Operating Instructions

Transcription

1 Operating Instructions Diesel engine 12V2000G76F 12V2000G86F 16V2000G76F 16V2000G86F 18V2000G76F MS15059/00E

2 Engine model kw/cyl. Application group 12V2000G76F 61 kw/cyl. 3D, Standby power, fuel stop power, IFN 12V2000G86F 73,9 kw/cyl. 3D, Standby power, fuel stop power, IFN 16V2000G76F 61,2 kw/cyl. 3D, Standby power, fuel stop power, IFN 16V2000G86F 68,8 kw/cyl. 3D, Standby power, fuel stop power, IFN 18V2000G76F 68,6 kw/cyl. 3D, Standby power, fuel stop power, IFN 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 prior written consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, translation, microfilming and storage or processing in electronic systems including databases and online services. All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen GmbH reserves the right to change, delete or supplement the information provided as and when required.

3 DCL-ID: Table of Contents 1 Safety 1.1 Important provisions for all products Personnel and organizational requirements Transport Safety precautions when working on the engine Fire prevention and environmental protection, fluids and lubricants, auxiliary materials Standards for safety notices in the text 13 2 General Information 2.1 Engine side and cylinder designations Engine Overview 15 3 Technical Data 3.1 Product data 12V2000G76F, 16V2000G76F, 18V2000G76F Product data 12V2000G86F, 16V2000G86F Firing order Main Engine Dimensions 29 4 Operation 4.1 Preparing startup after long out-of-service periods (>3 months) Preparations for startup after scheduled outof-service-period Starting the engine Operational monitoring Engine shutdown Emergency engine stop After stopping the engine Plant Cleaning 37 5 Maintenance 5.1 Maintenance task reference table [QL1] 38 6 Troubleshooting 6.1 Troubleshooting Engine Control Unit ECU9 fault messages 42 7 Task Description 7.1 Engine Engine Cranking manually Engine Barring with starting system Engine Test run Crankcase Breather Crankcase breather Oil mist fine separator replacement Valve Drive Valve clearance Check and adjustment Cylinder head cover Removal and installation Injection Valve / Injector Injector Replacement Injector Removal and installation Injector functions Fuel System Fuel system Venting Fuel Draining Fuel Filter Fuel filter Replacement Fuel prefilter (non-switchable) Draining Fuel prefilter (switchable) Draining Fuel prefilter Pressure ratios Fuel prefilter (non-switchable) Filter insert replacement Fuel prefilter (switchable) Filter insert replacement Fuel prefilter Venting Air Filter Air filter Replacement Air filter Removal and installation Air Intake Service indicator Signal ring position check Starting Equipment Electric starter Overview Starter Removal Starter Installation Pneumatic starter Overview Starter Removal Starter Installation Hydraulic starter Overview Starter Removal Starter Installation Lube Oil System, Lube Oil Circuit Engine oil Level check Engine oil Change Oil Filtration / Cooling Engine oil filter Replacement Centrifugal oil filter Cleaning and filtersleeve replacement 117 MS15059/00E Table of Contents 3

4 7.12 Coolant Circuit, General, High-Temperature Circuit Engine coolant Level check Engine coolant Change Engine coolant Draining Engine coolant Filling Engine coolant pump Relief bore check Engine coolant Sample extraction and analysis Belt Drive Drive belt Condition check Drive belt Tension check Drive belt Tension adjustment Drive belt Replacement Battery-Charging Generator Battery-charging generator drive Drive belt replacement Fuel Supply System Differential pressure gage Check Coolant level sensor Check Pump capacity Check Engine Governor Engine control system Overview Engine governor Removal and installation Engine governor plug connections Check Wiring (General) for Engine/Gearbox/Unit Engine cabling Check Accessories for (Electronic) Engine Governor / Control System Engine governor and connector Cleaning Appendix A 8.1 List of abbreviations MTU Contact/Service Partners Appendix B 9.1 Special Tools Index 154 DCL-ID: Table of Contents MS15059/00E

5 1 Safety 1.1 Important provisions for all products Nameplate The product is identified by nameplate, model designation or serial number and must match with the information on the title page of this manual. Nameplate, model designation or serial number can be found on the product. All EU-certified engines delivered by MTU come with a second nameplate. When operating the machine in the EU: The second nameplate must be affixed in a prominent position as described in the accompanying specifications. General information This product may pose a risk of injury or damage in the following cases: Incorrect use Operation, maintenance and repair by unqualified personnel Modifications or conversions Noncompliance with the safety instructions and warning notices Emission regulations and emission labels Responsibility for compliance with emission regulations Modification or removal of any mechanical/electronic components or the installation of additional components including the execution of calibration processes that might affect the emission characteristics of the product are prohibited by emission regulations. Emission control units/systems may only be maintained, exchanged or repaired if the components used for this purpose are approved by the manufacturer. Noncompliance with these regulations will invalidate the design type approval issued by the emissions regulation authorities. The manufacturer does not accept any liability for violations of the emission regulations. The maintenance schedules of the manufacturer must be observed over the entire life cycle of the product. TIM-ID: Replacing components with emission labels On all MTU engines fitted with emission labels, these labels must remain on the engine throughout its operational life. Engines used exclusively in land-based, military applications other than by US government agencies are excepted from this proviso. Please note the following when replacing components with emission labels: The relevant emission labels must be affixed to the spare part. Do not transfer the emission labels from the replaced part to the spare part. Remove the emission labels from the replaced part and destroy them. MS15059/00E Safety 5

6 1.2 Personnel and organizational requirements Organizational measures of the user/manufacturer This manual must be issued to all personnel involved in operation, maintenance, repair, assembly, installation, or transportation. Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance, repair, assembly, installation, and transport personnel at all times. Personnel must receive instruction on product handling and maintenance based on this manual with a special emphasis on safety requirements and warnings. This is important in the case of personnel who only occasionally perform work on or around the product. These personnel must be instructed repeatedly. Personnel requirements All work on the product shall be carried out by trained and qualified personnel only: Training at the Training Center of the manufacturer Technical personnel from the areas mechanical engineering, plant construction, and electrical engineering The operator must define the responsibilities of the personnel involved in operation, maintenance, repair, assembly, installation, and transport in writing. Personnel shall not report for duty under the influence of alcohol, drugs or strong medication. Clothing and personal protective equipment Always wear appropriate personal protective equipment, e.g. safety shoes, ear protectors, protective gloves, goggles, breathing mask. Follow the instructions concerning personal protective equipment in the descriptions of the individual activities. TIM-ID: Safety MS15059/00E

7 1.3 Transport Taking the engine's center of gravity into account For information regarding the center of gravity of the engine, refer to the installation/arrangement drawing of the engine/genset/system. Transport Lift the engine/genset/system only with the lifting eyes provided. Only use transport and lifting devices approved by MTU. The engine/genset/system must only be transported in installation position. Max. permissible diagonal pull 10. If the engine/genset/system is supplied with special aluminum foil packing, lift it at the lifting eyes of the trestle or use a means of transportation which is appropriate for the given weight (forklift truck). Prior to transporting the engine/genset/system, it is imperative to install the transport locking device for the crankshaft. Prior to transporting the engine/genset/system, it is imperative to install the transport locks for the engine mounts. Secure the engine/genset/system such as to preclude tipping during transport. Secure the engine/system/genset as to preclude slipping and tipping when driving up or down inclines and ramps. Setting the engine down after transport Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate. Never set an engine/genset/system down on the oil pan unless expressively authorized to do so by MTU on a case-to-case basis. Place the engine/genset/system on a firm, flat surface only. TIM-ID: MS15059/00E Safety 7

8 1.4 Safety precautions when working on the engine Safety regulations prior to maintenance and repair work Have maintenance or repair work carried out by qualified and authorized personnel only. Allow the product to cool down to less than 50 C (risk of explosion for oil vapors, fluids and lubricants, risk of burning). Relieve pressure in fluid and lubricant systems and compressed-air lines which are to be opened. Use suitable collecting vessels of adequate capacity to catch fluids and lubricants. When changing the oil or working on the fuel system, ensure that the service room is adequately ventilated. Never carry out maintenance and repair work with the product in operation, unless: It is expressly permitted to do so following a written procedure. The product is running in the low load range and only for as long as absolutely necessary. Lock-out the product to preclude undesired starting, e.g. Start interlock Key switch With hydraulic starting system: shut off supply line. Attach Do not operate sign in the operating area or to control equipment. Disconnect the battery cables or actuate the battery isolating switch, if fitted. Lock out circuit breakers. Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic starters are fitted. Disconnect the control equipment from the product. Use the recommended special tools or suitable equivalents when instructed to do so. Elastomer components (e.g. engine mounts, damping elements, couplings and V-belts) must not be painted. They may only be installed after painting the engine or must be covered before painting work is carried out. The following applies to starters with copper-beryllium alloy pinions: Wear a respirator mask (filter class P3). Do not blow out the interior of the flywheel housing or the starter with compressed air. Clean the flywheel housing inside with a class H dust extraction device. Observe the safety data sheet. Safety regulations during maintenance and repair work Take special care when removing ventilation or plug screws from the product. Release residual pressure before removing or replacing a component in the supply line. To depressurize pressurized lines, shut off the lines first, then release the residual pressure. Use only proper and calibrated tools. Observe the specified tightening torques during assembly or disassembly. Carry out work only on assemblies or plants which are properly secured. Make sure components or assemblies are placed on stable surfaces. Adopt suitable measures to avoid that components/tools fall down. Use the specified lifting equipment for all components. Never use the product as a climbing aid. When working high on the equipment, always use suitable ladders and work platforms. Never work on engines or components that are held in place by lifting equipment. Keep fuel injection lines and connections clean. Carry out appropriate cleaning procedures to clean and inspect components requiring special cleanness (e.g. components carrying oil, fuel, or air). Always seal connections with caps or covers if a line is removed or opened. Fit new seals when re-installing lines. TIM-ID: Safety MS15059/00E

9 Never bend lines and avoid damaging lines, particularly the fuel lines. Ensure that all retainers and dampers are installed correctly. Ensure that O-rings are not installed in a slanted/twisted condition. Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent contact with other components. Do not place fuel or oil lines near hot components. Do not touch elastomeric seals (e.g. Viton sealing rings) with your bare hands if they have a carbonized or resinous appearance. Note cooling time for components which are heated for installation or removal (risk of burning). Pay particular attention to cleanliness at all times. Remove any condensate from components which were chilled before assembly. If necessary, coat the components with a suitable corrosion inhibitor. Safety regulations following maintenance and repair work Before barring the engine, make sure that nobody is standing in the danger zone of the product. Check that all access ports/apertures which have been opened to facilitate working are closed again. Check that all safety equipment has been installed and that all tools and loose parts have been removed (especially the barring gear). Ensure that no unattached parts have been left in/on the product (e.g. including rags and cable straps). Ensure that the grounding system is properly connected. Welding work Welding operations on the product or mounted units are not permitted. Cover the product when welding 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 electronic equipment from the ground of the unit. No other maintenance or repair work must be carried out in the vicinity of the product while welding is going on. Risk of explosion or fire due to oil vapors and highly flammable process materials. Do not use product as ground terminal. Never position the welding power supply cable adjacent to, or crossing cabling harnesses of the product. The welding current may otherwise induce an interference voltage in the cabling harnesses which could conceivably damage the electrical system. Remove components (e.g. exhaust pipe) from the product before performing necessary welding work. TIM-ID: Hydraulic installation and removal Check satisfactory function and safe operating condition of tools, jigs and fixtures to be used. Use only the specified jigs and fixtures for hydraulic removal/installation procedures. Observe the max. permissible force-on pressure specified for the jig/fixture. Do not attempt to bend or exert force on H.P. lines. Before starting work, pay attention to the following: Vent the installation/removal device, the pumps and the pipework at the relevant designated points. During the installation procedure, screw on device with pushed-in plunger. During the removal procedure, screw on device with retracted plunger. For a hydraulic installation/removal device with central expansion pressure supply, screw spindle into shaft end until correct sealing is established. MS15059/00E Safety 9

10 During hydraulic installation/removal of components, ensure that no persons are in the direct vicinity of the component being pressed. Working with batteries Observe the safety instructions of the battery manufacturer when working with batteries. Gases released from the battery are explosive. Avoid sparks and naked flames. Do not allow battery acids to come into contact with skin or clothing. Wear protective clothing, goggles and protective gloves. Do not place objects on the battery. Before connecting the cable to the battery, check the battery polarity. Battery pole reversal may lead to injury through the sudden discharge of acid or bursting of the battery body. Working on electrical and electronic assemblies Always obtain the permission of the person in charge before commencing maintenance and repair work or switching off any part of the electronic system required to do so. De-energize the appropriate areas prior to working on assemblies. Do not damage cabling during removal work. When reconnecting, ensure that cabling cannot be damaged during operation by: Contact with 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 on connectors. Subject the device as well as the product to a functional testing on completion of all repair work. Check correct execution of the emergency stop function in particular. Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Package faulty electronic components or assemblies properly before dispatching for repair: Moisture-proof Shock-proof Wrapped in antistatic foil if necessary. Work with laser devices Work with laser devices shall be carried out by trained and qualified personnel only. Follow the safety instructions in the manufacturer's user manual when working with laser equipment. Wear special laser safety glasses when working with laser equipment (danger of concentrated radiation). Laser devices must be equipped, in accordance with their class and usage, with protective devices for ensuring safe operation. Measuring component dimensions Workpieces, components and measuring equipment lie in the specified tolerance range at a reference temperature of 20 C. TIM-ID: Safety MS15059/00E

11 1.5 Fire prevention and environmental protection, fluids and lubricants, auxiliary materials Fire prevention Flames, naked light and smoking are prohibited. When working with combustible indirect materials, e.g. cleaning agent, ensure area is well ventilated. The resultant steam/air mixture must be sufficiently diluted to prevent a potentially explosive atmosphere. Rectify any fuel or oil leaks immediately. Oil or fuel on hot components can cause fires therefore always keep the product in a clean condition. Do not leave rags saturated with fluids and lubricants on the product. Do not store combustible materials near the product. Do not carry out welding work on pipes and components carrying oil or fuel. Before welding, clean with a nonflammable fluid. When starting the engine with an external power source, connect the ground lead last and remove it first. To avoid sparks in the vicinity of the battery, connect the ground lead from the external power source to the ground lead of the engine or to the ground terminal of the starter. Always have a suitable extinguishing agent (fire extinguisher) on hand and familiarize yourself fully with its handling. Noise Noise can lead to an increased risk of accidents if acoustic signals, warning shouts or sounds indicating danger are drowned. Wear ear protectors in workplaces with a sound pressure level in excess of 85 db (A). Environmental protection and disposal Dispose of used fluids, lubricants and filters in accordance with local regulations. Within the EU, batteries can be returned free of charge to the manufacturer where they will be properly recycled. Auxiliary materials Process materials may also be hazardous or toxic. When using consumables and auxiliary materials as well as other chemical substances, observe the information contained in the safety data sheet for the product. The safety data sheet may be obtained from the relevant manufacturer or from MTU. Take special care when using hot, chilled or caustic materials. TIM-ID: Used oil Used oil contains combustion residues that are harmful to health. Wear protective gloves! Wash relevant areas after contact with used oil. Lead Adopt suitable measures to avoid the formation of lead dust. Switch on extraction system. When working with lead or lead-containing compounds, avoid direct contact to the skin and do not inhale lead vapors. Wash relevant areas after contact with lead or lead-containing substances. MS15059/00E Safety 11

