Technical data

ManualsBrandsMTU ManualsAutomotive12 V 4000 C21

Use and maintenance manual

MTU

Diesel Engine

12V 2000 G23/43/63/83

16V 2000 G23/43/63/83

18V 2000 G63/83

Réf. constructeur : M015560/00E Réf. GPAO : 33522055801

Summary of content (214 pages)

PAGE 1
Use and maintenance manual MTU Diesel Engine 12V 2000 G23/43/63/83 16V 2000 G23/43/63/83 18V 2000 G63/83 Réf. constructeur : M015560/00E Réf.
PAGE 2
Printed in Germany ã 2003 Copyright MTU Friedrichshafen GmbH Diese Veröffentlichung einschließlich aller seiner Teile ist urheberrechtlich geschützt. Jede Verwertung oder Nutzung bedarf der vorherigen schriftlichen Zustimmung der MTU Friedrichshafen GmbH. Das gilt insbesondere für Vervielfältigung, Verbreitung, Bearbeitung, Übersetzung, Mikroverfilmungen und die Einspeicherung und / oder Verarbeitung in elektronischen Systemen, einschließlich Datenbanken und Online-Diensten.
PAGE 3
1 Safety Safety, accident prevention and environmental protection instructions 2 Product Summary Engine layout, technical data 3 Operation Task descriptions 4 Maintenance and Servicing Maintenance schedule 5 Troubleshooting Malfunctions, causes, measures 6 Task Description Inspection and maintenance tasks 7 Annex Abbreviations Index
PAGE 4
PAGE 5
Wichtig - Important – Importante Bitte die Karte „Inbetriebnahmemeldung“ abtrennen und ausgefüllt an MTU Friedrichshafen GmbH zurücksenden. Die Informationen der Inbetriebnahmemeldung sind Grundlage für den vertraglich vereinbarten LogistikSupport (Gewährleistung, Ersatzteile etc.). Please complete and return the “Commissioning Note” card below to MTU Friedrichshafen GmbH. The Commissioning Note information serves as a basis for the contractually agreed logistic support (warranty, spare parts, etc.).
PAGE 6
Bitte in Blockschrift ausfüllen! Please use block capitals! Prière de remplir en lettres capitales! ¡A rellenar en letras de imprenta! Scrivere in stampatello! Favor preencher com letras de forma! Motornr.: Engine No.: No du moteur: No de motor: Motore N.: No. do motor: Auftragsnr.: MTU works order No.: No de commande: No de pedido: N. commessa: No.
PAGE 7
Amendment Service! Any changes in contents will be sent to you in the form of an amendment, provided you complete the reverse of this receipt card and return it to us.
PAGE 8
Please mark all filed amendments here. No. Date 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Please use block capitals! Receipt Amendment No. 1. 2. 3. 4. Publication number: M015560/00E 5. 6. Name .......................................................... Manufacturer ....................................................... 7. 8. 9. Department ......................................................... 10. Fax ....................Telephone..................... 11. Street .........
PAGE 9
Table of Contents 1 1–I Safety 1.1 General conditions ......................................................... 1.2 Personnel and organizational requirements 1 – 01 .................................... 1 – 02 1.3 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 03 1.4 Safety precautions when working on the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 04 1.
PAGE 11
Safety 1.1 1 – 01 General conditions General In addition to the instructions in this publication, the applicable country-specific legislation and other compulsory regulations regarding accident prevention must be observed. This engine is a state-of-the art product and conforms with all applicable specifications and regulations.
PAGE 12
1 – 02 1.2 Safety Personnel and organizational requirements Personnel Work on the engine must only be carried out by properly qualified and instructed personnel. The specified legal minimum age must be observed. Responsibilities of the operating, maintenance and repair personnel must be specified. Organization This publication must be issued to all personnel involved in operation, maintenance, repair or transportation.
PAGE 13
Safety 1.3 1 – 03 Transport Transport Lift the engine only with the lifting eyes provided. Use only the transport and lifting equipment approved by MTU. Take note of the engine center of gravity. The engine must only be transported in installation position, max. permissible diagonal pull 10 . In the case of special packaging with aluminum foil, suspend the engine on the lifting eyes of the transport pallet or transport with equipment for heavy loads (forklift truck).
PAGE 14
1 – 04 1.4 Safety Safety precautions when working on the engine Engine operation When the engine is running, always wear ear protectors. Ensure that the engine room is well ventilated. Mop up any leaked or spilt fluids and lubricants immediately or soak up with a suitable bonding agent. Exhaust gases from combustion engines are poisonous. Inhalation of poisonous exhaust gases is a health hazard. The exhaust pipework must be free of leaks and discharge the gases to atmosphere.
PAGE 15
Safety 1 – 05 • Ensure that all chains, hooks, slings, etc. are tested and authorized, are sufficiently strong and that hooks are correctly positioned. Lifting eyes must not be unevenly loaded. Welding work Never carry out welding work on the engine or engine-mounted units. Never use the engine as a ground connection.
PAGE 16
1 – 06 Safety Spare parts shall be properly stored prior to replacement, i.e. particularly protected against moisture. Defective electronic components and assemblies must be suitably packed when dispatched for repair, i.e. particularly protected against moisture and impact and wrapped in antistatic foil if necessary. Working with laser equipment When working with laser equipment, always wear special laser-protection goggles.
PAGE 17
Safety 1.5 1 – 07 Auxiliary materials, fire prevention and environmental protection Fire prevention Rectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause fires therefore always keep the engine in a clean condition. Do not leave cloths soaked with fluids and lubricants lying around on the engine. Do not store combustible fluids near the engine. Do not weld pipes and components carrying oil or fuel. Before welding, clean with an inflammable fluid.
PAGE 18
1 – 08 Safety • Do not store combustible substances, e.g. oils and greases, within 5 m of the working area! • Under no circumstances should clothing be oily or greasy. • Do not allow vapors to penetrate clothing! Oxygen enrichment in fabric can cause working clothes to ignite suddenly! • After working with liquid oxygen, do not smoke until clothing is free of vapors! • Avoid all knocks and jars to the containers, fixtures or workpieces.
PAGE 19
Safety 1.6 1 – 09 Standards for warning notices in the publication In the event of immediate danger. Consequences: Death or serious injury. DANGER • In the event of possibly dangerous situations. Consequences: Death or serious injury. WARNING • In the event of dangerous situations. Consequences: Slight injury or material damage.
PAGE 21
Table of Contents 2 2–I Product Summary 2.1 Engine Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.1 Engine layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 01 2 – 01 2.2 Engine Side and Cylinder Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.1 Engine side and cylinder designations . . . . . . . . . .
PAGE 23
Engine Layout 2 – 01 2.1 Engine Layout 2.1.
PAGE 24
2 – 02 Engine Layout Engine model designation Key to the engine model designations 812/16/18V 2000 Gxy 8/12/16/18 Number of cylinders V Cylinder configuration: V engine 2000 Series G Application X Application segment (2, 4, 6, 8) Y Design index (0,1, 2,...
PAGE 25
Engine Side and Cylinder Designations 2 – 03 2.2 Engine Side and Cylinder Designations 2.2.1 Engine side and cylinder designations Engine sides are always designated as viewed from the driving end (KS). The cylinders of the left engine side are designated "A" and those of the right side "B" (as per DIN ISO 1204). The cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end. The numbering of engine components is also from the driving end, starting with No. 1.
PAGE 26
2 – 04 Main Engine Dimensions 2.3 Main Engine Dimensions 2.3.1 Main engine dimensions Main engine dimensions Engine model 12V 2000 Gxy 16V 2000 Gxy 18V 2000 Gxy Length (A) approx. 2020 mm approx. 2365 mm approx. 2400 mm Width (B) approx. 1580 mm approx. 1580 mm approx. 1580 mm Height (C) approx. 1690 mm approx. 1925 mm approx.
PAGE 27
Engine Data 2 – 05 2.4 Engine Data 2.4.1 12/16/18V 2000 Standby operation: Application Group 3D, Air-cooled charge air, Optimized fuel consumption Explanation: DL Ref. value: Continuous power (CP) BL Ref. value: Fuel stop power (FSP) A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g.
PAGE 28
2 – 06 Engine Data MODEL-RELATED DATA (basic design) 12 12 16 16 18 Engine with exhaust turbocharging (ETC) and charge air cooling (CAC) X X X X X Exhaust piping, non-cooled X X X X X Working method: four-cycle, diesel, single-acting X X X X X Combustion method: direct fuel injection X X X X X Cooling system: conditioned water X X X X X Direction of rotation: c.c.w.
PAGE 29
Engine Data 2 – 07 COOLING SYSTEM (HT circuit) Number of cylinders 12 12 16 16 18 Coolant temperature (at engine outlet to cooling equipment) A C 95 95 95 95 95 Coolant temperature after engine, alarm R C 97 97 97 97 97 Coolant temperature after engine, shutdown L C 102 102 102 102 102 Coolant antifreeze content, max. permissible L % 50 50 50 50 50 Pressure loss in the external cooling system, max. permissible L bar 0.7 0.7 0.7 0.7 0.
PAGE 30
2 – 08 Engine Data FUEL SYSTEM Number of cylinders 12 12 16 16 18 Fuel pressure at supply connection to engine (when engine is starting), min. admissible L bar -0.3 -0.3 -0.3 -0.3 -0.3 Fuel pressure at supply connection to engine (when engine is starting), max. admissible L bar +0.5 +0.5 +0.5 +0.5 +0.
PAGE 31
Engine Data 2 – 09 WEIGHTS / MAIN DIMENSIONS Number of cylinders Engine weight, dry (basic engine configuration acc.
PAGE 32
2 – 10 2.4.2 Engine Data 12/16/18V 2000 Standby operation: Application Group 3D, Air-cooled charge air, Optimized exhaust emission (EPA 40 CFR89 / Tier 1) Explanation: DL Ref. value: Continuous power (CP) BL Ref. value: Fuel stop power (FSP) A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g.
