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MTU 12V2000M86106, Руководство по эксплуатации

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1.7 Standards for safety notices in the text

DANGER

In the event of immediate danger.
Consequences: Death, serious or permanent injury!
• Remedial action.

WARNING

In the event of a situation involving potential danger.
Consequences: Death, serious or permanent injury!
• Remedial action.

CAUTION

In the event of a situation involving potential danger.
Consequences: Minor or moderate injuries!
• Remedial action.

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 all safety instructions and safety notices must be issued to all personnel involved in opera-
tion, maintenance, repair, assembly, installation, or transportation.

2.

The higher level warning notice is used if several hazards apply at the same time. Warnings related to person-
al injury shall be considered to include a warning of potential damage.

MS150119/01E 2016-02

| Safety  | 15

TIM-ID: 0000040578 - 005

Содержание 12V2000M86106

Страница 1: ...Operating Instructions Diesel engine 12V 16V2000Mx6 12V 16V2000M96L MS150119 01E...

Страница 2: ...riable low utilization Table 1 Applicability 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 p...

Страница 3: ...AS 66 7 1 1 SOLAS shielding as per MTN 5233 Installation 66 7 1 2 SOLAS shielding Installation 67 7 1 3 Installation locations for SOLAS shielding 68 7 2 Engine 77 7 2 1 Barring engine manually 77 7 2...

Страница 4: ...g General for Engine Gearbox Unit 138 7 20 1 Engine cabling Check 138 7 21 Fuel Treatment System 139 7 21 1 Checks prior to start up 139 7 21 2 Fuel treatment system Switching on 140 7 21 3 Differenti...

Страница 5: ...l in 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 a...

Страница 6: ...e instructed repeatedly Personnel requirements All work on the product shall be carried out by trained and qualified personnel only Training at the Training Center of the manufacturer Technical person...

Страница 7: ...ing tackle as necessary If the engine is supplied with special aluminum foil packing Lift the engine at the lifting eyes of the bearing pedestal or use a means of transportation which is appropriate f...

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

Страница 9: ...Follow the applicable warning instructions pertaining to such devices MS150119 01E 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 pi...

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

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: ...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: ...ues MA are specified for screws of strength class 8 8 surface finish bare metal phosphatized or galvanized and 10 9 surface finish bare metal or phosphatized The values in the table are based on a fri...

Страница 17: ...for studs Thread Screwed into Steel M A Nm Gray cast iron MA Nm Al alloy MA Nm M6 9 6 6 M8 11 9 10 M10 17 13 13 M12 27 23 18 M14 37 33 33 M16 55 45 MA tightening torques Tightening torques for setscr...

Страница 18: ...on a friction coefficient tot 0 125 Threads and mating faces of screws and nuts must be coated with engine oil prior to assembly An assembly tolerance of 10 of the figures in the table is permitted d...

Страница 19: ...hen tightening MA tightening torques Tightening torques for plug screws to MTN 5183 1 standard This standard applies to plug screws to DIN 908 DIN 910 and DIN 7604 with threaded end to DIN 3852 Form A...

Страница 20: ...ightening torques for plug screws to DIN 908 DIN 910 and DIN 7604A with short threaded end Thread Screwed into Steel gray cast iron MA Nm AI alloy MA Nm M10 x 1 15 15 M12 x 1 5 25 25 M14 x 1 5 35 30 M...

Страница 21: ...Steel gray cast iron M A Nm Al alloy MA Nm M8 x 1 10 10 M22 x 1 5 80 65 M26 x 1 5 105 90 M30 x 1 5 130 130 M38 x 1 5 140 120 M45 x 1 5 160 140 MA tightening torques Tightening torques for banjo screws...

Страница 22: ...le deviations during the tightening process Tightening torques for steel banjo screws Thread inserted in steel gray cast iron aluminum alloy MA Nm M8 x 1 10 M10 x 1 15 M12 x 1 5 20 M14 x 1 5 25 M16 x...

Страница 23: ...iled or galvanized Threads and mating faces beneath heads must be coated with engine oil prior to assembly An assembly tolerance of 10 of the figures in the table is permitted due to unavoidable devia...

Страница 24: ...on nut firmly by hand noticeable increase in force it should be tightened another 1 4 turn 90 past this point Tightening torques for spigot unions with O ring to ISO 6149 2 Thread Torque Nm 10 M8 x 1...

