MTU 12 V 2000 P12 Operating Instructions Manual Download Page 1

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Operating Instructions

Diesel engine

12 V 2000 P12

16 V 2000 P12

MS150025/02E

Summary of Contents for 12 V 2000 P12

Page 1: ...Operating Instructions Diesel engine 12 V 2000 P12 16 V 2000 P12 MS150025 02E ...

Page 2: ...tten permission of MTU Friedrichshafen GmbH This restriction also applies to copyright distribution translation micro filming and storage or processing on electronic systems including data bases and online services This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage during operation Subject to alterations and amendments ...

Page 3: ... Emergency stop 56 4 9 After stopping the engine Engine remains ready for operation 57 4 10 After stopping the engine putting the engine out of service 58 4 11 Plant cleaning 59 5 Maintenance 5 1 Maintenance task reference table QL1 60 6 Troubleshooting 6 1 Troubleshooting 61 6 2 Fault indication on printed circuit board SAM 64 6 3 ECU alarms 73 7 Task Description 7 1 Engine 84 7 1 1 Engine Barrin...

Page 4: ...check 136 7 16 Low Temperature Circuit 137 7 16 1 Charge air coolant Filling 137 7 16 2 Charge air coolant Draining 139 7 16 3 Charge air coolant Change 140 7 16 4 Charge air coolant Level check 141 7 17 Belt Drive 142 7 17 1 Drive belt Condition check 142 7 18 Engine Mounting Support 143 7 18 1 Engine mounts Resilient elements check 143 7 19 Wiring General for Engine Gearbox Unit 144 7 19 1 Engin...

Page 5: ...n approved by MTU in writing engine and engine control parameters In compliance with all safety instructions and in adherence to all warning notices in these Operating Instructions In compliance with the maintenance and repair instructions contained in these Operating Instructions in particular with regard to the specified tightening torques Appointing only qualified personnel to carry out work re...

Page 6: ... personnel who only occasionally perform work on or around the engine or plant This personnel must be instructed repeatedly For the identification and layout of the spare parts during maintenance or repair work take photos or use the spare parts catalog Personnel requirements All work on the engine or plant shall be carried out by trained and qualified personnel only Training at the MTU Training C...

Page 7: ...klift 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 transportation The engine must be especially secured against slipping or tilting when going up or down inclines and ramps Setting the engine down after transport Place the engine only on an even firm surface Ensure appropr...

Page 8: ... H dust extraction de vice as an additional measure Safety regulations during maintenance and repair work Take special care when removing ventilation or plug screws from the engine or plant Cover the screw or plug with a rag to prevent fluids escaping under pressure Take care when draining hot fluids and lubricants risk of burning Use only proper and if applicable calibrated tools Observe the spec...

Page 9: ...ures Observe the max permissible push on pressure specified for the equipment Do not attempt to bend or apply force to lines Before starting work pay attention to the following Vent the hydraulic installation removal tool the pumps and the lines at the relevant points for the equipment to be used e g open vent plugs pump until bubble free air emerges close vent plugs For hydraulic installation scr...

Page 10: ...cial laser protection goggles Heavily focused ra diation Laser equipment must be fitted with the protective devices necessary for safe operation according to type and application For conducting light beam procedures and measurement work only the following laser devices must be used Laser devices of classes 1 2 or 3A Laser devices of class 3B which have maximum output in the visible wavelength rang...

Page 11: ...ine are prohibited by emission regulations Emission control units systems may only be main tained exchanged or repaired if the components used for this purpose are approved by MTU or equiva lent components Noncompliance with these guidelines will lead to forfeiture of the operating permit is sued by the emission monitoring authorities MTU does not accept any liability for violations of the emis si...

Page 12: ...r equipment is disconnected from the supply line or before the equipment or tool is to be replaced Carry out leak test in accordance with the specifications Paints and lacquers Observe the relevant safety data sheet for all materials When carrying out painting work outside the spray stands provided with fume extraction systems en sure that the area is well ventilated Make sure that neighboring wor...

Page 13: ...tion involving potentially adverse effects on the product Consequences Material damage Remedial action Additional product information Note This manual contains highlighted safety messages in accordance with the US ANSI Z535 standard which begin with one of the signal words listed above depending on the severity of the hazard Safety messages 1 Read and familiarize yourself with all safety message b...

Page 14: ...tives Unoccupied connections for the wiring harness must be sealed with protective caps The entire engine wiring harness must be covered with metal guards to protect it from mechanical im pact and UV radiation Continuous power supply to the engine must be ensured when the engine is in the hazardous zone 14 Safety MS150025 02E 2012 10 TIM ID 0000024691 001 ...

Page 15: ... 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 end Other components are numbered in the same way i e starting with No 1 on driving end 1 Left engine side 2 KGS Free end 3 Right engine side 4 KS Driving end MS150025 02E 2012 10 General Information 15 TIM ID 0000002185 010 ...

Page 16: ...on 5 Crankcase ventilation 6 Crankcase ventilation 7 Cylinder head cover 8 ECU 9 Engine lifting equipment 10 Fuel duplex filter 11 Oil filler neck 12 Engine coolant pump 13 Fuel pump 14 Oil cooler 15 Oil filter 16 Oil dipstick 17 Oil pan 18 Crankcase 19 Exhaust manifold 16 General Information MS150025 02E 2012 10 TIM ID 0000009974 001 ...

Page 17: ...gnation 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 1 6 8 9 2 Design index MS150025 02E 2012 10 General Information 17 TIM ID 0000009974 001 ...

Page 18: ...ring op tional 8 LOP optional Up to 8 additional 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 depending on operating state Indication of faulty operating states display SAM 1 18 General Information MS150025 02E 2012 10 TIM ID 0000009433 001 ...

Page 19: ...ed droop switching possible with engine running Straightforward engine governor replacement Engine and interface data stored in SAM Complete automatic software download following connection of a new unprogrammed engine gov ernor Design of the overall MDEC system 1 Monitoring and Control System MCS 5 PIMs optional 2 CAN bus between ECS 5 and MCS 5 3 Engine Control System ECS 5 4 RS422 interface and...

Page 20: ...o the MCS devices and the higher level control sys tems 5 Engine governor 6 System boundary ECS 5 The Engine Control System comprises the following devices Engine governor Sensors on engine Actuators on engine Injectors on engine Wiring harnesses on engine 20 General Information MS150025 02E 2012 10 TIM ID 0000009433 001 ...

Page 21: ...itoring 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 MS150025 02E 2012 10 General Information 21 TIM ID 0000009433 001 ...

Page 22: ...gn Functions SAM functions Display of fault codes from engine 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 fault code display Self diagnosis by diagnostic lamp 5 Steady SAM is OK Flashing SAM is faulty contact Service Dark Supply voltage missing 22...

Page 23: ...al subsystems This CAN bus is in redundant design The CAN bus is a standardized automation technology field bus which allows various systems and devi ces to communicate with each other providing they are equipped with a CAN bus interface Tasks of the CAN bus CAN bus Tasks Receiving plant signals desired speed and commands from higher level control systems Outputting all measured values limit value...

Page 24: ... 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 system is electrically isolated from ground This also applies to the sensors 5 All sensor signal lines and or supply lines are not connected to the corresponding sensor housings Signal to noise ratio Electrical isolation of the me...

Page 25: ...ant related setting variables in exchangeable memory modules In case of inadmissible states and limit value violations Initiation of power reduction engine stop and emergency engine stop configurable Diagnosis via RS232 interface for dialog unit Software structure Name Meaning Download software For downloading firmware and configuration data Dialog software For the dialog with a PC or notebook Aut...

Page 26: ...ctor wiring harness 7 Connector X5 Connection for power supply 8 Connector X2 Connection for sensor actuator wiring harness 9 Connector X3 BR 2000 Not used BR 4000 HP controller 10 Connector X1 Connection for CAN bus 11 Mounting lugs Technical data Dimensions width x height x depth 455 mm x 277 mm x 91 mm Draw out clearance 230 mm Weight 7 kg 26 General Information MS150025 02E 2012 10 TIM ID 0000...

Page 27: ... to 75 C Storage temperature range 10 C to 75 C Relative air humidity 0 to 95 condensing Degree of protection IP 65 DIN 40 050 Shock 15 g 11 ms semi sinusoidal shock Vibration 2 Hz to 13 Hz Xpp 1 6 mm 25 Hz to 100 Hz a 4 g 100 Hz to 2000 Hz Electrical noise 1 3 g rms EMC DIN EN 50081 2 DIN EN 50082 2 IEC 1000 4 2 IEC 1000 4 3 IEC 1000 4 4 IEC 1000 4 5 IEC 1000 4 6 MS150025 02E 2012 10 General Info...

