MTU 10V1600A70, Operating Instructions Manual

Page 1: ...Operating Instructions Diesel Engine 10V1600Ax0 10V1600Cx0 12V1600Ax0 12V1600Cx0 MS150100 04E...

Page 2: ...operation variable 12V1600C70 61 kW cyl 5B continuous operation variable Table 1 Applicability 2015 Copyright MTU Friedrichshafen GmbH This publication is protected by copyright and may not be used in...

Page 3: ...0 5 Operation 5 1 Putting the engine into operation after scheduled out of service period 51 5 2 Putting the engine into operation after extended out of service periods 3 months 52 5 3 Starting the en...

Page 4: ...d diverter pulley replacement 132 8 13 Drive Systems Driving End and Free End Coupling 134 8 13 1 Coupling Checking radial axial play 134 8 14 Wiring General for Engine Gearbox Unit 135 8 14 1 Engine...

Page 5: ...al as delivered configuration or in a configuration approved by the manufacturer in writing in cluding engine control parameters In compliance with all safety regulations and in adherence with all war...

Page 6: ...ation authorities The manufacturer does not accept any liability for violations of the emission regulations The maintenance schedules of the manufacturer must be observed over the entire life cycle of...

Page 7: ...ucted repeatedly Personnel requirements All work on the product shall be carried out by trained and qualified personnel only Training at the Training Center of the manufacturer Technical personnel fro...

Page 8: ...nts as well as the monitoring signaling and alarm systems are working properly Smoking is prohibited in the area of the product Safety regulations during operation The operator must be familiar with t...

Page 9: ...s must not be painted They may only be installed after painting the engine or must be covered before painting work is carried out The following applies to starters with copper beryllium alloy pinions...

Page 10: ...oduct when welding in its vicinity Before starting welding work Switch off the power supply master switch Disconnect the battery Separate the electrical ground of electronic equipment from the ground...

Page 11: ...es Chafing on components Contact with hot surfaces Do not secure cables on lines carrying fluids Do not use cable straps to secure cables Always use connector pliers to tighten union nuts on connector...

Page 12: ...th its han dling Noise Noise can lead to an increased risk of accidents if acoustic signals warning shouts or sounds indicating dan ger are drowned Wear ear protectors in workplaces with a sound press...

Page 13: ...test in accordance with the specifications Painting Observe the relevant safety data sheet for all materials When carrying out painting work outside the spray stands provided with fume extraction syst...

Page 14: ...edial action NOTICE In the event of a situation involving potentially adverse effects on the product Consequences Material damage Remedial action Additional product information Safety notices 1 This m...

Page 15: ...ine slowly Lifting cables chains must not touch the engine or any of its component parts when lifting Readjust lifting gear as necessary 7 For special packaging with aluminum foil Suspend the engine b...

Page 16: ...y Observe max admissible diagonal pull Max admissible diagonal pull in longitudinal direction is 10 degrees no transverse diagonal pull is admis sible in this case Max admissible diagonal pull in tran...

Page 17: ...nated in accordance with DIN ISO 1204 as viewed from driving end 4 For cylinder designation in accordance with DIN ISO 1204 the letter Ax refers to the cylinders on the left hand side of the engine 1...

Page 18: ...hermostat housing 4 EGR pipe with insulation 5 Cylinder head 6 Battery charging generator 7 Engine governor 8 Flywheel 9 Air compressor 10 Exhaust turbocharger low pressure charger 11 Exhaust turbocha...

Page 19: ...el filter 12 Belt 13 Engine coolant pump 14 Charge air coolant pump KGS Free end Engine model designation Key to the engine model designation 10 12V1600Ax0 Cx0 10 12 Number of cylinders V Cylinder arr...

Page 20: ...sure after filter 7 B9 1 Charge air temperature before exhaust gas recirculation 8 B26 Charge air coolant temperature 9 B10 Charge air pressure 10 B9 3 Charge air temperature after exhaust gas recircu...

Page 21: ...e 6 B48 2 HP fuel right side 12V only 7 B93 Oil level in oil pan 8 X2 Adaption of governor ECU9 9 X3 Adaption of governor ECU9 10 XF70 Water level in fuel prefilter 11 XF33 Engine coolant level 12 X21...

