MTU 12V2000Gx6 series Operating Instructions Manual Download

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Operating Instructions

Diesel engine

12V2000Gx6x
16V2000Gx6x

MS15054/03E

Summary of Contents for 12V2000Gx6 series

Page 1: ...Operating Instructions Diesel engine 12V2000Gx6x 16V2000Gx6x MS15054 03E ...

Page 2: ...0G76S 68 6 kW cyl 3D standby power fuel stop power IFN 3H mains backup mode special qualifications 16V2000G86S 85 7 kW cyl 3D standby power fuel stop power IFN 3H mains backup mode special qualifications Table 1 Applicability 2018 Copyright MTU Friedrichshafen GmbH This publication is protected by copyright and may not be used in any way whether in whole or in part without the prior writ ten conse...

Page 3: ...a 12V 16V2000Gx6S 3F mains backup mode unlimited ICXN EPA Nonroad T2 40CFR89 and EPA Stationary EMERG T2 40CFR60 52 4 9 Product data 12V 16V2000Gx6S 3G continuous operation time limited ICXN EPA Nonroad T2 40CFR89 56 4 10 Product data 12V 16V2000Gx6S 3H mains backup mode special qualification EPA Nonroad T2 40CFR89 and EPA Stationary EMERG T2 40CFR60 59 4 11 Firing order 63 4 12 Engine Main dimens...

Page 4: ...69 8 14 1 Engine coolant Level check 169 8 14 2 Engine coolant Change 170 8 14 3 Engine coolant Draining 171 8 14 4 Engine coolant Filling 172 8 14 5 Engine coolant pump Relief bore check 174 8 14 6 Engine coolant Sample extraction and analysis 175 8 15 Low Temperature Circuit 176 8 15 1 Charge air coolant Filling 176 8 15 2 Charge air coolant Draining 178 8 15 3 Charge air coolant Change 179 8 15...

Page 5: ... Governor Control System 222 8 22 1 Engine governor and connector Cleaning 222 9 Appendix A 9 1 List of abbreviations 223 9 2 MTU Contact Service Partners 225 10 Appendix B 10 1 Special Tools 226 10 2 Index 236 MS15054 03E 2018 07 Table of Contents 5 DCL ID 0000037216 007 ...

Page 6: ...uct are prohibited by emission regulations Emission related components must only be serviced ex changed or repaired if the components used for this purpose are approved by the manufacturer Noncompliance with these specifications will invalidate the design type approval or certification issued by the emissions regulation authorities The manufacturer does not accept any liability for violations of t...

Page 7: ...ased military applications other than by US government agen cies Please note the following when replacing components with emission labels The relevant emission labels must be affixed to the spare part Emission labels shall not be transferred from the replaced part to the spare part The emission labels must be removed from the replaced part and destroyed MS15054 03E 2018 07 Safety 7 TIM ID 00000405...

Page 8: ...tions contained in this manual in particular with regard to the specified tightening torques With the exclusive use of technical personnel trained in commissioning operation maintenance and re pair The product must not be operated in explosive atmospheres unless the engine fulfills the conditions for such use and approval has been granted Any other use particularly misuse is considered as being co...

Page 9: ...qualified personnel only Training at the Training Center of the manufacturer Qualified personnel from the areas mechanical engineering plant construction and electrical engineering and also for work with live parts The operator must define the responsibilities of the personnel involved in operation maintenance repair as sembly installation and transport in writing Personnel shall not report for du...

Page 10: ...rator terminals or cables against accidental contact Check that all connections have been correctly allocated e g polarity fuel line reduction agent line supply return Immediately after putting the product into operation make sure that all control and display instruments as well as the monitoring signaling and alarm systems work properly Smoking is prohibited in the area of the product Safety regu...

Page 11: ...uids and lubricants immediately or soak up with a suitable binding agent Operation of electrical equipment When electrical equipment is in operation certain components of these appliances are electrically live Follow the applicable operating and safety instructions when operating the devices and heed warnings at all times MS15054 03E 2018 07 Safety 11 TIM ID 0000040533 020 ...

Page 12: ...f fitted Lock circuit breakers Before starting work on CaPoS if used Switch off the charging system DC DC converter Discharge the UltraCap modules using the appropriate discharger Short circuit the UltraCap modules with a suitable wire jumper Close the main valve on the compressed air system and vent the compressed air line when air starters are fitted Before working on the exhaust gas aftertreatm...

Page 13: ...lines near hot components Miscellaneous Sufficient ventilation must be guaranteed during the work Wear a breathing mask offering protection against soot dust and mineral fibers filter class P3 when work ing on exhaust components Clean the work area with a dust extraction machine of class H Wear protective gloves and goggles for protection against acidic condensate Do not touch elastomeric seals e ...

Page 14: ...nd the pipework at the relevant designated points For hydraulic installation screw on the jig with the piston retracted For hydraulic removal screw on the jig with the piston extended For a hydraulic installation removal jig with central expansion pressure supply screw spindle into shaft end until correct sealing is established During hydraulic installation and removal of components ensure that no...

Page 15: ...erly prior to replacement i e protect them against moisture in particular Package faulty electronic components or assemblies properly before dispatching for repair Moisture proof Shock proof Wrapped in antistatic foil as necessary Working with laser equipment Work with laser devices shall be carried out by trained and qualified personnel only Follow the safety in structions in the manufacturer s u...

Page 16: ...nsure that suitable extinguishing agents fire extinguishers are always available and that staff are familiar with their correct handling A fire can result in the creation of toxic substances Always wear protective gloves when handling compo nents and wear additional personal protective equipment is necessary Noise Wear ear protectors in workplaces with a sound pressure level in excess of 85 dB A N...

Page 17: ...is well ventilated Make sure that neighboring work areas are not adversely affected Avoid open flames in the surrounding area No smoking Observe fire prevention regulations Always wear a mask providing protection against paint and solvent vapors Liquid nitrogen Observe the relevant safety data sheet for all materials Work with liquid nitrogen may be carried out only by qualified personnel Store li...

Page 18: ...t Consequences Material damage Remedial action Additional product information Warning notices 1 This manual with all safety instructions and warning notices must be issued to all personnel involved in oper ation maintenance repair assembly installation or transportation 2 The highest level warning notice is used if several hazards apply at the same time Warnings related to per sonal injury shall b...

Page 19: ...ny loose parts on the system engine generator 7 Always raise lower the engine slowly The lifting ropes or chains must not butt against the engine or its com ponents during the lifting procedure Readjust lifting tackle as necessary 8 Special packaging with aluminum foil Attach engine at the lifting eyes of the bearing pedestal or transport the engine with means of transport suitable for the load fo...

Page 20: ...ignated in accordance with DIN ISO 1204 as viewed from driving end 4 For cylinder designation in accordance with DIN ISO 1204 the letter Ax refers to the cylinders on the left hand side of the engine 1 and letter Bx refers to the cylinders on the right hand side 3 The cylinders of each bank are numbered consecutively starting with x 1 at driving end 4 The numbering of other engine components also ...

Page 21: ...uel system 10 Fuel filter 11 Exhaust turbocharger 12 HP fuel system 13 Starting equipment KS Driving end Key to the engine model designation 12 16 Number of cylinders V Cylinder arrangement Vee engine 2000 Series G Application G decentralized energy systems engineer ing x Application segment 0 1 2 9 6 Design index 0 1 2 9 S Additional feature S 60 Hz Table 2 Key to the engine model designation MS1...

Page 22: ... and actuators Driving end The following overviews are also applicable to 12V engines Item Name Monitoring of 1 B3 Intake air temperature Table 3 Sensors and actuators Driving end 22 General Information MS15054 03E 2018 07 TIM ID 0000060374 002 ...

Page 23: ...nitoring of 1 B5 1 Oil pressure after oil filter 2 B7 Oil temperature 3 B48 1 HP fuel system pressure A side 4 M8 1 Fuel pump pressure A side Table 4 Sensors and actuators A side MS15054 03E 2018 07 General Information 23 TIM ID 0000060374 002 ...

Page 24: ...nsors and actuators Free end Item Name Monitoring of 1 B5 3 Oil pressure before oil filter optional Table 5 Sensors and actuators Free end 24 General Information MS15054 03E 2018 07 TIM ID 0000060374 002 ...

Page 25: ...emperature 6 B6 Coolant temperature 7 A19 EIL electronic label 8 B26 Coolant temperature 9 XF46 Leak fuel level optional 10 M8 2 Fuel pump pressure B side 11 B34 3 Fuel pressure after intermediate filter stage optional 12 B34 2 Fuel pressure before main filter stage optional 13 B1 Camshaft speed 14 B13 Crankshaft speed 15 B48 2 HP fuel system pressure B side Table 6 Sensors and actuators B side MS...

Page 26: ...e not sufficiently guaranteed tolerance 10 Value not sufficiently guaranteed tolerance 5 ID Product type Application Speed Nominal pow er 1 12V2000G16S Power generation 3B continuous opera tion variable load ICXN 1800 rpm 60 Hz 716 kW 960 bhp Ref 25 C 55 C Wa ter charge air cooling external Optimized fuel con sumption 2 12V2000G26S Power generation 3B continuous opera tion variable load ICXN 1800 ...

Page 27: ...gement V angle Degrees 90 90 90 90 Bore mm 135 135 135 135 Stroke mm 156 156 156 156 Displacement cylinder Liters 2 233 2 233 2 233 2 233 Total displacement Liters 26 8 26 8 26 8 35 7 Compression ratio 16 16 16 16 Cylinder heads individual cylinder heads X X X X Cylinder liners wet replaceable X X X X Number of inlet valves per cylinder 2 2 2 2 Number of exhaust valves per cylinder 2 2 2 2 Standar...

Page 28: ...L C 103 103 103 103 Lube oil temperature before engine limit 2 L C 105 105 105 105 Lube oil operating pressure before en gine from R bar 6 5 6 5 6 5 6 5 Lube oil operating pressure before en gine to R bar 9 5 9 5 9 5 9 5 Lube oil operating pressure before en gine warning L bar 5 5 5 5 5 5 5 5 Lube oil operating pressure before en gine shutdown L bar 5 0 5 0 5 0 5 0 General operating data ID 1 2 3 ...

Page 29: ...ensions ID 1 2 3 4 Engine weight dry basic engine configu ration acc to scope of delivery specifica tion R kg 2710 2710 2710 3180 Acoustics ID 1 2 3 4 Exhaust noise not attenuated DL sound power level LW ISO 6798 3 dB A tolerance R dB A 128 130 130 131 Engine surface noise with attenuated in take noise filter DL sound power level LW ISO 6798 2 db A tolerance R dB A 125 122 123 123 MS15054 03E 2018...

Page 30: ...ot sufficiently guaranteed tolerance 10 Value not sufficiently guaranteed tolerance 5 ID Product type Application Speed Nominal pow er 1 12V2000G76S Power generation 3D standby current fuel stop power IFN 1800 rpm 60 Hz 890 kW 1193 bhp Ref 25 C 55 C Wa ter charge air cooling external Optimized fuel con sumption 2 12V2000G86S Power generation 3D standby current fuel stop power IFN 1800 rpm 60 Hz 98...