Page 28: ...le Start terminated if speed is n 300 within t2 configurable Start speed is too low Run up speed low 9 Starter off 10 Idling speed reached Start terminated if idling speed not 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 down following a stop comman...

Page 29: ...s the engine during operation Safety system generates automatic engine shutdown in case of limit value violation These two functional areas are constantly monitored by the internal Integral Test System ITS to en sure operational availability Engine protection system The engine governor incorporates an integral engine protection system It monitors the operational data of the engine Tasks of the eng...

Page 30: ...t plant requirements via the dialog unit Dynamic quantity limitation Dynamic quantity limits protect the engine against overloading and optimize exhaust emission values The engine governor determines the maximum injection quantity based on preset and stored engine per formance maps Following limits are applied Speed sensitive fuel quantity limitation DBR Fuel quantity limitation as a function of f...

Page 31: ...reases the setpoint speed by 1 rpm The setpoint speed is automatically adjusted at a configurable rate if the input is activated for longer than 0 3 seconds Safety functions Safety shutdowns Safety shutdowns are initiated by the engine protection system in case of Limit value violations Sensor faults depending of specific configuration This applies to the following measuring points Engine speed ov...

Page 32: ...he combined alarm output and the CAN bus to a higher level monitoring system if applicable where it can be visualized for the operator Monitoring of sensors and actuators The various sensor and actuator channels of the engine governor system are designed to tolerate faults to a large extent e g short circuit withstandability Faults such as broken wires short circuit etc are detected by plausibilit...

Page 33: ...7 and one PIM printed circuit 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 other slots may be populated with PIM printed circuit boards Example The n in n09 stands for the slot and 09 designates the terminal 209 means Slot 2 ter minal 9 MS150025 02E...

Page 34: ...Analog limit values Status messages 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 RS232 or RS422 MTU MASTER 34 General Information MS150025 02E 2012 10 TIM ID 0000008271 001 ...

Page 35: ...e active 8 Connector RS232 inter face A yellow LED lights o flashes only when data interchange is active at the relevant interface When there is no communication at the connected interface the LED remains dark Features 2 interfaces as per RS422 or RS232 standard Interface are electrically isolated Use SCB 3 is used as an interface extension additional serial interfaces as an interface converter or...

Page 36: ...the PIM or by a connector When connected by the connector the terminals of the RS232 interface are automatically switched off Transmission channel 2 is equipped with a connection for a serial RS422 interface and a serial RS232 interface Data processing and interface driver control baud rate depend on the processor printed circuit board used With processor printed circuit board MPU 23 Fixed 9600 kB...

Page 37: ...nterface n08 Channel 2 I1 of RS422 interface n09 Channel 1 I2 of RS422 interface n10 Channel 2 I2 of RS422 interface n11 Channel 1 TX of RS232 interface n12 Channel 2 TX of RS232 interface n13 Channel 1 Ground GND of RS232 interface n14 Channel 2 Ground GND of RS232 interface n15 Channel 1 RX of RS232 interface n16 Channel 2 RX of RS232 interface MS150025 02E 2012 10 General Information 37 TIM ID ...

Page 38: ...a level m 100 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 12 16 Nominal engine speed A rpm 1800 1800 Fuel stop power ISO 3046 A kW 600 800 GENERAL CONDITIONS for maximum power Number of cylinders 12 16 Intake air depression new filter A mbar 15 15 Intake air depression max L mbar 30 30 Exhaust overpressure A mbar 30 30 Exhaust gas overpressure max L...

Page 39: ...t from cooling equipment A C N N Coolant antifreeze content max L 50 50 Pressure loss in off engine cooling system max L bar 0 7 0 7 LUBE OIL SYSTEM Number of cylinders 12 16 Lube oil operating temperature before engine from R C 88 88 Lube oil operating temperature before engine to R C 98 98 Lube oil temperature before engine warning R C 99 99 Lube oil temperature before engine shutdown L C 102 10...

Page 40: ...ng standard oil system Option max operating inclinations R liter 95 123 Oil change quantity max standard oil system Option max operating inclinations R liter 90 120 Oil pan capacity dipstick mark min standard oil system Op tion max operating inclinations L liter 78 96 Oil pan capacity dipstick mark max standard oil system Op tion max operating inclinations L liter 85 103 ACOUSTICS Number of cylind...

Page 41: ...3 2 Firing order Firing order 12 V A1 B2 A5 B4 A3 B1 A6 B5 A2 B3 A4 B6 16 V A1 B5 A3 A5 B2 B8 A2 A8 B3 A7 B4 B6 A4 A6 B1 B7 MS150025 02E 2012 10 Technical Data 41 TIM ID 0000010708 001 ...

Page 42: ... Main dimensions Engine model 12 V 2000 Px2 16 V 2000 Px2 Length A approx 2165 mm approx 2505 mm Width B approx 1340 mm approx 1340 mm Height C approx 1475 mm approx 1495 mm 42 Technical Data MS150025 02E 2012 10 TIM ID 0000010031 001 ...

Page 43: ...Value Installation position As desired ensuring that the installed fault display is legible Operating voltage VDC 24 rated value 30 30 temporary 50 Power consumption W Below 7 0 25A at 24V without additional loads Degree of protection IP 40 according to DIN 40 050 Shock Rail mounting 10 g 11 ms Fixed mounting 30 g 11 ms Vibrations Rail mounting Hz 2 12 8 Xpp 3mm 12 8 1000 a 1g rms Fixed mounting H...

Page 44: ... EN 61000 4 3 Radiated interference immunity 80 MHz 2 GHz EN 61000 4 4 Burst interference immunity 2 kV EN 61000 4 5 Surge interference immunity 1 kV 2 kV EN 50155 Surge interference immunity 1 8 kV EN 61000 4 17 LF line related interference 0 03 10 kHz 3 Veff EN 61000 4 29 Line fluctuations STANAG 1008 IEC 60092 504 Dielectric strength 550 VAC 10 mA EN 50155 Isolation 500 V 10 Mohm Requirements f...

Page 45: ...cal design Term Unit Value Installation position Horizontal to ensure visibility of the fault display and labels on the SAM housing Note that space is required to connect cabling at the top and bottom when installing the SAM in control cabinets The device heats up as a result of power loss from the SAM Heat from the SAM is dissipated through the rear panel Ensure that heat can be conducted away fr...

Page 46: ...ections 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 circuit boards in slots 1 to 3 Observe the relevant technical data applicable to the printed circuit boards concerned when additional boards are used in the SAM 46 Technical Data MS150025 02E 2012 10 TIM ID 0000008286 003 ...

Page 47: ...ted circuit board used Power consumption mA 100 Power loss mW 425 Table 1 General information Term Unit Value Bit serial In accordance with RS422 standard Baud rate kBd 9600 with MPU 23 4800 9600 19200 with MPU 27 Electrical isolation By optocoupler Table 2 Data transmission MS150025 02E 2012 10 Technical Data 47 TIM ID 0000008261 002 ...

Page 48: ...LCD screen 2 White F2 3 White F3 4 White F4 5 White F5 6 White ALARM AC KNOWLEDGE Pressing the key the first time stops alarm signalization Pressing the key a second time acknowledges an active alarm LED spot lights up when an alarm is active 7 White DIMMER Holding down the key increases LCD background illumina tion 48 Operation MS150025 02E 2012 10 TIM ID 0000008856 004 ...

Page 49: ...between Not ready for operation and Ready for operation status LED spot lights up at Ready for operation switch posi tion 17 Green LOCAL OPERA TION Pressing the key switches between local operation and re mote control LED spot lights up when local mode is active 18 White START Pressing the key initiates automatic engine starting proce dure LED spot lights up as long as the starting procedure is ru...

Page 50: ... pressure gauge Align pointer with position of pressure indicator Page 113 Fuel system Vent Page 109 Coolant circuit If engine has been out of service for more than 1 year change engine coolant Page 132 Change charge air coolant Page 140 Coolant circuit Check engine coolant level Page 131 Check charge air coolant level Page 141 Coolant circuit Preheat coolant with preheating unit ECU Check plug co...

Page 51: ...123 Cooling system Check engine coolant level Page 131 Check charge air coolant level Page 141 Cooling system Preheat coolant with preheating unit Fuel prefilter Drain Page 114 Monitoring equipment Carry out lamp test see manufacturer s documentation Engine generator control system Switch ON Select operating mode e g MANUAL OPERATION AUTOMATIC OPER ATION MS150025 02E 2012 10 Operation 51 TIM ID 00...

