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8.6.2 Injector – Removal and installation

Preconditions

☑

Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use

Part No.

Qty.

Barring tool

F6557929

1

Puller

3555890163/00

1

Fuel suction device

F30378207

1

Torque wrench, 20–100 Nm

F30026582

1

Ratchet adapter

F30027340

1

Adapter

F30006234

1

Open-end socket wrench, 19 mm

F30025897

1

Crowfoot wrench, 19 mm

F30027424

1

Crowfoot box wrench, 22 mm

F30027425

1

Double-head box wrench

F30011450

1

Assembly compound (Kluthe Hakuform 30-15)

X00067260

1

Engine oil
Sealing ring

(→ Spare Parts Catalog)

Sealing ring

(→ Spare Parts Catalog)

Sealing

(→ Spare Parts Catalog)

WARNING

Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.

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 direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.

Preparatory steps

1.

Close fuel supply line before fuel filter.

2.

Drain fuel (→ Page 97).

3.

Remove engine governor as necessary (→ Page 142).

4.

Remove charge-air manifolds and take off seals (only on engines with air-to-air charge-air cooling).

5.

Remove cylinder head cover (→ Page 83).

MS15018/03E 2016-02

| Injection Valve / Injector | 89

TIM-ID: 0000000023 - 005

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Содержание 12V 2000 G65-TB

Страница 1: ...Operating Instructions Diesel engine 12V2000G65 G65 TB 16V2000G65 G65 TB 18V2000G65 G65 TB Application group 3A MS15018 03E...

Страница 2: ...pplicability 2016 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 consent of MTU Fri...

Страница 3: ...Maintenance task reference table QL1 42 7 Troubleshooting 7 1 Fault indication on SAM display Genset applications 43 7 2 Troubleshooting 67 8 Task Description 8 1 Engine 70 8 1 1 Engine Barring manua...

Страница 4: ...oolant Filling 125 8 16 2 Charge air coolant Draining 127 8 16 3 Charge air coolant Change 128 8 16 4 Charge air coolant Level check 129 8 17 Coolant System 130 8 17 1 Cooler Checking cooler elements...

Страница 5: ...cesses that might affect the emission characteristics of the product are prohibited by emission regulations Emission control units systems may only be maintained ex changed or repaired if the componen...

Страница 6: ...particular with regard to the specified tightening torques With the exclusive use of technical personnel trained in commissioning operation maintenance and re pair By contracting only workshops autho...

Страница 7: ...be instructed repeatedly Personnel requirements All work on the product shall be carried out by trained and qualified personnel only Training at the Training Center of the manufacturer Technical perso...

Страница 8: ...e product into operation make sure that all control and display instruments as well as the signaling and alarm systems work properly Smoking is prohibited in the area of the product Safety regulations...

Страница 9: ...Follow the applicable warning instructions pertaining to such devices MS15018 03E 2016 02 Safety 9 TIM ID 0000040533 012...

Страница 10: ...V belts must not be painted They may only be installed after painting the engine or must be covered before painting work is carried out The following applies to starters with copper beryllium alloy p...

Страница 11: ...g in its vicinity Before starting welding work Switch off the power supply master switch Disconnect the battery cables or actuate the battery isolating switch Separate the electrical ground of electro...

Страница 12: ...h sharp edges Chafing on components Contact with hot surfaces Do not secure cables on lines carrying fluids Do not use cable straps to secure cables Always use connector pliers to tighten union nuts o...

Страница 13: ...ully with its handling Noise Noise can lead to an increased risk of accidents if acoustic signals warning shouts or sounds indicating dan ger are drowned Wear ear protectors in workplaces with a sound...

Страница 14: ...rrying out painting work outside the spray stands provided with fume extraction systems ensure that the area is well ventilated Make sure that neighboring work areas are not adversely affected There m...

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

Страница 16: ...not rub against the engine or its compo nents during the lifting procedure Readjust lifting tackle as necessary 6 For special packaging with aluminum foil Attach engine to lifting eyes of bearing pede...