Page 31: ...od direct fuel injection X X X X Cooling method conditioned water X X X X Direction of rotation c c w facing driv ing end X X X X Cylinder arrangement V angle Degrees 90 90 90 90 Bore mm 135 135 135 135 Stroke mm 156 156 156 156 Displacement cylinder Liters 2 233 2 233 2 233 2 233 Total displacement Liters 26 8 26 8 35 7 35 7 Compression ratio 16 16 16 16 Cylinder heads individual cylinder heads X...

Page 32: ... 1 2 3 4 Lube oil operating temperature before engine from R C 75 75 75 75 Lube oil operating temperature before engine to R C 100 100 100 100 Lube oil temperature before engine limit 1 L C 103 103 103 103 Lube oil temperature before engine limit 2 L C 105 105 105 105 Lube oil operating pressure before en gine from R bar 6 5 6 5 6 5 6 5 Lube oil operating pressure before en gine to R bar 9 5 9 5 9...

Page 33: ...14 114 Oil change quantity max standard oil system option max operating inclina tions R Liters 80 80 102 102 Oil pan capacity at dipstick mark min standard oil system R Liters 65 65 88 88 Oil pan capacity at dipstick mark max standard oil system R Liters 70 70 94 94 Weights main dimensions ID 1 2 3 4 Engine weight dry basic engine configu ration acc to scope of delivery specifica tion R kg 2710 27...

Page 34: ... value Actual value must be lower than specified value Value not sufficiently guaranteed tolerance 10 Value not sufficiently guaranteed tolerance 5 ID Product type Application Speed Nominal pow er 1 12V2000G26S Power generation 3F standby operation mode unlimited ICXN 1800 rpm 60 Hz 810 kW 1086 bhp Ref 25 C 55 C Wa ter charge air cooling external Optimized fuel con sumption 2 16V2000G26S Power gen...

Page 35: ...ust valves per cylinder 2 2 Standard housing connecting flange engine main PTO side SAE 0 0 Flywheel connection DISC 18 18 Air exhaust ID 1 2 Charge air pressure before cylinder DL R bar abs 3 0 2 8 Coolant system HT circuit ID 1 2 Coolant temperature at engine connection outlet to cooling equipment A C 100 100 Coolant temperature after engine limit 1 L C 102 102 Coolant temperature after engine l...

Page 36: ...ase A R C 0 0 Coolant preheating preheating temperature min L C 32 32 Firing speed from R rpm 100 100 Firing speed to R rpm 120 120 Capacities ID 1 2 Engine coolant capacity engine side without cooling equipment R Liters 63 70 Charge air coolant engine side R Liters 20 25 Engine oil capacity initial filling standard oil system option max operating inclinations R Liters 92 114 Oil change quantity m...

Page 37: ...d value Actual value must be lower than specified value Value not sufficiently guaranteed tolerance 10 Value not sufficiently guaranteed tolerance 5 ID Product type Application Speed Nominal pow er 1 12V2000G26S Power generation 3G continuous opera tion time limited ICXN 1800 rpm 60 Hz 810 kW 1086 bhp Ref 25 C 55 C Wa ter charge air cooling external Optimized fuel con sumption 2 16V2000G26S Power ...

Page 38: ...ust valves per cylinder 2 2 Standard housing connecting flange engine main PTO side SAE 0 0 Flywheel connection DISC 18 18 Air exhaust ID 1 2 Charge air pressure before cylinder DL R bar abs 3 0 2 8 Coolant system HT circuit ID 1 2 Coolant temperature at engine connection outlet to cooling equipment A C 100 100 Coolant temperature after engine limit 1 L C 102 102 Coolant temperature after engine l...

Page 39: ...ase A R C 0 0 Coolant preheating preheating temperature min L C 32 32 Firing speed from R rpm 100 100 Firing speed to R rpm 120 120 Capacities ID 1 2 Engine coolant capacity engine side without cooling equipment R Liters 63 70 Charge air coolant engine side R Liters 20 25 Engine oil capacity initial filling standard oil system option max operating inclinations R Liters 92 114 Oil change quantity m...

Page 40: ... than specified value Value not sufficiently guaranteed tolerance 10 Value not sufficiently guaranteed tolerance 5 ID Product type Application Speed Nominal pow er 1 12V2000G76S Power generation 3H standby operation mode special qualifi cations 1800 rpm 60 Hz 890 kW 1193 bhp Ref 25 C 55 C Wa ter charge air cooling external Optimized fuel con sumption 2 16V2000G76S Power generation 3H standby opera...

Page 41: ...ent cylinder Liters 2 233 2 233 2 233 Total displacement Liters 26 8 35 7 35 7 Compression ratio 16 16 16 Cylinder heads individual cylinder heads X X X Cylinder liners wet replaceable X X X Number of inlet valves per cylinder 2 2 2 Number of exhaust valves per cylinder 2 2 2 Standard housing connecting flange engine main PTO side SAE 0 0 0 Flywheel connection DISC 18 18 18 Air exhaust ID 1 2 3 Ch...

Page 42: ...el pressure at engine inlet connection min when engine is starting L bar Fuel pressure at engine inlet connection max when engine is starting absolute pressure L bar abs 1 5 1 5 1 5 General operating data ID 1 2 3 Cold start capability air temperature w o start aid w o preheating case A R C 0 0 0 Coolant preheating preheating temperature min L C 32 32 32 Firing speed from R rpm 100 100 100 Firing ...

Page 43: ...g 2710 3180 3180 Acoustics ID 1 2 3 Exhaust noise not attenuated DL sound power lev el LW ISO 6798 3 dB A tolerance R dB A 130 132 134 Engine surface noise with attenuated intake noise fil ter DL sound power level LW ISO 6798 2 db A tolerance R dB A 122 124 125 MS15054 03E 2018 07 Technical Data 43 TIM ID 0000065015 004 ...

Page 44: ...ciently guaranteed tolerance 10 Value not sufficiently guaranteed tolerance 5 ID Product type Application Speed Nominal pow er 1 12V2000G16S Power generation 3B continuous opera tion variable load ICXN 1800 rpm 60 Hz 716 kW 960 bhp Ref 25 C 45 C Wa ter charge air cooling external EPA Nonroad T2 Comp 40CFR89 2 12V2000G26S Power generation 3B continuous opera tion variable load ICXN 1800 rpm 60 Hz 8...

Page 45: ...gement V angle Degrees 90 90 90 90 Bore mm 135 135 135 135 Stroke mm 156 156 156 156 Displacement cylinder Liters 2 233 2 233 2 233 2 233 Total displacement Liters 26 8 26 8 26 8 35 7 Compression ratio 16 16 16 16 Cylinder heads individual cylinder heads X X X X Cylinder liners wet replaceable X X X X Number of inlet valves per cylinder 2 2 2 2 Number of exhaust valves per cylinder 2 2 2 2 Standar...

Page 46: ...L C 103 103 103 103 Lube oil temperature before engine limit 2 L C 105 105 105 105 Lube oil operating pressure before en gine from R bar 6 5 6 5 6 5 6 5 Lube oil operating pressure before en gine to R bar 9 5 9 5 9 5 9 5 Lube oil operating pressure before en gine warning L bar 5 5 5 5 5 5 5 5 Lube oil operating pressure before en gine shutdown L bar 5 0 5 0 5 0 5 0 General operating data ID 1 2 3 ...

Page 47: ...sions ID 1 2 3 4 Engine weight dry basic engine configu ration acc to scope of delivery specifica tion R kg 2710 2710 2710 3180 Acoustics ID 1 2 3 4 Exhaust noise not attenuated DL sound power level LW ISO 6798 3 dB A tolerance R dB A X 129 130 130 133 Engine surface noise with attenuated in take noise filter DL sound power level LW ISO 6798 2 db A tolerance R dB A X 123 123 122 124 MS15054 03E 20...

Page 48: ...Actual value must be lower than specified value Value not sufficiently guaranteed tolerance 10 Value not sufficiently guaranteed tolerance 5 ID Product type Application Speed Nominal pow er 1 12V2000G76S Power generation 3D standby current fuel stop power IFN 1800 rpm 60 Hz 890 kW 1193 bhp Ref 25 C 45 C Wa ter charge air cooling external EPA Nonroad T2 40CFR89 EPA Nonroad T2 Comp 40CFR89 2 12V2000...

Page 49: ...r cooling intercooler X X X X Uncooled exhaust lines X X X X Operating method Four stroke cycle diesel single action X X X X Combustion method direct fuel injection X X X X Cooling method conditioned water X X X X Direction of rotation c c w facing driv ing end X X X X Cylinder arrangement V angle Degrees 90 90 90 90 Bore mm 135 135 135 135 Stroke mm 156 156 156 156 Displacement cylinder Liters 2 ...

Page 50: ...oss in engine external cooling system max L bar 1 0 1 0 1 1 Lube oil system ID 1 2 3 4 Lube oil operating temperature before engine from R C 75 75 75 75 Lube oil operating temperature before engine to R C 100 100 100 100 Lube oil temperature before engine limit 1 L C 103 103 103 103 Lube oil temperature before engine limit 2 L C 105 105 105 105 Lube oil operating pressure before en gine from R bar...

Page 51: ...14 114 Oil change quantity max standard oil system option max operating inclina tions R Liters 80 80 102 102 Oil pan capacity at dipstick mark min standard oil system R Liters 65 65 88 88 Oil pan capacity at dipstick mark max standard oil system R Liters 70 70 94 94 Weights main dimensions ID 1 2 3 4 Engine weight dry basic engine configu ration acc to scope of delivery specifica tion R kg 2710 27...

Page 52: ...duct type Actual value must be greater than the specified value Actual value must be lower than specified value Value not sufficiently guaranteed tolerance 10 Value not sufficiently guaranteed tolerance 5 ID Product type Application Speed Nominal pow er 1 12V2000G26S Power generation 3F standby operation mode unlimited ICXN 1800 rpm 60 Hz 810 kW 1086 bhp Ref 25 C 45 C Wa ter charge air cooling ext...

Page 53: ...8 35 7 Compression ratio 16 16 Cylinder heads individual cylinder heads X X Cylinder liners wet replaceable X X Number of inlet valves per cylinder 2 2 Number of exhaust valves per cylinder 2 2 Standard housing connecting flange engine main PTO side SAE 0 0 Flywheel connection DISC 18 18 Air exhaust ID 1 2 Charge air pressure before cylinder DL R bar abs 3 3 3 2 Coolant system HT circuit ID 1 2 Co...

Page 54: ...ing L bar 5 5 5 5 Lube oil operating pressure before engine shutdown L bar 5 0 5 0 General operating data ID 1 2 Cold start capability air temperature w o start aid w o preheat ing case A R C 0 0 Coolant preheating preheating temperature min L C 32 32 Firing speed from R rpm 100 100 Firing speed to R rpm 120 120 Capacities ID 1 2 Engine coolant capacity engine side without cooling equipment R Lite...

Page 55: ... DL sound power level LW ISO 6798 3 dB A tolerance R dB A 130 133 Engine surface noise with attenuated intake noise filter DL sound power level LW ISO 6798 2 db A tolerance R dB A 123 124 MS15054 03E 2018 07 Technical Data 55 TIM ID 0000065012 004 ...

Page 56: ...value Actual value must be lower than specified value Value not sufficiently guaranteed tolerance 10 Value not sufficiently guaranteed tolerance 5 ID Product type Application Speed Nominal pow er 1 12V2000G26S Power generation 3G continuous opera tion time limited ICXN 1800 rpm 60 Hz 810 kW 1086 bhp Ref 25 C 45 C Wa ter charge air cooling external EPA Nonroad T2 Comp 40CFR89 2 16V2000G26S Power ge...

