Professional Documents
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Diesel engine 12 V 2000 G25, G25 TB 12 V 2000 G45, G45 TB 12 V 2000 G65, G65 TB 12 V 2000 G85, G85 TB 16 V 2000 G25, G25 TB 16 V 2000 G45, G45 TB 16 V 2000 G65, G65 TB 16 V 2000 G85, G85 TB 18 V 2000 G25, G25 TB 18 V 2000 G45, G45 TB 18 V 2000 G65, G65 TB 18 V 2000 G85, G85 TB Application group 3A
MS15018/01E
Printed in Germany 2012 Copyright MTU Friedrichshafen GmbH This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, micro filming and storage or processing on electronic systems including data bases and online services. This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage during operation. Subject to alterations and amendments.
Table of Contents
1 Safety 1.1 1.2 1.3 1.4 General conditions Personnel and organizational requirements Transport Safety regulations for maintenance and repair work 1.5 Auxiliary materials, fluids and lubricants, fire prevention and environmental protection 1.6 Conventions for safety instructions in the text 5 6 7 8 6 Task Description 11 13 6.1 Engine
6.1.1 Engine Barring manually 6.1.2 Engine Barring with starting system 6.1.3 Engine Test run 6.2.1 Cylinder liner Endoscopic examination 6.2.2 Cylinder liner Instructions and comments on endoscopic and visual examination 6.3.1 Crankcase breather Oil separator element replacement, diaphragm check and replacement 6.3.2 Crankcase breather Wire mesh cleaning 6.4.1 Valve clearance Check and adjustment 6.4.2 Cylinder head cover Removal and installation 6.5.1 Injection pump Removal and installation 6.5.2 Injection pump Removal 6.5.3 Injection pump Installation 6.6.1 6.6.2 6.6.3 6.6.4 Injector Replacement Injector Removal and installation Injector Removal Injector Installation
5 Troubleshooting 5.1 Troubleshooting 5.2 Fault indication on SAM display Genset applications 37 40
65
65 66 67 68 70
2 Product Summary 2.1 2.2 2.3 2.4 Engine - Overview Engine Main dimensions Engine side and cylinder designations Technical Data 14 16 17 18
18 22 26
68
72
72 74
2.4.1 12/16/18 V 2000 Gx5 engine data, optimized fuel consumption 2.4.2 12/16/18 V 2000 Gx5-TB engine data, optimized fuel consumption 2.4.3 Firing order
75
75 78
3 Operation 3.1 Putting the engine into operation after extended out-of-service periods (>3 months) 3.2 Putting the engine into operation after scheduled out-of-service-period 3.3 Start engine in manual mode (testing mode) 3.4 Safety system Override 3.5 Operational checks 3.6 Stop engine in manual mode (testing mode) 3.7 Emergency stop 3.8 After stopping the engine Engine remains ready for operation 3.9 After stopping the engine putting the engine out of service
79
79 82 83 84 85 89 91
27 28 29 30 31 32 33 34 35
84
6.7.1 Fuel injection line Pressure pipe neck replacement 6.7.2 Fuel pressure maintaining valve Removal and installation 6.7.3 Fuel Draining 6.7.4 Fuel system Venting 6.8.1 Fuel filter Replacement 6.8.2 Fuel prefilter cleaning 6.8.3 Fuel prefilter Differential pressure gauge check and adjustment 6.8.4 Fuel prefilter Draining 6.8.5 Fuel prefilter Flushing
93
93 95 96 98
100
106
128
6.9.1 Intercooler Checking condensate drains for coolant discharge and obstructions
108
108
6.10.1 Air filter Replacement 6.10.2 Air filter Removal and installation 6.11.1 Service indicator Signal ring position check 6.12.1 Air starter Manual operation 6.13.1 Engine oil Level check 6.13.2 Engine oil Change
109
6.18.1 Drive belt Condition check 6.18.2 Battery-charging generator drive Drive-belt check and adjustment 6.18.3 Battery-charging generator drive Drive belt replacement 6.19.1 Fan drive Drive-belt check and adjustment 6.19.2 Fan drive Drive belt replacement 6.20.1 Engine wiring Check 6.20.2 Sensors and actuators
129
133
6.20 Cabling
138
115
6.21.1 Engine governor and connectors Cleaning 6.21.2 Engine governor Checking plug-in connections 6.21.3 ECU 7 engine governor Removal and installation
140
Engine coolant Filling Engine coolant Draining Engine coolant Change Engine coolant Level check Coolant pump Relief bore check Charge-air coolant Filling Charge-air coolant Draining Charge-air coolant Change Charge-air coolant Level check
116
122
8 Appendix B 8.1 8.2 8.3 8.4 Special Tools Consumables Spare Parts Index 147 155 158 161
127
127
1 Safety
1.1 General conditions
General
In addition to the instructions in this publication, the applicable country-specific legislation and other com pulsory regulations regarding accident prevention and environmental protection must be observed. This state-of-the-art engine has been designed to meet all applicable laws and regulations. The engine may nevertheless present a risk of injury or damage in the following cases: Incorrect use Operation, maintenance and repair by unqualified personnel Modifications or conversions Noncompliance with the Safety Instructions
Correct use
The engine is intended solely for use in accordance with contractual agreements and the purpose envis aged for it on delivery. Any other use is considered improper use. The engine manufacturer accepts no liability whatsoever for resultant damage or injury in such case. The responsibility is borne by the user alone. Correct use also includes observation of and compliance with the maintenance specifications.
Modifications or conversions
Unauthorized modifications to the engine represent a safety risk. MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or conversions.
Spare parts
Only genuine MTU spare parts must be used to replace components or assemblies. MTU accepts no liability whatsoever for damage or injury resulting from the use of other spare parts and the warranty shall be voided in such case.
Reworking components
Repair or engine overhaul must be carried out in workshops authorized by MTU.
Organizational measures
This publication must be issued to all personnel involved in operation, maintenance, repair or transporta tion. Keep it at hand at the operating site of the engine so that it is available to operating, maintenance, repair and transport personnel at all times. Use the manual as a basis for instructing personnel on engine operation and repair with an emphasis on explaining safety-relevant instructions. This is particularly important in the case of personnel who only occasionally perform work on or around the engine. This personnel must be instructed repeatedly. For the identification and layout of the spare parts during maintenance or repair work, take photos or use the spare parts catalog.
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). Prior to transporting the engine, it is imperative to install transportation locking devices for crankshaft and engine mounts. Secure the engine against tilting during transport. The engine must be especially secured against slip ping or tilting when going up or down inclines and ramps.
Welding work
Never carry out welding work on the assembly, system, or engine-mounted units. Cover the engine when welding in its vicinity. Do not use the assembly or system as ground terminal. Do not route the welding lead over or near the wiring harnesses of MTU systems. The welding current may otherwise induce an interference voltage in the wiring harnesses which could conceivably damage the electrical system. Remove parts (e.g. exhaust pipes) which are to be welded from the engine beforehand.
For conducting light-beam procedures and measurement work, only the following laser devices must be used: Laser devices of classes 1, 2 or 3A. Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700 nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to prevent any risk to the eyes.
1.5 Auxiliary materials, fluids and lubricants, fire prevention and environmental protection
Fire prevention
Rectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause fires therefore always keep the engine in a clean condition. Do not leave cloths soaked with fluids and lubri cants lying on or near the assembly or unit. Do not store inflammable material near the assembly or unit. Do not weld pipes and components carrying oil or fuel! Before welding, clean with a nonflammable fluid. When starting the engine with an external power source, connect the ground lead last and remove it first. To avoid sparks in the vicinity of the battery, connect the ground lead from the external power source to the ground lead of the engine or to the ground terminal of the starter. Always keep suitable firefighting equipment (fire extinguishers) at hand and familiarize yourself with their use.
Noise
Noise can lead to an increased risk of accident if acoustic signals, warning shouts or noises indicating danger are drowned. Wear ear protectors in work areas with a sound pressure level in excess of 85 dB (A).
Used oil
Used oil contains harmful combustion residues. Rub barrier cream into hands. Wash hands after contact with used oil. MS15018/01E 2012-05 | Safety | 11
Lead
When working with lead or lead-containing compounds, avoid direct contact to the skin and do not inhale lead vapors. Adopt suitable measures to avoid the formation of lead dust. Switch on extraction system. Wash hands after contact with lead or lead-containing substances.