12 Compressed air Observe special safety precautions when working with compressed air: Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of containers, risks causing an explosion. Wear goggles when blowing dirt off workpieces or blowing away swarf. Blowing compressed air into thin-walled containers (e.g. containers made of sheet metal, plastic or glass) for drying purposes or to check for leaks risks bursting them. Pay special attention to the pressure in the compressed air system or pressure vessel. Assemblies or products which are to be connected must be designed to withstand this pressure. Install pressure-reducing or safety valves set to the admissible pressure if this is not the case. Hose couplings and connections must be securely attached. Provide the snout of the air nozzle with a protective disk (e.g. rubber disk). Release residual pressure before removing or replacing pneumatic equipment in the supply line. To depressurize compressed-air lines, shut off the lines first, then release the residual pressure. Carry out leak test in accordance with the specifications. Painting Observe the relevant safety data sheet for all materials. When carrying 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 must be no naked flames in the vicinity. No smoking. Observe fire-prevention regulations. Always wear a mask providing protection against paint and solvent vapors. Liquid nitrogen Observe the relevant safety data sheet for all materials. Work with liquid nitrogen may be carried out only by qualified personnel. Store liquid nitrogen only in small quantities and always in specified containers without fixed covers. Avoid body contact (eyes, hands). Wear protective clothing, protective gloves, closed shoes and safety goggles. Make sure that working area is well ventilated. Avoid knocking or jolting the containers, valves and fittings or workpieces in any way. Acids/alkaline solutions/urea (AdBlue, DEF) Observe the relevant safety data sheet for all materials. When working with acids and alkaline solutions, wear goggles or face mask, gloves and protective clothing. Do not inhale vapors. If urea solution is swallowed, rinse out mouth and drink plenty of water. Remove any wet clothing immediately. After contact skin, wash body areas with plenty of water. Rinse eyes immediately with eyedrops or clean tap water. Seek medical attention as soon as possible. TIM-ID: Safety MS15059/00E

13 1.6 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 operation, 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 personal injury shall be considered to include a warning of potential damage. TIM-ID: MS15059/00E Safety 13

14 2 General Information 2.1 Engine side and cylinder designations 1 Left engine side (A-side) 2 Engine free end in accordance with DIN ISO 1204 (KGS = Kupplungsgegenseite) 3 Right engine side (B-side) 4 Engine driving end in accordance with DIN ISO 1204 (KS = Kupplungsseite) Engine sides are always designated (in accordance with DIN ISO 1204) as viewed from driving end (4). For cylinder designation (in accordance with DIN ISO 1204), the letter "Ax" refers to the cylinders on the lefthand side of the engine (1) and letter "Bx" refers to the cylinders on the right-hand side (3). The cylinders of each bank are numbered consecutively, starting with x=1 at driving end (4). The numbering of other engine components also starts with 1 at driving end (4). TIM-ID: General Information MS15059/00E

15 2.2 Engine Overview 12V2000G76F/G86F 1 Air intake/air supply 2 Charge-air pipe 3 Monitoring, control and regulation system 4 Charge-air line 5 Belt drive 6 Engine coolant pump 7 Fuel system (low pressure) 8 Fuel filter 9 Exhaust turbocharger 10 Fuel system (high pressure) 11 Charge-air line 12 Starting equipment 13 PTO system, driving end KS Driving end TIM-ID: MS15059/00E General Information 15

16 1 Cooler 2 Mounting/support 3 Cylinder head 4 Exhaust system 5 Open-loop control 6 Lube oil filter KGS Free end TIM-ID: General Information MS15059/00E

17 16V2000G76F/G86F 1 Air intake/air supply 2 Charge-air pipe 3 Monitoring, control and regulation system 4 Charge-air line 5 Belt drive 6 Engine coolant pump 7 Fuel system (low pressure) 8 Fuel filter 9 Exhaust turbocharger 10 Fuel system (high pressure) 11 Charge-air line 12 PTO system, driving end KS Driving end TIM-ID: MS15059/00E General Information 17

18 1 Cooler 2 Mounting/support 3 Cylinder head 4 Exhaust system 5 Open-loop control 6 Lube oil filter KGS Free end TIM-ID: General Information MS15059/00E

19 18V2000G76F 1 Air intake/air supply 2 Charge-air pipe 3 Monitoring, control and regulation system 4 Charge-air line 5 Belt drive 6 Engine coolant pump 7 Fuel system (low pressure) 8 Fuel filter 9 Exhaust turbocharger 10 Fuel system (high pressure) 11 Charge-air line 12 Starting equipment 13 PTO system, driving end KS Driving end TIM-ID: MS15059/00E General Information 19

20 1 Cooler 2 Mounting/support 3 Cylinder head 4 Exhaust system 5 Open-loop control 6 Lube oil filter KGS Free end Key to engine model designation 12, 16, 18 Number of cylinders V Cylinder arrangement (Vee engine) 2000 Series G Application (G for onsite power generation equipment) 7, 8 Application segment (marine, mean to high load index) 6 Design index (0, 1, 2,...,9) F Additional feature (F = 50 Hz) Table 2: Key to engine model designation TIM-ID: General Information MS15059/00E

21 3 Technical Data 3.1 Product data 12V2000G76F, 16V2000G76F, 18V2000G76F Legend DL Ref. value: Continuous power. Continuously attainable power at standard conditions. BL Ref. value: Fuel stop power. Maximum engine power. Not continuously attainable in some applications (margin for load fluctuations). A Design value. Value is used for the design of an external system (plant). R Guideline value. Typical average value for information, limited suitability for design purposes. L Limit value. Value which must not be fallen short of (lower limit, min. value) or exceeded (upper limit, max. value), not suitable for design purposes. N Not yet defined value. Value has not yet been defined or will not be defined. - Not applicable. Assembly is not applicable to the given product type X Applicable. Assembly is not applicable to the given product type > The actual value must be greater than the specified value. < The actual value must be smaller than the specified value. * Not sufficiently validated value (+/- 10% tolerance). ** Not sufficiently validated value (+/- 5% tolerance). ID Product type Application Engine speed Effective power 1 12V2000G76F Power generation 3D standby power, fuel stop power, IFN 2 16V2000G76F Power generation 3D standby power, fuel stop power, IFN 3 18V2000G76F Power generation 3D standby power, fuel stop power, IFN rpm 50 Hz rpm 50 Hz rpm 50 Hz 732 kw 981 bhp 979 kw 1312 bhp 1235 kw 1656 bhp Ref. 25 C/-; Air charge air cooling TA-Luft optimized (diesel) Ref. 25 C/-; Air charge air cooling TA-Luft optimized (diesel) Ref. 25 C/-; Air charge air cooling Optimized fuel consumption, Reference conditions TIM-ID: ID Intake air temperature C Charge air coolant temperature C Barometric pressure mbar Site altitude above sea level m Performance data ID Rated engine speed A rpm Continuous power ISO 3046 (10% overload possible) (power range DIN 6280, ISO 8528) A kw MS15059/00E Technical Data 21

22 Boundary conditions (for maximum power) ID Intake depression (new filter) A mbar Intake depression, max. L mbar Exhaust overpressure A mbar Exhaust overpressure, max. L mbar Model-related data (basic design) ID Engine with exhaust turbocharging (ETC) and chargeair cooling (CAC) - X X X Combustion method: direct fuel injection - X X X Direction of rotation: c.c.w. (facing driving end) - X X X Cylinder arrangement: Vee angle Degrees ( ) Bore mm Stroke mm Displacement of a cylinder Liters Total displacement Liters Compression ratio Cylinder heads: Individual cylinder heads - X X X Cylinder liners: wet, replaceable - X X X Number of inlet valves per cylinder Number of exhaust valves per cylinder Standard flywheel housing flange (engine main PTO side) SAE Flywheel interface (DISC) - 18" 18" 18" Air / exhaust gas ID Charge-air pressure before cylinder - DL R bar abs Coolant system (HT circuit) ID Coolant temperature (at engine connection: outlet to cooling system) A C Coolant temperature after engine, limit 1 L C Coolant temperature after engine, limit 2 L C Coolant antifreeze content, max. L % Pressure loss in external cooling system, max. L bar TIM-ID: Technical Data MS15059/00E

23 Coolant system (LT circuit) ID Coolant temperature before intercooler (at engine connection: cooling system inlet) A C Coolant antifreeze content, max. L % Pressure loss in external cooling system, max. L bar Lube-oil system ID Lube-oil operating temperature before engine, from R C Lube oil operating temperature before engine, to R C Lube oil temperature before engine, limit 1 L C Lube oil temperature before engine, limit 2 L C Lube oil operating pressure before engine, from R bar Lube-oil operating pressure before engine, to R bar Lube oil operating pressure before engine, warning L bar Lube oil operating pressure before engine, shutdown L bar General operating data ID Cold start capability: air temperature (w/o start aid. w/o preheating) - (case A) R C Coolant preheating: preheating temperature (min.) L C Firing speed, from R rpm Firing speed. to R rpm Capacities ID Engine coolant capacity, engine side (without cooling system) R Liters Charge-air coolant, engine side R Liters Engine oil capacity, initial filling (standard oil system) (Option: max. operating inclinations) Oil change quantity, max. (standard oil system) (option: max. operating inclinations) R Liters R Liters TIM-ID: Weights / main dimensions ID Engine weight, dry (basic engine configuration acc. to scope of delivery specification) R kg MS15059/00E Technical Data 23

24 Acoustics ID Exhaust noise, unsilenced - DL (sound power level LW, ISO 6798, +3 db(a) tolerance) Engine surface noise with attenuated intake noise (filter) - DL (sound power level LW, ISO db(a) tolerance) R db(a) R db(a) TIM-ID: Technical Data MS15059/00E

25 3.2 Product data 12V2000G86F, 16V2000G86F Legend DL Ref. value: Continuous power. Continuously attainable power at standard conditions. BL Ref. value: Fuel stop power. Maximum engine power. Not continuously attainable in some applications (margin for load fluctuations). A Design value. Value is used for the design of an external system (plant). R Guideline value. Typical average value for information, limited suitability for design purposes. L Limit value. Value which must not be fallen short of (lower limit, min. value) or exceeded (upper limit, max. value), not suitable for design purposes. N Not yet defined value. Value has not yet been defined or will not be defined. - Not applicable. Assembly is not applicable to the given product type X Applicable. Assembly is not applicable to the given product type > The actual value must be greater than the specified value. < The actual value must be smaller than the specified value. * Not sufficiently validated value (+/- 10% tolerance). ** Not sufficiently validated value (+/- 5% tolerance). ID Product type Application Engine speed Effective power 1 12V2000G86F Power generation 3D standby power, fuel stop power, IFN 2 16V2000G86F Power generation 3D standby power, fuel stop power, IFN rpm 50 Hz rpm 50 Hz 887 kw 1189 bhp 1100 kw 1475 bhp Ref. 25 C/-; Air charge air cooling Optimized fuel consumption, Ref. 25 C/-; Air charge air cooling Optimized fuel consumption, Reference conditions ID 1 2 Intake air temperature C Charge air coolant temperature C - - Barometric pressure mbar Site altitude above sea level m Performance data TIM-ID: ID 1 2 Rated engine speed A rpm Continuous power ISO 3046 (10% overload possible) (power range DIN 6280, ISO 8528) Boundary conditions (for maximum power) A kw - - ID 1 2 Intake depression (new filter) A mbar Intake depression, max. L mbar Exhaust overpressure A mbar Exhaust overpressure, max. L mbar MS15059/00E Technical Data 25

26 Model-related data (basic design) ID 1 2 Engine with exhaust turbocharging (ETC) and charge-air cooling (CAC) - X X Combustion method: direct fuel injection - X X Direction of rotation: c.c.w. (facing driving end) - X X Cylinder arrangement: Vee angle Degrees ( ) Bore mm Stroke mm Displacement of a cylinder Liters Total displacement Liters Compression ratio Cylinder heads: Individual cylinder heads - X X Cylinder liners: wet, replaceable - X X Number of inlet valves per cylinder Number of exhaust valves per cylinder Standard flywheel housing flange (engine main PTO side) SAE 0 0 Flywheel interface (DISC) - 18" 18" Air / exhaust gas ID 1 2 Charge-air pressure before cylinder - DL R bar abs - - Coolant system (HT circuit) ID 1 2 Coolant temperature (at engine connection: outlet to cooling system) A C Coolant temperature after engine, limit 1 L C Coolant temperature after engine, limit 2 L C Coolant antifreeze content, max. L % Pressure loss in external cooling system, max. L bar Coolant system (LT circuit) ID 1 2 Coolant temperature before intercooler (at engine connection: cooling system inlet) A C - - Coolant antifreeze content, max. L % - - Pressure loss in external cooling system, max. L bar - - TIM-ID: Lube-oil system ID 1 2 Lube-oil operating temperature before engine, from R C Lube oil operating temperature before engine, to R C Technical Data MS15059/00E

27 ID 1 2 Lube oil temperature before engine, limit 1 L C Lube oil temperature before engine, limit 2 L C Lube oil operating pressure before engine, from R bar Lube-oil operating pressure before engine, to R bar Lube oil operating pressure before engine, warning L bar Lube oil operating pressure before engine, shutdown L bar General operating data ID 1 2 Cold start capability: air temperature (w/o start aid. w/o preheating) - (case A) R C 0 0 Coolant preheating: preheating temperature (min.) L C Firing speed, from R rpm Firing speed. to R rpm Capacities ID 1 2 Engine coolant capacity, engine side (without cooling system) R Liters Charge-air coolant, engine side R Liters - - Engine oil capacity, initial filling (standard oil system) (Option: max. operating inclinations) Oil change quantity, max. (standard oil system) (option: max. operating inclinations) Weights / main dimensions R Liters R Liters ID 1 2 Engine weight, dry (basic engine configuration acc. to scope of delivery specification) Acoustics R kg ID 1 2 Exhaust noise, unsilenced - DL (sound power level LW, ISO 6798, +3 db(a) tolerance) Engine surface noise with attenuated intake noise (filter) - DL (sound power level LW, ISO db(a) tolerance) R db(a) R db(a) TIM-ID: MS15059/00E Technical Data 27

28 3.3 Firing order Firing order Number of cylinders 12V 16V 18V Firing order A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1 A1-B5-A3-A5-B2-B8-A2-A8-B3-A7-B4-B6-A4-A6-B1-B7 A1-B6-A3-B4-A5-B2-A7-B1-A9-B3-A8-B5-A6-B7-A4-B9-A2-B8 TIM-ID: Technical Data MS15059/00E

29 3.4 Main Engine Dimensions Engine model Length (A) Width (B) Height (C) 12V2000G76F/G86F Approx mm Approx mm Approx mm 16V2000G76F/G86F Approx mm Approx mm Approx mm 18V2000G76F Approx mm Approx mm Approx mm Table 3: Engine model / dimensions TIM-ID: MS15059/00E Technical Data 29

30 4 Operation 4.1 Preparing startup after long out-of-service periods (>3 months) Preconditions Engine is stopped and starting disabled. MTU Fluids and Lubricants Specifications (A001061/..) are available. Startup after long out-of-service periods (>3 months) Item Engine Action Remove preservative ( Preservation and Represervation Specifications (A001070/ )). Lube oil system Check engine oil level ( Page 114). Fuel system Fuel system Vent ( Page 86). Coolant circuit Use appropriate equipment to fill system via fuel supply line. If engine is out of service for more than one year, change engine coolant ( Page 120). Coolant circuit Check engine coolant level ( Page 119). Coolant circuit Preheat engine coolant with coolant preheating unit (if fitted). Engine control system Check plug connections ( Page 138). Engine control system Switch on. Table 4: Startup after long out-of-service periods (>3 months) TIM-ID: Operation MS15059/00E

31 4.2 Preparations for startup after scheduled out-of-service-period Preconditions Engine is stopped and starting disabled. Startup Item Action Lube oil system Check engine oil level ( Page 114). Coolant circuit Check engine coolant level ( Page 119). Coolant circuit Preheat engine coolant with coolant preheating unit, if fitted. Fuel prefilter (if fitted) Drain water, see manufacturer's documentation. Engine control system Switch on. Table 5: Startup TIM-ID: MS15059/00E Operation 31

32 4.3 Starting the engine Preconditions Engine with no load. DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! Before cranking the engine with starter system, make sure that there are no persons in the engine's danger zone. WARNING High level of engine noise when the engine is running. Risk of damage to hearing! Wear ear protectors. Starting the engine Item Engine Measure Start the engine ( documentation of the vehicle manufacturer/plant manufacturer). TIM-ID: Operation MS15059/00E

33 4.4 Operational monitoring DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running. Risk of damage to hearing! Wear ear protectors. Operational monitoring Item Control and display panels Action Check readings of operational data (speed, temperature, pressures). Engine oil Check engine oil level ( Page 114). Engine operation Check engine visually for leaks and general condition; Check engine for abnormal running noises, exhaust color and vibrations. Air filter Check service indicator of air filter ( Page 104). Exhaust system Check exhaust color ( Page 39). Fuel prefilter (if fitted) Engine coolant pump Check relief bore ( Page 124). Check pointer position of differential pressure gauge at fuel prefilter ( Page 94) Drain water and contaminants: Fuel prefilter (not switchable)( Page 89) Fuel prefilter (not switchable) ( Page 91). TIM-ID: MS15059/00E Operation 33