Page 52: ...g the engine Item Task Switchgear cabinet control panel etc depending on manufacturer If coolant temperature is 40 C with preheating equipment or 5 C without preheating equipment Press start button Automatic starting sequence is performed Engine speed display instrument indicates increasing crankshaft speed After the starting sequence is completed engine is running at rated speed Connect generator...

Page 53: ...n a pushbutton is provided Bypassing the safety system Override Item Action Switchgear cabinet control panel etc depending on manufacturer Activate pushbutton for Override input of the ECU Certain shutdown criteria and or starting prerequisites are ignored Switchgear cabinet control panel etc depending on manufacturer Actuate start button for further starting sequence refer to engine start Page 52...

Page 54: ...ing noises and vibrations Fuel prefilter Check whether indicated differential pressure is within the limit Page 113 Exhaust system Check exhaust color Page 61 Intercooler Check condensate drain s for water discharge and obstruction Page 119 Air filter Check signal ring position of service indicator Page 121 Replace air filter Page 120 if the signal ring is completely visible in the service indicat...

Page 55: ... breaker Item Task Engine After opening the generator breaker if provided allow to cool down off load for approx 5 minutes Preparing the pump drive diesel mechanical diesel electric Item Task Engine Allow to cool down for approx 5 minutes at reduced engine speed Ob serve natural resonance of engine installation dependent Stopping the engine Item Task Switchgear cabinet control panel etc depending ...

Page 56: ... from LOP Item Task EMERGENCY STOP but ton Press Engine is stopped by switching off power supply to ECU Signalization e g by horn flashing lamp is released After emergency stop from LOP Item Task Switching cabinet control panel etc depending on manufacturer Press button for alarm acknowledgement Audible and visual signalization stops 56 Operation MS150025 02E 2012 10 TIM ID 0000002305 002 ...

Page 57: ...he engine Engine remains ready for operation After stopping the engine Item Action Engine generator pump control Select operating mode e g MANUAL AUTOMATIC OPERATION MS150025 02E 2012 10 Operation 57 TIM ID 0000000983 002 ...

Page 58: ... the engine room is not heated the coolant is not maintained at a suitable temperature the antifreeze concentration is insufficient for the engine room tempera ture antifreeze concentration is 50 and engine room temperature is below 40 C Engine generator pump controller Switch OFF Air intake and exhaust sys tem If the engine is to remain out of service for more than 1 week seal the engine s air an...

Page 59: ... cleaning 1 Carry out plant cleaning only in areas where an appropriate oil separator is provided environmental pro tection 2 Prior to putting the cleaning unit into operation read the Operating Instructions of the water steam jet unit carefully and observe the safety precautions 3 During external cleaning of the plant with water steam jet units the pressure of the high pressure jet cleaning jet m...

Page 60: ...s Page 54 W0507 Drain water and contaminants from fuel prefilter Page 54 W0508 Check reading on differential pressure gage of fuel prefilter Page 54 W1001 Replace fuel filter or fuel filter element Page 110 W1002 Check valve clearance Page 95 W1003 Check belt condition and tension replace if necessary Page 142 W1005 Replace air filter Page 120 W1006 Replace fuel injectors Page 102 W1007 Replace fu...

Page 61: ...heck Page 144 Engine governor Plug in connections possibly loose Check plug in connections Page 147 Engine Blocked engine cannot be barred manually Contact Service Engine turns but does not fire Component Cause Measure Starter Poor rotation by starter Battery flat or defective Charge or replace battery see manu facturer s documentation Engine wiring Faulty Check Page 144 Fuel system Air in fuel sy...

Page 62: ...on pump defective Replace Page 98 Speed sensor Faulty Contact Service Fuel system Air in fuel system Vent fuel system Page 109 Engine governor Faulty Contact Service Charge air temperature too high Component Cause Measure Engine coolant Engine coolant treatment incorrect Check MTU test kit Intercooler Contaminated Contact Service Engine room Air intake temperature too high Check fan check air inle...

Page 63: ...gine oil level too high Drain engine oil Page 124 Oil separator or oil preseparator of crankcase breather clogged Replace Page 93 Exhaust turbocharger Cylinder head Piston rings Cylinder liner Faulty Contact Service White exhaust gas Component Cause Measure Engine Not at operating temperature Run engine to reach operating temper ature Fuel system Water in fuel Check fuel system at fuel prefilter D...

Page 64: ... ago Fault type e g SE03 Node number at which the fault occurred e g nd11 Second line Running text providing more information about the fault currently displayed Proceed to the next alarm by pressing key Fault type fault message text SE No Fault message text 0 Sensor Temperature Defect 1 Temperature failure 2 Sensor Voltage Defect 3 Voltage failure 4 CAN Bus 1 Error Bus Defec 5 CAN Bus 1 Overrun 6...

Page 65: ...st limit value Check oil level top up as necessary Engine operating instructions 016 L2 P LUBE OIL Oil pressure too low 2nd limit value automatic engine shut down 1 Check oil level top up as nec essary Engine operating in structions 2 Attempt to restart engine En gine operating instructions 019 L1 T EXHAUST A Exhaust temperature en gine A side too high 1st limit value 1 Check cabling Engine oper a...

Page 66: ...ns 044 L1 LEVEL INTER COOLER Charge air coolant level too high low 1st limit value violated Check coolant level Engine op erating instructions 045 L2 LEVEL INTER COOLER Charge air coolant level too high low 2nd limit value violated Check coolant level Engine op erating instructions 051 L1 T LUBE OIL Oil temperature too high 1st limit value Reduce power 052 L2 T LUBE OIL Lube oil temperature too hi...

Page 67: ... fuel consumption display checksum error in IDM EEPROM 2 redun dant data record 2 Contact Service 104 OP HOURS1 NOT VALID Checksum error of hour meter in EDM EEPROM 1 Hour meter remains operational 105 OP HOURS2 NOT VALID Checksum error of hour meter in IDM EEPROM 2 Hour meter remains operational 106 ERR REC1 NOT VALID Checksum error of fault memory in EDM EE PROM 1 redundant data record 1 Faults ...

Page 68: ...GOOD ECU DEFECT Power supply is faulty automatic engine shut down Replace engine governor En gine operating instructions 146 L1 AD TEST1 SUP PLY A D converter supply volt age too low Replace engine governor En gine operating instructions 147 AD TEST1 ECU DE FECT Electronics faulty automatic engine shut down Replace engine governor En gine operating instructions 148 L1 AD TEST2 SUP PLY A D converte...

Page 69: ...cabling Engine oper ating instructions 2 Contact Service Check sensor 203 SD T CHARGE AIR Sensor B09 faulty charge air temperature A side 1 Check cabling Engine oper ating instructions 2 Contact Service Check sensor 205 SD T COOLANT IN TERC Sensor fault charge air coolant temperature 1 Check cabling Engine oper ating instructions 2 Contact Service Check sensor 206 SD T EXHAUST A Sensor B4 21 fault...

Page 70: ...tions 2 Contact Service Check sensor 230 SD CRANKSHAFT SPEED Sensor B13 faulty crank shaft speed 1 Check cabling Engine oper ating instructions 2 Contact Service Check sensor 231 SD CAMSHAFT SPEED Sensor B1 faulty camshaft speed 1 Check cabling Engine oper ating instructions 2 Contact Service Check sensor 232 SD CHARGER SPEED 1 Sensor B44 faulty ETC speed 1 1 Check cabling Engine oper ating instru...

Page 71: ...nk 2 sole noid valve 1 Open load bank 2 solenoid valve 10 Contact Service Check solenoid valve 361 POWER STAGE FAIL 1 Fault in ECU solenoid valve output stage bank 1 Engine operating instructions 1 Check solenoid valve cabling 2 Replace engine governor 362 POWER STAGE FAIL 2 Fault in ECU solenoid valve output stage bank 2 Engine operating instructions 1 Check solenoid valve cabling 2 replace engin...

Page 72: ...ly 2 contact Service if alarm sig naled permanently 392 L1 T COOLANT RED Redundant coolant temper ature 1st limit value 1 Check cabling Engine oper ating instructions 2 Contact Service Check sensor 393 L2 T COOLANT RED Redundant coolant temper ature 2nd limit value 1 Check cabling Engine oper ating instructions 2 Contact Service Check sensor 394 L1 P LUBE OIL RED Redundant lube oil pres sure 1st l...