Page 22: ...side 2 M53 1 EGR shut off flap before cooler left side 3 XY39A2 Injector connection 4 XY57A Engine brake valve left side 5 XY39A1 Injector connection 6 B4 21 Exhaust temperature lambda sensor left si...

Page 23: ...d KS Item Name Description 1 B44 4 Speed of LP turbocharger right side 2 B50 Crankcase pressure 3 M52 2 HP turbine bypass flap right side 4 B13 Crankshaft speed MS150100 04E 2015 09 General Informatio...

Page 24: ...S Item Name Description 1 B7 Lube oil temperature 2 B34 2 Fuel pressure before filter 3 B34 1 Fuel pressure after filter 4 B6 3 Coolant temperature cylinder head 24 General Information MS150100 04E 20...

Page 25: ...0V1600 A70 Application group 5B 5B Charge air coolant temperature C 45 45 Barometric pressure mbar 981 981 Site altitude above sea level m 400 400 Power related data power ratings are net brake power...

Page 26: ...3 83 3 88 Exhaust gas temperature after exhaust turbocharger under stand ard conditions and at a site altitude of 400 m above sea level R C 370 420 Coolant system HT circuit Description 10V1600 A60 10...

Page 27: ...ne inlet connection min when engine is running L bar 0 65 0 65 Fuel pressure at engine inlet connection max when engine is starting L bar 0 0 Inclinations standard oil system reference waterline Descr...

Page 28: ...nd power level LW ISO 6798 3 dB A tolerance R dB A 122 122 Engine surface noise with attenuated intake noise filter BL free field sound pressure level Lp 1 m distance ISO 6798 2 dB A tolerance R dB A...

Page 29: ...arometric pressure mbar 981 981 Site altitude above sea level m 400 400 Power related data power ratings are net brake power as per ISO 3046 Description 10V1600 C60 10V1600 C70 Rated engine speed A rp...

Page 30: ...nt system HT circuit Description 10V1600 C60 10V1600 C70 Coolant temperature at engine connection outlet to cooling equipment A C 95 95 Coolant temperature after engine Limit 1 L C 107 107 Coolant tem...

Page 31: ...ressure at engine inlet connection max when engine is starting L bar 0 0 Inclinations standard oil system reference waterline Description 10V1600 C60 10V1600 C70 Longitudinal inclination continuous ma...

Page 32: ...nd power level LW ISO 6798 3 dB A tolerance R dB A 122 122 Engine surface noise with attenuated intake noise filter BL free field sound pressure level Lp 1 m distance ISO 6798 2 dB A tolerance R dB A...

Page 33: ...45 Barometric pressure mbar 981 981 Site altitude above sea level m 400 400 Power related data power ratings are net brake power as per ISO 3046 Description 10V1600 C60 10V1600 C70 Rated engine speed...

Page 34: ...nt system HT circuit Description 10V1600 C60 10V1600 C70 Coolant temperature at engine connection outlet to cooling equipment A C 95 95 Coolant temperature after engine Limit 1 L C 107 107 Coolant tem...

Page 35: ...ressure at engine inlet connection max when engine is starting L bar 0 0 Inclinations standard oil system reference waterline Description 10V1600 C60 10V1600 C70 Longitudinal inclination continuous ma...

Page 36: ...nd power level LW ISO 6798 3 dB A tolerance R dB A 122 122 Engine surface noise with attenuated intake noise filter BL free field sound pressure level Lp 1 m distance ISO 6798 2 dB A tolerance R dB A...

Page 37: ...mbar 981 981 981 Site altitude above sea level m 400 400 400 Power related data power ratings are net brake power as per ISO 3046 Description 12V1600 A50 12V1600 A60 12V1600 A70 Rated engine speed A r...

Page 38: ...max in DBR MCR performance map under max admissible operating conditions L C 550 550 550 Coolant system HT circuit Description 12V1600 A50 12V1600 A60 12V1600 A70 Coolant temperature at engine connec...

Page 39: ...inlet connection min when engine is running L bar 0 65 0 65 0 65 Fuel pressure at engine inlet connection max when engine is starting L bar 0 0 0 Inclinations standard oil system reference waterline D...

