Download MTU 12V 2000 C66 Operating instructions
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Operating Instructions Diesel engine 12V 2000 C66 16V 2000 C66 MS150094/01E Printed in Germany © 2012 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 permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, micro‐ filming and storage or processing on electronic systems including data bases and online services. This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage during operation. Subject to alterations and amendments. Table of Contents 1 Safety 1.1 1.2 1.3 1.4 General conditions Personnel and organizational requirements Transport Safety regulations for maintenance and repair work 1.5 Auxiliary materials, fluids and lubricants, fire prevention and environmental protection 1.6 Conventions for safety instructions in the text 5 Troubleshooting 5 6 7 8 11 13 Engine – Overview Engine side and cylinder designations Engine – Main dimensions Firing order Technical Data 2.5.1 12/16V 2000 C66 engine data 14 16 17 18 19 19 DCL-ID: 0000007590 - 003 3.1 Putting the engine into operation after extended out-of-service periods (>3 months) 3.2 Putting the engine into operation after scheduled out-of-service-period 3.3 Tasks after extended out-of-service periods (>3 weeks) 3.4 Checks prior to start-up 3.5 Fuel treatment system – Putting into operation 3.6 Starting the engine 3.7 Fuel treatment system – Switching on 3.8 Operational checks 3.9 Stopping the engine 3.10 Emergency stop 3.11 After stopping the engine 3.12 Fuel treatment system – Shutdown 3.13 Plant cleaning 22 23 24 25 26 28 29 30 31 32 33 34 35 41 6.2 Crankcase Breather 43 6.1.1 Engine – Barring manually 6.1.2 Engine – Barring with starting system 6.3 Valve Drive 6.3.1 Valve clearance – Check and adjustment 6.3.2 Cylinder head cover – Removal and installation 36 41 42 43 44 44 47 6.4 Injection Valve / Injector 48 6.5 Fuel System 54 6.4.1 Injector – Replacement 6.4.2 Injector – Removal and installation 6.6 Fuel Filter 6.6.1 Fuel filter – Replacement 6.6.2 Fuel prefilter – Differential pressure check and adjustment of gauge 6.6.3 Fuel prefilter – Draining 6.6.4 Fuel prefilter ‒ Flushing 6.6.5 Fuel prefilter – Filter element replacement 48 49 54 56 57 58 58 59 60 61 63 6.7 Air Filter 65 6.8 Air Intake 66 6.9 Exhaust Gas Recirculation 67 6.7.1 Air filter – Replacement 6.8.1 Service indicator – Check 6.9.1 Exhaust gas recirculation flaps – Overview 6.9.2 Exhaust gas circulation - Checking flap operation 65 66 67 68 6.10 Lube Oil System, Lube Oil Circuit 69 6.11 Oil Filtration / Cooling 71 6.10.1 Engine oil – Level check 6.10.2 Engine oil – Change 4 Maintenance 4.1 Maintenance task reference table [QL1] 6.1 Engine 6.5.1 HP fuel line and pressure pipe neck – Replacement 6.5.2 Fuel system – Venting 6.5.3 Fuel – Draining 3 Operation 37 38 6 Task Description 6.2.1 Crankcase breather – Oil mist fine separator replacement 2 Product Summary 2.1 2.2 2.3 2.4 2.5 5.1 Fuel treatment system – Troubleshooting 5.2 Troubleshooting 6.11.1 Engine oil filter – Replacement 69 70 71 MS150094/01E 2012-08 | Table of Contents | 3 6.11.2 Centrifugal oil filter – Cleaning and filter sleeve replacement 6.12 Coolant Circuit, General, HighTemperature Circuit 6.12.1 6.12.2 6.12.3 6.12.4 6.12.5 6.12.6 6.12.7 Drain and vent points 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 6.12.8 Coolant filter – Replacement 6.13 Low-Temperature Circuit 6.13.1 6.13.2 6.13.3 6.13.4 6.13.5 6.13.6 Intercooler – Vent and drain points Charge-air coolant – Level check Charge-air coolant – Change Charge-air coolant – Filling Charge-air coolant – Draining Charge-air coolant pump – Relief bore check 6.14 Belt Drive 6.14.1 6.14.2 6.14.3 6.14.4 Drive belt – Condition check Drive belt – Tension check Drive belt – Tension adjustment Drive belt – Replacement 6.15 Battery-Charging Generator 6.15.1 Battery-charging generator drive – Drive belt replacement 6.16 Fuel Supply System 74 74 79 80 81 82 84 85 86 87 87 88 89 90 92 93 94 94 95 96 97 98 6.16.5 Coalescer filter element – Replacement 6.17 Engine Governor 6.17.1 6.17.2 6.17.3 6.17.4 Engine governor – Overview Engine governor – Removal Engine governor – Installation Engine governor – Checking plug-in connections 6.18 Wiring (General) for Engine/Gearbox/Unit 6.18.1 Engine wiring – Check 6.18.2 Lambda, NOx and humidity sensors – Overview 6.18.3 Lambda sensor – Replacement 6.18.4 NOx sensor – Replacement 6.18.5 Humidity sensor – Replacement 6.19 Accessories for (Electronic) Engine Governor / Control System 6.19.1 CDC parameters – Reset with DiaSys® 6.19.2 Engine governor and connectors – Cleaning 6.19.3 Engine governor – Checking plug-in connections 103 105 105 106 107 108 109 109 110 111 113 115 117 117 118 119 7 Appendix A 7.1 List of abbreviations 7.2 MTU contact persons/service partners 120 123 98 99 99 100 101 102 8 Appendix B 8.1 Special Tools 8.2 Index 124 134 DCL-ID: 0000007590 - 003 6.16.1 Water drain valve – Check 6.16.2 Differential pressure gauge – Check 6.16.3 Water level probe (3-in-1 rod electrode) – Check 6.16.4 Pump capacity – Check 72 4 | Table of Contents | MS150094/01E 2012-08 1 Safety 1.1 General conditions General In addition to the instructions in this publication, the applicable country-specific legislation and other com‐ pulsory regulations regarding accident prevention and environmental protection must be observed. This state-of-the-art engine has been designed to meet all applicable laws and regulations. The engine may nevertheless present 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 Correct use The engine is intended solely for use in accordance with contractual agreements and the purpose envis‐ aged for it on delivery. Any other use is considered improper use. The engine manufacturer accepts no liability whatsoever for resultant damage or injury in such case. The responsibility is borne by the user alone. Correct use also includes observation of and compliance with the maintenance specifications. Modifications or conversions Unauthorized modifications to the engine represent a safety risk. MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or conversions. Spare parts Only genuine MTU spare parts must be used to replace components or assemblies. MTU accepts no liability whatsoever for damage or injury resulting from the use of other spare parts and the warranty shall be voided in such case. Reworking components TIM-ID: 0000000860 - 017 Repair or engine overhaul must be carried out in workshops authorized by MTU. MS150094/01E 2012-08 | Safety | 5 1.2 Personnel and organizational requirements Personnel requirements All work on the engine shall be carried out by trained and qualified personnel only. The specified legal minimum age must be observed. The operator must specify the responsibilities of the operating, maintenance and repair personnel. Organizational measures This publication must be issued to all personnel involved in operation, maintenance, repair or transporta‐ tion. Keep it at hand at the operating site of the engine so that it is available to operating, maintenance, repair and transport personnel at all times. Use the manual as a basis for instructing personnel on engine operation and repair with an emphasis on explaining safety-relevant instructions. This is particularly important in the case of personnel who only occasionally perform work on or around the engine. This personnel must be instructed repeatedly. For the identification and layout of the spare parts during maintenance or repair work, take photos or use the spare parts catalog. Working clothes and protective equipment Wear proper protective clothing for all work. TIM-ID: 0000000874 - 018 Use the necessary protective equipment for the given work to be done. 6 | Safety | MS150094/01E 2012-08 1.3 Transport Transport Also valid for 12V engines Only use the lifting eyes provided to lift the engine. Only use transport and lifting devices approved by MTU. Take the engine's center of gravity into account. The engine must only be transported in installation position, max. permissible diagonal pull 10°. If the engine is supplied with special aluminum foil packing, lift the engine at the lifting eyes of the bear‐ ing pedestal or use a means of transportation which is appropriate for the given weight (forklift truck). Install the crankshaft locking device and the locking screws for the engine mounts prior to engine trans‐ portation. TIM-ID: 0000024082 - 001 Secure the engine against tilting during transport. In particular when going down inclines or ramps, the engine must be secured against moving and tilting. Setting the engine down after transport Only set down engine on a firm, level surface. Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate. Never set an engine down on the oil pan unless expressively authorized to do so by MTU on a case-tocase basis . MS150094/01E 2012-08 | Safety | 7 1.4 Safety regulations for maintenance and repair work Safety regulations for maintenance and repair work Have maintenance and repair work carried out by qualified and authorized personnel only. Allow the engine to cool down before starting maintenance work (risk of explosion of oil vapors). Before starting work, relieve pressure in systems and compressed-air lines which are to be opened. Take special care when removing ventilation or plug screws from the engine. Cover the screw or plug with a rag to prevent fluids escaping under pressure. Take special care when draining hot fluids ⇒ Risk of injury. When changing the engine oil or working on the fuel system, ensure that the engine room is adequately ventilated. Allow the engine / system to cool down before starting to work. Observe the maintenance and repair instructions. Never carry out maintenance and repair work with the engine running unless expressly instructed to do so. Secure the engine against accidental starting. Disconnect the battery when electrical starters are fitted. 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 assembly or system. Use only proper, calibrated tools. Observe the specified tightening torques during assembly/disassembly. Carry out work only on assembles and/or units which are properly secured. Never use lines for climbing. Keep fuel injection lines and connections clean. Always seal connections with caps or covers if a line is removed or opened. Take care not to damage lines, in particular fuel lines, during maintenance and repair work. Ensure that all retainers and dampers are installed correctly. Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent con‐ tact with other components. Do not place fuel or oil lines near hot components. Do not touch elastomeric seals if they have carbonized or resinous appearance unless hands are proper‐ ly protected. When working high on the engine, always use suitable ladders and work platforms. Make sure compo‐ nents are placed on stable surfaces. Observe special cleanness when conducting maintenance and repair work on the assembly or system. After completion of maintenance and repair work, make sure that no loose objects are in/on the assem‐ bly or system. Before barring the engine, make sure that nobody is standing in the danger zone. Check that all guards have been reinstalled and that all tools and loose parts have been removed after working on the engine. The following additional instructions apply to starters with beryllium copper pinion: • Breathing protection of filter class P2 must be applied during maintenance work to avoid health haz‐ ards caused by the beryllium-containing pinion. 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 de‐ vice as an additional measure. 8 | Safety | MS150094/01E 2012-08 TIM-ID: 0000000879 - 023 Note cooling time for components which are heated for installation or removal ⇒ Risk of burning. Welding work Never carry out welding work on the assembly, system, or engine-mounted units. Cover the engine when welding in its vicinity. Do not use the assembly or system as ground terminal. Do not route the welding lead over or near the wiring harnesses of MTU systems. The welding current may otherwise induce an interference voltage in the wiring harnesses which could conceivably damage the electrical system. Remove parts (e.g. exhaust pipes) which are to be welded from the engine beforehand. Hydraulic installation and removal Check the function and safe operating condition of tools and fixtures to be used. Use only the specified devices for hydraulic removal/installation procedures. Observe the max. permissible push-on pressure specified for the equipment. Do not attempt to bend or apply force to lines. Before starting work, pay attention to the following: • Vent the hydraulic installation/removal tool, the pumps and the lines at the relevant points for the equipment to be used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs). • For hydraulic installation, screw on the tool with the piston retracted. • For hydraulic removal, screw on the tool with the piston extended. For a hydraulic installation/removal tool with central expansion pressure supply, screw spindle into shaft end until correct sealing is established. During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of the component to be installed/removed. Working on electrical/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 reinstalling ensure that wiring is not damaged during operation by contact with sharp objects, by rubbing against other components or by a hot surface. Do not secure cables on lines carrying fluids. Do not use cable binders to secure cables. Always use connector pliers to tighten connectors. Subject the device or system to a function check on completion of all repair work. TIM-ID: 0000000879 - 023 Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Pack de‐ fective electronic components and assemblies in a suitable manner when dispatched for repair, i.e. par‐ ticularly protected against moisture and impact and wrapped in antistatic foil if necessary. Working with laser equipment When working with laser equipment, always wear special laser-protection goggles ⇒ Heavily focused ra‐ diation. Laser equipment must be fitted with the protective devices necessary for safe operation according to type and application. MS150094/01E 2012-08 | Safety | 9 TIM-ID: 0000000879 - 023 For conducting light-beam procedures and measurement work, only the following laser devices must be used: • Laser devices of classes 1, 2 or 3A. • Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700 nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to prevent any risk to the eyes. 10 | Safety | MS150094/01E 2012-08 1.5 Auxiliary