34 4.5 Engine shutdown Preconditions Engine is not connected to load. CAUTION Shutting down from full-load operation may cause hot water to escape from the expansion tank. Risk of scalding! Allow engine to cool down. Wear protective clothing, protective gloves, and safety goggles / safety mask. NOTICE Stopping the engine when it is running at full load subjects it to extreme thermal and mechanical stresses. Overheating of and, therefore, damage to components is possible! Before shutting down the engine, allow it to idle until the engine temperatures decrease and constant levels are indicated. Preparation Item Engine Action Allow the engine to cool down by running it at idle speed for approx. 5 minutes. Stopping the engine Item Engine Action Stopping ( Documentation of the vehicle/plant manufacturer). TIM-ID: Operation MS15059/00E

35 4.6 Emergency engine stop CAUTION Shutting down from full-load operation may cause hot water to escape from the expansion tank. Risk of scalding! Allow engine to cool down. Wear protective clothing, protective gloves, and safety goggles / safety mask. NOTICE An emergency stop subjects the engine system to an extremely high load. Risk of overheating, damage to components! Trigger an emergency stop only in emergency situations. Emergency engine stop Item Emergency stop pushbutton Action Press EMERGENCY STOP pushbutton. Engine is stopped by disconnecting the power supply to the ECU; Emergency-air shutoff flaps close (if applicable); Signalization (e.g. by horn, beacon) is activated. After emergency engine stop Item Switch cabinet, operator station etc. (depending on manufacturer) Engine HP system Action Press pushbutton for alarm acknowledgment. Audible and visual signalization stops. Manually open emergency-air shutoff flaps (if provided). Switch on ECU power supply. Engine is ready for starting. Energize injectors (for pressure release in HP system using the function Blank Shot Afterrun ) Switch on ECU power supply. Blank Shots are carried out (requires approx. 20 to 30 s.) TIM-ID: MS15059/00E Operation 35

36 4.7 After stopping the engine Preconditions MTU Preservation and Represervation Instructions (A001070/..) are available. NOTICE Engine coolant with inadequate freeze protection. Water remaining in the pressure sensors freezes at temperatures below 0 C. Risk of sensor damage! Remove pressure sensors and shake off residual water. After stopping the engine Item Coolant circuit Engine control system Air intake and exhaust system HP system (injector noise) Action Drain engine coolant ( Page 121) if freezing temperatures are expected, the engine is to remain out of service for an extended period, but engine coolant has no antifreeze additive. the engine room is not heated. the coolant is not kept at a suitable temperature. the antifreeze concentration is insufficient for the engine-room temperature. the antifreeze concentration is 50% and the engine-room temperature is below -40 C. Switch off (see manufacturer's documentation). If the engine is to be taken out of service for longer than 1 week, seal the engine on the air and exhaust side. If the engine is to be taken out of service for longer than 1 month, it has to be preserved ( MTU Preservation and Represervation Instructions A001070/..). The pressure is released in the system by means of the function "Blank Shot Afterrun": Injectors are energized. A small injection quantity is diverted into the injector return line without the nozzle needle opening (actuation of the servo valve on the injector side, which does not result in injection into the combustion chamber). Explanation: The injectors do not leak permanently, which is why the pressure applied in the system during engine stop is maintained. Pressure is only released through actuation of the injectors. When actuated, the switched quantity of the servo valve and the injection quantity are discharged. This procedure results in injector noise. Depressurizing (pressure <400 bar) is necessary for the following reasons: Limitation of load on high-pressure pumps during start Safety during assembly activities TIM-ID: Operation MS15059/00E

37 4.8 Plant Cleaning Preconditions Engine is stopped and starting disabled. No operating voltage is applied. Special tools, Material, Spare parts Designation / Use Part No. Qty. High-pressure cleaning unit - 1 Cleaner (Hakupur 50/136) X WARNING Compressed air gun ejects a jet of pressurized air. Risk of injury to eyes and damage to hearing, risk of rupturing internal organs! Never direct air jet at people. Always wear safety goggles/face mask and ear defenders. WARNING Water jet from high-pressure cleaning unit. Risk of eye injury, risk of scalding! Do not direct water jet at persons. Wear protective clothing, protective gloves, and goggles/safety mask. NOTICE Cleaning agents should not be left to take effect for too long. Damage to components is possible! Observe manufacturer's instructions. NOTICE Blowing down product with compressed air. Entry of dirt and damage to components is possible! Do not aim compressed air gun directly at seals or electronic components such as connectors or ECUs. TIM-ID: Plant Cleaning 1. Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental protection). 2. Prior to putting the cleaning unit into operation, read the operating instructions of the high-pressure cleaning units carefully and observe the safety precautions. 3. The following requirements apply for cleaning the plant outside with a high-pressure cleaning unit: The pressure of the high-pressure jet (cleaning jet) must not exceed 50 bar. A minimum distance between spray nozzle and plant of 1 m must be observed. The temperature of the cleaning medium must not exceed 80 C. 4. For external cleaning with high-pressure jet, use a flat-mouth nozzle only. Note: Never direct compressed air directly at electronic components. 5. Carry out external cleaning as follows: a) Seal all openings in a suitable way. b) Remove coarse dirt. c) Spray on cleaner sparingly and leave it for 1 to 5 minutes. d) Use the high-pressure jet to remove the loosened dirt. e) Dry engine with compressed air. MS15059/00E Operation 37

38 5 Maintenance 5.1 Maintenance task reference table [QL1] The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Maintenance Schedule is a stand-alone publication. The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule. Task Option Maintenance tasks W0500 Check engine oil level. ( Page 114) W0501 Visually inspect engine for leaks and general condition. ( Page 33) W0503 Check service indicator of air filter. ( Page 33) W0505 Check relief bores of coolant pump(s). ( Page 33) W0506 Check engine for abnormal running noises, exhaust color and vibrations. ( Page 33) W0507 X Drain water and contaminants from fuel prefilter. ( Page 33) W0508 X Check pointer position of differential pressure gauge at fuel prefilter. W0534 Carry out test run, minimum duration: until steady-state temperature is reached, no less than 1/3 load (monthly). ( Page 33) ( Page 72) W1001 Replace fuel filter or fuel filter element. ( Page 88) W1003 X Check belt condition and tension, replace if necessary. ( Page 126) W1005 Replace air filter. ( Page 102) W1006 Replace fuel injectors. ( Page 78) W1008 Replace engine oil filter when changing engine oil, or when the interval (years) is reached, at the latest. W1009 X Clean centrifugal oil filter, measure thickness of oil residue layer, replace sleeve, together with every engine oil change, at the latest. ( Page 116) ( Page 117) W1055 Replace oil separator. ( Page 73) W1178 Replace pressure pipe neck in cylinder head. ( Page 79) W1207 Check valve clearance, adjust if necessary. ATTENTION! First adjustment after 1,000 operating hours on a new engine and 1,000 following each cylinder head overhaul. ( Page 74) W1244 X Check function of rod electrode. ( Page 134) W1245 X Check alarm function of differential pressure gauge. ( Page 133) W1246 X Check pump capacity. ( Page 135) W1636 Reset drift correction parameters (CDC) and enter injector codes (IIG). ( Page 85) W1675 X Replace fuel prefilter or filter element of fuel prefilter. Fuel prefilter (not switchable) ( Page 95) Fuel prefilter (switchable) ( Page 97) TIM-ID: Table 6: Maintenance task reference table [QL1] 38 Maintenance MS15059/00E

39 6 Troubleshooting 6.1 Troubleshooting Engine does not turn when starter is actuated Component Action Battery Low or faulty Charge or replace (see manufacturer's documentation). Cable connections faulty Check if cable connections are properly secured (see manufacturer's documentation). Starter Engine cabling or starter faulty Check if cable connections are properly secured, contact Service. Engine cabling Faulty Check ( Page 139). Engine/generator control system Assemblies or connectors possibly loose Perform visual inspection (see manufacturer's documentation). Engine governor Plug-in connections possibly loose Check plug connections ( Page 138). Engine Engine turns but does not fire Running gear blocked (engine cannot be barred manually) Component Action Starter Poor rotation by starter: Battery low or faulty Contact Service. Charge or replace battery (see manufacturer's documentation). Engine cabling Faulty Check ( Page 139). Fuel system Air in fuel system Vent fuel system ( Page 86). Engine governor Faulty Contact Service. Engine fires unevenly TIM-ID: Component Action Fuel injection equipment Injector faulty Replace ( Page 78). Injection pump faulty Contact Service. Engine cabling Faulty Check ( Page 139). Fuel system Air in fuel system Vent fuel system ( Page 86). Engine governor Faulty Contact Service. Engine does not reach rated speed Component Action Fuel supply Fuel prefilter (not switchable) clogged. Replace ( Page 89). Fuel prefilter (switchable) clogged. Replace ( Page 91). Easy-change fuel filter clogged Replace ( Page 88). Air supply Air filter clogged Check signal ring position of service indicator ( Page 104). MS15059/00E Troubleshooting 39

40 Component Action Fuel injection equipment Injector faulty Replace ( Page 78). Injection pump faulty Contact Service. Engine cabling Faulty Check ( Page 139). Engine Overloaded Contact Service. Engine speed not steady Component Action Fuel injection equipment Injector faulty Replace ( Page 78). Injection pump faulty Contact Service. Speed sensor Faulty Contact Service. Fuel system Air in fuel system Vent fuel system ( Page 86). Engine governor Faulty Contact Service. Charge-air temperature too high Component Action Engine coolant Engine coolant treatment incorrect Check (MTU test kit). Intercooler Contaminated Contact Service. Engine room Air-intake temperature too high Check fans and intake/exhaust lines. Charge-air pressure too low Component Action Air supply Air filter clogged Check signal ring position of service indicator ( Page 104). Leaking Replace seals/nuts. Intercooler Contaminated Contact Service. Exhaust turbocharger Faulty Contact Service. Coolant leaks at intercooler Component Action Intercooler Leaking, major coolant discharge. Contact Service. Black exhaust gas Component Action Air supply Air filter clogged Check signal ring position of service indicator ( Page 104). Fuel injection equipment Injector faulty Replace ( Page 78). Injection pump faulty Contact Service. Engine Overloaded Contact Service. TIM-ID: Troubleshooting MS15059/00E

41 Blue exhaust gas Component Action Engine oil Too much engine oil in the engine Drain engine oil ( Page 115). Exhaust turbocharger, cylinder head, piston rings, cylinder liner White exhaust gas Oil separator of crankcase breather contaminated Faulty Component Action Replace ( Page 73). Contact Service. Engine Not at operating temperature Run engine to reach operating temperature. Fuel system Water in fuel Check fuel system on fuel prefilter; Drain water from fuel prefilter (not switchable) ( Page 89). Drain fuel prefilter (switchable) ( Page 91). Intercooler Leaking Contact Service. TIM-ID: MS15059/00E Troubleshooting 41

42 6.2 Engine Control Unit ECU9 fault messages 5 HI T-Charge Air Charge-air temperature too high (Level 1). 1. Check coolant cooler and intercooler. 2. Contact Service if no malfunction can be detected. 6 SS T-Charge Air Yellow alarm; emergency stop Charge-air temperature too high (Level 2). 1. Check coolant cooler and intercooler. 2. Contact Service if no malfunction can be detected. 9 HI T-Coolant Intercooler Coolant temperature in intercooler too high (Level 1). 1. Check coolant cooler for leaks, contamination and operation. 2. Contact Service if no malfunction can be detected. 10 SS T-Coolant Intercooler Red alarm; emergency stop Coolant temperature in intercooler too high (Level 2). 1. Check coolant cooler for leaks, contamination and operation. 2. Contact Service if no malfunction can be detected. 15 LO P-Lube Oil Lube oil pressure too low (Level 1). 1. Check oil level, top up as necessary ( Page 114). 2. Contact Service if no malfunction can be detected. 16 SS P-Lube Oil Red alarm; emergency stop Lube oil pressure too low (Level 2). 1. Check oil level, top up as necessary ( Page 114). 2. Contact Service if no malfunction can be detected. TIM-ID: Troubleshooting MS15059/00E

43 23 LO Coolant Level Red alarm; emergency stop Coolant level too low 1. Check coolant circuit for leaks. Check coolant level in expansion tank, top up as necessary. 2. Contact Service if no malfunction can be detected. 25 HI P-Diff. Lube Oil Differential oil pressure at oil filter too high (Level 1). u Check oil filter, replace as necessary. 26 SS P-Diff. Lube Oil Differential oil pressure at oil filter too high (Level 2). u Check oil filter, replace as necessary. 27 HI Leak Fuel Level Leak-off fuel level too high u Contact Service. 30 SS Engine Overspeed Red alarm; emergency stop Engine speed too high. u Restart engine. 33 HI P-Diff-Fuel TIM-ID: Differential pressure at fuel filter too high (Level 1). 34 SS P-Diff-Fuel Differential pressure at fuel filter too high (Level 2). u Check fuel filter, replace as necessary. u Check fuel filter, replace as necessary. MS15059/00E Troubleshooting 43

44 44 LO Coolant Level Intercooler Red alarm; emergency stop Intercooler coolant level too low. 1. Check coolant circuit for leaks. 2. Check coolant level in expansion tank, top up as necessary. 3. Contact Service if no malfunction can be detected. 51 HI T-Lube Oil Lube oil temperature too high (Level 1). 1. Check cooling system. 2. Contact Service if no malfunction can be detected. 52 SS T-Lube Oil Red alarm; emergency stop Lube oil temperature too high (Level 2). 1. Check cooling system. 2. Contact Service if no malfunction can be detected. 53 HI T-Intake Air Intake air temperature too high (Level 1). 1. Check cooling system. 2. Contact Service if no malfunction can be detected. 54 HIHI T-Intake Air Intake air temperature too high (Level 2). 1. Check cooling system. 2. Contact Service if no malfunction can be detected. 59 SS T-Coolant L3 Red alarm; emergency stop Coolant temperature too high (Level 3). 1. Check cooling system. 2. Contact Service. TIM-ID: Troubleshooting MS15059/00E

45 65 LO P-Fuel Fuel supply pressure too low (Level 1). 1. Check fuel lines for leakage. 2. Drain water from fuel prefilter (not switchable) ( Page 89). Drain water from fuel prefilter (switchable) ( Page 91). 3. Replace filter element of fuel prefilter (not switchable) ( Page 95). Replace filter element of fuel prefilter (switchable) ( Page 97). 4. Replace main fuel filter and, if required, intermediate fuel filter ( Page 88). 66 SS P-Fuel Red alarm; emergency stop Fuel supply pressure too low (Level 2). 1. Check fuel lines for leakage. 2. Drain water from fuel prefilter (not switchable) ( Page 89). Drain water from fuel prefilter (switchable) ( Page 91). 3. Replace filter element of fuel prefilter (not switchable) ( Page 95). Replace filter element of fuel prefilter (switchable) ( Page 97). 4. Replace main fuel filter and, if required, intermediate fuel filter ( Page 88). 67 HI T-Coolant Coolant temperature too high (Level 1). 1. Check cooling system. 2. Contact Service if no malfunction can be detected. 68 SS T-Coolant Red alarm; emergency stop (3 min. delay) TIM-ID: Coolant temperature too high (Level 2). 81 AL Rail Leakage Rail pressure gradient too low for start or too high for stop => HP fuel system leaky, air in system 1. Check cooling system. 2. Contact Service if no malfunction can be detected. 1. On engine stopping: Seal off system, contact Service 2. On engine starting: Check engine for leakage, if none found, attempt restarting as per operating instructions (air in system). MS15059/00E Troubleshooting 45

