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Diesel engine
12V2000Gx5, Gx5 TB
16V2000Gx5, Gx5 TB
18V2000Gx5, Gx5 TB
Application group 3B
MS15019/04E
Engine model kW/cyl. Application group
12V2000G25 48.3 kW/cyl. 3B, continuous operation, variable load, ICXN
12V 2000 G25-TB 48.3 kW/cyl. 3B, continuous operation, variable load, ICXN
12V2000G45 59.2 kW/cyl. 3B, continuous operation, variable load, ICXN
12V2000G45-TB 59.2 kW/cyl. 3B, continuous operation, variable load, ICXN
12V2000G65 57.9 kW/cyl. 3B, continuous operation, variable load, ICXN
12V 2000 G65-TB 57.9 kW/cyl. 3B, continuous operation, variable load, ICXN
12V2000G85 67.5 kW/cyl. 3B, continuous operation, variable load, ICXN
12V2000G85-TB 67.5 kW/cyl. 3B, continuous operation, variable load, ICXN
16V2000G25 50.6 kW/cyl. 3B, continuous operation, variable load, ICXN
16V2000G25-TB 50.6 kW/cyl. 3B, continuous operation, variable load, ICXN
16V2000G45 57.2 kW/cyl. 3B, continuous operation, variable load, ICXN
16V2000G45-TB 57.2 kW/cyl. 3B, continuous operation, variable load, ICXN
16V2000G65 55.6 kW/cyl. 3B, continuous operation, variable load, ICXN
16V 2000 G65-TB 55.6 kW/cyl. 3B, continuous operation, variable load, ICXN
16V2000G85 63.1 kW/cyl. 3B, continuous operation, variable load, ICXN
16V2000G85-TB 63.1 kW/cyl. 3B, continuous operation, variable load, ICXN
18V2000G65 55.6 kW/cyl. 3B, continuous operation, variable load, ICXN
18V 2000 G65-TB 55.6 kW/cyl. 3B, continuous operation, variable load, ICXN
18V2000G85 66.2 kW/cyl. 3B, continuous operation, variable load, ICXN
18V2000G85-TB 66.2 kW/cyl. 3B, continuous operation, variable load, ICXN
Table 1: Applicability
8.11 Air Intake 131 8.19 Wiring (General) for Engine/Gearbox/Unit 154
8.11.1 Service indicator – Signal ring position check 131 8.19.1 Engine cabling – Check 154
General information
This product may pose a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Noncompliance with the safety instructions and warning notices
Modifications or conversions
Unauthorized changes to the product represent a contravention of its intended use and compromise safety.
Changes or modifications shall only be considered to comply with the intended use when expressly author-
ized by the manufacturer. The manufacturer shall not be held liable for any damage resulting from unauthor-
ized changes or modifications.
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Personnel requirements
All work on the product shall be carried out by trained and qualified personnel only:
• Training at the Training Center of the manufacturer
• Technical personnel from the areas mechanical engineering, plant construction, and electrical engineering
The operator must define the responsibilities of the personnel involved in operation, maintenance, repair, as-
sembly, installation, and transport in writing.
Personnel shall not report for duty under the influence of alcohol, drugs or strong medication.
Operation
Do not remain in the operating room when the product is running for any longer than absolutely necessary.
Keep a safe distance away from the product if possible. Do not touch the product unless expressly instructed
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Welding work
Welding operations on the product or mounted units are not permitted. Cover the product when welding in
its vicinity.
Before starting welding work:
• Switch off the power supply master switch.
• Disconnect the battery cables or actuate the battery isolating switch.
• Separate the electrical ground of electronic equipment from the ground of the unit.
No other maintenance or repair work must be carried out in the vicinity of the product while welding is going
on. Risk of explosion or fire due to oil vapors and highly flammable process materials.
Do not use product as ground terminal.
Never position the welding power supply cable adjacent to, or crossing cabling harnesses of the product. The
welding current may otherwise induce an interference voltage in the cabling harnesses which could conceiv-
ably damage the electrical system.
Remove components (e.g. exhaust pipe) from the product before performing necessary welding work.
Observe the max. permissible force-on pressure specified for the jig/fixture.
Do not attempt to bend or exert force on H.P. lines.
Before starting work, pay attention to the following:
• Vent the installation/removal device, the pumps and the pipework at the relevant designated points.
• During the installation procedure, screw on device with pushed-in plunger.
• During the removal procedure, screw on device with retracted plunger.