materials, fluids and lubricants, fire prevention and environmental protection Fire prevention Rectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause fires – therefore always keep the engine in a clean condition. Do not leave cloths soaked with fluids and lubri‐ cants lying on or near the assembly or unit. Do not store inflammable material near the assembly or unit. Do not weld 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 keep suitable firefighting equipment (fire extinguishers) at hand and familiarize yourself with their use. Noise Noise can lead to an increased risk of accident if acoustic signals, warning shouts or noises indicating danger are drowned. Wear ear protectors in work areas with a sound pressure level in excess of 85 dB (A). Environmental protection and disposal Modification or removal of mechanical or electronic components or the installation of additional compo‐ nents as well as the execution of calibration processes that might affect the emission characteristics of the engine are prohibited by emission regulations. Emission control units/systems may only be main‐ tained, exchanged or repaired if the components used for this purpose are approved by MTU or equiva‐ lent components. Noncompliance with these guidelines might represent a violation of the Clean Air Act and involves the termination of the operating license by the emission authorities. MTU does not accept any liability for violations of the emission regulations. MTU will provide assistance and advice if emissionrelevant components are intended to be modified. The MTU Maintenance Schedules ensure the reliabili‐ ty and performance of MTU engines and must be complied with over the entire life cycle of the engine. Use only fuel of prescribed quality to comply with emission limit values. Dispose of used fluids, lubricants and filters in accordance with local regulations. Within the EU, batteries can be returned free of charge to MTU FN / MTU Onsite Energy where they are subjected to proper recycling procedures. Auxiliary materials, fluids and lubricants TIM-ID: 0000000880 - 016 Use only fluids and lubricants that have been tested and approved by MTU. The Fluids and Lubricants Specifications will be amended or supplemented as necessary. Before using them, make sure you have the latest version. The latest version is also available at: http://www.mtu-on‐ line.com/mtu/mtu-valuecare/mtu-valueservice-Technische-Dokumentation. Keep fluids and lubricants in suitable, properly designated containers. When using fluids, lubricants and other chemical substances, follow the safety instructions that apply to the product. Take special care when using hot, chilled or caustic materials. When using flammable materials, avoid all sparks and do not smoke. Used oil Used oil contains harmful combustion residues. Rub barrier cream into hands. Wash hands after contact with used oil. MS150094/01E 2012-08 | Safety | 11 Lead • When working with lead or lead-containing compounds, avoid direct contact to the skin and do not inhale lead vapors. • Adopt suitable measures to avoid the formation of lead dust. • Switch on extraction system. • Wash hands after contact with lead or lead-containing substances. Compressed air Observe special safety precautions when working with compressed air: • Pay special attention to the pressure level in the compressed air network and pressure vessel. • Assemblies and equipment to be connected must either be designed for this pressure, or, if the per‐ mitted pressure for the connecting elements is lower than the pressure required, a pressure reducing valve and safety valve (set to permitted pressure) must form an intermediate connection. • Hose couplings and connections must be securely attached. • Wear goggles when blowing off components or blowing away chips. • Provide the snout of the air nozzle with a protective disk (e.g. rubber disk). • First shut off compressed air lines before compressed air equipment is disconnected from the supply line, or before equipment or tool is to be replaced. • Unauthorized use of compressed air, e.g. forcing flammable liquids (danger class AI, AII and B) out of containers, results in a risk of explosion. • Forcing compressed air into thin-walled containers (e.g. containers made of tin, plastic and glass) for drying purposes or to check for leaks, results in a risk of bursting. • Carry out leak test in accordance with the specifications. Paints and lacquers • When carrying out painting work outside the spray stands provided with fume extraction systems, en‐ sure that the area is well ventilated. Make sure that neighboring work areas are not impaired. • No open flames. • No smoking. • Observe fire prevention regulations. • Always wear a mask providing protection against paint and solvent vapors. Liquid nitrogen • • • • • Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers. Avoid body contact (eyes, hands). Wear protective clothing, protective gloves, closed shoes and protective goggles / safety mask. Make sure that working area is well ventilated. Avoid all knocks and jars to the containers, fixtures or workpieces. • When working with acids and alkaline solutions, wear protective goggles or face mask, gloves and protective clothing. • If such solutions are spilled onto clothing, remove the affected clothing immediately. • Rinse injured parts of the body thoroughly with clean water. • Rinse eyes immediately with eyedrops or clean tap water. 12 | Safety | MS150094/01E 2012-08 TIM-ID: 0000000880 - 016 Acids and alkaline solutions 1.6 Conventions for safety instructions in the text DANGER WARNING CAUTION NOTICE Note: In the event of immediate danger. Consequences: Death or serious injury • Remedial action In the event of potentially dangerous situations. Consequences: Death or serious injury • Remedial action In the event of dangerous situations. Consequences: Minor injury or material damage • Remedial action In the event of a situation involving potentially adverse effects on the product. Consequences: Material damage. • Remedial action • Additional product information This manual contains highlighted safety warnings in accordance with the US ANSI Z535 standard which begin with one of the signal words listed above depending on the severity of the hazard. Safety instructions Read and familiarize yourself with all safety notices before starting up or repairing the product. Pass on all safety instructions to your operating, maintenance, repair and transport personnel. TIM-ID: 0000000881 - 018 1. 2. MS150094/01E 2012-08 | Safety | 13 2 Product Summary 2.1 Engine – Overview 12/16 V 2000 C66/S96 This overview also applies to 16 V 2000 C66 and 16 V 2000 S96 engines. Exhaust turbocharger Air intake/air supply EGR cooler Intercooler Monitoring, control and regulation equipment, general electr. equip‐ ment 6 Lube oil system / lube oil circuit 7 8 9 10 11 Power supply Cooling air system Coolant system Mounting / support Fuel system (low pres‐ sure) 12 Fuel system (high pres‐ sure) 13 14 15 16 Valve gear Cylinder head Exhaust system PTO systems, driving end and free end (cou‐ pling) 17 Starting equipment Engine model designation Key to the engine model designation 12/16 Number of cylinders V Cylinder arrangement: V engine 2000 Series 14 | Product Summary | MS150094/01E 2012-08 TIM-ID: 0000023527 - 002 1 2 3 4 5 Key to the engine model designation C/S Application: C, charge-air cooling in internal circuit, with piston cooling Application S: Exhaust turbocharging with supercharger Application segment (0, 1, 2,...,9) 6 Design index (0, 1, 2,...,9) TIM-ID: 0000023527 - 002 6/9 MS150094/01E 2012-08 | Product Summary | 15 2.2 Engine side and cylinder designations Engine sides are always designated as viewed from the driving end (KS). The cylinders of the left engine side are designated "A" and those of the right side "B" (as per DIN ISO 1204). The cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end. Other components are numbered in the same way, i.e. starting with No. 1 on driving end. 3 Right engine side 4 KS = Driving end TIM-ID: 0000002185 - 010 1 Left engine side 2 KGS = Free end 16 | Product Summary | MS150094/01E 2012-08 2.3 Engine – Main dimensions Engine model / Dimension Engine model / Dimension 12 V 2000 C66/S96 16 V 2000 C66/S96 Length (A) approx. 2028 mm approx. 2378 mm Width (B) approx. 1276.5 mm approx. 1287 mm Height (C) approx. 1429 mm approx. 1442 mm TIM-ID: 0000023835 - 001 Item MS150094/01E 2012-08 | Product Summary | 17 2.4 Firing order Firing order for 12 / 16 V 2000 C66/S96 engines Firing order 12 V A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1 16 V A1-B5-A3-A5-B2-B8-A2-A8-B3-A7-B4-B6-A4-A6-B1-B7 TIM-ID: 0000023721 - 001 Number of cylin‐ ders 18 | Product Summary | MS150094/01E 2012-08 2.5 Technical Data 2.5.1 12/16V 2000 C66 engine data Explanation: DL BL A G R L N X Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated, without change (e.g. of power setting) Not yet defined value Not applicable Applicable Engine model Application group 12V2000 C66 16V2000 C66 5B 5B Intake air temperature °C 25 25 Charge-air coolant temperature °C 45 45 Barometric pressure mbar 1000 1000 Site altitude above sea level m 100 100 POWER-RELATED DATA (power ratings are net brake power as per ISO 3046) Number of cylinders 12 16 Rated engine speed A rpm 2100 2100 Effective power (w/o fan) (Fuel stop power ISO 3046) A kW 783 970 12 16 GENERAL CONDITIONS (for maximum power) TIM-ID: 0000024846 - 002 Number of cylinders Intake depression (new filter) A mbar 15 15 Intake depression, max. L mbar 50 50 Exhaust overpressure A mbar 30 30 Exhaust gas overpressure, max. L mbar 100 100 Fuel temperature at engine inlet connection R °C 37 37 Fuel temperature at engine inlet connection, max (w/o power re‐ L duction) °C 65 65 12 16 0.35 0.35 CONSUMPTION Number of cylinders Lube oil consumption after 100 h runtime (B = hourly fuel con‐ sumption) R % of B MS150094/01E 2012-08 | Product Summary | 19 MODEL RELATED DATA (basic design) Number of cylinders 12 16 Number of cylinders 12 16 90 90 Cylinder arrangement: V angle Degrees (°) Bore mm 135 135 Stroke mm 156 156 Cylinder displacement Liters 2.233 2.233 Total displacement Liters 26.80 35.73 Inlet valves per cylinder 2 2 Exhaust valves per cylinder 2 2 12 16 COMBUSTION AIR / EXHAUST GAS Number of cylinders Charge-air pressure before cylinder R bar abs 3.95 3.80 Exhaust temperature after turbocharger R °C 390 390 12 16 COOLANT SYSTEM (HT circuit) Number of cylinders Coolant temperature (at engine connection: outlet to cooling equipment) A °C 100 100 Coolant temperature after engine, warning R °C 101 101 Coolant temperature after engine, shutdown L °C 104 104 Coolant antifreeze content, max. L % 50 50 Coolant pump: inlet pressure, max. L bar 1.3 1.3 Thermostat: Starts to open R °C 79 79 Thermostat: Fully open R °C 92 92 12 16 Number of cylinders Coolant antifreeze content, max. L % 50 50 Charge-air temperature after charge-air cooler, max. L °C 95 95 Thermostat: Starts to open R °C 38 38 Thermostat: Fully open R °C 51 51 12 16 LUBE OIL SYSTEM Number of cylinders Lube oil operating temperature before engine, from R °C 80 80 Lube oil operating temperature before engine, to R °C 103 103 Lube oil temperature before engine, alarm R °C 103 103 Lube oil temperature before engine, shutdown L °C 106 106 Lube oil operating pressure before engine, warning R bar 6.0 6.0 Lube oil operating pressure before engine, shutdown L bar 5.5 5.5 20 | Product Summary | MS150094/01E 2012-08 TIM-ID: 0000024846 - 002 COOLING SYSTEM (LT circuit) FUEL SYSTEM Number of cylinders 12 16 Fuel pressure at engine inlet connection, min. (when engine is starting) L bar -0.5 -0.5 Fuel pressure at engine inlet connection, min. (when engine is running), L bar -0.5 -0.5 Fuel pressure at engine inlet connection, max. (when engine is starting) L bar 0.5 0.5 12 16 32 32 12 16 GENERAL OPERATING DATA Number of cylinders Coolant preheating: preheating temperature (min.) R °C INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline) Number of cylinders Longitudinal inclination, continuous max. driving end down (Op‐ L tion: max. operating inclinations) Degrees (°) 15 15 Longitudinal inclination, continuous max. driving end up (Option: L max. operating inclinations) Degrees (°) 15 15 Transverse inclination, continuous max. (option: max. operating L inclinations) Degrees (°) 15 15 12 16 CAPACITIES Number of cylinders Engine coolant capacity, engine side (without cooling equip‐ ment) R Liters 63 70 Charge-air coolant, engine side R Liters 25 28 Total engine oil capacity at initial filling (standard oil system) (Option: max. operating inclinations) R Liters 103 127 Oil pan capacity at dipstick mark “min.” (standard oil system) (Option: max. operating inclinations) L Liters 79 97 Oil pan capacity at dipstick mark “max.” (standard oil system) (Option: max. operating inclinations) L Liters 86 106 12 16 ACOUSTICS TIM-ID: 0000024846 - 002 Number of cylinders Exhaust noise, unsilenced - BL (free-field sound pressure level Lp, 1m distance, ISO 6798, +3dB(A) tolerance) R dB(A) 106 107 Exhaust noise, unsilenced - BL (sound power level LW, ISO 6798+3 db(A) tolerance) R dB(A) 119 120 Engine surface noise with attenuated intake noise (filter) - BL (free-field sound power level Lp, 1 m distance, ISO 6798, +2dB(A) tolerance) R dB(A) 102 103 Engine surface noise with attenuated intake noise (filter) - BL (sound power level LW, ISO 6798+2dB(A) tolerance) R dB(A) 120 121 MS150094/01E 2012-08 | Product Summary | 21 3 Operation 3.1 Putting the engine into operation after extended out-ofservice periods (>3 months) Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Putting into operation after long out-of-service periods (>3 months) Action Engine Depreserve (→ MTU Fluids and Lubricants Specifications A001061/..). Lube oil system Check engine oil level (→ Page 69). Fuel system Connect appropriate equipment to fuel supply line to fill the system. Fuel system Vent (→ Page 56). Coolant circuit If engine is out of service for more than one year, change engine coolant (→ Page 80). Change charge-air coolant (→ Page 89). Coolant circuit Check engine coolant level (→ Page 79); Check charge-air coolant level (→ Page 88). Coolant circuit Preheat engine coolant with coolant preheating unit (if fitted). Engine governor Check plug-in connections (→ Page 108). Engine control system Switch on. TIM-ID: 0000010073 - 002 Item 22 | Operation | MS150094/01E 2012-08 3.2 Putting the engine into operation after scheduled out-ofservice-period Preconditions ☑ Engine is stopped and starting disabled. Putting into operation Action Lube oil system Check engine oil level (→ Page 69). Coolant circuit Check engine coolant level (→ Page 79), check charge-air coolant level (→ Page 88). Coolant circuit Preheat engine coolant with coolant preheating unit, if fitted. Fuel prefilter (if fitted) Drain water and contaminants, see manufacturer's documentation. Engine control system Switch on. TIM-ID: 0000010642 - 002 Item MS150094/01E 2012-08 | Operation | 23 3.3 Tasks after extended out-of-service periods (>3 weeks) Tasks after extended out-of-service periods (>3 weeks) Operate fuel treatment system for at least 5 minutes. Start up fuel treatment system (→ Page 26). Shut down fuel treatment system (→ Page 34). TIM-ID: 0000007730 - 005 Note: 1. 