Page 73: ...lt itself as listed in the table below Alarms can also be caused by defective sensors actuators If troubleshooting in accordance with the following table is not successful contact Service to have the sensors actuators checked and if re quired replaced Fault code Alarm text Meaning Task 004 L2 T FUEL Fuel temperature too high 2nd limit Cool fuel tank 005 L1 T CHARGE AIR Charge air temperature too h...

Page 74: ...ct Service 069 L1 T EXTERN 1 Violation of first limit for exter nal temperature channel 1 Depending on the corresponding meas uring point which is read via CAN bus 070 L2 T EXTERN 1 Violation of second limit for external temperature channel 1 Depending on the corresponding meas uring point which is read via CAN bus 071 L1 T EXTERN 2 Violation of first limit for exter nal temperature channel 2 Depe...

Page 75: ...preheating tempera ture too low during starting 2nd limit Termination of starting proce dure depending on project design Check preheating pump preheating sys tem see manufacturer s documentation 094 PREHEAT TEMP LIMIT1 Coolant preheating tempera ture too low during starting 1st limit Check preheating pump preheating sys tem see manufacturer s documentation 100 EDM NOT VALID Check sum error of meas...

Page 76: ...onic equipment defec tive automatic engine shutdown Contact Service 136 15V NEG ECU DEFECT Electronic equipment defec tive automatic engine shutdown Contact Service 137 L1 5V BUFFER TEST Power supply for pressure sensors defective 1 Disconnect connectors X2 and X3 from ECU If alarm does not disap pear Contact Service 2 Check wiring pressure sensors 3 Contact Service 138 SENSORPO WERDEFECT Power su...

Page 77: ...1 NODE LOST At least one device not detect ed on Default CAN bus 1 Check wiring CAN bus 2 Contact Service 181 CAN2 NODE LOST At least one device not detect ed on Redundant CAN bus 1 Check wiring CAN bus 2 Contact Service 182 CAN WRONG PARAMETERS Consistency error in CAN pa rameters Contact Service 183 CAN NO PU DA TA Error during loading of CAN project design data into ECU Contact Service 184 CAN ...

Page 78: ...aft speed 1 Check wiring 2 Contact Service 231 SD CAMSHAFT SPEED Sensor defect camshaft speed 1 Check wiring 2 Contact Service 245 SD POWER SUPPLY Sensor defect ECU operating voltage Contact Service 246 SD T ELEC TRONIC Sensor defect temperature in ECU Contact Service 250 SD CAN SPEED DEMAND Sensor defect CAN nominal speed demand 1 Check speed transmitter 2 Check wiring CAN bus 3 Contact Service 2...

Page 79: ... CYLIN DER A7 Injection timing fault cylinder A7 If fault occurs repeatedly Contact Serv ice 308 TIMING CYLIN DER A8 Injection timing fault cylinder A8 If fault occurs repeatedly Contact Serv ice 309 TIMING CYLIN DER A9 Injection timing fault cylinder A9 If fault occurs repeatedly Contact Serv ice 310 TIMING CYLIN DER A10 Injection timing fault cylinder A10 If fault occurs repeatedly Contact Serv ...

Page 80: ...iring 2 Contact Service 326 WIRING CYLIN DER A6 Faulty wiring to solenoid valve cylinder A6 Misfiring 1 Check wiring 2 Contact Service 327 WIRING CYLIN DER A7 Faulty wiring to solenoid valve cylinder A7 Misfiring 1 Check wiring 2 Contact Service 328 WIRING CYLIN DER A8 Faulty wiring to solenoid valve cylinder A8 Misfiring 1 Check wiring 2 Contact Service 329 WIRING CYLIN DER A9 Faulty wiring to so...

Page 81: ...alve cylinder B10 Misfiring 1 Check wiring 2 Contact Service 341 OPEN_LOAD CYL A1 Disconnection in wiring to sol enoid valve cylinder A1 Misfiring 1 Check wiring 2 Contact Service 342 OPEN_LOAD CYL A2 Disconnection in wiring to sol enoid valve cylinder A2 Misfiring 1 Check wiring 2 Contact Service 343 OPEN_LOAD CYL A3 Disconnection in wiring to sol enoid valve cylinder A3 Misfiring 1 Check wiring ...

Page 82: ...enoid valve cylinder B4 Misfiring 1 Check wiring 2 Contact Service 355 OPEN_LOAD CYL B5 Disconnection in wiring to sol enoid valve cylinder B5 Misfiring 1 Check wiring 2 Contact Service 356 OPEN_LOAD CYL B6 Disconnection in wiring to sol enoid valve cylinder B6 Misfiring 1 Check wiring 2 Contact Service 357 OPEN_LOAD CYL B7 Disconnection in wiring to sol enoid valve cylinder B7 Misfiring 1 Check w...

Page 83: ...n 1 Check wiring 2 Try to re start the engine Page 52 3 Contact Service 381 TRAN OUT1 PLANT DEF Binary transistor output plant 1 defective Contact Service 382 TRAN OUT2 PLANT DEF Binary transistor output plant 2 defective Contact Service 383 TRAN OUT3 PLANT DEF Binary transistor output plant 3 defective Contact Service 384 TRAN OUT4 PLANT DEF Binary transistor output plant 4 defective Contact Serv...

Page 84: ...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 cover from flywheel housing 2 Install barring tool arrow on flywheel hous ing 3 Rotate crankshaft in engine direction of ro tation Apart from the normal compression resistance there should be no abnormal re sistance Result ...

Page 85: ...e engine Engine Barring with starting system 1 Disengage the bayonet coupling 4 of con nector X4 with connector pliers 2 and withdraw connector 3 from engine gover nor 2 Bar engine in unloaded condition Press START button 3 Let the crankshaft rotate until oil pressure is indicated 4 Engine start is automatically interrupted when specified starting period is expired If necessary re start the engine...

Page 86: ...t 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 52 2 Perform test run not below 1 3 load and at least until steady state temperature is reached 3 Carry out operational checks Page 54 4 Stop engine Page 55 86 Task Description MS150025 02E 2012 10 TIM ID 0000000870 007 ...

Page 87: ...s First signs of marks left by lower cooling bores Running pattern seems darker No action required Dark areas with even or varying degrees of discoloration Beginning and end of the discoloration are not sharply defined and do not cover the entire stroke area Dark areas in the upper section of the cooling bore remaining cir cumference without objections Piston rings without objections Further endos...

Page 88: ...Final steps 1 Install injector Page 103 2 Install cylinder head cover Page 97 88 Task Description MS150025 02E 2012 10 TIM ID 0000000015 014 ...

Page 89: ...e Smoothened areas appear brighter and more brilliant than the surrounding running surface Findings not critical Bright area Bright areas are on the running surface and show local removal of the honing pattern Grooves from honing process are not visible any more Discoloration This is caused by oxidation surface discoloration through oil or fuel and tem perature differences around the liner It appe...

Page 90: ...tion starting in TDC ring 1 have to be replaced Seizure marks scuff ing Irregular circumference lengths and depths Can be caused either by the piston skirt or the piston crown Material deposits on the liner smear heavy discolora tion Severe visible scoring Replace liner Evaluation of findings and further measures The findings in the start phase of oxidation discoloration and heat discoloration are...

Page 91: ...talog WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke WARNING Compressed air Risk of injury Do not direct compressed air jet at persons Wear protective goggles safety mask and ear protectors CAUTION Excessive reaction time of cleaning agents on components Damage to component Observe manufacturer s instructions Wear prot...

Page 92: ...lement wire mesh 3 with compressed air 9 Clean residual parts with cleaner 10 Remove cleaner 11 Insert washer 2 and filter element wire mesh 3 in the correct sequence in the oil separator housing 1 12 Coat sealing ring 8 with grease and insert in the groove of the oil separator housing 1 13 Install oil separator housing 1 deflector plate 6 and retainer 7 with new screws 4 on the cylinder head cove...

Page 93: ...s 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 oil separator element 1 Remove cover 2 with O ring 3 2 Remove filter element 1 from housing 4 3 Insert new filter element in housing 4 4 Install cover 2 with new O ring 5 Use torque wrench to tighten the screws of cover 2 to th...

Page 94: ...aphragm 3 on housing 1 5 Install new seal 2 and spring 5 together with cover 4 6 Use torque wrench to tighten the screws of cover 4 to the specified torque Name Size Type Lubricant Value Standard Screw Tightening torque Engine oil 10 Nm 2 Nm 7 Check diaphragms in further oil separators in the same way 94 Task Description MS150025 02E 2012 10 TIM ID 0000000017 008 ...