Page 40: ...und power level LW ISO 6798 3 dB A tolerance R dB A 118 121 121 Engine surface noise with attenuated intake noise fil ter BL free field sound pressure level Lp 1 m dis tance ISO 6798 2 dB A tolerance...

Page 41: ...mbar 981 981 981 Site altitude above sea level m 400 400 400 Power related data power ratings are net brake power as per ISO 3046 Description 12V1600 C50 12V1600 C60 12V1600 C70 Rated engine speed A r...

Page 42: ...max in DBR MCR performance map under max admissible operating conditions L C 550 550 550 Coolant system HT circuit Description 12V1600 C50 12V1600 C60 12V1600 C70 Coolant temperature at engine connec...

Page 43: ...inlet connection min when engine is running L bar 0 65 0 65 0 65 Fuel pressure at engine inlet connection max when engine is starting L bar 0 0 0 Inclinations standard oil system reference waterline D...

Page 44: ...und power level LW ISO 6798 3 dB A tolerance R dB A 118 121 121 Engine surface noise with attenuated intake noise fil ter BL free field sound pressure level Lp 1 m dis tance ISO 6798 2 dB A tolerance...

Page 45: ...sure mbar 981 981 981 Site altitude above sea level m 400 400 400 Power related data power ratings are net brake power as per ISO 3046 Description 12V1600 C50 12V1600 C60 12V1600 C70 Rated engine spee...

Page 46: ...max in DBR MCR performance map under max admissible operating conditions L C 550 550 550 Coolant system HT circuit Description 12V1600 C50 12V1600 C60 12V1600 C70 Coolant temperature at engine connec...

Page 47: ...inlet connection min when engine is running L bar 0 65 0 65 0 65 Fuel pressure at engine inlet connection max when engine is starting L bar 0 0 0 Inclinations standard oil system reference waterline D...

Page 48: ...und power level LW ISO 6798 3 dB A tolerance R dB A 118 121 121 Engine surface noise with attenuated intake noise fil ter BL free field sound pressure level Lp 1 m dis tance ISO 6798 2 dB A tolerance...

Page 49: ...s Firing order 10V A1 B4 A4 B3 A3 B2 A2 B5 A5 B1 12V A1 B2 A5 B4 A3 B1 A6 B5 A2 B3 A4 B6 Direction of rotation Direction of rotation viewed from driving end Counterclockwise non reversible MS150100 04...

Page 50: ...ons Engine model Height A Length B Width C 10V1600Ax0 Cx0 Approx 1402 mm Approx 1693 mm Approx 1231 mm 12V1600Ax0 Cx0 Approx 1402 mm Approx 1865 mm Approx 1231 mm 50 Technical Data MS150100 04E 2015 0...

Page 51: ...ction Lube oil system Check engine oil level Page 112 Coolant circuit Check engine coolant level Page 116 Check charge air coolant level Page 123 Coolant circuit Preheat engine coolant with coolant pr...

Page 52: ...servation Specifications A001070 Lube oil system Check engine oil level Page 112 Fuel system Vent Page 103 Coolant circuit If engine is out of service for more than one year change engine coolant Page...

Page 53: ...ing the engine with starter system make sure that there are no persons in the engine s danger zone WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear prot...

Page 54: ...data speed temperature pressures Engine oil Check engine oil level Page 112 Engine operation Check engine visually for leaks and general condition Check engine for abnormal running noises exhaust col...

Page 55: ...unning at full load subjects it to extreme thermal and mechanical stress es Overheating of and therefore damage to components is possible Before shutting down the engine allow it to idle until the eng...

Page 56: ...eratures are expected and the engine is to remain out of service for an extended period but engine coolant has no antifreeze addi tive the engine room is not heated the coolant is not kept at a suitab...

Page 57: ...ctly at seals or electronic components such as connectors or ECUs Plant Cleaning 1 Carry out plant cleaning only in areas where an appropriate oil separator is provided environmental protec tion 2 Pri...

Page 58: ...ts from fuel prefilter Page 108 W1001 Replace fuel filter or fuel filter element Page 106 W1008 Replace engine oil filter when changing engine oil or when the interval years is reached at the latest P...