46 82 HI P-Fuel (Common Rail) Rail pressure > Set value => HP fuel control block jamming or wiring faulty 1. Check wiring of HP fuel control block. 2. Contact Service if no fault can be detected. 83 LO P-Fuel (Common Rail) Rail pressure < set value; Suction restrictor of HP fuel control block faulty or leakage in HP fuel system 1. Check wiring of HP fuel control block. 2. Check high-pressure system for leaks. 3. Contact Service if no fault can be detected. 89 SS Engine Speed too Low Engine speed too low 1. Restart engine ( Page 32). 2. Observe additional messages. 90 SS Idle Speed Not Reached Idling speed not reached, start aborted 1. Restart engine ( Page 32). 2. Observe additional messages. 91 SS Release Speed Not Reached Run-up speed not reached, start aborted 1. Restart engine ( Page 32). 2. Observe additional messages. 92 SS Starter Speed Mot Reached Starter speed not reached; termination of starting sequence; starter does not turn or turns slowly. 1. Check battery. 2. Check wiring and voltage supply. 3. Check fuel supply. 4. Restart engine ( Page 32). 5. Observe additional messages. TIM-ID: Troubleshooting MS15059/00E

47 93 SS T-Preheat Red alarm; engine start interlock Preheating temperature too low (Level 2); coolant temperature too low for engine start. 1. Extend preheating period. 2. Check preheater. 94 LO T-Preheat Preheating temperature too low (Level 1); coolant temperature too low for engine start. 1. Extend preheating period. 2. Check preheater. 95 AL Prelubrication Fault Oil priming fault u Contact Service. 102 AL Fuel Cons. Meter Defect Consumption meter faulty u Replace Engine Control Unit at next opportunity. 104 AL Eng Hours Counter Defect Hour meter defective u Replace Engine Control Unit at next opportunity. 118 LO ECU Supply Voltage Supply voltage too low (Level 1). u Check batteries, charge as necessary; check alternator. TIM-ID: LOLO ECU Power Supply Voltage Supply voltage too low (Level 2). u Check batteries, charge as necessary; check alternator. MS15059/00E Troubleshooting 47

48 120 HI ECU Supply Voltage Supply voltage too high (Level 1). u Check batteries, charge as necessary; check alternator. 121 HIHI ECU Power Supply Voltage Supply voltage too high (Level 2). u Check batteries, charge as necessary; check alternator. 122 HI T-ECU Temperature in ECS too high u Check engine room ventilation. 141 AL Power too high The average power rate over the last 24 hours of engine operation has exceeded the set maximum value. u Reduce power. 180 AL CAN1 Node Lost Connection to a node on CAN bus 1 failed. 1. Check devices connected to CAN. 2. Check wiring (termination resistor installed?). 181 AL CAN2 Node Lost Connection to a node on CAN bus 2 failed. 1. Check devices connected to CAN. 2. Check wiring (termination resistor installed?). 182 AL CAN Wrong Parameters Incorrect parameter values entered in data record. u Contact Service. TIM-ID: Troubleshooting MS15059/00E

49 183 AL CAN No PU Data The selected CAN mode initializes communication by means of the PU data module. However, the required PU data module is not available or not valid. 1. Check devices connected to CAN. 2. Contact Service. 184 AL CAN PU Data Flash Error A programming error occurred when attempting to copy a received PU data module into the Flash module. u Contact Service. 186 AL CAN1 Bus Off CAN controller 1 is in "Bus-Off" status. 1. Check CAN bus for short circuit, rectify short circuit as necessary. 2. Check shielding, improve shielding as necessary. 3. Contact Service. 187 AL CAN1 Error Passive CAN controller 1 has signaled a warning. 1. Check CAN bus for short circuit, rectify short circuit as necessary. 2. Check shielding, improve shielding as necessary. 3. Contact Service. 188 AL CAN2 Bus Off TIM-ID: CAN controller 2 is in "Bus-Off" status. 189 AL CAN2 Error Passive 1. Check CAN bus for short circuit, rectify short circuit as necessary. 2. Check shielding, improve shielding as necessary. 3. Contact Service. CAN controller 2 has signaled a warning. 1. Check CAN bus for short circuit, rectify short circuit as necessary. 2. Check shielding, improve shielding as necessary. 3. Contact Service. MS15059/00E Troubleshooting 49

50 201 SD T-Coolant Coolant temperature sensor defective u Check sensor B6 and wiring, replace as necessary ( Page 139). 203 SD T-Charge Air Charge-air temperature sensor defective u Check sensor B9 and wiring, replace as necessary ( Page 139). 205 SD T-Coolant Intercooler Intercooler coolant temperature sensor faulty. u Check sensor B26 and wiring, replace as necessary ( Page 139). 208 SD P-Charge Air Charge-air pressure sensor defective u Check sensor B10 and wiring, replace as necessary ( Page 139). 211 SD P-Lube Oil Lube-oil pressure sensor defective u Check sensor B5.1 and wiring, replace as necessary ( Page 139). 215 SD P-HD Rail pressure sensor faulty; Highpressure governor emergency operation 216 SD T-Lube Oil Lube oil temperature sensor faulty. u Check sensor B48.1 and wiring, replace as necessary ( Page 139). u Check sensor B7 and wiring, replace as necessary ( Page 139). TIM-ID: Troubleshooting MS15059/00E

51 219 SD T-Intake Air Intake air temperature sensor faulty. u Check sensor B3 and wiring, replace as necessary ( Page 139). 220 SD Level Coolant Water Coolant level sensor faulty. 1. Check sensor F33 and wiring, replace as necessary ( Page 139). 2. Fault is rectified when electronics are switched back on. 221 SD P-Diff Lube Oil Lube oil differential pressure sensor faulty. u Check sensor B5.1 and B5.3 and wiring, replace as necessary ( Page 139). 222 SD Leak Fuel Level Leak-off fuel level sensor faulty. u Check sensor F46 and wiring, replace as necessary ( Page 139). 223 SD Level Coolant Intercooler Coolant level sensor for intercooler defective. 1. Check sensor F57 and wiring, replace as necessary ( Page 139). 2. Fault is rectified when electronics are switched back on. 227 SD P-Oil before Filter Sensor for lube oil pressure before filter faulty. u Check sensor B5.3 and wiring, replace as necessary ( Page 139). TIM-ID: SD P-Fuel before Filter Fuel pressure sensor (before main filter) faulty. u Check sensor B34.2 and wiring, replace as necessary ( Page 139). MS15059/00E Troubleshooting 51

52 229 AL Stop Camshaft Sensor Defect Red alarm; emergency stop Engine stop due to camshaft sensor fault and a previous crankshaft sensor fault in the same operating cycle. 1. Check sensor and wiring to connectors B1 and B13, replace as necessary ( Page 139). 2. Acknowledge alarm. 3. Restart engine ( Page 32). 230 SD Crankshaft Speed Crankshaft sensor faulty. 1. Check sensor B13 and wiring, replace as necessary ( Page 139). 2. Fault is rectified when engine is restarted, contact Service if this is not the case. 231 SD Camshaft Speed Camshaft sensor faulty. 1. Check sensor B1 and wiring, replace as necessary ( Page 139). 2. Fault is rectified when engine is restarted, contact Service if this is not the case. 239 SD P-Diff Fuel Fuel pressure sensors faulty. u Check sensor B34.2, sensor 34.3 and wiring, replace as necessary ( Page 139). 240 SD P-Fuel Fuel pressure sensor before intermediate filter faulty. u Check sensor B34.3 and wiring, replace as necessary ( Page 139). 245 SD ECU Supply Voltage Internal ECU fault. u Replace Engine Control Unit. TIM-ID: Troubleshooting MS15059/00E

53 266 SD Speed Setting Analog speed setting faulty. 1. Check speed setting transmitter and wiring, replace as necessary ( Page 139). 2. Fault is rectified when engine is restarted. 269 SD Loadp. Analog fil. Filtered analog signal of load pulse missing. 1. Check wiring, replace as necessary. 2. Fault is rectified when engine is restarted. 270 SD Frequency Input Frequency input faulty. 1. Check speed setting transmitter and wiring, replace as necessary ( Page 139). 2. Fault is rectified when engine is restarted. 321 AL Wiring Cylinder A1 Short circuit in cylinder A1 injector wiring. Result: Misfire 1. Check injector wiring. 2. Rectify injector solenoid valve short circuit (positive to negative) (e.g. by exchanging injectors). 3. Fault is rectified when engine is restarted. 322 AL Wiring Cylinder A2 Short circuit in cylinder A2 injector wiring. Result: Misfire 1. Check injector wiring. 2. Rectify injector solenoid valve short circuit (positive to negative) (e.g. by exchanging injectors). 3. Fault is rectified when engine is restarted. TIM-ID: AL Wiring Cylinder A3 Short circuit in cylinder A3 injector wiring. Result: Misfire 1. Check injector wiring. 2. Rectify injector solenoid valve short circuit (positive to negative) (e.g. by exchanging injectors). 3. Fault is rectified when engine is restarted. MS15059/00E Troubleshooting 53

54 324 AL Wiring Cylinder A4 Short circuit in cylinder A4 injector wiring. Result: Misfire 1. Check injector wiring. 2. Rectify injector solenoid valve short circuit (positive to negative) (e.g. by exchanging injectors). 3. Fault is rectified when engine is restarted. 325 AL Wiring Cylinder A5 Short circuit in cylinder A5 injector wiring. Result: Misfiring. 1. Check injector wiring. 2. Rectify injector solenoid valve short circuit (positive to negative) (e.g. by exchanging injectors). 3. Fault is rectified when engine is restarted. 326 AL Wiring Cylinder A6 Short circuit in cylinder A6 injector wiring. Result: Misfire 1. Check injector wiring. 2. Rectify injector solenoid valve short circuit (positive to negative) (e.g. by exchanging injectors). 3. Fault is rectified when engine is restarted. 327 AL Wiring Cylinder A7 Short circuit in cylinder A7 injector wiring. Result: Misfire 1. Check injector wiring. 2. Rectify injector solenoid valve short circuit (positive to negative) (e.g. by exchanging injectors). 3. Fault is rectified when engine is restarted. 328 AL Wiring Cylinder A8 Short circuit in cylinder A8 injector wiring. Result: Misfire 1. Check injector wiring. 2. Rectify injector solenoid valve short circuit (positive to negative) (e.g. by exchanging injectors). 3. Fault is rectified when engine is restarted. TIM-ID: Troubleshooting MS15059/00E

55 329 AL Wiring Cylinder A9 Short circuit in cylinder A9 injector wiring. Result: Misfire 1. Check injector wiring. 2. Rectify injector solenoid valve short circuit (positive to negative) (e.g. by exchanging injectors). 3. Fault is rectified when engine is restarted. 331 AL Wiring Cylinder B1 Short circuit in cylinder B1 injector wiring. Result: Misfire 1. Check injector wiring. 2. Rectify injector solenoid valve short circuit (positive to negative) (e.g. by exchanging injectors). 3. Fault is rectified when engine is restarted. 332 AL Wiring Cylinder B2 Short circuit in cylinder B2 injector wiring. Result: Misfire 1. Check injector wiring. 2. Rectify injector solenoid valve short circuit (positive to negative) (e.g. by exchanging injectors). 3. Fault is rectified when engine is restarted. 333 AL Wiring Cylinder B3 Short circuit in cylinder B3 injector wiring. Result: Misfire 1. Check injector wiring. 2. Rectify injector solenoid valve short circuit (positive to negative) (e.g. by exchanging injectors). 3. Fault is rectified when engine is restarted. 334 AL Wiring Cylinder B4 TIM-ID: Short circuit in cylinder B4 injector wiring. Result: Misfire 1. Check injector wiring. 2. Rectify injector solenoid valve short circuit (positive to negative) (e.g. by exchanging injectors). 3. Fault is rectified when engine is restarted. MS15059/00E Troubleshooting 55

56 335 AL Wiring Cylinder B5 Short circuit in cylinder B5 injector wiring. Result: Misfire 1. Check injector wiring. 2. Rectify injector solenoid valve short circuit (positive to negative) (e.g. by exchanging injectors). 3. Fault is rectified when engine is restarted. 336 AL Wiring Cylinder B6 Short circuit in cylinder B6 injector wiring. Result: Misfire 1. Check injector wiring. 2. Rectify injector solenoid valve short circuit (positive to negative) (e.g. by exchanging injectors). 3. Fault is rectified when engine is restarted. 337 AL Wiring Cylinder B7 Short circuit in cylinder B7 injector wiring. Result: Misfire 1. Check injector wiring. 2. Rectify injector solenoid valve short circuit (positive to negative) (e.g. by exchanging injectors). 3. Fault is rectified when engine is restarted. 338 AL Wiring Cylinder B8 Short circuit in cylinder B8 injector wiring. Result: Misfire 1. Check injector wiring. 2. Rectify injector solenoid valve short circuit (positive to negative) (e.g. by exchanging injectors). 3. Fault is rectified when engine is restarted. 339 AL Wiring Cylinder B9 Short circuit in cylinder B9 injector wiring. Result: Misfire 1. Check injector wiring. 2. Short circuit of injector solenoid valve (positive to negative) (e.g. by installing a new injector). 3. Fault is rectified when engine is restarted. TIM-ID: Troubleshooting MS15059/00E

57 341 AL Open Load Cylinder A1 Open circuit in cylinder A1 injector wiring. Result: Misfire 1. Check injector wiring, exclude disruption in solenoid valve (e.g. by injector replacement). 2. Fault is rectified after each working cycle. 342 AL Open Load Cylinder A2 Open circuit in cylinder A2 injector wiring. Result: Misfire 1. Check injector wiring, exclude disruption in solenoid valve (e.g. by injector replacement). 2. Fault is rectified after each working cycle. 343 AL Open Load Cylinder A3 Open circuit in cylinder A3 injector wiring. Result: Misfire 1. Check injector wiring, exclude disruption in solenoid valve (e.g. by injector replacement). 2. Fault is rectified after each working cycle. 344 AL Open Load Cylinder A4 Open circuit in cylinder A4 injector wiring. Result: Misfire 1. Check injector wiring, exclude disruption in solenoid valve (e.g. by injector replacement). 2. Fault is rectified after each working cycle. 345 AL Open Load Cylinder A5 Open circuit in cylinder A5 injector wiring. Result: Misfire 1. Check injector wiring, exclude disruption in solenoid valve (e.g. by injector replacement). 2. Fault is rectified after each working cycle. TIM-ID: AL Open Load Cylinder A6 Open circuit in cylinder A6 injector wiring. Result: Misfire 1. Check injector wiring, exclude disruption in solenoid valve (e.g. by injector replacement). 2. Fault is rectified after each working cycle. MS15059/00E Troubleshooting 57

58 347 AL Open Load Cylinder A7 Open circuit in cylinder A7 injector wiring. Result: Misfiring. 1. Check injector wiring, exclude disruption in solenoid valve (e.g. by injector replacement). 2. Fault is rectified after each working cycle. 348 AL Open Load Cylinder A8 Open circuit in cylinder A8 injector wiring. Result: Misfire 1. Check injector wiring, exclude disruption in solenoid valve (e.g. by injector replacement). 2. Fault is rectified after each working cycle. 349 AL Open Load Cylinder A9 Open circuit in cylinder A9 injector wiring. Result: Misfire 1. Check injector wiring, exclude disruption in solenoid valve (e.g. by injector replacement). 2. Fault is rectified after each working cycle. 351 AL Open Load Cylinder B1 Open circuit in cylinder B1 injector wiring. Result: Misfiring. 1. Check injector wiring, exclude disruption in solenoid valve (e.g. by injector replacement). 2. Fault is rectified after each working cycle. 352 AL Open Load Cylinder B2 Open circuit in cylinder B2 injector wiring. Result: Misfire 1. Check injector wiring, exclude disruption in solenoid valve (e.g. by injector replacement). 2. Fault is rectified after each working cycle. 353 AL Open Load Cylinder B3 Open circuit in cylinder B3 injector wiring. Result: Misfire 1. Check injector wiring, exclude disruption in solenoid valve (e.g. by injector replacement). 2. Fault is rectified after each working cycle. TIM-ID: Troubleshooting MS15059/00E