Page 95: ...tchet adapter F30027340 1 Measuring device Y4341106 1 Preparatory steps 1 Remove cylinder head cover Page 97 2 Install barring tool Page 84 3 Disassemble fuel injector of cylinder A1 Page 103 4 Screw the measuring device into the fuel in jector orifice 5 Turn the crankshaft checking the dial gauge in the direction of engine rotation until the piston stands at the breakover point on the dial gauge ...

Page 96: ...auge 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 clearance 1 Loosen locknut 1 and unscrew adjusting screw 2 slightly 2 Insert feeler gauge between valve bridge and rocker arm 3 Readjust adjusting screw 2 so that the feeler gauge just passes through the gap 4 Tighten locknut 1 to 50 N...

Page 97: ...covers with crankcase breather Loosen clamps 2 Slide rubber sleeves onto the pipe Cylinder head cover Removal and installation 1 Remove cylinder head cover with gasket from cylinder head 2 Clean installation surface 3 Check condition of gasket in cylinder head cover 4 Replace damaged gasket s 5 Install cylinder head cover with screws Final steps 1 Slide rubber sleeves onto the relevant pipe connec...

Page 98: ...eplacement Special tools Material Spare parts Designation Use Part No Qty Injection pump Spare Parts Catalog Injection pump Replacement u Remove injection pump and install new one Page 99 98 Task Description MS150025 02E 2012 10 TIM ID 0000000020 004 ...

Page 99: ...ier X00029933 Sealing ring Spare Parts Catalog Sealing ring Spare Parts Catalog 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 open flames electrical sparks and ignition sources Do not smoke Preparatory steps 1 Shut off fuel...

Page 100: ...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 Installing injection pump 1 Remove all blanking plugs and covers 2 Clean mating face of injection pump and roller Note Sealing ring 1 Ø47 mm 3 Coat sealing ring 1 with grease and fit on to injection pump Note Sealing ring 2 Ø45 mm ...

Page 101: ...to specified torque 20 Nm 5 Nm Maximum permissible tightening tor que 35 Nm 13 Install injection pump wiring 1 14 Tighten screws to specified torque 1 0 Nm 0 2 Nm using torque wrench Final steps 1 Remove barring tool Page 84 2 Clean mating faces on cylinder head and charge air pipe 3 Check gaskets for damage and replace them if required 4 Coat gaskets with grease and place onto cylinder head 5 Ins...

Page 102: ...tor Replacement Special tools Material Spare parts Designation Use Part No Qty Injector Spare Parts Catalog Replacing injector u Remove injector and install new injector Page 103 102 Task Description MS150025 02E 2012 10 TIM ID 0000000022 013 ...

Page 103: ...atchet adapter F30027340 1 Transition piece F30006234 1 Grease Kluthe Hakuform 30 10 Emulgier X00029933 Sealing ring Spare Parts Catalog Sealing ring Spare Parts Catalog WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke WARNING Compressed air Risk of injury Do not direct compressed air jet at persons Wear protective goggl...

Page 104: ...xtract 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 Remove sealing ring using a self made hook 11 Seal all openings with appropriate covers after removal 104 Task Description MS150025 02E 2012 10 TIM ID 0000004645 001 ...

Page 105: ...3 and pressure pipe neck 1 with compressed air 9 Coat sealing ring with grease and fit onto pressure pipe neck 1 10 Coat sealing cone of pressure pipe neck with engine oil 11 Insert pressure pipe neck into cylinder head until the sealing ring is in contact with cylin der head 12 Fully press in pressure pipe neck 1 by hand 13 Tighten thrust screw 2 to specified torque 40 Nm 5 Nm using torque wrench...

Page 106: ...d explosion Avoid open 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 sealing ring 3 5 Remove fuel pressure relief valve 4 from connecting piece 5 6 Insert new fuel pressure relief valve 4 into connecting piece 5 7 Screw in adapter 2 with sealing ring 3 and tighten 8 In...

Page 107: ...emove 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 rings 5 in reverse sequence of operations 8 Open fuel supply MS150025 02E 2012 10 Task Description 107 TIM ID 0000004989 001 ...

Page 108: ...ire 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 110 3 Catch fuel as it runs out 4 Install fuel filter Page 110 108 Task Description MS150025 02E 2012 10 TIM ID 0000004702 002 ...

Page 109: ...system Venting Fuel system Venting 1 Bar engine with starting system Page 85 2 Repeat procedure 2 to 3 times the fuel system is automatically vented MS150025 02E 2012 10 Task Description 109 TIM ID 0000004705 002 ...

Page 110: ...ble Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors CAUTION Damage to component Serious damage to plant For filter replacement with the engine running operate the engine at low engine load The filter which is to be exchanged must be cut out for a brief period only Fuel ...

Page 111: ...t fuel system Fuel filter replacement with the engine running 1 Cut out the filter to be replaced 2 Open vent plug of the cut out filter and make sure that the pressure is completely released from the filter 3 Close vent plugs 4 Remove cut out easy change filter using the filter wrench 5 Clean the sealing surface of the filter head 6 Check sealing ring of the new easy change filter and coat it wit...

Page 112: ...ff 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 re move filter element by pulling it downwards 5 Wash filter element in clean fuel using a smooth brush 6 Wash filter housing with clean fuel 7 Insert filter element into filter housing and secure with nut 8 Place new sealing ring into groove in...

Page 113: ...n installing the new filter element align adjustable pointer 2 with pressure indicat ing pointer 3 of pressure gauge 1 2 Check differential pressure Checking differential pressure of fuel prefilter 1 With the engine running at full load or rated power read off pressure at gauge 1 2 If differential pressure as indicated between position of adjustable pointer 2 and pressure indicating pointer 3 of p...

Page 114: ... drained 1 Left filter cut in 2 Right filter cut in 2 Open threaded vent plug 5 of filter to be drained 3 Unlock drain valve 6 by pressing toggle and open it 4 Drain water and contaminants from filter un til pure fuel emerges 5 Close drain valve 6 6 Remove screws for cover and take off cov er 2 7 Fill filter housing with clean fuel 8 Place new gasket in cover 2 9 Fit cover with gasket and secure i...

Page 115: ...e Take special care when working on a running engine WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors Fuel prefilter Flushing 1 Cut out clogged filter I Left filter cut in II Right filter cut in MS150025 02E 2012 10 Task Description 115 TIM ...

Page 116: ...alve 6 Fuel prefilter Topping up with fuel 1 Stop engine Page 55 and disable engine start 2 Remove screws for cover and take off cover 2 3 Fill filter housing with clean fuel 4 Place new gasket in cover 2 5 Fit cover with gasket and secure it with screws 6 Check differential pressure Page 113 Result If flushing did not lead to an improvement of the differential pressure replace filter element of f...

Page 117: ... Diesel fuel Filter element Spare Parts Catalog Gasket Spare Parts Catalog WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Replacing filter element 1 Cut out filter to be drained I Left filter cut in II Right filter cut in MS150025 02E 2012 10 Task Description 117 TIM ID 0000004944 005 ...

Page 118: ...2 7 Remove spring housing 4 and filter ele ment 3 8 Insert new filter element 3 and spring housing 4 9 Fill filter housing with clean fuel 10 Place new gasket in cover 2 11 Fit cover with gasket and secure it with screws 12 Cut in the cut out filter again 13 Close threaded vent plug 5 when fuel emerges 14 Adjust the differential pressure gauge Page 113 118 Task Description MS150025 02E 2012 10 TIM...

Page 119: ...e 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 escapes 3 Clean drain bore s and blow out with compressed air 4 More significant coolant leakage indicates a leaking intercooler Contact Service 5 Install plug screw s with new sealing ring and tighten Emergency measures prior to engine start with a leakin...

Page 120: ...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 unit manufacturer 120 Task Description MS150025 02E 2012 10 TIM ID 0000005460 001 ...

Page 121: ...gnal ring position of service indicator if fitted 1 If the signal ring is completely visible in the control window 2 replace air filter Page 120 2 After installation of new filter press reset button 1 Result Engaged piston with signal ring moves back to initial position MS150025 02E 2012 10 Task Description 121 TIM ID 0000005481 001 ...

Page 122: ...heck Preconditions Engine is stopped and starting disabled Checking starter condition 1 Check securing screws of starter for secure seating and tighten if required 2 Check wiring Page 144 122 Task Description MS150025 02E 2012 10 TIM ID 0000000905 017 ...