PAGE 33
Engine Data 2 – 11 MODEL-RELATED DATA (basic design) 12 12 16 16 18 Engine with exhaust turbocharging (ETC) and charge air cooling (CAC) X X X X X Exhaust piping, non-cooled X X X X X Working method: four-cycle, diesel, single-acting X X X X X Combustion method: direct fuel injection X X X X X Cooling system: conditioned water X X X X X Direction of rotation: c.c.w.
PAGE 34
2 – 12 Engine Data COOLING SYSTEM (HT circuit) Number of cylinders 12 12 16 16 18 Coolant temperature (at engine outlet to cooling equipment) A C 95 95 95 95 95 Coolant temperature after engine, alarm R C 97 97 97 97 97 Coolant temperature after engine, shutdown L C 102 102 102 102 102 Coolant antifreeze content, max. permissible L % 50 50 50 50 50 Pressure loss in the external cooling system, max. permissible L bar 0.7 0.7 0.7 0.7 0.
PAGE 35
Engine Data 2 – 13 FUEL SYSTEM Number of cylinders 12 12 16 16 18 Fuel pressure at supply connection to engine (when engine is starting), min. admissible L bar -0.3 -0.3 -0.3 -0.3 -0.3 Fuel pressure at supply connection to engine (when engine is starting), max. admissible L bar +0.5 +0.5 +0.5 +0.5 +0.
PAGE 36
2 – 14 Engine Data WEIGHTS / MAIN DIMENSIONS Number of cylinders Engine weight, dry (basic engine configuration acc.
PAGE 37
Engine Data 2.4.3 2 – 15 12/16/18V 2000 Continuous operation with variable load: Application group 3B, Air-cooled charge air, Optimized fuel consumption Explanation: DL Ref. value: Continuous power (CP) BL Ref. value: Fuel stop power (FSP) A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g.
PAGE 38
2 – 16 Engine Data MODEL-RELATED DATA (basic design) 12 12 16 16 18 Engine with exhaust turbocharging (ETC) and charge air cooling (CAC) X X X X X Exhaust piping, non-cooled X X X X X Working method: four-cycle, diesel, single-acting X X X X X Combustion method: direct fuel injection X X X X X Cooling system: conditioned water X X X X X Direction of rotation: c.c.w.
PAGE 39
Engine Data 2 – 17 COOLING SYSTEM (HT circuit) Number of cylinders 12 12 16 16 18 Coolant temperature (at engine outlet to cooling equipment) A C 95 95 95 95 95 Coolant temperature after engine, alarm R C 97 97 97 97 97 Coolant temperature after engine, shutdown L C 102 102 102 102 102 Coolant antifreeze content, max. permissible L % 50 50 50 50 50 Pressure loss in the external cooling system, max. permissible L bar 0.7 0.7 0.7 0.7 0.
PAGE 40
2 – 18 Engine Data FUEL SYSTEM Number of cylinders 12 12 16 16 18 Fuel pressure at supply connection to engine (when engine is starting), min. admissible L bar -0.3 -0.3 -0.3 -0.3 -0.3 Fuel pressure at supply connection to engine (when engine is starting), max. admissible L bar +0.5 +0.5 +0.5 +0.5 +0.
PAGE 41
Engine Data 2 – 19 WEIGHTS / MAIN DIMENSIONS Number of cylinders Engine weight, dry (basic engine configuration acc.
PAGE 42
2 – 20 2.4.4 Engine Data 12/16/18V Continuous operation with variable load: Application group 3B, Air-cooled charge air, Optimized exhaust emission (TA-Luft) Explanation: DL Ref. value: Continuous power (CP) BL Ref. value: Fuel stop power (FSP) A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g.
PAGE 43
Engine Data 2 – 21 MODEL-RELATED DATA (basic design) 12 12 16 16 18 Engine with exhaust turbocharging (ETC) and charge air cooling (CAC) X X X X X Exhaust piping, non-cooled X X X X X Working method: four-cycle, diesel, single-acting X X X X X Combustion method: direct fuel injection X X X X X Cooling system: conditioned water X X X X X Direction of rotation: c.c.w.
PAGE 44
2 – 22 Engine Data COOLING SYSTEM (HT circuit) Number of cylinders 12 12 16 16 18 Coolant temperature (at engine outlet to cooling equipment) A C 95 95 95 95 95 Coolant temperature after engine, alarm R C 97 97 97 97 97 Coolant temperature after engine, shutdown L C 102 102 102 102 102 Coolant antifreeze content, max. permissible L % 50 50 50 50 50 Pressure loss in the external cooling system, max. permissible L bar 0.7 0.7 0.7 0.7 0.
PAGE 45
Engine Data 2 – 23 FUEL SYSTEM Number of cylinders 12 12 16 16 18 Fuel pressure at supply connection to engine (when engine is starting), min. admissible L bar -0.3 -0.3 -0.3 -0.3 -0.3 Fuel pressure at supply connection to engine (when engine is starting), max. admissible L bar +0.5 +0.5 +0.5 +0.5 +0.
PAGE 46
2 – 24 Engine Data WEIGHTS / MAIN DIMENSIONS Number of cylinders Engine weight, dry (basic engine configuration acc.
PAGE 47
Engine Data 2.4.5 2 – 25 12/16/18V Continuous operation with variable load: Application group 3B, Air-cooled charge air, Optimized exhaust emission (EPA 40 CFR89 / Tier 1) Explanation: DL Ref. value: Continuous power (CP) BL Ref. value: Fuel stop power (FSP) A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g.
PAGE 48
2 – 26 Engine Data MODEL-RELATED DATA (basic design) 12 16 18 Engine with exhaust turbocharging (ETC) and charge air cooling (CAC) X X X Exhaust piping, non-cooled X X X Working method: four-cycle, diesel, single-acting X X X Combustion method: direct fuel injection X X X Cooling system: conditioned water X X X Direction of rotation: c.c.w.
PAGE 49
Engine Data 2 – 27 COOLING SYSTEM (HT circuit) Number of cylinders 12 16 18 Coolant temperature (at engine outlet to cooling equipment) A C 95 95 95 Coolant temperature after engine, alarm R C 97 97 97 Coolant temperature after engine, shutdown L C 102 102 102 Coolant antifreeze content, max. permissible L % 50 50 50 Pressure loss in the external cooling system, max. permissible L bar 0.7 0.7 0.
PAGE 50
2 – 28 Engine Data GENERAL OPERATING DATA Number of cylinders 12 16 18 Cold start capability: air temperature (w/o start aid, w/o preheating) (case A) R C 0** 0** 0** Coolant preheating: preheating temperature (min.
PAGE 51
Engine Data 2.4.6 2 – 29 12/16/18V 2000 Continuous operation, unrestricted: Application group 3B, Air-cooled charge air, Optimized fuel consumption, Optimized exhaust emission (EPA 40 CFR89 / Tier 1) Explanation: DL Ref. value: Continuous power (CP) BL Ref. value: Fuel stop power (FSP) A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g.
PAGE 52
2 – 30 Engine Data GENERAL CONDITIONS (for maximum power) Number of cylinders 12 16 18 12 16 18 Intake air depression (new filter) (design) A mbar 15 15 15 30 30 30 Intake air depression (limit value) L mbar 30 30 30 50 50 50 Exhaust backpressure (design) A mbar 30 30 30 50 50 50 Exhaust backpressure (limit value) L mbar 50 50 50 100 100 100 12 16 18 12 16 18 Engine with exhaust turbocharging (ETC) and charge air cooling (CAC) X X X X X X Exhaust pip
PAGE 53
Engine Data 2 – 31 Number of cylinders 12 16 18 12 16 18 Displacement, cylinder liter 1.99 1.99 1.99 1.99 1.99 1.99 Displacement, total liter 23.88 31.84 35.82 23.88 31.84 35.
PAGE 54
2 – 32 Engine Data COOLING SYSTEM (HT circuit) Number of cylinders 12 16 18 12 16 18 Coolant temperature (at engine outlet to cooling equipment) A C 95 95 95 95 95 95 Coolant temperature after engine, alarm R C 97 97 97 97 97 97 Coolant temperature after engine, shutdown L C 102 102 102 102 102 102 Coolant antifreeze content, max. permissible L % 50 50 50 50 50 50 Pressure loss in the external cooling system, max. permissible L bar 0.7 0.7 0.7 0.7 0.7 0.
PAGE 55
Engine Data 2 – 33 LUBE OIL SYSTEM Number of cylinders 12 16 18 12 16 18 Lube oil operating temperature before engine,from R C 88 88 88 88 88 88 Lube oil operating temp. before engine, to R C 98 98 98 98 98 98 Lube oil temperature before engine, alarm R C 103 103 103 103 103 103 Lube oil temperature before engine, shutdown L C --- N --- --- --- --- Lube oil operating press. bef. engine, from R bar 6.2 5.5 6.0 6.5 6.0 6.5 Lube oil operating press. bef.
PAGE 56
2 – 34 Engine Data GENERAL OPERATING DATA Number of cylinders 12 16 18 12 16 18 Cold start capability: air temperature (w/o start aid, w/o preheating) (case A) R C 0** 0** 0** 0** 0** 0** Coolant preheating: preheating temperature (min.
PAGE 57
Engine Data 2 – 35 CAPACITIES Number of cylinders 12 16 18 12 16 18 Engine coolant capacity (without cooling equipment) R liter 90 110 120 90 110 120 Intercooler coolant capacity R liter --- --- --- --- --- --- Engine oil capacity , initial filling (standard-oil system) (Option: max. operating inclinations) R liter 77 102 130 77 102 130 Oil change quantity, max. (standard oil system) R liter N N N N N N Oil change quantity, max.
PAGE 58
2 – 36 Engine Data ACOUSTICS Number of cylinders 12 16 18 12 16 18 Exhaust noise, unsilenced CP (sound power level LW, ISO 6798) R db(A) 123 123 125 126 126 126 Engine surface noise with attenuated CP intake noise (filter) (sound power level LW, ISO 6798) R db(A) 118 119 122 N N 122 M015560/00E 03-05 © MTU
PAGE 59
Engine Data 2.4.7 2 – 37 12/16/18V 2000 Standby operation: Application Group 3D, Water-cooled charge-air, Optimized fuel consumption Explanation: DL Ref. value: Continuous power (CP) BL Ref. value: Fuel stop power (FSP) A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g.