Compressed air
Observe special safety precautions when working with compressed air: Pay special attention to the pressure level in the compressed air network and pressure vessel. Assemblies and equipment to be connected must either be designed for this pressure, or, if the per mitted pressure for the connecting elements is lower than the pressure required, a pressure reducing valve and safety valve (set to permitted pressure) must form an intermediate connection. Hose couplings and connections must be securely attached. Wear goggles when blowing off components or blowing away chips. Provide the snout of the air nozzle with a protective disk (e.g. rubber disk). First shut off compressed air lines before compressed air equipment is disconnected from the supply line, or before equipment or tool is to be replaced. Unauthorized use of compressed air, e.g. forcing flammable liquids (danger class AI, AII and B) out of containers, results in a risk of explosion. Forcing compressed air into thin-walled containers (e.g. containers made of tin, plastic and glass) for drying purposes or to check for leaks, results in a risk of bursting. Carry out leak test in accordance with the specifications.
Liquid nitrogen
Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers. Avoid body contact (eyes, hands). Wear protective clothing, protective gloves, closed shoes and protective goggles / safety mask. Make sure that working area is well ventilated. Avoid all knocks and jars to the containers, fixtures or workpieces.
In the event of immediate danger. Consequences: Death or serious injury Remedial action
WARNING
In the event of potentially dangerous situations. Consequences: Death or serious injury Remedial action
CAUTION
In the event of dangerous situations. Consequences: Minor injury or material damage Remedial action
NOTICE
In the event of a situation involving potentially adverse effects on the product. Consequences: Material damage. Remedial action Additional product information This manual contains highlighted safety warnings in accordance with the US ANSI Z535 standard which begin with one of the signal words listed above depending on the severity of the hazard.
Note:
Safety instructions
1. 2. Read and familiarize yourself with all safety notices before starting up or repairing the product. Pass on all safety instructions to your operating, maintenance, repair and transport personnel.
2 Product Summary
2.1 Engine - Overview
Illustration is applicable to 12/16/18 V 2000 Gxy engines (with water-cooled intercooler)
010 Crankcase and add-on components 020 Gear train 030 Running gear 040 Cylinder head 050 Valve gear 070 Fuel system (high pres sure)
080 Fuel system (low pres sure) 100 Exhaust turbocharger 110 Charge-air cooling 120 Air intake/air supply 140 Exhaust system 170 Starting equipment
180 Lube oil system / lube oil circuit 200 Coolant system 210 Power generation / sup ply, engine side 220 Cooling air system 230 Mounting/support 500 Monitoring, control and regulation equipment, general electric equip ment
Key to the engine model designations 12/16/18V 2000 Gxy X y Application segment (2, 4, 6, 8) Design index (0,1, 2,...)
Engine model 12V 2000 Gxy 16V 2000 Gxy 18V 2000 Gxy
REFERENCE CONDITIONS
Engine model Application group Intake air temperature Barometric pressure Site altitude above sea level C mbar m 12V 2000 12V 2000 G25 3A 25 1000 100 G65 3A 25 1000 100 16V 2000 18V 2000 G65 3A 25 1000 100 G65 3A 25 1000 100
POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)
Number of cylinders Rated engine speed A rpm kW Continuous power ISO 3046 (10% over A load capability, design power DIN 6280, ISO 8528) 12 1500 452 12 1500 515 16 1500 655 18 1500 720
Number of cylinders Direction of rotation: c.c.w. (facing driv ing end) Number of cylinders Cylinder configuration: V angle Bore Stroke Displacement per cylinder Displacement, total Compression ratio Cylinder heads: single-cylinder Cylinder liners: wet, replaceable Inlet valves per cylinder Exhaust valves per cylinder Standard flywheel housing flange (en gine main PTO) Flywheel interface SAE DISC Degrees mm mm liters liters
LUBE-OIL SYSTEM
Number of cylinders
TIM-ID: 0000010804 - 001
Lube oil operating temperature before engine, from Lube-oil operating temperature before engine, to Lube-oil temperature before engine, alarm Lube-oil temperature before engine, shutdown Lube-oil operating pressure before en gine, from
Number of cylinders Lube-oil operating pressure before en gine, to Lube-oil pressure before engine, alarm Lube-oil pressure before engine, shut down R R L bar bar bar
FUEL SYSTEM
Number of cylinders Fuel pressure at engine supply connec tion, min. (when engine is starting) Fuel pressure at engine supply connec tion, max. (when engine is starting) L L bar bar 12 -0.3 +0.5 12 -0.3 +0.5 16 -0.3 +0.5 18 -0.3 +0.5
CAPACITIES
Number of cylinders Engine coolant capacity, engine side (without cooling equipment) Total engine oil capacity at initial filling (standard oil system) (Option: max. op erating inclinations) Oil change capacity, max. (standard oil system) Oil change quantity, max. (standard oil system) (Option: max. operating inclina tions) Oil pan capacity at dipstick mark "min." (standard oil system) (Option: max. op erating inclinations) Oil pan capacity at dipstick mark "max." (standard oil system) (Option: max. op erating inclinations) R R liters liters 12 90 77 12 90 77 16 110 102 18 120 130
R R
liters liters
N 74
N 74
N 99
N 114
liters
50
50
69
87
liters
67
67
92
110
ACOUSTICS
Number of cylinders Exhaust noise, unsilenced - DL (sound power level LW, ISO 6798) R dB(A) dB(A) 12 119 114 12 119 115 16 116 119 18 116 119
Engine surface noise with attenuated in R take noise filter) - DL (sound power level LW, ISO 6798)
2.4.2
REFERENCE CONDITIONS
Engine model Application group Intake air temperature Charge-air coolant temperature Raw water inlet temperature Barometric pressure Site altitude above sea level C C C mbar m 12V 2000 12V 2000 16V 2000 18V 2000 G25-TB G65-TB G65-TB G65-TB 3A 25 55 1000 100 3A 25 55 1000 100 3A 25 55 1000 100 3A 25 55 1000 100
POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)
Number of cylinders Rated engine speed A rpm kW Continuous power ISO 3046 (10% over A load capability, design power DIN 6280, ISO 8528) 12 1500 452 12 1500 515 16 1500 655 18 1500 720
Number of cylinders Direction of rotation: c.c.w. (facing driv ing end) Number of cylinders Cylinder configuration: V angle Bore Stroke Displacement per cylinder Displacement, total Compression ratio Cylinder heads: single-cylinder Cylinder liners: wet, replaceable Inlet valves per cylinder Exhaust valves per cylinder Standard flywheel housing flange (en gine main PTO) Flywheel interface SAE DISC Degrees mm mm liters liters
12 A L L C % bar 55 50 0.7
12 55 50 0.7
16 55 50 0.7
18 55 50 0.7
Coolant temperature before intercooler (at engine inlet from cooling equipment) Coolant antifreeze content, max. Pressure loss in off-engine cooling sys tem, max.
