Operating Instructions Diesel engine 12 V 2000 P12 16 V 2000 P12 MS150025/02E
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Table of Contents 1 Safety 1.1 Important provisions for all MTU engines or systems 1.2 Personnel and organizational requirements 1.3 Transport 1.4 Safety regulations for maintenance and repair work 1.5 Fire prevention and environmental protection, auxiliary materials, fluids and lubricants 1.6 Standards for safety messages in the text 1.7 ATEX precautions (if applicable) 5 6 7 8 11 13 14 4.9 After stopping the engine – Engine remains ready for operation 4.
7.8 Fuel Filter 7.8.1 Fuel filter – Replacement 7.8.2 Fuel prefilter cleaning 7.8.3 Fuel prefilter – Differential pressure gauge check and adjustment 7.8.4 Fuel prefilter – Draining 7.8.5 Fuel prefilter – Flushing 7.8.6 Fuel prefilter – Filter element replacement 7.9 Charge-Air Cooling General, Left-Hand Side 7.9.1 Intercooler – Checking condensate drains for coolant discharge and obstructions 109 110 110 112 113 114 115 117 119 119 7.10 Air Filter 120 7.11 Air Intake 121 7.
1 Safety 1.1 Important provisions for all MTU engines or systems Nameplate Engine identification is provided by the engine serial number on the nameplate. The nameplate is located on the engine.
1.2 Personnel and organizational requirements Organizational measures of the operator 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.
1.3 Transport Transport Lift the engine only with the lifting eyes provided. Use only the transport and lifting equipment approved by MTU. Take note of the engine center of gravity. The engine must only be transported in installation position, max. permissible diagonal pull 10°. In the case of special packaging with aluminum foil, suspend the engine on the lifting eyes of the trans‐ port pallet or transport with equipment for heavy loads (forklift truck).
1.4 Safety regulations for maintenance and repair work Safety regulations prior to maintenance and repair work Have maintenance and repair work carried out by qualified and authorized personnel only. Allow the engine or plant to cool down to less than 50°C before starting maintenance work (risk of explo‐ sion of oil vapors, fluids and lubricants, risk of burning). Before starting work, relieve pressure in systems and compressed-air lines which are to be opened.
Safety regulations after completion of maintenance and repair work Before barring the engine, make sure that nobody is standing in the danger zone of the engine or plant. Check that all guards have been reinstalled and that all tools and loose parts have been removed after working on the engine or plant (in particular, the barring tool). Welding work Never carry out welding work on the assembly or plant, or attached units. Cover the engine or plant when welding in its vicinity.
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.
1.5 Fire prevention and environmental protection, auxiliary materials, fluids and lubricants 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 or plant in a clean condition. Do not leave cloths soaked with fluids and lubricants on the engine or plant. Do not store combustible materials near the engine or plant. Do not weld pipes and components carrying oil or fuel.
Lead • Adopt suitable measures to avoid the formation of lead dust. • Switch on extraction system. • When working with lead or lead-containing compounds, avoid direct contact to the skin and do not inhale lead vapors. • Wash hands after contact with lead or lead-containing substances. Compressed air Observe special safety precautions when working with compressed air: • Unauthorized use of compressed air, e.g.
1.6 Standards for safety messages 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 hazardous situations. Consequences: Minor or moderate injuries • Remedial action In the event of a situation involving potentially adverse effects on the product. Consequences: Material damage.
1.7 ATEX precautions (if applicable) The following additional precautions must be taken to comply with the requirements of the ATEX explosion protection directives: TIM-ID: 0000024691 - 001 • Unoccupied connections for the wiring harness must be sealed with protective caps. • The entire engine wiring harness must be covered with metal guards to protect it from mechanical im‐ pact and UV radiation. • Continuous power supply to the engine must be ensured when the engine is in the hazardous zone.
2 General Information 2.1 Engine side and cylinder designations Engine sides are always designated as viewed from the driving end (KS). The cylinders of the left engine side are designated "A" and those of the right side "B" (as per DIN ISO 1204). The cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end. Other components are numbered in the same way, i.e. starting with No. 1 on driving end.
2.
1 Starter 2 Charge-air coolant pump Engine model designation Key to the engine model designation 12/16V 2000 Px2 Number of cylinders V Cylinder arrangement: V engine 2000 Series P Application X Application segment (1, 6, 8, 9) 2 Design index TIM-ID: 0000009974 - 001 12/16 MS150025/02E 2012-10 | General Information | 17
2.3 Use 1 Service and Automation Module (SAM) 2 Peripheral Interface Module 601 (option) 3 Peripheral Interface Module 602 (option) 4 CAN bus 5 Engine with generator 6 Engine governor 7 Engine monitoring (op‐ tional) 8 LOP (optional) Up to 8 additional Peripheral Interface Modules can be connected for linking to higher-level systems. Functions Control of the engine. Monitoring of operating states. Closed-loop control of fuel injection and engine speed (depending on operating state).
Features • • • • • • • • • • • • Electronic engine governing and control. Monitoring of inadmissible engine operating states. Display of fault messages and fault codes. Connecting cable for power supply to engine governor. Connecting cable for connection to a higher-level genset control system. Hardware interfaces to a higher-level control system (option). Inputs for plant sensors (option). Engine safety features including engine shutdown. Integral fault diagnosis system ITS.
Design of Engine Control System ECS-5 1 Engine with generator 2 Engine interface 3 Power supply +Ub 4 Signal connection to the MCS devices and the higher-level control sys‐ tems 5 Engine governor 6 System boundary ECS-5 TIM-ID: 0000009433 - 001 The Engine Control System comprises the following devices: • Engine governor • Sensors on engine • Actuators on engine • Injectors on engine • Wiring harnesses on engine 20 | General Information | MS150025/02E 2012-10
Basic scope of Monitoring and Control System MCS-5 3 Signal connection to ECS devices 4 System boundary MCS-5 5 SAM TIM-ID: 0000009433 - 001 1 Monitoring and Control System MCS-5 2 Power supply +Ub MS150025/02E 2012-10 | General Information | 21
Service and Automation Module (SAM) 1 Module cassette, slots for additional I/O PIM cards 2 Compact flash memory card 3 Display for fault codes and minidialog 4 Control keys for minidia‐ log 5 Diagnostic lamp 6 Interface for dialog unit 7 Connector with spring design Functions SAM functions Diagnosis • Straightforward diagnosis by fault code display. • Self-diagnosis by diagnostic lamp (5). • Steady = SAM is OK. • Flashing = SAM is faulty, contact Service. • Dark = Supply voltage missing.
Customer interface • • • • • • • • 24 binary outputs 3 PWM outputs 8 display outputs 28 channel binary input 10 analog inputs (e.g. PT100, 4–20 mA, 0-10 V, etc.) 4 frequency inputs 1 dialog interface Extendable with MCS 5 PIM I/O cards Data connections 1 Engine governor 2 SAM 3 PIM 601 (option) serial interface / slave 4 PIM 602 (option) serial interface / master TIM-ID: 0000009433 - 001 Data transmission The devices are equipped with a CAN bus for transmitting data between the individual subsystems.
Grounding 1 2 3 4 5 PIM SAM Engine governor Battery To engine sensors 6 Generating set 7 Equipotential bonding strip 8 Grounding 9 Equipotential bonding strip 10 Equipotential bonding strip 11 12 13 X! Mounting frame GND (-) +24 V VDC (+) Inadmissible connec‐ tion! Grounding Both the engine and the generator are connected to ground (8) via equipotential bonding strips (7, 9, 10) on the mounting frame (11).
2.4 ECS-5 – Use of devices Engine governor Central control and monitoring device for the engine • • • • • • • • • • Communication with other devices and higher-level systems via CAN bus. Control of injection system. Control of up to 20 injectors. Acquisition and evaluation of engine operating states. Monitoring of limit values.
Hardware structure Item.
Operating voltage Rated voltage: 24 VDC Continuous voltage: 16.5 VDC to 32 VDC Temporarily restricted operation: 11 VDC to 36 VDC Residual ripple: Max. 8 Vpp Power consumption Max. 30 A Heat loss Max. 35 W Operating temperature range 0 °C to +75 °C Storage temperature range –10 °C to +75 °C Relative air humidity 0% to 95 % condensing Degree of protection IP 65 DIN 40 050 Shock 15 g/11 ms semi-sinusoidal shock Vibration 2 Hz to 13 Hz: Xpp= ±1.