PAGE 60
2 – 38 Engine Data MODEL-RELATED DATA (basic design) 12 12 16 16 18 Engine with exhaust turbocharging (ETC) and charge air cooling (CAC) X X X X X Exhaust piping, non-cooled X X X X X Working method: four-cycle, diesel, single-acting X X X X X Combustion method: direct fuel injection X X X X X Cooling system: conditioned water X X X X X Direction of rotation: c.c.w.
PAGE 61
Engine Data 2 – 39 COOLING SYSTEM (HT circuit) Number of cylinders 12 12 16 16 18 Coolant temperature (at engine outlet to cooling equipment) A C 95 95 95 95 95 Coolant temperature after engine, alarm R C 97 97 97 97 97 Coolant temperature after engine, shutdown L C 102 102 102 102 102 Coolant antifreeze content, max. permissible L % 50 50 50 50 50 Pressure loss in the external cooling system, max. permissible L bar 0.7 0.7 0.7 0.7 0.
PAGE 62
2 – 40 Engine Data LUBE OIL SYSTEM Number of cylinders 12 12 16 16 18 Lube oil operating temperature before engine,from R C 88 88 88 88 88 Lube oil operating temp. before engine, to R C 98 98 98 98 98 Lube oil temperature before engine, alarm R C 103 103 103 103 103 Lube oil temperature before engine, shutdown L C --- --- --- --- --- Lube oil operating press. bef. engine, from R bar 6.2 6.2 5.5 5.5 6.0 Lube oil operating press. bef. engine, to R bar 7.5 7.
PAGE 63
Engine Data 2 – 41 CAPACITIES Number of cylinders 12 12 16 16 18 Engine coolant capacity (without cooling equipment) R liter 110 110 130 130 140 Intercooler coolant capacity R liter 20 20 20 20 20 Engine oil capacity , initial filling (standard-oil system) (Option: max. operating inclinations) R liter 77 77 102 102 130 Oil change quantity, max. (standard oil system) R liter N N N N N Oil change quantity, max. (standard oil system) (Option: max.
PAGE 64
2 – 42 2.4.8 Engine Data 12/16/18V 2000 Standby operation: Application Group 3D, Water-cooled charge-air, Optimized exhaust emission (EPA 40 CFR89 / Tier 1) Explanation: DL Ref. value: Continuous power (CP) BL Ref. value: Fuel stop power (FSP) A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g.
PAGE 65
Engine Data 2 – 43 MODEL-RELATED DATA (basic design) 12 12 16 16 18 Engine with exhaust turbocharging (ETC) and charge air cooling (CAC) X X X X X Exhaust piping, non-cooled X X X X X Working method: four-cycle, diesel, single-acting X X X X X Combustion method: direct fuel injection X X X X X Cooling system: conditioned water X X X X X Direction of rotation: c.c.w.
PAGE 66
2 – 44 Engine Data COOLING SYSTEM (HT circuit) Number of cylinders 12 12 16 16 18 Coolant temperature (at engine outlet to cooling equipment) A C 95 95 95 95 95 Coolant temperature after engine, alarm R C 97 97 97 97 97 Coolant temperature after engine, shutdown L C 102 102 102 102 102 Coolant antifreeze content, max. permissible L % 50 50 50 50 50 Pressure loss in the external cooling system, max. permissible L bar 0.7 0.7 0.7 0.7 0.
PAGE 67
Engine Data 2 – 45 LUBE OIL SYSTEM Number of cylinders 12 12 16 16 18 Lube oil operating temperature before engine,from R C 88 88 88 88 88 Lube oil operating temp. before engine, to R C 98 98 98 98 98 Lube oil temperature before engine, alarm R C 103 103 103 103 103 Lube oil temperature before engine, shutdown L C --- --- --- --- --- Lube oil operating press. bef. engine, from R bar 6.5 6.5 6.0 6.0 6.5 Lube oil operating press. bef. engine, to R bar 7.8 7.
PAGE 68
2 – 46 Engine Data CAPACITIES Number of cylinders 12 12 16 16 18 Engine coolant capacity (without cooling equipment) R liter 110 110 130 130 140 Intercooler coolant capacity R liter 20 20 20 20 20 Engine oil capacity , initial filling (standard-oil system) (Option: max. operating inclinations) R liter 77 77 102 102 130 Oil change quantity, max. (standard oil system) R liter N N N N N Oil change quantity, max. (standard oil system) (Option: max.
PAGE 69
Engine Data 2.4.9 2 – 47 12/16/18V 2000 Continuous operation with variable load: Application group 3B, Water-cooled charge-air, Optimized fuel consumption Explanation: DL Ref. value: Continuous power (CP) BL Ref. value: Fuel stop power (FSP) A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g.
PAGE 70
2 – 48 Engine Data MODEL-RELATED DATA (basic design) 12 12 16 16 18 Engine with exhaust turbocharging (ETC) and charge air cooling (CAC) X X X X X Exhaust piping, non-cooled X X X X X Working method: four-cycle, diesel, single-acting X X X X X Combustion method: direct fuel injection X X X X X Cooling system: conditioned water X X X X X Direction of rotation: c.c.w.
PAGE 71
Engine Data 2 – 49 COOLING SYSTEM (HT circuit) Number of cylinders 12 12 16 16 18 Coolant temperature (at engine outlet to cooling equipment) A C 95 95 95 95 95 Coolant temperature after engine, alarm R C 97 97 97 97 97 Coolant temperature after engine, shutdown L C 102 102 102 102 102 Coolant antifreeze content, max. permissible L % 50 50 50 50 50 Pressure loss in the external cooling system, max. permissible L bar 0.7 0.7 0.7 0.7 0.
PAGE 72
2 – 50 Engine Data LUBE OIL SYSTEM Number of cylinders 12 12 16 16 18 Lube oil operating temperature before engine,from R C 88 88 88 88 88 Lube oil operating temp. before engine, to R C 98 98 98 98 98 Lube oil temperature before engine, alarm R C 103 103 103 103 103 Lube oil temperature before engine, shutdown L C --- --- --- --- --- Lube oil operating press. bef. engine, from R bar 6.2 6.2 5.5 5.5 6.0 Lube oil operating press. bef. engine, to R bar 7.5 7.
PAGE 73
Engine Data 2 – 51 CAPACITIES Number of cylinders 12 12 16 16 18 Engine coolant capacity (without cooling equipment) R liter 110 110 130 130 140 Intercooler coolant capacity R liter --- 20 20 20 20 Engine oil capacity , initial filling (standard-oil system) (Option: max. operating inclinations) R liter 77 77 102 102 130 Oil change quantity, max. (standard oil system) R liter N N N N N Oil change quantity, max. (standard oil system) (Option: max.
PAGE 74
2 – 52 2.4.10 Engine Data 12/16/18V Continuous operation with variable load: Application group 3B, Water-cooled charge-air, Optimized exhaust emission (TA-Luft) Explanation: DL Ref. value: Continuous power (CP) BL Ref. value: Fuel stop power (FSP) A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g.
PAGE 75
Engine Data 2 – 53 MODEL-RELATED DATA (basic design) 12 12 16 16 18 Engine with exhaust turbocharging (ETC) and charge air cooling (CAC) X X X X X Exhaust piping, non-cooled X X X X X Working method: four-cycle, diesel, single-acting X X X X X Combustion method: direct fuel injection X X X X X Cooling system: conditioned water X X X X X Direction of rotation: c.c.w.
PAGE 76
2 – 54 Engine Data COOLING SYSTEM (HT circuit) Number of cylinders 12 12 16 16 18 Coolant temperature (at engine outlet to cooling equipment) A C 95 95 95 95 95 Coolant temperature after engine, alarm R C 97 97 97 97 97 Coolant temperature after engine, shutdown L C 102 102 102 102 102 Coolant antifreeze content, max. permissible L % 50 50 50 50 50 Pressure loss in the external cooling system, max. permissible L bar 0.7 0.7 0.7 0.7 0.
PAGE 77
Engine Data 2 – 55 LUBE OIL SYSTEM Number of cylinders 12 12 16 16 18 Lube oil operating temperature before engine,from R C 88 88 88 88 88 Lube oil operating temp. before engine, to R C 98 98 98 98 98 Lube oil temperature before engine, alarm R C 103 103 103 103 103 Lube oil temperature before engine, shutdown L C --- --- --- --- --- Lube oil operating press. bef. engine, from R bar 6.2 6.2 5.5 5.5 6.0 Lube oil operating press. bef. engine, to R bar 7.5 7.
PAGE 78
2 – 56 Engine Data CAPACITIES Number of cylinders 12 12 16 16 18 Engine coolant capacity (without cooling equipment) R liter 110 110 130 130 140 Intercooler coolant capacity R liter 20 20 20 20 20 Engine oil capacity , initial filling (standard-oil system) (Option: max. operating inclinations) R liter 77 77 102 102 130 Oil change quantity, max. (standard oil system) R liter N N N N N Oil change quantity, max. (standard oil system) (Option: max.
PAGE 79
Engine Data 2.4.11 2 – 57 12/16/18V Continuous operation with variable load: Application group 3B, Water-cooled charge-air, Optimized exhaust emission (EPA 40 CFR89 / Tier 1) Explanation: DL Ref. value: Continuous power (CP) BL Ref. value: Fuel stop power (FSP) A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g.
PAGE 80
2 – 58 Engine Data MODEL-RELATED DATA (basic design) 12 16 18 Engine with exhaust turbocharging (ETC) and charge air cooling (CAC) X X X Exhaust piping, non-cooled X X X Working method: four-cycle, diesel, single-acting X X X Combustion method: direct fuel injection X X X Cooling system: conditioned water X X X Direction of rotation: c.c.w.
PAGE 81
Engine Data 2 – 59 COOLING SYSTEM (HT circuit) Number of cylinders 12 16 18 Coolant temperature (at engine outlet to cooling equipment) A C 95 95 95 Coolant temperature after engine, alarm R C 97 97 97 Coolant temperature after engine, shutdown L C 102 102 102 Coolant antifreeze content, max. permissible L % 50 50 50 Pressure loss in the external cooling system, max. permissible L bar 0.7 0.7 0.