Страница 25: ...in valves see ISO 6149 47 and ISO 7789 Tightening torques for spigot unions with O ring to ISO 6149 3 Thread Torque Nm 10 M8 x 1 8 M10 x 1 15 M12 x 1 5 25 M14 x 1 5 35 M16 x 1 5 40 M18 x 1 5 45 M22 x...

Страница 26: ...tings In contrast to the instructions for pipe unions hose fittings with sealing heads and the matching adapters must be fitted and connected as follows Hose fitting forming metallic seal with union n...

Страница 27: ...2 35 290 M52 x 2 38 42 330 Sealing head with BSP union nut BSPP thread Torque Nm G1 4 20 G3 8 34 G1 2 60 G5 8 69 G3 4 115 G1 140 G1 1 4 210 G1 1 2 290 G2 400 SAE sealing cone with union nut JIC 37 UNF...

Страница 28: ...Torque Nm 9 16 18 4 14 2 11 16 16 6 24 3 13 16 16 8 43 4 1 14 10 60 8 1 3 16 12 12 90 5 1 3 16 12 14 90 5 1 7 16 12 16 125 10 1 11 16 12 20 170 20 2 12 24 200 25 2 1 2 20 32 460 30 28 General Informa...

Страница 29: ...cordance 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...

Страница 30: ...mits low surface temperature reduced thermal load absolute gas tightness Lube oil system Wet sump forced feed lubrication system Components supplied with oil Bearings Piston cooling Control and actuat...

Страница 31: ...are routed out via M threaded pins and are also integrated in the engine wiring harness Functions ECU supply EMU supply Plant signals ECU7 connector X1 Bus interface 2x MCS5 CAN CAN dialog output 1x...

Страница 32: ...nd coolant temperature are monitored and displayed Integrated safety system Integrated Test System Redundant CAN bus interface to governor and higher level control and monitoring system 24 V DC supply...

Страница 33: ...ording to DIN or an O ring ISO In case of a loose thread or a faulty sealing ring 1 the liquid first has to pass the thread The pressure is so greatly reduced by this and the faulty sealing ring 1 tha...

Страница 34: ...een distributor and HP accumulator 1 Union nut 2 O ring 3 Thrust ring 4 Thrust screw 5 O ring 6 O ring 7 Thrust ring 8 Pressure pipe 9 Jacket pipe 34 General Information MS150119 01E 2016 02 TIM ID 00...

Страница 35: ...ling cones or the HP lines is returned to the HP pump from where it is routed at atmospheric pressure into a leak fuel tank To facilitate the leak search the leak fuel pipework is divided into three s...

Страница 36: ...t flap 14 Actuating cylinder for air flap 15 Cylinder head cover 16 Electric starter 17 Engine mounting bracket 18 Exhaust housing 19 Oil pan 20 Oil filler neck 21 Oil dipstick 22 Engine coolant fille...

Страница 37: ...on 11 Flywheel 12 Flywheel housing 13 Carrier housing lower sec tion 14 Bleeder valve a Air intake b Exhaust outlet KS Kupplungsseite driving end Engine model designation Key to the engine model desig...

Страница 38: ...driving end Item Name Monitoring of 1 B4 21 Temperature before ETC A side 2 Y27 1 Flap control A side 3 B4 22 Temperature before ETC B side 4 B13 1 Crankshaft speed 5 B13 2 Crankshaft speed optional...

Страница 39: ...2 Lube oil pressure after filter optional 3 B5 1 Lube oil pressure after filter 4 F33 Coolant level probe in expansion tank 5 B21 Seawater pressure optional 6 B6 2 Coolant temperature optional 7 B6 1...

Страница 40: ...Sensors and actuators on left side Item Name Monitoring of 1 A18 EIM Engine Interface Module 40 General Information MS150119 01E 2016 02 TIM ID 0000055074 002...

Страница 41: ...l temperature 3 Y45 1 Pressure regulating valve 4 A19 EIL electronic label 5 B16 Coolant pressure optional 6 M8 CR pump activation of HP fuel control block 7 F46 Leak off fuel level optional 8 B1 Cams...

Страница 42: ...for charge air cooler seawater 3 Y56 4 2 directional control valve for blowing off only 16 V 4 A77 EMU Engine Monitoring Unit optional 5 B7 Lube oil temperature 6 B48 High pressure fuel 7 B9 Charge a...