Page 123: ...min and max marks 4 Top up to max if required Page 124 5 Insert oil dipstick into guide tube up to the stop Oil level check after the engine is stopped 1 5 minutes after stopping the engine remove oil dipstick from the guide tube and wipe it 2 Insert oil dipstick into guide tube up to the stop withdraw after approx 10 seconds and check oil level 3 Oil level must be between min and max marks 4 Top ...

Page 124: ...and 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 filter Page 125 Oil change with semirotary hand pump Oil extraction 1 Provide a suitable container to collect the oil 2 Extract all oil from oil pan using the semirotary hand pump 3 Replace engine oil filt...

Page 125: ...y mask Avoid contact with skin Do not inhale oil vapor CAUTION Damage to component Serious damage to plant For filter replacement with the engine running operate the engine at low engine load The filter which is to be exchanged must be cut out for a brief period only Oil filter replacement with the engine stopped 1 Stop engine Page 55 and disable en gine start 2 Remove oil filter using the filter ...

Page 126: ...rn switching lever to position B 2 Remove oil filter using the filter wrench 3 Clean the sealing face of the connecting piece 4 Check sealing ring of new oil filter and moisten it with oil 5 Install and tighten new oil filter by hand 6 Cut in the cut out filter Turn switching lever to position A 7 Replace other oil filters in the same way 8 Check oil level Page 123 126 Task Description MS150025 02...

Page 127: ...7 15 Coolant Circuit General High Temperature Circuit 7 15 1 Drain and venting points Top view 1 Engine coolant vent 2 Engine coolant vent MS150025 02E 2012 10 Task Description 127 TIM ID 0000006688 001 ...

Page 128: ...Left side 1 Engine coolant drain plug 2 Engine coolant drain plug 128 Task Description MS150025 02E 2012 10 TIM ID 0000006688 001 ...

Page 129: ...Right side 1 Engine oil drain plug heat exchanger 2 Engine coolant drain plug MS150025 02E 2012 10 Task Description 129 TIM ID 0000006688 001 ...

Page 130: ...Driving end KS 1 Engine coolant drain plug 2 Intercooler drain 3 Engine oil drain plug 130 Task Description MS150025 02E 2012 10 TIM ID 0000006688 001 ...

Page 131: ...sure to escape 2 Continue to turn breather valve counterclockwise and remove 3 Check engine coolant level coolant must be visible at the bottom edge of the filler neck s cast eye Checking engine coolant level at remote cooler 1 Check engine coolant level coolant must be visible at marker plate 2 Top up engine coolant if necessary Page 134 3 Check and clean breather valve 4 Place breather valve on ...

Page 132: ...ge Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant Change 1 Drain engine coolant Page 133 2 Fill with engine coolant Page 134 132 Task Description MS150025 02E 2012 10 TIM ID 0000000036 030 ...

Page 133: ...kwise until the first stop and allow pressure to escape 2 Continue to turn breather valve counter clockwise and remove 3 Draw off precipitated corrosion inhibitor oil from the expansion tank through filler neck 4 Open the drain valve at the drain point in the coolant pipe to the engine coolant cool er and drain the coolant see unit manufac turer 5 Draining of residual coolant At the preheating uni...

Page 134: ...ld coolant in hot engine can cause thermal stress Formation of cracks in components Fill top up coolant only into cold engine Preparatory steps 1 Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to escape 2 Continue to turn breather valve counter clockwise and remove Engine coolant Filling 1 Fill coolant through filler neck on expansion tank or th...

Page 135: ...inal steps 1 Start the engine and operate it at idle speed for some minutes 2 Check coolant level Page 131 top up with coolant if required MS150025 02E 2012 10 Task Description 135 TIM ID 0000000034 005 ...

Page 136: ... Check relief bore for oil and water dis charge 2 Permissible discharge Up to 10 drops of coolant per hour Up to 5 drops of oil per hour 3 If discharge exceeds the specified limits contact Service 4 If relief bore is dirty a Stop engine Page 55 and disable engine start b Clean relief bore with a wire c Start the engine Page 52 and oper ate it at idle speed for some minutes d Check relief bore agai...

Page 137: ...ective clothing gloves and goggles safety mask WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors CAUTION Cold coolant in hot engine can cause thermal stress Formation of cracks in components Fill top up coolant only into cold engine Preparatory steps 1 Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to escape 2 Cont...

Page 138: ...ing plate 2 Install plug screws of filling points with new sealing rings 3 Check proper condition of breather valve clean sealing faces if required 4 Fit breather valve and close it Final steps 1 Start the engine and operate it at idle speed for some minutes 2 Check coolant level Page 141 138 Task Description MS150025 02E 2012 10 TIM ID 0000000039 003 ...

Page 139: ...ockwise until the first stop and allow pressure to escape 3 Continue to turn breather valve counter clockwise and remove 4 Draw off precipitated corrosion inhibitor oil from the expansion tank through filler neck 5 Open the drain valve at the drain point in the coolant pipe to the charge air coolant cooler and drain the coolant see unit man ufacturer 6 Open drainage screw on the elbow of the charg...

Page 140: ...pecial tools Material Spare parts Designation Use Part No Qty Coolant Charge air coolant Change 1 Drain charge air coolant Page 139 2 Fill with charge air coolant Page 137 140 Task Description MS150025 02E 2012 10 TIM ID 0000000041 011 ...

Page 141: ...rclockwise 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 visible at marking plate 4 Top up coolant if necessary Page 137 5 Check proper condition of breather valve clean sealing faces if required 6 Fit breather valve and close it Checking charge air coolant level by means of level sensor 1 Switch ...

Page 142: ...uard is removed Item Findings Task Drive belt A Breaks in a few individual places None Drive belt Belt is oily shows signs of over heating Replace Drive belt B Breaks around the entire circum ference Drive belt C Areas of belt material missing 142 Task Description MS150025 02E 2012 10 TIM ID 0000003739 001 ...

Page 143: ...ipe rubber surface with dry cloth do not use organic detergents 2 Check resilient elements for crack formation and deformation by visual inspection 3 Have cracked elements replaced contact Service Setting dimension check 1 Measure setting dimension Dimension a 55 mm 2 If dimension a is less than 55 mm resilient elements must be replaced Contact Service MS150025 02E 2012 10 Task Description 143 TIM...

Page 144: ...annot swing freely 3 Check that cable ties are firm tighten loose cable ties 4 Replace faulty cable ties 5 Visually inspect the following electrical line components for damage connector housings contacts sockets cables and terminals plug in contacts 6 Contact Service if cable conductors are damaged Note Close male connectors that are not plugged in with the protective cap supplied 7 Clean dirty co...

Page 145: ...dirt from surface of connectors 1 connector sockets and shrink sleeves 2 using a cloth moistened with isopropyl alco hol 3 Check legibility of cable labels Clean or re place illegible labels Cleaning severely contaminated connectors on engine governor 1 Use connector pliers 2 to disengage bayo net union nut 4 and withdraw connec tor 3 2 Clean connector housings connector sock et housings 1 and all...

Page 146: ...f connectors 1 connector sockets and shrink sleeves 2 using a cloth moistened with isopropyl alco hol 3 Check legibility of cable labels Clean or re place illegible labels Cleaning severely contaminated EMU connectors 1 Use connector pliers 2 to disengage bayo net union nut 4 and withdraw connector 3 2 Clean connector housings connector sock et housings 1 and all contacts with iso propyl alcohol 3...

Page 147: ...plug connections 1 Use connector pliers 3 to make certain that all plug in connections on engine con trol unit are securely seated 2 Tighten loose bayonet couplings 2 with connector pliers 3 by turning them clock wise until they latch into place 3 Make sure that unassigned sockets are closed off with cover caps 4 Contact Service if bayonet union nut is de fective MS150025 02E 2012 10 Task Descript...

Page 148: ...it plug connections 1 Use connector pliers 3 to make certain that all engine monitoring unit plug connec tions are securely seated 2 Tighten loose bayonet union nuts 2 with connector pliers 3 by turning them clock wise until they lock into place 3 Make sure that unassigned sockets are closed off with cover caps 4 If bayonet couplings are defective contact Service 148 Task Description MS150025 02E ...

Page 149: ...5483 1 Covering caps for Cannon sockets Removing control unit from engine 1 Note or mark assignment of cables to con nector sockets 2 Use connector pliers 2 to disengage the bayonet union nuts 4 of the connectors 3 by turning them counterclockwise 3 Remove all connectors 4 Close connector sockets with appropriate covering caps 1 MS150025 02E 2012 10 Task Description 149 TIM ID 0000008487 004 ...