PAGE 82
2 – 60 Engine Data GENERAL OPERATING DATA Number of cylinders 12 16 18 Cold start capability: air temperature (w/o start aid, w/o preheating) (case A) R C 0** 0** 0** Coolant preheating: preheating temperature (min.
PAGE 83
Engine Data 2.4.12 2 – 61 12/16/18V 2000 Continuous operation, unrestricted: Application group 3B, Water-cooled charge-air, Optimized fuel consumption, Optimized exhaust emission (EPA 40 CFR89 / Tier 1) Explanation: DL Ref. value: Continuous power (CP) BL Ref. value: Fuel stop power (FSP) A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g.
PAGE 84
2 – 62 Engine Data GENERAL CONDITIONS (for maximum power) Number of cylinders 12 16 18 12 16 18 Intake air depression (new filter) (design) A mbar 15 15 15 30 30 30 Intake air depression (limit value) L mbar 30 30 30 50 50 50 Exhaust backpressure (design) A mbar 30 30 30 50 50 50 Exhaust backpressure (limit value) L mbar 50 50 50 100 100 100 12 16 18 12 16 18 Engine with exhaust turbocharging (ETC) and charge air cooling (CAC) X X X X X X Exhaust pip
PAGE 85
Engine Data 2 – 63 Number of cylinders 12 16 18 12 16 18 Displacement, cylinder liter 1.99 1.99 1.99 1.99 1.99 1.99 Displacement, total liter 23.88 31.84 35.82 23.88 31.84 35.
PAGE 86
2 – 64 Engine Data COOLING SYSTEM (HT circuit) Number of cylinders 12 16 18 12 16 18 Coolant temperature (at engine outlet to cooling equipment) A C 95 95 95 95 95 95 Coolant temperature after engine, alarm R C 97 97 97 97 97 97 Coolant temperature after engine, shutdown L C 102 102 102 102 102 102 Coolant antifreeze content, max. permissible L % 50 50 50 50 50 50 Pressure loss in the external cooling system, max. permissible L bar 0.7 0.7 0.7 0.7 0.7 0.
PAGE 87
Engine Data 2 – 65 LUBE OIL SYSTEM Number of cylinders 12 16 18 12 16 18 Lube oil operating temperature before engine,from R C 88 88 88 88 88 88 Lube oil operating temp. before engine, to R C 98 98 98 98 98 98 Lube oil temperature before engine, alarm R C 103 103 103 103 103 103 Lube oil temperature before engine, shutdown L C --- N --- --- --- --- Lube oil operating press. bef. engine, from R bar 6.2 5.5 6.0 6.5 6.0 6.5 Lube oil operating press. bef.
PAGE 88
2 – 66 Engine Data GENERAL OPERATING DATA Number of cylinders 12 16 18 12 16 18 Cold start capability: air temperature (w/o start aid, w/o preheating) (case A) R C 0** 0** 0** 0** 0** 0** Coolant preheating: preheating temperature (min.
PAGE 89
Engine Data 2 – 67 CAPACITIES Number of cylinders 12 16 18 12 16 18 Engine coolant capacity (without cooling equipment) R liter 110 130 140 110 130 140 Intercooler coolant capacity R liter 20 20 20 20 20 20 Engine oil capacity , initial filling (standard-oil system) (Option: max. operating inclinations) R liter 77 102 130 77 102 130 Oil change quantity, max. (standard oil system) R liter N N N N N N Oil change quantity, max. (standard oil system) (Option: max.
PAGE 90
2 – 68 Engine Data ACOUSTICS Number of cylinders 12 16 18 12 16 18 Exhaust noise, unsilenced CP (sound power level LW, ISO 6798) R db(A) 123 123 125 126 126 126 Engine surface noise with attenuated CP intake noise (filter) (sound power level LW, ISO 6798) R db(A) 116 119 120 118 119 N M015560/00E 03-05 © MTU
PAGE 91
Engine Data 2.4.
PAGE 92
2 – 70 2.4.
PAGE 93
Table of Contents 3 3–I Operation 3.1 Putting the engine into operation after extended out-of-service periods (>3 months) . . . 3 – 01 3.2 Putting the engine into operation after scheduled out-of-service-period ............. 3 – 02 ........................................... 3 – 03 ............................................. 3 – 04 ........................................................ 3 – 05 3.3 Starting the engine in manual mode 3.4 Emergency start (override mode) 3.
PAGE 95
Operation 3.1 3 – 01 Putting the engine into operation after extended out-of-service periods (>3 months) Preconditions • Engine is stopped and starting disabled. • MTU Fluids and Lubricants Specification (A001061/..) is available. Putting the engine into operation after extended out-of-service-periods (>3 months) Item Task Engine Depreserve (→ MTU Fluids and Lubricants Specification A001061/..). Lube oil system Check oil level (→ Page 6 – 41); Fuel prefilter Prime (→ Page 6 – 32).
PAGE 96
3 – 02 3.2 Operation Putting the engine into operation after scheduled out-of-service-period Preconditions • Engine is stopped and starting disabled. Putting the engine into operation Item Task Lube oil system Check oil level (→ Page 6 – 41); Cooling system Check engine coolant level (→ Page 6 – 46); Check charge-air coolant level (→ Page 6 – 52). Cooling system Preheat coolant with preheating unit. Fuel prefilter Drain (→ Page 6 – 28).
PAGE 97
Operation 3.3 3 – 03 Starting the engine in manual mode Preconditions • Generator is not connected to network. • External start interlock is not activated. DANGER Unguarded rotating and moving engine components. Risk of serious injury — danger to life! • Before barring or starting the engine, ensure that nobody is in the danger zone. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors.
PAGE 98
3 – 04 3.4 Operation Emergency start (override mode) Safety functions and engine shutdown alarms will be disregarded. Serious damage to plant! • Initiate emergency start only in emergency situations. CAUTION Preparation Item Task Operating mode selector switch (if provided) Change to manual mode. Emergency start Item Task Switching cabinet, control panel etc. (depending on manufacturer) Actuate switch/button for override input of ECU. Switching cabinet, control panel etc.
PAGE 99
Operation 3.5 3 – 05 Operational checks DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. Operational checks Item Task Control and display panels Check indicated operating parameters (speed, temperatures, pressures).
PAGE 100
3 – 06 3.6 Operation Stopping the engine in manual mode Preconditions • Generator is not connected to network. • Engine is running in manual mode. CAUTION Stopping the engine when it is running at full load causes extreme stress to the engine. Risk of overheating, damage to components! • Before stopping the engine, operate it at idle speed until operating temperatures decrease and stable values are indicated.
PAGE 101
Operation 3.7 3 – 07 Emergency stop CAUTION An emergency stop causes extreme stress to the engine. Risk of overheating, damage to components! • Initiate emergency stop only in emergency situations. Emergency stop from LOP Item Task EMERGENCY STOP button Press. • Engine is stopped by switching off power supply to ECU; • Signalization (e.g. by horn, flashing lamp) is released. After emergency stop from LOP Item Task Switching cabinet, control panel etc.
PAGE 102
3 – 08 3.8 Operation After stopping the engine – engine remains ready for operation After stopping the engine Item Task Engine/generator control system Select operating mode, e.g. MANUAL OPERATION, AUTOMATIC OPERATION.
PAGE 103
Operation 3.9 3 – 09 After stopping the engine – putting the engine out of service Preconditions • MTU Fluids and Lubricants Specification (A001061/..) is available.
PAGE 105
Table of Contents 4 4–I Maintenance 4.1 Maintenance and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.1 Maintenance and servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 01 4 – 01 4.2 Maintenance Schedule – Application Group 3D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.1 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 107
Maintenance and Servicing 4.1 Maintenance and Servicing 4.1.1 Maintenance and servicing 4 – 01 Preface Low operating and maintenance costs as well as operational reliability and availability depend on maintenance and servicing being carried out in compliance with MTU’s specifications and instructions. The overall system, of which the engine is an integral part, must be maintained in such a way as to ensure trouble-free engine operation.
PAGE 108
4 – 02 Maintenance Schedule – Application Group 3D 4.2 Maintenance Schedule – Application Group 3D 4.2.
PAGE 109
Maintenance Schedule – Application Group 3D 4 – 03 Combustion chambers Fuel injection pumps Fuel injectors Air filter Valve gear Fuel filter Coolant cooler Belt drive Engine oil filter Maintenance schedule matrix Maintenance level W2 W2 W3 W3 W3 W4 W4 W4 W4 Time limit, years 2 2 1 2 - 500 X X X 1000 X X X 1500 X X X 2000 X X X 2500 X X X X X X 3500 X X X 4000 X X X 4500 X X X 5000 X X X 5500 X X X X X X 3 - X X X X - 4 Operating hours
PAGE 110
4 – 04 Maintenance Schedule – Application Group 3D Maintenance tasks Maintenance level Interval (hours/years) Item Maintenance tasks W2 0/2 Engine oil filter Replace when changing the oil or when the interval/years is reached, at the latest (→ Page 6 – 42). W2 3000 / 2 Belt drive Check drive belt condition and tension, replace if necessary: • Battery-charging generator drive (→ Page 6 – 56) • Ventilator drive (→ Page 6 – 57). W3 500 / - Valve gear Check valve clearance (→ Page 6 – 10).
PAGE 111
Maintenance Schedule – Application Group 3B 4 – 05 4.3 Maintenance Schedule – Application Group 3B 4.3.