Страница 43: ...ation only conditionally suitable for design L Limit Value that must not be undershot lower limit value min value or exceeded upper limit value max value not suitable for design N Not yet defined valu...

Страница 44: ...A Marine T3 40CFR1042 RECREA TION EU Marine Directive 2013 53 EU Recrea tional Craft 3 12V2000M96L Marine ship s main propulsion 1 DS continuous vari able operation low uti lization 2450 1 min 1432 kW...

Страница 45: ...water system max L bar 4 0 4 0 4 0 Raw water pump Inlet pressure min L bar 0 4 0 4 0 4 Lube oil system ID 1 2 3 Lube oil operating temperature before engine from R C 75 75 75 Lube oil operating temper...

Страница 46: ...cities ID 1 2 3 Engine coolant capacity engine side with cooling equipment R Liters 125 125 125 Engine oil capacity initial filling standard oil system option max operating inclinations R Liters 123 1...

Страница 47: ...ly conditionally suitable for design L Limit Value that must not be undershot lower limit value min value or exceeded upper limit value max value not suitable for design N Not yet defined value Value...

Страница 48: ...A Marine T3 40CFR1042 RECREA TION EU Marine Directive 2013 53 EU Recrea tional Craft 3 16V2000M96L Marine ship s main propulsion 1 DS continuous vari able operation low uti lization 2450 1 min 1939 kW...

Страница 49: ...water system max L bar 4 0 4 0 4 0 Raw water pump Inlet pressure min L bar 0 4 0 4 0 4 Lube oil system ID 1 2 3 Lube oil operating temperature before engine from R C 75 75 75 Lube oil operating temper...

Страница 50: ...ID 1 2 3 Engine coolant capacity engine side with cooling equipment R Liters 135 135 135 Engine oil capacity initial filling standard oil system option max operating inclinations R Liters 145 145 145...

Страница 51: ...3 3 Firing order Firing order 12V A1 B5 A5 B3 A3 B6 A6 B2 A2 B4 A4 B1 16V A1 B5 A3 A5 B2 B8 A2 A8 B3 A7 B4 B6 A4 A6 B1 B7 MS150119 01E 2016 02 Technical Data 51 TIM ID 0000038135 002...

Страница 52: ...in dimensions Engine model Length A Width B Height C 16V2000M86 16V2000M96 16V2000M96L 2495 mm 1292 mm 1452 mm 12V2000M86 12V2000M96 12V2000M96L 2082 mm 1292 mm 1414 mm 52 Technical Data MS150119 01E...

Страница 53: ...Fuel prefilter pressure gage Align adjustable pointer with position of pressure indicator Page 100 Fuel system Vent Page 94 Raw water pump if located above waterline Prime approx 3 to 4 liters Fillin...

Страница 54: ...t level Page 126 Coolant circuit Heat engine coolant with coolant preheating unit Fuel prefilter Drain water and contaminants Page 102 Battery charging generator drive Check condition of drive belt Pa...

Страница 55: ...rsons in the engine s danger zone WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors The engine can be started from the following points Item A...

Страница 56: ...heck exhaust color Page 63 Fuel prefilter Check if suction side pressure indicated at the fuel prefilter is within the limit Page 100 Drain water and contaminants Page 102 Air filter Check signal ring...

Страница 57: ...the label on the engine match the label document in the Business Portal Equipment 3 Check emission label for intactness 4 Check content of emission label for complete readability 5 Does the engine num...

Страница 58: ...Risk of overheating damage to components Before shutting down disengage gear and run the engine at idle speed for at least 10 minutes until engine temperatures have dropped and constant values are dis...

Страница 59: ...extremely high load Risk of overheating damage to components Trigger an emergency stop only in emergency situations The engine can be stopped from the following points in an emergency Item Action Con...

Страница 60: ...coolant has no antifreeze addi tive the engine room is not heated the coolant is not kept at a suitable temperature the antifreeze concentration is insufficient for the engine room tempera ture antif...

Страница 61: ...ctly at seals or electronic components such as connectors or ECUs Plant Cleaning 1 Carry out plant cleaning only in areas where an appropriate oil separator is provided environmental protec tion 2 Pri...