Page 150: ...he screws 4 are not easily accessible 1 Unscrew screws 1 2 Remove engine control unit housing 3 together with mounting plates 2 3 Unscrew cable shock absorbers 5 and further fastening parts 6 as one unit from engine Installing engine control unit on engine 1 Install in reverse order Ensure correct assignment of plugs and sockets 2 Use connector pliers to turn the bayonet union nuts of the connecto...

Page 151: ...tch master power switch to OFF 3 Disconnect battery in accordance with battery manufacturer s instructions Checking housing and internal assemblies for secure seating 1 Open LOP front door 2 Check securing screws 1 3 4 7 for firm seating Tighten loose threaded connec tions 3 Check internal assemblies for firm seating this applies in particular to printed circuit board 2 and PIMs 5 6 Tighten loose ...

Page 152: ...gaged in the lugs 2 so that the covering cap 3 is held firmly in place in the socket 3 If this is not the case press the securing el ements 1 concerned in the direction of the arrow until they engage noticeably Checking pushbuttons and display 1 Pushbuttons Ensure that Pushbutton caps are not damaged cracks or similar damage Pushbuttons move easily Pushbutton housings are seated secure ly Seals 2 ...

Page 153: ...rer s instructions 2 Switch master power switch to ON 3 Switch on engine control system 4 Hold down LAMP TEST pushbutton Result Indicators and controls light up 5 Have damaged lamps immediately replaced by Service MS150025 02E 2012 10 Task Description 153 TIM ID 0000008868 005 ...

Page 154: ...l control mode is active Switching between Local and Remote mode automatic on board network 1 Press LOCAL OPERATION pushbutton 1 Result LOCAL OPERATION pushbutton 1 flashes Setting does not correspond with feedback signal from Engine Control Unit LOCAL OPERATION pushbutton 1 is illuminated at basic brightness Remote mode active 2 Press LOCAL OPERATION pushbutton 1 again Result LOCAL OPERATION push...

Page 155: ...ress ALARM ACKNOWLEDGE pushbut ton 1 again Result Power supply to Engine Control Unit is pro vided 4 On engines with emergency air shutoff flaps Open flaps Emergency stop simulation with the engine at standstill 1 Open cap of EMERGENCY STOP pushbut ton 2 2 Press EMERGENCY STOP pushbutton 2 Result Engine Control Unit is deenergized by the safety system Engine governing is completely deacti vated On...

Page 156: ...nputs BE1 to BE9 1 Engine Control Unit ECU 4 Function Function Source Acquisition of binary signals Switches pushbuttons monitors contacts Channel specification Type Isolated binary input external supply Input signal UIn high 24 V min 8 V UIn low 0 V max 4 V 156 Engine Governor Assignment and Circuitry MS150025 02E 2012 10 TIM ID 0000009437 001 ...

Page 157: ...el specification Measuring range IIn 4 to 20 mA Load At 20 mA approx 4 V iso lated Or UIn 0 to 10 V Binary sensor input NSE 1 1 Monitor contact 2 Engine Control Unit ECU 4 Function Function Source Lube oil differential pressure monitoring Lube oil differential pressure monitor MS150025 02E 2012 10 Engine Governor Assignment and Circuitry 157 TIM ID 0000009437 001 ...

Page 158: ...gle and crankshaft speed Inductive sensor NW1 Measuring of camshaft angle and camshaft speed Inductive sensor Speed measuring input DME 1 DME 2 1 Inductive sensor 2 Engine Control Unit ECU 4 Function Sensor Measuring of speeds e g ETC Inductive sensor 158 Engine Governor Assignment and Circuitry MS150025 02E 2012 10 TIM ID 0000009437 001 ...

Page 159: ...gas temperatures are measured with Pt100 Pressure inputs DE 1 to DE 7 1 Pressure sensor 2 Engine Control Unit ECU 4 Function Function Sensor Pressure range measuring Relative pressure sensors exception The charge air pressure sensor is an absolute pressure sen sor MS150025 02E 2012 10 Engine Governor Assignment and Circuitry 159 TIM ID 0000009437 001 ...

Page 160: ...P pump DEH rail pressure 1 Pressure sensor 2 Engine Control Unit ECU 4 Function Function Sensor Pressure measuring Relative pressure sensor Measuring channel specification Measuring range Sensor dependent Output signal UO 0 5 to 4 5 VDC Sensor supply 5 V 250 mV 160 Engine Governor Assignment and Circuitry MS150025 02E 2012 10 TIM ID 0000009437 001 ...

Page 161: ...tput Plant Channel specification Channel TAA1 to TAA6 positive switching 24 VDC Output current TAA1 to TAA4 lO 150 mA max TAA5 lO 300 mA max TAA6 lO 1 A max Voltage outputs UA 1 to UA 4 1 Engine Control Unit ECU 4 MS150025 02E 2012 10 Engine Governor Assignment and Circuitry 161 TIM ID 0000009437 001 ...

Page 162: ...ification Output voltage UO 0 to 10 V Output current lO 5 mA max 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 4 162 Engine Governor Assignment and Circuitry MS150025 02E 2012 10 TIM ID 0000009437 001 ...

Page 163: ...on 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 Function Target CAN1 CAN2 Bus connection to external sys tems MCS MS150025 02E 2012 10 Engine Governor Assignment and Circuitry 163 TIM ID 0000009437 001 ...

Page 164: ...ud Electrical isolation 50 V The CAN bus interfaces operate independently of each other Serial interface RS232 1 Dialog unit 2 Connector XC6 3 Engine Control Unit ECU 4 4 Dialog cable Channel Function Target RS232 Serial interface for data transmis sion between dialog unit and en gine governor Dialog unit 164 Engine Governor Assignment and Circuitry MS150025 02E 2012 10 TIM ID 0000009437 001 ...

Page 165: ...e input polarity BE1 Stop input This input is inverted line break protected i e 24 V DC must always be applied to BE1 for engine operation BE2 Cylinder cutout The cylinder cutout function is deactivated via this input BE3 SISY override Activating BE8 suppresses all VDS operation shut down messages such as Lube oil pressure too low The corresponding outputs such as Com bined alarm red are still set...

Page 166: ...too low Analog MDEC inputs IEU1 0 to 10 V or 4 to 20 mA It is possible to activate different analog desired speed settings for the MDEC governor Default setting Characteristic curve 71 50 Hz in MDEC gover nor 0 to 10 V activated Parameterized desired speed setting 4 to 20 mA must be changed if desired Same applies to characteristic curve 72 60 Hz 166 Engine Governor Assignment and Circuitry MS1500...

Page 167: ...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_ISO b 5 V 20 mA electrically isolated IUE2 U_IN r 0 V to 10 V IUE2 I_IN A 0 V to 23 7 mA IUE2 GND_ISO W UA1 OUT HH 0 V to 10 V 8 mA UA1 GND GG UA2 OUT DD 0 V to 10 V 8 mA UA2 GND CC UA3 OUT t 0 V to 10 V 8 mA UA3 GND s MS150025 02E 2012 10 Engine Governor Assignment and Circuit...

Page 168: ...IN v U 4 V low U 8 V high BE6 IN u Electrically isolated BE7 IN f U 4 V low U 8 V high BE7 IN e Electrically isolated BE8 IN d U 4 V low U 8 V high BE8 IN c Electrically isolated BE9 IN N U 4 V low U 8 V high BE9 IN M Electrically isolated FE1 GND J U 1 5 V low U 3 5 V high FE1 IN H Frequency input TAA1 GND V 24 V 600 mA TAA1 GND U TAA2 OUT p 24 V 600 mA TAA2 GND n TAA3 OUT T 24 V 600 mA TAA3 GND ...

Page 169: ... VPT 06 GSE 22 55 PW Target Engine wiring harness Pin assignment Channel Signal Pin Comments TE1 IN k 0 V to 5 V internal 2 k0 pullup to 5 V_TE_BUF TE1 GND z TE2 IN N 0 V to 5 V internal 2 k0 pullup to 5 V_TE_BUF TE2 GND P TE5 IN M 0 V to 5 V internal 2 k0 pullup to 5 V_TE_BUF TE5 GND g TE6 IN y 0 V to 5 V internal 2 k0 pullup to 5 V_TE_BUF TE6 GND FF MS150025 02E 2012 10 Engine Governor Assignmen...