For a hydraulic installation/removal device with central expansion pressure supply, screw spindle into shaft
end until correct sealing is established.
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 pressure level in excess of 85 dB (A).
Auxiliary materials
Process materials may also be hazardous or toxic. When using consumables and auxiliary materials as well
as other chemical substances, observe the information contained in the safety data sheet for the product.
The safety data sheet may be obtained from the relevant manufacturer or from MTU.
Take special care when using hot, chilled or caustic materials.
Used oil
Used oil contains combustion residues that are harmful to health.
Wear protective gloves!
Wash relevant areas after contact with used oil.
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Lead
• Adopt suitable measures to avoid the formation of lead dust.
• Switch on extraction system.
• When working with lead or lead-containing compounds, avoid direct contact to the skin and do not inhale
lead vapors.
• Wash relevant areas after contact with lead or lead-containing substances.
Painting
• Observe the relevant safety data sheet for all materials.
• When carrying out painting work outside the spray stands provided with fume extraction systems, ensure
that the area is well ventilated. Make sure that neighboring work areas are not adversely affected.
• There must be no naked flames in the vicinity.
• No smoking.
• Observe fire-prevention regulations.
• Always wear a mask providing protection against paint and solvent vapors.
Liquid nitrogen
• Observe the relevant safety data sheet for all materials.
• Work with liquid nitrogen may be carried out only by qualified personnel.
• Store liquid nitrogen only in small quantities and always in specified containers without fixed covers.
• Avoid body contact (eyes, hands).
• Wear protective clothing, protective gloves, closed shoes and safety goggles.
• Make sure that working area is well ventilated.
• Avoid knocking or jolting the containers, valves and fittings or workpieces in any way.
WARNING
In the event of a situation involving potential danger.
Consequences: Death, serious or permanent injury!
• Remedial action.
CAUTION
In the event of a situation involving potential danger.
Consequences: Minor or moderate injuries!
• Remedial action.
NOTICE
In the event of a situation involving potentially adverse effects on the product.
Consequences: Material damage!
• Remedial action.
• Additional product information.
Warning notices
1. This manual with all safety instructions and safety notices must be issued to all personnel involved in opera-
tion, maintenance, repair, assembly, installation, or transportation.
2. The higher level warning notice is used if several hazards apply at the same time. Warnings related to person-
al injury shall be considered to include a warning of potential damage.
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DANGER
Suspended load.
Danger to life!
• Use appropriate lifting devices and appliances.
• Never stand beneath a suspended load.
Transportation
1. Use lifting eyes provided for transporting the engine (→ Page 17).
2. Only use suitable transportation and lifting equipment.
3. The engine must only be transported in installation position: Max. admissible diagonal pull 10°. (→ Page 17)°
4. Remove any loose parts on engine.
5. Always raise/lower engine slowly. The lifting ropes or chains must not rub against the engine or its compo-
nents during the lifting procedure. Readjust lifting tackle as necessary.
6. For special packaging with aluminum foil: Attach engine to lifting eyes of bearing pedestal or transport with
means of transportation device suitable for the load (forklift truck).
7. Secure engine against tilting during transportation. Secure such as to preclude slipping and tipping when
driving up or down inclines and ramps.