PAGE 112
4 – 06 Maintenance Schedule – Application Group 3B Combustion chambers Fuel injection pumps Fuel injectors Air filter Valve gear Fuel filter Coolant cooler Belt drive Engine oil filter Maintenance schedule matrix Maintenance level W2 W2 W3 W3 W3 W4 W4 W4 W4 Time limit, years 2 2 1 2 - 500 X X X 1000 X X X 1500 X X X 2000 X X X 2500 X X X X X X 3500 X X X 4000 X X X 4500 X X X 5000 X X X 5500 X X X X X X 3 - X X X X - 4 Operating hours
PAGE 113
Maintenance Schedule – Application Group 3B 4 – 07 Maintenance tasks Maintenance level Interval (hours/years) Item Maintenance tasks W2 0/2 Engine oil filter Replace when changing the oil or when the interval/years is reached, at the latest (→ Page 6 – 42). W2 3000 / 2 Belt drive Check drive belt condition and tension, replace if necessary: • Battery-charging generator drive (→ Page 6 – 56) • Ventilator drive (→ Page 6 – 57). W3 500 / - Valve gear Check valve clearance (→ Page 6 – 10).
PAGE 114
4 – 08 Maintenance Schedule – Application Group 3B TAL 4.4 Maintenance Schedule – Application Group 3B TAL 4.4.
PAGE 115
X 3000 X 3250 X 3500 X 3750 X 4000 X 4250 X 4500 X 4750 X 5000 X 5250 X 5500 X 5750 X 6000 X M015560/00E 03-05 X X X X X X X X X X X X X X X X X X X X X X X X X X X Combustion chambers X Fuel injection pumps X Fuel injectors 2750 X Air filter X Valve gear 2500 Fuel filter X Coolant cooler 2250 Belt drive Engine oil 4 – 09 Engine oil filter Maintenance Schedule – Application Group 3B TAL X X X © MTU
PAGE 116
4 – 10 Maintenance Schedule – Application Group 3B TAL Maintenance tasks Maintenance level Interval (hours/years) Item Maintenance tasks W2 1/2 Engine oil filter Replace when changing the oil or when the interval/years is reached, at the latest (→ Page 6 – 42). W2 250 / - Engine oil Change engine oil (→ Page 6 – 39). W2 3000 / 2 Belt drive Check drive belt condition and tension, replace if necessary: • Battery-charging generator drive (→ Page 6 – 56) • Ventilator drive (→ Page 6 – 57).
PAGE 117
Maintenance Schedule – Application Group 3A 4 – 11 4.5 Maintenance Schedule – Application Group 3A 4.5.
PAGE 118
4 – 12 Maintenance Schedule – Application Group 3A Combustion chambers Fuel injection pumps Fuel injectors Air filter Valve gear Fuel filter Coolant cooler Belt drive Engine oil filter Maintenance schedule matrix Maintenance level W2 W2 W3 W3 W3 W4 W4 W4 W4 Time limit, years 2 2 1 2 - 3 - X X X X - 4 Operating hours Daily 500 X 1000 X 1500 X X 2000 X 2500 X X X 3000 X X 3500 X X X X 4000 X 4500 X X X 5000 X 5500 X X X 6000 M015560/00E X X 03-0
PAGE 119
Maintenance Schedule – Application Group 3A 4 – 13 Maintenance tasks Maintenance level Interval (hours/years) Item Maintenance tasks W2 0/2 Engine oil filter Replace when changing the oil or when the interval/years is reached, at the latest (→ Page 6 – 42). W2 3000 / 2 Belt drive Check drive belt condition and tension, replace if necessary: • Battery-charging generator drive (→ Page 6 – 56) • Ventilator drive (→ Page 6 – 57).
PAGE 121
Table of Contents 5 5–I Troubleshooting 5.1 Troubleshooting 5.2 ECU alarms M015560/00E 03-05 ........................................................... 5 – 01 ...............................................................
PAGE 123
Troubleshooting 5.1 5 – 01 Troubleshooting Engine does not turn when starter is actuated Component Probable Cause Task Battery Low or defective Charge or replace (see manufacturer’s documentation). Cable connections defective Check if cable connections are properly secured (see manufacturer’s documentation). Starter Engine wiring or starter defective Check if cable connections are properly secured, contact Service. Engine wiring Defective Check (→ Page 6 – 62).
PAGE 124
5 – 02 Troubleshooting Engine does not reach nominal speed Component Probable Cause Task Fuel supply Fuel prefilter clogged Replace (→ Page 6 – 32). Fuel filter clogged Replace (→ Page 6 – 25). Air supply Air filter clogged Check signal ring position of service indicator (→ Page 6 – 37). Fuel injection equipment Injector defective Replace (→ Page 6 – 18). Injection pump defective Replace (→ Page 6 – 15). Engine wiring Defective Check (→ Page 6 – 62). Engine Overloaded Contact Service.
PAGE 125
Troubleshooting 5 – 03 Coolant leaks on intercooler Component Probable Cause Task Intercooler Leaking, major coolant discharge Contact Service. Component Probable Cause Task Air supply Air filter clogged Check signal ring position of service indicator (→ Page 6 – 37). Fuel injection equipment Injector defective Replace (→ Page 6 – 18). Injection pump defective Replace (→ Page 6 – 15). Overloaded Contact Service.
PAGE 126
5 – 04 5.
PAGE 127
Troubleshooting 5 – 05 Fault code Alarm text Meaning Task 023 L1 COOLANT LEVEL Engine coolant level too low Check coolant level and top up, if required (→ Page 6 – 46) . 024 L2 COOLANT LEVEL Engine coolant level too low Check coolant level and top up, if required (→ Page 6 – 46) . 030 ENGINE OVERSPEED Engine overspeed; automatic engine shutdown 044 L1 LEVEL INTERCOOLER Charge-air coolant level too low (1st limit) Check coolant level and top up, if required (→ Page 6 – 52) .
PAGE 128
5 – 06 Troubleshooting Fault code Alarm text Meaning Task 069 L1 T-EXTERN 1 Violation of first limit for external temperature channel 1 (Depending on the corresponding measuring point, which is read via CAN bus) 070 L2 T-EXTERN 1 Violation of second limit for external temperature channel 1 (Depending on the corresponding measuring point, which is read via CAN bus) 071 L1 T-EXTERN 2 Violation of first limit for external temperature channel 2 (Depending on the corresponding measuring point, w
PAGE 129
Troubleshooting 5 – 07 Fault code Alarm text Meaning Task 083 RAIL PRESSURE LOW Pressure in HP fuel system lower than the specified value; HP fuel control block defective or system leaking NOTE: With very large generators having a run-out time of more than > 20 sec this alarm is not a relevant fault. Contact Service. 089 ENGINE SPEED LOW Engine speed lower than 200 rpm; automatic engine shutdown Re-start the engine (→ Page 3 – 03).
PAGE 130
5 – 08 Troubleshooting Fault code Alarm text Meaning Task 104 OP HOURS1 NOT VALID Check sum error of hour meter data in EDM If fault occurs repeatedly: Contact Service. 105 OP HOURS2 NOT VALID Check sum error of hour meter data in IDM If fault occurs repeatedly: Contact Service. 106 ERR REC1 NOT VALID Check sum error of fault memory in EDM (redundant data record 1) If fault occurs repeatedly: Contact Service.
PAGE 131
Troubleshooting 5 – 09 Fault code Alarm text Meaning Task 144 BANK2 ECU DEFECT Internal electronic fault; Engine does not start Contact Service. 145 15V_GOOD ECU DEFECT Electronic equipment defective; automatic engine shutdown Contact Service. 146 L1 AD-TEST1 SUPPLY A/D-converter supply voltage too low Contact Service. 147 AD-TEST1 ECU DEFECT Electronic equipment defective; automatic engine shutdown Contact Service.
PAGE 132
5 – 10 Troubleshooting Fault code Alarm text Meaning Task 187 CAN1 ERROR PASSIVE Light fault on Default CAN bus (e.g.shortage overload) (none) 188 CAN2 BUS OFF Severe fault on Redundant CAN bus; automatic change-over to Default CAN bus Contact Service. 189 CAN2 ERROR PASSIVE Light fault on Redundant CAN bus (e.g.short-time overload) (none) 201 SD T-COOLANT Sensor defect (coolant temperature) 1. Check wiring. 2. Contact Service. 202 SD T-FUEL Sensor defect (Fuel temperature) 1.
PAGE 133
Troubleshooting 5 – 11 Fault code Alarm text Meaning 250 SD CAN SPEED DEMAND Sensor defect (CAN nominal speed demand) 1. Check speed transmitter. 2. Check wiring (CAN bus). 3. Contact Service. 266 SD SPEED DEMAND AN. Sensor defect (analog nominal speed demand) 1. Check speed transmitter. 2. Check wiring. 3. Contact Service. 267 SD SP.DEM.TEST BENCH Sensor defect (analog speed demand); NOTE: Only used in test-stand operation. 1. Check speed transmitter. 2. Check wiring. 3. Contact Service.
PAGE 134
5 – 12 Troubleshooting Fault code Alarm text Meaning Task 307 TIMING CYLINDER A7 Injection timing fault cylinder A7 If fault occurs repeatedly: Contact Service. 308 TIMING CYLINDER A8 Injection timing fault cylinder A8 If fault occurs repeatedly: Contact Service. 309 TIMING CYLINDER A9 Injection timing fault cylinder A9 If fault occurs repeatedly: Contact Service. 310 TIMING CYLINDER A10 Injection timing fault cylinder A10 If fault occurs repeatedly: Contact Service.
PAGE 135
Troubleshooting 5 – 13 Fault code Alarm text Meaning 326 WIRING CYLINDER A6 Faulty wiring to solenoid valve cylinder A6; Misfiring 1. Check wiring. 2. Contact Service. 327 WIRING CYLINDER A7 Faulty wiring to solenoid valve cylinder A7; Misfiring 1. Check wiring. 2. Contact Service. 328 WIRING CYLINDER A8 Faulty wiring to solenoid valve cylinder A8; Misfiring 1. Check wiring. 2. Contact Service. 329 WIRING CYLINDER A9 Faulty wiring to solenoid valve cylinder A9; Misfiring 1. Check wiring.
PAGE 136
5 – 14 Troubleshooting Fault code Alarm text Meaning 340 WIRING CYLINDER B10 Faulty wiring to solenoid valve cylinder B10; Misfiring 1. Check wiring. 2. Contact Service. 341 OPEN_LOAD CYL. A1 Disconnection in wiring to solenoid valve cylinder A1; Misfiring 1. Check wiring. 2. Contact Service. 342 OPEN_LOAD CYL. A2 Disconnection in wiring to solenoid valve cylinder A2; Misfiring 1. Check wiring. 2. Contact Service. 343 OPEN_LOAD CYL.
