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MTU 12 V 1600 R50, Руководство по эксплуатации

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5 Maintenance

5.1 Maintenance task reference table [QL1]

The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The
Maintenance Schedule is a stand-alone publication.
The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance
Schedule.

Task

Option

Maintenance tasks

W0500

Check engine oil level.

(→ Page 97)

W0503

X Check service indicator of air filter.

(→ Page 30)

W0506

Check engine for abnormal running noises, exhaust color
and vibrations.

(→ Page 30)

W0507

Drain water and contaminants from fuel prefilter.

(→ Page 30)

W1001

Replace fuel filter or fuel filter element

(→ Page 89)

W1005

X Replace air filter.

(→ Page 95)

W1008

Replace engine oil filter when changing engine oil, or when
the interval (years) is reached, at the latest.

(→ Page 99)

W1013

Replace drive belt.

(→ Page 113)

W1019

X Check radial play.

(→ Page 118)

W1027

X Clean air filter, empty dust bowl.

(→ Page 94)

W1207

Check valve clearance, adjust as necessary. ATTENTION!
First adjustment after 1,000 operating hours.

(→ Page 83)

W1326

X Replace battery-charging generator belt tensioner and

diverter pulley.

(→ Page 115)

W1525

Replace sensor.

(→ Page 123)

W1526

Replace sensor.

(→ Page 125)

W1636

Reset drift correction parameters (CDC) and enter injector
coding (IIG).

(→ Page 120)

W1675

Replace fuel prefilter or fuel prefilter element.

(→ Page 92)

Table 2: Maintenance task reference table [QL1]

36 | Maintenance | MS15033/02E 2015-02

TIM-ID: 0000045401 - 002

Содержание 12 V 1600 R50

Страница 1: ...Operating Instructions Diesel engine 12 V 1600 R50 MS15033 02E...

Страница 2: ...hout the prior written consent of MTU Friedrichshafen GmbH This particularly applies to its reproduction distribution editing transla tion microfilming and storage or processing in electronic systems...

Страница 3: ...er 89 7 3 1 Fuel filter Replacement 89 7 3 2 Fuel prefilter Drain condensate 91 7 3 3 Fuel prefilter Filter element replacement 92 7 4 Air Filter 93 7 4 1 Air filter element Removal and installation o...

Страница 4: ...s Cleaning 121 7 14 3 Engine governor Checking plug in connections 122 7 14 4 NOx sensor Replacement 123 7 14 5 Lambda sensor Replacement 125 8 Appendix A 8 1 Abbreviations 127 8 2 MTU contact persons...

Страница 5: ...with the Spare Parts Catalog MTU contact Service partner In the original as delivered configuration or in a configuration approved by the manufacturer in writ ing including engine control parameters...

Страница 6: ...tion authorities The manufacturer does not accept any liability for violations of the emission reg ulations The maintenance schedules of the manufacturer must be observed over the entire life cycle of...

Страница 7: ...around the product This personnel must be instructed repeatedly Personnel requirements All work on the product shall be carried out by trained and qualified personnel only Training at the Training Cen...

Страница 8: ...engine must only be transported in installation position max permissible diagonal pull 10 If the engine is supplied with special aluminum foil packing lift the engine at the lifting eyes of the bear...

Страница 9: ...truments as well as the monitoring signaling and alarm systems are working properly Safety requirements for operation The operator must be familiar with the controls and displays The operator must be...

Страница 10: ...ounts damping elements couplings and V belts must not be painted They may only be installed after painting the engine or must be covered before painting work is carried out The following applies to st...

Страница 11: ...he power supply master switch Disconnect the battery Separate the electrical ground of electronic equipment from the ground of the unit No other maintenance or repair work must be carried out in the v...

Страница 12: ...Always use connector pliers to tighten union nuts on connectors Subject the device as well as the product to a functional testing on completion of all repair work In particular check the function of t...