LUBE-OIL SYSTEM
Number of cylinders Lube oil operating temperature before engine, from Lube-oil operating temperature before engine, to Lube-oil temperature before engine, alarm Lube-oil temperature before engine, shutdown Lube-oil operating pressure before en gine, from Lube-oil operating pressure before en gine, to Lube-oil pressure before engine, alarm Lube-oil pressure before engine, shut down R R R L R R R L C C C C bar bar bar bar 12 88 98 100 105 6.2 7.5 4.4 3.9 12 88 98 100 105 6.2 7.5 4.4 3.9 16 88 98 100 105 5.5 6.5 4.4 3.9 18 88 98 100 105 6.0 8.0 4.4 3.9
FUEL SYSTEM
Number of cylinders Fuel pressure at engine supply connec tion, min. (when engine is starting) Fuel pressure at engine supply connec tion, max. (when engine is starting) L L bar bar 12 -0.3 +0.5 12 -0.3 +0.5 16 -0.3 +0.5 18 -0.3 +0.5
CAPACITIES
Number of cylinders Engine coolant capacity, engine side (without cooling equipment) Charge-air coolant, engine side Total engine oil capacity at initial filling (standard oil system) (Option: max. op erating inclinations) Oil change capacity, max. (standard oil system) Oil change quantity, max. (standard oil system) (Option: max. operating inclina tions) 24 | Product Summary | MS15018/01E 2012-05 R R R liters liters liters 12 110 20 77 12 110 20 77 16 130 20 102 18 140 20 130
TIM-ID: 0000010846 - 001
R R
liters liters
N 74
N 74
N 99
N 114
Number of cylinders Oil pan capacity at dipstick mark "min." (standard oil system) (Option: max. op erating inclinations) Oil pan capacity at dipstick mark "max." (standard oil system) (Option: max. op erating inclinations) L liters
12 50
12 50
16 69
18 87
liters
67
67
92
110
ACOUSTICS
Number of cylinders Exhaust noise, unsilenced - DL (sound power level LW, ISO 6798) R dB(A) dB(A) 12 119 114 12 119 115 16 116 119 18 116 119
Engine surface noise with attenuated in R take noise filter) - DL (sound power level LW, ISO 6798)
2.4.3
Firing order
Firing order
12 V 16 V 18 V A1-B2-A5-B4-A3-B1-A6-B5-A2-B3-A4-B6 A1-B5-A3-A5-B2-B8-A2-A8-B3-A7-B4-B6-A4-A6-B1-B7 A1-B6-A3-B4-A5-B2-A7-B1-A9-B3-A8-B5-A6-B7-A4-B9-A2-B8
3 Operation
3.1 Putting the engine into operation after extended out-ofservice periods (>3 months)
Preconditions
Engine is stopped and starting disabled. MTU Fluids and Lubricants Specifications (A001061/..) are available.
Putting the engine into operation after extended out-of-service-periods (>3 months)
Item Engine Lube oil system Fuel prefilter Fuel prefilter, pressure gauge Fuel system Cooling system Task Depreserve ( MTU Fluids and Lubricants Specifications A001061/..). Check engine oil level ( Page 113); Prime ( Page 104). Align adjustable pointer with position of pressure indicator ( Page 102). Vent ( Page 98). If engine is out of service for more than one year, change engine coolant ( Page 119); Change charge-air coolant ( Page 125). Cooling system Cooling system Engine Governor Monitoring equipment Engine/generator control system Check engine coolant level ( Page 120); Check charge-air coolant level ( Page 126). Preheat coolant with preheating unit. Check plug-in connections ( Page 141). Carry out lamp test (see manufacturer's documentation). Switch ON; Select operating mode, e.g. MANUAL, AUTOMATIC OPERATION.
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.
WARNING
Engine noise above 85 dB (A). Risk of damage to hearing! Wear ear protectors.
Preparation
Item Operating mode selector switch (if provided) Task Change to manual mode.
Connect generator to network (if provided), run engine to reach operating temperature )
Item
TIM-ID: 0000002226 - 002
Task
Switchgear cabinet, control Close the generator circuit breaker. panel etc. (depending on manufacturer) Engine Apply full load only after engine has reached operating temperature (cool ant temperature approx. 75 C).
Safety functions and engine shutdown alarms will be disregarded. Serious damage to plant! Initiate emergency start only in emergency situations.
CAUTION
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.
Unguarded rotating and moving engine components. Risk of serious injury danger to life! Take special care when working on a running engine.
WARNING
Engine noise above 85 dB (A). Risk of damage to hearing! Wear ear protectors.
Operational checks
Item Control and display panels Engine under load, Engine at nominal speed Fuel prefilter Exhaust system Intercooler Air filter Task Check indicated operating parameters (speed, temperatures, pressures). Check engine/plant and pipework for leaks, rectify any leaks with the en gine stopped; Check for abnormal running noises and vibration. Check whether indicated differential pressure is within the limit ( Page 102). Check exhaust color ( Page 37). Check condensate drain(s) for water discharge and obstruction ( Page 108). Check signal ring position of service indicator ( Page 111). Replace air filter ( Page 109), if the signal ring is completely visible in the red area of the service indicator control window. Coolant pump Compressed-air system (if installed) Check relief bore ( Page 121). Check operating pressure at pressure gauge; Fill compressed-air tank to maximum pressure; Drain condensate from compressed-air tank, pressure drop must not ex ceed 1 bar.
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.
An emergency stop causes extreme stress to the engine. Risk of overheating, damage to components! Initiate emergency stop only in emergency situations.
3.8 After stopping the engine Engine remains ready for operation
After stopping the engine
Item Engine/generator/pump control Action Select operating mode, e.g. MANUAL, AUTOMATIC OPERATION.
3.9 After stopping the engine putting the engine out of service
Preconditions
MTU Fluids and Lubricants Specifications (A001061/..) is available.
Air intake and exhaust sys If the engine is to remain out of service for more than 1 week, seal the tem engine's air and exhaust sides. If the engine is to remain out of service for more than 1 month, preserve engine ( MTU Fluids and Lubricants Speci fications A001061/.. ).
4 Maintenance
4.1 Maintenance task reference table [QL1]
The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Maintenance Schedule is a stand-alone publication. The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule. Task W0500 W0501 W0502 W0503 W0505 W0506 W0507 W0508 W0534 W1001 W1002 W1003 W1005 W1006 W1007 W1008 W1010 W1011 W1056 W1178 Maintenance tasks Check engine oil level. Visually inspect engine for leaks and general condition. Check intercooler drain. Check signal ring position of service indicator on air filter. Check relief bores of water pump(s). Check engine for abnormal running noises, exhaust color and vibrations. Drain water and contaminants from fuel prefilter. Check reading on differential pressure gage of fuel prefilter. Carry out test run, minimum duration: until steady-state tem perature is reached, no less than 1/3 load (monthly). Replace fuel filter or fuel filter element. Check valve clearance. Check belt condition and tension, replace if necessary. Replace air filter. Replace fuel injectors. Replace fuel injection pump(s). Replace engine oil filter when changing engine oil, or when the time limit (years) is reached, at the latest. Coolant cooler: Check exterior of cooler elements for dirt. Perform endoscopic examination. Replace fuel pressure maintaining valve. Replace pressure pipe neck in cylinder head. ( Page 113) ( Page 31) ( Page 31) ( Page 31) ( Page 31) ( Page 31) ( Page 31) ( Page 31) ( Page 67) ( Page 100) ( Page 75) ( Page 129) ( Page 109) ( Page 84) ( Page 79) ( Page 115) ( Page 127) ( Page 68) ( Page 95) ( Page 93)
5 Troubleshooting
5.1 Troubleshooting
Engine does not turn when starter is actuated
Component Battery Probable Cause Low or defective Cable connections defective Starter Engine wiring Engine/generator control system Engine Governor Engine Engine wiring or starter defective Defective Secure seating of assemblies or con nectors not provided Plug-in connections are loose Running gear blocked (engine cannot be barred manually) Task Charge or replace (see manufacturer's documentation). Check if cable connections are proper ly secured (see manufacturer's docu mentation). Check if cable connections are proper ly secured, contact Service. Check (REFDM TARGET NOT FOUND). Perform visual inspection (see manu facturer's documentation). Check plug-in connections ( Page 141). Contact Service.
Probable Cause Injector defective Injection pump defective Defective Not vented Defective
Task Replace ( Page 84). Replace ( Page 79). Check (REFDM TARGET NOT FOUND). Vent fuel system ( Page 98). Contact Service.
Component Air supply Fuel injection equip ment Engine wiring Engine
Probable Cause Air filter clogged Injector defective Injection pump defective Defective Overloaded
Task Check signal ring position of service in dicator ( Page 111). Replace ( Page 84). Replace ( Page 79). Check (REFDM TARGET NOT FOUND). Contact Service.
The structure of the display is as follows: First line Time indicator for alarms (e.g. #) Type of fault (e.g. SE03) Node number at which the fault occurred (e.g. nd11) Second line (option) Running text, providing more information about the fault currently displayed Time indicator for alarms # A B C D E Meaning Alarm is no longer active, does not appear on next power-up. Alarm is active. Alarm was active during the last hour. Alarm was active during the last four hours. Alarm was active during the last four to twelve hours. Alarm was active more than twelve hours ago.