PAGE 137
Troubleshooting 5 – 15 Fault code Alarm text Meaning 354 OPEN_LOAD CYL. B4 Disconnection in wiring to solenoid valve cylinder B4; Misfiring 1. Check wiring. 2. Contact Service. 355 OPEN_LOAD CYL. B5 Disconnection in wiring to solenoid valve cylinder B5; Misfiring 1. Check wiring. 2. Contact Service. 356 OPEN_LOAD CYL. B6 Disconnection in wiring to solenoid valve cylinder B6; Misfiring 1. Check wiring. 2. Contact Service. 357 OPEN_LOAD CYL.
PAGE 138
5 – 16 Troubleshooting Fault code Alarm text Meaning Task 385 TRAN.OUT5 PLANT DEF Binary transistor output plant 5 defective Contact Service. 386 TRAN.OUT6 PLANT DEF Binary transistor output plant 6 defective Contact Service.
PAGE 139
Table of Contents 6 6–I Task Description 6.1 Engine 6.1.1 6.1.2 6.1.3 ................................................................... Engine – Barring manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine – barring with starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine test run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 140
6 – II Table of Contents 6.14 Oil Filtration / Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14.1 Engine oil filter – Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 42 6 – 42 6.15 Cooling System, General, HT Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15.1 Engine coolant filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 141
Engine 6 – 01 6.1 Engine 6.1.1 Engine – Barring manually Preconditions • Engine is stopped and starting disabled. Special tools Designation / Use Part No. Qty. Barring tool for 12V engines Barring tool for 16/18V engines DANGER Unguarded rotating and moving engine components. Risk of serious injury - danger to life! • Before barring or starting the engine, ensure that nobody is in the danger zone.
PAGE 142
6 – 02 6.1.2 Engine Engine – barring with starting system Special tools Designation / Use Part No. Qty. Connector pliers DANGER Unguarded rotating and moving engine components. Risk of serious injury - danger to life! • Before barring or starting the engine, ensure that nobody is in the danger zone. • After working on the engine, check that all protective devices have been reinstalled and all tools removed from the engine. Barring engine with starting system 1.
PAGE 143
Engine 6.1.3 6 – 03 Engine test run DANGER Unguarded rotating and moving engine components. Risk of serious injury — danger to life! • Before barring or starting the engine, ensure that nobody is in the danger zone. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. Engine test run 1. Start engine (→ Page 3 – 03). 2. Perform test run at not below 1/3 load and at least until steady-state temperature is reached. 3. Carry out operational checks (→ Page 3 – 05). 4.
PAGE 144
6 – 04 Cylinder Liner 6.2 Cylinder Liner 6.2.1 Cylinder-liner endoscopic examination Preconditions • Engine is stopped and starting disabled. Special tools Designation / Use Part No. Qty. Rigid endoscope, max. diameter: 7 mm Preparatory steps 1. Remove cylinder-head cover (→ Page 6 – 13). 2. Remove injector (→ Page 6 – 19). Bringing the piston to BDC position 1. Use the barring tool to rotate the crankshaft until the crank pin of the cylinder to be inspected is at BDC position. 2.
PAGE 145
Cylinder Liner 6 – 05 Final steps 1. Install injector (→ Page 6 – 19). 2. Install cylinder-head cover (→ Page 6 – 13).
PAGE 146
6 – 06 6.2.2 Cylinder Liner Instructions and comments on endoscopic and visual examination of cylinder liner Terms used for endoscopic examination Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic examination report. Minor dirt scores Light scoring can take place during the assembly of a new engine (honing products, particles, broken-off burrs). Removed cylinders clearly show such scoring on the running surface under endoscope magnification.
PAGE 147
Cylinder Liner 6 – 07 Evaluation of findings and further measures The findings in the start phase of oxidation discoloration and heat discoloration are similar. A definite opinion can first be made after a careful inspection and reference to the above criteria. To avoid unnecessary disassembly work, it is recommended that another inspection be carried out after further operation of the engine.
PAGE 148
6 – 08 Crankcase Breather 6.3 Crankcase Breather 6.3.1 Crankcase breather – oil separator replacement and diaphragm check Preconditions • Engine is stopped and starting disabled. Special tools Designation / Use Part No. Qty. Part No. Qty. Torque wrench Spare parts Designation / Use Filter element Diaphragm O-ring Oil separator replacement 1. Remove cover (2) with O-ring (3). 2. Remove filter element (1) from housing (4). 3.
PAGE 149
Crankcase Breather 6 – 09 Diaphragm check 1. Remove cover (5). 2. Take off spring (6), seal (4) and diaphragm (3). 3. Check diaphragm (3) for damage. 4. Replace diaphragm if damaged. 5. Mount diaphragm (3) on housing (2). 6. Install new seal (4) and spring (6) together with cover (5). 7. Tighten screws of cover (5) to 6 Nm + 2 Nm. 8. Check diaphragms in further oil separators in the same way.
PAGE 150
6 – 10 Valve Gear 6.4 Valve Gear 6.4.1 Valve clearance – Check and adjustment Preconditions • Engine is stopped and starting disabled. • Engine coolant temperature is max. 40 C. • Valves are closed. Special tools Designation / Use Part No. Qty. Feeler gauge Preparatory steps 1. Remove cylinder-head cover (→ Page 6 – 13). 2. Use barring tool to bar engine manually in engine direction of rotation (→ Page 6 – 01), until the markings are aligned.
PAGE 151
Valve Gear 6 – 11 Adjusting valve clearance in two crankshaft positions 1. Check TDC position of piston in cylinder A1: • If the rocker arms are not under load on cylinder A, the piston is in firing TDC. • If the rocker arms are under load on cylinder A, the piston is in overlap TDC. 2. Check valve clearance with cold engine: • Inlet = 0.4 mm; • Exhaust = 0.6 mm; 3. Check all valve clearances in two crankshaft positions (firing and overlap TDC for cylinder A1) as per diagram. 4.
PAGE 152
6 – 12 Valve Gear Final steps 1. Remove barring tool. 2. Install cylinder-head cover (→ Page 6 – 13). 3. Install cover.
PAGE 153
Valve Gear 6.4.2 6 – 13 Cylinder-head cover – Removal and installation Preconditions • Engine is stopped and starting disabled. Special tools Designation / Use Part No. Qty. Part No. Qty. Torque wrench Spare parts Designation / Use Gasket Preparatory steps 1. On cylinder-head covers with crankcase breather: Loosen clamps. 2. Slide rubber sleeves onto the pipe. Cylinder-head cover – Removal and installation 1. Remove screws. 2. Remove cylinder-head cover with gasket from cylinder head. 3.
PAGE 154
6 – 14 Injection Pump / HP Pump 6.5 Injection Pump / HP Pump 6.5.1 Injection pump replacement Spare parts Designation / Use Part No. Qty. Injection pump Remove injection pump and install new one (→ Page 6 – 15).
PAGE 155
Injection Pump / HP Pump 6.5.2 6 – 15 Injection pump removal and installation Preconditions • Engine is stopped and starting disabled. Special tools Designation / Use Part No. Qty. Part No. Qty. Part No. Qty. Barring tool Material Designation / Use Petroleum jelly Spare parts Designation / Use Sealing ring Sealing ring DANGER WARNING Unguarded rotating and moving engine components.
PAGE 156
6 – 16 Injection Pump / HP Pump Injection pump removal 1. Mark installation position of injection pump. 2. Disconnect wiring (1) from injection pump. 3. Remove fuel line (2). 4. Remove injection pump securing screws. Note: Never try to prise loose a jammed injection pump at the solenoid valve or the intermediate plate. 5. Pull out injection pump, if required, press out carefully at the recess of the injection pump head. 6. Remove sealing rigs from injection pump. 7. Cover installation bore.
PAGE 157
Injection Pump / HP Pump 6 – 17 Final steps 1. Remove barring tool (→ Page 6 – 01). 2. Clean mating faces on cylinder head and charge-air manifold. 3. Check gaskets for damage and replace them, if required. 4. Set gasket onto cylinder head. 5. Install charge-air manifold. 6. Install engine control system (→ Page 6 – 63). 7. Open fuel supply line before fuel filter. 8. Vent fuel system (→ Page 6 – 23).
PAGE 158
6 – 18 Fuel Injector 6.6 Fuel Injector 6.6.1 Injector replacement Spare parts Designation / Use Part No. Qty. Injector Remove injector and install new one (→ Page 6 – 19).
PAGE 159
Fuel Injector 6.6.2 6 – 19 Injector removal and installation Preconditions • Engine is stopped and starting disabled. Special tools Designation / Use Part No. Qty. Part No. Qty. Part No. Qty. Impact extractor Fuel suction device Torque wrench Material Designation / Use Petroleum jelly Spare parts Designation / Use Sealing ring Sealing ring WARNING WARNING Fuels are combustible. Risk of fire and explosion! • Avoid naked flames, electrical sparks and ignition sources. • Do not smoke.
PAGE 160
6 – 20 Fuel Injector Injector removal 1. Remove leak-off-fuel lines. 2. Remove fuel line (3). 3. Remove thrust screw (2). 4. Pull off pressure pipe neck (1). 5. Extract fuel from the exposed bores using the suction device. 6. Seal all connections with appropriate plugs. 7. Remove screw (2). 8. Take off clamp (1). 9. Screw extractor into injector. 10. Remove injector using the impact extractor. 11. Remove sealing ring using a self-made hook.
PAGE 161
Fuel Injector 6 – 21 Injector installation 1. Prior to installation, remove all plugs. 2. Clean sealing surface on cylinder head and protective sleeve. 3. Coat new sealing ring (1) with petroleum jelly and fit onto injector. 4. Coat new sealing ring (2) with petroleum jelly and fit onto injector. 5. Press injector into cylinder head by hand. Result: • The pin must be at 11-o’clock position to the longitudinal axis of the engine. • The pin must be engaged in the groove of the clamp (4). 6.