Страница 17: ...ppropriate lifting devices and appliances Never stand beneath a suspended load 1 Lifting eye 2 Center of gravity Take note of the engine center of gravity See Installation Arrangement drawings for det...

Страница 18: ...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 19: ...Oil heat exchanger 8 Oil filter 9 Coolant pump 10 Fuel priming pump 11 Air outlet 12 Exhaust turbocharger 13 Exhaust elbow 14 Charge air manifold 15 Cylinder head 16 Flywheel housing 17 Starter 18 St...

Страница 20: ...aust elbow 14 Charge air manifold 15 Cylinder head 16 Flywheel housing 17 Storage 18 Crankcase breather Figure also applies similarly to 12V 16V 18V2000Gxy Engine type designation Explanation of engin...

Страница 21: ...2 B5 Lube oil pressure 3 B9 Charge air coolant temperature 4 B10 Charge air pressure 5 B1 Camshaft speed 6 B13 Crankshaft speed 7 B6 Coolant temperature 8 B33 Fuel temperature The coolant level senso...

Страница 22: ...sure 3 B9 Charge air coolant temperature 4 B10 Charge air pressure 5 B1 Camshaft speed 6 B13 Crankshaft speed 7 B6 Coolant temperature 8 B33 Fuel temperature The coolant level sensor F33 is located in...

Страница 23: ...A Intake air temperature C 25 25 25 Barometric pressure mbar 1000 1000 1000 Site altitude above sea level M 100 100 100 Power related data power ratings are net brake power as per ISO 3046 Description...

Страница 24: ...er 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...

Страница 25: ...bar 0 5 0 5 0 5 General operating data Description 12V2000 G65 16V2000 G65 18V2000 G65 Cold start capability air temperature w o start aid w o preheating case A R C 0 0 0 Coolant preheating preheating...

Страница 26: ...kg 2490 3100 3500 Acoustics Description 12V2000 G65 16V2000 G65 18V2000 G65 Exhaust noise unsilenced DL sound power level LW ISO 6798 3 dB A tolerance R dB A 123 124 125 Engine surface noise with att...

Страница 27: ...oolant temperature C 55 55 55 Raw water inlet temperature C Barometric pressure mbar 1000 1000 1000 Site altitude above sea level M 100 100 100 Power related data power ratings are net brake power as...

Страница 28: ...ads 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 engin...

Страница 29: ...e engine from R bar 6 2 5 5 6 0 Lube oil operating pressure before engine to R bar 7 5 6 5 8 0 Lube oil operating pressure before engine warning R bar 4 4 4 4 4 4 Lube oil operating pressure before en...

Страница 30: ...y dipstick mark min standard oil system design max operating inclinations L Liter 50 69 87 Oil pan capacity dipstick mark max standard oil system design max operating inclinations L Liter 67 92 110 We...

Страница 31: ...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 18V A1 B6 A3 B4 A5 B2 A7 B1 A9 B3 A8 B5 A6 B7 A4 B9 A2 B8 MS15018 03E 2016 02 Tec...

Страница 32: ...prox 2226 mm approx 1580 mm approx 1572 mm 18V2000Gx5 approx 2398 mm approx 1580 mm approx 1603 mm 12V2000Gx5 TB approx 1836 mm approx 1580 mm approx 1585 mm 16V2000Gx5 TB approx 2180 mm approx 1580 m...

Страница 33: ...el prefilter pressure gauge Align adjustable pointer with position of pressure indicator Page 103 Fuel system Vent Page 100 Coolant circuit If engine is out of service for more than one year change en...

Страница 34: ...116 Cooling system Check engine coolant level Page 119 Check charge air coolant level Page 129 Cooling system Preheat coolant with preheating unit Fuel prefilter Drain Page 104 Monitoring equipment Ca...

Страница 35: ...if fitted Switch on Starting the engine Item Action Switchgear cabinet control panel etc depending on manufacturer If coolant temperature is 40 C with preheating system or 5 C without preheating syste...