59 354 AL Open Load Cylinder B4 Open circuit in cylinder B4 injector wiring. Result: Misfire 1. Check injector wiring, exclude disruption in solenoid valve (e.g. by injector replacement). 2. Fault is rectified after each working cycle. 355 AL Open Load Cylinder B5 Open circuit in cylinder B5 injector wiring. Result: Misfire 1. Check injector wiring, exclude disruption in solenoid valve (e.g. by injector replacement). 2. Fault is rectified after each working cycle. 356 AL Open Load Cylinder B6 Open circuit in cylinder B6 injector wiring. Result: Misfire 1. Check injector wiring, exclude disruption in solenoid valve (e.g. by injector replacement). 2. Fault is rectified after each working cycle. 357 AL Open Load Cylinder B7 Open circuit in cylinder B7 injector wiring. Result: Misfire 1. Check injector wiring, exclude disruption in solenoid valve (e.g. by injector replacement). 2. Fault is rectified after each working cycle. 358 AL Open Load Cylinder B8 Open circuit in cylinder B8 injector wiring. Result: Misfire 1. Check injector wiring, exclude disruption in solenoid valve (e.g. by injector replacement). 2. Fault is rectified after each working cycle. TIM-ID: AL Open Load Cylinder B9 Open circuit in cylinder B9 injector wiring. Result: Misfire 1. Check injector wiring, exclude disruption in solenoid valve (e.g. by injector replacement). 2. Fault is rectified after each working cycle. MS15059/00E Troubleshooting 59

60 361 AL Injector Power Stage Low Internal electronic fault, electronics possibly faulty. 1. Start engine governor self-test. 2. Replace ECU in case of fault; if self-test diagnoses Electronics OK check for additional fault messages (e.g. wiring fault). 362 AL Injector Power Stage High Internal electronic fault, electronics possibly faulty. 1. Start engine governor self-test. 2. Replace ECU in case of fault; if self-test diagnoses Electronics OK check for additional fault messages (e.g. wiring fault). 363 AL Stop Injector Power Stage Red alarm; self-restoring Internal electronic fault, electronics possibly faulty. 1. Start engine governor self-test. 2. Replace ECU in case of fault; if self-test diagnoses Electronics OK check for additional fault messages (e.g. wiring fault). 365 AL Stop SV-Wiring Ground Red alarm; self-restoring Injector wiring fault. u Check wiring, replace wiring harness as necessary. 381 AL Wiring TOP 1 Short circuit or wire break on transistor output 1 plant-side (TOP 1). u Check wiring ( Page 139). 382 AL Wiring TOP 2 Short circuit or wire break on transistor output 2 plant-side (TOP 2). u Check wiring ( Page 139). TIM-ID: Troubleshooting MS15059/00E

61 383 AL Wiring TOP 3 Short circuit or wire break on transistor output 3 plant-side (TOP 3). u Check wiring ( Page 139). 384 AL Wiring TOP 4 Short circuit or wire break on transistor output 4 plant-side (TOP 4). u Check wiring ( Page 139). 390 AL MCR exceeded DBR/MCR function: MCR (continuous maximum rate) was exceeded. 1. No action required if alarm only applied temporarily. 2. Contact Service if alarm applied constantly. 400 AL Open Load Digital Input 1 Line disruption at digital input 1. u Check wiring ( Page 139). 401 AL Open Load Digital Input 2 Line disruption at digital input 2. u Check wiring ( Page 139). 402 AL Open Load Digital Input 3 TIM-ID: Line disruption at digital input 3. u Check wiring ( Page 139). 403 AL Open Load Digital Input 4 Line disruption at digital input 4. u Check wiring ( Page 139). MS15059/00E Troubleshooting 61

62 404 AL Open Load Digital Input 5 Line disruption at digital input 5. u Check wiring ( Page 139). 405 AL Open Load Digital Input 6 Line disruption at digital input 6. u Check wiring ( Page 139). 406 AL Open Load Digital Input 7 Line disruption at digital input 7. u Check wiring ( Page 139). 407 AL Open Load Digital Input 8 Line disruption at digital input 8. u Check wiring ( Page 139). 408 AL Open Load Emerg. Stop Input ESI Open circuit at input for emergency stop. u Check wiring ( Page 139). 410 LO U-PDU Injector voltage too low (Level 1). u Perform Engine Control Unit self-test, replace as necessary. 411 LOLO U-PDU Injector voltage too low (Level 2). 412 HI U-PDU Injector voltage too high (Level 1). u Perform Engine Control Unit self-test, replace as necessary. u Perform Engine Control Unit self-test, replace as necessary. TIM-ID: Troubleshooting MS15059/00E

63 413 HIHI U-PDU Injector voltage too high (Level 2). u Perform Engine Control Unit self-test, replace as necessary. 414 HI Level Water Fuel Prefilter Water level in fuel prefilter too high. u Empty fuel prefilter. 415 LO P-Coolant Intercooler Coolant pressure in intercooler too low (Level 1). 1. Check coolant level in expansion tank, top up as necessary. 2. Check coolant circuit for leaks. 3. Check coolant pump. 416 SS P-Coolant Intercooler Coolant pressure in intercooler too low (Level 2). 1. Check coolant level in expansion tank, top up as necessary. 2. Check coolant circuit for leaks. 3. Check coolant pump. 417 SD Level Water Fuel Prefilter Water level sensor of fuel prefilter faulty, short circuit or wire break. u Check sensor F70 and wiring, replace as necessary. 438 LO P-Fuel 2 (Common Rail) TIM-ID: Rail pressure below specified value. Suction restrictor of HP fuel control block faulty or leakage in HP fuel system u Contact Service. MS15059/00E Troubleshooting 63

64 439 HI P-Fuel 2 (Common Rail) Rail pressure above specified value. Suction restrictor of HP fuel block jamming or HP fuel control block wiring faulty 1. Check wiring of HP fuel control block. 2. Contact Service if no fault can be detected. 441 AL System 2 Leaky Pressure gradient in rail is too low during starting or too high during stopping. 1. On engine stopping: Seal off system, contact Service. 2. On engine starting: Check engine for leakage, if none found, attempt restarting as per operating instructions (air in system). 444 SD U-PDU Sensor defect of injector power stage. u Replace Engine Control Unit. 445 SD P-Ambient Air Ambient air pressure sensor faulty. u Replace Engine Control Unit (sensor is in the ECU). 446 SD P-HD2 Rail pressure sensor faulty, highpressure regulator emergency mode. u Check sensor B48.2 and wiring, replace as necessary ( Page 139). 450 SD Idle/End-Torque Input [%] Input signal for initial/final torque faulty. 1. Check signal transmitter and wiring, replace as necessary. 2. Restart engine ( Page 32). TIM-ID: Troubleshooting MS15059/00E

65 454 SS Power Reduction Active Power reduction activated. u Observe any other messages. 470 SD T-ECU Temperature sensor for engine governor faulty. u Replace Engine Control Unit at next opportunity. 471 SD HP fuel control block Control of HP fuel control block faulty. 1. Check HP fuel control block and wiring, replace as necessary ( Page 139). 2. Fault is rectified when engine is restarted. 472 AL Stop SD Red alarm; emergency stop Sensor fault of shutdown channels. u Contact Service. 474 AL Wiring FO Wire break or short circuit at FO channel. u Contact Service. 476 AL Crash Rec. Init. Error TIM-ID: Initialization error of crash recorder. 478 AL Comb. Alarm Yel (Plant) u Contact Service. Combined alarm initiated by plant (yellow). u Observe any other fault messages. MS15059/00E Troubleshooting 65

66 479 AL Comb. Alarm Red (Plant) Combined alarm initiated by plant (red). u Observe any other fault messages. 480 AL Ext. Engine Protection External engine protection function active. u Contact Service. 514 Write Error Flash Value was not accepted into flash. u Contact Service. 536 AL Wiring PWM_CM1 Wire break or short circuit on channel PWM_CM1. u Check wiring to connected device or check connected device (actuator/sensor), replace as necessary. 549 AL Power Cut-Off detected Entered in fault memory only. The operating voltage of the Engine Control Unit was switched of with the engine running. This may lead to overpressure in the HP fuel system, which might cause damage to the engine. u Instruct the operator only to disconnect the power supply when the engine has stopped. 551 SS Engine Overspeed Camshaft Red alarm, emergency stop Engine overspeed, camshaft. u Restart engine ( Page 32). 558 AL Wiring PWM_CM2 TIM-ID: Wire break or short circuit on channel PWM_CM2. u Check wiring to connected device or check connected device (actuator/sensor), replace as necessary. 66 Troubleshooting MS15059/00E

67 582 AL Emergency Stop Failure Entered in fault memory only. Emergency stop command was not executed. u Contact Service. 596 AL Cons. Parameter Record Standard production data record available. The data record stored is for testing. u Contact Service. 602 AL CAN Engine Start Lock Start interlock initiated by plant. 1. Check plant configuration. 2. Restart engine ( Page 32). 610 AL Wiring HP Control Block 1 Wire break or short circuit at PWM channel HP fuel control block. u Check wiring or HP fuel control block, replace as necessary. 611 AL Wiring HP Control Block 2 Fuel prefilter differential pressure too high. u Check wiring or HP fuel control block, replace as necessary. 615 AL EIL Protection Yellow alarm; emergency stop (15 min. delay) TIM-ID: Alarm for Protection module as reaction to faulty or manipulated EIL. 616 AL EIL Error Alarm with faulty or manipulated EIL. u Replace EIL. u Replace EIL. MS15059/00E Troubleshooting 67

68 762 AL Smart Connect Lost Smart Connect device has failed on CAN bus. u Check wiring or Smart Connect, replace as necessary. 832 AL EIL Engine Number Differs Alarm when fault numbers differ between ECU and EIL. u Contact Service. 836 AL Nominal Speed Setting Fail Active analog speed setting faulty. u Check wiring (CAN MD). 851 AL Extern Start and HD too high Entered in fault memory only An external start is pending and high pressure is too high. u Contact Service. 852 AL Max. Blankshot Time Expired High pressure could not be released in the max. blankshot time. u Contact Service. 947 AL Wrong LSI Channel Config Data fault on allocating LSI channels. 973 AL Checksum IIG Checksum calculation or word limit check for one of the injectors is not correct. u Contact Service. u Contact Service. TIM-ID: Troubleshooting MS15059/00E

69 1130 AL Short Circuit Analog Output 1 The value output at analog output 1 deviates excessively from the value read back. u Check wiring AL Short Circuit Analog Output 2 The value output at analog output 2 deviates excessively from the value read back. u Check wiring. TIM-ID: MS15059/00E Troubleshooting 69

70 7 Task Description 7.1 Engine Engine Cranking manually Preconditions Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring tool F Ratchet F DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled 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 tools are removed from the engine. Cranking engine manually (lateral installation) 1. Remove starting equipment from flywheel housing ( Page 106). 2. Engage barring tool (2) with ring gear and install on flywheel housing. 3. Apply ratchet (1) to barring tool (2). 4. Rotate crankshaft in engine direction of rotation. Apart from the normal compression resistance, there should be no other resistance. Result: If the resistance exceeds the normal compression resistance, contact Service. 5. For removal, carry out reverse sequence. 6. Install starting equipment on flywheel housing ( Page 107). TIM-ID: Task Description MS15059/00E

71 7.1.2 Engine Barring with starting system Preconditions External pushbutton Bar engine without starting is provided. DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! Before cranking the engine with starter system, make sure that there are no persons in the engine's danger zone. Barring engine with starting system 1. If fitted, press pushbutton Bar engine without starting and keep depressed. 2. Let the crankshaft rotate until oil pressure is indicated, but not longer than 10 seconds. 3. Repeat procedure after about 20 seconds if necessary. TIM-ID: MS15059/00E Engine 71

72 7.1.3 Engine Test run DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! Before cranking the engine with starter system, make sure that there are no persons in the engine's danger zone. WARNING High level of engine noise when the engine is running. Risk of damage to hearing! Wear ear protectors. Engine Test run 1. Start engine ( Page 32). 2. Perform test run not below 1/3 load and at least until steady-state temperature is reached. 3. Carry out operational checks ( Page 33). 4. Stop engine ( Page 34). TIM-ID: Engine MS15059/00E

73 7.2 Crankcase Breather Crankcase breather Oil mist fine separator replacement Preconditions Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil Oil mist fine separator O-ring ( Spare Parts Catalog) ( Spare Parts Catalog) WARNING Engine oil is hot. Engine oil can contain combustion residues which are harmful to health. Risk of injury and poisoning! Allow the engine to cool to below 50 C before beginning work. Wear protective clothing, protective gloves, and safety glasses / facial protection. Avoid contact with skin. Do not inhale oil vapor. Replacing oil mist fine separator 1. Unscrew screws (1) and remove together with washers (2) and retainer (3). 2. Replace oil mist fine separator (4). 3. Replace O-ring (5) as necessary. 4. Screw in screws (1) with washers (2) and retainer (3). 5. Replace other oil mist fine separators in the same way. TIM-ID: MS15059/00E Crankcase Breather 73

74 7.3 Valve Drive Valve clearance Check and adjustment Preconditions Engine is stopped and starting disabled. Engine coolant temperature is max. 40 C. Valves are closed. Special tools, Material, Spare parts Designation / Use Part No. Qty. Valve clearance gauge Y Barring device F Ratchet F Double-end box wrench F Offset screwdriver F Socket wrench F Torque wrench, Nm F Measuring device Y Preparatory steps 1. Install barring device ( Page 70). 2. Remove cylinder head cover ( Page 77). Move piston of cylinder A1 into TDC position (without marking on flywheel) Note: With cylinder head and valve gear installed. 1. Insert preloaded dial gauge (2) into measuring device (4) and clamp using screw (1). 2. Install measuring device (4) in cylinder head and secure using knurled screw (3). 3. Zero dial gauge (2). 4. Turn engine using barring device until piston A1 reaches firing TDC. Result: The piston is at firing TDC when both rocker arms are unloaded, i.e. have clearance. Move piston of cylinder A1 into TDC position (without marking on flywheel) 1. Unscrew plug screw on B-side of flywheel housing. 2. Bar engine in direction of rotation until marking on flywheel is visible in the middle. Result: The piston is at firing TDC when both rocker arms are unloaded, i.e. have clearance. TIM-ID: Valve Drive MS15059/00E

75 Checking valve clearance at two crankshaft positions 1. Check TDC position of piston in cylinder 1. Check A-side: If the rocker arms are relieved at cylinder 1, A-side, the piston is in firing TDC. If the rocker arms are loaded at cylinder 1, A-side, the piston is in overlap TDC. 2. Check valve clearance with engine cold (at max. 40 C): Inlet (I) = 0.3 mm; Exhaust (X) = 0.4 mm. 3. Check all valve clearance values at two crankshaft positions (firing TDC and overlap TDC) according to the table below. Position Cylinder V Firing TDC in cylinder A1 Side A I X I X I X Side B I X I I X X Overlap TDC in cylinder A1 Side A X I X I I X 16V Side B X I X I X I Firing TDC in cylinder A1 Side A I X X X I X I Side B I X I I X I I X X Overlap TDC in cylinder A1 Side A I I X I X I X I X 18V Side B X I I X X X I Firing TDC in cylinder A1 Side A I X I X I X X Side B X X I X I X I I X I Overlap TDC in cylinder A1 Side A X I X I I X I I X I X I Inlet: Inlet valve adjustment permitted X exhaust: Exhaust valve adjustment permitted Valve adjustment not permitted Table 7: Valve clearance adjustments Side B I I I X I X X X 4. Use feeler gauge to check the distance between valve bridge and rocker arm. 5. If the deviation from the specified value exceeds 0.1 mm, adjust valve clearance. TIM-ID: MS15059/00E Valve Drive 75

76 Adjusting valve clearance 1. Undo locknut (1) and unscrew adjusting screw (2) a few turns. 2. Insert feeler gauge between valve bridge and rocker arm (3). 3. Readjust adjusting screw (2) so that the feeler gauge just passes through the gap. 4. Tighten locknut (1) with torque wrench to the specified tightening torque, holding the 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 arm to verify that the gauge just passes through the gap. Result: If not, adjust valve clearance. Final steps 1. Remove barring device. 2. Install cylinder head cover ( Page 77). TIM-ID: Valve Drive MS15059/00E

77 7.3.2 Cylinder head cover Removal and installation Preconditions Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 8 40 Nm F Torque wrench, Nm Ratchet adapter F Engine oil Gasket Preparatory steps 1. Open wiring harness safety clips on cylinder head cover. 2. Disconnect wiring harness. Removing and installing cylinder head cover Note: Before removing the gasket, release injector clamps and remove spade lugs. 1. Remove cylinder head cover (2) with gasket (1) from cylinder head. 2. Clean mating face. 3. Check condition of gasket (1) in cylinder head cover (2). 4. Replace gasket (1) if damaged. 5. Place gasket (1) in correct position on cylinder head. ( Spare Parts Catalog) 6. Push spade lugs under the terminals on the injector and tighten with torque wrench to the specified tightening torque. Name Size Type Lubricant Value/Standard Nut M4 Tightening torque (Engine oil) 1.5 Nm ±0.25 Nm TIM-ID: Install cylinder head cover (2) with screws (4) and washer (3). Final steps 1. Connect wiring harness. 2. Close wiring harness safety clips on cylinder head cover. MS15059/00E Valve Drive 77