2. 24 | Operation | MS150094/01E 2012-08 3.4 Checks prior to start-up Checks prior to start-up 1. 2. 3. 4. 5. 6. Result: TIM-ID: 0000007736 - 005 7. Result: Check tank and the entire pipework for cleanness. If microorganisms are detected: a) Clean affected components. b) Disinfect affected components with biocides (→ MTU Fluids and Lubricants Specifications A001061/..). Close drain valves on housing. Open all supply and discharge valves. Switch on fuel treatment system (→ Page 29). Check direction of rotation of pump. Vent bypass and fuel lines of the system. a) Open ball valve for pressure tank. b) Open ball valve for overflow tank. c) Close ball valve at the inlet to the fuel treatment system. Bypass line is vented via the overflow tank. d) Open ball valve at the inlet to the fuel treatment system. Check the fuel treatment system for leaks. The fuel treatment system is ready for operation. MS150094/01E 2012-08 | Operation | 25 3.5 Fuel treatment system – Putting into operation Fuel treatment system – Overview 1. 2. Result: Switch on fuel treatment system (→ Page 29). Check the differential pressure at differential pressure gauge (8). Differential pressure in a new system: 0.1 bar to 0.3 bar. If no differential pressure is measured, the coalescer filter element is probably being bypassed. 1. Remove coalescer filter element (→ Page 103). 2. Check sealing faces on coalescer filter element and in the pressure tank. Initial operation: HAT Note: 2. 3. Result: 4. 5. 6. Note: 7. 8. Result: Replace fuel filter on engine (→ Page 58). Determine the suction pressure upstream of the engine-mounted fuel delivery pump. Install a pressure gauge in the fuel supply line from the shipyard-side fuel system to the engine. Switch on fuel treatment system and operate it for some minutes (→ Page 29). Fuel is sucked from the tank, dirt particles and water are filtered and separated, then the fuel is delivered via the overflow tank back to the tank. Water which has settled in the tank is separated. Start engine (→ Page 28). Run engine at idling speed. Check suction pressure (see technical data of the engine) at the engine-mounted fuel delivery pump. If the suction pressure is within the permissible limits and engine operation is satisfactory: Increase engine speed to 1000 rpm and monitor suction pressure. Check suction pressure at the engine-mounted fuel delivery pump. If the values are within the limits specified by the manufacturer, the system is ready to start filter replace‐ ment simulation with the engine running as part of the Harbor Acceptance Tests. 26 | Operation | MS150094/01E 2012-08 TIM-ID: 0000007738 - 005 1. Simulation of filter replacement with the engine running: HAT 1. 2. 3. 4. Result: 5. Result: 6. Note: 7. Result: Switch on fuel treatment system (→ Page 29). Start engine (→ Page 28). Run engine at idling speed. Close ball cock (5) at the inlet to the fuel treatment system. The pressure upstream of the fuel treatment system increases until the overflow valve at the pump unit opens and fuel flows through bypass (3) and bypass (2). Open ball cock (19). Fuel emerges. If no fuel emerges: • Open ball cock (5) at the inlet to the fuel treatment system. • No function of bypasses (2) and (3); carry out functional test of bypasses (2) and (3). Check suction pressure (see technical data of the engine) at the fuel delivery pump. If the suction pressure is within the permissible limits and engine operation is satisfactory: Increase engine speed to 1000 rpm and monitor suction pressure. If all engine operating values are within the specified limits, open ball cock (5) at the inlet to the fuel treat‐ ment4 system. Simulation of power failure (emergency): HAT 1. 2. 3. 4. Result: 5. Switch on fuel treatment system (→ Page 29). Start engine (→ Page 28). Run engine at idling speed. Switch off pump (21) on switch cabinet. The engine-mounted fuel delivery pump sucks fuel via bypass (2) directly from the tank. Check suction pressure at the engine-mounted fuel delivery pump. Note: 6. Result: If the suction pressure is within the permissible limits and engine operation is satisfactory. Increase engine speed to 1000 rpm and monitor suction pressure. If the suction pressure is within the specified limits, simulation was successful. Simulation of power failure (emergency): SAT Switch on fuel treatment system (→ Page 29). Start engine (→ Page 28). Run engine at idling speed. Switch off pump (21) on switch cabinet. The engine-mounted fuel delivery pump sucks fuel via bypass (2) directly from the tank. Check suction pressure at the engine-mounted fuel delivery pump. Note: 6. Result: If the suction pressure is within the permissible limits and engine operation is satisfactory: Operate engine at full load and monitor suction pressure. If the suction pressure is within the specified limits, simulation was successful. TIM-ID: 0000007738 - 005 1. 2. 3. 4. Result: 5. MS150094/01E 2012-08 | Operation | 27 3.6 Starting the engine Preconditions ☑ Engine is not connected to load. DANGER WARNING Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Before barring or starting the engine, make sure that nobody is in the danger zone. Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. TIM-ID: 0000010107 - 004 Start engine (For required operations, refer to the documentation of the vehicle/plant manufacturer). 28 | Operation | MS150094/01E 2012-08 3.7 Fuel treatment system – Switching on Preconditions ☑ The on-board power supply is switched on. CAUTION Damage to engine/plant. Major material damage! • Before switching on, ensure that the engine/plant is ready for operation. • Before switching on, ensure that all housings are closed. • Before switching on, ensure that no work is in progress anywhere on the entire system. Switching on fuel treatment system Carry out checks prior to start-up (→ Page 25). Switch on master switch on switch cabinet. Signal lamp “Control voltage present” lights up. Switch on switch for pump. Signal lamp “Pump running” lights up. TIM-ID: 0000007731 - 005 1. 2. Result: 3. Result: MS150094/01E 2012-08 | Operation | 29 3.8 Operational checks DANGER WARNING Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. Operational checks Item Action Control and display panels Check readings of operational data (speed, temperature, pressures). Engine oil Check engine oil level (→ Page 69). Engine operation Check engine visually for leaks and general condition; Check engine for abnormal running noises, exhaust color and vibra‐ tions. Check service indicator at air filter (if fitted), see manufacturer's docu‐ mentation. Exhaust system Check exhaust color (→ Page 38). Fuel prefilter (if fitted) Check reading at differential pressure gauge of fuel prefilter, see manu‐ facturer's documentation. Intercooler Check condensate drain(s) for water discharge and obstruction. Engine coolant pump Check relief bore (→ Page 84). Charge-air coolant pump Check relief bore (→ Page 93). TIM-ID: 0000025277 - 002 Air filter 30 | Operation | MS150094/01E 2012-08 3.9 Stopping the engine Preconditions ☑ Engine is not connected to load. CAUTION Stopping the engine when it is running at full load causes extreme stress to the engine. Risk of overheating, damage to components! • Before stopping the engine, operate it at idle speed until operating temperatures decrease and stable values are indicated. Preparation Item Action Engine Allow the engine to cool down by running idle for approx. 5 minutes. TIM-ID: 0000010138 - 004 Stop engine (For required operations, refer to the documentation of the vehicle/plant manufacturer). MS150094/01E 2012-08 | Operation | 31 3.10 Emergency stop CAUTION An emergency stop causes extreme stress to the engine. Risk of overheating, damage to components! • Initiate emergency stop only in emergency situations. Emergency stop Item Action Emergency stop pushbut‐ ton Press EMERGENCY STOP button. • Engine is stopped by disconnecting the power supply to the ECU; • Emergency air shutoff flaps close (if provided); • signalization (e.g. by horn, beacon) is activated. After emergency stop Item Action Switchgear cabinet, control Press pushbutton for alarm acknowledgment. panel etc. (depending on • Audible and visual signalization stops. manufacturer) Engine Manually open emergency air shutoff flaps (if provided). TIM-ID: 0000002307 - 002 • Engine is ready for starting. 32 | Operation | MS150094/01E 2012-08 3.11 After stopping the engine Preconditions ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Note: If freezing temperatures are to be expected: Coolant pressure sensors installed in vertical position may be damaged if the coolant does not contain antifreeze additive. After stopping the engine Item Action Coolant circuit Drain engine coolant (→ Page 81); Drain charge-air coolant (→ Page 92) if: • freezing temperatures are expected and 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 tempera‐ ture; • antifreeze concentration is 50 % and engine-room temperature is below -40 °C. Engine control system Switch off. TIM-ID: 0000002709 - 005 Air intake and exhaust sys‐ If the engine is to remain out of service for more than 1 week, seal the tem engine's air and exhaust sides. If the engine is to remain out of service for more than 1 month, carry out preservation (→ MTU Fluids and Lubricants Specifications A001061/..). MS150094/01E 2012-08 | Operation | 33 3.12 Fuel treatment system – Shutdown Shutting down fuel treatment system 1. TIM-ID: 0000007732 - 005 2. 3. 4. 5. Press the illuminated pushbutton "Water drain" on the switch cabinet until water discharge from the outlet stops. Switch off fuel treatment system. Close ball valve at the inlet to the fuel treatment system. Close ball valve at the outlet of the fuel treatment system. Open drain valve until pressure has escaped from fuel treatment system. 34 | Operation | MS150094/01E 2012-08 3.13 Plant cleaning Preconditions ☑ Engine is stopped and starting disabled. ☑ Operating voltage is not present. Special tools, Material, Spare parts Designation / Use Part No. Qty. Steam jet cleaner - 1 30390 1 Cleaner (Hakupur 312) WARNING WARNING CAUTION NOTICE Compressed air Risk of injury! • Do not direct compressed-air jet at persons. • Wear protective goggles / safety mask and ear protectors. Water jet. Risk of injury and scalding! • Do not direct water jet at persons. • Wear protective clothing, gloves, and goggles / safety mask. Excessive reaction time of cleaning agents on components. Damage to component! • Observe manufacturer's instructions. • Wear protective clothing, gloves, and goggles / safety mask. Dry with compressed air. Damage to component! • Never aim compressed air directly at electronic components. Plant cleaning 1. 2. TIM-ID: 0000010171 - 024 3. 4. 5. Note: Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental pro‐ tection). Prior to putting the cleaning unit into operation, read the Operating Instructions of the water/steam jet unit carefully and observe the safety precautions. During external cleaning of the plant with water/steam-jet units, 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. For external cleaning with high-pressure jet, use a flat-mouth nozzle only. Carry out external cleaning as follows: a) Seal all openings in a suitable fashion. 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. Never aim compressed air directly at electronic components. e) Dry engine. MS150094/01E 2012-08 | Operation | 35 4 Maintenance 4.1 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. Task Maintenance tasks W0500 Check engine oil level. (→ Page 69) W0501 Visually inspect engine for leaks and general condition. (→ Page 30) W0502 Check intercooler drain(s). (→ Page 30) W0503 Check signal ring position of service indicator on air filter. (→ Page 30) W0505 Check relief bores of water pump(s). (→ Page 30) W0506 Check engine for abnormal running noises, exhaust color and vibrations. (→ Page 30) W0507 Drain water and contaminants from fuel prefilter. (→ Page 30) W0508 Check reading on differential pressure gauge of fuel prefilter. (→ Page 30) W1001 Replace fuel filter or fuel filter element. (→ Page 58) W1003 Check drive belt condition and tension, replace if necessary. (→ Page 94) W1005 Replace air filter. (→ Page 65) W1006 Replace fuel injectors. (→ Page 48) W1008 Replace engine oil filter when changing engine oil, or when the interval (years) is reached, at the latest. (→ Page 71) W1009 Check layer thickness of the oil residue, clean out and re‐ place filter sleeve, at each oil change, at the latest. (→ Page 72) W1178 Replace pressure pipe neck in cylinder head. (→ Page 54) W1207 Check valve clearance, adjust if necessary. Attention!First adjustment after 1,000operating hours! (→ Page 44) W1244 Check function of rod electrode. (→ Page 101) W1245 Check alarm function of differential pressure gauge. (→ Page 100) W1246 Check pump capacity. (→ Page 102) W1523 Check operation of flaps and actuators. (→ Page 68) W1525 Replace NOx sensor. (→ Page 110) W1526 Replace Lambda sensor. (→ Page 110) W1547 Replace oil mist separator. (→ Page 43) W1636 Reset drift correction parameters (CDC) and enter coding of injectors (IIG). (→ Page 117) Table 1: Maintenance task reference table [QL1] 36 | Maintenance | MS150094/01E 2012-08 TIM-ID: 0000022887 - 003 The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule. 5 Troubleshooting 5.1 Fuel treatment system – Troubleshooting Illuminated pushbutton “Water alarm” is lit. Cause Corrective action When the maximum water level is reached, the water level elec‐ trode opens the water drain valve and water is discharged. If the opening period of the valve exceeds a preset limit (4 mi‐ nutes), the pump will switch off and an alarm is initiated. 1. Press illuminated pushbutton “Water alarm” to acknowledge. 