Страница 13: ...lubricants and filters in accordance with local regulations Within the EU batteries can be returned free of charge to the manufacturer where they will be properly recycled Fluids and lubricants auxili...

Страница 14: ...e spray stands provided with fume extraction systems ensure that the area is well ventilated Make sure that neighboring work areas are not adversely af fected There must be no naked flames in the vici...

Страница 15: ...medial action NOTICE In the event of a situation involving potentially adverse effects on the product Consequences Material damage Remedial action Additional product information Safety notices 1 This...

Страница 16: ...gnated 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...

Страница 17: ...flap before EGR cool er 13 Lifting eye free end 14 Cylinder head 15 EGR cooler 16 Engine mount 17 Engine governor 18 Oil pan 19 Exhaust elbow 20 Flywheel housing 21 Coupling 22 Starter Engine model d...

Страница 18: ...ore exhaust gas recirculation 6 B9 2 Charge air temperature after exhaust gas recirculation left side 7 B5 3 Lube oil pressure before filter option 8 B88 2 NOx sensor right side nitrogen oxide levels...

Страница 19: ...91 3 Exhaust gas pressure 3 B48 2 Fuel pressure in HP system HP line right side 4 B26 Charge air coolant temperature 5 B93 Lube oil level and temperature option 6 A19 EIL Engine Ident Label 7 B1 Camsh...

Страница 20: ...er high pressure speed right side 4 M52 2 Bypass flap of HP turbocharger right side 5 B50 Crankcase pressure option 6 B4 22 Exhaust temperature ritght side 7 B13 Crankshaft speed 8 B44 1 Speed of HP t...

Страница 21: ...e 2 B7 Lube oil temperature 3 M53 1 EGR shut off flap before cooler left side 4 B34 1 Fuel pressure after filter 5 B34 2 Fuel pressure before filter option 6 B6 3 Engine coolant temperature in cylinde...

Страница 22: ...Data 3 1 Firing order 12 V A1 B2 A5 B4 A3 B1 A6 B5 A2 B3 A4 B6 Direction of rotation Direction of rotation as viewed on driving end c c w not reversible 22 Technical Data MS15033 02E 2015 02 TIM ID 00...

Страница 23: ...3 2 Engine Main dimensions Item Dimensions Length B approx 1871 mm Width C approx 1228 mm Height A approx 1327 mm MS15033 02E 2015 02 Technical Data 23 TIM ID 0000035495 003...

Страница 24: ...greater than the specified value The actual value must be smaller than the specified value Not sufficiently validated value 10 tolerance Not sufficiently validated value 5 tolerance ID Produkttyp Pro...

Страница 25: ...C 95 Coolant temperature after engine shutdown L C 112 Coolant pump Inlet pressure max L bar 2 5 Thermostat Starts to open R C 79 Thermostat Fully open R C 92 Coolant system low temperature circuit I...

Страница 26: ...Oil pan capacity at dipstick mark max standard oil system Option max operating inclinations L Liters 65 Weights main dimensions ID 1 Dry engine weight basic configuration engine R kg 2290 Acoustics I...

Страница 27: ...Action Lube oil system Check engine oil level Page 97 Coolant circuit Check engine coolant level Page 100 Check charge air coolant level Page 107 Coolant circuit Preheat engine coolant with coolant pr...

Страница 28: ...reservation Specifications A001070 Lube oil system Check engine oil level Page 97 Fuel system Vent Page 87 Coolant circuit If engine is out of service for more than one year change engine coolant Page...

Страница 29: ...t there are no persons in the en gine s danger zone WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Starting engine Item Action Switchgear c...

Страница 30: ...and display panels Check readings of operational data speed temperature pressures Engine oil Check engine oil level Page 97 Engine operation Check engine visually for leaks and general condition Check...

Страница 31: ...ossible Before shutting down the engine allow it to idle until the engine temperatures decrease and constant levels are indicated Stopping engine Item Action Temperature indications Wait until engine...