The coolant level sensor F33 is located in the coolant expansion tank at the cooler
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The coolant level sensor F33 is located in the coolant expansion tank at the cooler
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Reference condition
Description 12V 2000 12V 2000 16V 2000 16V 2000 18V 2000
G25 G65 G25 G65 G65
Application group 3B 3B 3B 3B 3B
Intake air temperature °C 25 25 25 25 25
Barometric pressure mbar 1000 1000 1000 1000 1000
Site altitude above sea level M 100 100 100 100 100
Power-related data (power ratings are net brake power as per ISO 3046)
Description 12V 2000 12V 2000 16V 2000 16V 2000 18V 2000
G25 G65 G25 G65 G65
Rated engine speed A rpm 1500 1500 1500 1500 1500
Continuous power ISO 3046 A kW 580 695 810 890 1000
(10% overload possible) (pow-
er range DIN 6280, ISO 8528)
cylinder - DL
Fuel system
Description 12V 2000 12V 2000 16V 2000 16V 2000 18V 2000
G25 G65 G25 G65 G65
Fuel pressure at engine inlet L bar -0.3 -0.3 -0.3 -0.3 -0.3
connection, min. (when en-
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gine is starting)
Fuel pressure at engine inlet L bar +0.5 +0.5 +0.5 +0.5 +0.5
connection, max. (when en-
gine is starting)
Reference condition
Description 12V 2000 12V 2000 16V 2000 16V 2000 18V 2000
G25-TB G65-TB G25-TB G65-TB G65-TB
Application group 3B 3B 3B 3B 3B
Intake air temperature °C 25 25 25 25 25
Charge-air coolant tempera- °C 55 55 55 55 55
ture
Raw-water inlet temperature °C - - - - -
Barometric pressure mbar 1000 1000 1000 1000 1000
Site altitude above sea level M 100 100 100 100 100
Power-related data (power ratings are net brake power as per ISO 3046)
Description 12V 2000 12V 2000 16V 2000 16V 2000 18V 2000
G25-TB G65-TB G25-TB G65-TB G65-TB
Rated engine speed A rpm 1500 1500 1500 1500 1500
Continuous power ISO 3046 A kW 580 695 810 890 1000
(10% overload possible) (pow-
er range DIN 6280, ISO 8528)
cylinder - DL
Acoustics
Description 12V 2000 12V 2000 16V 2000 16V 2000 18V 2000
G25-TB G65-TB G25-TB G65-TB G65-TB
Exhaust noise, unsilenced - DL R dB(A) 124 127 126 128 128
(sound power level LW, ISO
6798, +3 dB(A) tolerance)
Engine surface noise with at- R dB(A) 117 118 120 121 123
tenuated intake noise (filter) -
DL (sound power level LW,
ISO 6798, +2 dB(A) tolerance)
Reference condition
Description 12V 2000 12V 2000 12V 2000 12V 2000
G25 G45 G65 G85
Application group 3B 3B 3B 3B
Intake air temperature °C 25 25 25 25
Barometric pressure mbar 1000 1000 1000 1000
Site altitude above sea level M 100 100 100 100
Power-related data (power ratings are net brake power as per ISO 3046)
Description 12V 2000 12V 2000 12V 2000 12V 2000
G25 G45 G65 G85
Rated engine speed A rpm 1500 1800 1500 1800
Continuous power ISO 3046 (10% over- A kW 580 710 695 810
load possible) (power range DIN 6280,
ISO 8528)
max.
Fuel system
Description 12V 2000 12V 2000 12V 2000 12V 2000
G25 G45 G65 G85
Fuel pressure at engine inlet connection, L bar -0.3 -0.3 -0.3 -0.3
min. (when engine is starting)
Fuel pressure at engine inlet connection, L bar +0.5 +0.5 +0.5 +0.5
max. (when engine is starting)
nations)
Oil change capacity, max. (standard oil R Liter N N N N
system)
Oil change quantity max. (standard oil sys- R Liter 74 74 74 74
tem) (design: max. operating inclinations)
Acoustics
Description 12V 2000 12V 2000 12V 2000 12V 2000
G25 G45 G65 G85
Exhaust noise, unsilenced - DL (sound R dB(A) 124 127 127 129
power level LW, ISO 6798, +3 dB(A) toler-
ance)
Engine surface noise with attenuated in- R dB(A) 117 117 118 120
take noise (filter) - DL (sound power level
LW, ISO 6798, +2 dB(A) tolerance)
Reference condition
Description 16V 2000 16V 2000 16V 2000 16V 2000 18V 2000 18V 2000
G25 G45 G65 G85 G65 G85
Application group 3B 3B 3B 3B 3B 3B
Intake air temper- °C 25 25 25 25 25 25
ature
Barometric pres- mbar 1000 1000 1000 1000 1000 1000
sure
Site altitude M 100 100 100 100 100 100
above sea level
Power-related data (power ratings are net brake power as per ISO 3046)
Description 16V 2000 16V 2000 16V 2000 16V 2000 18V 2000 18V 2000
G25 G45 G65 G85 G65 G85
Rated engine A rpm 1500 1800 1500 1800 1500 1800
speed
Continuous power A kW 810 915 890 1010 1000 1191
ISO 3046 (10%
overload possible)
(power range DIN
6280, ISO 8528)
Number of ex- 2 2 2 2 2 2
haust valves, per
cylinder
Standard housing SAE 0 0 0 0 0 0
connecting flange
(engine main PTO)
Flywheel interface DISC 18" 18" 18" 18" 18" 18"
gine, shutdown
Lube-oil operating R bar 5.5 6.0 5.5 6.0 6.0 6.5
pressure before
engine, from
Lube-oil operating R bar 6.5 7.0 6.5 7.0 8.0 8.5
pressure before
engine, to
Fuel system
Description 16V 2000 16V 2000 16V 2000 16V 2000 18V 2000 18V 2000
G25 G45 G65 G85 G65 G85
Fuel pressure at L bar -0.3 -0.3 -0.3 -0.3 -0.3 -0.3
engine inlet con-
nection, min.