Страница 36: ...when a pushbutton is provided Safety system Override Item Action Switchgear cabinet control panel etc depending on manufacturer Activate pushbutton for Override input of the ECU Certain shutdown crit...

Страница 37: ...for abnormal running noises and vibration Fuel prefilter Check reading on differential pressure gage to ensure that maximum admis sible value is not exceeded Page 103 Exhaust system Check exhaust col...

Страница 38: ...After the generator breaker if provided has been opened allow the engine to cool down by running it idle for approx 5 minutes Preparing a pump drive diesel mechanical diesel electric Item Action Engin...

Страница 39: ...from LOP Item Action Emergency stop pushbutton Press pushbutton Engine is stopped by disconnecting the power supply to the ECU Signaling e g by horn flashing lamp is tripped After emergency engine sto...

Страница 40: ...he engine Engine remains ready for operation After stopping the engine Item Action Engine generator pump control Select operating mode e g MANUAL AUTOMATIC OPERATION 40 Operation MS15018 03E 2016 02 T...

Страница 41: ...o the coolant the engine room is not heated the coolant is not kept at a suitable temperature the antifreeze concentration is insufficient for the engine room tempera ture antifreeze concentration is...

Страница 42: ...from fuel prefilter Page 104 W0508 Check reading on differential pressure gage of fuel prefilter Page 103 W0534 Carry out test run minimum duration until steady state tem perature is reached no less t...

Страница 43: ...rred e g nd11 Second line option Running text providing more information about the fault currently displayed Time indicator for alarms Meaning Alarm is no longer active does not appear on next power u...

Страница 44: ...Module Slot5 Defect 24 I O Module Slot6 Defect 25 I O Module Slot7 Defect 26 I O Module Slot8 Defect 27 Download Server Collision 28 not projected node Engine governor messages Recommended action in c...

Страница 45: ...e below lists possible fault codes Fault code no Full designation Meaning Action Setting parame ter no 003 HI T Fuel Prewarning Fuel tempera ture too high limit value 1 alarm configuration parame ter...

Страница 46: ...8008 100 for explanation Automatic en gine shutdown Check oil level con tact Service 2 0100 922 024 SS Coolant Level Coolant level too low limit value 2 alarm configuration parameter see PR 2 8008 100...

Страница 47: ...leaking alarm configuration parame ter see PR 2 8008 100 for explanation On stopping Seal off system contact Service On starting Check engine for leakage if none found attempt re starting as per oper...

Страница 48: ...arameter see PR 2 8008 100 for explanation Engine start inter lock is active as coolant temperature is too low for engine start preheating necessary 2 1090 921 095 AL Prelubrication Fault Oil priming...

Страница 49: ...or CAN bus to backup system is dis rupted alarm configuration parameter see PR 2 8008 100 for explanation Contact Service 2 4000 004 177 AL LifeData restore in complete This fault message is gener ate...

Страница 50: ...warning Causes are e g missing associate nodes mi nor disruptions and tempora ry bus overload alarm con figuration parameter see PR 2 8008 100 for explanation Contact Service 2 0500 687 188 AL CAN2 B...

Страница 51: ...pressure sensor faulty HP controller in emergency mode short circuit or wire break Check sensor and wiring B48 replace as necessary 1 8004 567 216 SD T Lube Oil SD alarm configuration lube oil temper...

Страница 52: ...ration cam shaft sensor faulty short cir cuit or wiring damage engine remains operational Check sensor and wiring B1 attempt restart fault may be rectified when en gine is restarted Contact Service if...

Страница 53: ...mp if this occurs frequently 1 8004 502 304 AL Timing Cylinder A4 Time of flight measuring fault injector cylinder A4 Time of flight value measured ex tremely small or large alarm configuration parame...

Страница 54: ...B1 Time of flight measuring fault injector cylinder B1 Time of flight value measured ex tremely small or large alarm configuration parameter see PR 2 8008 100 for explana tion Replace plug in pump if...