2. In addition to the automatic water drain function, water can also be drained manually. To do so, press the illuminated pushbutton “Water drain” to open the drain valve. Signal lamp “Pump fault” is lit. Cause The drive motor is equipped with an overload protection. If the maximum permissible current consumption is exceeded, e.g. in case of a blockage or dry-run‐ ning, the motor protection relay triggers and the pump is switch‐ ed off. Corrective action u Reset motor protection relay. Signal lamp “Warning filter” is lit. Cause The differential pressure exceed‐ ed 1.3 bar. Corrective action u Replace coalescer filter element (→ Page 103). Illuminated pushbutton “Replace filter element” is lit. TIM-ID: 0000007734 - 006 Cause The max. permissible differential pressure of 1.5 bar was exceed‐ ed. If the coalescer filter element is not replaced, pressure will in‐ crease further and the safety valve will open. Fuel will be led via the bypass directly into the overflow tank. Corrective action 1. Replace coalescer filter element (→ Page 103). 2. Press illuminated pushbutton “Replace filter element” to ac‐ knowledge. MS150094/01E 2012-08 | Troubleshooting | 37 5.2 Troubleshooting Engine does not turn when starter is actuated Component Cause Action Battery Low or faulty Charge or replace (see manufacturer's documentation). Cable connections faulty Check if cable connections are proper‐ ly secured (see manufacturer's docu‐ mentation). Starter Engine cabling or starter faulty Check cable connections for secure seating ; contact Service. Engine wiring Faulty Check (→ Page 109). Engine governor Plug-in connections possibly loose Check plug-in connections (→ Page 108). Engine Running gear blocked (engine cannot be barred manually) Contact Service. Engine turns but does not fire Component Cause Action Starter Poor rotation by starter: Battery low or faulty Charge or replace battery (see manu‐ facturer's documentation). Engine wiring Faulty Check (→ Page 108). Fuel system Air in fuel system, if fault occurs after filling the system. Vent fuel system (→ Page 56). Engine governor Faulty Contact Service. Engine fires unevenly Component Cause Action Fuel injection equip‐ ment Injector faulty Replace (→ Page 48). Engine wiring Faulty Check (→ Page 109). Fuel system Air in fuel system, if fault occurs after filling the system. Vent fuel system (→ Page 56). Engine governor Faulty Contact Service. Component Cause Action Fuel supply Fuel prefilter (if fitted) clogged. Clean filter element (see manufactur‐ er's documentation). Fuel filter clogged Replace (→ Page 58). Air supply Air filter clogged Replace air filter (→ Page 65). Fuel injection equip‐ ment Injector faulty Replace (→ Page 48). Engine wiring Faulty Check (→ Page 109). Engine Overloaded Contact Service. 38 | Troubleshooting | MS150094/01E 2012-08 TIM-ID: 0000025278 - 001 Engine does not reach rated speed Engine speed not steady Component Cause Action Fuel injection equip‐ ment Injector faulty Replace (→ Page 48). Speed sensor Faulty Contact Service. Fuel system Air in fuel system, if fault occurs after filling the system. Vent fuel system (→ Page 56). Engine governor Faulty Contact Service. Charge-air temperature too high Component Cause Action Engine coolant Engine coolant treatment incorrect Check (MTU test kit). Intercooler Contaminated Contact Service. Engine room Air-intake temperature too high Check fan; check air inlet/outlet ducts. Charge-air pressure too low Component Cause Action Air supply Air filter clogged Replace air filter (see manufacturer's documentation). Intercooler Contaminated Contact Service. Exhaust turbocharger Faulty Contact Service. Coolant leaks at intercooler Component Cause Action Intercooler Leaking, major coolant discharge Contact Service. Component Cause Action Air supply Air filter clogged Replace air filter (see manufacturer's documentation). Fuel injection equip‐ ment Injector faulty Replace (→ Page 48). Engine Overloaded Contact Service. Component Cause Action Engine oil Too much oil in engine Drain engine oil (→ Page 70). Oil mist fine separator of crankcase breather clogged Replace (→ Page 43). Black exhaust gas TIM-ID: 0000025278 - 001 Blue exhaust gas Exhaust turbocharger Faulty Contact Service. Cylinder head Piston rings Cylinder liner MS150094/01E 2012-08 | Troubleshooting | 39 White exhaust gas Component Cause Action Engine Not at operating temperature Run engine to reach operating temper‐ ature. Fuel system Water in fuel Check fuel system at fuel prefilter Drain fuel prefilter (→ Page 60). Leaking Contact Service. TIM-ID: 0000025278 - 001 Intercooler 40 | Troubleshooting | MS150094/01E 2012-08 6 Task Description 6.1 Engine 6.1.1 Engine – Barring manually Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use DANGER Part No. Qty. Barring tool F6783914 1 Ratchet F30006212 1 Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Before barring or starting the engine, ensure that nobody is in the danger zone. • After working on the engine, check that all protective devices have been reinstalled and all tools removed from the engine. Engine – Barring manually 1. 2. TIM-ID: 0000002527 - 002 Result: Fit ratchet with barring tool on barring tool connection at the vibration damper on engine free end. Rotate crankshaft in engine direction of rotation. Apart from the normal compression resistance, there should be no resistance. If the resistance exceeds the normal compression resistance, contact Service. MS150094/01E 2012-08 | Task Description | 41 6.1.2 DANGER Engine – Barring with starting system Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Before barring or starting the engine, ensure that nobody is in the danger zone. • After working on the engine, check that all protective devices have been reinstalled and all tools removed from the engine. Engine – Barring with starting system Bar engine, preventing it from firing, see documentation of vehicle/plant manufacturer. Do not actuate starter for more than 10 seconds. Repeat this procedure after approx. 20 seconds if required. TIM-ID: 0000010695 - 002 1. 2. 3. 42 | Task Description | MS150094/01E 2012-08 6.2 Crankcase Breather 6.2.1 Crankcase breather – Oil mist fine separator replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use WARNING Part No. Engine oil Oil mist fine separator (→ Spare Parts Catalog) O-ring (→ Spare Parts Catalog) Qty. Hot oil. Oil can contain combustion residues which are harmful to health. Risk of injury and poisoning! • Wear protective clothing, gloves, and goggles / safety mask. • Avoid contact with skin. • Do not inhale oil vapor. Replacing oil mist fine separator 1. TIM-ID: 0000018590 - 005 2. 3. 4. Loosen screws (1) and remove together with retainer (2). Replace oil mist fine separator (3). Check O-ring (4), replace if necessary. Replace further oil mist fine separators in the same way. MS150094/01E 2012-08 | Task Description | 43 6.3 Valve Drive 6.3.1 Valve clearance – Check and adjustment Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine coolant temperature is max. 40 °C. ☑ Valves are closed. Special tools, Material, Spare parts Designation / Use WARNING Part No. Qty. Feeler gauge Y4345893 1 Barring device F6783914 1 Ratchet F30006212 1 Double-head box wrench F30002800 1 Ring socket, 19 mm F30038493 1 Torque wrench, 10-60 Nm F30510423 1 Valve gear is moving. Risk of crushing! • Keep hands clear of the danger zone when barring the engine. Preparatory steps u Remove cylinder head cover (→ Page 47). Positioning A1 piston at TDC Install barring device. Release plug screw (1) and remove. Using ratchet and barring device, rotate crankshaft in engine direction of rotation un‐ til the bore (2) on the flywheel is visible in the center of the exposed opening. TIM-ID: 0000023895 - 003 1. 2. 3. 44 | Task Description | MS150094/01E 2012-08 Checking valve clearance at two crankshaft positions 1. 2. 3. Check TDC position of piston in cylinder A1: • If the rocker arms are unloaded on cylinder A1, the piston is in firing TDC. • If the rocker arms are loaded on cylinder A1, the piston is in overlap TDC. Check valve clearance with cold engine: • Inlet (E) = 0.3 mm; • Exhaust (A) = 0.4 mm. Check all valve clearances at two crankshaft positions (firing TDC and overlap TDC) according to the table below. 12 V 2000 Position Cylinder 1 2 3 4 5 6 Firing TDC in cylinder A1 Bank A EA E- -A E- -A -- Bank B E- -- -A E- EA -A Bank A -- -A E- -A E- EA Bank B -A EA E- -A -- E- Overlap TDC in cylinder A1 7 8 “E” = inlet valve clearance adjustment permitted, “A” = exhaust valve clearance adjustment permitted 16 V 2000 Position Cylinder 1 2 3 4 5 6 Firing TDC in cylinder A1 Bank A E A - A E A E - -A E - - - Bank B E - - A - - - - E A E - EA - Bank A - - E - - - - A E - -A EA E A Bank B -A E - E A E A - - -A -- Overlap TDC in cylinder A1 7 8 - A E- “E” = inlet valve clearance adjustment permitted, “A” = exhaust valve clearance adjustment permitted 4. 5. Use feeler gauge to determine the distance between valve bridge and rocker arm. If the deviation from the reference value exceeds 0.1 mm, adjust valve clearance. Valve clearance adjustment 1. 2. TIM-ID: 0000023895 - 003 3. Loosen locknut (1) and unscrew adjusting screw (2) by a few threads. Insert feeler gauge between valve bridge and rocker arm. Readjust adjusting screw (2) so that the feeler gauge just passes through the gap. MS150094/01E 2012-08 | Task Description | 45 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 Locknut 5. Result: Type Tightening torque Lubricant Value/Standard 50 Nm +5 Nm Insert feeler gauge between valve bridge and rocker arm to verify that the gauge just passes through the gap. If not, adjust valve clearance again. Final steps Insert plug screw and tighten. Remove barring device. Install cylinder head cover (→ Page 47). TIM-ID: 0000023895 - 003 1. 2. 3. 46 | Task Description | MS150094/01E 2012-08 6.3.2 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 F30043446 1 Ratchet F30027340 1 Gasket (→ Spare Parts Catalog) Preparatory steps 1. 2. On cylinder head covers with crankcase breather: Loosen clamps. Slide rubber sleeves onto the pipe. Cylinder head cover – Removal and installation 1. 2. 3. 4. 5. Remove cylinder head cover with gasket from cylinder head. Clean installation surface. Check condition of gasket in cylinder head cover. Replace damaged gasket(s). Install cylinder head cover with screws. Final steps Slide rubber sleeves onto the relevant pipe connection. Tighten all clamps. TIM-ID: 0000000019 - 003 1. 2. MS150094/01E 2012-08 | Task Description | 47 6.4 Injection Valve / Injector 6.4.1 Injector – Replacement Special tools, Material, Spare parts Designation / Use Injector Part No. Qty. (→ Spare Parts Catalog) Replacing injector Remove injector and install new injector (→ Page 49). TIM-ID: 0000000022 - 013 u 48 | Task Description | MS150094/01E 2012-08 6.4.2 Injector – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Installation device F6790085 1 Puller F6790636 1 Fuel suction device F30378207 1 Torque wrench, 0.5-5 Nm 0015384230 1 Torque wrench, 20-100 Nm F30026582 1 Ratchet F30027340 1 Adapter F30006234 1 Open-end socket wrench, 19 mm F30453236 1 Crowfoot wrench, 19 mm F30027424 1 Crowfoot wrench, 22 mm F30027425 1 Double-head box wrench F30011450 1 Open-end socket wrench, 24 mm F30453238 1 Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 1 Engine oil Sealing ring WARNING WARNING (→ Spare Parts Catalog) Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Compressed air Risk of injury! • Do not direct compressed-air jet at persons. • Wear protective goggles / safety mask and ear protectors. TIM-ID: 0000023980 - 002 Preparatory steps 1. 2. 3. Shut off fuel supply line. Drain fuel (→ Page 57). Remove cylinder head cover (→ Page 47). MS150094/01E 2012-08 | Task Description | 49 Removing injector 1. 2. 3. 4. Remove fuel line (1). Unscrew union nut (2). Pull out pressure pipe neck (3). Extract fuel from the exposed bores using the suction device. 5. 6. Disconnect terminals (arrow) on injector and pull out cable lugs. Remove gasket. 7. Remove screw (3). Screw (3) may be installed only once. Take off hold-down clamp (2). Use the puller to pull out injector (1). After removal, seal all openings with suita‐ ble covers. TIM-ID: 0000023980 - 002 Note: 8. 9. 10. 50 | Task Description | MS150094/01E 2012-08 Installing injector 1. 2. 3. Note: 4. 5. Remove all covers before installation. Clean sealing surface on cylinder head and protective sleeve. Coat sealing ring on injector (1) with grease. Use either the installation tool or the holddown clamp to press injector (1) into the cylinder head. Align square on injector (1) with the seat in the hold-down clamp (2) and insert injector by hand straight into the cylinder head. Place hold-down clamp (2) in position by hand, ensuring the position is correct. Installation without installation device 1. 2. Screw in new screw (3) and press injector (1) carefully into the cylinder head by tightening screw (3). Name Size Type Screw M8 Preload torque Lubricant Value/Standard 2 Nm +2 Nm Release screw (3) again and relieve hold-down clamp. Installation with installation device 1. 2. Place installation tool on hold-down clamp to press injector (1) carefully into the cylinder head. Place clamping piece (2) in correct position, screw in screw (3) and tighten snug-fit. Installing pressure pipe neck 1. 2. 3. 4. 5. TIM-ID: 0000023980 - 002 6. 7. Blow out fuel line (1) and pressure pipe neck (3) with compressed air. Coat sealing ring with grease. Coat sealing cone of pressure pipe neck (3) with engine oil. Slide pressure pipe neck (3) into cylinder head until it makes contact with the sealing ring. Press in pressure pipe neck (3) by hand un‐ til it will not go any further. Align HP connection of injector with pres‐ sure pipe neck (3). Coat thread and shoulder of union nut (2) with engine oil and tighten with torque wrench to the specified tightening torque. Name Union nut Size Type Lubricant Value/Standard Preload torque (Engine oil) 15 Nm + 5 Nm MS150094/01E 2012-08 | Task Description | 51 9. Use torque wrench to tighten screw (3) for hold-down clamp (2) to the specified tightening torque. Name Size Type Lubricant Value/Standard Screw M8 Tightening torque (Engine oil) 40 Nm +4 Nm Tighten union nut (2) on pressure pipe neck with torque wrench to the specified tightening torque. Name Size Union nut Type Lubricant Tightening torque Value/Standard 45 Nm +5 Nm Installing fuel line 1. Coat thread and shoulder of union nuts on fuel line (1) with engine oil. Note: 2. Position fuel line, ensuring it is free of tension. Position fuel line (1) so that the union nut with the torque specification faces the fuel rail and the end without torque specification faces the pressure pipe neck (2), and tighten snug-fit. 3. Tighten union nut of fuel line (1) on fuel rail to the specified tightening torque using a torque wrench. Name Size Union nut 52 | Task Description | MS150094/01E 2012-08 Type Lubricant Value/Standard Tightening torque (Engine oil) 45 Nm +5 Nm TIM-ID: 0000023980 - 002 8. 