Страница 32: ...service for an extended period but engine coolant has no antifreeze addi tive the engine room is not heated the coolant is not kept at a suitable temperature the antifreeze concentration is insufficie...

Страница 33: ...sed air gun directly at seals or electronic components such as connectors or ECUs Plant Cleaning 1 Carry out plant cleaning only in areas where an appropriate oil separator is provided environmental p...

Страница 34: ...011619 1 Ratchet adapter F30027340 1 DANGER Rotating and moving engine parts Risk of crushing danger of parts of the body being caught or pulled in Before cranking the engine with starter system make...

Страница 35: ...ing steps Barring engine manually Var iant B Note Remove starter if necessary 1 Remove screw 2 on flywheel housing 2 Remove end cover 1 3 Engage barring device 2 in ring gear and install on flywheel h...

Страница 36: ...or fuel filter element Page 89 W1005 X Replace air filter Page 95 W1008 Replace engine oil filter when changing engine oil or when the interval years is reached at the latest Page 99 W1013 Replace dr...

Страница 37: ...tion by starter Battery low or faulty u Charge or replace battery manufacturer s documentation Engine wiring defective u Check Page 119 Air in fuel system u Vent fuel system Page 87 Engine governor de...

Страница 38: ...w Cause Corrective action Air filter clogged u Replace air filter Page 95 Intercooler clogged u Contact Service Exhaust turbocharger defective u Contact Service Coolant leaks at intercooler Cause Corr...

Страница 39: ...not at operating temperature u Run engine to reach operating temperature Water in fuel u Check fuel system on fuel prefilter Drain fuel prefilter Page 91 Intercooler leaky u Contact Service MS15033 0...

Страница 40: ...ive action Charge air temperature too high 1 Reduce power 2 If fault code number 9 is signaled at the same time then it has priority 6 SS T Charge Air Limit 2 ZKP Number 2 0121 932 Yellow alarm power...

Страница 41: ...100 922 Red alarm engine stop Cause Corrective action Lube oil pressure too low 1 Check oil level top up as necessary Page 97 2 Acknowledge alarm 3 Restart engine Page 29 4 Request towing locomotive i...

Страница 42: ...P Diff Lube Oil ZKP Number 2 0154 931 Yellow alarm warning Cause Corrective action Differential pressure at oil filter too high u Replace oil filter Page 99 26 SS P Diff Lube Oil ZKP Number 2 0154 93...

Страница 43: ...otive if required 33 Hi P Diff Fuel ZKP Number 2 0114 931 Yellow alarm warning Cause Corrective action Differential pressure on fuel filter too high u Check fuel filter replace if necessary 34 SS P Di...

Страница 44: ...en it has priority 52 SS T Lube Oil Limit 2 ZKP Number 2 0125 932 Red alarm power reduction 20 Cause Corrective action Lube oil temperature too high 1 Reduce power 2 If fault code number 67 is signale...

Страница 45: ...engine stop Cause Corrective action Crankcase pressure too high 1 Contact Service 2 Request towing locomotive if required 65 LO P Fuel ZKP Number 2 0102 921 Yellow alarm warning Cause Corrective acti...

Страница 46: ...Corrective action Rail pressure set value DBR fuel limitation start of injection readjusted retarded HP fuel control block jamming or wiring faulty u Contact Service 83 LO P Fuel Common Rail Limit 1...

Страница 47: ...ached ZKP Number 2 1090 923 Yellow alarm warning Cause Corrective action Starter speed not reached termination of starting sequence starter does not turn or turns slowly 1 Initiate new starting attemp...

Страница 48: ...meter faulty u Replace consumption meter 104 AL Eng Hours Counter Defect ZKP Number 1 8004 623 Yellow alarm warning Cause Corrective action Hour meter faulty u Replace hour meter 118 LO ECU Power Sup...