Страница 55: ...ctor cylinder B8 Time of flight value measured ex tremely small or large alarm configuration parameter see PR 2 8008 100 for explana tion Replace plug in pump if this occurs frequently 1 8004 517 319...

Страница 56: ...itive to negative e g by exchanging injec tors Fault rectifica tion When engine is restarted 1 8004 523 325 AL Wiring Cylinder A5 Wiring fault in injector wiring cylinder A5 Result Misfiring alarm con...

Страница 57: ...sitive to negative e g by exchanging injec tors Fault rectifica tion When engine is restarted 1 8004 529 331 AL Wiring Cylinder B1 Wiring fault in injector wiring cylinder B1 Result Misfiring alarm co...

Страница 58: ...itive to negative e g by exchanging injec tors Fault rectifica tion When engine is restarted 1 8004535 337 AL Wiring Cylinder B7 Wiring fault in injector wiring cylinder B7 Result Misfiring alarm conf...

Страница 59: ...de disrup tion in solenoid valve e g by injec tor replacement Fault rectification After each working cycle 1 8004 541 343 AL Open Load Cylinder A3 Disruption fault in injector wiring cylinder A3 Resul...

Страница 60: ...in solenoid valve e g by injec tor replacement Fault rectification After each working cycle 1 8004 547 349 AL Open Load Cylinder A9 Disruption fault in injector wiring cylinder A9 Result Misfiring ala...

Страница 61: ...in solenoid valve e g by injec tor replacement Fault rectification After each working cycle 1 8004 553 355 AL Open Load Cylinder B5 Disruption fault in injector wiring cylinder B5 Result Misfiring al...

Страница 62: ...ve If parameter 1 1020 021 Pow er Stage Failure Stop En gine is set engine is stop ped here additionally alarm configuration parameter see PR 2 8008 100 for explana tion Start engine gover nor self te...

Страница 63: ...ring TOP 3 Short circuit or wire break at transistor output 3 plant side TOP 3 alarm configuration parameter see PR 2 8008 100 for explanation Check wiring 2 8006 640 384 AL Wiring TOP 4 Short circuit...

Страница 64: ...ty or no re sistance via switch alarm configuration parameter see PR 2 8008 100 for explana tion Check wiring 2 8006 631 407 AL Open Load Digital Input 8 Line disruption at digital in put 8 wiring fau...

Страница 65: ...ure Alarm con figuration parameter see PR 2 8008 100 for explanation None 2 7000 011 463 SD AUX 2 SD alarm configuration ana log input signal for Aux 2 faulty short circuit or wiring damage Check sign...

Страница 66: ...rror of crash re corder Contact Service 1 8010 007 478 AL Comb Alarm Yel Plant YELLOW combined alarm from plant alarm configura tion parameter see PR 2 8008 100 for explanation Contact Service 2 8006...

Страница 67: ...or rotation by starter Battery flat or faulty u Charge or replace battery see manufacturer s documentation Engine wiring is faulty u Check Page 139 Air in fuel system u Vent fuel system Page 100 Engin...

Страница 68: ...supply ventilation ducts Charge air pressure too low Cause Corrective action Air filter clogged u Check signal ring position of contamination indicator Page 114 Charge air cooler is contaminated u Co...

Страница 69: ...is faulty u Contact Service Piston rings are faulty u Contact Service Cylinder liner is faulty u Contact Service White exhaust gas Cause Corrective action Engine is not at operating temperature u Run...

Страница 70: ...rsons in the engine s danger zone After finishing work on the engine make sure that all safety devices are put back in place and all tools are removed from the engine Engine Barring manually 1 Remove...

Страница 71: ...lled in Before cranking the engine with starter system make sure that there are no persons in the engine s danger zone Engine Barring with starting system 1 Press pushbutton Bar engine without startin...

Страница 72: ...re are no persons in the engine s danger zone WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Engine Test run 1 Start engine Page 35 2 Perfo...