Страница 62: ...eck for presence readability and content of emission la bel Page 57 W1001 Replace fuel filter or fuel filter element Page 97 W1002 Check valve clearance and adjust as necessary Page 84 W1005 Replace a...

Страница 63: ...s documentation Engine wiring faulty u Check Page 138 Air in fuel system u Vent fuel system Page 94 Engine governor ECU is defective u Contact Service Engine fires unevenly Cause Corrective action Inj...

Страница 64: ...arge air cooler is contaminated u Contact Service Exhaust turbocharger faulty u Contact Service Coolant leaks at charge air cooler Cause Corrective action Major coolant discharge at drain valve of the...

Страница 65: ...at operating temperature u Run engine to reach operating temperature Water in fuel u Check fuel system at fuel prefilter Drain fuel prefilter Page 102 Charge air cooler leaky u Contact Service MS1501...

Страница 66: ...nation Use Part No Qty Shield A4 735233000100 15 Shield A5 12V 735233000101 31 Shield A5 16V 735233000101 33 Shield A6 735233000102 1 Shield A7 735233000103 8 Shield B2 735233000200 2 Installing SOLAS...

Страница 67: ...s cooled down to ambient temperature Special tools Material Spare parts Designation Use Part No Qty Oil filter shield X00009628 2 pcs Installing SOLAS shielding for oil filter 1 Pinpoint installation...

Страница 68: ...66 Free end B side Item Type of shielding Comments 1 Shield A7 For fuel priming pump 2 Shield A7 For HP fuel pump Item Type of shielding Comments 1 Shield A7 For fuel priming pump 2 Shield A7 For HP...

Страница 69: ...mp outlet 2 Shield A6 Lubrication of HP fuel pump 3 Shield A7 HP fuel pump supply line Item Type of shielding Comments 1 Shield A7 Fuel priming pump supply line 2 Shield A7 Fuel priming pump return li...

Страница 70: ...em Type of shielding Comments 1 Shield A5 Oil sampling point on crankcase B side Item Type of shielding Comments 1 Shield A5 Oil sampling point on crankcase 70 SOLAS MS150119 01E 2016 02 TIM ID 000006...

Страница 71: ...rom valve 2 Shield B2 Oil supply line 3 Shield A4 Oil supply to seawater valve cylin der 4 Shield A4 Oil supply to seawater valve cylin der 5 Shield A4 Remove shield from bleeder valve 6 Shield A4 Rem...

Страница 72: ...supply to seawater valve cylin der 7 Shield A4 Connection to bleeder valve 8 Shield A4 Connection to bleeder valve Free end A side Item Type of shielding Comments 1 Shield A4 Oil supply to cylinder se...

Страница 73: ...f hydraulic cylinder B side Item Type of shielding Comments 1 Shield A5 Exhaust turbocharger flaps 2 Shield A5 Exhaust turbocharger flaps 3 Shield A5 Oil supply for air flap 4 Shield A5 Oil supply for...

Страница 74: ...supply for air flap 2 Shield A5 Oil supply for exhaust turbocharg er 3 Shield A4 Oil return line in crankcase 4 Shield A5 Oil supply for air flap 5 Shield A4 Oil supply for air flap 6 Shield A5 Exhau...

Страница 75: ...ield A4 Exhaust turbocharger lubrication center 3 Shield A5 Turbocharger lubrication left side 4 Shield A5 Turbocharger lubrication left side 5 Shield A5 Oil supply for exhaust turbocharg er 6 Shield...

Страница 76: ...ments 1 Shield A4 Turbocharger lubrication right side 2 Shield A5 Oil supply 3 Shield A5 Turbocharger lubrication right side 4 Shield A5 Oil supply for exhaust turbocharg er 76 SOLAS MS150119 01E 2016...

Страница 77: ...t there are no persons in the engine s danger zone After finishing work on the engine make sure that all safety devices are put back in place and all tools are removed from the engine Barring engine m...

Страница 78: ...led in Before barring the engine make sure that there are no persons in the engine s danger zone After finishing work on the engine make sure that all safety devices are put back in place and all tool...

Страница 79: ...rences around 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 direc...

Страница 80: ...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 81: ...ven honing 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 d...

Страница 82: ...Final steps 1 Install injector Page 89 2 Install cylinder head cover Page 83 82 Cylinder Liner MS150119 01E 2016 02 TIM ID 0000067215 001...