TIM-ID: 0000008508 - 002
Fault type fault message text SE no. 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Error message text Sensor Temperatur Defect Temperature failure Sensor Voltage Defect Voltage failure CAN Bus- 1 Error/Bus Defec CAN Bus- 1 Overrun CAN Bus- 2 Error/Bus Defec CAN Bus- 2 Overrun Temperatur Compensation Error I/O-Module Slot2 Defect I/O-Module Slot3 Defect I/O-Module Slot4 Defect Serial Conection Lost CAN Bus- 3 Error/Bus Defec CAN Bus- 3 Overrun S/A Bus Faulty PAN 1 Defect PAN 2 Defect PAN 3 Defect PAN 4 Defect PAN 5 Defect PAN 6 Defect I/O-Module Slot1 Defect I/O-Module Slot5 Defect I/O-Module Slot6 Defect I/O-Module Slot7 Defect I/O-Module Slot8 Defect Download Server Collision not projected node
Recommended action in case of alarm Yellow alarm: 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.
Fault and alarm messages The fault code numbers are generated by the engine governor and transmitted to the display below.
The fault code (1) comprises three digits. Fault messages can also be caused by faulty sensors/actuators. Contact Service to have sensors/actua tors checked and replaced as necessary if the troubleshooting measures listed in the table below prove unsuccessful. IMPORTANT NOTE: The information provided in the columns Meaning and Action applies to the standard default state of the genset on delivery. Differing system responses requiring different action may result when settings are changed by the OEM. The OEM is responsible for documenting any changes and defining appropriate counteraction. The table below lists possible fault codes: Fault code no. 003 Full designation HI T-Fuel Meaning Prewarning: Fuel tempera ture too high (limit value 1, alarm configuration parame ter, see PR 2.8008.100 for explanation). Main warning: Fuel temper ature too high (limit value 2, alarm configuration parame ter, see PR 2.8008.100 for explanation). Action Setting param eter no.
004
SS T-Fuel
Check tank temper 2.0122932 ature, contact Serv ice if no fault de tected.
Check tank temper 2.0122931 ature, contact Serv ice if no fault de tected.
Meaning Prewarning: Charge-air temperature too high (limit value 1, alarm configuration parameter, see PR 2.8008.100 for explanation). Main warning: Charge-air temperature too high (limit value 2, alarm configuration parameter, see PR 2.8008.100 for explanation). Prewarning: Coolant tem perature in intercooler too high (limit value 1, alarm configuration parameter, see PR 2.8008.100 for ex planation).
Action Check cooler, check intercooler, contact Service if no fault detected. Check cooler, check intercooler, contact Service if no fault detected. Check cooler, con tact Service if no fault detected.
006
SS T-Charge Air
2.0121.932
009
2.0124.931
010
Main warning: Coolant tem Check cooler, con perature in intercooler too tact Service if no high (limit value 2, alarm fault detected. configuration parameter, see PR 2.8008.100 for ex planation). Prewarning: Lube-oil pres Check oil level, sure too low (limit value 1, contact Service if alarm configuration parame no fault detected. ter, see PR 2.8008.100 for explanation). Main warning: Lube-oil Check oil level, pressure too low (limit value contact Service. 2, alarm configuration pa rameter, see PR 2.8008.100 for explanation). Automatic engine shutdown. Coolant level too low (limit value 2, alarm configuration parameter, see PR 2.8008.100 for explanation). Automatic engine shutdown.
2.0124.932
015
LO P-Lube Oil
2.0100.921
016
SS P-Lube Oil
2.0100.922
024
SS Coolant Level
Check coolant level 2.0152.912 in expansion tank, check for leakage and seal any leaks as necessary. 2.2510.932
030
SS Engine Overspeed Engine overspeed (limit val Attempt to restart ue 2, alarm configuration engine. parameter, see PR 2.8008.100 for explanation). Automatic engine shutdown. LO Coolant Level In tercooler Intercooler coolant level too low (limit value 1, alarm configuration parameter, see PR 2.8008.100 for ex planation). Automatic en gine shutdown.
044
Check coolant level 2.0153.921 in expansion tank, check for leakage and seal any leaks as necessary.
Meaning Lube-oil temperature too high (limit value 1, alarm configuration parameter, see PR 2.8008.100 for ex planation). Warning. Lube-oil temperature too high (limit value 2, alarm configuration parameter, see PR 2.8008.100 for ex planation). Automatic en gine shutdown.
052
SS T-Lube Oil
Check cooling sys tem, contact Serv ice if cooling sys tem is in order.
2.0125.932
065
LO P-Fuel
Fuel inlet pressure too low Check filter, check (limit value 1, alarm configu genset fuel supply. ration parameter, see PR 2.8008.100 for explanation). Warning. Fuel inlet pressure too low Check filter, check (limit value 2, alarm configu genset fuel supply. ration parameter, see PR 2.8008.100 for explanation). Warning. Coolant temperature too high (limit value 1, alarm configuration parameter, see PR 2.8008.100 for ex planation). Warning. Coolant temperature too high (limit value 2, alarm configuration parameter, see PR 2.8008.100 for ex planation). Automatic en gine shutdown. Pressure gradient in rail too low on starting or too high on stopping, HP system leaking (alarm configuration parameter, see PR 2.8008.100 for explanation). Check cooling sys tem.
2.0102.921
066
SS P-Fuel
2.0102.922
067
HI T-Coolant
2.0120.931
068
SS T-Coolant
Check cooling sys tem. Contact Serv ice if cooling sys tem is in order.
2.0120.932
081
AL Rail Leakage
On stopping: Seal 1.8004.046 off system, contact Service; On start ing: Check engine for leakage, if none found, attempt re starting as per op erating instructions (air in system).
TIM-ID: 0000008508 - 002
082
Rail pressure is greater than set value (alarm configura tion parameter, see PR 2.8008.100 for explanation). Warning. Rail pressure is less than set value (alarm configura tion parameter, see PR 2.8008.100 for explanation). Warning.
Check HP fuel con 2.0104.931 trol block wiring, if no fault detected, contact Service. Check HP fuel con 2.0104.921 trol block wiring, check HP system for leakage, if no fault detected, con tact Service.
083
Meaning
Action
Engine speed too low Check for addition (alarm configuration param al messages. eter, see PR 2.8008.100 for explanation). Engine stop. Idling speed not reached Check for addition (alarm configuration param al messages. eter, see PR 2.8008.100 for explanation). Start terminat ed. Runup speed not reached (alarm configuration param eter, see PR 2.8008.100 for explanation). Start terminat ed.
090
2.1090.925
091
Check for addition 2.1090.924 al messages. Re charge battery. En gine under load: Check fuel supply; if no fault detected, contact Service. Check for addition 2.1090.923 al messages. Re charge battery. En gine under load: Check fuel supply; if no fault detected, contact Service. Engine start inter lock is active as coolant tempera ture is too low for engine start, pre heating necessary. Engine start inter lock is active as coolant tempera ture is too low for engine start, pre heating necessary. 2.1090.922
092
SS Starter Speed Not Starter speed not reached Reached (alarm configuration param eter, see PR 2.8008.100 for explanation). Start terminat ed. Starter does not turn or turns slowly. SS T-Preheat Preheating temperature too low (limit value 2, alarm configuration parameter, see PR 2.8008.100 for ex planation). Preheating temperature too low (limit value 1, alarm configuration parameter, see PR 2.8008.100 for ex planation).
093
094
LO T-Preheat
2.1090.921
095
AL Prelubrication Fault
Oil priming pressure not Contact Service. reached (alarm configura tion parameter, see PR 2.8008.100 for explanation). Electronic fault: Consump tion counter faulty (alarm configuration parameter, see PR 2.8008.100 for ex planation). Replace engine governor at next opportunity.
2.1090.920
102
TIM-ID: 0000008508 - 002
1.8004.624
104
Electronic fault: Hour meter Replace engine faulty (alarm configuration governor at next parameter, see PR opportunity. 2.8008.100 for explanation).
1.8004.623
Meaning Supply voltage too low (limit value 1, alarm configuration parameter, see PR 2.8008.100 for explanation). Warning. Supply voltage too low (limit value 2, alarm configuration parameter, see PR 2.8008.100 for explanation). Warning.