Page 59: ...n by starter Battery low or faulty u Charge or replace battery manufacturer s documentation Engine wiring defective u Check Page 135 Air in fuel system u Vent fuel system Page 103 Engine governor defe...

Page 60: ...Cause Corrective action Air filter clogged u Replace air filter Page 110 Intercooler clogged u Contact Service Exhaust turbocharger defective u Contact Service Coolant leaks at intercooler Cause Corre...

Page 61: ...not at operating temperature u Run engine to reach operating temperature Water in fuel u Check fuel system on fuel prefilter Drain fuel prefilter Page 108 Intercooler leaky u Contact Service MS150100...

Page 62: ...signaled 3 Contact Service 9 HI T Coolant Intercooler Cause Corrective action The intercooler coolant temperature measured at sensor B26 has violated limit value 1 The intercooler coolant temperature...

Page 63: ...too high u Contact Service 21 HI T Exhaust B Cause Corrective action The exhaust gas temperature measured at sensor B4 22 has violated limit value 1 The exhaust gas temperature is too high u Contact S...

Page 64: ...as been tripped Emergency engine stop has been tripped 1 Restart the engine if the emergency stop was tripped by an engine overspeed test 2 Contact Service if the emergency stop was tripped by the eng...

Page 65: ...1 Reduce power 2 Contact Service 37 SS ETC2 Overspeed Cause Corrective action The speed of the LP turbocharger on the B side measured at sensor B44 2 has violated limit value 2 The turbocharger speed...

Page 66: ...ine 2 Contact Service 64 SS P Crankcase Cause Corrective action The crankcase pressure measured at sensor B50 has violated limit value 2 The crankcase pressure is too high 1 Stop engine 2 Contact Serv...

Page 67: ...vice 83 LO P Fuel Common Rail Cause Corrective action The HP fuel pressure measured at sensor B48 has violated the limit value The fuel pressure is too low u Contact Service 89 SS Engine Speed too Low...

Page 68: ...Check state of battery charge plant 2 Check plug connections to Engine Control Unit Page 137 3 Contact Service 119 LOLO ECU Power Supply Voltage Cause Corrective action The ECU supply voltage has vio...

Page 69: ...tion CAN bus 1 to MTU automation system e g ECU MAU SAM disrupted or faulty 1 Check plug connections to Engine Control Unit Page 137 2 Contact Service 187 AL CAN1 Error Passive Cause Corrective action...

Page 70: ...e Corrective action The signal from the exhaust gas temperature sensor B4 21 in the exhaust pipe on the A side is faulty or missing 1 Check engine wiring Page 135 2 Contact Service 207 SD T Exhaust B...

Page 71: ...The signal from the coolant level sensor F33 is faulty or missing 1 Check engine wiring Page 135 2 Contact Service 221 SD P Diff Lube Oil Cause Corrective action The signal s from lube oil pressure se...

Page 72: ...Corrective action The signal from the speed sensor B44 1 ETC A side is faulty or missing 1 Check engine wiring Page 135 2 Contact Service 233 SD Charger 2 Speed Cause Corrective action The signal fro...

Page 73: ...Short circuit fault in injector wiring of cylinder A3 or injector faulty 1 Check wiring of injector concerned Page 135 2 Contact Service 324 AL Wiring Cylinder A4 Cause Corrective action Short circui...

Page 74: ...r B4 or injector faulty 1 Check wiring of injector concerned Page 135 2 Contact Service 335 AL Wiring Cylinder B5 Cause Corrective action Short circuit fault in injector wiring of cylinder B5 or injec...

Page 75: ...r A6 1 Check wiring of injector concerned Page 135 2 Contact Service 351 AL Open Load Cylinder B1 Cause Corrective action Disruption fault in injector wiring of cylinder B1 1 Check wiring of injector...

Page 76: ...utput 2 plant TOP 2 1 Check wiring Page 135 2 Contact Service 383 AL Wiring TOP 3 Cause Corrective action Short circuit or wire break on transistor output 3 plant TOP 3 1 Check wiring Page 135 2 Conta...

Page 77: ...ck engine wiring Page 135 2 Contact Service 438 LO P Fuel 2 Common Rail Cause Corrective action The HP fuel pressure measured at sensor B48 2 has violated the limit value The fuel pressure is too high...

