condition check 102 Startup After extended out of service periods 3 months 45 Putting into operation after scheduled out of service pe riod 46 T Tasks After...

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