Action
Check batteries 2.0140.921 and charge as nec essary; check gen erator. Check batteries 2.0140.922 and charge as nec essary; check gen erator. 2.0140.931
119
120
HI ECU Power Supply Supply voltage too high Check batteries Voltage (limit value 1, alarm configu and generator. ration parameter, see PR 2.8008.100 for explanation). Warning. HIHI ECU Power Sup Supply voltage too high Check batteries ply Voltage (limit value 2, alarm configu and generator. ration parameter, see PR 2.8008.100 for explanation). Warning. HI T-ECU
121
2.0140.932
122
Electronics temperature too Check engine room 2.0132.921 high (limit value 1, alarm ventilation. configuration parameter, see PR 2.8008.100 for ex planation). Warning. No (suitable) LifeData back Contact Service. up system available, backup system has no LifeData function when timeout fol lowing ECU reset expires or CAN bus to backup system is disrupted (alarm configu ration parameter, see PR 2.8008.100 for explanation). 2.4000.004
176
177
180
Connection to a node on Test devices con 2.0500.680 CAN bus 1 has failed (alarm nected to CAN, test configuration parameter, wiring. see PR 2.8008.100 for ex planation).
AL LifeData restore in This fault message is gener Contact Service. complete ated when a CRC is faulty (stated for each module) or upload is incomplete during a restore data upload proc ess (into ADEC) (alarm con figuration parameter, see PR 2.8008.100 for explana tion).
2.4000.006
Meaning
Action
Connection to a node on Check devices con 2.0500.681 CAN bus 2 has failed (alarm nected to CAN. configuration parameter, see PR 2.8008.100 for ex planation). Incorrect parameter values entered in data record (alarm configuration param eter, see PR 2.8008.100). 2.0500.682
182
183
AL CAN No PU-Data
The selected CAN mode ini Check devices con 2.0500.683 tializes communication by nected to CAN. means of the PU data mod ule. However, the required PU data module is unavaila ble or invalid (alarm configu ration parameter, see PR 2.8008.100 for explanation). Programming error on at Contact Service. tempting to copy a received PU data module into the Flash module (alarm config uration parameter, see PR 2.8008.100 for explanation). CAN controller 1 is in "Bus Contact Service. Off" state, automatic switch ing to CAN2 results. Causes are e.g. short circuit, mas sive disruptions or baud rate incompatibility (alarm con figuration parameter, see PR 2.8008.100 for explana tion). CAN controller 1 has indi Contact Service. cated a warning. Causes are e.g. missing associate nodes, minor disruptions and temporary bus overload (alarm configuration param eter, see PR 2.8008.100 for explanation). CAN controller 2 is in "Bus Contact Service. Off" state, automatic switch ing to CAN1 results. Causes are e.g. short circuit, mas sive disruptions or baud rate incompatibility (alarm con figuration parameter, see PR 2.8008.100 for explana tion). 2.0500.684
184
186
2.0500.686
187
2.0500.687
188
TIM-ID: 0000008508 - 002
2.0500.688
Meaning
Action
CAN controller 2 has indi Contact Service. cated a warning. Causes are e.g. missing associate nodes, minor disruptions and temporary bus overload (alarm configuration param eter, see PR 2.8008.100 for explanation). SD alarm configuration, coolant temperature sensor faulty, short circuit or wire break.
201
SD T-Coolant
202
SD T-Fuel
SD alarm configuration, fuel Check sensor and temperature sensor faulty, wiring (B33), re short circuit or wire break. place as necessa ry.
203
SD T-Charge Air
SD alarm configuration, Check sensor and 1.8004.571 charge-air temperature sen wiring (B9), replace sor faulty, short circuit or as necessary. wire break. SD alarm configuration, coolant temperature sensor of intercooler faulty, short circuit or wire break. SD alarm configuration, charge-air pressure sensor faulty, short circuit or wire break. SD alarm configuration, lube-oil pressure sensor faulty, short circuit or wire break. SD alarm configuration, rail pressure sensor faulty, HP controller in emergency mode, short circuit or wire break. SD alarm configuration, lube-oil temperature sensor faulty, short circuit or wire break. Check sensor and wiring (B26), re place as necessa ry. Check sensor and wiring (B10), re place as necessa ry. 1.8004.574
205
208
SD P-Charge Air
1.8004.566
211
SD P-Lube Oil
Check sensor and 1.8004.563 wiring (B5), replace as necessary. Check sensor and wiring (B48), re place as necessa ry. 1.8004.567
215
SD P-HD
216
SD T-Lube Oil
219
SD T-Intake Air
SD alarm configuration, in Check sensor and 1.8004.573 take air temperature sensor wiring (B3), replace faulty, short circuit or wire as necessary. break. Check sensor and wiring (F33), re place as necessa ry.Fault is rectified when electronics are switched back on 1.8004.584
220
SD Level Coolant Wa SD alarm configuration, ter coolant level sensor faulty, short circuit or wire break.
Meaning SD alarm configuration, coolant level sensor faulty, short circuit or wire break.
Action Check sensor and wiring (F57), re place as necessa ry. Fault is rectified when electronics are switched back on.
229
Engine stop due to cam shaft sensor fault (and a previous crankshaft sensor fault in the same operating cycle).Alarm configuration parameter, see PR 2.8008.100 for explanation.
Check connector 1.8004.562 and wiring to sen sor B1, replace as necessary. Fault is rectified when en gine is restarted. If camshaft and crankshaft sensor are both faulty, check connector and wiring to sen sor B1 and B13. Restart. Fault is rectified when en gine is restarted, contact Service if this is not the case. Check sensor and 1.8004.498 wiring (B13), at tempt restart, fault may be rectified when engine is re started. Contact Service if this is not the case Check sensor and 1.8004.499 wiring (B1), attempt restart, fault may be rectified when engine is restarted. Contact Service if this is not the case. Check sensor and wiring (B34), re place as necessa ry. 1.8004.565
230
SD Crankshaft Speed SD alarm configuration, crankshaft sensor faulty, short circuit or wiring dam age, engine remains opera tional.
231
SD Camshaft Speed
SD alarm configuration, camshaft sensor faulty, short circuit or wiring dam age, engine remains opera tional.
240
SD P-Fuel
SD alarm configuration, en gine remains operational, fuel pressure sensor faulty, short circuit or wiring dam age.
245
SD alarm configuration, in Execute engine 2.8006.589 ternal engine governor fault. governor self-test, replace engine gov ernor in case of fault.
Meaning SD alarm configuration, an alog speed setting faulty, short circuit or wiring dam age.
Action
Check speed set 2.8006.586 ting transmitter and wiring, replace as necessary. Fault is rectified when en gine is restarted. Check wiring, re place as necessa ry.Fault is rectified when engine is re started. 2.8006.588
269
SD Loadp.Analog filt.
SD alarm configuration, fil tered analog signal of load pulse not available, short circuit or wiring damage
270
SD Frequency Input
SD alarm configuration, fre Contact Service. quency input faulty, short circuit or wiring damage.
2.8006.590
301
AL Timing Cylinder A1 Time-of-flight measuring Replace plug-in fault injector cylinder A1: pump if this occurs Time-of-flight value meas frequently. ured extremely small or large (alarm configuration parameter, see PR 2.8008.100 for explanation). AL Timing Cylinder A2 Time-of-flight measuring Replace plug-in fault injector cylinder A2 pump if this occurs Time-of-flight value meas frequently. ured extremely small or large (alarm configuration parameter, see PR 2.8008.100 for explanation). AL Timing Cylinder A3 Time-of-flight measuring Replace plug-in fault injector cylinder A3: pump if this occurs Time-of-flight value meas frequently. ured extremely small or large (alarm configuration parameter, see PR 2.8008.100 for explanation). AL Timing Cylinder A4 Time-of-flight measuring Replace plug-in fault injector cylinder A4 pump if this occurs Time-of-flight value meas frequently. ured extremely small or large (alarm configuration parameter, see PR 2.8008.100 for explanation). AL Timing Cylinder A5 Time-of-flight measuring Replace plug-in fault injector cylinder A5 pump if this occurs Time-of-flight value meas frequently. ured extremely small or large (alarm configuration parameter, see PR 2.8008.100 for explanation).