78 7.4 Injection Valve / Injector Injector Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Injector ( Spare Parts Catalog) Screw for hold-down clamp ( Spare Parts Catalog) Replacing injector u Remove injector and install new one ( Page 79). TIM-ID: Injection Valve / Injector MS15059/00E

79 7.4.2 Injector Removal and installation Preconditions Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Installation device F Puller F Fuel suction device F Torque wrench, Nm F Torque wrench, Nm Ratchet adapter F Plug-in open-end wrench, 19 mm F Crowfoot wrench, 19 mm F Ring socket, 22 mm F Double-head box wrench F Socket wrench, 24 mm F Assembly compound (Kluthe Hakuform 30-15) X Engine oil Sealing 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 protective clothing, protective gloves, and safety glasses / facial protection. WARNING Residual pressure in HP fuel system. Risk of injury due to fuel escaping at high pressure! Energize the Engine Control Unit for around 30 s after emergency stop or engine stall. Wear protective gloves and goggles/safety mask. Slowly open straight unions. TIM-ID: WARNING WARNING Internal tension and residual pressure in the HP fuel system.parts can be ejected when loosening them. Risk of injury by ejected parts! Only use specified tools and devices. Wear goggles/facial protection. Liquid or gaseous media, e.g. fuel, are poisonous. Escaping vapors of highly volatile media, e.g. fuel or ether. Risk of fatal injury through swallowing; risk of poisoning through inhalation; irritation to eyes and skin! Seek medical attention immediately; do not induce vomiting. Do not inhale vapors or mist. Wear protective clothing, protective gloves, and safety glasses. If contact is made with skin, wash off with water and soap. MS15059/00E Injection Valve / Injector 79

80 WARNING Compressed air gun ejects a jet of pressurized air. Risk of injury to eyes and damage to hearing, risk of rupturing internal organs! Never direct air jet at people. Always wear safety goggles/face mask and ear defenders. Preparatory steps 1. Close fuel inlet line. 2. Drain fuel ( Page 87). 3. Remove cylinder head cover ( Page 77). Removing pressure pipe neck 1. Remove HP fuel line (1). 2. Unscrew union nut (2). 3. Pull off pressure pipe neck (3). 4. Extract fuel from the exposed bores using the suction device. Remove injector 1. Disconnect terminals (arrowed) on injector and pull out cable lugs. 2. Remove gasket. TIM-ID: Injection Valve / Injector MS15059/00E

81 3. Remove screw (3). 4. Take off hold-down clamp (2). Note: Support ring on injector must likewise be removed if it does not come out with the injector. 5. Use the puller to pull out injector (1). 6. After removal, seal all openings with suitable covers. Installing injector 1. Remove all covers before installation. 2. Clean sealing surface on cylinder head and protective sleeve. Note: Use a new sealing ring whenever the injector is installed. 3. Coat sealing ring on injector (1) with assembly compound. Note: Use either the press-fitting tool or the holddown clamp (2) to press injector (1) into the cylinder head. 4. Align faces on injector (1) for mounting in the hold-down clamp (2) and insert injector by hand in a straight line into the cylinder head. 5. Fit hold-down clamp (2) in correct position by hand. Installing without press-fitting tool 1. Screw in screw (3) and tighten screw (3) to carefully press injector (1) into cylinder head. Name Size Type Lubricant Value/Standard Screw M8 Preload torque (Engine oil) 5 Nm 2. Release screw (3) again and relieve hold-down clamp (2). TIM-ID: Installing with press-fitting tool 1. Place press-fitting tool on hold-down clamp (2) to press injector (1) carefully into the cylinder head. 2. Place hold-down clamp (2) in correct position, screw in screw (3) and tighten hand-tight. MS15059/00E Injection Valve / Injector 81

82 Installing pressure pipe neck Note: Minimize contamination! 1. Visually inspect HP fuel line (1) and replace as necessary. Note: Pressure pipe neck may be reused twice at most. 2. Visually check sealing surfaces and pins on pressure pipe neck for plastic deformation and replace as necessary. 3. Coat sealing ring with assembly compound. 4. Coat sealing cone of pressure pipe neck (3) with engine oil. 5. Slide pressure pipe neck (3) up to contact point on sealing ring in cylinder head. 6. Press pressure pipe neck (3) in completely by hand. 7. Align HP connection of injector with pressure pipe neck (3). 8. Coat thread and shoulder of union nut (2) with engine oil and tighten to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Retaining screw M24 Preload torque (Engine oil) 15 Nm +5 Nm 9. Tighten screw (3) for hold-down clamp (2) to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Screw M8 Tightening torque (Engine oil) 40 Nm +4 Nm TIM-ID: Injection Valve / Injector MS15059/00E

83 10. Tighten union nut (2) on pressure pipe neck (3) to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Retaining screw M24 Tightening torque 50 Nm +5 Nm Installing fuel line 1. Coat thread and shoulder of union nuts on HP fuel line (1) with engine oil. Note: Position fuel line, ensuring it is free of tension. 2. Position HP fuel line (1) with union nut (2) in correct position between rail and pressure pipe neck (3), then tighten by hand. 3. Tighten union nut of HP fuel line (1) on rail to specified torque using a torque wrench a) In case of single-wall HP fuel system Name Size Type Lubricant Value/Standard Union nut M20 Tightening torque (Engine oil) 37 Nm +3 Nm b) In case of double-wall (jacketed) HP fuel system Name Size Type Lubricant Value/Standard Union nut M20 Tightening torque (Engine oil) 50 Nm +5 Nm 4. If the fuel system is jacketed, tighten retaining screw of HP fuel line (1) on pressure pipe neck (3) to specified torque using a torque wrench Name Size Type Lubricant Value/Standard Retaining screw M25 Tightening torque (Engine oil) 15 Nm +5 Nm TIM-ID: Tighten union nut of HP fuel line (1) on pressure pipe neck (3) to specified torque using a torque wrench Name Size Type Lubricant Value/Standard Union nut M16 Tightening torque (Engine oil) 37 Nm +3 Nm MS15059/00E Injection Valve / Injector 83

84 Fitting gasket and connecting injector cable 1. Place gasket on cylinder head, ensuring correct installation position. Name Size Type Lubricant Value/Standard Union nut M16 Tightening torque (Engine oil) 37 Nm +3 Nm 2. Push cable lugs under the terminals (arrowed) on the injector and tighten to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Nut M4 Tightening torque (Engine oil) 1.5 Nm ±0.25 Nm Final steps 1. Install cylinder head cover ( Page 77). 2. Open fuel supply line. 3. Vent fuel system ( Page 86). TIM-ID: Injection Valve / Injector MS15059/00E

85 7.4.3 Injector functions Preconditions Engine is stopped and starting disabled. Note: The engine will lose its emissions certification of the drift correction parameters (CDC) are not reset. Resetting drift correction parameters (CDC) with DiaSys Note: After successful installation of DiaSys, document can be found here: C:\DiaSys\Doku auf ihrem Service- PC. 1. ( Dialog system DiaSys E531920/..). 2. If no DiaSys is available, contact Service. Entering injector coding (IIG) Note: After successful installation of DiaSys, document can be found here: C:\DiaSys\Doku auf ihrem Service- PC. 1. ( Dialog system DiaSys E531920/..). 2. If no DiaSys is available, contact Service. TIM-ID: MS15059/00E Injection Valve / Injector 85

86 7.5 Fuel System Fuel system Venting Preconditions Engine is stopped. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 6-50 Nm F Ring socket, 22 mm F WARNING Fuels are combustible and explosive. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke. Wear protective clothing, protective gloves, and safety glasses / facial protection. WARNING Liquid or gaseous media, e.g. fuel, are poisonous. Escaping vapors of highly volatile media, e.g. fuel or ether. Risk of fatal injury through swallowing; risk of poisoning through inhalation; irritation to eyes and skin! Seek medical attention immediately; do not induce vomiting. Do not inhale vapors or mist. Wear protective clothing, protective gloves, and safety glasses. If contact is made with skin, wash off with water and soap. Fuel system Venting 1. Open threaded vent plug (2) on filter head and connect suitable hose. 2. Provide suitable container to collect escaping fuel. 3. Actuate hand pump (1) until bubble-free fuel emerges at the threaded vent plug. 4. Close vent plug. TIM-ID: Name Size Type Lubricant Value/Standard Threaded vent plug M16 Tightening torque 6 Nm +2 Nm 5. Lock hand pump (1). 86 Fuel System MS15059/00E

87 7.5.2 Fuel Draining Preconditions Engine is stopped and starting disabled. WARNING Fuels are combustible and explosive. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke. Wear protective clothing, protective gloves, and safety glasses / facial protection. WARNING Liquid or gaseous media, e.g. fuel, are poisonous. Escaping vapors of highly volatile media, e.g. fuel or ether. Risk of fatal injury through swallowing; risk of poisoning through inhalation; irritation to eyes and skin! Seek medical attention immediately; do not induce vomiting. Do not inhale vapors or mist. Wear protective clothing, protective gloves, and safety glasses. If contact is made with skin, wash off with water and soap. Fuel Draining 1. Provide a suitable container in which to collect the fuel. 2. Remove fuel filter ( Page 88). 3. Catch fuel as it runs out. 4. Install fuel filter ( Page 88). TIM-ID: MS15059/00E Fuel System 87

88 7.6 Fuel Filter Fuel filter Replacement Preconditions Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F Easy-change filter ( Spare Parts Catalog) WARNING Fuels are combustible and explosive. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke. Wear protective clothing, protective gloves, and safety glasses / facial protection. WARNING Liquid or gaseous media, e.g. fuel, are poisonous. Escaping vapors of highly volatile media, e.g. fuel or ether. Risk of fatal injury through swallowing; risk of poisoning through inhalation; irritation to eyes and skin! Seek medical attention immediately; do not induce vomiting. Do not inhale vapors or mist. Wear protective clothing, protective gloves, and safety glasses. If contact is made with skin, wash off with water and soap. Fuel filter Replacement 1. Remove easy-change filter (3) with filter wrench. 2. Clean sealing surface on retainer (1). 3. Slightly lubricate seal (2) on easy-change filter. 4. Install and tighten easy-change filter by hand. 5. Replace further easy-change filters in the same way. 6. Vent fuel system ( Page 86). TIM-ID: Fuel Filter MS15059/00E

89 7.6.2 Fuel prefilter (non-switchable) Draining DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! Only run the engine at low power. Keep away from the engine's danger zone. WARNING Fuels are combustible and explosive. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke. Wear protective clothing, protective gloves, and safety glasses / facial protection. WARNING Liquid or gaseous media, e.g. fuel, are poisonous. Escaping vapors of highly volatile media, e.g. fuel or ether. Risk of fatal injury through swallowing; risk of poisoning through inhalation; irritation to eyes and skin! Seek medical attention immediately; do not induce vomiting. Do not inhale vapors or mist. Wear protective clothing, protective gloves, and safety glasses. If contact is made with skin, wash off with water and soap. WARNING High level of engine noise when the engine is running. Risk of damage to hearing! Wear ear protectors. WARNING Fuel in the prefilter can be pressurized. Risk of injury through spraying fuel! Wear protective gloves and eye protectors/safety mask. Open screw-coupling slowly. Preparatory steps u Pressure ratios in the fuel prefilter, see ( Page 94). In case of underpressure, drain fuel prefilter according to version A, see ( Page 89). In case of overpressure, drain fuel prefilter according to version B, see ( Page 90). TIM-ID: Draining fuel prefilter with underpressure, version A Note: The fuel prefilter must only be drained with the engine at a standstill! 1. Provide a suitable container to collect the water. 2. Stop engine and disable engine start. 3. Close fuel supply if a shutoff valve is available. MS15059/00E Fuel Filter 89

90 4. Open threaded vent plug (1) of filter to be serviced. 5. Open drain screw (1). 6. Allow water to drain. 7. Close drain screw (2) again. 8. Drain second filter on module, from ( Step 4). 9. Open fuel supply. 10. Vent fuel prefilter ( Page 100). Draining fuel prefilter with overpressure, version B Note: The fuel prefilter can be drained during engine operation or with the engine at a standstill! 1. Provide a suitable container to collect the water. 2. Take care when opening drain screw (1) because fuel or water can spurt out. 3. Allow water to drain. 4. Close drain screw (2) again. TIM-ID: Fuel Filter MS15059/00E

91 7.6.3 Fuel prefilter (switchable) Draining DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! Only run the engine at low power. Keep away from the engine's danger zone. WARNING Fuels are combustible and explosive. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke. Wear protective clothing, protective gloves, and safety glasses / facial protection. WARNING Liquid or gaseous media, e.g. fuel, are poisonous. Escaping vapors of highly volatile media, e.g. fuel or ether. Risk of fatal injury through swallowing; risk of poisoning through inhalation; irritation to eyes and skin! Seek medical attention immediately; do not induce vomiting. Do not inhale vapors or mist. Wear protective clothing, protective gloves, and safety glasses. If contact is made with skin, wash off with water and soap. WARNING High level of engine noise when the engine is running. Risk of damage to hearing! Wear ear protectors. WARNING Fuel in the prefilter can be pressurized. Risk of injury through spraying fuel! Wear protective gloves and eye protectors/safety mask. Open screw-coupling slowly. Preparatory steps u Pressure ratios in the fuel prefilter, see ( Page 94). In case of underpressure, drain fuel prefilter according to version A, see ( Page 91). In case of overpressure, drain fuel prefilter according to version B, see ( Page 93). TIM-ID: Draining fuel prefilter with underpressure, version A Note: During engine operation, only the cut-out filter module must be drained! At engine standstill, both filter modules can be drained! 1. Provide a suitable container to collect the water. MS15059/00E Fuel Filter 91

92 2. During engine operation, turn the switchover level as far as the stop (arrow) to cut out the filter module to be serviced. Result: Filter module (1) is cut in Filter module (2) is cut out 3. Open threaded vent plug (1) of filter to be serviced. 4. Open drain screw (1). 5. Allow water to drain. 6. Close drain screw (2) again. 7. Drain the second filter on the module to be serviced, from ( Step 3). 8. Vent fuel prefilter ( Page 100). TIM-ID: Fuel Filter MS15059/00E

93 Draining fuel prefilter with overpressure, version B Note: The filter modules can be drained without switchover during engine operation and at engine standstill! 1. Provide a suitable container to collect the water. 2. Take care when opening drain screw (1) because fuel or water can spurt out. 3. Allow water to drain. 4. Close drain screw (2) again. TIM-ID: MS15059/00E Fuel Filter 93

94 7.6.4 Fuel prefilter Pressure ratios Note: u Pressure ratios If the fuel prefilter is above the full level of the fuel tank, during engine operation the fuel pressure in the filter is lower than ambient pressure (vacuum). If the fuel prefilter is below the empty level of the fuel tank, during engine operation the fuel pressure in the filter is higher than ambient pressure (overpressure). In the case of overpressure, fuel can escape under pressure. The pressure ratios shown be known from commissioning. Pressure ratios can be checked with the engine shut down. Checking pressure ratios 1. Stop engine and disable engine start. 2. Carefully open threaded vent plug (1) slightly: Result: If no fuel emerges, this is an indication of vacuum or pressure balance. If fuel emerges, this is a sign of overpressure. 3. Collect fuel as it emerges. TIM-ID: Fuel Filter MS15059/00E