2.5 MDEC – Functions Control functions Following engine functions are controlled: • • • • • • • Engine start Engine stop Emergency start Restart response Sequences with activated “Override” function (safety system bypass). Nominal speed switching between two set values (optional operation as 50 Hz or 60 Hz genset). Injection quantity as a function of engine loading and speed. Engine start The starting sequence is controlled by the software integrated in the engine governor as follows. 1. Engine start 2.
Override (safety system bypass) The “Override” feature is used to bypass safety functions tripped by limit value violations or sensor faults and to bypass start interlocks. Operating states which would normally lead to engine shutdown are ignored when the “Override” function is activated.
Speed - injection control Functions of the closed-loop engine speed control integrated in the engine governor: • Maintaining the desired engine speed under changing load conditions. • Adjusting the engine speed when the setting is changed by the operator. Additional tasks with an effect on closed-loop engine speed control: • Setting a defined fuel injection quantity on starting the engine. • Engine safety shutdown. • Optimizing operation, exhaust emissions and fuel consumption.
Switching to an external speed setting takes place automatically once the nominal speed has been reached. The following speed setting variants are possible: • Desired speed setting via an analog input: The setpoint speed can be adjusted within a (configurable) range around the preset synchronous speed (depending on the set network frequency). In this case the voltage can either control the speed window only or cover the entire speed range.
Fault messages are stored in two memories: • Chronological memory The fault message numbers are stored in a ring memory in chronological order of their occurrence or cancellation together with the hour meter reading. The ring memory stores the last 80 setting and can‐ cellation procedures. • Statistical memory Fault message occurrences are counted in a statistical memory. A counter counting up to max. 10 000 is set up for each fault message number .
2.6 Peripheral Interface Modules (PIMs) PIMs for use with processor printed circuit board MPU 23 and MPU 27 PIM design 1 Module cassette 1 2 Basic module 1 3 Printed circuit board PIM 601/602 comprises: • Module cassette 1 (1) to accommodate one MPU 23, MPU 27 and one PIM printed circuit board. • Basic module 1 (2) with printed circuit board COB 1-0X (3).
The following information is transmitted via the optional interface modules PIM 601 and PIM 602: • Analog operational data • Analog limit values • Status messages • Alarms • Shutdowns Function of PIM 601 Serial interface • Computer coupling 512 • Procedure 3964 (R) • RS232 or • RS422 • MTU (SLAVE) Function of PIM 602 TIM-ID: 0000008271 - 001 Serial interface • Computer coupling 512 • Procedure 3964 (R) • RS232 or • RS422 • MTU (MASTER) 34 | General Information | MS150025/02E 2012-10
2.7 Printed circuit board SCB 3 Purpose and design Design 1 Component side 2 Soldering side 3 Top view 4 LED (red) “Printed circuit board RESET” 5 LED (green) “Ready” 6 LED (yellow) “Interface 1: Receiving and trans‐ mitting line active” 7 LED (yellow) “Interface 2: Receiving and trans‐ mitting line active” 8 Connector RS232 inter‐ face A yellow LED lights (o flashes) only when data interchange is active at the relevant interface.
Function 1 Transmission channel 1 2 Connector 3 Module housing with SCB 3 SCB 3 is equipped with two serial transmission channels routed to the terminal strip of the PIM. The software of the relevant processor printed circuit board determines which interface is active on which transmission channel. Only one interface may be active for any one transmission channel. • Transmission channel 1 is equipped with a connection for a serial RS422 interface and a serial RS232 interface.
Name n03 Channel 1: O2 of RS422 interface n04 Channel 2: O2 of RS422 interface n05 Channel 1: Ground (GND) of RS422 interface n06 Channel 2: Ground (GND) of RS422 interface n07 Channel 1: I1 of RS422 interface n08 Channel 2: I1 of RS422 interface n09 Channel 1: I2 of RS422 interface n10 Channel 2: I2 of RS422 interface n11 Channel 1: TX of RS232 interface n12 Channel 2: TX of RS232 interface n13 Channel 1: Ground (GND) of RS232 interface n14 Channel 2: Ground (GND) of RS232 interface
3 Technical Data 3.1 12/16 V 2000 P12 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.
Number of cylinders 12 16 Cylinder displacement liter 1.99 1.99 Total displacement liter 23.88 31.
GENERAL OPERATING DATA Number of cylinders 12 16 Cold start capability: air temperature without starting aid, with‐ out preheating) - (case A) R °C 0** 0** Coolant preheating: preheating temperature (min.
3.
3.3 Engine – Main dimensions Engine – Main dimensions 12 V 2000 Px2 16 V 2000 Px2 Length (A) approx. 2165 mm approx. 2505 mm Width (B) approx. 1340 mm approx. 1340 mm Height (C) approx. 1475 mm approx.
3.4 SAM Use/application • Installation in enclosed control cabinets. • Suitable for mounting on mounting rails (rail installation) or for installation with screws on the rear wall of the cabinet (fixed installation). • Suitable for connection wires or leads up to AWG16 (US) (1.5 mm2). Technical data Term Unit TIM-ID: 0000008286 - 003 Installation position Value As desired, ensuring that the installed fault display is legible.
Term Unit Value Ambient temperature: °C -40 – +70 with circulating ambient air. Storage temperature: °C -40 - +100 Relative humidity % 5 – 97, no condensation. Color: Blue (RAL5015) Material: % Polycarbonate, reinforced with 10 % fiberglass. Dimensions: mm L x W x H (295 x 151 x 75) Weight: kg Approx. 1.6 Note: Values stated above may be restricted when MCS 5 extension modules are used.
Electrical requirements Term Unit Value Operating voltage: V 24, -30 % to +30 % (+16.8 – +32) Permissible residual ripple less than 5% acc. to STA‐ NAG 1008. Note: The processor is automatically reset if the voltage falls below 7 V. Power supply: W Below 7 W. Without activated loads at SAM outputs Additional output power amperage of positive or nega‐ tive line may not exceed 10 A DC. Power connection terminals: mm 5.08 terminals (spring-type terminals) • A wire diameter of AWG14 (US) or 2.
Terminals Term Unit Value Terminal strip modules: WAGO spring terminals Current-carrying capacity (at 70 A °C): 10 per contact Rated voltage: V 250 Rated surge voltage: V Wire cross-sections: Clamping range: 2500 mm 2 Up to 1.5 or AWG15 mm 2 0.08 – 1.5 or AWG15 Other terminals (RM 5.08) are used for power supply and CAN bus connections.
3.5 SCB 3 – Technical data Term Unit Value Dimensions (H x W x D) mm 59 x 63 x 15 Weight kg 0.036 Input voltage VDC +5 (±5 %) from processor printed circuit board used Power consumption mA < 100 Power loss mW < 425 Unit Value Table 1: General information Term Bit-serial Baud rate Electrical isolation In accordance with RS422 standard kBd • 9600 with MPU 23 • 4800, 9600, 19200 with MPU 27 By optocoupler.
4 Operation 4.1 LOP – Controls Item Color Inscription Meaning / Function 1 White F1 Function keys for operating the screen. 2 White F2 Functions vary and are displayed on the LCD screen. 3 White F3 4 White F4 5 White F5 6 White ALARM AC‐ KNOWLEDGE Pressing the key the first time stops alarm signalization. Pressing the key a second time acknowledges an active alarm. LED (spot) lights up when an alarm is active.
Item Color Inscription Meaning / Function 8 White DIMMER ↓ Holding down the key decreases LCD background illumina‐ tion. 9 White LAMP TEST Pressing the key initiates lamp test. 10 Red TEST OVER‐ SPEED Pressing the key initiates overspeed test. LED (spot) lights up as long as the overspeed test is run‐ ning. 11 Green (none) (none) 12 Green (none) (none) 13 Green (none) (none) 14 White ENGINE SPEED INCREASE Engine speed is increased as long as the key is held down.