Page 57: ...ust valves per cylinder 2 2 Standard housing connecting flange engine main PTO side SAE 0 0 Flywheel connection DISC 18 18 Air exhaust ID 1 2 Charge air pressure before cylinder DL R bar abs 3 3 3 2 Coolant system HT circuit ID 1 2 Coolant temperature at engine connection outlet to cooling equipment A C 100 100 Coolant temperature after engine limit 1 L C 102 102 Coolant temperature after engine l...

Page 58: ...perature min L C 32 32 Firing speed from R rpm 100 100 Firing speed to R rpm 120 120 Capacities ID 1 2 Engine coolant capacity engine side without cooling equipment R Liters 63 70 Charge air coolant engine side R Liters 20 25 Engine oil capacity initial filling standard oil system option max operating inclinations R Liters 92 114 Oil change quantity max standard oil system option max op erating in...

Page 59: ...al value must be lower than specified value Value not adequately verified tolerance 10 Value not adequately verified tolerance 5 ID Product type Application Speed Nominal pow er 1 12V2000G76S Power generation 3H standby operation mode special qualifi cations 1800 rpm 60 Hz 890 kW 1193 bhp Ref 25 C 45 C Wa ter charge air cooling external EPA Nonroad T2 Comp 40CFR89 EPA Stationary EMERG T2 40CFR60 2...

Page 60: ...ion method direct fuel injection X X X Cooling method conditioned water X X X Direction of rotation c c w facing driving end X X X Cylinder arrangement V angle Degrees 90 90 90 Bore mm 135 135 135 Stroke mm 156 156 156 Displacement cylinder Liters 2 233 2 233 2 233 Total displacement Liters 26 8 35 7 35 7 Compression ratio 16 16 16 Cylinder heads individual cylinder heads X X X Cylinder liners wet...

Page 61: ...ture before engine limit 1 L C 103 103 103 Lube oil temperature before engine limit 2 L C 105 105 105 Lube oil operating pressure before engine from R bar 6 5 6 5 6 5 Lube oil operating pressure before engine to R bar 9 5 9 5 9 5 Lube oil operating pressure before engine warning L bar 5 5 5 5 5 5 Lube oil operating pressure before engine shutdown L bar 5 0 5 0 5 0 Fuel system ID 1 2 3 Fuel pressur...

Page 62: ...acity at dipstick mark max standard oil system R Liters 70 94 94 Weights main dimensions ID 1 2 3 Engine weight dry basic engine configuration acc to scope of delivery specification R kg 2710 3180 3180 Acoustics ID 1 2 3 Exhaust noise not attenuated DL sound power lev el LW ISO 6798 3 dB A tolerance R dB A 130 133 134 Engine surface noise with attenuated intake noise fil ter DL sound power level L...

Page 63: ...ring order Firing order Number of cylinders Firing order 12V A1 B2 A5 B4 A3 B1 A6 B5 A2 B3 A4 B6 16V A1 B5 A3 A5 B2 B8 A2 A8 B3 A7 B4 B6 A4 A6 B1 B7 MS15054 03E 2018 07 Technical Data 63 TIM ID 0000010708 002 ...

Page 64: ... 1928 3 mm Length A for 16V approx 2278 3 mm Width B for 12V approx 1545 6 mm Width B for 16V approx 1568 4 mm Height C for 12V approx 1420 2 mm Height C for 16V approx 1420 2 mm Table 7 Main engine dimensions 64 Technical Data MS15054 03E 2018 07 TIM ID 0000060300 003 ...

Page 65: ...m Check engine oil level Page 166 Fuel system Connect appropriate equipment to fuel supply line to fill the system Fuel system Vent Page 136 Coolant circuit If engine is out of service for more than one year change engine coolant Page 170 Change charge air coolant Page 179 Coolant circuit Check engine coolant level Page 169 Check charge air coolant level Page 180 Coolant circuit Preheat engine coo...

Page 66: ...tem Check engine oil level Page 166 Coolant circuit Check engine coolant level Page 169 check charge air coolant level Page 180 Coolant circuit Preheat engine coolant with coolant preheating unit if fitted Fuel prefilter if fitted Drain water and contaminants see manufacturer s documentation Engine control system Switch on 66 Operation MS15054 03E 2018 07 TIM ID 0000010642 002 ...

Page 67: ...he hands Avoid skin contact with the starter Wear suitable protective equipment e g industrial gloves WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors WARNING Exhaust gases are harmful to health and may cause cancer Risk of poisoning and suffocation Keep the engine room well ventilated at all times Repair leaking exhaust pipework immediate...

Page 68: ...tified or eliminated contact Service Note If an engine has been shutdown by a fault red alarm the engine may only be re started when the fault has been identified and eliminated Procedure following an automatic safety shutdown 1 Eliminate fault 2 If the root cause cannot be identified or eliminated contact Service Important The function Overdrive safety system if fitted which is only used in emerg...

Page 69: ... leaks and general condition Check engine for abnormal running noises exhaust color and vibrations Engine oil system Check engine oil level Page 166 Air filters Check signal ring position of maintenance indicator on air filter Page 159 Exhaust system Check exhaust color Page 77 Fuel prefilter if fitted Check reading at differential pressure gauge of fuel prefilter see manufac turer s documentation...

Page 70: ... emission label for intactness 3 Check that emission label is fully legible 4 Check content of emission label Does the label on the engine match the label document in the Business Portal Equipment Does the engine number on the emission label match the engine identification plate Does the Manufacturing Date match the year of manufacture on the identification plate 70 Operation MS15054 03E 2018 07 T...

Page 71: ... running at full load subjects it to extreme thermal and mechanical stress es Overheating of and therefore damage to components is possible Before shutting down the engine allow it to idle until the engine temperatures decrease and constant levels are indicated Preparation Item Action Engine Allow the engine to cool down by running it at idle speed for approx 5 mi nutes Stopping the engine Item Ac...

Page 72: ...ant manufacturer Engine is stopped by disconnecting the power supply to the ECU Emergency air shutoff flaps close if applicable Signalization e g by horn beacon is activated Tripped fuse Power failure for an extend ed time A power failure leads to an engine shutdown The fuel system remains under high residual pressure The blank shot function cannot be performed because there is no power supply Aft...

Page 73: ...m If the engine is to be taken out of service for longer than 1 week seal the engine on the air and exhaust side If the engine is to be taken out of service for longer than one month it has to be preserved MTU Preservation and Represervation Specifications A001070 HP system injector noise The pressure is released in the system by means of the function Blank Shot Afterrun Injectors are energized A ...

Page 74: ...gun directly at seals or electronic components such as connectors or ECUs Cleaning the plant 1 Carry out plant cleaning only in areas where an appropriate oil separator is provided environmental protec tion 2 Prior to putting the cleaning unit into operation read the operating instructions of the high pressure cleaning units carefully and observe the safety precautions 3 The following requirements...

Page 75: ...unt visual inspection Page 215 WM00094 041 055 Check valve clearance adjust as necessary IMPORTANT Initial setting after 1 000 operating hours and every overhaul of cylinder heads after 1 000 operat ing hours Page 121 WM00170 BATTERY CHARGING GENERA TOR Check condition of belt and replace as required Adjust belt tension X Page 183 Page 186 WM00076 AIR FILTER Replace air filter Page 157 WM00106 CRA...

Page 76: ...INE MOUNTING Check general condition of rubber mount visual inspection Page 215 WM00094 041 055 Check valve clearance adjust as necessary IMPORTANT Initial setting after 1 000 operating hours and every overhaul of cylinder heads after 1 000 operat ing hours Page 121 WM00170 BATTERY CHARGING GENERA TOR Check condition of belt and replace as required Adjust belt tension X Page 183 Page 186 WM00076 A...

Page 77: ...s but does not fire Component Cause Action Starter Poor rotation by starter Battery low or faulty Charge or replace battery see manufac turer s documentation Engine cabling Faulty Check Page 221 Fuel system Air in fuel system Vent fuel system Page 136 Engine governor Faulty Contact Service Engine fires unevenly Component Cause Action Fuel injection equip ment Injector faulty Replace Page 126 HP pu...

Page 78: ...er Contaminated Contact Service Engine room Air intake temperature too high Check fans and intake exhaust lines Charge air pressure too low Component Cause Action Air supply Air filter clogged Check signal ring position of service in dicator Page 159 Leaking Replace seals nuts Intercooler Contaminated Contact Service Exhaust turbocharger Faulty Contact Service Coolant leaks at intercooler Componen...

Page 79: ... rings cylinder liner Faulty Contact Service White exhaust gas Component Cause Action Engine Not at operating temperature Run engine to reach operating tempera ture Fuel system Water in fuel Check fuel system on fuel prefilter Drain water from fuel prefilter not switchable Page 143 Drain fuel prefilter switchable Page 145 Intercooler Leaking Contact Service MS15054 03E 2018 07 Troubleshooting 79 T...

Page 80: ...Check coolant cooler and intercooler 2 Contact Service if no malfunction can be detected 9 HI T Coolant Intercooler Yellow alarm warning Cause Corrective action Coolant temperature in intercooler too high Level 1 1 Check coolant cooler for leaks contamination and operation 2 Contact Service if no malfunction can be detected 10 SS T Coolant Intercooler Red alarm emergency stop Cause Corrective acti...

Page 81: ...fferential oil pressure at oil filter too high Level 1 u Check oil filter replace as necessary 26 SS P Diff Lube Oil Yellow alarm warning Cause Corrective action Differential oil pressure at oil filter too high Level 2 u Check oil filter replace as necessary 27 HI Level Leakage Fuel Yellow alarm warning Cause Corrective action Leak off fuel level too high u Contact Service 30 SS Engine Overspeed R...

Page 82: ...function can be detected 52 SS T Lube Oil Red alarm emergency stop Cause Corrective action Lube oil temperature too high Level 2 1 Check cooling system 2 Contact Service if no malfunction can be detected 53 HI T Intake Air Yellow alarm warning Cause Corrective action Intake air temperature too high Level 1 1 Check cooling system 2 Contact Service if no malfunction can be detected 54 HIHI T Intake ...

Page 83: ...r not switchable Page 150 Replace filter element of fuel prefilter switchable Page 152 4 Replace main fuel filter and if required intermediate fuel filter Page 141 67 HI T Coolant Yellow alarm warning Cause Corrective action Coolant temperature too high Level 1 1 Check cooling system 2 Contact Service if no malfunction can be detected 68 SS T Coolant Red alarm emergency stop 3 min delay Cause Corr...

Page 84: ...rective action Engine speed too low 1 Restart engine Page 67 2 Observe any other messages 90 SS Idle Speed Not Reached Yellow alarm warning Cause Corrective action Idling speed not reached start aborted 1 Restart engine Page 67 2 Observe any other messages 91 SS Release Speed Not Reached Yellow alarm warning Cause Corrective action Run up speed not reached start aborted 1 Restart engine Page 67 2 ...

Page 85: ... Service 102 AL Fuel Cons Meter Defect Yellow alarm warning Cause Corrective action Consumption meter faulty u Replace Engine Control Unit at next opportunity 104 AL Eng Hours Counter Defect Yellow alarm warning Cause Corrective action Hour meter faulty u Replace Engine Control Unit at next opportunity 118 LO ECU Power Supply Voltage Yellow alarm warning Cause Corrective action Supply voltage too ...