Страница 49: ...rm warning Cause Corrective action Electronic unit temperature too high 1 Reduce power 2 Observe subsequent fault messages e g intercooler 180 AL CAN1 Node Lost ZKP Number 2 0500 680 Yellow alarm warn...

Страница 50: ...arning Cause Corrective action A programming error occurred when attempting to copy a received PU data module into the Flash module u Contact Electroncs Service 186 AL CAN1 Bus Off ZKP Number 2 0500 6...

Страница 51: ...e shielding as necessary 201 SD T Coolant ZKP Number 1 8004 570 Yellow alarm power limitation 20 Cause Corrective action Coolant temperature sensor faulty short circuit or wire break u Check sensors B...

Страница 52: ...77 Yellow alarm warning Cause Corrective action Exhaust temperature sensor on B side faulty short circuit or wire break u Check sensor B4 22 and wiring replace as necessary Page 119 208 SD P Charge Ai...

Страница 53: ...Lube Oil ZKP Number 1 8004 575 Yellow alarm warning Cause Corrective action Lube oil temperature sensor faulty short circuit or wire break u Check sensor B7 and wiring replace as necessary Page 119 21...

Страница 54: ...stop Cause Corrective action Engine stop due to camshaft sensor fault and a previous crankshaft sensor fault in the same operating cycle 1 Check sensor and wiring to connectors B1 and B13 replace as...

Страница 55: ...w alarm warning Cause Corrective action Pressure sensors for differential fuel pressure faulty short circuit or wire break Fault only occurs in connection u Check sensors B34 1 B34 2 and cabling repla...

Страница 56: ...mitter 3 Contact Service 321 AL Wiring Cylinder A1 ZKP Number 1 8004 520 Yellow alarm warning Cause Corrective action Short circuit in cylinder injector wiring Result Misfiring u Check solenoid valve...

Страница 57: ...t in cylinder injector wiring Result Misfiring u Check solenoid valve 331 AL Wiring Cylinder B1 ZKP Number 1 8004 530 Yellow alarm warning Cause Corrective action Short circuit in cylinder injector wi...

Страница 58: ...n cylinder injector wiring Result Misfiring u Check solenoid valve 341 AL Open Load Cylinder A1 ZKP Number 1 8004 540 Yellow alarm warning Cause Corrective action Open circuit in cylinder injector wir...

Страница 59: ...t in cylinder injector wiring Result Misfiring u Check solenoid valve 351 AL Open Load Cylinder B1 ZKP Number 1 8004 550 Yellow alarm warning Cause Corrective action Open circuit in cylinder injector...

Страница 60: ...id valve 361 AL Power Stage Low Internal Electronic Failure ZKP Number 1 8004 496 Red alarm engine stop Cause Corrective action Internal electronic fault electronics possibly faulty 1 Observe any othe...

Страница 61: ...st towing locomotive if required 381 AL Wiring TOP 1 ZKP Number 2 8006 638 Yellow alarm warning Cause Corrective action Short circuit or wire break on transistor output 1 plant side 1 TOP 1 u Check wi...

Страница 62: ...U PDU Low Injector Voltage Limit 1 ZKP Number 2 0141 921 Yellow alarm warning Cause Corrective action Injector voltage too low 1 Check wiring Page 119 2 Check supply 411 LOLO U PDU Injector Voltage L...

Страница 63: ...Yellow alarm warning Cause Corrective action Water level sensor of fuel prefilter faulty short circuit or wire break u Check sensor and wiring replace as necessary 422 SD T Charge Air B ZKP Number 2 0...

Страница 64: ...low alarm warning Cause Corrective action Injector power stage sensor defect internal fault in engine governor u Replace engine governor 446 SD P HD2 ZKP Number 1 8004 599 Yellow alarm power limitatio...

Страница 65: ...required 470 SD T ECU ZKP Number 1 8004 587 Yellow alarm warning Cause Corrective action Temperature sensor for engine governor faulty short circuit or wire break u Check sensor and wiring replace as...