Страница 83: ...Cylinder head cover removal and installation 1 Unscrew screws 5 and take off with wash ers 4 2 Remove cylinder head cover 3 with gas ket 2 from cylinder head 3 Clean mounting surface 1 4 Check conditi...

Страница 84: ...adapter F30027340 1 Measuring instrument Y4348409 1 Preparatory steps 1 Remove air filter Page 115 2 Remove cylinder head cover Page 83 3 Remove HP line and injector Page 89 Positioning A1 piston at...

Страница 85: ...rmine the distance between valve bridge and rocker arm 5 If the deviation from the reference value exceeds 0 1 mm adjust valve clearance Valve clearance Adjustment Position Cylinder 1 2 3 4 5 6 7 8 9...

Страница 86: ...e adjusting screw 2 with Allen key to prevent it from turning Name Size Type Lubricant Value Standard Locknut M12x1 Tightening torque 50 Nm 5 Nm 5 Insert feeler gauge between valve bridge and rocker a...

Страница 87: ...ses facial protection WARNING Oils oil vapors are combustible explosive Risk of fire and explosion Avoid open flames electric sparks and ignition sources Do not smoke NOTICE HP fuel pump not filled wi...

Страница 88: ...Replacement Special tools Material Spare parts Designation Use Part No Qty Injector Spare Parts Catalog Injector Replacement u Remove injector and install new one Page 89 88 Injector MS150119 01E 201...

Страница 89: ...ng Spare Parts Catalog O ring 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 prot...

Страница 90: ...le plugs Injector Installation 1 Remove all covers and plugs prior to installation Note Lubrication is not required if a sliding varnish coated O ring is used 2 Fit new O ring on injector with assembl...

Страница 91: ...fied tightening torque Name Size Type Lubricant Value Standard Retaining screw M8 Preload torque Engine oil 40 4 Nm Note Check and clean surface of bottom side of cylinder head cover lower section 9 A...

Страница 92: ...socket wrench and torque wrench to specified tightening torque Name Size Type Lubricant Value Standard HP line Tightening torque Engine oil 37 Nm 3 Nm Note Ensure they run centrally A Do not pinch the...

Страница 93: ...t reset the emission certification of the engine becomes void 20 Reset drift correction CDC with DiaSys and enter injector coding IIG Page 144 Final steps 1 Install cylinder head cover upper section P...

Страница 94: ...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 vapo...

Страница 95: ...pump with the handle 2 until bubble free fuel emerges from the threaded vent plug 1 4 Tighten vent screw 1 to specified torque Name Size Type Lubricant Value Standard Threaded vent plug M8 Tightening...

Страница 96: ...bubble free fuel emerges from the threaded vent plugs 1 and 3 4 Tighten threaded vent plugs 1 and 3 to specified torque Name Size Type Lubricant Value Standard Threaded vent plug M8 Tightening torque...

Страница 97: ...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 i...

Страница 98: ...change filter and moisten with fuel 6 Install and tighten easy change filter by hand 7 Vent fuel system Page 94 Fuel filter change with reversi ble filters and running engine 1 Cut out the filter to...

Страница 99: ...ighten threaded vent plugs 1 and 2 to specified torque Name Size Type Lubricant Value Standard Threaded vent plug M8 Tightening torque 6 Nm 2 Nm MS150119 01E 2016 02 Fuel Filter 99 TIM ID 0000064785 0...

Страница 100: ...ointer 3 of pressure gauge 1 2 Verify that differential pressure is within the limit Fuel prefilter checking differential pressure with single stage filter 1 With the engine running at full load or ra...

Страница 101: ...ll load or rated power read off pressure at gauge 1 2 If differential pressure as indicated between position of adjustable pointer 2 and pressure indicating point er 3 of pressure gauge is 0 3 bar flu...

Страница 102: ...l 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 WARN...

Страница 103: ...vent plugs 2 Draining fuel prefilter with re versible duplex filter 1 Switch off filter which is to be drained A or B 1 Filter A cut out 2 Filter B cut out 2 Open threaded vent plug 1 of the filter to...

Страница 104: ...uel until fuel emerges from the vent pipe 3 8 Close vent valve 2 9 Open rotary slide valve 4 a little by approx 30 and open vent valve s 2 until fuel emerges from the vent pipe 3 10 Close vent valve s...