4.2 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 the engine into operation after extended out-of-service-periods (>3 months) Item Task Engine Depreserve (→ MTU Fluids and Lubricants Specifications A001061/..). Lube oil system Check engine oil level (→ Page 123). Fuel prefilter Prime (→ Page 115).
4.3 Putting the engine into operation after scheduled out-ofservice-period Preconditions ☑ Engine is stopped and starting disabled. Putting the engine into operation Item Task Lube oil system Check oil level (→ Page 123); Cooling system Check engine coolant level (→ Page 131); Check charge-air coolant level (→ Page 141). Cooling system Preheat coolant with preheating unit. Fuel prefilter Drain (→ Page 114). Monitoring equipment Carry out lamp test (see manufacturer's documentation).
4.4 Start engine in manual mode (testing mode) Preconditions ☑ Generator (if provided) not connected to network. ☑ External start interlock is not activated. 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.
4.5 Safety system – Override CAUTION CAUTION Safety functions and engine shutdown alarms will be disregarded. Serious damage to plant! • Initiate emergency start only in emergency situations. Inadmissible operational condition. Major material damage! • Use override function only in hazardous situations to ensure full capability in case of engine mal‐ functions. Preparation Note: This function is only available when a pushbutton is provided.
4.6 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 Task Control and display panels Check indicated operational data (speed, temperatures, pressures).
4.7 Stop engine in manual mode (testing mode) Preconditions ☑ Generator (if provided) not connected to network. ☑ Engine is running in manual mode. CAUTION Stopping the engine when it is running at full load causes extreme stress to the engine. Risk of overheating, damage to components! • Before stopping the engine, operate it at idle speed until operating temperatures decrease and stable values are indicated.
4.8 Emergency stop CAUTION An emergency stop causes extreme stress to the engine. Risk of overheating, damage to components! • Initiate emergency stop only in emergency situations. Emergency stop from LOP Item Task EMERGENCY STOP but‐ ton Press. • Engine is stopped by switching off power supply to ECU; • Signalization (e.g. by horn, flashing lamp) is released. After emergency stop from LOP Item Task Switching cabinet, control panel etc.
4.9 After stopping the engine – Engine remains ready for operation After stopping the engine Action Engine/generator/pump control Select operating mode, e.g. MANUAL, AUTOMATIC OPERATION.
4.10 After stopping the engine – putting the engine out of service Preconditions ☑ MTU-Preservation and Represervation Specifications (A001070/..) are available.
4.11 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.
5 Maintenance 5.1 Maintenance task reference table [QL1] The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Maintenance Schedule is a stand-alone publication. The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule. Maintenance tasks W0500 Check engine oil level. (→ Page 54) W0501 Visually inspect engine for leaks and general condition.
6 Troubleshooting 6.1 Troubleshooting Engine does not turn when starter is actuated Component Cause Measure Battery Flat or defective Charge or replace (see manufacturer's documentation). Cable connections faulty Check if cable connections are proper‐ ly secured (see manufacturer's docu‐ mentation). Starter (electric) Engine wiring or starter faulty Check if cable connections are proper‐ ly secured, contact Service.
Engine does not reach rated speed Component Cause Measure Fuel supply Fuel inlet blocked Completely open shutoff valve up‐ stream of fuel prefilter. Fuel prefilter clogged Replace (→ Page 117). Easy-change fuel filter contaminated Replace (→ Page 110). Air supply Air filter clogged Check signal ring position of contami‐ nation indicator (→ Page 121). Fuel injection equip‐ ment Injector faulty Replace (→ Page 102). Injection pump defective Replace (→ Page 98).
Black exhaust gas Component Cause Measure Air supply Air filter clogged Check signal ring position of contami‐ nation indicator (→ Page 121). Fuel injection equip‐ ment Injector faulty Replace (→ Page 102). Injection pump defective Replace (→ Page 98). Engine Overloaded Contact Service. Component Cause Measure Engine oil Engine oil level too high Drain engine oil (→ Page 124). Oil separator or oil-preseparator of crankcase breather clogged Replace (→ Page 93).
6.2 Fault indication on printed circuit board SAM The structure of the display (1) is as follows: • First line • Fault indication • # (2) = Alarm is no longer active, does not appear on next power-up, • A = Currently active alarms, • B = Alarm was active during the last hour, • C = Alarm was active during the last four hours, • C = Alarm was active during the last four to twelve hours, • E = Alarm was active more than twelve hours ago. . • Fault type (e.g. SE03).
SE No.
Fault code Fault message Meaning 023 L1 COOLANT LEVEL Coolant level too low (1st limit value) Check coolant level in expansion tank (→ Engine operating instruc‐ tions). 024 L2 COOLANT LEVEL Coolant level too low (2nd limit value) Check coolant level in expansion tank (→ Engine operating instruc‐ tions). 025 L1 P-OILFILTER DIFF Oil filter differential pres‐ sure too high (1st limit val‐ ue) Check oil filter (→ Engine operating instructions). 027 L1 LEVEL LEAKAGE Leak fuel (1st limit value).
Fault code Fault message Meaning Action 067 L1 T-COOLANT Coolant temperature too high (1st limit value); Reduce power. 068 L2 T-COOLANT Coolant temperature too high (2nd limit value); TIM-ID: 0000008959 - 001 automatic engine shutdown 1. Allow engine to cool down. 2. Contact Service • Check engine coolant cooler, clean if dirty (→ Engine Workshop Manual). 3. Restart engine. 089 ENGINE SPEED LOW Engine speed has failed to reach 200 rpm. Stop is ac‐ tivated. Check for additional messages.
Fault code Fault message Meaning 122 L1 T-ELECTRONIC Temperature in ECU hous‐ ing too high (1st limit value) 134 15V POS ECU DE‐ FECT Internal voltage (-15 VDC) faulty; Action 1. Improve engine room ventila‐ tion. 2. Reduce engine power. Replace engine governor (→ En‐ gine operating instructions). automatic engine shut‐ down. 136 15V NEG ECU DE‐ FECT Internal voltage (-15 VDC) missing; Contact Service. automatic engine shutdown 139 L1 TE BUFFER TEST Temperature sensor supply Contact Service.
TIM-ID: 0000008959 - 001 Fault code Fault message Meaning Action 187 CAN 1 ERROR PAS‐ CAN 1 in Error-Passive SIVE state, minor bus disruption or missing CAN node . Contact Service. • Check that at least one CAN node is present. Check cabling as necessary. • Check shielding, improve shield‐ ing as necessary. 188 CAN 2 BUS OFF Contact Service. • Check CAN bus for short circuit, rectify short circuit as necessary. • Check shielding, improve shield‐ ing as necessary.
Fault message Meaning 216 SD T-LUBE OIL Sensor B07 faulty (lube oil temperature). 1. Check cabling (→ Engine oper‐ ating instructions); 2. Contact Service • Check sensor. 219 SD T-INTAKE AIR Sensor B03 faulty (intake air temperature). 1. Check cabling (→ Engine oper‐ ating instructions); 2. Contact Service • Check sensor. 220 SD COOLANT LEV‐ EL Sensor F33 faulty (engine coolant level 1). 1. Switch system off and back on; 2. check fault message; 3.
Fault code Fault message Meaning Action 267 SD SP. DEM. TEST BENCH External test bench speed setting faulty. Check potentiometer and cabling (→ Engine operating instructions). 270 SD SPEED DE‐ MAND Sensor fault frequency set‐ ting. 301...310 TIMING CYLINDER Timing bank 1 (solenoid valve 1) ... Timing bank 1 (solenoid valve 10) Replace injector if fault message oc‐ curs frequently (→ Engine operating instructions). Timing bank 2 (solenoid valve 1) ...
Fault code Fault message Meaning 373 TRAN.OUT3 EN‐ GINE DEF Binary transistor output en‐ gine 3 faulty. 374 TRAN.OUT4 EN‐ GINE DEF Binary transistor output en‐ gine 4 faulty. 381 TRAN.OUT1 PLANT DEF Binary transistor output TAA 1 faulty. Check cabling to plant. 382 TRAN.OUT2 PLANT DEF Binary transistor output TAA 2 faulty. Check cabling to plant. 383 TRAN.OUT3 PLANT DEF Binary transistor output TAA 3 faulty. Check cabling to plant. 384 TRAN.