(when engine is
starting)
Fuel pressure at L bar +0.5 +0.5 +0.5 +0.5 +0.5 +0.5
engine inlet con-
nection, max.
(when engine is
starting)
Engine coolant ca- R Liter 110 110 110 110 120 120
pacity, engine
side (without cool-
ing equipment)
Charge-air cool- R Liter - - - - - -
ant, engine side
Reference condition
Description 12V 2000 12V 2000 16V 2000 16V 2000 18V 2000
G45-TB G85-TB G45-TB G85-TB G85-TB
Application group 3B 3B 3B 3B 3B
Intake air temperature °C 25 25 25 25 25
Charge-air coolant tempera- °C 45 45 45 45 45
ture
Raw-water inlet temperature °C - - - - -
Barometric pressure mbar 1000 1000 1000 1000 1000
Site altitude above sea level M 100 100 100 100 100
Power-related data (power ratings are net brake power as per ISO 3046)
Description 12V 2000 12V 2000 16V 2000 16V 2000 18V 2000
G45-TB G85-TB G45-TB G85-TB G85-TB
Rated engine speed A rpm 1800 1800 1800 1800 1800
Continuous power ISO 3046 A kW 710 810 915 1010 1191
(10% overload possible) (pow-
er range DIN 6280, ISO 8528)
cylinder - DL
Acoustics
Description 12V 2000 12V 2000 16V 2000 16V 2000 18V 2000
G45-TB G85-TB G45-TB G85-TB G85-TB
Exhaust noise, unsilenced - DL R dB(A) 127 129 127 128 129
(sound power level LW, ISO
6798, +3 dB(A) tolerance)
Engine surface noise with at- R dB(A) 117 120 121 122 123
tenuated intake noise (filter) -
DL (sound power level LW,
ISO 6798, +2 dB(A) tolerance)
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DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Before cranking the engine with starter system, make sure that there are no persons in the engine's
danger zone.
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.
Preparation
Item Action
Operating mode switch (if Change to manual mode.
fitted)
Preheating pump (if fitted) Switch on.
Engine Apply full load only after engine has reached operating temperature (coolant
temperature approx. 75 °C).
NOTICE
Inadmissible operating status.
Severe damage to property!
• Use override function only in hazardous situations to ensure full capability in the event of engine
faults.
Preparation
Note: This function is only available when a pushbutton is provided.
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.
Operational monitoring
Item Measure
Control and display panels Check readings of operational data (speed, temperature, pressures).
Engine under load, Check engine/plant and all pipework visually for leaks, rectify any leaks with
engine at nominal speed the engine stopped;
Check for abnormal running noises and vibration.
Fuel prefilter Check reading on differential pressure gage to ensure that maximum admis-
sible value is not exceeded (→ Page 120).
Exhaust system Check exhaust color (→ Page 84).
Intercooler Check condensate drain(s) for water discharge and obstruction
(→ Page 128).
Air filter Check signal ring position of service indicator (→ Page 131).
Replace air filter (→ Page 129), if the signal ring is completely visible in the
red area of the service indicator observation window.
Coolant pump Check relief bore (→ Page 141).
Compressed-air system (if Check operating pressure on pressure gauge;
installed) Always fill compressed-air tank to max. pressure;
Drain condensate from compressed-air tank, pressure drop must not exceed
1 bar .
NOTICE
Stopping the engine when it is running 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 engine temperatures decrease and constant
levels are indicated.
A Alarm is active.
B Alarm was active during the last hour.
C Alarm was active during the last four hours.
D Alarm was active during the last four to twelve hours.
E Alarm was active more than twelve hours ago.
The engine can still be operated providing that automatic engine shutdown to protect the engine has not
been configured or is not tripped. Contact Service immediately/start fault rectification.
Red alarm:
Caution, the engine is running at its limits. Shut down manually without further delay if the engine does not
shut itself down immediately after a red alarm is signaled.
tion).
401 AL Open Load Digital Line disruption at digital in- Check wiring. 2.8006.626
Input 2 put 2, wiring faulty or no re-
sistance via switch, (alarm
configuration parameter, see
PR 2.8008.100 for explana-
tion).
Air filter clogged. u Check signal ring position of contamination indicator (→ Page 131).