4. Tighten union nut of fuel line (1) on pressure pipe neck (2) to the specified tightening torque using a tor‐ que wrench. Name Size Union nut Type Lubricant Value/Standard Tightening torque (Engine oil) 37 Nm +3 Nm Fitting gasket and connecting injector cable 1. Place gasket on cylinder head, ensuring correct installation position. 2. Push cable lugs under the terminals (arrow) on the injector and tighten with torque wrench to the speci‐ fied tightening torque. Name Size Type Lubricant Value/Standard Nut M4 Tightening torque (Engine oil) 1.5 Nm ±0.25 Nm Final steps Install cylinder head cover (→ Page 47). Open fuel supply line. Vent fuel system (→ Page 56). TIM-ID: 0000023980 - 002 1. 2. 3. MS150094/01E 2012-08 | Task Description | 53 6.5 Fuel System 6.5.1 HP fuel line and pressure pipe neck – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use WARNING Part No. Qty. Torque wrench, 20-100 Nm F30026582 1 Ratchet adapter F30027340 1 Adapter F30006234 1 Socket wrench, 19 mm F30025897 1 Crowfoot wrench, 19 mm F30027424 1 Crowfoot wrench, 22 mm F30027425 1 Double box wrench F30011450 1 Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 1 Engine oil Pressure pipe neck (→ Spare Parts Catalog) HP fuel line (→ Spare Parts Catalog) Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Preparatory steps Shut off fuel supply line. Drain fuel (→ Page 57). TIM-ID: 0000012538 - 001 1. 2. 54 | Task Description | MS150094/01E 2012-08 HP fuel line and pressure pipe neck – Replacement 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Remove leak-off fuel line from cylinder head. Remove HP fuel line (2). Remove thrust screw (4). Withdraw pressure pipe neck (5). Coat sealing ring of new pressure pipe neck with grease. Coat sealing cone of pressure pipe neck with engine oil. Insert pressure pipe neck into cylinder head until it is in contact with the sealing ring. Fully press in pressure pipe neck by hand. Tighten thrust screw (4) to specified torque 40 Nm ±5 Nm using torque wrench. Coat mating face between union nut and HP fuel line, ball seal and thread on both ends of the new HP fuel line (2) with engine oil. Install new HP fuel line (2). Observe marking on union nut (1). • Use torque wrench to tighten union nut (1) with marking “35+3 Nm” to speci‐ fied tightening torque 35 Nm +3 Nm. • Tighten union nut (1) without marking to specified torque 30 Nm +5 Nm. Observe marking on union nut (3). • Use torque wrench to tighten union nut (3) with marking “35+3 Nm” to speci‐ fied tightening torque 35 Nm +3 Nm. • Tighten union nut (3) without marking to specified torque 25 Nm +3 Nm. Install leak-off fuel line on cylinder head. Final steps Open fuel supply. Vent fuel system (→ Page 56). TIM-ID: 0000012538 - 001 1. 2. MS150094/01E 2012-08 | Task Description | 55 6.5.2 Fuel system – Venting Preconditions ☑ Engine is not connected to load. Fuel system – Venting The fuel system can only be vented with the engine running. Start engine (→ Page 28). Operate the engine until it runs smoothly. TIM-ID: 0000012554 - 002 Note: 1. 2. 56 | Task Description | MS150094/01E 2012-08 6.5.3 Fuel – Draining Preconditions ☑ Engine is stopped and starting disabled. WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Fuel – Draining Provide a suitable container in which to collect the fuel. Remove fuel filter (→ Page 58). Catch fuel as it runs out. Install fuel filter (→ Page 58). TIM-ID: 0000004702 - 002 1. 2. 3. 4. MS150094/01E 2012-08 | Task Description | 57 6.6 Fuel Filter 6.6.1 Fuel filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Filter wrench Diesel fuel Easy-change filter WARNING Part No. Qty. F30379104 1 (→ Spare Parts Catalog) Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Fuel filter – Replacement 1. 2. 3. 4. 5. TIM-ID: 0000012700 - 002 6. 7. Remove easy-change filter using the filter wrench. Clean sealing surface on filter head. Check sealing ring of the new easy-change filter and moisten it with fuel. Fill the new easy-change filter with clean fuel. Screw on easy-change filter and tighten hand-tight. Replace further fuel filters in the same way. Vent fuel system (→ Page 56). 58 | Task Description | MS150094/01E 2012-08 6.6.2 DANGER WARNING Fuel prefilter – Differential pressure check and adjustment of gauge Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. Differential pressure gauge adjustment 1. 2. When installing the new filter element: align adjustable pointer (2) with pressure-indicat‐ ing pointer (3) of pressure gauge (1). Verify that differential pressure is within the limit. Fuel prefilter – Checking differential pressure With the engine running at full load or rated power, read off pressure at gauge (1). If differential pressure as indicated between position of adjustable pointer (2) and pressure indicator of pressure gauge (3) is ≥ 0.3 bar, flush filter element of the cut-in filter (→ Page 61). TIM-ID: 0000004926 - 003 1. 2. MS150094/01E 2012-08 | Task Description | 59 6.6.3 Fuel prefilter – Draining Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Diesel fuel Seal WARNING Part No. Qty. (→ Spare Parts Catalog) Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. 1. Cut out the filter to be drained. I Left filter cut in II Right filter cut in 2. Open threaded vent plug (5) of the filter to be drained. Unlock drain valve (6) by pressing toggle and open it. Drain water and contaminants from the filter until pure fuel emerges. Close drain valve (6). Remove screws securing the cover and take off cover (2). Fill filter housing with clean fuel. Place new seal in cover (2). Fit cover with gasket and secure it with screws. Cut in the cut-out filter again. Close threaded vent plug (5) when fuel emerges from system. 3. 4. 5. 6. 7. 8. 9. 10. 11. 60 | Task Description | MS150094/01E 2012-08 TIM-ID: 0000004933 - 004 Fuel prefilter – Draining 6.6.4 Fuel prefilter ‒ Flushing Special tools, Material, Spare parts Designation / Use Part No. Fuel Gasket DANGER WARNING WARNING Qty. (→ Spare Parts Catalog) Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. Fuel prefilter ‒ Flushing Cut out clogged filter. I Left filter cut in II Right filter cut in TIM-ID: 0000004937 - 015 1. MS150094/01E 2012-08 | Task Description | 61 2. 3. Result: 4. Open threaded vent plug (5) of filter to be flushed. Unlock drain valve (6) by pressing valve toggle, open it and drain fuel. Fuel flows from filtered side back to the un‐ filtered side, flushing the filter deposits downwards out of the filter. Close threaded vent plug (5) and drain valve (6). Fuel prefilter – Topping up with fuel Stop engine (→ Page 31) and disable engine start. Remove screws for cover and take off cover (2). Fill filter housing with clean fuel. Place new gasket in cover (2). Fit cover with gasket and secure it with screws. Check differential pressure (→ Page 59). If flushing did not lead to an improvement of the differential pressure, replace filter element of fuel prefil‐ ter (→ Page 63). TIM-ID: 0000004937 - 015 1. 2. 3. 4. 5. 6. Result: 62 | Task Description | MS150094/01E 2012-08 6.6.5 Fuel prefilter – Filter element replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use WARNING Part No. Diesel fuel Filter element (→ Spare Parts Catalog) Seal (→ Spare Parts Catalog) Qty. Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Replacing filter element Cut out the contaminated filter. I Left filter cut in II Right filter cut in TIM-ID: 0000004946 - 004 1. MS150094/01E 2012-08 | Task Description | 63 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. TIM-ID: 0000004946 - 004 14. Open threaded vent plug (5) of contaminat‐ ed filter. Unlock drain valve (6) by pressing toggle and open it. Drain water and contaminants from the fil‐ ter. Close drain valve (6). Remove screws securing the cover and take off cover (2). Remove spring housing (4) and filter ele‐ ment (3). Insert new filter element (3) and spring housing (4). Fill filter housing with clean fuel. Place new seal in cover (2). Fit cover with gasket and secure it with screws. Cut in the cut-out filter again. Close threaded vent plug (5) when fuel emerges. Set adjustable pointer of differential pres‐ sure gauge (→ Page 59). 64 | Task Description | MS150094/01E 2012-08 6.7 Air Filter 6.7.1 Air filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. TIM-ID: 0000013387 - 003 For air filter replacement, carry out operations as specified by the manufacturer – filter is plant/vehicle manufacturer's supply. MS150094/01E 2012-08 | Task Description | 65 6.8 Air Intake 6.8.1 Service indicator – Check TIM-ID: 0000005482 - 003 See manufacturer's documentation. 66 | Task Description | MS150094/01E 2012-08 6.9 Exhaust Gas Recirculation Exhaust gas recirculation flaps – Overview TIM-ID: 0000024288 - 001 6.9.1 MS150094/01E 2012-08 | Task Description | 67 6.9.2 Exhaust gas circulation - Checking flap operation Preconditions ☑ Engine is stopped and starting disabled. WARNING Component is hot. Risk of burning! • Wear protective gloves. Checking exhaust flap operation 1. For installation position of exhaust flaps, refer to overview (→ Page 67). 2. Check operability and ease of movement of exhaust flaps and control linkage by moving the assembly at the points (arrowed) shown in the illustration. If exhaust flap is jammed or sluggish:Con‐ tact Service. TIM-ID: 0000024000 - 001 Result: 68 | Task Description | MS150094/01E 2012-08 6.10 Lube Oil System, Lube Oil Circuit 6.10.1 Engine oil – Level check Preconditions ☑ Engine is stopped and starting disabled. Oil level check prior to engine start 1. 2. 3. 4. 5. Withdraw oil dipstick from guide tube and wipe it. Insert oil dipstick into guide tube up to the stop, withdraw after approx. 10 seconds and check oil level. Oil level must be between "min." and "max." marks. Top up to "max." if required (→ Page 70). Insert oil dipstick into guide tube up to the stop. Oil level check after the engine is stopped 5 minutes after stopping the engine, remove oil dipstick from the guide tube and wipe it. Insert oil dipstick into guide tube up to the stop, withdraw after approx. 10 seconds and check oil level. Oil level must be between “min.” and "max." marks. Top up to "max." if required (→ Page 70). Insert oil dipstick into guide tube up to the stop. TIM-ID: 0000000032 - 002 1. 2. 3. 4. 5. MS150094/01E 2012-08 | Task Description | 69 6.10.2 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 Engine oil Sealing ring WARNING Part No. Qty. (→ Spare Parts Catalog) Hot oil. Oil can contain combustion residues which are harmful to health. Risk of injury and poisoning! • Wear protective clothing, gloves, and goggles / safety mask. • Avoid contact with skin. • Do not inhale oil vapor. Oil change without semirotary hand pump: Draining oil at drain plug on oil pan 1. 2. 3. 4. Provide a suitable container to collect the oil. Remove drain plug and drain oil. Install drain plug with new sealing ring. Replace engine oil filter (→ Page 71). Oil change with semirotary hand pump: Oil extraction 1. 2. 3. Provide a suitable container to collect the oil. Extract all oil from oil pan using the semirotary hand pump. Replace engine oil filter (→ Page 71). Filling with new oil 1. 2. TIM-ID: 0000000031 - 005 3. 4. 5. Open cover on filler neck. Pour oil in at filler neck up to "max." mark at oil dipstick. Close cover on filler neck. Check engine oil level (→ Page 69). After oil change and filter replacement, bar engine with starting system (→ Page 42). 70 | Task Description | MS150094/01E 2012-08 6.11 Oil Filtration / Cooling 6.11.1 Engine oil filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Filter wrench Engine oil Oil filter WARNING Part No. Qty. F30379104 1 (→ Spare Parts Catalog) Hot oil. Oil can contain combustion residues which are harmful to health. Risk of injury and poisoning! • Wear protective clothing, gloves, and goggles / safety mask. • Avoid contact with skin. • Do not inhale oil vapor. Engine oil filter – Replacement 1. 2. 3. 4. 5. 6. TIM-ID: 0000014212 - 002 7. Remove oil filter with filter wrench. Clean the sealing surface on the oil filter housing. Check condition of the new sealing ring and coat it with oil. Screw on oil filter and tighten hand-tight. Replace other oil filters in the same way. After each oil change and filter replace‐ ment, bar engine with starting system (→ Page 42). Check oil level (→ Page 69). MS150094/01E 2012-08 | Task Description | 71 6.11.2 Centrifugal oil filter – Cleaning and filter sleeve replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use WARNING Qty. Torque wrench, 6-50 Nm F30027336 1 Cold cleaner (Hakutex 60) X00056750 1 Filter sleeve (→ Spare Parts Catalog) Sealing ring (→ Spare Parts Catalog) Sealing ring (→ Spare Parts Catalog) Hot oil. Oil can contain combustion residues which are harmful to health. Risk of injury and poisoning! • Wear protective clothing, gloves, and goggles / safety mask. • Avoid contact with skin. • Do not inhale oil vapor. Compressed air Risk of injury! • Do not direct compressed-air jet at persons. • Wear protective goggles / safety mask and ear protectors. TIM-ID: 0000000934 - 008 WARNING Part No. 72 | Task Description | MS150094/01E 2012-08 Centrifugal oil filter cleaning and filter sleeve replacement 1. 2. 16. Remove clamp (14). Release cover screw (2) and take off cov‐ er (1). Carefully lift rotor (11), allow oil to drain and remove from housing. Holding the rotor (11) firmly, release rotor cover nut (3). Take off rotor cover (4). Remove filter sleeve (6). Measure thickness of oil residues on filter sleeve (6). If maximum layer thickness of oil residues exceeds 45 mm, shorten maintenance in‐ terval. Disassemble rotor tube (7), conical disk (8) and rotor base (10). Wash rotor cover (4), rotor tube (7), conical disk (8) and rotor base (10) with cold clean‐ er. Blow out with compressed air. Check sealing ring (9), fit new one if neces‐ sary. Assemble rotor tube (7), conical disk (8) and rotor base (10) with sealing ring (9). Insert new filter sleeve (6) in rotor tube (7) with the smooth paper surface facing the outer wall. Check sealing ring (5), fit new one if neces‐ sary. Mount rotor cover (4) with sealing ring (5). 17. Tighten rotor cover nut (3) with torque wrench to the specified torque. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Name Size Nut Lubricant Tightening torque Place rotor (11) in housing (12) and check for ease of movement. Check sealing ring (13), fit new one if necessary. Fit sealing ring (13) on housing (12). Fit cover (1). Fit cover screw (2) by hand. 23. Install clamp (14) and tighten with torque wrench to the specified torque. Size Clamp 24. Type Value/Standard 35 Nm to 45 Nm 18. 19. 20. 21. 22. Name TIM-ID: 0000000934 - 008 Type Lubricant Tightening torque Value/Standard 8 Nm to 10 Nm Tighten cover nut (2) with torque wrench to the specified torque. Name Screw Size Type Tightening torque Lubricant Value/Standard 5 Nm to 7 Nm MS150094/01E 2012-08 | Task Description | 73 6.12 Coolant Circuit, General, High-Temperature Circuit 6.12.1 Drain and vent points 12 V, 16 V TIM-ID: 0000025286 - 001 1 Engine coolant vent 74 | Task Description | MS150094/01E 2012-08 Left side 2 Oil drain plug 3 Engine coolant drain plug TIM-ID: 0000025286 - 001 1 Engine coolant drain plug MS150094/01E 2012-08 | Task Description | 75 Right side 3 Oil drain plug 4 Engine coolant drain plug TIM-ID: 0000025286 - 001 1 Engine coolant drain plug 2 Engine coolant drain plug 76 | Task Description | MS150094/01E 2012-08 Driving end (KS) TIM-ID: 0000025286 - 001 1 Oil drain plug MS150094/01E 2012-08 | Task Description | 77 Free end (KGS) 3 Oil drain plug 4 Engine coolant drain plug TIM-ID: 0000025286 - 001 1 Oil drain plug 2 Engine coolant filling plug 78 | Task Description | MS150094/01E 2012-08 6.12.2 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. 2. 3. 4. 5. 6. Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to escape. Continue to turn breather valve counter‐ clockwise and remove. Check coolant level (coolant must be visible at the lower edge of the cast-in eye or at the marking plate). Top up with treated coolant as necessary (→ Page 82). Check and clean breather valve. Place breather valve on filler neck and close. Coolant-level check by means of level sensor: Switch on engine control system and check readings on the display. Top up with treated coolant as necessary (→ Page 82). TIM-ID: 0000000037 - 004 1. 2. MS150094/01E 2012-08 | Task Description | 79 6.12.3 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant – Change Drain engine coolant (→ Page 81). Fill with engine coolant (→ Page 82). TIM-ID: 0000000036 - 030 1. 2. 80 | Task Description | MS150094/01E 2012-08 6.12.4 Engine coolant – Draining Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Sealing rings WARNING Qty. (→ Spare Parts Catalog) 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 – Draining 1. 2. 3. 4. 5. 6. 7. 8. 9. Drain engine coolant: • At the engine coolant pump elbow; • At the crankcase, left and right sides; • At the thermostat housing. Close all drain valves and install drain plugs with new sealing rings. Set breather valve onto filler neck and close it. TIM-ID: 0000014583 - 001 10. Provide an appropriate container to drain the coolant into. Switch off preheating unit, if fitted. Turn breather valve of filler neck on coolant expansion tank counterclockwise to first stop and allow pressure to escape. Continue to turn breather valve counter‐ clockwise and remove. Draw off precipitated corrosion inhibitor oil from the expansion tank through filler neck. Open drain plug at drain point in coolant line to engine coolant cooler and drain cool‐ ant. Draining of residual coolant: • At the preheating unit, if fitted. MS150094/01E 2012-08 | Task Description | 81 6.12.5 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 WARNING CAUTION Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask. Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. Cold coolant in hot engine can cause thermal stress. Formation of cracks in components! • Fill / top up coolant only into cold engine. Preparatory steps 2. Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to escape. Continue to turn breather valve counter‐ clockwise and remove. Engine coolant – Filling 1. 2. 3. Fill coolant through filler neck on expansion tank or through filling line until coolant level reaches lower edge of cast-in eye or marking plate. Check proper condition of breather valve, clean sealing faces if required. Fit breather valve and close it. 82 | Task Description | MS150094/01E 2012-08 TIM-ID: 0000000034 - 005 1. Final steps Start the engine and operate it at idle speed for some minutes. Check coolant level (→ Page 79), top up with coolant if required. TIM-ID: 0000000034 - 005 1. 2. MS150094/01E 2012-08 | Task Description | 83 6.12.6 DANGER WARNING Engine coolant pump – Relief bore check Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. Engine coolant pump – Relief bore check 1. Result: TIM-ID: 0000025150 - 001 2. Check relief bore for oil and coolant dis‐ charge. • Permissible coolant discharge: up to 10 drops per hour; • Permissible oil discharge: up to 5 drops per hour. If discharge exceeds the specified limits, contact Service. If relief bore is dirty: • Stop engine (→ Page 31) and disable en‐ gine start. • Clean relief bore with a wire. 84 | Task Description | MS150094/01E 2012-08 6.12.7 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 MTU test kit WARNING Part No. Qty. 5605892099/00 1 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. 2. 3. 4. 5. TIM-ID: 0000014607 - 002 6. 7. Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to escape. Continue to turn breather valve counterclockwise and remove. Draw off precipitated corrosion inhibitor oil from expansion tank and dispose of oil. Draw off approx. 1 liter coolant and drain into a clean container. Using the equipment and chemicals from the MTU test kit, examine coolant for: • antifreeze concentration; • corrosion inhibitor concentration; • pH value. Fit breather valve and close it. Engine coolant change intervals (→ MTU Fluids and Lubricants Specifications A001061/..). MS150094/01E 2012-08 | Task Description | 85 6.12.8 Coolant filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Oil filter wrench Coolant filter WARNING Part No. Qty. F30379104 1 (→ Spare Parts Catalog) Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask. Coolant filter – Replacement 1. 2. 3. 4. 5. TIM-ID: 0000006921 - 004 6. 7. 8. Turn breather valve of coolant expansion tank counterclockwise (→ Page 14) to the first stop and allow pressure to escape. Continue to turn breather valve counter‐ clockwise and remove. Remove coolant filter using the oil filter wrench. Clean the sealing face on the adapter. Coat sealing ring of the new coolant filter with engine oil. Install and tighten coolant filter by hand. Close breather valve. Check coolant level (→ Page 79). 86 | Task Description | MS150094/01E 2012-08 6.13 Low-Temperature Circuit 6.13.1 Intercooler – Vent and drain points 12 V, 16 V TIM-ID: 0000025297 - 002 1 Intercooler vent plugs MS150094/01E 2012-08 | Task Description | 87 6.13.2 Charge-air 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 charge-air coolant level at filler neck: 1. 2. 3. 4. 5. 6. Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to escape. Continue to turn breather valve counter‐ clockwise and remove. Check coolant level (coolant must be visible at marking plate). Top up coolant if necessary (→ Page 90). Check proper condition of breather valve, clean sealing faces if required. Fit breather valve and close it. Checking charge-air coolant level by means of level sensor: 1. TIM-ID: 0000000042 - 007 2. Switch on engine control system and check display (coolant level is automatically monitored by engine control system). Top up coolant if necessary (→ Page 90). 88 | Task Description | MS150094/01E 2012-08 6.13.3 Charge-air coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Charge-air coolant – Change Drain charge-air coolant (→ Page 92). Fill with charge-air coolant (→ Page 90). TIM-ID: 0000000041 - 011 1. 2. MS150094/01E 2012-08 | Task Description | 89 6.13.4 Charge-air coolant – Filling Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Coolant Sealing ring WARNING WARNING CAUTION Part No. Qty. (→ Spare Parts Catalog) 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 noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. Cold coolant in hot engine can cause thermal stress. Formation of cracks in components! • Fill / top up coolant only into cold engine. Preparatory steps 1. 2. TIM-ID: 0000000039 - 003 3. Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to escape. Continue to turn breather valve counter‐ clockwise and remove. Remove plug screw from filling point on coolant line to intercooler. 90 | Task Description | MS150094/01E 2012-08 Charge-air coolant – Filling 1. 2. 3. 4. Fill treated coolant through filling line or through filler neck of coolant expansion tank until coolant level reaches marking plate. Install plug screws of filling points with new sealing rings. Check proper condition of breather valve, clean sealing faces if required. Fit breather valve and close it. Final steps Start the engine and operate it at idle speed for some minutes. Check coolant level (→ Page 88). TIM-ID: 0000000039 - 003 1. 2. MS150094/01E 2012-08 | Task Description | 91 6.13.5 Charge-air coolant – Draining Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use WARNING Part No. Sealing ring (→ Spare Parts Catalog) Sealing ring (→ Spare Parts Catalog) Qty. Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask. Charge-air coolant – Draining 1. 2. 3. 4. 5. TIM-ID: 0000000040 - 002 6. 7. Provide an appropriate container to drain the coolant into. Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to escape. Continue to turn breather valve counter‐ clockwise and remove. Draw off precipitated corrosion inhibitor oil from the expansion tank through filler neck. Open drain plugs and drain coolant at the following points: • At the charge-air coolant pump; • At the intercooler, engine driving end and free end sides. Screw in drain plugs with new sealing rings. Place breather valve on filler neck and close. 92 | Task Description | MS150094/01E 2012-08 6.13.6 DANGER WARNING Charge-air coolant pump – Relief bore check Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. Charge-air coolant pump – Relief bore check 1. Result: TIM-ID: 0000025276 - 001 2. Check relief bore for oil and coolant dis‐ charge. • Permissible coolant discharge: up to 10 drops per hour; • Permissible oil discharge: up to 5 drops per hour. If discharge exceeds the specified limits, contact Service. If relief bore is dirty: • Stop engine (→ Page 31) and disable en‐ gine start. • Clean relief bore with a wire. MS150094/01E 2012-08 | Task Description | 93 6.14 Belt Drive 6.14.1 Drive belt – Condition check Preconditions ☑ Engine is stopped and starting disabled. ☑ Guard is removed. Drive belt – Condition check Findings Action Drive belt A Singular cracks None Drive belt Belt is oily, shows signs of over‐ heating Replace (→ Page 98) Drive belt B Cracks on entire circumference Drive belt C Chunking TIM-ID: 0000000920 - 010 Item 94 | Task Description | MS150094/01E 2012-08 6.14.2 Drive belt – Tension check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Tester Y4345711 1 Belt tension tester, 150-600 N Y20097429 1 Fan drive – Checking belt tension 1. 2. 3. 4. 5. 6. Remove protective cover. Set belt tension tester onto the drive belt in the middle between the belt pulleys (arrow). Using pushbutton, press vertically on top side of drive belt exerting even pressure un‐ til spring engages noticeably. Do not press any further, otherwise the dis‐ play value will be falsified. Take off tension tester without changing the position of the display arm. Read off measured value at the intersection of display arm and "KG" scale. For specifi‐ cations, refer to table below. Application Fan drive belt Specification Specification Initial installation (new belt) Operating tension (used belt) Frequency: 99 ±1 Hz Frequency: 86 ±1 Hz Table 2: Measuring belt tension with frequency meter Application Fan drive belt Specification Specification Initial installation (new belt, run‐ time 0.5-2 h) (used belt, runtime 500 h) Depression depth: 5.6 mm Depression depth: 7.2 mm Test force: 188 N Test force: 188 N TIM-ID: 0000025518 - 002 Table 3: Measuring depression depth with tension tester Application Fan drive belt Specification Specification Initial installation (new belt, run‐ time 0.5-2 h) (used belt, runtime 500 h) Static tension: 4000 N Static tension: 3000 N Table 4: Measuring static belt tension 7. 8. If the measured values deviate from the specifications above, adjust drive belt tension (→ Page 96). Install protective cover. MS150094/01E 2012-08 | Task Description | 95 6.14.3 Drive belt – Tension adjustment Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 20-100 Nm F30026582 1 Ratchet adapter ½" F30027340 1 Torque wrench, 40-200 Nm F30027337 1 Engine oil Drive belt – Tension adjustment 1. 2. Undo screws (1). Set distance (A) to 100 mm with screw (2). 3. Use torque wrench (1) to tighten screws to specified tightening torque. Size Type Lubricant Value/Standard Screw M16x50 Tightening torque (Engine oil) 180 Nm +18 Nm Tighten screw (2) to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Screw M16x280 Tightening torque (Engine oil) 70 Nm +7 Nm 5. 6. Undo screws (3). Adjust belt tension with screw (4) (→ Page 95). 7. Use torque wrench to tighten screws (3) to specified tightening torque. 8. Name Size Type Lubricant Value/Standard Screw M12 Tightening torque (Engine oil) 74 Nm +7 Nm Use torque wrench to tighten screw (4) to specified tightening torque. Name Size Type Lubricant Value/Standard Screw M12x240 Tightening torque (Engine oil) 30 Nm +3 Nm 96 | Task Description | MS150094/01E 2012-08 TIM-ID: 0000025520 - 001 4. Name 6.14.4 Drive belt – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Drive belt Part No. Qty. (→ Spare Parts Catalog) Fan drive – Drive belt replacement 1. 2. 3. 4. 5. Note: 6. 7. 8. When placing the drive belt in the grooves, no force must be applied. Fit new drive belt. Screw in screw (2) until distance (A) is 100 mm. Adjust and check drive belt tension (→ Page 96). Install fan. Install protective cover. TIM-ID: 0000025462 - 001 9. 10. Remove protective cover from radiator. Remove fan. Slacken off securing screws (1). Screw out screw (2) as far as necessary to allow drive belt removal. Check belt pulley on radiator bearing mount and crankshaft for contamination and clean if necessary. MS150094/01E 2012-08 | Task Description | 97 6.15 Battery-Charging Generator 6.15.1 Battery-charging generator drive – Drive belt replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Mandrel Part No. Qty. 8205892861/08 1 Preparatory steps 1. 2. 3. Remove safety equipment (if fitted). Remove screws of protective cover (engine free end). Remove protective cover. Drive belt – Replacement 1. 