Страница 73: ...pattern First signs of marks left by lower cooling bores Running pattern seems darker No action required Darker areas of even or varying color intensity Beginning and end of the discoloration are not...

Страница 74: ...Final steps 1 Install injector Page 89 2 Install cylinder head cover Page 83 74 Cylinder Liner MS15018 03E 2016 02 TIM ID 0000000015 016...

Страница 75: ...ound the liner It appears rather darker within the honed struc ture in contrast to the bright metallic running surface The honing pattern is undis turbed Discolorations extend in stroke direction and...

Страница 76: ...ation are similar A thorough inves tigation and compliance with the above evaluation criteria allow an unambiguous evaluation To avoid unnec essary disassembly work it is recommended that another insp...

Страница 77: ...r defenders NOTICE Cleaning agents should not be left to take effect for too long Damage to components is possible Observe manufacturer s instructions Crankcase breather Wire mesh cleaning 1 Remove ho...

Страница 78: ...re harmful to health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Replacing oil separator filter el ement 1 Remo...

Страница 79: ...hragm 3 on housing 1 5 Install new gasket 2 and spring 5 together with cover 4 6 Use torque wrench to tighten the screws of cover 4 to the specified torque Name Size Type Lubricant Value Standard Scre...

Страница 80: ...inder head cover Page 83 2 Install barring tool Page 70 3 Bar crankshaft with barring tool in engine di rection of rotation until TDC pointer and TDC mark on the flywheel are aligned Checking valve cl...

Страница 81: ...Inlet Inlet valve adjustment admissible X Exhaust Exhaust valve adjustment admissible Valve adjustment not admissible Table 2 Valve clearance settings 4 Use feeler gage to determine the distance betw...

Страница 82: ...to verify that the gage just passes through the gap Result Adjust valve clearance if this is not the case Final steps 1 Remove barring tool Page 70 2 Install cylinder head cover Page 83 3 Install cap...

Страница 83: ...s with crankcase breather Loosen clamps 2 Slide rubber sleeves onto the pipe Cylinder head cover Removal and installation 1 Remove cylinder head cover 2 with gas ket 1 from cylinder head 2 Clean insta...

Страница 84: ...acement Special tools Material Spare parts Designation Use Part No Qty Injection pump Spare Parts Catalog Injection pump Replacement u Remove injection pump and install new one Page 85 84 Injection Pu...

Страница 85: ...nd 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 sure that there are no persons in the engine s danger...

Страница 86: ...6 Remove injection pump 7 Remove sealing rings from injection pump 8 After removal seal all openings with suitable covers Installing injection pump 1 Remove all blanking plugs and covers 2 Clean mati...

Страница 87: ...3 Tighten union nuts 2 and 4 marked with 30 3 Nm see arrow to specified torque using a torque wrench Name Size Type Lubricant Value Standard Union nut M14 Tightening torque Engine oil 30 Nm 3 Nm 14 In...

Страница 88: ...Replacement Special tools Material Spare parts Designation Use Part No Qty Injector Spare Parts Catalog Replacing injector u Remove injector and install new injector Page 89 88 Injection Valve Injecto...

Страница 89: ...g Spare Parts Catalog WARNING Fuels are combustible and explosive Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Wear protective clothing protective g...

Страница 90: ...ew 2 4 Pull off pressure pipe neck 3 5 Extract fuel from the exposed bores using the suction device 6 Remove sealing ring from pressure pipe neck 3 7 Remove screw 1 8 Take off clamp 2 9 Screw puller i...

Страница 91: ...rom cylinder head with screwdriver 14 Remove sealing ring Installing injector 1 Remove all covers before installation 2 Clean sealing surface on cylinder head and protective sleeve 3 Coat sealing ring...

Страница 92: ...on the injector is engaged in the groove of the clamp 2 Forked clamp end 2 is engaged in the cover recess 10 Tighten screw 3 of the clamp by hand Result Injector can still be turned 11 Blow out fuel l...