6.
Alarm text Meaning 016 L2 P-LUBE OIL Lube-oil pressure too low (2nd limit) automatic engine shutdown Task 1. Check engine-oil level and top up, if required (→ Page 123); 2. Try to re-start the engine (→ Page 52). 3. Contact Service. 023 L1 COOLANT LEVEL Engine coolant level too low Check coolant level and top up, if re‐ quired (→ Page 131) . 024 L2 COOLANT LEVEL Engine coolant level too low Check coolant level and top up, if re‐ quired (→ Page 131).
Fault code Alarm text Meaning Task 078 LIM INTER‐ COOLER LEV.
Fault code Alarm text Meaning Task 106 ERR REC1 NOT VALID Check sum error of fault mem‐ If fault occurs repeatedly: Contact Serv‐ ory in EDM (redundant data ice. record 1) 107 ERR REC2 NOT VALID Check sum error of fault mem‐ If fault occurs repeatedly: Contact Serv‐ ory in EDM (redundant data ice. record 2) 118 L1 SUPPLY VOLT. LOW Supply voltage too low (1st limit) Check ECU supply voltage. 119 L2 SUPPLY VOLT. LOW Supply voltage too low (2nd limit) Check ECU supply voltage.
Fault code Alarm text Meaning Task 146 L1 AD-TEST1 SUPPLY A/D-converter supply voltage too low Contact Service. 147 AD-TEST1 ECU DEFECT Electronic equipment defec‐ tive; Contact Service. automatic engine shutdown 148 L1 AD-TEST2 SUPPLY A/D-converter supply voltage too low Contact Service. 149 AD-TEST2 ECU DEFECT Electronic equipment defec‐ tive; Contact Service. automatic engine shutdown 150 L1 AD-TEST3 SUPPLY A/D-converter supply voltage too low Contact Service.
Alarm text Meaning 201 SD T-COOLANT Sensor defect (coolant tem‐ perature) 1. Check wiring. 2. Contact Service. 202 SD T-FUEL Sensor defect (Fuel tempera‐ ture) 1. Check wiring. 2. Contact Service. 203 SD T-CHARGE AIR Sensor defect (charge-air temperature) 1. Check wiring. 2. Contact Service. 205 SD T-COOLANT INTERC. Sensor defect (charge-air coolant temperature) 1. Check wiring. 2. Contact Service. 208 SD P-CHARGE AIR Sensor defect (charge-air pressure) 1. Check wiring. 2.
TIM-ID: 0000003157 - 001 Fault code Alarm text Meaning Task 274 SD P-EXTERN 2 External device defective (CAN P-EXTERN 2) Contact Service. 275 SD EXT.COOL‐ ANT LEVEL External coolant-level monitor‐ Contact Service. ing defective (CAN) 276 SD INTERCOOL‐ External charge-air coolantER LEVEL level monitoring defective (CAN) Contact Service. 277 SD BIN-EXTERN External device defective 3 (CAN BIN-EXTERN 3) Contact Service.
Fault code Alarm text Meaning Task 319 TIMING CYLIN‐ DER B9 Injection timing fault cylinder B9 If fault occurs repeatedly: Contact Serv‐ ice. 320 TIMING CYLIN‐ DER B10 Injection timing fault cylinder B10 If fault occurs repeatedly: Contact Serv‐ ice. 321 WIRING CYLIN‐ DER A1 Faulty wiring to solenoid valve cylinder A1; 1. Check wiring. 2. Contact Service. Misfiring 322 WIRING CYLIN‐ DER A2 Faulty wiring to solenoid valve cylinder A2; 1. Check wiring. 2. Contact Service.
Fault code Alarm text Meaning Task 334 WIRING CYLIN‐ DER B4 Faulty wiring to solenoid valve cylinder B4; 1. Check wiring. 2. Contact Service. Misfiring 335 WIRING CYLIN‐ DER B5 Faulty wiring to solenoid valve cylinder B5; 1. Check wiring. 2. Contact Service. Misfiring 336 WIRING CYLIN‐ DER B6 Faulty wiring to solenoid valve cylinder B6; 1. Check wiring. 2. Contact Service. Misfiring 337 WIRING CYLIN‐ DER B7 Faulty wiring to solenoid valve cylinder B7; 1. Check wiring. 2. Contact Service.
Fault code Alarm text Meaning 348 OPEN_LOAD CYL. A8 Disconnection in wiring to sol‐ enoid valve cylinder A8; Task 1. Check wiring. 2. Contact Service. Misfiring 349 OPEN_LOAD CYL. A9 Disconnection in wiring to sol‐ enoid valve cylinder A9; 1. Check wiring. 2. Contact Service. Misfiring 350 OPEN_LOAD CYL. A10 Disconnection in wiring to sol‐ enoid valve cylinder A10; 1. Check wiring. 2. Contact Service. Misfiring 351 OPEN_LOAD CYL.
Fault code Alarm text Meaning Task 363 STOP POWER STAGE 1 Solenoid valve or wiring or ECU defective automatic engine shutdown 364 STOP POWER STAGE 2 Solenoid valve or wiring or ECU defective automatic engine shutdown 1. Check wiring. 2. Try to re-start the engine (→ Page 52). 3. Contact Service. STOP MV-WIR‐ ING Solenoid-valve wiring faulty; 381 TRAN.OUT1 PLANT DEF Binary transistor output plant 1 defective Contact Service. 382 TRAN.
7 Task Description 7.1 Engine 7.1.1 Engine – Barring manually Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use DANGER Part No. Qty. Barring tool for 12V engines F6558556 1 Barring tool for 16V engines F6558557 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.
7.1.2 Engine – Barring with starting system Special tools, Material, Spare parts DANGER Designation / Use Part No. Qty. Connector pliers 0135315483 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 with starting system 1. 2. 3. 4.
7.1.3 DANGER WARNING Engine – Test run 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. Engine – Test run Start engine (→ Page 52). Perform test run not below 1/3 load and at least until steady-state temperature is reached. Carry out operational checks (→ Page 54). Stop engine (→ Page 55).
7.2 Cylinder Liner 7.2.1 Cylinder liner – Endoscopic examination Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Rigid endoscope Y20097353 1 Preparatory steps 1. 2. Remove cylinder head cover (→ Page 97). Remove injector (→ Page 103). Positioning crankshaft at BDC 1. 2. Using barring gear, turn crankshaft until crankshaft journal of the cylinder to be inspected has reached BDC.
Final steps Install injector (→ Page 103). Install cylinder head cover (→ Page 97). TIM-ID: 0000000015 - 014 1. 2.
7.2.2 Instructions and comments on endoscopic and visual examination of cylinder liners Terms used for endoscopic examination Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic exami‐ nation report. Findings Action Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing prod‐ ucts, particles, broken-off burrs). Removed cylinders clearly show such scoring on the running surface under endoscope magnification.
Findings Action Burn mark This is caused by a malfunction in the liner / ring tribosystem. Usually they run over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring and be‐ coming more visible from the second TDC-ring 2 onwards and less pronounced from TDC-ring 1. The honing pattern is usually no longer visible and displays a clearly defined (straight) edge to the undisturbed surface. The damaged surface is usually discolored. The circumferential length varies.
7.3 Crankcase Breather 7.3.1 Crankcase breather – Wire mesh cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Cleaner Diesel fuel Grease (Kluthe Hakuform 30-10/Emulgier) WARNING WARNING Qty. X00029933 1 Sealing ring (→ Spare Parts Catalog) Screw (→ Spare Parts Catalog) Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke.
Crankcase breather – Wire mesh cleaning 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. TIM-ID: 0000000016 - 001 14. 15. Remove hose from oil separator hous‐ ing (1). Remove cylinder head cover (5). Release screws (4), remove deflector plate (6) and retainer (7). Take off oil separator housing (1). Remove sealing ring (8) from oil separator housing (1). Remove individual parts from oil separator housing (1). Wash filter element (wire mesh) (3) with diesel fuel.