Страница 66: ...ated by plant u Observe any other messages 500 AL Wiring POM Starter 1 ZKP Number 1 4500 900 Yellow alarm warning Cause Corrective action A cabling fault in connection of starter 1 to POM has been det...

Страница 67: ...Node Lost ZKP Number 1 4500 904 Yellow alarm warning Cause Corrective action POM missing on CAN bus u Check connection and POM 506 AL Low Starter Voltage ZKP Number 1 4500 906 Yellow alarm warning Cau...

Страница 68: ...ation value into flash or SD of level sensor u Check sensor and wiring replace as necessary Page 119 536 AL Wiring PWM_CM1 ZKP Number 1 1041 921 Yellow alarm warning Cause Corrective action Wire break...

Страница 69: ...orrective action T Lube Oil Pan has violated the limit value too cold significantly increased engine wear Engine start might be inhibited by the locomotive control system 1 Extend preheating period 2...

Страница 70: ...ered Cause Corrective action Pressure relief valve of second rail faulty u Check pressure relief valve replace as necessary 600 SD T Exhaust A B ZKP Number 1 8004 646 Red alarm power reduction 20 Caus...

Страница 71: ...1041 927 Yellow alarm warning Cause Corrective action Wire break or short circuit on channel PWM_CM7 u Check wiring to connected device or check connected device actuator sensor replace if necessary...

Страница 72: ...AL AGR Throttle B Defect ZKP Number 1 0700 031 Yellow alarm warning Cause Corrective action Actuator at EGR shutoff flap B or flap mechanism faulty u Replace actuator or flap 631 AL Bypass Throttle D...

Страница 73: ...0700 105 Yellow alarm warning Cause Corrective action CAN lube oil level sensor faulty short circuit or wire break u Check sensor and wiring replace as necessary 637 SD T Lube Oil Pan J1939 ZKP Numbe...

Страница 74: ...r Element ZKP Number 1 0700 141 Yellow alarm warning Cause Corrective action SD Smart NOx heating element faulty short circuit or wire break u Check sensors B88 1 B88 2 and cabling replace if necessar...

Страница 75: ...800 990 Yellow alarm warning Cause Corrective action Bosch LSU lambda sensor faulty u Check sensor and wiring replace as necessary 757 AL Lim T Coolant NT Fan ZKP Number 2 2800 900 Yellow alarm warnin...

Страница 76: ...place as necessary Page 119 807 SD Charger 4 Speed ZKP Number 1 3010 903 Yellow alarm warning Cause Corrective action Speed sensor of secondary turbocharger faulty short circuit or wire break u Check...

Страница 77: ...Corrective action Charge air temperature sensor faulty short circuit or wire break u Check sensor B9 1 and wiring replace as necessary Page 119 844 AL HI T Charge Air before AGR ZKP Number 2 0147 931...

Страница 78: ...or flap 872 AL EGR A Fast learn failed ZKP Number 1 0700 021 Yellow alarm warning Cause Corrective action Actuator at bypass flap or flap mechanism faulty u Replace actuator or flap 876 AL EGR B Fast...

Страница 79: ...emperature too high 1 Check belt drive 2 Check coolant pump 903 AL SD T Coolant at cylinder head ZKP Number 1 0054 007 Yellow alarm warning Cause Corrective action Cylinder head coolant temperature se...

Страница 80: ...ck engine in steady state condition for black exhaust color 5 Check if fault code 961 is active 6 Check engine for idle speed hunting Verify with DiaSys that the engine speed signal does not vary 7 Co...

Страница 81: ...warning Cause Corrective action Internal engine fault u Contact Service 961 AL NOx p5 max BOI min active ZKP Number 1 1600 919 Yellow alarm warning Cause Corrective action Internal engine fault u Con...