1.8004.500
302
1.8004.501
303
1.8004.502
304
1.8004.503
305
1.8004.504
Full designation
Meaning
Action
AL Timing Cylinder A6 Time-of-flight measuring Replace plug-in fault injector cylinder A6 pump if this occurs Time-of-flight value meas frequently. ured extremely small or large (alarm configuration parameter, see PR 2.8008.100 for explanation). AL Timing Cylinder A7 Time-of-flight measuring Replace plug-in fault injector cylinder A7 pump if this occurs Time-of-flight value meas frequently. ured extremely small or large (alarm configuration parameter, see PR 2.8008.100 for explanation). AL Timing Cylinder A8 Time-of-flight measuring Replace plug-in fault injector cylinder A8 pump if this occurs Time-of-flight value meas frequently. ured extremely small or large (alarm configuration parameter, see PR 2.8008.100 for explanation). AL Timing Cylinder A9 Time-of-flight measuring Replace plug-in fault injector cylinder A9 pump if this occurs Time-of-flight value meas frequently. ured extremely small or large (alarm configuration parameter, see PR 2.8008.100 for explanation). AL Timing Cylinder A10 Time-of-flight measuring Replace plug-in fault injector cylinder A10: pump if this occurs Time-of-flight value meas frequently. ured extremely small or large (alarm configuration parameter, see PR 2.8008.100 for explanation).
307
1.8004.506
308
1.8004.507
309
1.8004.508
310
1.8004.509
311
AL Timing Cylinder B1 Time-of-flight measuring Replace plug-in fault injector cylinder B1: pump if this occurs Time-of-flight value meas frequently. ured extremely small or large (alarm configuration parameter, see PR 2.8008.100 for explanation). AL Timing Cylinder B2 Time-of-flight measuring Replace plug-in fault injector cylinder B2: pump if this occurs Time-of-flight value meas frequently. ured extremely small or large (alarm configuration parameter, see PR 2.8008.100 for explanation).
1.8004.510
312
1.8004.511
Full designation
Meaning
Action
AL Timing Cylinder B3 Time-of-flight measuring Replace plug-in fault injector cylinder B3: pump if this occurs Time-of-flight value meas frequently. ured extremely small or large (alarm configuration parameter, see PR 2.8008.100 for explanation). AL Timing Cylinder B4 Time-of-flight measuring Replace plug-in fault injector cylinder B4: pump if this occurs Time-of-flight value meas frequently. ured extremely small or large (alarm configuration parameter, see PR 2.8008.100 for explanation). AL Timing Cylinder B5 Time-of-flight measuring Replace plug-in fault injector cylinder B5: pump if this occurs Time-of-flight value meas frequently. ured extremely small or large (alarm configuration parameter, see PR 2.8008.100 for explanation). AL Timing Cylinder B6 Time-of-flight measuring Replace plug-in fault injector cylinder B6: pump if this occurs Time-of-flight value meas frequently. ured extremely small or large (alarm configuration parameter, see PR 2.8008.100 for explanation). AL Timing Cylinder B7 Time-of-flight measuring Replace plug-in fault injector cylinder B7: pump if this occurs Time-of-flight value meas frequently. ured extremely small or large (alarm configuration parameter, see PR 2.8008.100 for explanation). AL Timing Cylinder B8 Time-of-flight measuring Replace plug-in fault injector cylinder B8: pump if this occurs Time-of-flight value meas frequently. ured extremely small or large (alarm configuration parameter, see PR 2.8008.100 for explanation). AL Timing Cylinder B9 Time-of-flight measuring Replace plug-in fault injector cylinder B9: pump if this occurs Time-of-flight value meas frequently. ured extremely small or large (alarm configuration parameter, see PR 2.8008.100 for explanation).
314
1.8004.513
315
1.8004.514
316
1.8004.515
317
1.8004.516
318
1.8004.517
319
1.8004.518
Meaning
Action
Time-of-flight measuring Replace plug-in fault injector cylinder B10: pump if this occurs Time-of-flight value meas frequently. ured extremely small or large (alarm configuration parameter, see PR 2.8008.100 for explanation).
321
AL Wiring Cylinder A1 Wiring fault in injector wiring cylinder A1. Result: Misfir ing (alarm configuration pa rameter, see PR 2.8008.100 for explanation).
Check injector wir 1.8004.520 ing, rectify injector solenoid valve short circuit (posi tive to negative) (e.g. by exchanging injectors). Fault rectification: When engine is restarted. Check injector wir 1.8004.521 ing, rectify injector solenoid valve short circuit (posi tive to negative) (e.g. by exchanging injectors). Fault rectification: When engine is restarted. Check injector wir 1.8004.522 ing, rectify injector solenoid valve short circuit (posi tive to negative) (e.g. by exchanging injectors). Fault rectification: When engine is restarted. Check injector wir 1.8004.523 ing, rectify injector solenoid valve short circuit (posi tive to negative) (e.g. by exchanging injectors). Fault rectification: When engine is restarted. Check injector wir 1.8004.524 ing, rectify injector solenoid valve short circuit (posi tive to negative) (e.g. by exchanging injectors). Fault rectification: When engine is restarted.
322
AL Wiring Cylinder A2 Wiring fault in injector wiring cylinder A2. Result: Misfir ing (alarm configuration pa rameter, see PR 2.8008.100 for explanation).
323
AL Wiring Cylinder A3 Wiring fault in injector wiring cylinder A3. Result: Misfir ing (alarm configuration pa rameter, see PR 2.8008.100 for explanation).
324
AL Wiring Cylinder A4 Wiring fault in injector wiring cylinder A4. Result: Misfir ing (alarm configuration pa rameter, see PR 2.8008.100 for explanation).
325
AL Wiring Cylinder A5 Wiring fault in injector wiring cylinder A5. Result: Misfir ing (alarm configuration pa rameter, see PR 2.8008.100 for explanation).
Full designation
Meaning
Action
AL Wiring Cylinder A6 Wiring fault in injector wiring cylinder A6. Result: Misfir ing (alarm configuration pa rameter, see PR 2.8008.100 for explanation).
Check injector wir 1.8004.525 ing, rectify injector solenoid valve short circuit (posi tive to negative) (e.g. by exchanging injectors). Fault rectification: When engine is restarted. Check injector wir 1.8004.526 ing, rectify injector solenoid valve short circuit (posi tive to negative) (e.g. by exchanging injectors). Fault rectification: When engine is restarted. Check injector wir 1.8004.527 ing, rectify injector solenoid valve short circuit (posi tive to negative) (e.g. by exchanging injectors). Fault rectification: When engine is restarted. Check injector wir 1.8004.528 ing, rectify injector solenoid valve short circuit (posi tive to negative) (e.g. by exchanging injectors). Fault rectification: When engine is restarted. Check injector wir 1.8004.529 ing, rectify injector solenoid valve short circuit (posi tive to negative) (e.g. by exchanging injectors). Fault rectification: When engine is restarted. Check injector wir 1.8004.530 ing, rectify injector solenoid valve short circuit (posi tive to negative) (e.g. by exchanging injectors). Fault rectification: When engine is restarted.
327
AL Wiring Cylinder A7 Wiring fault in injector wiring cylinder A7. Result: Misfir ing (alarm configuration pa rameter, see PR 2.8008.100 for explanation).
328
AL Wiring Cylinder A8 Wiring fault in injector wiring cylinder A8. Result: Misfir ing (alarm configuration pa rameter, see PR 2.8008.100 for explanation).
329
AL Wiring Cylinder A9 Wiring fault in injector wiring cylinder A9. Result: Misfir ing (alarm configuration pa rameter, see PR 2.8008.100 for explanation).
330
Wiring fault in injector wiring cylinder A10. Result: Misfir ing (alarm configuration pa rameter, see PR 2.8008.100 for explanation).
331
AL Wiring Cylinder B1 Wiring fault in injector wiring cylinder B1. Result: Misfir ing (alarm configuration pa rameter, see PR 2.8008.100 for explanation).
Full designation
Meaning
Action
AL Wiring Cylinder B2 Wiring fault in injector wiring cylinder B2. Result: Misfir ing (alarm configuration pa rameter, see PR 2.8008.100 for explanation).