Page 78: ...P HD2 Cause Corrective action The signal from the rail pressure sensor B48 2 B side is faulty or missing u Contact Service 448 HI P Charge Air Cause Corrective action The charge air pressure measured...

Page 79: ...alarm 1 Check for additional messages 2 Contact Service 480 AL Ext Engine Protection Cause Corrective action External engine protection function is active 1 Check plant signal 2 Contact Service 488 H...

Page 80: ...de of the HP fuel pump cannot be activated 1 Check engine wiring Page 135 2 Contact Service 549 AL Power Failure Cause Corrective action ECU operating voltage was switched off while the engine was run...

Page 81: ...ruption or short circuit in wiring to servomotor of bypass flap B side M52 2 1 Check engine wiring Page 135 2 Contact Service 609 AL Wiring PWM_CM7 Cause Corrective action Wire break or short circuit...

Page 82: ...wiring Page 135 2 Contact Service 629 AL EGR Shutoff Flap A Faulty Cause Corrective action The EGR shutoff flap on the A side M53 1 is faulty u Contact Service 630 AL EGR Shutoff Flap B Faulty Cause...

Page 83: ...135 2 Contact Service 647 SD P Exhaust Lambda Cause Corrective action The signal from the exhaust gas pressure sensor B91 3 is faulty or missing 1 Check engine wiring Page 135 2 Contact Service 693 A...

Page 84: ...e 796 AL HI T Charge Air B Cause Corrective action The charge air temperature on the B side measured at sensor B9 3 has violated limit value 1 The charge air temperature is too high u Contact Service...

Page 85: ...ion fault alarm 1 Check for additional messages 2 Contact Service 843 SD T Charge Air Before EGR Cause Corrective action The signal from the charge air temperature sensor B9 1 BT9 1 is faulty or missi...

Page 86: ...ged when the pressure in the HP accumulator has violated the limit value u Contact Service 852 AL Max Blankshot Time Expired Cause Corrective action The alarm is generated when the engine is at stands...

Page 87: ...ction Faulty rapid reference movement of the EGR shutoff flap on the B side M53 2 always executed after restarting the ECU 1 Check state of battery charge plant 2 Contact Service 877 AL Bypass FlpA Cl...

Page 88: ...lue invalid Cause Corrective action Status information of the lambda sensor B89 generated in case of temporarily implausible measured values or lambda sensor defect 1 Acknowledge alarm 2 Replace lambd...

Page 89: ...ective action The first Engine CAN CAN 3 connected to the engine sensors actuators is faulty 1 Check engine wiring Page 135 2 Contact Service 976 AL CAN4 Bus Off Cause Corrective action The second Eng...

Page 90: ...rvice 1097 AL Flap Egr A Communication Lost Cause Corrective action The ECU can no longer detect the EGR shutoff flap on the A side M53 1 MA53 1 on the bus 1 Check engine wiring Page 135 2 Contact Ser...

Page 91: ...too high Cause Corrective action The internal electronics of the servomotor for the bypass flap on the A side M52 1 MA52 1 signal excessively high temperature u Contact Service 1105 AL Flap Bypass A T...

Page 92: ...the ECU has violated limit value 2 The intake air differential pressure is too high 1 Check air filter for dirt plant 2 Contact Service 1120 AL Flap Egr A Calibration Drive Err Cause Corrective actio...

Page 93: ...ation movement is not plausible The teach in angle does not lie between the minimum and maximum range u Contact Service 1130 AL Short Circuit Analog Out 1 Cause Corrective action Incorrect plant value...

Page 94: ...t value 2 u Contact Service 1178 AL J1939 Heartbeat1 Lost Cause Corrective action No message on plant bus u Contact Service 1179 AL J1939 Heartbeat2 Lost Cause Corrective action No message on plant bu...

Page 95: ...Service 1188 AL Bypass FlpA Wear Limit2 Cause Corrective action Faulty rapid reference movement of the bypass flap on the A side M52 1 MA52 1 always executed after restarting the ECU Limit value 2 1...

Page 96: ...nger zone After finishing work on the engine make sure that all safety devices are put back in place and all tools are removed from the engine Barring engine manually 1 Remove guard plate from flywhee...