Страница 93: ...tion pump hand tight 22 Tighten union nut 3 on pressure pipe neck 5 hand tight Note Observe the lettering on the union nuts 1 and 3 23 Tighten union nuts 1 and 3 marked with 35 3 Nm see arrows to spec...

Страница 94: ...Catalog WARNING Fuels are combustible and explosive Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Wear protective clothing protective gloves and safe...

Страница 95: ...ne oil 12 Connect fuel line 2 to injection pump and pressure pipe neck 5 13 Tighten union nut 1 on injection pump hand tight 14 Tighten union nut 3 on pressure pipe neck 5 hand tight Note Observe the...

Страница 96: ...eck gaskets for damage and replace them if required 3 Coat gaskets with grease and place onto cylinder head 4 Install charge air pipes 5 Install engine governor Page 142 6 Open fuel supply line 7 Vent...

Страница 97: ...e combustible and explosive Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Wear protective clothing protective gloves and safety glasses facial protec...

Страница 98: ...nd tighten to specified torque using a torque wrench Name Size Type Lubricant Value Standard Non return valve Tightening torque Engine oil 10 Nm 1 Nm 5 Install fuel line 6 Tighten nut on banjo union 9...

Страница 99: ...d explosion Avoid open flames electrical sparks and ignition sources Do not smoke Wear protective clothing protective gloves and safety glasses facial protection Removing and installing pres sure reli...

Страница 100: ...d explosion Avoid open flames electrical sparks and ignition sources Do not smoke Wear protective clothing protective gloves and safety glasses facial protection Venting fuel system 1 Unlock fuel prim...

Страница 101: ...arrowed 10 Operate the pump with the handle until bub ble free fuel emerges 11 Tighten non return valve to specified torque using a torque wrench Name Size Type Lubricant Value Standard Non return val...

Страница 102: ...ve Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Wear protective clothing protective gloves and safety glasses facial protection Replacing fuel filte...

Страница 103: ...of dif ferential pressure gage 1 After installation of a new filter element Align adjustable pointer 2 with pressure indicat ing pointer 3 of pressure gage 1 2 Verify that differential pressure is wi...

Страница 104: ...ep away from the engine s danger zone WARNING Fuels are combustible and explosive Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Wear protective cloth...

Страница 105: ...se drain valve 6 6 Remove screws securing the cover and take off cover 2 7 Fill filter housing with clean fuel 8 Place new seal in cover 2 9 Fit cover with seal and secure it with screws Note Only in...

Страница 106: ...parks and ignition sources Do not smoke Wear protective clothing protective gloves and safety glasses facial protection WARNING Liquid or gaseous media e g fuel are poisonous Escaping vapors of highly...

Страница 107: ...ered side flushing the filter deposits down wards out of the filter 4 Close threaded vent plug 5 and drain valve 6 Fuel prefilter Filling with fuel 1 Remove screws securing cover and take off cover 2...

Страница 108: ...safety glasses facial protection Cleaning fuel prefilter 1 Close fuel supply 2 Remove nuts from filter head 3 Unscrew filter bowl and drain fuel into a suit able container 4 Remove securing nut for fi...

Страница 109: ...g Gasket Spare Parts Catalog WARNING Fuels are combustible and explosive Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Wear protective clothing prote...

Страница 110: ...ve spring housing 4 and filter ele ment 3 8 Insert new filter element 3 and spring hous ing 4 9 Fill filter housing with clean fuel 10 Place new gasket in cover 2 11 Fit cover with gasket and secure i...

Страница 111: ...s Checking 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 bo...

Страница 112: ...Part No Qty Air filter Spare Parts Catalog Filter insert Spare Parts Catalog Filter element Spare Parts Catalog Air filter Replacement 1 Remove air filter s and install new one s Page 113 2 Reset sig...

Страница 113: ...e of the intake housing 3 and clean it 4 Fit air filter 1 and clamp 2 on connecting flange of intake housing 3 5 Tighten clamp 2 Variant B 1 Release latches 1 2 Take off cover 2 3 Remove filter insert...