7.3.2 Crankcase breather – Oil separator element replacement, diaphragm check and replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use WARNING Part No. Qty. Torque wrench, 6-50 Nm F30027336 1 Ratchet adapter F30027340 1 Engine oil Filter element (→ Spare Parts Catalog) Diaphragm (→ Spare Parts Catalog) Gasket (→ Spare Parts Catalog) Hot oil. Oil can contain combustion residues which are harmful to health.
Checking diaphragm 1. 2. 3. 4. 5. 6. Remove cover (4). Remove spring (5), gasket (2) and dia‐ phragm (3). Check diaphragm (3) for damage, fit new diaphragm if used one is damaged. Install diaphragm (3) on housing (1). Install new seal (2) and spring (5) together with cover (4). Use torque wrench to tighten the screws of cover (4) to the specified torque. Name Size Screw Lubricant Value/Standard Tightening torque (Engine oil) 10 Nm −2 Nm Check diaphragms in further oil separators in the same way.
7.4 Valve Drive 7.4.1 Valve clearance – Check and adjustment Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine coolant temperature is max. 40 °C. ☑ Valves are closed. Special tools, Material, Spare parts Designation / Use Part No. Qty. Feeler gauge Y20010128 1 Torque wrench, 20–100 Nm F30026582 1 Ratchet adapter F30027340 1 Measuring device Y4341106 1 Preparatory steps 1. 2. 3. 4. TIM-ID: 0000004351 - 001 5. Remove cylinder head cover (→ Page 97).
Checking valve clearance at two crankshaft positions 1 2 I X 1. 2. 3. 4. 5. Cylinder A1 is in firing TDC Cylinder A1 is in overlap TDC Inlet valve Exhaust valve Check TDC position of piston in cylinder A1: • The piston is at firing TDC when the rockers are unloaded at cylinder A1. • The piston is at overlap TDC when the rockers are loaded at cylinder A1. Check valve clearance with cold engine: • Inlet = 0.4 mm; • Exhaust = 0.
7.4.2 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.
7.5 Injection Pump / HP Pump 7.5.1 Injection pump – Replacement Special tools, Material, Spare parts Designation / Use Injection pump Part No. Qty. (→ Spare Parts Catalog) Injection pump – Replacement Remove injection pump and install new one (→ Page 99).
7.5.2 Injection pump – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use DANGER WARNING Part No. Qty. Crowfoot wrench, 19 mm F30027424 1 Crowfoot wrench, 22 mm F30027425 1 Torque wrench, 20–100 Nm F30026582 1 Ratchet adapter F30027340 1 Transition piece F30006234 1 Torque wrench, 0.
Removing injection pump 1. 2. 3. 4. 5. 6. 7. 8. Mark installation position of injection pump. Disconnect wiring (1) from injection pump. Remove fuel line (2). Unscrew securing screws of injection pump by approx. 6 mm. • The pretensioned compression spring will press the injection pump out of the crankcase, if this does not happen: a) Turn crankshaft with engine barring tool (→ Page 84) • The pump cam presses the injection pump out of the crankcase, if not: .
8. 9. 10. 11. 12. 13. 14. Install injection pump, observing marked in‐ stallation position. Install securing screws of injection pump and tighten with torque wrench to specified torque 60 Nm + 12 Nm. Install fuel line (2). Use torque wrench to tighten union nut at injection pump to specified torque 20 Nm + 5 Nm. • Maximum permissible tightening tor‐ que: 35 Nm Use torque wrench to tighten union nut on pressure pipe neck to specified torque 20 Nm + 5 Nm.
7.6 Injection Valve / Injector 7.6.1 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 103).
7.6.2 Injector – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use WARNING WARNING Part No. Qty.
Removing fuel injector 1. 2. 3. 4. 5. Remove leak-off-fuel lines. Remove fuel line (3). Remove thrust screw (2). Pull off pressure pipe neck (1). Extract fuel from the exposed bores using the suction device. 6. 7. 8. 9. 10. Remove screw (2). Take off clamp (1). Screw extractor into injector. Remove injector using the extractor. Remove sealing ring using a self-made hook. Seal all openings with appropriate covers after removal. TIM-ID: 0000004645 - 001 11.
Installing fuel injector 1. 2. 3. 4. 5. Result: 6. Result: 7. Result: 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. TIM-ID: 0000004645 - 001 18. Remove all covers before installation. Clean sealing surface on cylinder head and protective sleeve. Coat sealing ring (1) with grease and fit on‐ to injector. Coat sealing ring (2) with grease and fit on‐ to injector. Press injector into cylinder head by hand. • The pin is at 11-o'clock position to the longitudinal axis of the engine.
7.7 Fuel System 7.7.1 Fuel pressure relief valve – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use WARNING Part No. Pressure relief valve (→ Spare Parts Catalog) Sealing ring (→ Spare Parts Catalog) Qty. Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Fuel pressure relief valve – Replacement, variant A 1. 2. 3. 4. 5. 6. 7.
Fuel pressure relief valve – Replacement, variant B 1. 2. 3. 4. 5. 6. 7. TIM-ID: 0000004989 - 001 8. Close fuel supply. Remove fuel line (7). Remove banjo screw (4). Remove sealing rings (5). Remove screws (2) with washer (3). Remove screws (6) and take off bracket. Install new pressure relief valve (1) with new sealing rings (5) in reverse sequence of operations. Open fuel supply.
7.7.2 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 110). Catch fuel as it runs out. Install fuel filter (→ Page 110). TIM-ID: 0000004702 - 002 1. 2. 3. 4.
7.7.3 Fuel system – Venting Fuel system – Venting Bar engine with starting system (→ Page 85). Repeat procedure 2 to 3 times, the fuel system is automatically vented. TIM-ID: 0000004705 - 002 1. 2.
7.8 Fuel Filter 7.8.1 Fuel filter – Replacement Special tools, Material, Spare parts Designation / Use Filter wrench DANGER WARNING WARNING CAUTION Part No. Qty. F30379104 1 Diesel fuel Easy-change filter (→ Spare Parts Catalog) Synthetic ring (→ 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.
1. 2. 3. 4. 5. 6. 7. 8. 9. Stop engine (→ Page 55) and disable engine start. Cut out the filter to be replaced. Remove cut-out easy-change filter using the filter wrench. Clean the sealing surface of the filter head. Check sealing ring of the new easy-change filter and coat it with fuel. Install and tighten new filter by hand. Set three-way cock to operating position (both filters cut in). Replace further fuel filters in the same way. Vent fuel system. Fuel filter replacement with the engine running 1. 2.
7.8.2 Fuel prefilter cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Diesel fuel Sealing ring 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. Fuel prefilter cleaning 1. 2. 3. 4. 5. 6. 7. 8. 9. TIM-ID: 0000004936 - 001 10. Shut off fuel supply. Remove nuts from filter head.
7.8.3 DANGER WARNING Fuel prefilter – Differential pressure gauge check and adjustment 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. Adjusting differential pressure gauge 1. 2. When installing the new filter element: align adjustable pointer (2) with pressure-indicat‐ ing pointer (3) of pressure gauge (1).
7.8.4 Fuel prefilter – Draining Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Diesel fuel Gasket 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 filter to be drained. 1 Left filter cut in 2 Right filter cut in 2. Open threaded vent plug (5) of filter to be drained.
7.8.5 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).
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 55) and disable engine start. Remove screws for cover and take off cover (2). Fill filter housing with clean fuel.
7.8.6 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) Gasket (→ 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 filter to be drained.
2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. TIM-ID: 0000004944 - 005 14. Open threaded vent plug (5) of contaminat‐ ed filter. Unlock drain valve (6) by pressing toggle and open it. Drain water and dirt from filter. 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 gasket in cover (2).
7.9 Charge-Air Cooling General, Left-Hand Side 7.9.1 Intercooler – Checking condensate drains for coolant discharge and obstructions Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Sealing ring WARNING Qty. (→ Spare Parts Catalog) Compressed air Risk of injury! • Do not direct compressed-air jet at persons. • Wear protective goggles / safety mask and ear protectors.
7.10 Air Filter 7.10.1 Air filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. TIM-ID: 0000005460 - 001 Replace air filter, carry out work in accordance with the instructions of the manufacturer – scope of supply of the unit manufacturer.