Page 97: ...no persons in the engine s danger zone WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Engine Test run 1 Start engine Page 53 2 Perform tes...

Page 98: ...0128 1 Torque wrench 20 100 Nm F30026582 1 Box wrench 14 mm F30028346 1 Allen keys 2 10 mm F30453050 1 Barring tool F6790714 1 Preparatory steps 1 Remove cylinder head cover Page 101 2 Install barring...

Page 99: ...firing TDC 2 Cylinder A1 is in overlap TDC I Inlet valve X Exhaust valve 4 Use feeler gage to determine the distance between valve bridge and rocker arm 5 Adjust valve clearance if the deviation from...

Page 100: ...en key 5 mm Name Size Type Lubricant Value Standard Nut M10x1 Tightening torque 43 4 Nm 6 Check valve clearance readjust as necessary Final steps 1 Remove barring tool Page 96 2 Install cylinder head...

Page 101: ...oil 1 Undo and remove screws 2 Remove cylinder head cover 3 Clean installation surface 4 Check condition of gasket and replace if re quired Installing cylinder head cover 10V 1 Coat gasket with engin...

Page 102: ...nder head cover and screws at positions 1 to 4 and tighten with torque wrench to the prescribed initial tightening torque Name Size Type Lubricant Value Standard Screw with twin col lar M8 Preload tor...

Page 103: ...ing fuel system with external fuel pump Note Do not open the high pressure system when putting into operation and servicing 1 Open the unpressurized return to the tank 1 and connect to the tank or a s...

Page 104: ...readed vent plug 3 and tighten by hand Venting fuel filter with cooler 1 Unlock fuel priming pump at fuel prefilter screw out handle see above Step 1 2 Provide a suitable container in which to collect...

Page 105: ...ndle until bub ble free fuel emerges from the threaded vent plug arrowed 5 Screw in threaded vent plug arrowed and tighten to specified torque using a torque wrench Name Size Type Lubricant Value Stan...

Page 106: ...stem Variant A Replacing fuel filter with cooler 1 Provide a suitable container in which to col lect the fuel Note Do not completely remove drain plug 2 Unscrew drain plug 3 at the side 3 Loosen screw...

Page 107: ...torque Engine oil 6 5 1 3 Nm 12 Vent fuel system Page 103 Variant B Replacing fuel filter without cooler 1 Provide a suitable container in which to col lect the fuel Note Do not completely remove drai...

Page 108: ...pen flames electrical sparks and ignition sources Do not smoke Wear protective clothing protective gloves and safety glasses facial protection Draining fuel prefilter 1 Provide a suitable container to...

Page 109: ...eparatory step u Provide a suitable container in which to collect the fuel Replacing fuel prefilter 1 Close fuel supply 2 Unscrew filter cover 1 3 Remove filter cover 1 with filter element 3 from filt...

Page 110: ...e is stopped and starting disabled Note Component is genset manufacturer s or vehicle manufacturer s scope of supply Air filter Replacement u Perform tasks according to manufacturer s specifications 1...

Page 111: ...8 6 Air Intake 8 6 1 Service indicator Check See manufacturer s documentation MS150100 04E 2015 09 Task Description 111 TIM ID 0000005482 004...

Page 112: ...d back to the oil pan Engine oil level Check 1 Remove oil dipstick 1 from guide tube and wipe it 2 Insert oil dipstick 1 into guide tube up to the stop pull out after approx 10 seconds and check oil l...

Page 113: ...nd goggles safety mask Avoid contact with skin Do not inhale oil vapor Draining oil via drain plug on oil pan 1 Provide a suitable container to collect the oil 2 Remove drain plug 2 and drain oil 3 In...

Page 114: ...t 32 mm F30006120 1 Engine oil Sealing ring Spare Parts Catalog Oil filter element Spare Parts Catalog WARNING Hot oil Oil can contain combustion residues which are harmful to health Risk of injury an...

Page 115: ...ace sealing ring 2 if damaged 8 Coat sealing ring 2 with oil 9 Insert new oil filter element 3 in screw cap 1 and press in until it locks in place 10 Screw on screw cap 1 with oil filter element 3 and...