Injector is faulty. u Replace (→ Page 105).
Injection pump is faulty. u Replace (→ Page 102).
Engine wiring is faulty. u Check (→ Page 154).
Overload. u Contact Service.
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Before barring the engine, make sure that there are no persons in the engine's danger zone.
• After finishing work on the engine, make sure that all safety devices are put back in place and all
tools are removed from the engine.
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Before cranking the engine with starter system, make sure that there are no persons in the engine's
danger zone.
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.
Preparatory steps
1. Remove cylinder head cover (→ Page 100).
2. Remove injector (→ Page 106).
age
• Heat discoloration of piston rings
clearly defined (straight) edge to the undisturbed surface. The damaged surface is
usually discolored. The circumferential length varies.
Liners with burn marks, or heat discoloration, starting in TDC-ring 1 have to be re-
placed.
Seizure marks, scuff- Irregular circumference lengths and depths. Can be caused either by the piston
ing skirt or the piston crown. Material deposits on the liner (smear), heavy discolora-
tion. Severe, visible scoring.
Replace liner.
WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.
5. Use torque wrench to tighten the screws of cover (2) to the specified torque.
Name Size Type Lubricant Value/Standard
Screw Tightening torque (Engine oil) 10 Nm −2 Nm
6. Use torque wrench to tighten the screws of cover (4) to the specified torque.
Name Size Type Lubricant Value/Standard
Screw Tightening torque (Engine oil) 10 Nm −2 Nm
WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.
WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.
NOTICE
Cleaning agents should not be left to take effect for too long.
Damage to components is possible!
• Observe manufacturer's instructions.
Preparatory steps
1. Remove cylinder head cover (→ Page 100).
2. Install barring tool (→ Page 87).
3. Bar crankshaft with barring tool in engine di-
rection of rotation until TDC pointer and TDC
mark on the flywheel are aligned.
4. Tighten locknut (1) to specified torque using a torque wrench while holding adjusting screw (2) firmly with a
screwdriver.
Name Size Type Lubricant Value/Standard
Locknut M12 x 1 Tightening torque (Engine oil) 50 Nm
Final steps
1. Remove barring tool (→ Page 87).
2. Install cylinder head cover (→ Page 100).
3. Install cap.
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Preparatory steps
1. On cylinder head covers with crankcase breather: Loosen clamps.
2. Slide rubber sleeves onto the pipe.
Final steps
1. Slide rubber sleeves onto the relevant fitting.
2. Tighten all clamps.
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DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Before cranking the engine with starter system, make sure that there are no persons in the engine's
danger zone.
WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.
Preparatory steps
1. Close fuel supply line upstream of fuel filter.
2. Drain fuel (→ Page 114).
3. Remove engine governor as necessary (→ Page 157).
4. Remove charge-air manifolds and remove gaskets (only on engines with air-to-air charge-air cooling).
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10. Coat the mating face between union nut and fuel line, ball seal and thread on both ends of the fuel line (3)
with engine oil.
11. Install fuel line (3).
Note: Observe the lettering on the union nuts (2) and 4).
12. Tighten union nuts (2) and (4) marked with “35 +3 Nm” (see arrow) to specified torque using a torque
wrench.
Name Size Type Lubricant Value/Standard
Union nut M14 Tightening torque (Engine oil) 35 Nm +3 Nm
13. Tighten union nuts (2) and (4) marked with “30 +3 Nm” (see arrow) to specified torque using a torque
wrench.
Name Size Type Lubricant Value/Standard
Union nut M14 Tightening torque (Engine oil) 30 Nm +3 Nm
Final steps
1. Remove barring tool (→ Page 87).
2. Clean mating faces on cylinder head and charge-air manifold.
3. Check gaskets for damage and replace as necessary.
4. Coat gaskets with assembly compound and place onto cylinder head.
5. Install charge-air pipes.
6. Install engine governor (→ Page 157).
7. Open fuel supply line.
8. Vent fuel system (→ Page 117).
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Replacing injector
u Remove injector and install new injector (→ Page 106).
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WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.
WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.
Preparatory steps
1. Close fuel supply line before fuel filter.
2. Drain fuel (→ Page 114).
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Installing injector
1. Remove all covers before installation.
2. Clean sealing surface on cylinder head and
protective sleeve.
3. Coat sealing ring with grease and insert in
groove of sealing cap.