7.11 Air Intake 7.11.1 Service indicator – Signal ring position check Preconditions ☑ Engine is stopped and starting disabled. Checking signal ring position of service indicator (if fitted) 1. 2. TIM-ID: 0000005481 - 001 Result: If the signal ring is completely visible in the control window (2), replace air filter (→ Page 120). After installation of new filter, press reset button (1). Engaged piston with signal ring moves back to initial position.
7.12 Starting Equipment 7.12.1 Starter – Condition check Preconditions ☑ Engine is stopped and starting disabled. Checking starter condition Check securing screws of starter for secure seating and tighten if required. Check wiring (→ Page 144). TIM-ID: 0000000905 - 017 1. 2.
7.13 Lube Oil System, Lube Oil Circuit 7.13.1 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 124). Insert oil dipstick into guide tube up to the stop.
7.13.2 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.
7.14 Oil Filtration / Cooling 7.14.1 Engine oil filter – Replacement Special tools, Material, Spare parts Designation / Use Filter wrench Engine oil Oil filter DANGER WARNING WARNING CAUTION Part No. Qty. F30379104 1 (→ 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. Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. Hot oil.
Oil filter replacement with the engine running A Filter in operation (normal position) B Filter switched off Note: 1. 2. 3. 4. 5. 6. Remove oil filter using the filter wrench. Clean the sealing face of the connecting piece. Check sealing ring of new oil filter and moisten it with oil. Install and tighten new oil filter by hand. Cut in the cut-out filter: Turn switching lever to position A. Replace other oil filters in the same way. Check oil level (→ Page 123). TIM-ID: 0000014211 - 001 7. 8.
7.15 Coolant Circuit, General, High-Temperature Circuit 7.15.
Left side 2 Engine coolant drain plug TIM-ID: 0000006688 - 001 1 Engine coolant drain plug 128 | Task Description | MS150025/02E 2012-10
Right side 2 Engine coolant drain plug TIM-ID: 0000006688 - 001 1 Engine oil drain plug (heat exchanger) MS150025/02E 2012-10 | Task Description | 129
Driving end (KS) 2 Intercooler drain 3 Engine oil drain plug TIM-ID: 0000006688 - 001 1 Engine coolant drain plug 130 | Task Description | MS150025/02E 2012-10
7.15.2 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 engine coolant level at filler neck: 1. 2. 3. Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to escape.
7.15.3 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant – Change Drain engine coolant (→ Page 133). Fill with engine coolant (→ Page 134). TIM-ID: 0000000036 - 030 1. 2.
7.15.4 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. Preparatory steps 1. 2. Provide an appropriate container to drain the coolant into. Switch off preheating unit. Draining engine coolant 1. 2.
7.15.5 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.
Final steps Start the engine and operate it at idle speed for some minutes. Check coolant level (→ Page 131), top up with coolant if required. TIM-ID: 0000000034 - 005 1. 2.
7.15.6 DANGER WARNING 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. Coolant pump – Relief bore check 1. 2. 3. TIM-ID: 0000000038 - 001 4. Check relief bore for oil and water dis‐ charge.
7.16 Low-Temperature Circuit 7.16.1 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 Part No. Coolant Sealing ring WARNING WARNING CAUTION 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.
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 141). TIM-ID: 0000000039 - 003 1. 2.
7.16.2 Charge-air 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. Draining charge-air coolant 1. 2. 3. 4. 5. 6. 7. 8. TIM-ID: 0000014854 - 001 9.
7.16.3 Charge-air coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Charge-air coolant – Change Drain charge-air coolant (→ Page 139). Fill with charge-air coolant (→ Page 137). TIM-ID: 0000000041 - 011 1. 2.
7.16.4 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.
7.17 Belt Drive 7.17.1 Drive belt – Condition check Preconditions ☑ Engine is stopped and starting disabled. ☑ Guard is removed.
7.18 Engine Mounting / Support 7.18.1 Engine mounts – Resilient elements check Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine is filled with coolant and engine oil. Engine mounts – Resilient elements check 1. 2. 3. Wipe rubber surface with dry cloth, do not use organic detergents. Check resilient elements for crack formation and deformation by visual inspection. Have cracked elements replaced, contact Service. Setting dimension check 1. TIM-ID: 0000007552 - 001 2.
7.19 Wiring (General) for Engine/Gearbox/Unit 7.19.1 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.
7.20 Accessories for (Electronic) Engine Governor / Control System 7.20.1 Engine governor and connectors – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Connector pliers 0135315483 1 Isopropyl alcohol X00058037 1 Engine governor and connectors Cleaning 1. 2. 3. Remove coarse dirt from housing surface with isopropyl alcohol.
7.20.2 Engine monitoring unit and connectors – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Connector pliers 0135315483 1 Isopropyl alcohol X00058037 1 Engine monitoring unit and connectors – Cleaning 1. 2. 3. Remove coarse dirt from housing surface with isopropyl alcohol. Remove dirt from surface of connectors (1), connector sockets and shrink sleeves (2) using a cloth moistened with isopropyl alco‐ hol.
7.20.3 Checking engine control unit plug connections Preconditions ☑ Engine shut down and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Connector pliers 0135315483 1 Checking engine control unit plug connections 1. 2. 3. TIM-ID: 0000000949 - 003 4. Use connector pliers (3) to make certain that all plug-in connections on engine con‐ trol unit are securely seated.
7.20.4 Engine monitoring unit – Plug connection check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Connector pliers 0135315483 1 Checking engine monitoring unit plug connections 1. 2. 3. TIM-ID: 0000008394 - 003 4. Use connector pliers (3) to make certain that all engine monitoring unit plug connec‐ tions are securely seated.
7.20.5 Engine control unit – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Connector pliers 0135315483 1 Covering caps for Cannon sockets Removing control unit from engine 1. 2. TIM-ID: 0000008487 - 004 3. 4. Note or mark assignment of cables to con‐ nector sockets. Use connector pliers (2) to disengage the bayonet union nuts (4) of the connectors (3) by turning them counterclockwise.
5. 6. 7. Disconnect ground strap from engine con‐ trol unit grounding stud (7). If the screws (4) are easily accessible: 1. Remove screws (4). 2. Remove engine control unit housing (3) from mounting plates (2). 3. Unscrew mounting plates (2), cable shock absorbers (5) and further fasten‐ ing parts (6) as one unit from engine. If the screws (4) are not easily accessible: 1. Unscrew screws (1). 2. Remove engine control unit housing (3) together with mounting plates (2). 3.
7.21 Emergency Instrumentation (Local Operating Panel) 7.21.1 LOP – Visual inspection Preconditions ☑ Engine is stopped and starting disabled. Preparatory steps 1. Result: 2. 3. If READY FOR OPERATION pushbutton is illuminated brightly, press switch briefly. READY FOR OPERATION pushbutton returns to basic brightness. Switch master power switch to OFF. Disconnect battery in accordance with battery manufacturer's instructions. Checking housing and internal assemblies for secure seating 1. 2. 3.
Checking threaded connections 1. 2. Check all connected cables to verify that the two securing elements (1) are engaged on the lugs (2) so that the respective male connector (3) is held firmly in place in the socket. If this is not the case, press the securing el‐ ements (1) concerned in the direction of the arrow until they engage noticeably. Checking unassigned connector sockets 1. 2. 3. Ensure that non-assigned connector sock‐ ets are protected with covering caps.
Performing lamp test 1. TIM-ID: 0000008868 - 005 2. 3. 4. Result: 5. Connect battery in accordance with battery manufacturer's instructions. Switch master power switch to ON. Switch on engine control system. Hold down LAMP TEST pushbutton: Indicators and controls light up. Have damaged lamps immediately replaced by Service.
7.21.2 LOP – Test procedures Preconditions ☑ Engine is stopped and starting disabled. Preparatory steps 1. 2. 3. Result: Connect battery in accordance with battery manufacturer's instructions. Switch master power switch to ON. Switch on engine management system ECS-5. • LOCAL OPERATION pushbutton (1) is il‐ luminated brightly (local control mode is active);. Switching between Local and Remote mode (automatic on-board network) 1. Result: TIM-ID: 0000008872 - 004 2.