95 7.6.5 Fuel prefilter (non-switchable) Filter insert replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 6-50 Nm F Ratchet F Diesel fuel Filter parts kit ( Spare Parts Catalog) WARNING Fuels are combustible and explosive. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke. Wear protective clothing, protective gloves, and safety glasses / facial protection. WARNING Liquid or gaseous media, e.g. fuel, are poisonous. Escaping vapors of highly volatile media, e.g. fuel or ether. Risk of fatal injury through swallowing; risk of poisoning through inhalation; irritation to eyes and skin! Seek medical attention immediately; do not induce vomiting. Do not inhale vapors or mist. Wear protective clothing, protective gloves, and safety glasses. If contact is made with skin, wash off with water and soap. WARNING Fuel in the prefilter can be pressurized. Risk of injury through spraying fuel! Wear protective gloves and eye protectors/safety mask. Open screw-coupling slowly. Preparatory steps u Pressure ratios in the fuel prefilter, see ( Page 94). Replacing filter insert Note: The filter insert on the fuel prefilter must only be changed with the engine at a standstill! 1. Provide a suitable container in which to collect the fuel. 2. Stop engine and disable engine start. 3. Close fuel supply if a shutoff valve is available. TIM-ID: MS15059/00E Fuel Filter 95

96 4. Open threaded vent plug and ensure that fuel does not emerge continuously. Result: The filter can now be changed! 5. If fuel emerges continuously, check shutoff valve in fuel supply, notify Service. Note: As soon as the filter housing is opened, absolute cleanness is imperative! 6. Unscrew filter cover (1) and withdraw with filter insert (3) from filter housing (4). 7. Unclip filter insert (3) from filter cover (1). 8. Install new O-ring (2) on filter cover (1). 9. Coat new O-rings on filter cover and filter insert with fuel. 10. Clip new filter insert (3) into filter cover (1). 11. Screw filter cover (1) into filter housing. Result: Filter cover (1) must lie flat on the housing (4). 12. Tighten filter cover (1) with torque wrench to the specified tightening torque. Name Size Type Lubricant Value/Standard Filter cover Tightening torque 40 Nm 13. Replace second filter insert in the same manner. 14. Open fuel supply. 15. Vent fuel prefilter ( Page 100). 16. Check fuel prefilter for leaks. TIM-ID: Fuel Filter MS15059/00E

97 7.6.6 Fuel prefilter (switchable) Filter insert replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 6-50 Nm F Ratchet F Diesel fuel Filter parts kit ( Spare Parts Catalog) DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! Only run the engine at low power. Keep away from the engine's danger zone. WARNING Fuels are combustible and explosive. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke. Wear protective clothing, protective gloves, and safety glasses / facial protection. WARNING Liquid or gaseous media, e.g. fuel, are poisonous. Escaping vapors of highly volatile media, e.g. fuel or ether. Risk of fatal injury through swallowing; risk of poisoning through inhalation; irritation to eyes and skin! Seek medical attention immediately; do not induce vomiting. Do not inhale vapors or mist. Wear protective clothing, protective gloves, and safety glasses. If contact is made with skin, wash off with water and soap. WARNING High level of engine noise when the engine is running. Risk of damage to hearing! Wear ear protectors. WARNING Fuel in the prefilter can be pressurized. Risk of injury through spraying fuel! Wear protective gloves and eye protectors/safety mask. Open screw-coupling slowly. TIM-ID: Preparatory steps u Pressure ratios in the fuel prefilter, see ( Page 94). In case of underpressure, replace fuel prefilter according to version A, see ( Page 97). In case of overpressure, replace fuel prefilter according to version B, see ( Page 98). Replacing fuel prefilter with underpressure, version A Note: During engine operation, the filter inserts must only be replaced on the cut-out filter module! At engine standstill, the filter inserts on both filter modules can be replaced! 1. Provide a suitable container in which to collect the fuel. MS15059/00E Fuel Filter 97

98 2. During engine operation, turn the switchover level as far as the stop (arrow) to cut out the filter module to be serviced. Result: Filter module (1) is cut in Filter module (2) is cut out 3. Check fuel level in filter. Result: If the fuel level is stable, the filter can be changed! 4. If the fuel level falls, the switchover point is leaking. Screw on the filter cover again immediately and vent the filter ( Page 100). Check the switchover point, contact Service. Note: As soon as the filter housing is opened, absolute cleanness is imperative! 5. Unscrew filter cover (1) and withdraw with filter insert (3) from filter housing (4). 6. Unclip filter insert (3) from filter cover (1). 7. Install new O-ring (2) on filter cover (1). 8. Coat new O-rings on filter cover and filter insert with fuel. 9. Clip new filter insert (3) into filter cover (1). 10. Screw filter cover (1) into filter housing. Result: Filter cover (1) must lie flat on the housing (4). 11. Tighten filter cover (1) with torque wrench to the specified tightening torque. Name Size Type Lubricant Value/Standard Filter cover Tightening torque 40 Nm 12. Replace other filter inserts in the same way. 13. Vent fuel prefilter ( Page 100). 14. Check fuel prefilter for leaks. Replacing fuel prefilter with overpressure, version B Note: The filter modules must only be replaced with the engine at a standstill! 1. Provide a suitable container in which to collect the fuel. 2. Stop engine and disable engine start. 3. Close fuel supply. TIM-ID: Fuel Filter MS15059/00E

99 4. Open threaded vent plug and ensure that fuel does not emerge continuously. Result: The filter can now be changed! 5. If fuel emerges continuously, check shutoff valve in fuel supply, notify Service. Note: As soon as the filter housing is opened, absolute cleanness is imperative! 6. Unscrew filter cover (1) and withdraw with filter insert (3) from filter housing (4). 7. Unclip filter insert (3) from filter cover (1). 8. Install new O-ring (2) on filter cover (1). 9. Coat new O-rings on filter cover and filter insert with fuel. 10. Clip new filter insert (3) into filter cover (1). 11. Screw filter cover (1) into filter housing. Result: Filter cover (1) must lie flat on the housing (4). 12. Tighten filter cover (1) with torque wrench to the specified tightening torque. Name Size Type Lubricant Value/Standard Filter cover Tightening torque 40 Nm 13. Replace other filter inserts in the same way. 14. Open fuel supply. 15. Vent fuel prefilter ( Page 100). 16. Check fuel prefilter for leaks. TIM-ID: MS15059/00E Fuel Filter 99

100 7.6.7 Fuel prefilter Venting DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! Only run the engine at low power. Keep away from the engine's danger zone. WARNING Fuels are combustible and explosive. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke. Wear protective clothing, protective gloves, and safety glasses / facial protection. WARNING Liquid or gaseous media, e.g. fuel, are poisonous. Escaping vapors of highly volatile media, e.g. fuel or ether. Risk of fatal injury through swallowing; risk of poisoning through inhalation; irritation to eyes and skin! Seek medical attention immediately; do not induce vomiting. Do not inhale vapors or mist. Wear protective clothing, protective gloves, and safety glasses. If contact is made with skin, wash off with water and soap. WARNING High level of engine noise when the engine is running. Risk of damage to hearing! Wear ear protectors. WARNING Fuel in the prefilter can be pressurized. Risk of injury through spraying fuel! Wear protective gloves and eye protectors/safety mask. Open screw-coupling slowly. Preparatory steps 1. Pressure ratios in the fuel prefilter, see ( Page 94). In case of underpressure, drain fuel prefilter according to version A, see ( Page 100). In case of overpressure, drain fuel prefilter according to version B, see ( Page 101). 2. With the non-switchable fuel prefilter, the engine must be shut down and secured against starting. 3. With the switchable fuel prefilter, the cut-out filter module can be vented during engine operation. Venting fuel prefilter with underpressure, version A 1. Open fuel inlet if necessary. TIM-ID: Fuel Filter MS15059/00E

101 2. Release threaded vent plugs (2, 3) and unscrew at least one rotation. Note: Only operate the fuel priming pump manually! Only hold the pump plunger vertically to avoid damaging the pump! 3. Unlock fuel priming pump, screw out handle (1). Note: Catch emerging fuel with a suitable cloth. 4. Operate fuel priming pump handle (1) until bubble-free fuel emerges from the threaded vent plugs (2, 3). Note: Never actuate the handle with the threaded vent plugs closed! 5. Move handle (1) of fuel priming pump back and screw in. 6. Close threaded vent plugs (2, 3) and tighten by hand. Venting fuel prefilter with overpressure, version B 1. Open fuel supply if necessary. 2. Carefully release threaded vent plugs (1) and unscrew at least one rotation. 3. Leave threaded vent plugs (1) opened until bubble-free fuel emerges at the vent plugs. 4. Close threaded vent plugs (1) and tighten by hand. TIM-ID: MS15059/00E Fuel Filter 101

102 7.7 Air Filter Air filter Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Air filter Filter insert Filter element Air filter Replacement 1. Remove air filter(s) and install new one(s) ( Page 103). 2. Reset signal ring of service indicator ( Page 104). ( Spare Parts Catalog) ( Spare Parts Catalog) ( Spare Parts Catalog) TIM-ID: Air Filter MS15059/00E

103 7.7.2 Air filter Removal and installation Preconditions Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque screwdriver, 1 5 Nm F Air filter, removal and installation 1. Release clamp (2). 2. Remove air filter (1) and clamp (2) from connecting flange of intake housing (3). 3. Clean the connecting flange of the intake housing (3) and check it for free passage. 4. Fit air filter (1) and clamp (2) on connecting flange of intake housing (3). 5. Tighten screw on clamp (2) to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Screw Tightening torque 5 Nm TIM-ID: MS15059/00E Air Filter 103

104 7.8 Air Intake Service indicator Signal ring position check Preconditions Engine is stopped and starting disabled. Checking signal ring position 1. Replace air filter if the signal ring (2) is completely visible in the red area of the observation window (3) ( Page 102). 2. After installation of new filter, press reset button (1). Result: Signal ring returns to initial position. TIM-ID: Air Intake MS15059/00E

105 7.9 Starting Equipment Electric starter Overview 1 Starter 2 Gasket 3 Flange 4 Gasket 5 Stud 6 Washer 7 Nut TIM-ID: MS15059/00E Starting Equipment 105

106 7.9.2 Starter Removal Preconditions Engine is stopped and starting disabled. DANGER Electric voltage supply for operation. Danger of burns and fatal electric shock! Make certain that the power supply to the product is switched off before starting work. Secure against unintentional switching on! WARNING Heavy part, risk of falling or overturning due to lack of stability. Risk of crushing body or limbs! Use appropriate lifting gear and appliances. Wear safety shoes. Disconnecting and removing starter 1. Disconnect starter battery. 2. Prior to disconnection, mark all cables. 3. Remove all cables from starter. 4. Protect all cables from damage. 5. Remove starter nuts as shown in overview drawing ( Page 105). 6. Remove starter. 7. Protect starter from damage. TIM-ID: Starting Equipment MS15059/00E

107 7.9.3 Starter Installation Preconditions Engine is stopped and starting disabled. DANGER Electric voltage supply for operation. Danger of burns and fatal electric shock! Make certain that the power supply to the product is switched off before starting work. Secure against unintentional switching on! WARNING Heavy part, risk of falling or overturning due to lack of stability. Risk of crushing body or limbs! Use appropriate lifting gear and appliances. Wear safety shoes. Starter Installation 1. Coat starter pinion with lubricating grease. 2. Install starter as per overview drawing ( Page 105). Connecting starter to the electric system 1. Connect cables in accordance with the marking. 2. Screw on nuts of connections and use torque wrench to tighten to specified tightening torque. 3. Terminal 30 (battery connection) (2): Name Size Type Lubricant Value/Standard Nut M12 Tightening torque 24.7 to 27.5 Nm TIM-ID: Terminal 31 (negative terminal) (3): Name Size Type Lubricant Value/Standard Nut M10 Tightening torque 13.5 to 15.8 Nm 5. Terminal 50 (switching connection) (1): Name Size Type Lubricant Value/Standard Nut M6 Tightening torque 5 to 7 Nm 6. Check if starter works properly. MS15059/00E Starting Equipment 107

108 7.9.4 Pneumatic starter Overview 1 Pressure reducing valve 2 Starting valve 3 Gasket 4 Flange 5 Gasket 6 Stud 7 Washer 8 Hex nut 9 Threaded adapter 10 Pneumatic starter TIM-ID: Starting Equipment MS15059/00E

109 7.9.5 Starter Removal Preconditions Preparatory steps have been completed. WARNING Heavy part, risk of falling or overturning due to lack of stability. Risk of crushing body or limbs! Use appropriate lifting gear and appliances. Wear safety shoes. Starter Removal 1. Remove pressure hose. 2. Remove starter as per overview drawing ( Page 108). 3. Protect starter from damage. TIM-ID: MS15059/00E Starting Equipment 109

110 7.9.6 Starter Installation Special tools, Material, Spare parts Designation / Use Part No. Qty. Tool kit F Lubricating grease (Molykote Longtherm 2 Plus NLGI 2) X Sealing tape WARNING Heavy part, risk of falling or overturning due to lack of stability. Risk of crushing body or limbs! Use appropriate lifting gear and appliances. Wear safety shoes. Starter Installation 1. Coat starter pinion with lubricating grease. 2. Install starter as shown in overview drawing ( Page 108). Connecting air starter 1. Install pressure hose from starting valve (5) to starter (4) and from starting valve (5) to pressure reducing valve (6). 2. Install pressure hose from starter (4) to 3/2- way control valve (1) and starting valve (5), and from 3/2-way control valve to starting valve (1). 3. Fit sealing tape on unions (2, 3), cover the entire area of the union thread. 4. Tighten union (3) to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Union M52X1.5 (1 1/2" NPT) Tightening torque (Sealing tape) 180 Nm 5. Tighten union (2) to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Union M16x1.5 (1/4" NPT) Tightening torque (Sealing tape) 40 Nm TIM-ID: Check if starter (4) works properly. 110 Starting Equipment MS15059/00E

111 7.9.7 Hydraulic starter Overview Hydraulic starter 1 Hydraulic starter 2 Gasket 3 Flange 4 Gasket 5 Screw TIM-ID: MS15059/00E Starting Equipment 111

112 7.9.8 Starter Removal Preconditions Preparatory steps have been completed. WARNING Copper-beryllium alloy dust. Risk of poisoning and danger of cancer! Wear filter class P3 respirator. Do not blow out with compressed air. Do not breath in dust caused by abrasion. WARNING Hydraulic fluid is highly pressurized. Risk of injury! Before starting work, release pressure from system. WARNING Heavy part, risk of falling or overturning due to lack of stability. Risk of crushing body or limbs! Use appropriate lifting gear and appliances. Wear safety shoes. Starter Removal 1. Remove hydraulic connection. 2. Remove starter as shown in overview drawing ( Page 111). 3. Protect starter from damage and ingress of foreign matter. TIM-ID: Starting Equipment MS15059/00E

113 7.9.9 Starter Installation Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, Nm F Screwdriver bit F Lubricating grease (Molykote Longtherm 2 Plus NLGI 2) X WARNING Heavy part, risk of falling or overturning due to lack of stability. Risk of crushing body or limbs! Use appropriate lifting gear and appliances. Wear safety shoes. Installing starter 1. Coat starter pinion with long-life grease and turn back into initial position as necessary. 2. Install starter as per overview drawing ( Page 111). 3. Tighten hydraulic connection IN/OUT to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard SAE 12 ORB Tightening torque (Lubricating grease (Molykote Longtherm 2 Plus NLGI 2)) 120 to 127 Nm TIM-ID: MS15059/00E Starting Equipment 113

114 7.10 Lube Oil System, Lube Oil Circuit Engine oil Level check Preconditions Engine is stopped and starting disabled. Oil level check prior to engine start 1. Withdraw oil dipstick from guide tube and wipe it. 2. Insert oil dipstick into guide tube up to the stop, withdraw after approx. 10 seconds and check oil level. 3. Oil level must be between "min." (2) and "max." (1) marks. 4. Top up with oil up to the "max" (1) mark ( Page 115) 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, remove oil dipstick from the guide tube and wipe it. 2. Insert oil dipstick into guide tube up to the stop, withdraw after approx. 10 seconds and check oil level. 3. Oil level must be between "min." and "max." marks. 4. Top up to "max." if required ( Page 115). 5. Insert oil dipstick into guide tube up to the stop. TIM-ID: Lube Oil System, Lube Oil Circuit MS15059/00E