Page 86: ...ctive action The average power rate over the last 24 hours of engine operation has exceeded the set maximum value u Reduce power 180 AL CAN1 Node Lost Yellow alarm warning Cause Corrective action Connection to a node on CAN bus 1 failed 1 Check devices connected to CAN 2 Check wiring termination resistor installed 181 AL CAN2 Node Lost Yellow alarm warning Cause Corrective action Connection to a n...

Page 87: ...ing improve shielding as necessary 3 Contact Service 187 AL CAN1 Error Passive Yellow alarm warning Cause Corrective action CAN controller 1 has signaled a warning 1 Check CAN bus for short circuit rectify short circuit as necessary 2 Check shielding improve shielding as necessary 3 Contact Service 188 AL CAN2 Bus Off Yellow alarm warning Cause Corrective action CAN controller 2 is in Bus Off stat...

Page 88: ...rge Air Yellow alarm warning Cause Corrective action Charge air pressure sensor faulty u Check sensor B10 and wiring replace as necessary Page 221 211 SD P Lube Oil Yellow alarm warning Cause Corrective action Lube oil pressure sensor faulty u Check sensor B5 1 and wiring replace as necessary Page 221 215 SD P HD Yellow alarm warning Cause Corrective action Rail pressure sensor faulty High pressur...

Page 89: ...arm warning Cause Corrective action Leak off fuel level sensor faulty u Check sensor F46 and wiring replace as necessary Page 221 223 SD Level Coolant Intercooler Yellow alarm warning Cause Corrective action Coolant level sensor for intercooler faulty 1 Check sensor F57 and wiring replace as necessary Page 221 2 Fault is rectified when electronics are switched back on 227 SD P Oil before Filter Ye...

Page 90: ...1 SD Camshaft Speed Yellow alarm warning Cause Corrective action Camshaft sensor faulty 1 Check sensor B1 and wiring replace as necessary Page 221 2 Fault is rectified when engine is restarted contact Service if this is not the case 239 SD P Diff Fuel Yellow alarm warning Cause Corrective action Fuel pressure sensors faulty u Check sensor B34 2 sensor 34 3 and wiring replace as necessary Page 221 ...

Page 91: ...on Short circuit in cylinder A1 injector wiring Result Misfiring 1 Check injector wiring 2 Rectify injector solenoid valve short circuit positive to negative e g by exchanging injectors 3 Fault is rectified when engine is restarted 322 AL Wiring Cylinder A2 Yellow alarm warning Cause Corrective action Short circuit in cylinder A2 injector wiring Result Misfiring 1 Check injector wiring 2 Rectify i...

Page 92: ...rcuit in cylinder A6 injector wiring Result Misfiring 1 Check injector wiring 2 Rectify injector solenoid valve short circuit positive to negative e g by exchanging injectors 3 Fault is rectified when engine is restarted 327 AL Wiring Cylinder A7 Yellow alarm warning Cause Corrective action Short circuit in cylinder A7 injector wiring Result Misfiring 1 Check injector wiring 2 Rectify injector sol...

Page 93: ...rcuit in cylinder B2 injector wiring Result Misfiring 1 Check injector wiring 2 Rectify injector solenoid valve short circuit positive to negative e g by exchanging injectors 3 Fault is rectified when engine is restarted 333 AL Wiring Cylinder B3 Yellow alarm warning Cause Corrective action Short circuit in cylinder B3 injector wiring Result Misfiring 1 Check injector wiring 2 Rectify injector sol...

Page 94: ...uit in cylinder B7 injector wiring Result Misfiring 1 Check injector wiring 2 Rectify injector solenoid valve short circuit positive to negative e g by exchanging injectors 3 Fault is rectified when engine is restarted 338 AL Wiring Cylinder B8 Yellow alarm warning Cause Corrective action Short circuit in cylinder B8 injector wiring Result Misfiring 1 Check injector wiring 2 Rectify injector solen...

Page 95: ... by exchanging injectors 2 Fault is rectified after each working cycle 344 AL Open Load Cylinder A4 Yellow alarm warning Cause Corrective action Open circuit in cylinder A4 injector wiring Result Misfiring 1 Check injector wiring exclude disruption in solenoid valve e g by exchanging injectors 2 Fault is rectified after each working cycle 345 AL Open Load Cylinder A5 Yellow alarm warning Cause Cor...

Page 96: ... by exchanging injectors 2 Fault is rectified after each working cycle 351 AL Open Load Cylinder B1 Yellow alarm warning Cause Corrective action Open circuit in cylinder B1 injector wiring Result Misfiring 1 Check injector wiring exclude disruption in solenoid valve e g by exchanging injectors 2 Fault is rectified after each working cycle 352 AL Open Load Cylinder B2 Yellow alarm warning Cause Cor...

Page 97: ... by exchanging injectors 2 Fault is rectified after each working cycle 357 AL Open Load Cylinder B7 Yellow alarm warning Cause Corrective action Open circuit in cylinder B7 injector wiring Result Misfiring 1 Check injector wiring exclude disruption in solenoid valve e g by exchanging injectors 2 Fault is rectified after each working cycle 358 AL Open Load Cylinder B8 Yellow alarm warning Cause Cor...

Page 98: ...ed alarm self restoring Cause Corrective action Internal electronic fault electronics possibly faulty 1 Start engine governor self test 2 Replace ECU in case of fault if self test diagnoses Electronics OK check for additional fault messages e g wiring fault 365 AL Stop MV Wiring Ground Red alarm self restoring Cause Corrective action Injector wiring fault u Check wiring replace wiring harness as n...

Page 99: ...applied temporarily 2 Contact Service if alarm applied constantly 400 AL Open Load Digital Input 1 Yellow alarm warning Cause Corrective action Line disruption at digital input 1 u Check wiring Page 221 401 AL Open Load Digital Input 2 Yellow alarm warning Cause Corrective action Line disruption at digital input 2 u Check wiring Page 221 402 AL Open Load Digital Input 3 Yellow alarm warning Cause ...

Page 100: ... digital input 8 u Check wiring Page 221 408 AL Open Load Emerg Stop Input ESI Yellow alarm warning Cause Corrective action Open circuit at input for emergency stop u Check wiring Page 221 410 LO U PDU Yellow alarm warning Cause Corrective action Injector voltage too low Level 1 u Perform Engine Control Unit self test replace as necessary 411 LOLO U PDU Yellow alarm warning Cause Corrective action...

Page 101: ... coolant pump 416 SS P Coolant Intercooler Yellow alarm warning Cause Corrective action Coolant pressure in intercooler too low Level 2 1 Check coolant level in expansion tank top up as necessary 2 Check coolant circuit for leaks 3 Check coolant pump 417 SD Level Water Fuel Prefilter Yellow alarm warning Cause Corrective action Water level sensor of fuel prefilter faulty short circuit or wire brea...

Page 102: ...operating instructions air in system 444 SD U PDU Yellow alarm warning Cause Corrective action Sensor defect of injector power stage u Replace Engine Control Unit 445 SD P Ambient Air Yellow alarm warning Cause Corrective action Ambient air pressure sensor faulty u Replace Engine Control Unit sensor is in the ECU 446 SD P HD2 Yellow alarm warning Cause Corrective action Rail pressure sensor faulty...

Page 103: ...necessary Page 221 2 Fault is rectified when engine is restarted 472 AL Stop SD Red alarm emergency stop Cause Corrective action Sensor fault of shutdown channels u Contact Service 474 AL Wiring FO Yellow alarm warning Cause Corrective action Wire break or short circuit at FO channel u Contact Service 476 AL Crash Rec Init Error Yellow alarm warning Cause Corrective action Initialization error of ...

Page 104: ...sensor replace as necessary 549 AL Power Cut Off detected Entered in fault memory only Cause Corrective action The operating voltage of the Engine Control Unit was switched of with the engine running This may lead to overpressure in the HP fuel system which might cause damage to the engine u Instruct the operator only to disconnect the power supply when the engine has stopped 551 SS Engine Overspe...

Page 105: ...r 1 Yellow alarm warning Cause Corrective action Wire break or short circuit at PWM channel HP fuel control block u Check wiring or HP fuel control block replace as necessary 611 AL Wiring Suction Restrictor 2 Yellow alarm warning Cause Corrective action Fuel prefilter differential pressure too high u Check wiring or HP fuel control block replace as necessary 615 AL EIL Protection Yellow alarm eme...

Page 106: ...rt and HD too high Entered in fault memory only Cause Corrective action An external start is pending and high pressure is too high u Contact Service 852 AL Max Blank Shot time expired Yellow alarm warning Cause Corrective action High pressure could not be released in the max blankshot time u Contact Service 947 AL Wrong LSI Channel Config Yellow alarm warning Cause Corrective action Data fault on ...

Page 107: ...utput 1 deviates excessively from the value read back u Check cabling 1131 AL Short Circuit Analog Out 2 Yellow alarm warning Cause Corrective action The value output at analog output 2 deviates excessively from the value read back u Check cabling MS15054 03E 2018 07 Troubleshooting 107 TIM ID 0000060724 005 ...

Page 108: ...se cancer Risk of poisoning and suffocation Keep the engine room well ventilated at all times Repair leaking exhaust pipework immediately WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Engine Test run 1 Start engine Page 67 2 Perform test run not below 1 3 load and at least until steady state temperature is reached 3 Carry out operationa...

Page 109: ...e If a starter is also installed on the B side Re move starter on A or B side from flywheel housing electric starter Page 161 air starter Page 164 Barring tool can be in stalled on A or B side 1 Undo screws 1 and remove cover 2 2 Engage barring tool 2 in ring gear and install on flywheel housing 3 Set ratchet 1 onto barring tool 2 4 Rotate crankshaft in engine direction of rota tion Apart from the...

Page 110: ... in Before cranking the engine with starter system make sure that there are no persons in the engine s danger zone Barring engine with starting system 1 If fitted press pushbutton Bar engine without starting and keep depressed 2 Let the crankshaft rotate until oil pressure is indicated but not longer than 10 seconds 3 Repeat procedure after about 20 seconds if necessary 110 Engine MS15054 03E 2018...

Page 111: ...the liner It appears rather darker within the honed struc ture in contrast to the bright metallic running surface The honing pattern is undis turbed Discolorations extend in stroke direction and may be interrupted Findings not critical Corrosion fields spots Corrosion fields spots result from moisture condensate with the valves in the overlap open position They are clearly visible due to the dark ...

Page 112: ...rks are similar A thorough investigation and compliance with the above evaluation criteria allow an unambiguous evaluation To avoid unnecessary disassembly work it is recommended that another inspection be carried out after further operation of the engine 112 Cylinder Liner MS15054 03E 2018 07 TIM ID 0000000014 017 ...

Page 113: ...g pattern First signs of marks left by lower cooling bores Running pattern seems darker No actions required Dark areas with even or varying degrees of discoloration Beginning and end of the discoloration are not sharply defined and do not cover the entire stroke area Dark areas in the upper section of the cooling bore remaining circum ference can not be faulted Piston rings cannot be faulted Furth...

Page 114: ...Final steps 1 Install injector Page 127 2 Install cylinder head cover Page 124 114 Cylinder Liner MS15054 03E 2018 07 TIM ID 0000067215 003 ...