Страница 105: ...ses If contact is made with skin wash off with water and soap WARNING Fuels are combustible and explosive Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smo...

Страница 106: ...tial pres sure replace fuel prefilter element Page 108 Flushing fuel prefilter with re versible duplex filter 1 Cut out contaminated filter A or B 1 Filter A cut out 2 Filter B cut out 2 Open threaded...

Страница 107: ...rges from the vent pipe 3 4 Close vent valve 2 5 Open rotary slide valve 4 a little by approx 30 and open vent valve s 2 until fuel emerges from the vent pipe 3 6 Close vent valve s 2 7 Turn rotary sl...

Страница 108: ...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 vapo...

Страница 109: ...ilter cartridge 4 8 Insert new level monitor 3 and new filter cartridge 4 9 Place new gasket in filter cartridge housing 10 Close filter cartridge housing and tighten screws 2 11 Open fuel shutoff val...

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

Страница 111: ...RNING 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 m...

Страница 112: ...With the engine shut down check leak line 1 on B side driving end for liquid dis charge 2 Check line for free passage 3 With the engine stationary blow through clogged line with compressed air 112 Ch...

Страница 113: ...t Wait until the first coolant emerges from the drain line of the intercooler 3 Completely drain coolant from the intercool er 4 Blow through line with compressed air 5 Close union nut on drain line 2...

Страница 114: ...Spare parts Designation Use Part No Qty Air filter Spare Parts Catalog Replacing the air filter 1 Remove old air filter and install new air filter Page 115 2 Reset signal ring of contamination indicat...

Страница 115: ...mps 2 and 3 2 Remove air filter 4 and clamps from con necting flange 1 of intake neck 3 Clean connecting flange 1 of intake neck and check for free passage 4 Attach air filter 4 with clamps 2 and 3 on...

Страница 116: ...arting disabled Checking signal ring position 1 When the yellow piston has reached the red shaded Service lettering 2 replace air filter Page 114 2 After installation of new filter press reset button...

Страница 117: ...ck Preconditions Engine is stopped and starting disabled Checking starter condition 1 Check securing screws of starter for secure seating and tighten if required 2 Check wiring Page 138 MS150119 01E 2...

Страница 118: ...4 Top up with oil up to the max 1 mark Page 119 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 119: ...ective gloves and safety glasses facial protection Avoid contact with skin Do not inhale oil vapor Version with extraction equipment Engine oil extraction 1 Position a suitable container to drain the...

Страница 120: ...he engine is running Risk of damage to hearing Wear ear protectors WARNING Engine oil is hot Engine oil can contain combustion residues which are harmful to health Risk of injury and poisoning Allow t...

Страница 121: ...vel Page 118 Oil filter change with reversible filters and stationary engine 1 Stop engine Page 58 and disable engine start 2 Cut out the filter to be replaced A Right filter cut out B Both filters cu...

Страница 122: ...th oil filter wrench 4 Clean the sealing face on the adapter 5 Check condition of the new sealing ring and coat it with oil 6 Fit SOLAS shield Page 66 7 Screw on and tighten new engine oil filter by h...

Страница 123: ...olant drain and venting points Drain points free end 1 Engine coolant drain screw 2 Filling screw on seawater pump 3 Seawater pump drain 4 Preheating line outlet con nection MS150119 01E 2016 02 Coola...

Страница 124: ...points driving end 1 Engine coolant drain screw 2 Engine coolant drain screw Preheating line inlet con nection 124 Coolant Circuit General High Temperature Circuit MS150119 01E 2016 02 TIM ID 00000552...

Страница 125: ...e coolant overflow line 2 Engine coolant filler neck 3 Engine coolant drain screw Drain points right side 1 Engine coolant drain screw MS150119 01E 2016 02 Coolant Circuit General High Temperature Cir...

Страница 126: ...es cape 2 Continue to turn breather valve counterclockwise and remove 3 Check coolant level coolant must be visible at the bottom edge of the cast in eye of the filler neck Checking coolant level at e...

Страница 127: ...Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 128 2 Fill with engine coolant Page 129 MS150119 01E 2016 02 Coolant Circuit General High Tem...

Страница 128: ...eheating unit Draining engine coolant 1 Turn breather valve of filler neck on coolant expansion tank Page 123 counterclockwise to first stop and allow pressure to escape 2 Continue to turn breather va...