Страница 114: ...sabled Checking signal ring position 1 Replace air filter if the signal ring 2 is com pletely visible in the red area of the observa tion window 3 Page 112 2 After installation of new filter press res...

Страница 115: ...em make sure that there are no persons in the engine s danger zone WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Air starter Manual operat...

Страница 116: ...4 Top up with oil up to the max 1 mark Page 117 if required 5 Insert oil dipstick into guide tube up to the stop Oil level check after the engine is stopped 1 5 minutes after stopping the engine remov...

Страница 117: ...Draining oil at drain plug on oil pan 1 Provide a suitable container to collect the oil 2 Remove drain plug and drain oil 3 Install drain plug with new sealing ring 4 Replace engine oil filter Page 1...

Страница 118: ...ar protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Engine oil filter Replacement 1 Remove oil filter with filter wrench 2 Clean the sealing face on t...

Страница 119: ...on 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 o...

Страница 120: ...erial Spare parts Designation Use Part No Qty Engine coolant Engine coolant Change 1 Drain engine coolant Page 121 2 Fill with engine coolant Page 122 120 Coolant Circuit General High Temperature Circ...

Страница 121: ...ing unit Engine coolant Draining 1 Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to escape 2 Continue to turn breather valve counterclock wise and...

Страница 122: ...n 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 countercl...

Страница 123: ...rt the engine and operate it at idle speed for some minutes 2 Check coolant level Page 119 top up with coolant if required MS15018 03E 2016 02 Coolant Circuit General High Temperature Circuit 123 TIM...

Страница 124: ...elief bore check 1 Check relief bore for oil and coolant dis charge 2 Permissible discharge Up to 10 drops of coolant per hour Up to 5 drops of oil per hour 3 If discharge exceeds the specified limits...

Страница 125: ...nd 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 f...

Страница 126: ...ate 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...

Страница 127: ...te 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 counterclock wi...

Страница 128: ...al tools Material Spare parts Designation Use Part No Qty Coolant Charge air coolant Change 1 Drain charge air coolant Page 127 2 Fill with charge air coolant Page 125 128 Low Temperature Circuit MS15...

Страница 129: ...pressure to escape 2 Continue to turn cap counterclockwise and remove Note Charge air coolant must be visible at marker plate 3 Check charge air coolant level 4 Top up charge air coolant as necessary...

Страница 130: ...rnally for dirt Preconditions Engine is stopped and starting disabled Check cooler elements externally for dirt 1 Inspect cooler elements visually for dirt 2 Clean badly soiled cooler elements Page 13...

Страница 131: ...ions for use NOTICE Cleaning agents should not be left to take effect for too long Damage to components is possible Observe manufacturer s instructions NOTICE Inappropriate cleaning tool Risk of damag...

Страница 132: ...429 1 Torque wrench 20 100 Nm F30026582 1 Ratchet adapter F30027340 1 Engine oil Preparatory steps u Remove protective cover Drive belt Condition check u Visually inspect condition of drive belt Item...

Страница 133: ...below Application Specified value new drive belt Specified value used drive belt Battery charging generator drive belt 450 N 50 N 350 N 50 N 6 If the measured value does not correspond to the specifi...

Страница 134: ...n drive Page 138 3 Undo securing screws 2 and 3 4 Release tensioning nut 1 until the drive belt can be removed 5 Check belt pulleys for cleanliness remove dirt if any 6 Fit new drive belt 7 Tension dr...

Страница 135: ...check var iant A 1 Place belt tension tester onto drive midway between the belt pulleys arrowed 2 Actuate pushbutton to press the tester uni formly on the drive belt surface until the spring disengage...

Страница 136: ...le The speci fied values are listed in the table below Application Specified value new drive belt Specified value used drive belt Drive belt of fan drive 670 N 50 N 570 N 50 N 6 If the measured value...