Overspeed test with the engine at standstill Note: 1. Result: 2. Result: 3. Result: 4. Overspeed test with the engine at standstill can only be carried out if the engine is equipped with Engine Monitoring Unit. Press OVERSPEED TEST illuminated pushbutton (3). Observe speed limit and speed simulated by Engine Monitoring Unit on display. • Engine Control Unit is de-energized by the safety system. • Engine governing is completely deacti‐ vated. • On engines with emergency air-shutoff flaps: Flaps close.
8 Engine Governor Assignment and Circuitry 8.1 Engine Governor 8.1.1 Engine governor channel circuitry Engine governor channel circuitry Binary inputs BE1 to BE9 1 Engine Control Unit ECU 4 Function Function Source Acquisition of binary signals. Switches, pushbuttons, monitors, contacts. Channel specification Type Isolated binary input, external supply. Input signal UIn(high) = 24 V (min. 8 V). TIM-ID: 0000009437 - 001 UIn(low) = 0 V (max. 4 V).
Current input IUE 1 1 Current source, voltage source 2 Engine Control Unit ECU 4 Function Function Source Acquisition of a current signal (4 to 20 mA). - Measuring channel specification Measuring range IIn = 4 to 20 mA; Load: At 20 mA approx. 4 V; iso‐ lated. Or: UIn = 0 to 10 V Binary sensor input NSE 1 TIM-ID: 0000009437 - 001 1 Monitor contact 2 Engine Control Unit ECU 4 Function Function Source Lube oil differential pressure monitoring.
Pulse measuring inputs KW 1 and NW 1 1 Inductive sensor 2 Engine Control Unit ECU 4 Channel Function Sensor KW1 Measuring of crankshaft angle and crankshaft speed. Inductive sensor NW1 Measuring of camshaft angle and Inductive sensor camshaft speed. Speed measuring input DME 1, DME 2 Function Sensor Measuring of speeds (e.g. ETC).
Temperature inputs TE 1 to TE 9 1 Engine Control Unit ECU 4 Function Sensor Temperature measuring Temperature-dependent resistor Pt100/Pt1000 (exhaust gas temperatures are measured with Pt100). Pressure inputs DE 1 to DE 7 TIM-ID: 0000009437 - 001 1 Pressure sensor 2 Engine Control Unit ECU 4 Function Function Sensor Pressure range measuring Relative pressure sensors (exception: The chargeair pressure sensor is an absolute pressure sen‐ sor).
Measuring channel specification Measuring range Sensor-dependent Output signal UO 0.5 to 4.5 VDC Sensor supply 5 V ± 250 mV Pressure measuring input HP pump DEH (rail pressure) 1 Pressure sensor 2 Engine Control Unit ECU 4 Function Function Sensor Pressure measuring Relative pressure sensor Measuring channel specification Sensor-dependent Output signal UO 0.5 to 4.
Transistor outputs TAA 1 to TAA 6 1 Engine Control Unit ECU 4 Function Function Sensor Switching output Plant Channel specification Channel TAA1 to TAA6 positive-switching 24 VDC. Output current TAA1 to TAA4: lO = 150 mA max. TAA5: lO = 300 mA max. TAA6: lO = 1 A max.
Function Function Sensor Output voltage 0 to 10 V, e.g. for display instru‐ ments Plant Channel specification Output voltage UO = 0 to 10 V Output current lO = 5 mA max.
Function Sensor Switching output Engine Solenoid valve outputs MVA 1 to MVA 20 1 Engine Control Unit ECU 4 Function Sensor Injector control Injection solenoid valve CAN bus interface TIM-ID: 0000009437 - 001 1 2 3 4 CAN bus Terminator Electrical isolation Engine Control Unit ECU 4 Function Channel Function Target CAN1 / CAN2 Bus connection to external sys‐ tems.
Channel specification Physical level ISO 11 898 CAN specification Version 2.0 A Data format MTU-specific Terminator In connector (no bus disruption when connector disconnected) Baud rate 125 kbaud Electrical isolation ± 50 V The CAN bus interfaces operate independently of each other.
8.1.2 MDEC governor assignment Scope of delivery Included in the scope of delivery are: • SAM • W004 MDEC connector X1 10 m long (15 m and 25 m available as an option). • W003 (4x2.5 mm2) MDEC connector X5 (15 m and 25 m available as an option). The MDEC governor is protected by a 20 A automatic cutout via cable W003 connector X5. The PIM modules are wired to a separate 10 A fuse (see MTU wiring diagram). All control, display and communication signals are in interface cable W004 MDEC connector X1.
TAA3 Combined alarm All warning messages (Limit1) are indicated here as a combined alarm. TAA4 n > 300 Indication of engine speed > 300 rpm. TAA5 SS T-coolant Shutdown, coolant temperature too high. TAA6 SS P-lube oil Shutdown, lube oil pressure too low. Analog MDEC inputs IEU1 = 0 to 10 V or 4 to 20 mA It is possible to activate different analog desired speed settings for the MDEC governor. Default setting: • Characteristic curve 71 (50 Hz) in MDEC gover‐ nor 0 to 10 V activated.
8.2 Connector Assignment 8.2.1 Connector pin assignment Connector pin assignment Connector X1, view to socket Connector X1 Connector type VPT 06 GSE 22–55 P Target Plant wiring harness TIM-ID: 0000009431 - 001 Pin assignment Channel Signal Pin Comments IUE1 5V_ISO BB 5 V / 20 mA electrically isolated IUE1 U_IN AA 0 V to 10 V IUE1 I_IN X 0 V to 23.7 mA IUE1 GND_ISO q IUE2 5V_ISO b 5 V / 20 mA electrically isolated IUE2 U_IN r 0 V to 10 V IUE2 I_IN A 0 V to 23.
Channel Signal Pin Comments UA4 OUT Z 0 V to 10 V/ 8 mA UA4 GND Y BE1 +IN h U < 4 V = low / U > 8 V = high BE1 -IN g Electrically isolated BE2 +IN x U < 4 V = low / U > 8 V = high BE2 -IN w Electrically isolated BE3 +IN R U < 4 V = low / U > 8 V = high BE3 -IN P Electrically isolated BE4 +IN j U < 4 V = low / U > 8 V = high BE4 -IN i Electrically isolated BE5 +IN FF U < 4 V = low / U > 8 V = high BE5 -IN EE Electrically isolated BE6 +IN v U < 4 V = low /
Channel Signal Pin Comments TAA6 GND K (Plant supply, coil instru‐ ments FZ) CAN1 HIGH G Electrically isolated CAN1 LOW F CAN1 GND E CAN2 HIGH C CAN2 LOW B CAN2 GND D Electrically isolated Connector X2, view to socket Connector X2 Connector type VPT 06 GSE 22–55 PW Target Engine wiring harness TIM-ID: 0000009431 - 001 Pin assignment Channel Signal Pin Comments TE1 IN k 0 V to 5 V/ internal 2 k0 pullup to 5 V_TE_BUF TE1 GND z TE2 IN N TE2 GND P TE5 IN M T
Channel Signal Pin Comments TE7 IN w 0 V to 5 V/ internal 2 k0 pullup to 5 V_TE_BUF TE7 GND x TE8 IN t TE8 GND a TE9 IN E TE9 GND F DE1 5 V_BUF1 D 5 V / 20 mA DE1 IN Z 0 V to 5 V / inter‐ nal 47k5 pulldown DE1 GND Y DE2 5 V_BUF1 r 5 V / 20 mA DE2 IN s 0 V to 5 V / inter‐ nal 47k5 pulldown DE2 GND CC DE3 5 V_BUF2 BB 5 V / 20 mA DE3 IN GG 0 V to 5 V / inter‐ nal 47k5 pulldown DE3 GND HH DE4 5 V_BUF2 d 5 V / 20 mA DE4 IN H 0 V to 5 V / inter‐ nal 4
Channel Signal Pin Comments NSE2 IN q 0 V to 5 V/ internal 47k5 pullup to 5 V_TE_BUF NSE2 GND V KW +IN m KW -IN S NW +IN T NW -IN n DME1 +IN p DME1 -IN AA DME2 +IN A DME2 -IN U PDM1 OUT K PDM1 GND L TAM1 OUT R TAM1 GND j TAM2 OUT h TAM2 GND i U < 0 V = low / U > 400 mV = high U < 0 V = low / U > 400 mV = high U < -400 mV = low / U > 400 mV = high U < -400 mV = low / U > 400 mV = high 24 V / 3 A 24 V / 1.5 A 24 V / 1.