Check injector wir 1.8004.531 ing, rectify injector solenoid valve short circuit (posi tive to negative) (e.g. by exchanging injectors). Fault rectification: When engine is restarted. Check injector wir 1.8004.532 ing, rectify injector solenoid valve short circuit (posi tive to negative) (e.g. by exchanging injectors). Fault rectification: When engine is restarted. Check injector wir 1.8004.533 ing, rectify injector solenoid valve short circuit (posi tive to negative) (e.g. by exchanging injectors). Fault rectification: When engine is restarted. Check injector wir 1.8004.534 ing, rectify injector solenoid valve short circuit (posi tive to negative) (e.g. by exchanging injectors). Fault rectification: When engine is restarted. Check injector wir 1.8004535 ing, rectify injector solenoid valve short circuit (posi tive to negative) (e.g. by exchanging injectors). Fault rectification: When engine is restarted. Check injector wir 1.8004.536 ing, rectify injector solenoid valve short circuit (posi tive to negative) (e.g. by exchanging injectors). Fault rectification: When engine is restarted.
333
AL Wiring Cylinder B3 Wiring fault in injector wiring cylinder B3. Result: Misfir ing (alarm configuration pa rameter, see PR 2.8008.100 for explanation).
334
AL Wiring Cylinder B4 Wiring fault in injector wiring cylinder B4. Result: Misfir ing (alarm configuration pa rameter, see PR 2.8008.100 for explanation).
335
AL Wiring Cylinder B5 Wiring fault in injector wiring cylinder B5. Result: Misfir ing (alarm configuration pa rameter, see PR 2.8008.100 for explanation).
336
AL Wiring Cylinder B6 Wiring fault in injector wiring cylinder B6. Result: Misfir ing (alarm configuration pa rameter, see PR 2.8008.100 for explanation).
337
AL Wiring Cylinder B7 Wiring fault in injector wiring cylinder B7. Result: Misfir ing (alarm configuration pa rameter, see PR 2.8008.100 for explanation).
Full designation
Meaning
Action
AL Wiring Cylinder B8 Wiring fault in injector wiring cylinder B8. Result: Misfir ing (alarm configuration pa rameter, see PR 2.8008.100 for explanation).
Check injector wir 1.8004.537 ing, rectify injector solenoid valve short circuit (posi tive to negative) (e.g. by exchanging injectors). Fault rectification: When engine is restarted. Check injector wir 1.8004.538 ing, rectify injector solenoid valve short circuit (posi tive to negative) (e.g. by exchanging injectors). Fault rectification: When engine is restarted. Check injector wir 1.8004539 ing, rectify injector solenoid valve short circuit (posi tive to negative) (e.g. by exchanging injectors). Fault rectification: When engine is restarted. Check injector wir 1.8004.540 ing, exclude disrup tion in solenoid valve (e.g. by injec tor replacement). Fault rectification: After each working cycle. Check injector wir 1.8004.541 ing, exclude disrup tion in solenoid valve (e.g. by injec tor replacement). Fault rectification: After each working cycle. Check injector wir 1.8004.542 ing, exclude disrup tion in solenoid valve (e.g. by injec tor replacement). Fault rectification: After each working cycle.
339
AL Wiring Cylinder B9 Wiring fault in injector wiring cylinder B9. Result: Misfir ing (alarm configuration pa rameter, see PR 2.8008.100 for explanation).
340
Wiring fault in injector wiring cylinder B10. Result: Misfir ing (alarm configuration pa rameter, see PR 2.8008.100 for explanation).
341
Disruption fault in injector wiring to cylinder A1. Re sult: Misfiring (alarm config uration parameter, see PR 2.8008.100 for explanation).
342
Disruption fault in injector wiring cylinder A2. Result: Misfiring (alarm configura tion parameter, see PR 2.8008.100 for explanation).
343
Disruption fault in injector wiring cylinder A3. Result: Misfiring (alarm configura tion parameter, see PR 2.8008.100 for explanation).
Meaning Disruption fault in injector wiring cylinder A4. Result: Misfiring (alarm configura tion parameter, see PR 2.8008.100 for explanation).
Action
Check injector wir 1.8004.543 ing, exclude disrup tion in solenoid valve (e.g. by injec tor replacement). Fault rectification: After each working cycle. Check injector wir 1.8004.544 ing, exclude disrup tion in solenoid valve (e.g. by injec tor replacement). Fault rectification: After each working cycle. Check injector wir 1.8004.545 ing, exclude disrup tion in solenoid valve (e.g. by injec tor replacement). Fault rectification: After each working cycle. Check injector wir 1.8004.546 ing, exclude disrup tion in solenoid valve (e.g. by injec tor replacement). Fault rectification: After each working cycle. Check injector wir 1.8004.547 ing, exclude disrup tion in solenoid valve (e.g. by injec tor replacement). Fault rectification: After each working cycle. Check injector wir 1.8004.548 ing, exclude disrup tion in solenoid valve (e.g. by injec tor replacement). Fault rectification: After each working cycle.
345
Disruption fault in injector wiring cylinder A5. Result: Misfiring (alarm configura tion parameter, see PR 2.8008.100 for explanation).
346
Disruption fault in injector wiring cylinder A6. Result: Misfiring (alarm configura tion parameter, see PR 2.8008.100 for explanation).
347
Disruption fault in injector wiring cylinder A7. Result: Misfiring (alarm configura tion parameter, see PR 2.8008.100 for explanation).
348
Disruption fault in injector wiring cylinder A8. Result: Misfiring (alarm configura tion parameter, see PR 2.8008.100 for explanation).
349
TIM-ID: 0000008508 - 002
Disruption fault in injector wiring cylinder A9. Result: Misfiring (alarm configura tion parameter, see PR 2.8008.100 for explanation).
Meaning Disruption fault in injector wiring cylinder A10. Result: Misfiring (alarm configura tion parameter, see PR 2.8008.100 for explanation).
Action
Check injector wir 1.8004.549 ing, exclude disrup tion in solenoid valve (e.g. by injec tor replacement). Fault rectification: After each working cycle. Check injector wir 1.8004.550 ing, exclude disrup tion in solenoid valve (e.g. by injec tor replacement). Fault rectification: After each working cycle. Check injector wir 1.8004.551 ing, exclude disrup tion in solenoid valve (e.g. by injec tor replacement). Fault rectification: After each working cycle. Check injector wir 1.8004.552 ing, exclude disrup tion in solenoid valve (e.g. by injec tor replacement). Fault rectification: After each working cycle. Check injector wir 1.8004.553 ing, exclude disrup tion in solenoid valve (e.g. by injec tor replacement). Fault rectification: After each working cycle. Check injector wir 1.8004.554 ing, exclude disrup tion in solenoid valve (e.g. by injec tor replacement). Fault rectification: After each working cycle.
351
Disruption fault in injector wiring cylinder B1. Result: Misfiring (alarm configura tion parameter, see PR 2.8008.100 for explanation).
352
Disruption fault in injector wiring cylinder B2. Result: Misfiring (alarm configura tion parameter, see PR 2.8008.100 for explanation).
353
Disruption fault in injector wiring cylinder B3. Result: Misfiring (alarm configura tion parameter, see PR 2.8008.100 for explanation).
354
Disruption fault in injector wiring cylinder B4. Result: Misfiring (alarm configura tion parameter, see PR 2.8008.100 for explanation).
355
Disruption fault in injector wiring cylinder B5. Result: Misfiring (alarm configura tion parameter, see PR 2.8008.100 for explanation).
Meaning Disruption fault in injector wiring cylinder B6. Result: Misfiring (alarm configura tion parameter, see PR 2.8008.100 for explanation).
Action
Check injector wir 1.8004.555 ing, exclude disrup tion in solenoid valve (e.g. by injec tor replacement). Fault rectification: After each working cycle. Check injector wir 1.8004.556 ing, exclude disrup tion in solenoid valve (e.g. by injec tor replacement). Fault rectification: After each working cycle. Check injector wir 1.8004.557 ing, exclude disrup tion in solenoid valve (e.g. by injec tor replacement). Fault rectification: After each working cycle. Check injector wir 1.8004.558 ing, exclude disrup tion in solenoid valve (e.g. by injec tor replacement). Fault rectification: After each working cycle. Check injector wir 1.8004.559 ing, exclude disrup tion in solenoid valve (e.g. by injec tor replacement). Fault rectification: After each working cycle. Start engine gover 1.8004.496 nor self-test. Re place engine gover nor in case of fault; if self-test diagno ses Electronics OK check for addi tional fault messag es (e.g. wiring fault).
357
Disruption fault in injector wiring cylinder B7. Result: Misfiring (alarm configura tion parameter, see PR 2.8008.100 for explanation).