Страница 137: ...2 Screw in screw 2 to tension drive belt 3 Check drive belt tension 4 Tighten screws 1 and 4 to specified torque using a torque wrench Name Size Type Lubricant Value Standard Screw M18 Tightening tor...

Страница 138: ...ithout applying any force 5 Fit new set of drive belts 6 To check drive tension the fan bearing ped estal must rest against the gearcase 7 Adjust and check drive belt tension Page 135 Drive belt repla...

Страница 139: ...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...

Страница 140: ...propyl alcohol to remove coarse dirt from housing surface 2 Use isopropyl alcohol to remove dirt from the connector and cable surfaces 3 Check legibility of cable labels Clean or replace illegible lab...

Страница 141: ...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 seati...

Страница 142: ...ine governor from engine 1 Note or mark assignment of cables and plugs 2 Remove all screws 3 3 Undo clips 2 on connectors 4 Remove all male connectors 5 Remove screws 1 6 Take off engine governor Inst...

Страница 143: ...lamp rectify fault as soon as possible 2nd function Read out fault codes CKT Circuit CLS Coolant Level Sensor Monitors coolant level CM Current Measurement Current measured value CPS Coolant Pressure...

Страница 144: ...ssure HI High Alarm Measured value exceeds 1st maximum limit HIHI High High Alarm Measured value exceeds 2nd maximum limit HT High Temperature IDM Interface Data Module Memory module for interface dat...

Страница 145: ...ng lamp stop engine and rectify fault 2nd function Read out fault codes SID System Identifier SRS Synchronous Reference Sensor TDC cylinder 1 SS Safety System Security Shutdown Safety system alarm TBS...

Страница 146: ...of a malfunction for information on changes in conditions of use and for supplying spare parts Your contact person in our Customer Assistance Center E mail info mtu online com Tel 49 7541 9077777 Fax...

Страница 147: ...and installation Page 89 Qty Used in 1 8 7 1 Fuel injection line Pressure pipe neck replacement Page 94 Barring device for 12V engines Part No F6558556 Qty Used in 1 8 1 1 Engine Barring manually Page...

Страница 148: ...sed in 1 8 19 1 Fan drive Drive belt check and adjustment Page 135 Belt tension tester 150 600 N Part No Y20097429 Qty Used in 1 8 18 1 Battery charging generator drive Drive belt check and adjustment...

Страница 149: ...ion pump Removal and installation Page 85 Qty Used in 1 8 6 2 Injector Removal and installation Page 89 Qty Used in 1 8 7 1 Fuel injection line Pressure pipe neck replacement Page 94 Double head box w...

Страница 150: ...in 1 8 6 2 Injector Removal and installation Page 89 Open end socket wrench 19 mm Part No F30025897 Qty Used in 1 8 6 2 Injector Removal and installation Page 89 Qty Used in 1 8 7 1 Fuel injection li...

Страница 151: ...d installation Page 83 Qty Used in 1 8 5 2 Injection pump Removal and installation Page 85 Qty Used in 1 8 6 2 Injector Removal and installation Page 89 Qty Used in 1 8 7 1 Fuel injection line Pressur...

Страница 152: ...Used in 1 8 5 2 Injection pump Removal and installation Page 85 Qty Used in 1 8 6 2 Injector Removal and installation Page 89 Qty Used in 1 8 7 1 Fuel injection line Pressure pipe neck replacement Pa...

Страница 153: ...Crankcase breather Oil separator replacement di aphragm check and replacement Page 78 Qty Used in 1 8 4 2 Cylinder head cover Removal and installation Page 83 Qty Used in 1 8 7 2 Fuel Draining Page 97...

Страница 154: ...cover Removal and installation 83 Cylinder liner Endoscopic examination 73 Instructions and comments on endoscopic and visual examination 75 D Differential pressure gage Adjustment Fuel prefilter 103...

Страница 155: ...ondensate drain for obstructions Check 111 L Lifting requirements 17 M MTU contact persons 146 O Operational checks 37 Overview Engine 19 P Putting the engine into operation after extended out of serv...

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