Page 116: ...ank counterclockwise to the first stop and allow pressure to escape 2 Continue to turn breather valve counterclock wise and remove 3 Check coolant level coolant must be visible at the lower edge of th...

Page 117: ...e Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 118 2 Fill with engine coolant Page 120 MS150100 04E 2015 09 Task Description...

Page 118: ...ory steps 1 Provide an appropriate container to drain the coolant into 2 Switch off preheater if installed Engine coolant Draining 1 Turn breather valve of filler neck on coolant expansion tank counte...

Page 119: ...g with new sealing ring on engine coolant pump and use torque wrench to tighten to specified tightening torque Name Size Type Lubricant Value Standard Screw M14x1 5 Tightening torque 35 3 Nm 2 Install...

Page 120: ...ICE Cold coolant in hot engine can cause thermal stress Possible formation of cracks in the engine Fill top up coolant only into cold engine Preparatory steps 1 Turn breather valve 1 of coolant expans...

Page 121: ...nal steps 1 Start the engine and operate it at idle speed for some minutes 2 Check coolant level Page 116 top up with coolant if required MS150100 04E 2015 09 Task Description 121 TIM ID 0000000909 00...

Page 122: ...ne is running Risk of damage to hearing Wear ear protectors Engine coolant pump Relief bore check 1 Check relief bore 1 for coolant discharge Permissible coolant discharge Up to 0 1 ml per hour respec...

Page 123: ...tank counterclockwise to the first stop and allow pressure to escape 2 Continue to turn breather valve counterclock wise and remove 3 Check coolant level coolant must be visible at marker plate 4 Top...

Page 124: ...ecial tools Material Spare parts Designation Use Part No Qty Coolant Charge air coolant Change 1 Drain charge air coolant Page 125 2 Fill with charge air coolant Page 126 124 Task Description MS150100...

Page 125: ...on coolant expansion tank counterclockwise to the first stop and allow pressure to escape 3 Continue to turn breather valve counterclock wise and remove 4 Draw off precipitated corrosion inhibitor oi...

Page 126: ...thermal stress Possible formation of cracks in the engine Fill top up coolant only into cold engine Preparatory steps 1 Turn breather valve 1 on coolant expansion tank counterclockwise to the first st...

Page 127: ...Final steps 1 Start the engine and operate it at idle speed for some minutes 2 Check coolant level Page 123 MS150100 04E 2015 09 Task Description 127 TIM ID 0000031875 006...

Page 128: ...ne is running Risk of damage to hearing Wear ear protectors Charge air coolant pump Re lief bore check 1 Check relief bore 1 for coolant discharge Permissible coolant discharge Up to 0 1 ml per hour r...

Page 129: ...uare wrench with extension into square hole 2 on belt tensioner 2 Turn belt tensioner clockwise against the spring force almost up to the stop 3 Insert 8 mm steel pin e g punch 1 to lock belt tensione...

Page 130: ...he grooves no force must be applied 6 Fit new drive belt 4 7 Turn belt tensioner clockwise against the spring force almost up to the stop to remove the 8 mm steel pin 8 Remove 8 mm steel pin 9 Release...

Page 131: ...force almost up to the stop to remove the 8 mm steel pin 6 Remove 8 mm steel pin 7 Release belt tensioner and remove square wrench with extension Installing battery charging gen erator drive belt 1 F...

Page 132: ...Diverter pulley Spare Parts Catalog WARNING Belt tensioner spring is pretensioned Risk of hands being crushed Lock belt tensioner in position Only use specified tools and devices Preparatory step u R...

Page 133: ...with screw 2 5 Tighten screw 2 to specified torque using a torque wrench Name Size Type Lubricant Value Standard Screw Tightening torque Engine oil 60 Nm 10 Nm Final steps Note Remove pin before reli...

Page 134: ...8 13 Drive Systems Driving End and Free End Coupling 8 13 1 Coupling Checking radial axial play See manufacturer s documentation 134 Task Description MS150100 04E 2015 09 TIM ID 0000054164 002...

Page 135: ...closed and intact 4 Replace faulty cable clips 5 Check cable clamps for secure fit tighten loose clamps 6 Replace faulty cable clamps 7 Visually inspect the following electrical components for damage...