PAGE 162
6 – 22 Fuel System (Low Pressure) 6.7 Fuel System (Low Pressure) 6.7.1 Fuel – Draining Preconditions • Engine is stopped and starting disabled. WARNING Fuels are combustible. Risk of fire and explosion! • Avoid naked flames, electrical sparks and ignition sources. • Do not smoke. Fuel – Draining 1. Loosen nut (arrow) on banjo union. 2. Remove fuel line from non-return valve. 3. Unscrew non-return valve on end piece (arrow) and drain fuel into a suitable container. 4.
PAGE 163
Fuel System (Low Pressure) 6.7.2 6 – 23 Fuel system – Venting Preconditions • Engine is stopped and starting disabled. WARNING Fuels are combustible. Risk of fire and explosion! • Avoid naked flames, electrical sparks and ignition sources. • Do not smoke. Fuel system – Venting 1. Unlock fuel priming pump, unscrew handle. 2. Loosen nut (arrow) on banjo union. 3. Operate the pump with the handle until fuel without bubbles comes out of the vent plugs. 4. Tighten nut on banjo union.
PAGE 164
6 – 24 Fuel System (Low Pressure) 5. Loosen banjo screw (arrow). 6. Operate the pump with the handle until fuel without bubbles comes out of the nipple. 7. Tighten banjo screw. 8. Loosen union nut of fuel return line. 9. Loosen non-return valve (arrow). 10. Operate the pump with the handle until fuel without bubbles comes out of the nipple. 11. Tighten non-return valve. 12. Tighten union nut of fuel return line. 13. Lock fuel priming pump, screw in handle.
PAGE 165
Fuel Filter 6 – 25 6.8 Fuel Filter 6.8.1 Fuel filter – Replacement Preconditions • Engine is stopped and starting disabled. Special tools Designation / Use Part No. Qty. Part No. Qty. Part No. Qty. Strap wrench Material Designation / Use Diesel fuel Spare parts Designation / Use Easy-change filter WARNING Fuels are combustible. Risk of fire and explosion! • Avoid naked flames, electrical sparks and ignition sources. • Do not smoke. Fuel filter – Replacement 1.
PAGE 166
6 – 26 6.8.2 Fuel Filter Fuel prefilter cleaning Preconditions • Engine is stopped and starting disabled. Material Designation / Use Part No. Qty. Part No. Qty. Diesel fuel Spare parts Designation / Use Sealing ring WARNING Fuels are combustible. Risk of fire and explosion! • Avoid naked flames, electrical sparks and ignition sources. • Do not smoke. Fuel prefilter cleaning 1. Shut off fuel supply. 2. Remove nuts from filter head. 3.
PAGE 167
Fuel Filter 6.8.3 6 – 27 Fuel prefilter – differential pressure check and adjustment of gauge DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. Setting adjustable pointer of differential pressure gauge 1.
PAGE 168
6 – 28 6.8.4 Fuel Filter Fuel prefilter – draining Preconditions • Engine is stopped and starting disabled. Material Designation / Use Part No. Qty. Part No. Qty. Diesel fuel Spare parts Designation / Use Gasket WARNING Fuels are combustible. Risk of fire and explosion! • Avoid naked flames, electrical sparks and ignition sources. • Do not smoke. Fuel prefilter – draining 1. Cut out the filter to be drained.
PAGE 169
Fuel Filter 6 – 29 2. Open vent plug (5) of the filter to be drained. 3. Unlock drain cock (6) by pressing toggle and open it. 4. Drain water and contaminants from the filter until pure fuel emerges. 5. Close drain cock (6). 6. Remove screws securing the cover and take off cover (2). 7. Fill filter housing with clean fuel. 8. Place new gasket in cover (2). 9. Fit cover with gasket and secure it with screws. 10. Cut the cut-out filter in again. 11. When fuel emerges from system, close vent plug (5).
PAGE 170
6 – 30 6.8.5 Fuel Filter Fuel prefilter – flushing Material Designation / Use Part No. Qty. Part No. Qty. Diesel fuel Spare parts Designation / Use Gasket DANGER WARNING WARNING Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. Fuels are combustible. Risk of fire and explosion! • Avoid naked flames, electrical sparks and ignition sources. • Do not smoke. Engine noise above 85 dB (A).
PAGE 171
Fuel Filter 6 – 31 2. Open vent plug (5) of the filter to be flushed. 3. Unlock drain cock (6) by pressing toggle, open it and drain fuel. Result: Fuel flows from filtered side back to the unfiltered side, flushing the filter deposits downwards out of the filter. 4. Close vent plug (5) and drain cock (6). Fuel prefilter – filling fuel 1. Stop engine (→ Page 3 – 06)and disable engine start. 2. Remove screws securing the cover and take off cover (2). 3. Fill filter housing with clean fuel. 4.
PAGE 172
6 – 32 6.8.6 Fuel Filter Fuel prefilter – filter element replacement Preconditions • Engine is stopped and starting disabled. Material Designation / Use Part No. Qty. Part No. Qty. Diesel fuel Spare parts Designation / Use Filter element Gasket WARNING Fuels are combustible. Risk of fire and explosion! • Avoid naked flames, electrical sparks and ignition sources. • Do not smoke. Fuel prefilter – filter element replacement 1. Cut out the contaminated filter.
PAGE 173
Fuel Filter 6 – 33 2. Open vent plug (5) of the contaminated filter. 3. Unlock drain cock (6) by pressing toggle and open it. 4. Drain water and contaminants from the filter. 5. Close drain cock (6). 6. Remove screws securing the cover and take off cover (2). 7. Remove spring (4) and filter element (3). 8. Insert new filter element (3) and spring (4). 9. Fill filter housing with clean fuel. 10. Place new gasket in cover (2). 11. Fit cover with gasket and secure it with screws. 12.
PAGE 174
6 – 34 Charge-Air Cooling, General, Left Side 6.9 Charge-Air Cooling, General, Left Side 6.9.1 Intercooler – Checking condensate drains for coolant discharge and obstructions Preconditions • Engine is stopped and starting disabled. Spare parts Designation / Use Part No. Qty. Sealing ring WARNING Compressed air. Risk of injury! • Do not direct compressed-air jet at persons. • Wear protective goggles / safety mask and ear protectors.
PAGE 175
Air Filter 6 – 35 6.10 Air Filter 6.10.1 Air filter replacement Spare parts Designation / Use Part No. Qty. Air filter Remove air filter and install new one (→ Page 6 – 36). Reset signal ring of service indicator (→ Page 6 – 37).
PAGE 176
6 – 36 6.10.2 Air Filter Air filter removal and installation Preconditions • Engine is stopped and starting disabled. Air filter removal and installation 1. Loosen clamp (2). 2. Remove air filter (3) and clamp (2) from flange of intake housing (1). 3. Verify that there are no objects in the flange of the intake housing (1) and clean it. 4. Place new air filter (3) with clamp (2) onto intake housing (1). 5. Tighten clamp (2).
PAGE 177
Air Intake 6 – 37 6.11 Air Intake 6.11.1 Service indicator – signal ring position check Preconditions • Engine is stopped and starting disabled. Signal ring position check 1. If the signal ring is completely visible in the control window (2), replace air filter (→ Page 6 – 35). 2. After installation of new filter, press reset button (1). Result: Engaged piston with signal ring moves back to initial position.
PAGE 178
6 – 38 Starting System 6.12 Starting System 6.12.1 Air starter – manual operation DANGER Unguarded rotating and moving engine components. Risk of serious injury — danger to life! • Before barring or starting the engine, ensure that nobody is in the danger zone. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. Air starter – manual operation 1. Press pushbutton for manual start and hold it. 2.
PAGE 179
Lube Oil System 6 – 39 6.13 Lube Oil System 6.13.1 Engine oil change Preconditions • Engine is stopped and starting disabled. • Engine is at operating temperature. • MTU Fluids and Lubricants Specification (A001061/..) is available. Material Designation / Use Part No. Qty. Part No. Qty. Engine oil Spare parts Designation / Use Sealing ring WARNING Hot engine oil. Engine oil can contain combustion residues which are harmful to health.
PAGE 180
6 – 40 Lube Oil System Engine oil system filling 1. Determine amount of engine oil required for oil change (→ Product Summary - Technical Data). 2. Open cover of filler neck. 3. Pour oil in at filler neck up to "max." mark at oil dipstick. 4. Close cover of filler neck. 5. Check oil level (→ Page 6 – 41). 6. After oil change and oil filter replacement, bar engine with starting system (→ Page 6 – 02).
PAGE 181
Lube Oil System 6.13.2 6 – 41 Engine oil level check Preconditions • Engine is stopped and starting disabled. Oil level check prior to engine start 1. Withdraw dipstick from guide tube and wipe it. 2. Insert dipstick into guide tube to stop, withdraw after approx. 10 seconds and check oil level. 3. Oil level must be between "min." and "max." marks. 4. If necessary, top up to "max." mark (→ Page 6 – 39). 5. Insert dipstick into guide tube to stop. Oil level check after the engine is stopped 1.
PAGE 182
6 – 42 Oil Filtration / Cooling 6.14 Oil Filtration / Cooling 6.14.1 Engine oil filter – Replacement Preconditions • Engine is stopped and starting disabled. Special tools Designation / Use Part No. Qty. Part No. Qty. Part No. Qty. Strap wrench Material Designation / Use Engine oil Spare parts Designation / Use Oil filter WARNING Hot engine oil. Engine oil can contain combustion residues which are harmful to health.
PAGE 183
Cooling System, General, HT Circuit 6 – 43 6.15 Cooling System, General, HT Circuit 6.15.1 Engine coolant filling Preconditions • Engine is stopped and starting disabled. • MTU Fluids and Lubricants Specification (A001061/..) is available. Material Designation / Use Part No. Qty. Engine coolant WARNING CAUTION Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask.
PAGE 184
6 – 44 6.15.2 Cooling System, General, HT Circuit Engine coolant – Draining Preconditions • Engine is stopped and starting disabled. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask. Preparatory steps 1. Provide an appropriate container to drain the coolant into. 2. Switch off preheating unit. Engine coolant – Draining 1.