Page 115: ...harmful to health Risk of injury and poisoning Allow the product to cool to below 50 C before beginning work Wear protective clothing protective gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Replacing oil mist separator 1 Unscrew screws 1 and remove together with washers 2 and retainer 3 2 Replace oil mist separator 4 3 Replace O ring 5 4 Screw in screws 1 with was...

Page 116: ...sabled Guard is removed Drive belt Condition check Item Findings Action Drive belt A Singular cracks None Drive belt B Cracks on entire circumference Replace Page 120 Drive belt C Chunking Drive belt Belt is oily shows signs of over heating 116 Fan Drive MS15054 03E 2018 07 TIM ID 0000061050 002 ...

Page 117: ...800 mm Fan Frequency 88 1 Hz Frequency 77 1 Hz Drive belt 1520 mm Fan Frequency 104 1 Hz Frequency 92 1 Hz Table 11 Specified values Measurement with frequency meter Measuring depression depth with preload gauge Note The frequency measurement procedure is the preferred one because it provides more exact measurement results 1 Remove protective cover 2 Set preload gauge onto the drive belt in the mi...

Page 118: ...500 h Drive belt 1800 mm Fan Depression depth 7 mm Test force 188 N Depression depth 8 mm Test force 188 N Drive belt 1520 mm Fan Depression depth 6 mm Test force 188 N Depression depth 7 mm Test force 188 N Table 12 Specified values Measurement with preload gauge 118 Fan Drive MS15054 03E 2018 07 TIM ID 0000053489 004 ...

Page 119: ...ly 4 Adjust belt tension as per specifications with screw 1 Page 117 5 Tighten screws 2 to specified torque using a torque wrench Name Size Type Lubricant Value Standard Screw M16 x 50 Tightening torque Engine oil 180 Nm 18 Nm 6 Tighten screw 1 to specified torque using a torque wrench Name Size Type Lubricant Value Standard Screw M16 x 200 Tightening torque Engine oil 50 Nm 5 Nm 7 Install protect...

Page 120: ...until drive belt can be re moved 6 Check belt pulley on cooler bearing mount and crankshaft for contamination and clean as necessary Note When placing the drive belt in the grooves no force must be applied 7 Fit new drive belt 8 Adjust drive belt tension Page 119 9 Install fan Vehicle plant manufacturer s tightening specifications 10 Install protective grill on fan Vehicle plant manufacturer s tig...

Page 121: ...TDC position without marking on flywheel Note With cylinder head and valve gear installed 1 Insert preloaded measuring gauge 2 into measuring device 4 and secure using screw 1 2 Install measuring device 4 in cylinder head and secure using knurled screw 3 3 Set dial gauge 2 to zero 4 Turn engine using barring device until piston A1 reaches firing TDC Result The piston is at firing TDC when both roc...

Page 122: ...arance Diagram for 12V 16V engines two crankshaft positions Position Cylinder 1 2 3 4 5 6 7 8 9 10 12V Firing TDC in cylinder A1 Side A I X I X I X Side B I X I I X X Overlap TDC in cylinder A1 Side A X I X I I X Side B X I X I X I 16V Firing TDC in cylinder A1 Side A I X X X I X I Side B I X I I X I I X X Overlap TDC in cylinder A1 Side A I I X I X I X I X Side B X I I X X X I I Inlet Inlet valve...

Page 123: ... Size Type Lubricant Value Standard Locknut M12x1 Tightening torque 50 Nm 5 Nm 5 Insert feeler gauge between valve bridge and rocker arm to verify that the gauge just passes through the gap Result If not adjust valve clearance Final steps 1 Remove barring device 2 Install cylinder head cover Page 124 MS15054 03E 2018 07 Valve Drive 123 TIM ID 0000060301 002 ...

Page 124: ...Nm 0015384230 1 Ratchet bit F30027340 1 Engine oil Seal Spare Parts Catalog Preparatory steps 1 Open wiring harness safety clips on cylinder head cover 2 Disconnect wiring harness Removing and installing cylin der head cover 1 Remove cylinder head cover 2 from cylinder head 2 Disconnect terminals arrowed on injector and pull out cable lugs 3 Clean mating face 124 Valve Drive MS15054 03E 2018 07 TI...

Page 125: ...jector and tighten to specified torque using a torque wrench Name Size Type Lubricant Value Standard Nut M4 Tightening torque Engine oil 1 5 Nm 0 25 Nm 8 Install cylinder head cover 2 with screws 4 and washer 3 Final steps 1 Connect wiring harness 2 Close wiring harness safety clips on cylinder head cover MS15054 03E 2018 07 Valve Drive 125 TIM ID 0000053452 003 ...

Page 126: ...tools Material Spare parts Designation Use Part No Qty Injector Spare Parts Catalog Screw for hold down clamp Spare Parts Catalog Replacing injector u Remove injector and install new one Page 127 126 Injector MS15054 03E 2018 07 TIM ID 0000053453 001 ...

Page 127: ...ses facial protection WARNING Residual pressure in high pressure fuel system Risk of injury from fuel escaping under high pressure After an emergency stop or engine stall energize the engine governor for approx 30 s Always wear protective gloves and protective goggles safety mask Loosen threaded connections slowly WARNING Internal tension and residual pressure in the HP fuel system Parts can be ej...

Page 128: ... Close fuel supply line 2 Remove cylinder head cover Page 124 Removing pressure pipe neck 1 Remove HP fuel line 1 2 Unscrew union nut 2 3 Pull off pressure pipe neck 3 4 Extract fuel from the exposed bores using the suction device Removing injector 1 Remove screw 3 2 Take off hold down clamp 2 3 Use the puller to pull out injector 1 4 After removal seal all openings with suitable covers 128 Inject...

Page 129: ...rd Screw M8 Preload torque Engine oil 5 Nm 2 Loosen screw 3 again and relieve hold down clamp 2 Installing with press in tool 1 Place press in tool on hold down clamp 2 to press injector 1 carefully into the cylinder head 2 Place hold down clamp 2 in correct position screw in screw 3 and tighten hand tight Installing pressure pipe neck Note Minimize contamination 1 Visually inspect HP fuel line 1 ...

Page 130: ... Nm 9 Tighten screw 3 for hold down clamp 2 to specified torque using a torque wrench Name Size Type Lubricant Value Standard Screw M8 Tightening torque Engine oil 40 Nm 4 Nm 10 Tighten union nut 2 on pressure pipe neck 3 to specified torque using a torque wrench Name Size Type Lubricant Value Standard Union nut M24 Tightening torque 50 Nm 5 Nm 130 Injector MS15054 03E 2018 07 TIM ID 0000050909 01...

Page 131: ...stem Name Size Type Lubricant Value Standard Union nut M20 Tightening torque Engine oil 37 Nm 3 Nm b In case of double wall jacketed HP fuel system Name Size Type Lubricant Value Standard Union nut M20 Tightening torque Engine oil 50 Nm 5 Nm 4 Tighten union nut of HP fuel line 1 on pressure pipe neck 3 to specified torque using a torque wrench Name Size Type Lubricant Value Standard Union nut M16 ...

Page 132: ...rameters CDC with DiaSys Note Document can be found on the service PC in C DiaSys Doku after successful installation of DiaSys 1 Dialog system DiaSys E531920 2 If no DiaSys is available contact Service Entering injector coding IIG Note Document can be found on the service PC in C DiaSys Doku after successful installation of DiaSys 1 Dialog system DiaSys E531920 2 If no DiaSys is available contact ...

Page 133: ... Residual pressure in high pressure fuel system Risk of injury from fuel escaping under high pressure After an emergency stop or engine stall energize the engine governor for approx 30 s Always wear protective gloves and protective goggles safety mask Loosen threaded connections slowly WARNING Internal tension and residual pressure in the HP fuel system Parts can be ejected when loosening them Ris...

Page 134: ... torque Engine oil 15 Nm 5 Nm Union nut M24 Tightening torque 50 Nm 5 Nm 11 Coat mating face with engine oil between union nut 1 3 and HP fuel line 2 end of line and thread on both sides of the new HP fuel line 2 12 Install new HP fuel line 2 13 Tighten union nut 1 of HP fuel line 2 on rail to specified torque using a torque wrench a In case of single wall HP fuel system Name Size Type Lubricant V...

Page 135: ...e and replace as necessary 3 Coat gaskets with assembly compound and place on cylinder head 4 Install leak off fuel lines 5 Install charge air pipes 6 Install Engine Control Unit Page 219 7 Open fuel supply line 8 Vent fuel system Page 136 MS15054 03E 2018 07 Fuel System 135 TIM ID 0000050910 007 ...

Page 136: ...tective gloves and safety glasses facial protection Fuel system Venting 1 Open the unpressurized return to the tank 2 and connect to the tank or a suitably large vessel 2 Open vent valve 3 on fuel filter 3 Vent fuel filter by actuating hand pump 1 4 Close vent valve 3 on fuel filter and tighten to specified tightening torque Name Size Type Lubricant Value Standard Threaded vent plug M14 Tightening...

Page 137: ...ighly volatile media e g fuel or ether Risk of fatal injury through swallowing risk of poisoning through inhalation irritation to eyes and skin Seek medical attention immediately do not induce vomiting Do not inhale vapors or mist Wear protective clothing protective gloves and safety glasses If contact is made with skin wash off with water and soap Fuel Draining 1 Provide a suitable container in w...

Page 138: ...uel are poisonous Escaping vapors of highly volatile media e g fuel or ether Risk of fatal injury through swallowing risk of poisoning through inhalation irritation to eyes and skin Seek medical attention immediately do not induce vomiting Do not inhale vapors or mist Wear protective clothing protective gloves and safety glasses If contact is made with skin wash off with water and soap Fuel cooler...

Page 139: ...through inhalation irritation to eyes and skin Seek medical attention immediately do not induce vomiting Do not inhale vapors or mist Wear protective clothing protective gloves and safety glasses If contact is made with skin wash off with water and soap WARNING Compressed air gun ejects a jet of pressurized air Risk of injury to eyes and damage to hearing risk of rupturing internal organs Never di...

Page 140: ...To avoid damage to cooling elements only aim water jet parallel to the cooling fins applying moderate pressure To improve the cleaning effect add a suitable degreasing agent to the water in accordance with the rec ommendations of the high pressure cleaner manufacturer The degreasing agent must be approved for light metal containing coolers 1 Use high pressure cleaner to clean cooling elements work...

Page 141: ...of highly volatile media e g fuel or ether Risk of fatal injury through swallowing risk of poisoning through inhalation irritation to eyes and skin Seek medical attention immediately do not induce vomiting Do not inhale vapors or mist Wear protective clothing protective gloves and safety glasses If contact is made with skin wash off with water and soap Fuel filter Replacement 1 Remove easy change ...

Page 142: ... to heavy duty fuel prefilters Fuel prefilter non switchable u Drain water and contaminants from fuel prefilter Page 143 Fuel prefilter switchable u Drain water and contaminants from fuel prefilter Page 145 142 Fuel Filter MS15054 03E 2018 07 TIM ID 0000072630 001 ...

Page 143: ...sh off with water and soap WARNING Exhaust gases are harmful to health and may cause cancer Risk of poisoning and suffocation Keep the engine room well ventilated at all times Repair leaking exhaust pipework immediately WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors WARNING Fuel in the prefilter can be pressurized Risk of injury through ...