2. 3. 4. 5. 6. 7. Hold adjusting lever at square. Rotate adjusting lever until drive belt is released. Use mandrel to lock adjusting lever in position. Remove drive belt. Check cleanness of belt pulleys. Fit new drive belt. Remove mandrel. Final steps Install protective cover. Install screws of protective cover. Install safety equipment (if fitted). Check function of safety equipment (if fitted). TIM-ID: 0000007424 - 003 1. 2. 3. 4. 98 | Task Description | MS150094/01E 2012-08 6.16 Fuel Supply System 6.16.1 Water drain valve – Check Water drain valve – Check Open water drain valve. Check water outlet for obstructions. Close water drain valve. TIM-ID: 0000007733 - 007 1. 2. 3. MS150094/01E 2012-08 | Task Description | 99 6.16.2 WARNING Differential pressure gauge – Check Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Differential pressure gauge – Check Switch on fuel treatment system (→ Page 26). Set the alarm points at the differential pressure gauge to zero. Alarm is initiated with preset delay. Reset the alarm points at the differential pressure gauge to the specified values. TIM-ID: 0000023563 - 001 1. 2. Result: 3. 100 | Task Description | MS150094/01E 2012-08 6.16.3 Water level probe (3-in-1 rod electrode) – Check Preconditions ☑ System is put out of service and emptied. WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Water level probe (3-in-1 rod electrode) – Check Disconnect plug from water level probe. Unscrew water level probe. Disconnect plug from water level probe. Immerse water level probe into a tank filled with water until water level reaches the thread. Water drain valve opens. Leave water level probe in tank. Alarm must be triggered with the preset delay. Disconnect plug from water level probe. Remove water level probe from tank. Screw in water level probe. Connect plug for water level probe. Put the fuel treatment system into operation. TIM-ID: 0000023558 - 001 1. 2. 3. 4. Result: 5. Result: 6. 7. 8. 9. 10. MS150094/01E 2012-08 | Task Description | 101 6.16.4 WARNING Pump capacity – Check Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Pump capacity – Check 1. 2. Note: 3. 4. Install suitable pressure gauge in the intake connection of the pump. Check pump pressure. a) Switch on fuel treatment system (→ Page 29). 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 gauge in the inlet to the fuel treatment system and note down. Checking pump pressure with reduced suction 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 gauge in the inlet to the fuel treatment system and note down. c) Open ball valve at inlet and outlet of fuel treatment system. Calculate wear limit. Example: Measured value (normal condition). 3 bar Measured value (reduced suction condition). 2.6 bar TIM-ID: 0000023567 - 001 If the measured value (reduced suction condition) is 10% lower than the measured value (normal con‐ dition), the wear limit is reached. Repair pump (contact Service). 102 | Task Description | MS150094/01E 2012-08 6.16.5 Coalescer filter element – Replacement Preconditions ☑ System is switched off and starting disabled. Special tools, Material, Spare parts Designation / Use WARNING CAUTION CAUTION Part No. Qty. Torque wrench, 6-50 Nm F30027336 1 Ratchet adapter F30027339 1 Diesel fuel Engine oil Coalescer filter element (→ Spare Parts Catalog) Gasket (→ Spare Parts Catalog) Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Contamination of components. Damage to component! • Observe manufacturer's instructions. • Check components for special cleanness. Incorrect installation of components and lines. Damage to component! • Ensure that components/lines are installed so that they are never under tension or strain. • Ensure correct installation position of components. Coalescer filter element – Replacement TIM-ID: 0000007735 - 007 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Close ball valve at the inlet and outlet of the fuel treatment system. Open drain valve. Drain fuel. Close drain valve. Remove nut (9) with washer (2). Remove screws (1). Remove cover with gasket (10). Remove nut (3), washer (8) and end plate (7). Remove coalescer filter element (4). Catch fuel as it runs out. Clean housing with a non-linting cloth, rinse with fuel if required. Check housing for corrosion. Clean housing sealing surfaces. Install coalescer filter element. Install end plate (7), washer (8) and nut (3). MS150094/01E 2012-08 | Task Description | 103 16. Name Size Type Lubricant Value/Standard Nut M16 Tightening torque (Engine oil) 30 Nm +3 Nm Fit gasket (10). Install cover. Install screw (1), washer (2) and nut (9). Tighten nut (9). Open ball valve at the inlet and outlet of the fuel treatment system. The fuel treatment system is ready for operation. TIM-ID: 0000007735 - 007 17. 18. 19. 20. 21. Result: Tighten nut (3) to specified tightening torque using a torque wrench. 104 | Task Description | MS150094/01E 2012-08 6.17 Engine Governor 6.17.1 Engine governor – Overview Screw Washer Damper Engine governor Connector X3 Screw Connector X1 Screw for grounding strap TIM-ID: 0000031588 - 001 1 2 3 4 5 6 7 8 MS150094/01E 2012-08 | Task Description | 105 6.17.2 Engine governor – Removal Preconditions ☑ Engine is stopped and starting disabled. Preparatory steps 1. 2. 3. Observe safety instructions. Switch off operating voltage. Note or mark assignment of cables and plugs. Engine governor – Removal Remove engine governor as per overview drawing (→ Page 105). TIM-ID: 0000031586 - 001 u 106 | Task Description | MS150094/01E 2012-08 6.17.3 Engine governor – Installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Engine oil Damper Part No. Qty. (→ Spare Parts Catalog) 8 Engine governor – Installation 1. 2. 3. Install engine governor as per overview drawing (→ Page 105). Name Size Type Lubricant Value/Standard Screw for ground‐ ing strap M6x12 Tightening torque (Engine oil) Max. 8 Nm Fit connector X1 and X3 on Engine Control Unit and engage locks. Fit retainers for engine wiring. Final step Enable engine start. TIM-ID: 0000031642 - 001 u MS150094/01E 2012-08 | Task Description | 107 6.17.4 Engine governor – Checking plug-in connections Preconditions ☑ Engine is stopped and starting disabled. Note: Always use test connectors to enter the connectors. Never use test leads for this purpose.Otherwise the contacts could be bent. Checking plug-in connections on engine governor Check all plug-in connections for secure seating. Latch connectors if loose. TIM-ID: 0000000048 - 005 1. 2. 108 | Task Description | MS150094/01E 2012-08 6.18 Wiring (General) for Engine/Gearbox/Unit 6.18.1 Engine wiring – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol X00058037 1 Engine wiring – Check 1. 2. 3. 4. 5. 6. Close male connectors that are not plugged in with the protective cap supplied. Clean dirty connector housings, sockets and contacts with isopropyl alcohol. Ensure that all sensor connectors are securely engaged. TIM-ID: 0000000029 - 018 Note: 7. 8. Check securing screws of cable clamps on engine and tighten loose threaded connections. Ensure that cables are fixed in their clamps and cannot swing freely. Check that cable ties are firm, tighten loose cable ties. Replace faulty cable ties. Visually inspect the following electrical line components for damage: • connector housings; • contacts; • sockets; • cables and terminals; • plug-in contacts. (→ Contact Service) if cable conductors are damaged. MS150094/01E 2012-08 | Task Description | 109 6.18.2 Lambda, NOx and humidity sensors – Overview 2 NOx sensor 3 Lambda sensor TIM-ID: 0000025179 - 001 1 Humidity sensor 110 | Task Description | MS150094/01E 2012-08 6.18.3 Lambda sensor – Replacement Preconditions ☑ Engine is stopped and starting disabled. ☑ Preparatory steps have been completed. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10-60 Nm F30510423 1 Ratchet adapter ½" F30027340 1 Lambda sensor WARNING CAUTION CAUTION 1 Component is hot. Risk of burning! • Wear protective gloves. Overvoltage. Damage to component! • Switch off ignition voltage before exchanging component(s). Fracture of ceramic cell due to shock load or impact. Damage to component! • Avoid shock load and impact. • Handle sensors with extreme care. Removing lambda sensor 1. TIM-ID: 0000025194 - 002 2. 3. Observe the following general information: • Arrangement and position of sensor (→ Page 110). Unplug and remove male connector (1). Remove sensor via nut (2). MS150094/01E 2012-08 | Task Description | 111 Installing lambda sensor Note: 1. Note: The sensor is considered defective after be‐ ing exposed to shock load or impact and must not be used. Remove the protective cap from the thread immediately before installation. 2. Do not wipe off the grease the manufactur‐ er applied on the thread. Manually screw sensor into bore. 3. Tighten nut (2) to specified tightening torque using a torque wrench. 4. Note: Size Type Sensor M18 x 1.5 Tightening torque Lubricant Value/Standard 40 Nm to 60 Nm Fit male connector (1) and latch. The CDC parameters must be reset, otherwise the emission certification of the engine is no longer appli‐ cable. Reset CDC parameters (→ Page 117). TIM-ID: 0000025194 - 002 5. Name 112 | Task Description | MS150094/01E 2012-08 6.18.4 NOx sensor – Replacement Preconditions ☑ Engine is stopped and starting disabled. ☑ Preparatory steps have been completed. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10-60 Nm F30510423 1 Ratchet adapter ½" F30027340 1 NOx sensor WARNING CAUTION CAUTION 1 Component is hot. Risk of burning! • Wear protective gloves. Overvoltage. Damage to component! • Switch off ignition voltage before exchanging component(s). Fracture of ceramic cell due to shock load or impact. Damage to component! • Avoid shock load and impact. • Handle sensors with extreme care. Removing NOx sensor 1. TIM-ID: 0000025205 - 002 2. 3. Observe the following general information: • Arrangement and position of sensor (→ Page 110). Unplug and remove male connector (1). Remove sensor via nut (2). MS150094/01E 2012-08 | Task Description | 113 Installing NOx sensor Note: 1. Note: The sensor is considered defective after be‐ ing exposed to shock load or impact and must not be used. Remove the protective cap from the thread immediately before installation. 2. Do not wipe off the grease the manufactur‐ er applied on the thread. Manually screw sensor into bore. 3. Tighten nut (2) to specified tightening torque using a torque wrench. 4. Note: Size Type Sensor M20 x 1.5 Tightening torque Lubricant Value/Standard 50 Nm ±10 Nm Fit male connector (1) and latch. The CDC parameters must be reset, otherwise the emission certification of the engine is no longer appli‐ cable. Reset CDC parameters (→ Page 117). TIM-ID: 0000025205 - 002 5. Name 114 | Task Description | MS150094/01E 2012-08 6.18.5 Humidity sensor – Replacement Preconditions ☑ Engine is stopped and starting disabled. ☑ Preliminary steps are completed. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10-60 Nm F30510423 1 Ratchet adapter ½" F30027340 1 Engine NOx sensor CAUTION 1 1 Contamination of components. Damage to component! • Observe manufacturer's instructions. • Check components for special cleanness. NOx sensor – Removal 1. TIM-ID: 0000025206 - 001 2. 3. 4. Observe the following general information: • Layout and position of sensor (→ Page 110). Unplug and remove male connector. Remove screws (1). Remove sensor (2). MS150094/01E 2012-08 | Task Description | 115 Humidity sensor – Installation Note: 1. Apply lubricant for O-ring sparingly. Insert sensor (2) in bore, ensuring correct installation position. Note: 2. Take direction of air flow into account. Screw in screws (1). 3. Name Size Type Sensor M6 Tightening torque Lubricant Value/Standard 12 Nm +5 Nm Fit male connector and latch. TIM-ID: 0000025206 - 001 4. Use torque wrench to tighten screws (1) to the specified tightening torque. 116 | Task Description | MS150094/01E 2012-08 6.19 Accessories for (Electronic) Engine Governor / Control System 6.19.1 CDC parameters – Reset with DiaSys® Preconditions ☑ Engine is stopped and starting disabled. Resetting CDC parameters (DiaSys® is available) Note: u The CDC parameters must be reset, otherwise the emission certification of the engine is no longer appli‐ cable. Reset the CDC parameters with DiaSys® (→ Manufacturer's documentation). Resetting CDC parameters (DiaSys® is not available) Note: TIM-ID: 0000029731 - 002 u The CDC parameters must be reset, otherwise the emission certification of the engine is no longer appli‐ cable. Contact Service. MS150094/01E 2012-08 | Task Description | 117 6.19.2 Engine governor and connectors – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Note: Designation / Use Part No. Qty. Isopropyl alcohol X00058037 1 Always use test connectors to enter the connectors. Never use test leads for this purpose.Otherwise the contacts could be bent. Engine governor and connectors – Cleaning 1. 2. 3. Remove coarse dirt from housing surface with isopropyl alcohol. Remove dirt from connector and cable surfaces with isopropyl alcohol. Check legibility of cable labels. Clean or replace illegible labels. Cleaning severely contaminated connectors on the engine governor Seal unused connectors with the supplied protective cap. Release the latch and pull off connectors. Clean connector housings, connector socket housings and all contacts with isopropyl alcohol. When connectors, sockets and all contacts are dry: Fit connectors and lock them. TIM-ID: 0000000047 - 009 Note: 1. 2. 3. 118 | Task Description | MS150094/01E 2012-08 6.19.3 Engine governor – Checking plug-in connections Preconditions ☑ Engine is stopped and starting disabled. Note: Always use test connectors to enter the connectors. Never use test leads for this purpose.Otherwise the contacts could be bent. Checking plug-in connections on engine governor Check all plug-in connections for secure seating. Latch connectors if loose. TIM-ID: 0000000048 - 005 1. 