4. Insert sealing cap in bore.
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17. Loosen thrust screw (4) and tighten it again with torque wrench to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Thrust screw M22 x 1.5 Tightening torque (Engine oil) 45 Nm ±2.5 Nm
18. Use torque wrench to tighten screw for clamp at injector to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw M10 Tightening torque (Engine oil) 50 Nm
19. Coat the mating face between union nut and fuel line, ball seal and thread on both ends of the fuel line (2)
with engine oil.
20. Connect fuel line (2) to injection pump and pressure pipe neck (5).
21. Tighten union nut (1) on injection pump hand-tight.
22. Tighten union nut (3) on pressure pipe neck (5) hand-tight.
Note: Observe the lettering on the union nuts (1) and 3).
23. Tighten union nuts (1) and (3) marked with “35 +3 Nm” (see arrows) to specified torque using a torque
wrench.
Name Size Type Lubricant Value/Standard
Union nut M14 Tightening torque (Engine oil) 35 Nm +3 Nm
24. Tighten union nuts (1) and (3) marked with “30 +3 Nm” (see arrows) to specified torque using a torque
wrench.
Name Size Type Lubricant Value/Standard
Union nut M14 Tightening torque (Engine oil) 30 Nm +3 Nm
Final steps
1. Install cylinder head cover (→ Page 100).
2. Clean mating faces on cylinder head and charge-air manifold.
3. Check gaskets for damage and replace them, if required.
4. Coat gaskets with assembly compound and place onto cylinder head.
5. Install charge-air pipes.
6. Install engine governor (→ Page 157).
7. Open fuel supply line.
8. Vent fuel system (→ Page 117).
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WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.
WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.
Preparatory steps
1. Close fuel supply line upstream of fuel filter.
2. Drain fuel (→ Page 114).
3. Remove engine governor as necessary (→ Page 157).
4. Remove charge-air manifolds and take off seals (only on engines with air-to-air charge-air cooling).
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9. Tighten thrust screw (4) with torque wrench to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Thrust screw M22 x 1.5 Tightening torque (Engine oil) 45 Nm ±2.5 Nm
10. Loosen thrust screw (4) and tighten it again with torque wrench to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Thrust screw M22 x 1.5 Tightening torque (Engine oil) 45 Nm ±2.5 Nm
11. Coat the mating face between union nut and fuel line, ball seal and thread on both ends of the fuel line (2)
with engine oil.
12. Connect fuel line (2) to injection pump and pressure pipe neck (5).
13. Tighten union nut (1) on injection pump hand-tight.
14. Tighten union nut (3) on pressure pipe neck (5) hand-tight.
Note: Observe the tightening torque according to the lettering on the union nuts (1) and 3).
15. Tighten union nuts (1) marked with "35 +3 Nm" (see arrows) with torque wrench to the specified tightening
torque.
Name Size Type Lubricant Value/Standard
Union nut M14 Tightening torque (Engine oil) 35 Nm +3 Nm
16. Tighten union nuts (1) marked with "30 +3 Nm" (see arrows) with torque wrench to the specified tightening
torque.
Name Size Type Lubricant Value/Standard
Union nut M14 Tightening torque (Engine oil) 30 Nm +3 Nm
17. Tighten union nuts (3) marked with "35 +3 Nm" (see arrows) with torque wrench to the specified tightening
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torque.
Name Size Type Lubricant Value/Standard
Union nut M14 Tightening torque (Engine oil) 35 Nm +3 Nm
18. Tighten union nuts (3) marked with "30 +3 Nm" (see arrows) with torque wrench to the specified tightening
torque.
Name Size Type Lubricant Value/Standard
Union nut M14 Tightening torque (Engine oil) 30 Nm +3 Nm
WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.
Draining fuel
1. Loosen nut (arrowed) on banjo union.
WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.
WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.
WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.
WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
• Only run the engine at low power. Keep away from the engine's danger zone.
WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.
WARNING
Liquid or gaseous media, e.g. fuel, are poisonous.
Escaping vapors of highly volatile media, e.g. fuel or ether.
Risk of fatal injury through swallowing; risk of poisoning through inhalation; irritation to eyes
and skin!
• Seek medical attention immediately; do not induce vomiting.
• Do not inhale vapors or mist.
• Wear protective clothing, protective gloves, and safety glasses.
• If contact is made with skin, wash off with water and soap.
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.
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WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.
WARNING
Fuels are combustible and explosive.
Risk of fire and explosion!
• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
• Wear protective clothing, protective gloves, and safety glasses / facial protection.
WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
• Never direct air jet at people.
• Always wear safety goggles/face mask and ear defenders.