Страница 129: ...engine Fill top up coolant only into cold engine Filling with engine coolant 1 Turn breather valve of coolant expansion tank Page 36 counterclockwise until the first stop and allow pressure to escape...

Страница 130: ...level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors HT coolant pump Relief bore check 1 Check relief bore 1 for oil and coolant dis charge Result No fluid s...

Страница 131: ...ank Page 123 counterclockwise until the first stop and allow pressure to escape 2 Continue to turn breather valve counterclockwise and remove 3 Draw off precipitated corrosion inhibitor oil from expan...

Страница 132: ...thing gloves and goggles safety mask Preparatory steps u Switch off preheating unit Breather valve Replacement 1 Turn breather valve 1 on coolant expansion tank counterclockwise to the first stop and...

Страница 133: ...s danger zone WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Raw water pump Relief bore check 1 Check relief bore 1 for oil and coolant di...

Страница 134: ...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 conne...

Страница 135: ...king 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 s...

Страница 136: ...abled Guard is removed Drive belt Condition check Item Findings Action Drive belt A Singular cracks None Drive belt B Cracks on entire circumference Replace Page 137 Drive belt C Chunking Drive belt B...

Страница 137: ...rive belt Replacement 1 Counterhold adjusting lever at square 1 2 Rotate adjusting lever until drive belt is re leased 3 Secure adjusting lever with screwdriver 2 4 Remove drive belt 5 Check cleanness...

Страница 138: ...intact 4 Replace faulty cable clips 5 Check cable clamps for secure fit tighten loose clamps 6 Replace faulty cable clamps 7 Visually inspect the following electrical components for damage Connector h...

Страница 139: ...arge valves 4 Switch on fuel treatment system Page 140 5 Check direction of rotation of pump 6 Vent bypass and fuel lines of the system a Open ball valve for pressure tank b Open ball valve for overfl...

Страница 140: ...itching on ensure that all housings are closed Before switching on ensure that no work is in progress anywhere on the entire system Fuel treatment system Switching on 1 Carry out checks prior to start...

Страница 141: ...ective clothing protective gloves and safety glasses facial protection Checking differential pressure gauge 1 Switch on fuel treatment system Page 140 2 Set the alarm points at the differential pressu...

Страница 142: ...he outlet of the fuel treatment system c Check pressure at the pressure gauge in the inlet to the fuel treatment system and note down 3 Checking pump pressure with reduced suction a Reduce suction pre...

Страница 143: ...probe 2 Unscrew water level probe 3 Disconnect connector from water level probe 4 Immerse water level probe into a tank filled with water until water level reaches the thread 5 Switch on the system Re...

Страница 144: ...tification becomes invalid Resetting parameters for drift correction CDC with DiaSys 1 Use DiaSys to reset the CDC parameters Dialog system DiaSys E531920 2 If no DiaSys is available contact Service E...

Страница 145: ...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 connect...

Страница 146: ...coarse dirt from housing surface using a cloth moistened with isopropyl alcohol 2 Remove dirt from the connector and cable surfaces with isopropyl alcohol 3 Check legibility of cable labels Clean or...

Страница 147: ...The contacts in the plug connection can be bent Carry out check of plug connection only with test connectors Checking plug connections at engine governor 1 Check all plug connections for secure seatin...

Страница 148: ...king EMU plug connections 1 Check both connectors on EMU 2 for firm seating Ensure that the clips 1 are engag ed 2 Check screws 3 of cable clamps on EMU 2 for firm seating Ensure that cable clamps are...

Страница 149: ...EIM plug connections 1 Check both Tyco plugs 62 pole 2 on EIM for firm seating Ensure that clips 3 are en gaged 2 Check screws 1 of cable clamps on EIM for firm seating Ensure that cable clamps are no...

Страница 150: ...ctors 2 b Unplug connector 2 3 Switch on power supply Result The Engine Control Unit is operable if the diagnostic lamp 1 changes to continuous illumination within 30 seconds after power has been swit...

Страница 151: ...e 1 Note or mark assignment of cables and con nectors 2 Remove all screws 2 3 Undo clips 3 on connectors 4 Remove all male connectors 5 Remove screws 1 6 Take off engine governor Installing engine gov...