Page 170: ...E3 IN GG 0 V to 5 V inter nal 47k5 pulldown DE3 GND HH DE4 5 V_BUF2 d 5 V 20 mA DE4 IN H 0 V to 5 V inter nal 47k5 pulldown DE4 GND J DE5 5 V_BUF3 f 5 V 20 mA DE5 IN v 0 V to 5 V inter nal 47k5 pulldown DE5 GND e DE6 5 V_BUF3 EE 5 V 20 mA DE6 IN DD 0 V to 5 V inter nal 47k5 pulldown DE6 GND u DE7 5 V_BUF4 c 5 V 20 mA DE7 IN G 0 V to 5 V inter nal 47k5 pulldown DE7 GND b NSE1 24 V_NSE1 X Sensor sup...

Page 171: ...U 400 mV low U 400 mV high DME1 IN AA DME2 IN A U 400 mV low U 400 mV high DME2 IN U PDM1 OUT K 24 V 3 A PDM1 GND L TAM1 OUT R 24 V 1 5 A TAM1 GND j 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 Pin assignment MS150025 02E 2012 10 Engine Governor Assignment and Circuitry 171 TIM ID 0000009431 001 ...

Page 172: ...down DE8 GND K DEH 5 V_BUF5 B 5 V 20 mA DEH IN T 0 V to 5 V inter nal 47k5 pulldown TP2 20 Hz DEH GND C NSE3 24 V_NSE3 A Sensor supply max 300 mA NSE3 IN R 0 V to 5 V internal 47k5 pullup to 5 V_TE_BUF NSE3 GND S PDM2 OUT M 24 V 3 A PDM2 GND N TAM3 OUT L 24 V 1 5 A TAM3 GND Z TAM4 OUT P 24 V 1 5 A TAM4 GND a EDM TXD X RS232 EDM RXD H RS232 EDM GND F RS232 TA_EDM 24 V_OUT G EDM supply 2 A TA_EDM GN...

Page 173: ...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 20 A MV5 LOW G Bank 1 MV6 HIGH s 24 V 20 A MV6 LOW r Bank 1 MV7 HIGH Y 24 V 20 A MV7 LOW X Bank 1 MV8 HIGH W 24 V 20 A MV8 LOW V Bank 1 MV9 HIGH k 24 V 20 A MV9 LOW j Bank 1 MV10 HIGH B 24 V 20 A MV10 LOW A Bank 1 MV11 HIGH S 24 V 20 A MS150025 02E 2012 10 Engine Governor Assignment and Circuit...

Page 174: ...HIGH K 24 V 20 A MV16 LOW J Bank 2 MV17 HIGH M 24 V 20 A MV17 LOW L Bank 2 MV18 HIGH e 24 V 20 A MV18 LOW d Bank 2 MV19 HIGH c 24 V 20 A MV19 LOW b Bank 2 MV20 HIGH q 24 V 20 A MV20 LOW p Bank 2 Connector X5 view to socket Connector X5 Connector type CIR 06 G2 18 11 S Target Plant wiring harness power supply Pin assignment 174 Engine Governor Assignment and Circuitry MS150025 02E 2012 10 TIM ID 00...

Page 175: ... E 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 GND C POWER GND E MS150025 02E 2012 10 Engine Governor Assignment and Circuitry 175 TIM ID 0000009431 001 ...

Page 176: ...as soon as possible 2nd function Read out fault codes CKT Circuit CLS Coolant level sensor CPS Coolant pressure sensor CTS Coolant temperature sensor DDEC Detroit Diesel Electronic Controls Engine control system made by Detroit Diesel DDL Diagnostic Data Link DDR Diagnostic Data Reader DIN Deutsches Institut für Normung e V At the same time identifier of German standards DIN Deutsche Industrie Nor...

Page 177: ...d in accordance with DIN ISO 1204 KS Kraftseite Engine driving end in accordance with DIN ISO 1204 LED Light Emitting Diode LO Low Alarm Measured value lower than 1st minimum limit value LOLO Low Low Alarm Measured value lower than 2nd minimum limit value LSG Limiting Speed Governor N A Not Applicable LP Low pressure OEM Original Equipment Manufacturer OI Optimized Idle OLS Oil Level Sensor OPS Oi...

Page 178: ... air pressure TCI Turbo Compressor Inlet TCO Turbo Compressor Outlet TD Transmitter Deviation Alarm Deviation in transmitter values TPS Throttle Position Sensor TRS Timing Reference Sensor T xyz Temperature xyz Temperature measuring point xyz specifies the measuring point designation UT Unterer Totpunkt Bottom dead center BDC VNT Variable nozzle turbine VSG Variable speed governor VSS Vehicle Spee...

Page 179: ...ou either during operation for preventive maintenance corrective work in case of malfunction or changed operating conditions or for spare parts supply Your contact at Headquarters Service support mtu online com Spare parts service Fast simple and correct identification of spare parts for your drive system or vehicle fleet The right spare part at the right time at the right place With this aim in m...

Page 180: ...7 1 2 Engine Barring with starting system Page 85 Qty Used in 1 7 20 1 Engine governor and connectors Cleaning Page 145 Qty Used in 1 7 20 2 Engine monitoring unit and connectors Clean ing Page 146 Qty Used in 1 7 20 3 Checking engine control unit plug connections Page 147 Qty Used in 1 7 20 4 Engine monitoring unit Plug connection check Page 148 Qty Used in 1 7 20 5 Engine control unit Removal an...

Page 181: ...art No F30027425 Qty Used in 1 7 5 2 Injection pump Removal and installation Page 99 Qty Used in 1 7 6 2 Injector Removal and installation Page 103 Double box wrench Part No F30011450 Qty Used in 1 7 6 2 Injector Removal and installation Page 103 Extractor Part No F30377999 Qty Used in 1 7 6 2 Injector Removal and installation Page 103 MS150025 02E 2012 10 Appendix B 181 DCL ID 0000009057 002 ...

Page 182: ...Fuel filter Replacement Page 110 Qty Used in 1 7 14 1 Engine oil filter Replacement Page 125 Fuel suction device Part No F30378207 Qty Used in 1 7 6 2 Injector Removal and installation Page 103 Measuring device Part No Y4341106 Qty Used in 1 7 4 1 Valve clearance Check and adjustment Page 95 182 Appendix B MS150025 02E 2012 10 DCL ID 0000009057 002 ...

Page 183: ...Qty Used in 1 7 4 1 Valve clearance Check and adjustment Page 95 Qty Used in 1 7 5 2 Injection pump Removal and installation Page 99 Qty Used in 1 7 6 2 Injector Removal and installation Page 103 Rigid endoscope Part No Y20097353 Qty Used in 1 7 2 1 Cylinder liner Endoscopic examination Page 87 Socket wrench Part No F30025897 Qty Used in 1 7 6 2 Injector Removal and installation Page 103 MS150025 ...

Page 184: ...installation Page 99 Torque wrench 20 100 Nm Part No F30026582 Qty Used in 1 7 6 2 Injector Removal and installation Page 103 Torque wrench 20 100 Nm Part No F30026582 Qty Used in 1 7 4 1 Valve clearance Check and adjustment Page 95 Qty Used in 1 7 5 2 Injection pump Removal and installation Page 99 184 Appendix B MS150025 02E 2012 10 DCL ID 0000009057 002 ...

Page 185: ...t Page 93 Torque wrench 8 40 Nm Part No F30043446 Qty Used in 1 7 4 2 Cylinder head cover Removal and installation Page 97 Transition piece Part No F30006234 Qty Used in 1 7 5 2 Injection pump Removal and installation Page 99 Qty Used in 1 7 6 2 Injector Removal and installation Page 103 MS150025 02E 2012 10 Appendix B 185 DCL ID 0000009057 002 ...

Page 186: ...e of devices 25 ECU alarms 73 Emergency stop 56 Engine Test run 86 Wiring check 144 Engine control unit Removal and installation 149 Engine coolant Change 132 Filling 134 Level check 131 Engine coolant Draining 133 Engine governor Cleaning 145 Engine governor channel circuitry 156 Engine layout 16 Engine monitoring unit Cleaning 146 Plug connection check 148 Engine mounts Resilient elements check ...

Page 187: ...6 Plant Cleaning 59 Printed circuit board SCB 3 35 Provisions 5 Putting the engine into operation after extended out of service periods 3 months 50 Putting the engine into operation after scheduled out of service period 51 R Repair work Safety regulations 8 S Safety messages Standards 13 Safety regulations 8 Safety system Override 53 SAM 43 SCB 3 Printed circuit board 35 Technical data 47 Service ...

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MTU 12 V 2000 P12, Operating Instructions Manual

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