Page 144: ...y 11 Vent fuel prefilter Page 155 Draining fuel prefilter with high pressure version B Note The fuel prefilter can be drained during engine operation or with the engine at a standstill 1 Provide a suitable container to collect the wa ter 2 Take care when opening drain plug 1 be cause fuel or water can spurt out 3 Allow water to drain until fuel emerges 4 Close drain plug 2 again 144 Fuel Filter MS...

Page 145: ...ade with skin wash off with water and soap WARNING Exhaust gases are harmful to health and may cause cancer Risk of poisoning and suffocation Keep the engine room well ventilated at all times Repair leaking exhaust pipework immediately WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors WARNING Fuel in the prefilter can be pressurized Risk of...

Page 146: ...ilter module 2 is cut out 3 Open threaded vent plug 1 of filter to be serviced 4 Open drain plug 1 5 Allow water to drain until fuel emerges 6 Close drain plug 2 again 7 Drain the second filter on the module to be serviced from Step 3 8 Close threaded vent plug again 9 Vent fuel prefilter Page 155 146 Fuel Filter MS15054 03E 2018 07 TIM ID 0000066393 005 ...

Page 147: ...over during engine operation and at engine stand still 1 Provide a suitable container to collect the water 2 Take care when opening drain plug 1 be cause fuel or water can spurt out 3 Allow water to drain until fuel emerges 4 Close drain plug 2 again MS15054 03E 2018 07 Fuel Filter 147 TIM ID 0000066393 005 ...

Page 148: ...ff with water and soap Pressure ratios Note If the fuel prefilter is above the full level of the fuel tank during engine operation the fuel pressure in the filter is lower than ambient pressure vacuum If the fuel prefilter is below the empty level of the fuel tank during engine operation the fuel pressure in the filter is higher than ambient pressure overpressure In the case of overpressure fuel c...

Page 149: ...reading at low pressure gauge 3 Red zone 1 1 0 bar to 0 4 bar low pressure Green zone 2 0 4 bar to 0 5 bar nor mal operation 2 Switch over the fuel prefilter or replace a fil ter element Page 152 when the low pres sure gauge 3 indicates minimum admissible fuel pressure during operation 1 MS15054 03E 2018 07 Fuel Filter 149 TIM ID 0000074064 002 ...

Page 150: ...g through inhalation irritation to eyes and skin Seek medical attention immediately do not induce vomiting Do not inhale vapors or mist Wear protective clothing protective gloves and safety glasses If contact is made with skin wash off with water and soap WARNING Fuel in the prefilter can be pressurized Risk of injury through spraying fuel Wear protective gloves and eye protectors safety mask Open...

Page 151: ...ogether with filter element 3 out of filter housing 4 7 Unclip filter element 3 from filter cover 1 8 Install new O ring 2 on filter cover 1 9 Coat new O rings on filter cover and filter ele ment with fuel 10 Clip new filter element 3 into filter cover 1 11 Screw filter cover 1 into filter housing Result Filter cover 1 must lie flat on the housing 4 12 Tighten filter cover 1 with torque wrench to ...

Page 152: ...k medical attention immediately do not induce vomiting Do not inhale vapors or mist Wear protective clothing protective gloves and safety glasses If contact is made with skin wash off with water and soap WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors WARNING Fuel in the prefilter can be pressurized Risk of injury through spraying fuel We...

Page 153: ...and pull it together with filter element 3 out of filter housing 4 6 Unclip filter element 3 from filter cover 1 7 Install new O ring 2 on filter cover 1 8 Coat new O rings on filter cover and filter ele ment with fuel 9 Clip new filter element 3 into filter cover 1 10 Screw filter cover 1 into filter housing Result Filter cover 1 must lie flat on the housing 4 11 Tighten filter cover 1 with torqu...

Page 154: ... together with filter element 3 from filter housing 4 7 Unclip filter element 3 from filter cover 1 8 Install new O ring 2 on filter cover 1 9 Coat new O rings on filter cover and filter ele ment with fuel 10 Clip new filter element 3 into filter cover 1 11 Screw filter cover 1 into filter housing Result Filter cover 1 must lie flat on the housing 4 12 Tighten filter cover 1 with torque wrench to ...

Page 155: ...er and soap WARNING Exhaust gases are harmful to health and may cause cancer Risk of poisoning and suffocation Keep the engine room well ventilated at all times Repair leaking exhaust pipework immediately WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors WARNING Fuel in the prefilter can be pressurized Risk of injury through spraying fuel W...

Page 156: ...e threaded vent plugs 2 3 Note Never actuate the handle with the threaded vent plugs closed 5 Move handle 1 of fuel priming pump back and screw in 6 Close threaded vent plugs 2 3 and tighten by hand Venting fuel prefilter with high pressure version B 1 Open fuel supply as necessary 2 Carefully release threaded vent plugs 1 and unscrew at least one rotation 3 Leave threaded vent plugs 1 opened unti...

Page 157: ...ir intake results in a strong vac uum Risk of injury if body parts are drawn in There is also a danger if opening of the entrance door can be prevented Only operate the engine with installed air filters Never open air carrying components during operation Ensure that the engine room is well ventilated Replacing air filter 1 Remove air filter s and install new one s Page 158 2 Reset signal ring of c...

Page 158: ...ly operate the engine with installed air filters Never open air carrying components during operation Ensure that the engine room is well ventilated Air filter removal and installa tion 1 Release clamp 2 2 Remove air filter 1 and clamp 2 from con necting flange of intake housing 3 3 Clean the connecting flange of the intake housing 3 and check it for free passage 4 Fit air filter 1 and clamp 2 on c...

Page 159: ...arting disabled Checking signal ring position 1 When the yellow piston 2 has reached the red shaded Service lettering 3 replace air filter Page 157 2 After installation of new filter press reset button 1 Result Signal ring returns to initial position MS15054 03E 2018 07 Air Intake 159 TIM ID 0000076623 001 ...

Page 160: ...8 11 Starting Equipment 8 11 1 Electric starter Overview 1 Starter 2 Gasket 3 Flange 4 Gasket 5 Stud 6 Washer 7 Nut 160 Starting Equipment MS15054 03E 2018 07 TIM ID 0000029152 003 ...

Page 161: ...in contact with the starter Wear suitable protective equipment e g industrial gloves WARNING Heavy part risk of falling or overturning due to lack of stability Risk of crushing body or limbs Use appropriate lifting gear and appliances Wear safety shoes Disconnecting and removing starter 1 Disconnect starter battery 2 Prior to disconnection mark all cables 3 Disconnect all cables from starter 4 Pro...

Page 162: ...nion with lubricating grease 2 Install starter as per overview drawing Page 160 Connecting starter electrically 1 Connect cables in accordance with the marking 2 Screw on nuts of connections and tighten to specified torque using a torque wrench a Terminal 30 battery connection Name Size Type Lubricant Value Standard Nut M12 Tightening torque 24 7 to 27 5 Nm b Terminal 50 switching connection Name ...

Page 163: ... starter Overview 1 Pressure reducing valve 2 Starting valve 3 Gasket 4 Flange 5 Gasket 6 Stud 7 Washer 8 Hex nut 9 Threaded adapter 10 Pneumatic starter MS15054 03E 2018 07 Starting Equipment 163 TIM ID 0000067217 002 ...

Page 164: ...ompressed air pipes may still be under pressure although the shut off valve is closed Risk of injury Before starting work release pressure from pipework WARNING Heavy part risk of falling or overturning due to lack of stability Risk of crushing body or limbs Use appropriate lifting gear and appliances Wear safety shoes Removing starter 1 Remove pressure hose 2 Remove starter as per overview drawin...

Page 165: ...ing gear and appliances Wear safety shoes Starter Installation 1 Coat starter pinion with lubricating grease 2 Install starter as shown in overview drawing Page 163 Connecting air starter 1 Install pressure hose 2 Fit sealing tape on screw fitting union It should cover the entire thread of the union 3 Tighten threaded adapter to specified torque using a torque wrench Name Size Type Lubricant Value...

Page 166: ... Top up with oil up to the max 1 mark Page 167 if required 5 Insert oil dipstick into guide tube up to the stop Checking engine oil level after engine has stopped 1 5 minutes after stopping the engine pull out oil dipstick from guide tube and wipe it 2 Insert dipstick into guide tube up to the stop pull it out after approx 10 seconds and check oil level 3 Oil level must be between min and max mark...

Page 167: ... oil pan 1 Provide a suitable container to collect the oil 2 Remove the drain plug and drain the oil 3 Screw in drain plug with new sealing ring 4 Replace engine oil filter Page 168 Version with semirotary hand pump Extracting oil 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 filter Page 168 Filling with new oil...

Page 168: ...id contact with skin Do not inhale oil vapor Replacing engine oil filter 1 Provide a suitable container to collect the oil 2 Remove drain plug 2 and drain oil 3 Close drain plug 2 again 4 Remove oil filter 3 with filter wrench 5 Clean sealing face on connecting piece 1 6 Check sealing ring arrowed of new oil filter and moisten with oil 7 Screw on and tighten oil filter by hand 8 Replace other oil ...

Page 169: ...ion tank counterclockwise to the first stop and allow pressure to escape 2 Continue to turn breather valve counterclock wise and remove 3 Check coolant level coolant must be visible at the lower edge of the cast in eye or at the marking plate 4 Top up with treated coolant as necessary Page 172 5 Check and clean breather valve 6 Place breather valve on filler neck and close Coolant level check by m...

Page 170: ...s Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 171 2 Fill with engine coolant Page 172 170 Coolant Circuit General High Temperature Circuit MS15054 03E 2018 07 TIM ID 0000000036 031 ...

Page 171: ...e on coolant expansion tank counterclockwise to the first stop and allow pressure to escape 2 Continue to turn breather valve counterclock wise and remove 3 Draw off precipitated corrosion inhibitor oil from the coolant expansion tank through filler neck 4 Open drain screws and drain engine coolant at the following drain points At the preheating unit At HT coolant pump 1 At crankcase 2 and 3 right...

Page 172: ...hearing Wear ear protectors NOTICE Cold coolant in hot engine can cause thermal stress Possible formation of cracks in the engine Fill top up coolant only into cold engine Preparatory steps 1 Turn breather valve 1 on coolant expansion tank counterclockwise to the first stop and allow pressure to escape 2 Continue to turn breather valve 1 counter clockwise and remove Filling engine coolant 1 Pour i...

Page 173: ...Start the engine and operate it at idle speed for some minutes 2 Check coolant level top up coolant if necessary Page 169 MS15054 03E 2018 07 Coolant Circuit General High Temperature Circuit 173 TIM ID 0000061049 001 ...

Page 174: ... of the engine WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Engine coolant pump Relief bore check u Check relief bore for oil and coolant dis charge Permissible coolant discharge Up to 2 5 ml 10 hours Result Contact Service if discharge exceeds the specified limits 174 Coolant Circuit General High Temperature Circuit MS15054 03E 2018 0...

Page 175: ...er valve on coolant expansion tank counterclockwise to the first stop and allow pressure to es cape 2 Continue to turn breather valve counterclockwise and remove 3 Draw off precipitated corrosion inhibitor oil from expansion tank and dispose of oil 4 Draw off approx 1 liter coolant and drain into a clean container 5 Using the equipment and chemicals from the MTU test kit examine coolant for antifr...