Страница 152: ...Unit 1 with Engine Monitoring Unit 4 Removing Engine Monitoring Unit 1 Unscrew screws on base of Engine Monitoring Unit 4 2 Remove Engine Monitoring Unit 4 with Engine Control Unit 1 Installing Engine...

Страница 153: ...e correct assignment between cables and plugs 2 Check seal before installing Result Replace seal if porous or defective Downloading software 1 The new EIM still does not have appropriate FSW and param...

Страница 154: ...ation loader active 5 External RAM faulty 6 External FLASH faulty 7 No firmware 8 Application crashed Fuse lamp SILA A second indicator is the fuse lamp This is also integrated in the housing of the E...

Страница 155: ...rgency stop current path failed 24 V internal S9 11 ES pushbutton current path failed 24 V external S10 12 Key switch current path failed S11 13 SDAF 1 and 2 current path failed S12 14 PIM current pat...

Страница 156: ...e 1 2 second steps Note These bit patterns are continuously transmitted The CAN message Status of internal power supply also contains information on the current path states of the EIM 156 Accessories...

Страница 157: ...cpsi cells per square inch CR Common Rail CSMF Coated Sintered Metal Filter DIN Deutsches Institut f r Normung e V German Standardization Organization at the same time identifier of German standards D...

Страница 158: ...ntrol MCS Monitoring and Control System MG Message MPU Microprocessor Unit Microprocessing Unit OT Oberer Totpunkt Top Dead Center TDC P xyz Pressure xyz Pressure measuring point xyz PAN Panel Control...

Страница 159: ...Abbre viation Meaning Explanation VS Voith Schneider Voith Schneider drive WJ Water jet Water jet drive WZK Werkzeugkatalog Tool catalog TC MS150119 01E 2016 02 Appendix A 159 TIM ID 0000002045 020...

Страница 160: ...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 161: ...r Removal and installation Page 89 Angular screw driver Part No F30453001 Qty Used in 1 7 4 2 Valve clearance Check and adjustment Page 84 Assembly sleeve Part No F30454554 Qty Used in 1 7 6 2 Injecto...

Страница 162: ...ge 84 Double head box wrench Part No F30002800 Qty Used in 1 7 4 2 Valve clearance Check and adjustment Page 84 Endoscope Part No Y20097353 Qty Used in 1 7 3 2 Cylinder liner Endoscopic examination Pa...

Страница 163: ...t Part No Qty Used in 1 4 9 Plant Cleaning Page 61 HP line alignment device Part No F6795725 Qty Used in 1 7 6 2 Injector Removal and installation Page 89 Injector alignment device Part No F6795554 Qt...

Страница 164: ...Part No F30038494 Qty Used in 1 7 7 1 Fuel system Venting Page 94 Measuring instrument Part No Y4348409 Qty Used in 1 7 4 2 Valve clearance Check and adjustment Page 84 MTU test kit Part No 560589209...

Страница 165: ...and installation Page 89 Ratchet adapter Part No F30027340 Qty Used in 1 7 4 2 Valve clearance Check and adjustment Page 84 Ratchet with extension Part No F30006212 Qty Used in 1 7 2 1 Barring engine...

Страница 166: ...wrench 20 100 Nm Part No F30026582 Qty Used in 1 7 4 2 Valve clearance Check and adjustment Page 84 Qty Used in 1 7 6 2 Injector Removal and installation Page 89 Torque wrench 8 40 Nm Part No F3004344...

Страница 167: ...Torque wrench 8 40 Nm Part No F30453004 21 Qty Used in 1 7 7 1 Fuel system Venting Page 94 MS150119 01E 2016 02 Special Tools 167 DCL ID 0000033801 003...

Страница 168: ...emoval and installation 83 D Diagnostic features On EIM 154 Diagnostic lamp DILA On EIM 154 Differential pressure gauge Check 141 Drive belt Condition check 136 Replacement Battery charging generator...

Страница 169: ...LA On EIM 154 H Hotline 160 HP fuel pump Filling with engine oil 87 I IIG Input 144 Injector Installation 89 Removal 89 Replacement 88 Injector coding IIG Input 144 Intercooler Check Coolant discharge...

Страница 170: ...160 Starter Condition check 117 Startup After extended out of service periods 3 months 53 Putting into operation after scheduled out of service pe riod 54 T Tightening specifications Nuts 16 Screws an...

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