Страница 82: ...e 91 3 Replace filter element of fuel prefilter Page 92 4 Replace fuel filter Page 89 1025 LOLO P Fuel Common RailB ZKP Number 2 0115 911 Yellow alarm warning Cause Corrective action Fuel pressure in...

Страница 83: ...y 5 mm F30002815 1 Barring device F6790714 1 Preparatory steps u Remove cylinder head cover Page 86 Diagram for 12V engines two crankshaft positions 1 Cylinder A1 is in firing TDC 2 Cylinder A1 is in...

Страница 84: ...B side Page 34 A Cylinder A1 is in firing TDC B Cylinder A1 is in overlap TDC 2 Bar engine manually in direction of rotation of the engine until the straight surface arrow points up wards and the ang...

Страница 85: ...locknut 1 with torque wrench to specified torque holding adjusting screw 2 firm with Allen screw Name Size Type Lubricant Value Standard Nut M10 x 1 Tightening torque 43 Nm 4 Nm 5 Check if the feeler...

Страница 86: ...and re place if required 5 Position cylinder head cover and screws at positions 1 to 4 and tighten to specified initial tightening torque using a torque wrench Name Size Type Lubricant Value Standard...

Страница 87: ...1 Unlock fuel priming pump screw out han dle 1 Note Catch emerging fuel with a suitable cloth 2 Loosen threaded vent plug 2 and screw out by approx 3 to 4 turns 3 Operate the pump with the handle 1 un...

Страница 88: ...fuel Note Do not remove threaded vent plug 3 Open threaded vent plug arrow 4 Screw in threaded vent plug arrowed and tighten to specified torque using a torque wrench Name Size Type Lubricant Value S...

Страница 89: ...crew it approx 3 to 4 turns 3 Wait 10 minutes until fuel has drained from filter housing 2 4 Remove threaded cover 1 5 Remove fuel filter element 6 Check condition of the sealing ring on the threaded...

Страница 90: ...12 Vent fuel system Page 87 90 Task Description MS15033 02E 2015 02 TIM ID 0000035537 004...

Страница 91: ...f fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Draining condensate from fuel prefilter 1 Provide a suitable container to collect the water 2 Open drain scre...

Страница 92: ...r in which to collect the fuel Replacing fuel prefilter 1 Close fuel supply 2 Unscrew filter cover 1 3 Remove filter cover 1 with filter ele ment 3 from filter housing 4 Remove filter element 3 from f...

Страница 93: ...lement Removal and installation 1 Release latches 9 2 Remove dust bowl 8 and partition 7 3 Remove collar nut 6 4 Screw off air filter element 4 5 Clean housing 3 and dust bowl 8 6 Check seal 5 for dam...

Страница 94: ...Note Clean paper filter element dry only 1 Open air filter and remove filter element Page 93 2 Check seal for damage and cleanness re place if necessary 3 Clean all mating and sealing surfaces Note De...

Страница 95: ...isabled Special tools Material Spare parts Designation Use Part No Qty Air filter Spare Parts Catalog Replacing air filter 1 Remove air filter and install new one Page 93 2 Reset signal ring of servic...

Страница 96: ...led Checking signal ring position 1 Replace air filter if the signal ring 2 is completely visible in the red area of the ob servation window 3 Page 95 2 After installation of new filter press reset bu...

Страница 97: ...and max 1 marks 4 If necessary top up to the max 2 mark Page 98 5 Insert oil dipstick 1 in guide tube up to the stop Checking oil level after the engine is stopped 1 5 minutes after stopping the engin...

Страница 98: ...Avoid contact with skin Do not inhale oil vapor Draining oil via drain plug on oil pan 1 Provide a suitable container to collect the oil 2 Remove drain plug 2 and drain oil 3 Insert drain plug 2 and u...

Страница 99: ...ilter covers 1 approx 3 to 4 revolutions 2 Wait 10 minutes until the oil has drained from the filter housings 3 Take off threaded cover 1 with oil filter el ement 3 4 Pull oil filter element 3 to deta...