Page 176: ...and goggles safety mask WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors NOTICE Cold coolant in hot engine can cause thermal stress Possible formation of cracks in the engine Fill top up coolant only into cold engine Preparatory steps 1 Turn breather valve 1 on coolant expansion tank counterclockwise to the first stop and allow pressure to...

Page 177: ...late 2 Install plug screws of filling points with new sealing rings 3 Check proper condition of breather valve 1 clean sealing faces if required 4 Fit breather valve 1 and close it Final steps 1 Start the engine and operate it at idle speed for some minutes 2 Check coolant level Page 180 MS15054 03E 2018 07 Low Temperature Circuit 177 TIM ID 0000000039 006 ...

Page 178: ...harge air coolant 1 Provide a suitable container to catch the coolant 2 Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to escape 3 Continue to turn breather valve counterclock wise and remove 4 Draw off precipitated corrosion inhibitor oil from the coolant expansion tank through filler neck 5 Open drain plug and drain coolant at charge air coola...

Page 179: ...ial tools Material Spare parts Designation Use Part No Qty Coolant Charge air coolant Change 1 Drain charge air coolant Page 178 2 Fill with charge air coolant Page 176 MS15054 03E 2018 07 Low Temperature Circuit 179 TIM ID 0000000041 011 ...

Page 180: ...eze Wear protective clothing protective gloves and goggles safety mask Wipe up escaped spilled coolant immediately Checking charge air coolant level at filler neck 1 Turn cover on coolant expansion tank counterclockwise to the first stop and allow pressure to escape 2 Continue to turn cover counterclockwise and remove Note Charge air coolant must be visible at marker plate 3 Check charge air coola...

Page 181: ... danger zone of the engine WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Charge air coolant pump Re lief bore check u Check relief bore for oil and coolant dis charge Permissible coolant discharge Up to 2 5 ml 10 hours Result Contact Service if discharge exceeds the specified limits MS15054 03E 2018 07 Low Temperature Circuit 181 TIM ID...

Page 182: ...intercooler condensate drain for coolant discharge and obstruc tions 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 engin...

Page 183: ...isabled 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 187 Drive belt C Chunking Drive belt Belt is oily shows signs of over heating MS15054 03E 2018 07 Battery Charging Generator 183 TIM ID 0000081228 001 ...

Page 184: ...lue Initial installation new belt Measured value Operating tension used belt Drive belt Battery charging gen erator Frequency 95 9 2 Hz Frequency 84 1 2 Hz Table 14 Specified values Measuring with frequency meter Measuring depression depth with preload gauge Note The frequency measurement procedure is the preferred one because it provides more exact measurement results 1 Set preload gauge onto the...

Page 185: ...7 8 mm Test force 60 N Depression depth 8 9 mm Test force 60 N Table 15 Specified values Measuring with preload gauge 7 Complete final steps Final steps 1 Install protective cover 2 Install screws of protective cover 3 Install safety equipment if applicable 4 Check function of safety equipment if applicable MS15054 03E 2018 07 Battery Charging Generator 185 TIM ID 0000081231 001 ...

Page 186: ...3 and battery charging generator mount 2 2 Undo locknut 5 3 Tighten screws 1 to specified tightening torque Name Size Type Lubricant Value Standard Screw M10 Preload torque 10 Nm 4 Tighten clamping bolt 4 to specified tightening torque and tension belt to desired value Page 184 Name Size Type Lubricant Value Standard Clamping bolt Preload torque approx 8 Nm 5 Tighten screws 1 6 Secure clamping bol...

Page 187: ...initial installation Moisten running surfa ces of the battery charging generator mount 2 with oil 2 Loosen screws 1 and trickle oil into the gap between gearcase 3 and battery charging generator mount 2 3 Undo locknut 5 4 Undo clamping bolt 4 5 Remove drive belt 6 Check cleanness of belt pulleys 7 Fit new drive belt on belt pulleys without ten sion 8 Adjust belt tension Page 186 Final steps 1 Inst...

Page 188: ...0 V 50 60 Hz Page 199 Preheater 6 kW 280 V 50 60 Hz Cleaning heating element and replacing gasket Preheater 3 kW 230 V 50 Hz Page 193 Preheater 3 kW 240 V 60 Hz Page 196 Preheater 6 kW 400 V 50 60 Hz Page 190 Preheater 6 kW 280 V 50 60 Hz Replacing thermostat Preheater 3 kW 230 V 50 Hz Page 208 Preheater 3 kW 240 V 60 Hz Page 211 Preheater 6 kW 400 V 50 60 Hz Page 205 Preheater 6 kW 280 V 50 60 Hz...

Page 189: ...fety glasses facial protection Function check Note The preheater operates properly if the measured value of the coolant temperature is within the control range of the thermostat 1 Check coolant preheating temperature 2 Contact Service if the temperatures are out of normal range Leak check 1 Check unit for leaks at coolant inlet and coolant outlet 2 Tighten leaking connections MS15054 03E 2018 07 P...

Page 190: ...is hot and under pressure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask WARNING Coolant contains antifreeze and is toxic Risk of poisoning and slipping Avoid contact with eyes and skin Do not inhale vapors or mist wear breathing protection Do not eat drink smoke when working with antifreeze Wear protective clothing protective gloves an...

Page 191: ...oned 6 Insert cleaned or new heating element into housing 7 Install electrical part 2 and tighten screws 1 Installing coolant lines 1 Clean drain plug and screw in thread arrow at preheater 2 Coat drain plug with screw locking compound Loctite 586 and screw in 3 Connect coolant return and supply lines to preheater and tighten clamps 4 Vent coolant preheating circuit a Open return line valve b Undo...

Page 192: ...Final steps 1 Connect preheater power sources 2 Switch on preheater 192 Preheater MS15054 03E 2018 07 TIM ID 0000081913 004 ...

Page 193: ...is hot and under pressure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask WARNING Coolant contains antifreeze and is toxic Risk of poisoning and slipping Avoid contact with eyes and skin Do not inhale vapors or mist wear breathing protection Do not eat drink smoke when working with antifreeze Wear protective clothing protective gloves an...

Page 194: ...oned 6 Insert cleaned or new heating element into housing 7 Install electrical part 2 and tighten screws 1 Installing coolant lines 1 Clean drain plug and screw in thread ar rowed at preheater 2 Coat drain plug with screw locking compound Loctite 586 and screw in 3 Connect coolant return and supply lines to preheater and tighten clamps 4 Vent coolant preheating circuit a Open return line valve b U...

Page 195: ...Final steps 1 Connect preheater power sources 2 Switch on preheater MS15054 03E 2018 07 Preheater 195 TIM ID 0000082979 001 ...

Page 196: ...is hot and under pressure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask WARNING Coolant contains antifreeze and is toxic Risk of poisoning and slipping Avoid contact with eyes and skin Do not inhale vapors or mist wear breathing protection Do not eat drink smoke when working with antifreeze Wear protective clothing protective gloves an...

Page 197: ...oned 6 Insert cleaned or new heating element into housing 7 Install electrical part 2 and tighten screws 1 Installing coolant lines 1 Clean drain plug and screw in thread ar rowed at preheater 2 Coat drain plug with screw locking compound Loctite 586 and screw in 3 Connect coolant return and supply lines to preheater and tighten clamps 4 Vent coolant preheating circuit a Open return line valve b U...

Page 198: ...Final steps 1 Connect preheater power sources 2 Switch on preheater 198 Preheater MS15054 03E 2018 07 TIM ID 0000082980 001 ...

Page 199: ... pressure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask WARNING Hot components surfaces Risk of burns Allow the engine to cool down to below 50 C before beginning work Wear suitable protective equipment thermal gloves Avoid unprotected contact with hot surfaces Preparatory steps 1 Switch off preheater 2 Disconnect all preheater power s...

Page 200: ...er and slide the solenoid switch off the rail 5 Fit a new solenoid switch on the rail and fully engage the spring clip 6 Connect up all wires as marked previously 7 Close the control box and tighten the screws Final steps 1 Open shutoff valves in the supply and return line to from preheater 2 Disconnect preheater power sources 3 Switch on preheater 200 Preheater MS15054 03E 2018 07 TIM ID 00000819...

Page 201: ... pressure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask WARNING Hot components surfaces Risk of burns Allow the engine to cool down to below 50 C before beginning work Wear suitable protective equipment thermal gloves Avoid unprotected contact with hot surfaces Preparatory steps 1 Switch off preheater 2 Disconnect all preheater power s...

Page 202: ... switch 2 5 Install new solenoid switch 2 and tighten screws 3 6 Connect up all wires as marked previously 7 Close the control box and tighten the screws Final steps 1 Open shutoff valves in the supply and return line to from preheater 2 Disconnect preheater power sources 3 Switch on preheater 202 Preheater MS15054 03E 2018 07 TIM ID 0000082982 001 ...

Page 203: ... pressure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask WARNING Hot components surfaces Risk of burns Allow the engine to cool down to below 50 C before beginning work Wear suitable protective equipment thermal gloves Avoid unprotected contact with hot surfaces Preparatory steps 1 Switch off preheater 2 Disconnect all preheater power s...

Page 204: ... switch 2 5 Install new solenoid switch 2 and tighten screws 3 6 Connect up all wires as marked previously 7 Close the control box and tighten the screws Final steps 1 Open shutoff valves in the supply and return line to from preheater 2 Disconnect preheater power sources 3 Switch on preheater 204 Preheater MS15054 03E 2018 07 TIM ID 0000082983 001 ...

Page 205: ...ot components surfaces Risk of burns Allow the engine to cool down to below 50 C before beginning work Wear suitable protective equipment thermal gloves Avoid unprotected contact with hot surfaces WARNING Coolant is hot and under pressure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Preparatory steps 1 Switch off preheater 2 Disconnec...

Page 206: ... clip 7 Connect cable 8 Fit cover and tighten screws Replacing control thermostat 1 Undo screws 1 on housing cover 2 of con trol thermostat and remove cover 2 Mark cables prior to disconnection 3 Disconnect wires 4 Remove screws 2 and control thermo stat 1 5 Install new control thermostat 1 with screws 2 6 Connect cable 7 Fit housing cover and tighten screws 206 Preheater MS15054 03E 2018 07 TIM I...

Page 207: ...Final steps 1 Connect preheater to power supply 2 Switch on preheater MS15054 03E 2018 07 Preheater 207 TIM ID 0000081762 002 ...

Page 208: ...Hot components surfaces Risk of burns Allow the engine to cool down to below 50 C before beginning work Wear suitable protective equipment thermal gloves Avoid unprotected contact with hot surfaces WARNING Coolant is hot and under pressure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Preparatory steps 1 Switch off preheater 2 Disconne...

Page 209: ... clip 7 Connect cable 8 Fit cover and tighten screws Replacing control thermostat 1 Undo screws 1 on housing cover 2 of con trol thermostat and remove cover 2 Mark cables prior to disconnection 3 Disconnect wires 4 Remove screws 2 and control thermo stat 1 5 Install new control thermostat 1 with screws 2 6 Connect cable 7 Fit housing cover and tighten screws MS15054 03E 2018 07 Preheater 209 TIM I...

Page 210: ...Final steps 1 Connect preheater to power supply 2 Switch on preheater 210 Preheater MS15054 03E 2018 07 TIM ID 0000082984 001 ...