Page 136: ...r Cleaning 1 Use isopropyl alcohol to remove coarse dirt from housing surface 2 Use isopropyl alcohol to remove dirt from the connector and cable surfaces 3 Check legibility of cable labels Clean or r...

Page 137: ...plug in connections on engine governor 1 Check firm seating of all connectors on the engine governor Ensure that the clips 1 are engaged 2 Check firm seating of all screws 2 on engine governor cable c...

Page 138: ...beginning work Wear suitable protective equipment thermal gloves Avoid unprotected contact with hot surfaces NOTICE High voltage Risk of damage to components Switch off ignition before replacing compo...

Page 139: ...M6 Tightening torque max 12 Nm 2 Remove protective cap on thread of sensor 3 only just before installation Note Do not wipe off the thread lubricant applied by the manufacturer 3 Coat sensor 3 thread...

Page 140: ...ol down to below 50 C before beginning work Wear suitable protective equipment thermal gloves Avoid unprotected contact with hot surfaces NOTICE Ceramic cell breakage due to shock or impact Risk of da...

Page 141: ...sensor thread with specified assembly compound as required 3 Screw in sensor by hand 4 Tighten nut 2 to specified torque using a torque wrench Name Size Type Lubricant Value Standard Nut M18 x 1 5 Tig...

Page 142: ...ture Sensor DDEC Detroit Diesel Electronic Controls Engine control system made by Detroit Diesel DDL Diagnostic Data Link Diagnostic lines DDR Diagnostic Data Reader Diagnostic unit DIN Deutsches Inst...

Page 143: ...value lower than 1st mini mum limit value LOLO Low Low Alarm Measured value lower than 2nd mini mum limit value LSG Limiting Speed Governor Maximum speed governor N A Not applicable not available ND N...

Page 144: ...Alarm Sensor comparison fault TPS Throttle Position Sensor TRS Timing Reference Sensor T xyz Temperature xyz Temperature measuring point xyz UT Unterer Totpunkt Bottom Dead Center BDC VNT Variable No...

Page 145: ...e work in case of malfunction or changed oper ating conditions or for spare parts supply Your contact person in our Customer Assistance Center E mail info mtu online com Tel 49 7541 9077777 Fax 49 754...

Page 146: ...eys 2 10 mm Part No F30453050 Qty Used in 1 8 2 1 Valve clearance Check and adjustment Page 98 Assembly jig Part No F6794712 Qty Used in 1 8 11 1 Drive belt Replacement Page 129 Barring tool Part No F...

Page 147: ...1 Valve clearance Check and adjustment Page 98 Crossbeam Part No T80092479 Qty Used in 1 2 1 Transportation Page 15 Feeler gage Part No Y20010128 Qty Used in 1 8 2 1 Valve clearance Check and adjustm...

Page 148: ...ed in 1 8 4 3 Fuel prefilter Filter element replacement Page 109 Qty Used in 1 8 12 2 Battery charging generator Belt tensioner and diverter pulley replacement Page 132 Qty Used in 1 8 15 3 NOx sensor...

Page 149: ...ment Page 140 Torque wrench 4 20 Nm Part No F30044239 Qty Used in 1 8 3 1 Fuel system Venting Page 103 Torque wrench 8 40 Nm Part No F30043446 Qty Used in 1 8 2 2 Cylinder head cover Removal and insta...

Page 150: ...Torque wrench 4 20 Nm Part No F30044239 Qty Used in 1 8 4 1 Fuel filter Replacement Page 106 150 Appendix B MS150100 04E 2015 09 DCL ID 0000010268 006...

Page 151: ...hange 117 124 Coolant level Check 116 Coupling Axial play Check 134 Radial play Check 134 Cylinder Designation 17 Cylinder head cover Installation 101 Removal 101 D Direction of rotation 49 Diverter p...

Page 152: ...9 62 Firing order 49 Fuel filter Replacement 106 Fuel prefilter Draining 108 Filter element replacement 109 Fuel system Venting 103 H Hotline 145 L Lambda sensor Replacement 140 Layout Engine 18 Lifti...

Page 153: ...Startup After extended out of service periods 3 months 52 After scheduled out of service period 51 T Transportation Description 15 Lifting requirements 16 Troubleshooting 59 V Valve clearance Adjustme...