Страница 100: ...ank counterclockwise to the first stop and allow pressure to escape 2 Continue to turn breather valve counter clockwise and remove 3 Check coolant level coolant must be visi ble at the lower edge of t...

Страница 101: ...e Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 102 2 Fill with engine coolant Page 104 MS15033 02E 2015 02 Task Description...

Страница 102: ...Preparatory steps 1 Provide a suitable container to catch the coolant 2 Switch off preheater if installed Engine coolant Draining 1 Turn breather valve of filler neck on coolant expansion tank counter...

Страница 103: ...nkcase right side 1 2 6 Open drain plugs and drain coolant at crankcase left side 1 2 7 Install drain plug with new sealing ring 8 Position breather valve on filler neck and close MS15033 02E 2015 02...

Страница 104: ...ICE 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 of coolant expan...

Страница 105: ...inal steps 1 Start the engine and operate it at idle speed for some minutes 2 Check coolant level Page 100 top up with coolant if required MS15033 02E 2015 02 Task Description 105 TIM ID 0000000909 00...

Страница 106: ...f engine noise when the engine is running Risk of damage to hearing Wear ear protectors Engine coolant pump Relief bore check 1 Check relief bore 1 for coolant discharge Permissible coolant discharge...

Страница 107: ...ank counterclockwise to the first stop and allow pressure to escape 2 Continue to turn breather valve counter clockwise and remove 3 Check coolant level coolant must be visi ble at marker plate 4 Top...

Страница 108: ...ecial tools Material Spare parts Designation Use Part No Qty Coolant Charge air coolant Change 1 Drain charge air coolant Page 109 2 Fill with charge air coolant Page 110 108 Task Description MS15033...

Страница 109: ...ate container to drain the coolant into 2 Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to escape 3 Continue to turn breather valve counter clockw...

Страница 110: ...thermal stress Possible formation of cracks in the engine Fill top up coolant only into cold engine Preparatory steps 1 Turn breather valve 1 on coolant expan sion tank counterclockwise to the first s...

Страница 111: ...Final steps 1 Start the engine and operate it at idle speed for some minutes 2 Check coolant level Page 107 MS15033 02E 2015 02 Task Description 111 TIM ID 0000031875 006...

Страница 112: ...ine is running Risk of damage to hearing Wear ear protectors Charge air coolant pump Re lief bore check 1 Check relief bore 1 for coolant discharge Permissible coolant discharge Up to 0 1 ml per hour...

Страница 113: ...engine make sure that all safety devices are put back in place and all tools are removed from the engine Preparatory step 1 Install barring gear Page 34 2 Cut poly vee belt 2 on charge air coolant pum...

Страница 114: ...kshaft 2 Fit poly vee belt 2 on front three grooves of belt pulley 3 to crankshaft and preload with assembly jig 4 3 Bar engine with barring gear until poly vee belt 2 lies completely on belt pulley 3...

Страница 115: ...are Parts Catalog Diverter pulley Spare Parts Catalog WARNING Belt tensioner spring is pretensioned Risk of hands being crushed Lock belt tensioner in position Only use specified tools and devices Pre...

Страница 116: ...with screw 2 5 Tighten screw 2 to specified torque using a torque wrench Name Size Type Lubricant Value Standard Screw Tightening torque Engine oil 60 Nm 10 Nm Final steps Note Remove pin before relea...

Страница 117: ...to the stop to re move the 8 mm steel pin 6 Remove 8 mm steel pin 7 Release belt tensioner and remove square wrench with extension Install battery charging genera tor drive belt 1 Fit square wrench w...

Страница 118: ...auge 7 Carry out this measuring procedure two times with the measuring points arranged 90 degrees from each other 8 Bearing bushing wear is equal to the half of the measured value If the measured valu...