115 Engine oil Change Preconditions Engine is stopped and starting disabled. Engine is at operating temperature. MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil Sealing ring ( Spare Parts Catalog) WARNING Engine oil is hot. Engine oil can contain combustion residues which are harmful to health. Risk of injury and poisoning! Allow the engine to cool to below 50 C before beginning work. Wear protective clothing, protective gloves, and safety glasses / facial protection. Avoid contact with skin. Do not inhale oil vapor. Oil change without semirotary hand pump: Draining oil at drain plug on oil pan 1. Provide a suitable container to collect the oil. 2. Remove drain plug and drain oil. 3. Install drain plug with new sealing ring. 4. Replace engine oil filter ( Page 116). Oil change with semirotary hand pump: Oil extraction 1. Provide a suitable container to collect the oil. 2. Extract all oil from oil pan using the semirotary hand pump. 3. Replace engine oil filter ( Page 116). Filling with new oil TIM-ID: Open cover on filler neck. 2. Pour oil in at filler neck up to "max." mark at oil dipstick. 3. Close cover on filler neck. 4. Check engine oil level ( Page 114). 5. After oil change and filter replacement, bar engine with starting system ( Page 71). MS15059/00E Lube Oil System, Lube Oil Circuit 115

116 7.11 Oil Filtration / Cooling Engine oil filter Replacement Preconditions Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F Engine oil Oil filter ( Spare Parts Catalog) WARNING Engine oil is hot. Engine oil can contain combustion residues which are harmful to health. Risk of injury and poisoning! Allow the engine to cool to below 50 C before beginning work. Wear protective clothing, protective gloves, and safety glasses / facial protection. Avoid contact with skin. Do not inhale oil vapor. Engine oil filter Replacement 1. Remove oil filter (2) with filter wrench. 2. Clean sealing face on connecting piece (1). 3. Check sealing ring (arrow) of new oil filter and moisten with oil. 4. Screw on and tighten oil filter by hand. 5. Replace other oil filters in the same way. 6. After each oil change and filter replacement, crank engine with starting equipment ( Page 71). 7. Check oil level ( Page 114). TIM-ID: Oil Filtration / Cooling MS15059/00E

117 Centrifugal oil filter Cleaning and filter-sleeve replacement Preconditions Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 8-40 Nm F Ratchet F Cold cleaner(hakutex 60) X Filter sleeve ( Spare Parts Catalog) Sealing ring ( Spare Parts Catalog) WARNING Engine oil is hot. Engine oil can contain combustion residues which are harmful to health. Risk of injury and poisoning! Allow the engine to cool to below 50 C before beginning work. Wear protective clothing, protective gloves, and safety glasses / facial protection. Avoid contact with skin. Do not inhale oil vapor. WARNING Compressed air gun ejects a jet of pressurized air. Risk of injury to eyes and damage to hearing, risk of rupturing internal organs! Never direct air jet at people. Always wear safety goggles/face mask and ear defenders. TIM-ID: Centrifugal oil filter Cleaning and filter-sleeve replacement 1. Slacken off nuts (4) crosswise. 2. Remove housing cover (1). 3. Carefully remove rotor (3) from lower part of housing (5). 4. Remove nut (2). 5. Carefully remove rotor cap. 6. Remove filter sleeve from rotor cap. 7. Measure thickness of oil residues on filter sleeve. Result: If the oil residues exceed the maximum layer thickness of 25 mm, shorten the maintenance interval. 8. Disassemble rotor tube, filter cone and rotor bottom. 9. Wash out rotor cover, rotor tube, filter cone and rotor bottom with cold cleaner. 10. Blow out with compressed air. 11. Check sealing ring, fit new one if necessary. 12. Insert new filter sleeve into rotor cap with the smooth paper surface facing the outer wall. 13. Assemble rotor tube, filter cone and rotor bottom with sealing ring. 14. Carefully insert rotor in lower part of housing. MS15059/00E Oil Filtration / Cooling 117

118 15. Use torque wrench to tighten nut (2) to specified tightening torque. Name Size Type Lubricant Value/Standard Nut Tightening torque 8 Nm + 1 Nm 16. Fit housing cover (1). 17. Screw on nuts (4). 18. Use torque wrench to tighten nuts (4) crosswise to specified tightening torque. Name Size Type Lubricant Value/Standard Nut Tightening torque 12 Nm + 2 Nm TIM-ID: Oil Filtration / Cooling MS15059/00E

119 7.12 Coolant Circuit, General, High-Temperature Circuit Engine coolant Level check Preconditions Engine is stopped and starting disabled. MTU Fluids and Lubricants Specifications (A001061/..) are 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. Checking coolant level at filler neck: 1. Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to escape. 2. Continue to turn breather valve counterclockwise and remove. 3. Check coolant level (coolant must be visible at the lower edge of the cast-in eye or at the marking plate). 4. Top up with treated coolant as necessary ( Page 122). 5. Check and clean breather valve. 6. Place breather valve on filler neck and close. Coolant-level check by means of level sensor: 1. Switch on engine control system and check readings on the display. 2. Top up with treated coolant as necessary ( Page 122). TIM-ID: MS15059/00E Coolant Circuit, General, High-Temperature Circuit 119

120 Engine coolant Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change 1. Drain engine coolant ( Page 121). 2. Fill with engine coolant ( Page 122). TIM-ID: Coolant Circuit, General, High-Temperature Circuit MS15059/00E

121 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 a suitable container to catch the coolant. 2. Switch off preheating unit. Engine coolant Draining 1. Turn valve cover on coolant expansion tank counterclockwise to the first stop and release pressure. 2. Continue to turn valve cover counterclockwise and remove. 3. Open drain screws and drain engine coolant at the following drain points: At the preheating unit; At the HT coolant pump HT (1); At the crankcase (2) and (3), right side. 4. Draining of residual coolant: At the crankcase (1) and (2), left side. At the oil heat exchanger. 5. Close all open drain points. 6. Fit valve cover on filler neck and close it. TIM-ID: MS15059/00E Coolant Circuit, General, High-Temperature Circuit 121

122 Engine coolant Filling Preconditions Engine is stopped and starting disabled. MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant 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. WARNING High level of engine noise when the engine is running. Risk of damage to hearing! Wear ear protectors. NOTICE Cold coolant in hot engine can cause thermal stress. Possible formation of cracks in the engine! Fill / top up coolant only into cold engine. Preparatory steps 1. Turn breather valve (1) on coolant expansion tank counterclockwise to the first stop and allow pressure to escape. 2. Continue to turn breather valve (1) counterclockwise and remove. Filling engine coolant 1. Pour in coolant via filler neck on expansion tank. 2. Check proper condition of breather valve (1), clean sealing faces if required. 3. Fit breather valve (1) and close it. TIM-ID: Coolant Circuit, General, High-Temperature Circuit MS15059/00E

123 Final steps 1. Start the engine and operate it at idle speed for some minutes. 2. Check coolant level, top up coolant if necessary ( Page 119). TIM-ID: MS15059/00E Coolant Circuit, General, High-Temperature Circuit 123

124 Engine coolant pump Relief bore check DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running. Risk of damage to hearing! Wear ear protectors. Engine coolant pump Relief bore check 1. Check relief bore for oil and coolant discharge. Permissible coolant discharge: up to 10 drops per hour; Permissible oil discharge: up to 5 drops per hour. Result: If discharge exceeds the specified limits, contact Service. 2. If relief bore is dirty: Stop engine ( Page 34) and disable engine start. Clean relief bore with a wire. TIM-ID: Coolant Circuit, General, High-Temperature Circuit MS15059/00E

125 Engine coolant Sample extraction and analysis Preconditions Engine is stopped and starting disabled. MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. MTU test kit /00 1 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. Engine coolant Sample extraction and analysis 1. Turn breather valve on coolant expansion tank counterclockwise to 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 expansion tank and dispose of oil. 4. Draw off approx. 1 liter coolant and drain into a clean container. 5. Using the equipment and chemicals from the MTU test kit, examine coolant for: antifreeze concentration; corrosion inhibitor concentration; ph value. 6. Fit breather valve and close it. 7. Engine coolant change intervals ( MTU Fluids and Lubricants Specifications A001061/..). TIM-ID: MS15059/00E Coolant Circuit, General, High-Temperature Circuit 125

126 7.13 Belt Drive Drive belt Condition check Preconditions Engine is stopped and starting disabled. 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 130) Drive belt C Chunking ( Page 131) Drive belt Belt is oily, shows signs of overheating TIM-ID: Belt Drive MS15059/00E

127 Drive belt Tension check Preconditions Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Tester Y Belt tension tester, N Y Measuring depression depth with preload measuring device Note: The frequency measurement procedure is the preferred one because it provides more exact measurement results. 1. Remove protective cover. 2. Set preload measuring device onto the drive belt in the middle between the belt pulleys (arrow). 3. Using pushbutton, press vertically on top of drive belt exerting even pressure until spring can be heard or felt to engage. 4. Do not exert any more pressure as displayed value will otherwise be falsified. 5. Remove preload measuring device without changing the position of the display arm. 6. Read off measured value at the intersection of display arm and KG scale. Refer to table below for set-point value. 7. If the measured values deviate from the specified values, adjust drive belt tension ( Page 129). 8. Install protective cover. Belt length Application Drive belt 1800 mm Fan Drive belt 1520 mm Fan Measured value Initial installation (new belt, runtime h) Depression depth: 7 mm Test force: 188 N Depression depth: 6 mm Test force: 188 N Measured value (used belt, runtime 500 h) Depression depth: 8 mm Test force: 188 N Depression depth: 7 mm Test force: 188 N Table 8: Set-point values Measurement with preload measuring device TIM-ID: Measuring belt tension with frequency meter 1. Remove protective cover. 2. Tap against the belt with the handle of a hammer or with a wrench to initiate belt vibration. 3. Hold measuring tip of the frequency meter over belt drive. 4. The measured frequency value appears on the display of the frequency meter. 5. Compare measured value with value in the table. 6. If the measured values deviate from the specified values, adjust drive belt tension ( Page 129). 7. Install protective cover. MS15059/00E Belt Drive 127

128 Belt length Application Measured value Initial installation (new belt) Measured value Operating tension (used belt) Drive belt 1800 mm Fan Frequency: 88 ±1 Hz Frequency: 77 ±1 Hz Drive belt 1520 mm Fan Frequency: 104 ±1 Hz Frequency: 92 ±1 Hz Table 9: Set-point values Measurement with frequency meter TIM-ID: Belt Drive MS15059/00E

129 Drive belt Tension adjustment Preconditions Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, Nm F Ratchet adapter F Torque wrench, Nm F Ring socket, 24 mm F Engine oil Drive belt Tension adjustment 1. Remove protective cover from cooler. 2. Remove protective grill from fan. 3. Loosen screws (2) slightly. 4. Adjust belt tension acc. to specifications with screw (1) ( Page 127). 5. Use torque wrench to tighten screws (2) to specified tightening torque. Name Size Type Lubricant Value/Standard Screw M16 x 50 Tightening torque (Engine oil) 180 Nm +18 Nm 6. Tighten screw (1) to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Screw M16 x 200 Tightening torque (Engine oil) 50 Nm +5 Nm TIM-ID: Install protective grill on fan. 8. Install protective cover on cooler. MS15059/00E Belt Drive 129

130 Drive belt Replacement Preconditions Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Ring socket, 24 mm F Drive belt Replacing fan drive belt 1. Remove protective cover from cooler. 2. Remove protective grill from fan. 3. Remove fan. 4. Slacken off securing screws (2). 5. Screw out screw (1) until drive belt can be removed. 6. Check belt pulley on cooler bearing mount and crankshaft for contamination and clean if necessary. Note: When placing the drive belt in the grooves, no force must be applied. 7. Fit new drive belt. 8. Adjust and check drive belt tension ( Page 129). 9. Install fan. 10. Install protective grill on fan. 11. Install protective cover on cooler. ( Spare Parts Catalog) TIM-ID: Belt Drive MS15059/00E

131 7.14 Battery-Charging Generator Battery-charging generator drive Drive belt replacement Preconditions Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, Nm F Tester Y Belt tension tester, N Y Engine oil Drive belt ( Spare Parts Catalog) 1 Preparatory steps 1. Remove safety equipment (if fitted). 2. Remove screws of protective cover (engine free end). 3. Take off protective cover. Replacing drive belt 1. For initial installation: Moisten running surfaces of the battery charger carrier (2) with oil. 2. For re-tensioning: Undo screws (1) and trickle oil into the gap between gearcase (3) and battery charger carrier (2). 3. Remove drive belt. 4. Check cleanness of belt pulleys. 5. Fit new drive belt on belt pulleys without tension. 6. Tighten screws (1) to torque. Name Size Type Lubricant Value/Standard TIM-ID: Screw M10 Preload torque 10 Nm 7. Insert and tighten clamping bolt (4) to torque and tension drive belt to specified set value. Name Size Type Lubricant Value/Standard Clamping bolt - Preload torque 8 Nm MS15059/00E Battery-Charging Generator 131

132 Belt Application Drive belt Battery-charging generator Measurand Initial installation (new belt) Frequency: Hz Measurand Operating tension (used belt) Frequency: Hz Table 10: Setpoint values Measurement with frequency meter Belt Application Drive belt Battery-charging generator Measurand Initial installation (new belt) Depression depth: 7.8 mm Test force: 60 N Measurand Operating tension (used belt) Depression depth: 8.9 mm Test force: 60 N Table 11: Setpoint values Measurement with preload measuring device 8. Tighten screws (1) to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Screw M10 Tightening torque 40 Nm 9. Use nut (5) to fasten the clamping bolt (4). Final steps 1. Install guard. 2. Install screws of protective cover. 3. Install safety equipment (if fitted). 4. Check function of safety equipment (if fitted). TIM-ID: Battery-Charging Generator MS15059/00E

133 7.15 Fuel Supply System Differential pressure gage Check WARNING Fuels are combustible and explosive. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke. Wear protective clothing, protective gloves, and safety glasses / facial protection. Checking differential pressure gage 1. Switch on fuel treatment system (optional). 2. Set both alarm points at the differential pressure gage to zero. Result: Alarm is triggered after preset time. 3. Rest both alarm points at the differential pressure gage (see manufacturer's documentation). TIM-ID: MS15059/00E Fuel Supply System 133

134 Coolant level sensor Check Preconditions Plant has been put out of operation. WARNING Fuels are combustible and explosive. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke. Wear protective clothing, protective gloves, and safety glasses / facial protection. Checking coolant level sensor 1. Drain coolant slowly. Result: Alarm must be issued after the preset time. 2. Put plant into operation. TIM-ID: Fuel Supply System MS15059/00E

135 Pump capacity Check WARNING Fuels are combustible and explosive. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke. Wear protective clothing, protective gloves, and safety glasses / facial protection. Checking pump capacity 1. Install suitable pressure gage in the intake connection of the pump. 2. Check pump pressure. a) Switch on fuel treatment system (optional). Note: The pressure limiting valve at the pump might respond and open. Audible noise is caused by overflowing fuel and can be disregarded. b) Close ball valve at the outlet of the fuel treatment system. c) Check pressure at the pressure gage in the inlet to the fuel treatment system and note down. 3. Checking pump pressure in throttled condition. a) Reduce suction pressure of pump to -0.8 bar with the shut-off valve at the pump intake side. b) Check pressure at the pressure gage in the inlet to the fuel treatment system and note down. c) Open ball valve at inlet and outlet of fuel treatment system. 4. Calculate wear limit. Example: Measured value (normal condition). Measured value (throttled). 3 bar 2.6 bar If the determined pressure (throttled) is undershot by the determined pressure (normal) by 10%, the wear limit is reached. Repair pump (inform Service). TIM-ID: MS15059/00E Fuel Supply System 135

136 7.16 Engine Governor Engine control system Overview 1 Connector X2 2 Engine control system 3 Connector X3 4 Washer 5 Screw 6 Damper TIM-ID: Engine Governor MS15059/00E

137 Engine governor Removal and installation Preconditions Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine governor ( Spare Parts Catalog) 1 Resilient mount ( Spare Parts Catalog) NOTICE Wrong engine governor installed. Engine damage! When reassembling an engine, make sure that the governor with the data record for the given engine is installed. Removing engine governor from engine 1. Note or mark assignment of cables and connectors. 2. Release latches on connectors (1) and (3). 3. Disconnect all connectors. 4. Remove all screws (5). 5. Remove engine governor (2). Installing engine governor on engine 1. Install in reverse order. Ensure correct assignment of connectors and sockets in so doing. 2. Check resilient mount before installation. Result: Replace resilient mount if porous or defective. TIM-ID: MS15059/00E Engine Governor 137