Variant A
1. Loosen clamp (2).
2. Remove air filter (1) and clamp (2) from con-
necting flange of intake housing (3).
3. Verify that there are no objects in the flange
of the intake housing (3) and clean it.
4. Fit air filter (1) and clamp (2) on connecting
flange of intake housing (3).
5. Tighten clamp (2).
Variant B
1. Release latches (1).
2. Take off cover (2).
3. Remove filter insert (3) and filter element (4).
4. Wipe out filter housing (5) and cover (2) with
moist cloth.
5. Insert new filter element (4) and filter in-
sert (3).
6. For installation, follow reverse sequence of
working steps.
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.
WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.
Oil change without semirotary hand pump: Draining oil at drain plug on oil
pan
1. Provide a suitable container to collect the oil.
2. Remove drain plug and drain oil.
3. Install drain plug with new sealing ring.
4. Replace engine oil filter (→ Page 135).
WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
• Wear protective clothing, gloves, and goggles / safety mask.
• Avoid contact with skin.
• Do not inhale oil vapor.
WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.
WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.
Preparatory steps
1. Provide an appropriate container to drain the coolant into.
2. Switch off preheating unit.
WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.
NOTICE
Cold coolant in hot engine can cause thermal stress.
Possible formation of cracks in the engine!
• Fill / top up coolant only into cold engine.
Preparatory steps
1. Turn breather valve (1) on coolant expansion
tank counterclockwise to the first stop and
allow pressure to escape.
2. Continue to turn breather valve (1) counter-
clockwise and remove.
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WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.
WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
• Wear ear protectors.
NOTICE
Cold coolant in hot engine can cause thermal stress.
Possible formation of cracks in the engine!
• Fill / top up coolant only into cold engine.
Preparatory steps
1. Turn breather valve (1) on coolant expansion
tank counterclockwise to the first stop and
allow pressure to escape.
2. Continue to turn breather valve (1) counter-
clockwise and remove.
3. Remove plug screw from filling point on cool-
ant line to intercooler.
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Final steps
1. Start the engine and operate it at idle speed for some minutes.
2. Check coolant level (→ Page 146).
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WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
• Let the engine cool down.
• Wear protective clothing, gloves, and goggles / safety mask.
WARNING
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
u Remove protective cover.
Application Specified value (new drive belt) Specified value (used drive belt)
Battery-charging generator drive 450 N -50 N 350 N -50 N
belt
6. If the measured value does not correspond to the specified measured value, adjust the drive belt tension.
Final steps
u Install protective cover.
Battery-charging generator
drive – Drive belt replacement
1. Remove protective cover.
2. Remove drive belt for fan drive (→ Page 153).
3. Undo securing screws (2) and (3).
4. Release tensioning nut (1) until the drive belt
can be removed.
5. Check belt pulleys for cleanliness, remove
dirt, if any.
6. Fit new drive belt.
7. Tension drive belt with tensioning nut (1) and
check belt tension (→ Page 147).
Preparatory steps
u Remove protective cover.
Application Specified value (new drive belt) Specified value (used drive belt)
Drive belt of fan drive 660 N 510 N
6. If the measured value does not correspond to the specified measured value, adjust the drive belt tension.
Application Specified value (new drive belt) Specified value (used drive belt)
Drive belt of fan drive 670 N -50 N 570 N -50 N
6. If the measured value does not correspond to the specified measured value, adjust the drive belt tension.
4. Tighten screws (1) and (4) to specified torque using a torque wrench.
Name Size Type Lubricant Value/Standard
Screw M18 Tightening torque (Engine oil) 69 Nm
Final steps
u Install protective cover.
Preparatory steps
1. Remove protective cover from cooler.
2. Remove fan.
Final steps
1. Install fan.
2. Install protective cover.
NOTICE
Insertion of unsuitable test probe, e.g. test prod.
The contacts in the plug connection can be bent!
• Carry out check of plug connection only with test connectors.
MS15019/04E 2016-02 | Accessories for (Electronic) Engine Governor / Control System | 155
8.20.2 Engine governor plug connections – Check
Preconditions
☑ Engine stopped and starting disabled.
☑ Electronic engine management system is de-energized.
NOTICE
Insertion of unsuitable test probe, e.g. test prod.
The contacts in the plug connection can be bent!
• Carry out check of plug connection only with test connectors.
156 | Accessories for (Electronic) Engine Governor / Control System | MS15019/04E 2016-02
8.20.3 Engine governor ECU 7 – Removal and installation
Preconditions
☑ Engine is stopped and starting disabled.