Страница 119: ...lips are closed and intact 4 Replace faulty cable clips 5 Check that cable clamps are firm tighten loose cable clamps 6 Replace faulty cable clamps 7 Visually inspect the following electrical line com...

Страница 120: ...pensation parameters CDC will void the emissions certification for the en gine Resetting drift correction parameters CDC with DiaSys 1 Dialog system DiaSys E531920 2 If no DiaSys is available contact...

Страница 121: ...surface using a cloth moistened with isopropyl alcohol 2 Remove dirt from the connector and cable surfaces with isopropyl alcohol 3 Check legibility of cable labels Clean or replace illegible labels...

Страница 122: ...plug in connections on engine governor 1 Check firm seating of all connectors on the engine governor Ensure that the clips 1 are engaged 2 Check firm seating of all screws 2 on en gine governor cable...

Страница 123: ...ar suitable protective equipment thermal gloves Avoid unprotected contact with hot surfaces NOTICE High voltage Risk of damage to components Switch off ignition before replacing components NOTICE Cera...

Страница 124: ...Tightening torque max 12 Nm 2 Remove protective cap on thread of sensor 3 only just before installation Note Do not wipe off the thread lubricant applied by the manufacturer 3 Coat sensor 3 thread wi...

Страница 125: ...ore beginning work Wear suitable protective equipment thermal gloves Avoid unprotected contact with hot surfaces NOTICE Ceramic cell breakage due to shock or impact Risk of damage to components Avoid...

Страница 126: ...the manufacturer 2 Coat sensor thread with specified assembly compound as required 3 Screw in sensor by hand 4 Tighten nut 2 to specified torque using a torque wrench Name Size Type Lubricant Value S...

Страница 127: ...y Control Check sum procedure to detect data transmission faults DC Direct Current DEF Diesel Exhaust Fluid Urea solution with 32 5 urea concentration Designation used in Northern America DIFF Differe...

Страница 128: ...integration of peripheral components PDU Process Data Unit POM Power Output Module Module to control starter and battery charging gen erator PU Projektierungsumgebung Project engineering environment P...

Страница 129: ...e work in case of malfunction or changed operating conditions or for spare parts supply Your contact person in our Customer Assistance Center E mail info mtu online com Tel 49 7541 9077777 Fax 49 7541...

Страница 130: ...ne Barring manually Page 34 Allen key 5 mm Part No F30002815 Qty Used in 1 7 1 1 Valve clearance Check and adjustment Page 83 Assembly jig Part No F6794712 Qty Used in 1 7 10 1 Coolant pump Drive belt...

Страница 131: ...ge 83 Barring device Part No F6797426 Qty Used in 1 4 8 Engine Barring manually Page 34 Box wrench 14 mm Part No F30028346 Qty Used in 1 7 1 1 Valve clearance Check and adjustment Page 83 Feeler gauge...

Страница 132: ...lacement Page 99 Qty Used in 1 7 11 1 Battery charging generator Belt tensioner and diverter pulley replacement Page 115 Qty Used in 1 7 14 4 NOx sensor Replacement Page 123 Qty Used in 1 7 14 5 Lambd...

Страница 133: ...sed in 1 7 14 4 NOx sensor Replacement Page 123 Qty Used in 1 7 14 5 Lambda sensor Replacement Page 125 Torque wrench 4 20 Nm Part No F30044239 Qty Used in 1 7 2 1 Fuel system Venting Page 87 Qty Used...

Страница 134: ...on 86 Removal 86 D Diverter pulley Replacement On battery charging generator 115 Drift correction parameters Reset 120 Drive belt Charge air coolant pump Replacement 113 Engine coolant pump Replacemen...

Страница 135: ...duct data 12V1600R50 24 R Relief bore Engine coolant pump Check 106 S Safety notices standards 15 Safety regulations Auxiliary materials 13 Environmental protection 13 Fire prevention 13 Fluids and lu...

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