2. MS150094/01E 2012-08 | Task Description | 119 7 Appendix A 7.1 List of abbreviations Abbrevia‐ tion Meaning Explanation ADEC Advanced Diesel Engine Controller Engine management system AL Alarm General alarm ANSI American National Standards Institute Umbrella organization administering and coordinat‐ ing U.S. standards ATL Abgasturbolader BDM Backup Data Module BR Baureihe Series BV Betriebsstoffvorschrift MTU Fluids and Lubricants Specifications, Publica‐ tion No. A01061/.. CAN Controller Area Network Data bus system, bus standard CPP Controllable Pitch Propeller CR Common Rail DIN Deutsches Institut für Normung e. V. German Standardization Organization, at the same time identifier of German standards ("Deutsche In‐ dustrie-Norm") DIS Display Unit Display panel DL Default Lost Alarm: CAN bus missing DPF Diesel Particulate Filter ECS Engine Control System ECU Engine Control Unit Engine governor EDM Engine Data Module Memory module for engine data EGR Exhaust Gas Recirculation EIL Engine Ident Label EMU Engine Monitoring Unit ETK Ersatzteilkatalog FPP Fixed Pitch Propeller GCU Gear Control Unit GMU Gear Monitoring Unit HI High Alarm: Measured value exceeds 1st maximum limit value HIHI High High Alarm: Measured value exceeds 2nd maximum lim‐ it value HT High Temperature ICFN ISO – Continuous rating – Fuel stop power – Net Power specification in accordance with DIN-ISO 3046-7 IDM Interface Data Module Memory module for interface data 120 | Appendix A | MS150094/01E 2012-08 Exhaust turbocharger (ETC) TIM-ID: 0000002045 - 013 Spare Parts Catalog (SPC) TIM-ID: 0000002045 - 013 Abbrevia‐ tion Meaning Explanation IMO International Maritime Organization ISO International Organization for Stand‐ ardization International umbrella organization of all standards institutes KGS Kraftgegenseite Engine free end in accordance with DIN ISO 1204 KS Kraftseite Engine driving end in accordance with DIN ISO 1204 LCD Liquid Crystal Display, Liquid Crystal Device LCU Local Control Unit LED Light Emitting Diode LMU Local Monitoring Unit LOP subassembly LO Low Alarm: Measured value below 1st minimum limit value LOLO Low Low Alarm: Measured value below 2nd minimum limit value LOP Local Operating Panel Control console, control panel LOS Local Operating Station MCS Monitoring and Control System MG Message MPU Microprocessor Unit, Microprocessing Unit OT Oberer Totpunkt Top dead center (TDC) P-xyz Pressure-xyz Pressure measuring point xyz PAN Panel Control panel PAU Power Automation Unit Module for monitoring, control and plant-related system integration of peripheral components PCU Propeller Control Unit PIM Peripheral Interface Module PLD Pumpe Leitung Düse Pump-line-nozzle (injection system) POM Power Output Module Module to control starter and battery-charging gen‐ erator RCS Remote Control System RL Redundancy Lost Alarm: Redundant CAN bus failure SAE Society of Automotive Engineers US standardization organization SD Sensor Defect Alarm: Defective sensor SDAF Shut Down Air Flaps Emergency-air shutoff flap(s) SS Safety System Safety system alarm SSK Schnellschlussklappe(n) Emergency-air shutoff flap(s) T-xyz Temperature-xyz Temperature measuring point xyz TD Transmitter Deviation Alarm: Deviation in transmitter values UT Unterer Totpunkt Bottom dead center (BDC) VS Voith Schneider Voith-Schneider drive LOP subassembly MS150094/01E 2012-08 | Appendix A | 121 Meaning Explanation WJ Water Jet Water jet drive WZK Werkzeugkatalog Tool Catalog (TC) TIM-ID: 0000002045 - 013 Abbrevia‐ tion 122 | Appendix A | MS150094/01E 2012-08 7.2 MTU contact persons/service partners Our worldwide sales network with its subsidiaries, sales offices, representatives and customer service centers ensures fast and direct support on site and the high availability of our products. Local support Experienced and qualified specialists place their knowledge and expertise at your disposal. For locally available support, go to the MTU Internet site: http://www.mtu-online.com 24h hotline With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist you – either during operation, for preventive maintenance, corrective work in case of malfunction or changed operating conditions, or for spare parts supply. Your contact at Headquarters: [email protected] Spare parts service Fast, simple and correct identification of spare parts for your drive system or vehicle fleet. The right spare part at the right time at the right place. With this aim in mind, we can call on a globally networked spares logistics system, a central warehouse at headquarters and on-site stores at our subsidiary companies, agencies and service workshops. Your contact at Headquarters: E-mail: [email protected] Phone: +49 7541 908555 TIM-ID: 0000000873 - 014 Fax: +49 7541 908121 MS150094/01E 2012-08 | Appendix A | 123 8 Appendix B 8.1 Special Tools Adapter Part No.: F30006234 Qty.: Used in: 1 6.4.2 Injector – Removal and installation (→ Page 49) Qty.: Used in: 1 6.5.1 HP fuel line and pressure pipe neck – Replace‐ ment (→ Page 54) Part No.: F6783914 Qty.: Used in: 1 6.3.1 Valve clearance – Check and adjustment (→ Page 44) Part No.: F6783914 Qty.: Used in: 1 6.1.1 Engine – Barring manually (→ Page 41) Barring device DCL-ID: 0000007590 - 003 Barring tool 124 | Appendix B | MS150094/01E 2012-08 Belt tension tester, 150-600 N Part No.: Y20097429 Qty.: Used in: 1 6.14.2 Drive belt – Tension check (→ Page 95) Part No.: F30027424 Qty.: Used in: 1 6.4.2 Injector – Removal and installation (→ Page 49) Qty.: Used in: 1 6.5.1 HP fuel line and pressure pipe neck – Replace‐ ment (→ Page 54) Part No.: F30027425 Qty.: Used in: 1 6.4.2 Injector – Removal and installation (→ Page 49) Qty.: Used in: 1 6.5.1 HP fuel line and pressure pipe neck – Replace‐ ment (→ Page 54) Part No.: F30011450 Qty.: Used in: 1 6.5.1 HP fuel line and pressure pipe neck – Replace‐ ment (→ Page 54) Crowfoot wrench, 19 mm Crowfoot wrench, 22 mm DCL-ID: 0000007590 - 003 Double box wrench MS150094/01E 2012-08 | Appendix B | 125 Double-head box wrench Part No.: F30002800 Qty.: Used in: 1 6.3.1 Valve clearance – Check and adjustment (→ Page 44) Part No.: F30011450 Qty.: Used in: 1 6.4.2 Injector – Removal and installation (→ Page 49) Part No.: Y4345893 Qty.: Used in: 1 6.3.1 Valve clearance – Check and adjustment (→ Page 44) Part No.: F30379104 Qty.: Used in: 1 6.6.1 Fuel filter – Replacement (→ Page 58) Qty.: Used in: 1 6.11.1 Engine oil filter – Replacement (→ Page 71) Double-head box wrench Feeler gauge 126 | Appendix B | MS150094/01E 2012-08 DCL-ID: 0000007590 - 003 Filter wrench Fuel suction device Part No.: F30378207 Qty.: Used in: 1 6.4.2 Injector – Removal and installation (→ Page 49) Part No.: F6790085 Qty.: Used in: 1 6.4.2 Injector – Removal and installation (→ Page 49) Part No.: 8205892861/08 Qty.: Used in: 1 6.15.1 Battery-charging generator drive – Drive belt re‐ placement (→ Page 98) Part No.: 5605892099/00 Qty.: Used in: 1 6.12.7 Engine coolant – Sample extraction and analysis (→ Page 85) Installation device Mandrel DCL-ID: 0000007590 - 003 MTU test kit MS150094/01E 2012-08 | Appendix B | 127 Oil filter wrench Part No.: F30379104 Qty.: Used in: 1 6.12.8 Coolant filter – Replacement (→ Page 86) Open-end socket wrench, 19 mm Part No.: F30453236 Qty.: Used in: 1 6.4.2 Injector – Removal and installation (→ Page 49) Open-end socket wrench, 24 mm Part No.: F30453238 Qty.: Used in: 1 6.4.2 Injector – Removal and installation (→ Page 49) Part No.: F6790636 Qty.: Used in: 1 6.4.2 Injector – Removal and installation (→ Page 49) DCL-ID: 0000007590 - 003 Puller 128 | Appendix B | MS150094/01E 2012-08 Ratchet Part No.: F30006212 Qty.: Used in: 1 6.1.1 Engine – Barring manually (→ Page 41) Qty.: Used in: 1 6.3.1 Valve clearance – Check and adjustment (→ Page 44) Part No.: F30027340 Qty.: Used in: 1 6.3.2 Cylinder head cover – Removal and installation (→ Page 47) Qty.: Used in: 1 6.4.2 Injector – Removal and installation (→ Page 49) Part No.: F30027340 Qty.: Used in: 1 6.5.1 HP fuel line and pressure pipe neck – Replace‐ ment (→ Page 54) Part No.: F30027339 Qty.: Used in: 1 6.16.5 Coalescer filter element – Replacement (→ Page 103) Ratchet Ratchet adapter DCL-ID: 0000007590 - 003 Ratchet adapter MS150094/01E 2012-08 | Appendix B | 129 Ratchet adapter ½" Part No.: F30027340 Qty.: Used in: 1 6.14.3 Drive belt – Tension adjustment (→ Page 96) Part No.: F30027340 Qty.: Used in: 1 6.18.3 Lambda sensor – Replacement (→ Page 111) Qty.: Used in: 1 6.18.4 NOx sensor – Replacement (→ Page 113) Qty.: Used in: 1 6.18.5 Humidity sensor – Replacement (→ Page 115) Part No.: F30038493 Qty.: Used in: 1 6.3.1 Valve clearance – Check and adjustment (→ Page 44) Part No.: F30025897 Qty.: Used in: 1 6.5.1 HP fuel line and pressure pipe neck – Replace‐ ment (→ Page 54) Ratchet adapter ½" Ring socket, 19 mm DCL-ID: 0000007590 - 003 Socket wrench, 19 mm 130 | Appendix B | MS150094/01E 2012-08 Steam jet cleaner Part No.: - Qty.: Used in: 1 3.13 Plant cleaning (→ Page 35) Part No.: Y4345711 Qty.: Used in: 1 6.14.2 Drive belt – Tension check (→ Page 95) Part No.: 0015384230 Qty.: Used in: 1 6.4.2 Injector – Removal and installation (→ Page 49) Part No.: F30510423 Qty.: Used in: 1 6.3.1 Valve clearance – Check and adjustment (→ Page 44) Tester Torque wrench, 0.5-5 Nm DCL-ID: 0000007590 - 003 Torque wrench, 10-60 Nm MS150094/01E 2012-08 | Appendix B | 131 Torque wrench, 10-60 Nm Part No.: F30510423 Qty.: Used in: 1 6.18.3 Lambda sensor – Replacement (→ Page 111) Qty.: Used in: 1 6.18.4 NOx sensor – Replacement (→ Page 113) Qty.: Used in: 1 6.18.5 Humidity sensor – Replacement (→ Page 115) Part No.: F30026582 Qty.: Used in: 1 6.4.2 Injector – Removal and installation (→ Page 49) Qty.: Used in: 1 6.5.1 HP fuel line and pressure pipe neck – Replace‐ ment (→ Page 54) Part No.: F30026582 Qty.: Used in: 1 6.14.3 Drive belt – Tension adjustment (→ Page 96) Part No.: F30027337 Qty.: Used in: 1 6.14.3 Drive belt – Tension adjustment (→ Page 96) Torque wrench, 20-100 Nm Torque wrench, 20-100 Nm DCL-ID: 0000007590 - 003 Torque wrench, 40-200 Nm 132 | Appendix B | MS150094/01E 2012-08 Torque wrench, 6-50 Nm Part No.: F30027336 Qty.: Used in: 1 6.16.5 Coalescer filter element – Replacement (→ Page 103) Part No.: F30027336 Qty.: Used in: 1 6.11.2 Centrifugal oil filter – Cleaning and filter sleeve replacement (→ Page 72) Part No.: F30043446 Qty.: Used in: 1 6.3.2 Cylinder head cover – Removal and installation (→ Page 47) Torque wrench, 6-50 Nm DCL-ID: 0000007590 - 003 Torque wrench, 8-40 Nm MS150094/01E 2012-08 | Appendix B | 133 8.2 Index After stopping the engine 33 Air filter – Replacement 65 Auxiliary materials 11 B Battery-charging generator drive – Drive belt – Replacement 98 Belt – Drive – Replacement 97 – Tension adjustment 96 – Tension check 95 C CDC parameters – Reset 117 Centrifugal oil filter – Cleaning and filter sleeve replacement 72 Charge-air coolant – Change 89 – Level check 88 Charge-air coolant – Draining 92 – Filling 90 Charge-air coolant level – Check 88 Charge-air coolant pump – Relief bore check 93 Checks – Prior to start-up 25 Coalescer filter element – Replacement 103 Connectors – Cleaning 118 Contact persons 123 Coolant – Change 89 – Charge-air – Draining 92 – Filling 90 – Filling 82 – Filter – Replacement 58 – Sample – Extraction and analysis 85 Coolant - charge air – Level check 88 Coolant filter – Replacement 86 Coolant level – Check 79 Crankcase breather – Oil mist fine separator replacement 43 134 | Appendix B | MS150094/01E 2012-08 Cylinder – Designation 16 Cylinder head cover – Removal and installation 47 D Data – Engine 19 Differential pressure – Pressure gauge – Check 100 Dimensions – Engine 17 Drain and vent points 74 Drive belt – Condition check 94 – Replacement 97 – Tension check 95 Drive belt – Adjustment 96 E Emergency stop – Engine 32 Engine – Barring manually 41 – Data 19 – Emergency stop 32 – Main dimensions 17 – Overview 14 – Start 28 – Stop 31 – Wiring check 109 – With starting system – Barring 42 Engine coolant – Change 80 – Filling 82 – Sample – Extraction and analysis 85 Engine coolant level – Check 79 Engine coolant pump – Relief bore check 84 Engine coolant – Draining 81 Engine governor – Checking plug-in connections 108, 119 – Cleaning 118 – Installation 107 – Overview 105 – Removal 106 Engine oil – Centrifugal oil filter – Cleaning and filter sleeve re‐ placement 72 – Change 70 – Filter – Replacement 58 DCL-ID: 0000007590 - 003 A Engine oil filter – Replacement 71 Engine oil level – Check 69 Engine side – Designation 16 Engine wiring – Check 109 Environmental protection 11 Exhaust gas recirculation – Flaps – Operation check 68 DCL-ID: 0000007590 - 003 F Filter – Air – Replacement 65 – Coalescer Element – Replacement 103 – Coolant – Replacement 86 – Engine oil – Replacement 71 – Fuel – Replacement 58 Fire prevention 11 Firing order 18 Flaps – Exhaust gas recirculation – Flaps 67 – Operation check 68 – Overview 67 Fluids and lubricants 11 Fuel – Draining 57 – Filter – Replacement 58 – Injector – Removal and Installation 49 – Prefilter – Differential pressure gauge - Check and adjust‐ ment 59 – Draining 60 – Filter element replacement 63 – prefilter – Flushing 61 – Treatment system – Troubleshooting 37 – treatment system – Shutdown 34 – Switching on 29 Fuel filter – Replacement 58 Fuel prefilter – Differential pressure gauge – Check and adjustment 59 – Draining 60 – Filter element – Replacement 63 – Flushing 61 Fuel system – Venting 56 Fuel treatment system – Putting into operation 26 – Shutdown 34 – Switching on 29 G General conditions 5 H Hotline 123 HP fuel line and pressure pipe neck – Replacement 54 Humidity sensor – Replacement 115 I Injector – Removal and Installation 49 – Replacement 48 Intercooler – Vent and drain points 87 L Lambda sensor – Replacement 111 List of abbreviations 120 M Maintenance – Maintenance Schedule – Maintenance task reference table [QL1] 36 Maintenance work – Safety regulations 8 MTU contact persons 123 N NOx sensor – Replacement 113 O Operational checks 30 Overview – Exhaust gas recirculation – Flaps 67 – Operation check 68 – Overview 67 – Lambda, NOx and humidity sensor 110 P Personnel and organizational requirements 6 MS150094/01E 2012-08 | Appendix B | 135 Plant – Cleaning 35 Pressure gauge – Differential pressure – Check 100 Pump – Charge-air coolant – Relief bore check 93 – Engine coolant – Relief bore check 84 Pump capacity – Check 102 Putting into operation – After scheduled out-of-service period – Preparation 23 – Fuel treatment system 26 Putting the engine into operation after extended out-ofservice periods (>3 months) 22 Putting the engine into operation after scheduled out-ofservice-period 23 Water level probe – Check 101 Wiring - engine – Check 109 R Repair work – Safety regulations 8 S Safety instructions 13 Safety regulations 8 Sensor – Humidity – Replacement 115 Sensors – Lambda – Replacement 111 – NOx – Replacement 113 Service indicator – Check 66 Service partners 123 Spare parts service 123 Tasks – After extended out-of-service periods 24 Tasks after extended out-of-service periods (>3 weeks) 24 Transport 7 Troubleshooting 38 – Fuel treatment system 37 V Valve clearance – Check and adjustment 44 Vent and drain points 74 – Intercooler 87 W Water drain valve – Check 99 136 | Appendix B | MS150094/01E 2012-08 DCL-ID: 0000007590 - 003 T