☑ Engine electronics is powered off.
NOTICE
Wrong engine governor installed.
Engine damage!
• When reassembling an engine, make sure that the governor with the data record for the given engine
is installed.
MS15019/04E 2016-02 | Accessories for (Electronic) Engine Governor / Control System | 157
9 Appendix A
9.1 Abbreviations
Abbrevia- Meaning Explanation
tion
ADEC Advanced Diesel Engine Control Engine governor
AL Alarm Alarm (general)
ANSI American National Standards Institute Association of American standardization organiza-
tions
ATL Abgasturbolader Exhaust turbocharger (ETC)
BR Baureihe Series
BV Betriebsstoffvorschrift MTU Fluids and Lubricants Specifications, Publication
No. A01061/..
CAN Controller Area Network Data bus system, bus standard
CCG Cross Connection Gear Transfer gearbox
CODAG Combined Diesel (engine) And Gas (tur-
bine propulsion)
CPP Controllable Pitch Propeller
DAG Diesel (engine) And Gas (turbine)
DE Diesel Engine
DIN Deutsches Institut für Normung e. V. At the same time identifier of German standards (DIN
= “Deutsche Industrie-Norm”)
DIS Display unit
DL Default Lost Alarm: CAN bus missing
ECS Engine Control System
ECS-UNI Engine Control System UNIversal
ECU Engine Control Unit Engine governor
EDM Engine Data Module
EMU Engine Monitoring Unit
ETK Ersatzteilkatalog Spare Parts Catalog (SPC)
FPP Fixed Pitch Propeller
GCU Gear Control Unit
GMU Gear Monitoring Unit
GT Gas Turbine
HAT Harbor Acceptance Test
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Local Support
Experienced and qualified specialists place their knowledge and expertise at your disposal.
For locally available support, go to the MTU Internet site: http://www.mtu-online.com
24h Hotline
With our 24h hotline and high flexibility, we're your contact around the clock: during each operating phase,
preventive maintenance and corrective operations in case of a malfunction, for information on changes in
conditions of use and for supplying spare parts.
Your contact person in our Customer Assistance Center:
E-mail: info@mtu-online.com
Tel.: +49 7541 9077777
Fax.: +49 7541 9077778
Asia/Pacific: +65 6100 2688
North and Latin America: +1 248 560 8000
Crossbeam
Part No.: T80092210
Qty.: 1
Used in: 2.1 Transportation (→ Page 16)
DCL-ID: 0000014859 - 005
Crowfoot wrench, 19 mm
Part No.: F30027424
Qty.: 1
Used in: 8.5.2 Injection pump – Removal and installation
(→ Page 102)
Qty.: 1
Used in: 8.6.2 Injector – Removal and installation (→ Page 106)
Qty.: 1
Used in: 8.7.1 Fuel injection line – Pressure pipe neck replacement
(→ Page 111)
Feeler gage
Part No.: Y4342013
Qty.: 1
Used in: 8.4.1 Valve clearance – Check and adjustment
(→ Page 97)
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Ratchet adapter
Part No.: F30027340
Qty.: 1
Used in: 8.3.1 Crankcase breather – Oil separator replacement, di-
aphragm check and replacement (→ Page 94)
Qty.: 1
Used in: 8.4.1 Valve clearance – Check and adjustment
(→ Page 97)
Qty.: 1
Used in: 8.4.2 Cylinder head cover – Removal and installation
(→ Page 100)
Qty.: 1
Used in: 8.5.2 Injection pump – Removal and installation
(→ Page 102)
Qty.: 1
Used in: 8.6.2 Injector – Removal and installation (→ Page 106)
Qty.: 1
Used in: 8.7.1 Fuel injection line – Pressure pipe neck replacement
(→ Page 111)
Qty.: 1
Used in: 8.17.1 Battery-charging generator drive – Drive-belt check
and adjustment (→ Page 147)
Qty.: 1
Used in: 8.17.2 Battery-charging generator drive – Drive belt re-
placement (→ Page 149)
Qty.: 1
Used in: 8.18.1 Fan drive – Drive-belt check and adjustment
(→ Page 150)
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– Replacement 101
Injector T
– Installation 106 Transportation
– Removal 106 – Description 16
– Replacement 105 – Lifting requirements 17
Intercooler Troubleshooting 84
– Condensate drain for coolant discharge
– Check 128 V
– Condensate drain for obstructions Valve clearance
– Check 128 – Adjustment 97
– Check 97