Channel Signal Pin Comments TE3 IN b 0 V to 5 V/ internal 2 k0 pullup to 5 V_TE_BUF TE3 GND c TE4 IN U TE4 GND V TE10 IN E TE10 GND D DE8 5 V_BUF4 J 5 V / 20 mA DE8 IN Y 0 V to 5 V / inter‐ nal 47k5 pulldown DE8 GND K DEH 5 V_BUF5 B 5 V / 20 mA DEH IN T 0 V to 5 V / inter‐ nal 47k5 pulldown/ TP2:20 Hz DEH GND C NSE3 24 V_NSE3 A Sensor supply max.
Connector X4, view to socket Connector X4 Connector type VPT 06 GSE 21–41 PW Target Engine wiring harness (solenoid valves) TIM-ID: 0000009431 - 001 Pin assignment Channel Signal Pin Comments MV1 HIGH n 24 V / 20 A MV1 LOW m Bank 1 MV2 HIGH D 24 V / 20 A MV2 LOW C Bank 1 MV3 HIGH F 24 V / 20 A MV3 LOW E Bank 1 MV4 HIGH a 24 V / 20 A MV4 LOW Z Bank 1 MV5 HIGH H 24 V / 20 A MV5 LOW G Bank 1 MV6 HIGH s 24 V / 20 A MV6 LOW r Bank 1 MV7 HIGH Y 24 V / 2
Channel Signal Pin Comments MV11 LOW R Bank 2 MV12 HIGH P 24 V / 20 A MV12 LOW N Bank 2 MV13 HIGH i 24 V / 20 A MV13 LOW h Bank 2 MV14 HIGH g 24 V / 20 A MV14 LOW f Bank 2 MV15 HIGH U 24 V / 20 A MV15 LOW T Bank 2 MV16 HIGH K 24 V / 20 A MV16 LOW J Bank 2 MV17 HIGH M 24 V / 20 A MV17 LOW L Bank 2 MV18 HIGH e 24 V / 20 A MV18 LOW d Bank 2 MV19 HIGH c 24 V / 20 A MV19 LOW b Bank 2 MV20 HIGH q 24 V / 20 A MV20 LOW p Bank 2 TIM-ID:
Channel Signal Pin Comments POWER +24 V A Usupp = 24 V / 30 A POWER +24 V D POWER GND B POWER GND C POWER GND E Connector X6, view to socket Connector X6 Connector type VPT 06 GSE 12-10 P Target Dialog unit Pin assignment Signal Pin Comments POWER +24 V A Usupp = 24 V / 30 A POWER +24 V D POWER GND B POWER GND C POWER GND E TIM-ID: 0000009431 - 001 Channel MS150025/02E 2012-10 | Engine Governor Assignment and Circuitry | 175
9 Appendix A 9.
Abbre‐ Meaning viation EMU Engine Monitoring Unit ETK Ersatzteilkatalog EUI Electronic Unit Injector FPS Fuel Pressure Sensor FRS Fuel Differential Pressure Sensor FTS Fuel Temperature Sensor Explanation Spare Parts Catalog (SPC) TIM-ID: 0000000858 - 010 FWCP Fire Water Control Panel GND Ground HP High pressure HI High Alarm: Measured value exceeds 1st maximum limit HIHI High High Alarm: Measured value exceeds 2nd maximum limit value HT High Temperature IDM Interface Data Module
Abbre‐ Meaning viation Explanation SEL 1st function: Warning lamp (stop engine and rectify fault) Stop engine light 2nd function: Read out fault codes SID System Identifier SRS Synchronous Reference Sensor TDC cylinder 1 SS Safety System Safety system alarm TBS Turbocharger Boost Sensor Monitors charge-air pressure TCI Turbo Compressor Inlet TCO Turbo Compressor Outlet TD Transmitter Deviation TPS Throttle Position Sensor TRS Timing Reference Sensor T-xyz Temperature-xyz Temperat
9.2 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.
10 Appendix B 10.1 Special Tools Barring tool for 12V engines Part No.: F6558556 Qty.: Used in: 1 7.1.1 Engine – Barring manually (→ Page 84) Part No.: F6558557 Qty.: Used in: 1 7.1.1 Engine – Barring manually (→ Page 84) Part No.: 0135315483 Qty.: Used in: 1 7.1.2 Engine – Barring with starting system (→ Page 85) Qty.: Used in: 1 7.20.1 Engine governor and connectors – Cleaning (→ Page 145) Qty.: Used in: 1 7.20.2 Engine monitoring unit and connectors – Clean‐ ing (→ Page 146) Qty.
Crowfoot wrench, 19 mm Part No.: F30027424 Qty.: Used in: 1 7.5.2 Injection pump – Removal and installation (→ Page 99) Qty.: Used in: 1 7.6.2 Injector – Removal and installation (→ Page 103) Part No.: F30027425 Qty.: Used in: 1 7.5.2 Injection pump – Removal and installation (→ Page 99) Qty.: Used in: 1 7.6.2 Injector – Removal and installation (→ Page 103) Part No.: F30011450 Qty.: Used in: 1 7.6.2 Injector – Removal and installation (→ Page 103) Part No.: F30377999 Qty.: Used in: 1 7.
Feeler gauge Part No.: Y20010128 Qty.: Used in: 1 7.4.1 Valve clearance – Check and adjustment (→ Page 95) Part No.: F30379104 Qty.: Used in: 1 7.8.1 Fuel filter – Replacement (→ Page 110) Qty.: Used in: 1 7.14.1 Engine oil filter – Replacement (→ Page 125) Part No.: F30378207 Qty.: Used in: 1 7.6.2 Injector – Removal and installation (→ Page 103) Part No.: Y4341106 Qty.: Used in: 1 7.4.
Ratchet Part No.: F30027340 Qty.: Used in: 1 7.4.2 Cylinder head cover – Removal and installation (→ Page 97) Part No.: F30027340 Qty.: Used in: 1 7.3.2 Crankcase breather – Oil separator element re‐ placement, diaphragm check and replacement (→ Page 93) Qty.: Used in: 1 7.4.1 Valve clearance – Check and adjustment (→ Page 95) Qty.: Used in: 1 7.5.2 Injection pump – Removal and installation (→ Page 99) Qty.: Used in: 1 7.6.2 Injector – Removal and installation (→ Page 103) Part No.
Steam jet cleaner Part No.: - Qty.: Used in: 1 4.11 Plant cleaning (→ Page 59) Part No.: 0015384230 Qty.: Used in: 1 7.5.2 Injection pump – Removal and installation (→ Page 99) Part No.: F30026582 Qty.: Used in: 1 7.6.2 Injector – Removal and installation (→ Page 103) Part No.: F30026582 Qty.: Used in: 1 7.4.1 Valve clearance – Check and adjustment (→ Page 95) Qty.: Used in: 1 7.5.2 Injection pump – Removal and installation (→ Page 99) Torque wrench, 0.
Torque wrench, 6-50 Nm Part No.: F30027336 Qty.: Used in: 1 7.3.2 Crankcase breather – Oil separator element re‐ placement, diaphragm check and replacement (→ Page 93) Part No.: F30043446 Qty.: Used in: 1 7.4.2 Cylinder head cover – Removal and installation (→ Page 97) Part No.: F30006234 Qty.: Used in: 1 7.5.2 Injection pump – Removal and installation (→ Page 99) Qty.: Used in: 1 7.6.
10.
Injection pump – Replacement 98 Injection pump – Removal and installation 99 Injector – Replacement 102 Injector – Removal and installation 103 Intercooler – Condensate drains for coolant discharge – Check 119 – Condensate drains for obstructions – Check 119 Service partners 179 Spare parts service 179 Start engine in manual mode (testing mode) 52 Starter – Condition check 122 Stop engine in manual mode (testing mode) 55 T Technical data – SCB 3 47 Transport 7 Troubleshooting 61 L U LOP – Controls 48 –