Page 211: ...Hot components surfaces Risk of burns Allow the engine to cool down to below 50 C before beginning work Wear suitable protective equipment thermal gloves Avoid unprotected contact with hot surfaces WARNING Coolant is hot and under pressure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Preparatory steps 1 Switch off preheater 2 Disconne...

Page 212: ... clip 7 Connect cable 8 Fit cover and tighten screws Replacing control thermostat 1 Undo screws 1 on housing cover 2 of con trol thermostat and remove cover 2 Mark cables prior to disconnection 3 Disconnect wires 4 Remove screws 2 and control thermo stat 1 5 Install new control thermostat 1 with screws 2 6 Connect cable 7 Fit housing cover and tighten screws 212 Preheater MS15054 03E 2018 07 TIM I...

Page 213: ...Final steps 1 Connect preheater to power supply 2 Switch on preheater MS15054 03E 2018 07 Preheater 213 TIM ID 0000082985 001 ...

Page 214: ... for firm seating Preconditions Engine is stopped and starting disabled Engine mounting checking securing screws for firm seating 1 Check securing screws for firm seating 2 Tighten loose threaded connections 214 Engine Mounting Support MS15054 03E 2018 07 TIM ID 0000007548 009 ...

Page 215: ...cking the condition of resilient mounts 1 Wipe rubber surface with dry cloth do not use organic detergents 2 Visually inspect resilient mounts for cracking and deformation 3 Check rubber surfaces for swelling 4 Have cracked or swollen mounts replaced contact Service MS15054 03E 2018 07 Engine Mounting Support 215 TIM ID 0000038938 001 ...

Page 216: ...enerator mounting Checking condition of resilient mounts 1 Wipe rubber surface with dry cloth do not use organic detergents 2 Visually inspect resilient mounts for cracks and deformation 3 Check rubber surfaces for swelling 4 Have cracked or swollen mounts replaced contact Service 216 Generator MS15054 03E 2018 07 TIM ID 0000079447 002 ...

Page 217: ...ring screws Preconditions Engine is stopped and starting disabled Generator mounting Checking firm seating of securing screws 1 Check securing screws for firm seating 2 Tighten loose screw connections MS15054 03E 2018 07 Generator 217 TIM ID 0000079448 001 ...

Page 218: ...ine Governor 8 20 1 Engine Control Unit Overview 1 Connector X2 2 Connector X1 customer connection 3 Connector X3 4 Washer 5 Screw 6 Damping element 218 Engine Governor MS15054 03E 2018 07 TIM ID 0000053491 002 ...

Page 219: ...cord for the given engine is installed Removing Engine Control Unit from engine 1 Note or mark assignment of cables and con nectors 2 Undo latches on connectors 1 2 custom er connection and 3 3 Disconnect all connectors 4 Remove all screws 5 with washers 4 5 Take off Engine Control Unit Installing Engine Control Unit on engine 1 Install in reverse order Ensure correct assignment of connectors and ...

Page 220: ...st probe e g test prod The contacts in the plug connection can be bent Carry out check of plug connection only with test connectors Checking plug connections at engine governor 1 Check all plug connections for secure seating 2 Lock loose connectors 3 Check dust cap on ECU and EXU connectors for damage and correct seating 220 Engine Governor MS15054 03E 2018 07 TIM ID 0000000048 009 ...

Page 221: ...d intact 4 Replace faulty cable clips 5 Check cable clamps for secure fit tighten loose clamps 6 Replace faulty cable clamps 7 Visually inspect the following electrical components for damage Connector housings Contacts Plug connectors Cables and terminals Plug in contacts Result If cable conductors are damaged contact Service Note Close connectors that are not plugged in with the protective cap su...

Page 222: ...opropyl alcohol to remove coarse dirt from housing surface 2 Use isopropyl alcohol to remove dirt from the connector and cable surfaces 3 Check legibility of cable labels Clean or replace illegible labels Heavily contaminated connectors on engine governor Cleaning Note Close connectors that are not plugged in with the protective cap supplied 1 Release latches of connectors and withdraw connectors ...

Page 223: ...ory module for engine data EMU Engine Monitoring Unit ETC Exhaust turbocharger GCU Gear Control Unit GMU Gear Monitoring Unit HAT Harbor Acceptance Test HI High Range violation alarm 1st upper limit value HIHI High High Range violation alarm 2nd upper limit value IDM Interface Data Module Memory module for interface data ISO International Organization for Stand ardization International umbrella or...

Page 224: ...ule PPC Priming Pump Control RCS Remote Control System RL Redundancy Lost Alarm Redundant CAN bus failure SAT Sea Acceptance Test SD Sensor Defect Alarm Sensor failure SDAF Shut Down Air Flap s Emergency air shutoff flap s SS Safety System Safety system alarm SSK Schnellschlussklappen Emergency air shutoff flap s TD Transmitter Deviation Alarm Sensor comparison fault UT Unterer Totpunkt Bottom dea...

Page 225: ...e of a malfunction for information on changes in conditions of use and for supplying spare parts Your contact person in our Customer Assistance Center E mail info mtu online com Tel 49 7541 9077777 Fax 49 7541 9077778 Asia Pacific 65 6100 2688 North and Latin America 1 248 560 8000 Spare Parts Service Fast simple and correct identification of spare parts for your drive system or vehicle fleet The ...

Page 226: ...justment Page 121 Barring device Part No F6792910 Qty Used in 1 8 5 1 Valve clearance Check and adjustment Page 121 Barring tool Part No F6792910 Qty Used in 1 8 1 2 Engine Barring manually Page 109 Qty Used in 1 8 2 2 Cylinder liner Endoscopic examination Page 113 226 Appendix B MS15054 03E 2018 07 DCL ID 0000037216 007 ...

Page 227: ...line and pressure pipe neck Replacement Page 133 Double head box wrench Part No F30002800 Qty Used in 1 8 5 1 Valve clearance Check and adjustment Page 121 Double head box wrench Part No F30011450 Qty Used in 1 8 6 2 Injector Removal and installation Page 127 Qty Used in 1 8 7 1 HP fuel line and pressure pipe neck Replacement Page 133 MS15054 03E 2018 07 Special Tools 227 DCL ID 0000037216 007 ...

Page 228: ... 2 Injector Removal and installation Page 127 Filter wrench Part No F30379104 Qty Used in 1 8 8 1 Fuel filter Replacement Page 141 Qty Used in 1 8 13 1 Engine oil filter Replacement Page 168 Fuel suction pipe Part No F30378207 Qty Used in 1 8 6 2 Injector Removal and installation Page 127 228 Special Tools MS15054 03E 2018 07 DCL ID 0000037216 007 ...

Page 229: ...1 Valve clearance Check and adjustment Page 121 MTU test kit Part No 5605892099 00 Qty Used in 1 8 14 6 Engine coolant Sample extraction and analysis Page 175 Plug in open end wrench 19 mm Part No F30453236 Qty Used in 1 8 6 2 Injector Removal and installation Page 127 MS15054 03E 2018 07 Special Tools 229 DCL ID 0000037216 007 ...

Page 230: ...ad gauge 150 600 N Part No Y20097429 Qty Used in 1 8 4 2 Drive belt Tension check Page 117 Preload measuring device Part No Qty Used in 1 8 16 2 Drive belt Tension check Page 184 Press in tool Part No F6790085 Qty Used in 1 8 6 2 Injector Removal and installation Page 127 230 Special Tools MS15054 03E 2018 07 DCL ID 0000037216 007 ...

Page 231: ...stallation Page 127 Qty Used in 1 8 7 1 HP fuel line and pressure pipe neck Replacement Page 133 Qty Used in 1 8 8 7 Fuel prefilter non switchable Filter element re placement Page 150 Qty Used in 1 8 8 8 Fuel prefilter switchable Filter element replace ment Page 152 Qty Used in 1 8 16 3 Drive belt Tension adjustment Page 186 Qty Used in 1 8 16 4 Drive belt Replacement Page 187 Ratchet with extensi...

Page 232: ...19 Qty Used in 1 8 4 4 Drive belt Replacement Page 120 Qty Used in 1 8 7 1 HP fuel line and pressure pipe neck Replacement Page 133 Qty Used in 1 8 11 6 Starter Installation Page 165 Socket wrench Part No F30030450 Qty Used in 1 8 5 1 Valve clearance Check and adjustment Page 121 Socket wrench 24 mm Part No F30453238 Qty Used in 1 8 6 2 Injector Removal and installation Page 127 232 Special Tools ...

Page 233: ...ve clearance Check and adjustment Page 121 Torque wrench 20 100 Nm Part No F30026582 Qty Used in 1 8 4 3 Drive belt Tension adjustment Page 119 Qty Used in 1 8 6 2 Injector Removal and installation Page 127 Qty Used in 1 8 7 1 HP fuel line and pressure pipe neck Replacement Page 133 Qty Used in 1 8 8 7 Fuel prefilter non switchable Filter element re placement Page 150 Qty Used in 1 8 8 8 Fuel pref...

Page 234: ... Page 136 Qty Used in 1 8 11 6 Starter Installation Page 165 Torque wrench 8 40 Nm Part No F30453004 21 Qty Used in 1 8 16 3 Drive belt Tension adjustment Page 186 Qty Used in 1 8 16 4 Drive belt Replacement Page 187 Torque wrench 0 5 5 Nm Part No 0015384230 Qty Used in 1 8 5 2 Cylinder head cover Cylinder head cover Page 124 Qty Used in 1 8 6 2 Injector Removal and installation Page 127 234 Speci...

Page 235: ...Valve clearance gauge Part No Y4345893 Qty Used in 1 8 5 1 Valve clearance Check and adjustment Page 121 MS15054 03E 2018 07 Special Tools 235 DCL ID 0000037216 007 ...

Page 236: ...ersons 225 Coolant Change 170 179 Charge air Filling 176 Filling 172 Intercooler Draining 178 Sample Extraction and analysis 175 Coolant level Check 169 Crankcase breather Oil mist separator Replacement 115 Cylinder Designation 20 Cylinder head cover Installation 124 Removal 124 Cylinder liner Endoscopic examination 113 Endoscopic inspection Instructions and comments on endoscopic and visu al exam...

Page 237: ...ngine Control Unit 80 Firing order 63 Fuel Draining 137 Fuel cooler Check External contamination 138 Leak tightness 138 Cleaning 139 Fuel filter Replacement 141 Fuel prefilter Draining 142 Non switchable 143 Switchable 145 Filter element replacement Non switchable 150 Switchable 152 Low pressure indicator check Switchable 149 Pressure ratios 148 Venting 155 Fuel system Installation Injector 127 Re...

Page 238: ...ICXN 52 3H mains backup mode special qualification 59 EPA Stationary EMERG T2 40CFR60 3F mains backup mode unlimited ICXN 52 3H mains backup mode special qualification 59 Optimized fuel consumption 3B continuous operation variable load ICXN 26 3D standby power fuel stop power IFN 30 3F mains backup mode unlimited ICXN 34 3G continuous operation time limited ICXN 37 3H mains backup mode special qua...

Page 239: ...Installation 165 Overview 163 Removal 164 T Thermostat Replacement Preheater 205 208 211 Transport Description 19 Troubleshooting 77 V Valve clearance Adjustment 121 Check 121 W Warning notices standards 18 MS15054 03E 2018 07 Index 239 DCL ID 0000037216 007 ...

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MTU 12V2000Gx6 series, Operating Instructions Manual

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