PAGE 185
Cooling System, General, HT Circuit 6.15.3 6 – 45 Engine coolant change Material Designation / Use Part No. Qty. Coolant Drain engine coolant (→ Page 6 – 44). Fill engine coolant system (→ Page 6 – 43).
PAGE 186
6 – 46 6.15.4 Cooling System, General, HT Circuit Engine coolant-level check Preconditions • Engine is stopped and starting disabled. • MTU Fluids and Lubricants Specification (A001061/..) is available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask. Coolant-level check at filler neck: 1.
PAGE 187
Cooling System, General, HT Circuit 6.15.5 6 – 47 Cooling pump - Relief bore check DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. Cooling pump - Relief bore check 1. Check relief bore for oil and water discharge. 2. Stop engine (→ Page 3 – 06) and disable engine start. 3.
PAGE 188
6 – 48 Cooling System, LT Circuit 6.16 Cooling System, LT Circuit 6.16.1 Charge-air coolant filling Preconditions • Engine is stopped and starting disabled. • MTU Fluids and Lubricants Specification (A001061/..) is available. Material Designation / Use Part No. Qty. Part No. Qty. Coolant Spare parts Designation / Use Sealing ring WARNING Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. CAUTION Cold coolant in hot engine can cause thermal stress.
PAGE 189
Cooling System, LT Circuit 6 – 49 Final steps 1. Start the engine and operate it at idle speed for some minutes. 2. Check coolant level (→ Page 6 – 52).
PAGE 190
6 – 50 6.16.2 Cooling System, LT Circuit Charge-air coolant – Draining Preconditions • Engine is stopped and starting disabled. Spare parts Designation / Use Part No. Qty. Sealing ring WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask. Charge-air coolant – Draining 1. Provide an appropriate container to drain the coolant into. 2.
PAGE 191
Cooling System, LT Circuit 6.16.3 6 – 51 Charge-air coolant change Material Designation / Use Part No. Qty. Coolant Drain charge-air coolant system (→ Page 6 – 50). Fill charge-air coolant system (→ Page 6 – 48).
PAGE 192
6 – 52 6.16.4 Cooling System, LT Circuit Charge-air coolant level check Preconditions • Engine is stopped and starting disabled. • MTU Fluids and Lubricants Specification (A001061/..) is available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask. Charge-air coolant level check at filler neck: 1.
PAGE 193
Battery-Charging Generator 6 – 53 6.17 Battery-Charging Generator 6.17.1 Battery-charging generator drive – Drive-belt check and adjustment Preconditions • Engine is stopped and starting disabled. Special tools Designation / Use Part No. Qty. Belt-tension tester Belt condition check 1. Remove guard cover. 2. Check belt for contamination by oil, cracks, wear, and signs of overheating. 3.
PAGE 194
6 – 54 Battery-Charging Generator Belt tension adjustment 1. Loosen securing screws (2 and 3). 2. Tension ribbed drive belt with tensioning nut (1) and check belt tension 3. Tighten securing screw (2). • Tightening torque: 40 Nm +4 Nm 4. Tighten securing screw (3). 5. Check drive belt tension. 6. Install guard cover.
PAGE 195
Battery-Charging Generator 6.17.2 6 – 55 Battery-charging generator drive – drive belt condition check Preconditions • Engine is stopped and starting disabled. Belt condition check 1. Remove guard cover. 2. Check belt for contamination by oil, cracks, wear, and signs of overheating. 3.
PAGE 196
6 – 56 6.17.3 Battery-Charging Generator Battery-charging generator drive – Drive belt replacement Preconditions • Engine is stopped and starting disabled. Spare parts Designation / Use Part No. Qty. Ribbed belt Battery-charging generator drive – Drive belt replacement 1. Remove guard cover. 2. Remove ventilator drive belt (applicable only to TD cooling). (→ Page 6 – 60) 3. Loosen securing screws (2 and 3). 4. Release tensioning screw (1) until the ribbed belt can be removed. 5.
PAGE 197
Ventilator Drive 6 – 57 6.18 Ventilator Drive 6.18.1 Ventilator drive – Drive-belt check and adjustment Preconditions • Engine is stopped and starting disabled. Special tools Designation / Use Part No. Qty. Belt-tension tester Preparatory steps 1. Remove screws from guard cover. 2. Remove guard cover. Belt 1. 2. 3. condition check Remove guard cover. Check V-belt for contamination by oil, cracks, wear, chunking and signs of overheating.
PAGE 198
6 – 58 Ventilator Drive Belt-tension check on 18V engines: 1. Place belt-tension tester onto V-belt midway between the belt pulleys (arrow). 2. Press button uniformly against V-belt surface until spring disengagement can be heard and felt. 3. Take off belt-tension tester without changing the position of the indication arm. 4. Read off measured value at the intersection of indication arm and "KG" scale.
PAGE 199
Ventilator Drive 6 – 59 Final steps 1. Install guard cover. 2. Fit screws and tighten.
PAGE 200
6 – 60 6.18.2 Ventilator Drive Ventilator drive – Drive belt replacement Preconditions • Engine is stopped and starting disabled. Spare parts Designation / Use Part No. Qty. V-belt Preparatory steps 1. Remove guard cover from cooler. 2. Remove ventilator. Drive belt replacement on 12V/16V engines: 1. Loosen securing screws (3). 2. Release locknut (2). 3. Screw out tensioning screw (1) until V-belts can be removed. 4.
PAGE 201
Engine Mounts 6 – 61 6.19 Engine Mounts 6.19.1 Engine mounts – Resilient elements check Preconditions • Engine is stopped and starting disabled. • Engine is filled with coolant and engine oil. Engine mounts – Resilient elements check 1. Wipe rubber surface with dry cloth, do not use organic detergents. 2. Check resilient elements for crack formation and deformation by visual inspection. 3. Have cracked elements replaced, contact Service. Setting dimension check 1.
PAGE 202
6 – 62 General Wiring, Engine / Gearbox / Plant 6.20 General Wiring, Engine / Gearbox / Plant 6.20.1 Engine wiring check Preconditions • Engine is stopped and starting disabled. Material Designation / Use Part No. Qty. Isopropyl alcohol Engine wiring check 1. Check securing screws of cable clamps on the engine and tighten loose screw connections. 2. Make certain that cables are securely seated in clamps and cannot move freely. 3. Check cable binders for secure seating, tighten loose cable binders.
PAGE 203
Engine Governor (Electronic) Control System 6 – 63 6.21 Engine Governor (Electronic) Control System 6.21.1 ECU – Removal and installation Preconditions • Engine is stopped and starting disabled. Special tools Designation / Use Part No. Qty. Connector pliers Covering caps for Cannon sockets ECU – Removal 1. Note or mark assignment of cables to connector sockets. 2. Use connector pliers (2) to disengage the bayonet union nuts (4) of the connectors (3) by turning them counterclockwise. 3.
PAGE 204
6 – 64 6.21.2 Engine Governor (Electronic) Control System ECU and connectors cleaning Preconditions • Engine is stopped and starting disabled. Special tools Designation / Use Part No. Qty. Part No. Qty. Connector pliers Material Designation / Use Isopropyl alcohol ECU and connectors cleaning 1. Remove coarse dirt from housing surface using a cloth moistened with isopropyl alcohol. 2.
PAGE 205
Engine Governor (Electronic) Control System 6.21.3 6 – 65 ECU – checking plug-in connections Preconditions • Engine is stopped and starting disabled. Special tools Designation / Use Part No. Qty. Connector pliers ECU – checking plug-in connections 1. Use connector pliers (3) to make certain that all plug-in connections of ECU are securely seated. 2. Tighten loose bayonet union nuts (2) with connector pliers (3) by turning them clockwise until they lock into place. 3.
PAGE 207
Table of Contents 7 7–I Annex 7.1 Abbreviations 7.2 Index M015560/00E ............................................................. 7 – 01 ....................................................................
PAGE 209
Annex 7.1 7 – 01 Abbreviations Abbreviation Meaning ANSI American National Standards Institute ATL Abgasturbolader Turbocharger BR Baureihe Engine Series CAN Controller Area Network DIN Deutsches Institut für Normung e. V.
PAGE 210
7 – 02 Annex Abbreviation Meaning SPC Spare Parts Catalog T-xyz Temperature-xyz TC Tools Catalog TD Transmitter Deviation UT Unterer Totpunkt M015560/00E 03-05 Explanation Temperature measuring point xyz Bottom dead center (BDC) © MTU
PAGE 211
Index 7.2 7 – 03 Index 12/16/18V 2000 Continuous operation with variable load: Application group 3B, Air-cooled charge air, Optimized fuel consumption . . . . . 2 – 15 12/16/18V 2000 Continuous operation with variable load: Application group 3B, Water-cooled charge-air, Optimized fuel consumption . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 212
7 – 04 Index Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 04 Cylinder-liner endoscopic examination . . . . . . . . . . . . . . . . . . . . . 6 – 04 Instructions and comments on endoscopic and visual examination of cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 06 Cylinder-head cover – Removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 13 Cylinder-liner endoscopic examination . . . . . .
PAGE 213
Index 7 – 05 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel filter – Replacement . . . . . . . . . . . Fuel prefilter – differential pressure check and adjustment of gauge . . . . . . . . . . . Fuel prefilter – draining . . . . . . . . . . . . . Fuel prefilter – filter element replacement . . . . . . . . . . . . . . . . . . . . . Fuel prefilter – flushing . . . . . . . . . . . . . Fuel prefilter cleaning . . . . . . . . . . . . . . Fuel filter – Replacement . . . . . . . . . . .
PAGE 214
7 – 06 Index Valve Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder-head cover – Removal and installation . . . . . . . . . . . . . . . . . . . . . . . Valve clearance – Check and adjustment . . . . . . . . . . . . . . . . . . . . . . Ventilator Drive . . . . . . . . . . . . . . . . . . . . . . . . Ventilator drive – Drive belt replacement . . . . . . . . . . . . . . . . . . . . . M015560/00E 03-05 6 – 10 6 – 13 6 – 10 6 – 57 Ventilator drive – Drive-belt check and adjustment . . .