358
Disruption fault in injector wiring cylinder B8. Result: Misfiring (alarm configura tion parameter, see PR 2.8008.100 for explanation).
359
Disruption fault in injector wiring cylinder B9. Result: Misfiring (alarm configura tion parameter, see PR 2.8008.100 for explanation).
360
Disruption fault in injector wiring cylinder B10. Result: Misfiring (alarm configura tion parameter, see PR 2.8008.100 for explanation).
361
TIM-ID: 0000008508 - 002
Internal electronic fault (electronics may be defec tive). If parameter 1.1020.021 (Power Stage Failure: Stop Engine) is set, engine is stopped here ad ditionally (alarm configura tion parameter, see PR 2.8008.100 for explanation).
Meaning Internal electronic fault (electronics may be defec tive). If parameter 1.1020.021 (Power Stage Failure: Stop Engine) is set, engine is stopped here ad ditionally (alarm configura tion parameter, see PR 2.8008.100 for explanation). Internal electronic fault (electronics may be defec tive). If parameter 1.1020.021 (Power Stage Failure: Stop Engine) is set, engine is stopped here ad ditionally (alarm configura tion parameter, see PR 2.8008.100 for explanation).
Action
Start engine gover 1.8004.497 nor self-test. Re place engine gover nor in case of fault; if self-test diagno ses Electronics OK check for addi tional fault messag es (e.g. wiring fault). Start engine gover 1.8004.560 nor self-test. Re place engine gover nor in case of fault; if self-test diagno ses Electronics OK check for addi tional fault messag es (e.g. wiring fault).
363
365
Injector wiring fault. Engine Check wiring, re 1.8004.561 stop configurable (alarm place wiring har configuration parameter, ness as necessary. see PR 2.8008.100 for ex planation). Possible causes: 1. Short circuit of injector positive connection to ground of one or more injec tors. 2. Short circuit of injec tor negative connection to ground of one or more injec tors. Short circuit or wire break at Check wiring. transistor output 1 plant side (TOP 1, alarm configuration parameter, see PR 2.8008.100 for explanation). Short circuit or wire break at Check wiring. transistor output 2 plant side (TOP 2, alarm configuration parameter, see PR 2.8008.100 for explanation). Short circuit or wire break at Check wiring. transistor output 3 plant side (TOP 3, alarm configuration parameter, see PR 2.8008.100 for explanation). Short circuit or wire break at Check wiring. transistor output 4 plant side (TOP 4, alarm configuration parameter, see PR 2.8008.100 for explanation). 2.8006.638
381
AL Wiring TOP 1
382
AL Wiring TOP 2
2.8006.639
384
AL Wiring TOP 4
2.8006.641
383
AL Wiring TOP 3
2.8006.640
Meaning
Action
DBR/MCR function: MCR None. (maximum continuous rate) exceeded. Engine power is limited to admissible contin uous power (alarm configu ration parameter, see PR 2.8008.100 for explanation). Line disruption at digital in put 1, wiring faulty or no re sistance via switch, (alarm configuration parameter, see PR 2.8008.100 for ex planation). Line disruption at digital in put 2, wiring faulty or no re sistance via switch, (alarm configuration parameter, see PR 2.8008.100 for ex planation). Line disruption at digital in put 3, wiring faulty or no re sistance via switch, (alarm configuration parameter, see PR 2.8008.100 for ex planation). Line disruption at digital in put 4, wiring faulty or no re sistance via switch, (alarm configuration parameter, see PR 2.8008.100 for ex planation). Line disruption at digital in put 5, wiring faulty or no re sistance via switch, (alarm configuration parameter, see PR 2.8008.100 for ex planation). Line disruption at digital in put 6, wiring faulty or no re sistance via switch, (alarm configuration parameter, see PR 2.8008.100 for ex planation). Line disruption at digital in put 7, wiring faulty or no re sistance via switch, (alarm configuration parameter, see PR 2.8008.100 for ex planation). Check wiring.
400
2.8006.625
401
Check wiring.
2.8006.626
402
Check wiring.
2.8006627
403
Check wiring.
2.8006.628
404
Check wiring.
2.8006.629
405
Check wiring.
2.8006.630
406
Check wiring.
2.8006.631
Meaning Line disruption at digital in put 8, wiring faulty or no re sistance via switch, (alarm configuration parameter, see PR 2.8008.100 for ex planation).
408
AL Open Load Emerg. Line disruption at input for Check wiring. Stop Input ESI emergency stop, wiring faul ty or no resistance via switch LO U-PDU Injector voltage too low (lim it value 1, alarm configura tion parameter, see PR 2.8008.100 for explanation). Injector voltage too low (lim it value 2, alarm configura tion parameter, see PR 2.8008.100 for explanation). Injector voltage too high (limit value 1, alarm configu ration parameter, see PR 2.8008.100 for explanation). Injector voltage too high (limit value 2, alarm configu ration parameter, see PR 2.8008.100 for explanation).
2.8006.633
410
Execute engine 2.0141.921 governor self-test, replace engine gov ernor in case of fault. Execute engine 2.0141.922 governor self-test, replace engine gov ernor in case of fault. Execute engine 2.0141.931 governor self-test, replace engine gov ernor in case of fault. Execute engine 2.0141.932 governor self-test, replace engine gov ernor in case of fault. 1.8004.578
411
LOLO U-PDU
412
HI U-PDU
413
HIHI U-PDU
444
SD U-PDU
SD alarm configuration, Replace engine sensor fault at injector out governor. put stage. Engine governor internal fault. Engine gover nor replacement. SD alarm configuration, in put signal for initial/final tor que faulty, short circuit or wiring damage
450
Check signal trans 2.8006.592 mitter and wiring, replace as neces sary.Fault is recti fied when engine is restarted.
TIM-ID: 0000008508 - 002
Meaning
Action
Power reduction activated, None. engine operating outside standard limits. The follow ing variables may also com bine to lead to this mes sage: Intake depression, ex haust back pressure, charge-air coolant tempera ture, intake air temperature. Alarm configuration param eter, see PR 2.8008.100 for explanation. SD alarm configuration, an alog input signal for Aux 2 faulty, short circuit or wiring damage. SD alarm configuration, an alog input signal for pres sure Aux 1 faulty, short cir cuit or wiring damage. Analog input for tempera ture Aux 1 faulty, short cir cuit or wiring damage SD alarm configuration, an alog input signal for Aux 1 faulty, short circuit or wiring damage. Engine governor defective.
463
SD AUX 2
Check signal trans 1.8004.591 mitter and wiring, replace as neces sary. Check pressure 1.8004.589 transmitter and wir ing, replace as nec essary. Check signal trans 1.8004.579 mitter and wiring, replace as neces sary. Check signal trans 1.8004.590 mitter and wiring, replace as neces sary. Replace engine governor at next opportunity. Check sensor and wiring, replace as necessary.Fault is rectified when en gine is restarted. 1.8004.587
464
SD P-AUX 1
468
SD T-AUX 1
469
SD AUX 1
470
SD T-ECU
471
SD Coil Current
SD alarm configuration, HP fuel control block activation, short circuit or wiring dam age.
1.8004.592
472
AL Stop SD
Engine stop as shutdown Contact Service. channels have "sensor fault" (alarm configuration parameter, see PR 2.8008.100 for explanation). Line break or short circuit at Contact Service. channel FO (alarm configu ration parameter, see PR 2.8008.100 for explanation). Replace engine governor at next opportunity. Contact Service.
2.8006.593
474
AL Wiring FO
2.8006.655
475
AL CR Trigger Engine Tripped by crash recorder Stop triggering due to engine shutdown. AL Crash Rec. Init. Er Initialization error of crash ror recorder.
1.8010.009
476
1.8010.007
Meaning
Action
YELLOW combined alarm Contact Service. from plant (alarm configura tion parameter, see PR 2.8008.100 for explanation). RED combined alarm from Contact Service. plant (alarm configuration parameter, see PR 2.8008.100 for explanation). External engine protection Contact Service. function active (alarm con figuration parameter, see PR 2.8008.100 for explana tion). Power reduction caused by Contact Service. maintenance function (maintenance concept, alarm configuration parame ter, see PR 2.8008.100 for explanation).
479
2.8006.002
480
2.0291.921
555
2.0555.001
6 Task Description
6.1 Engine
6.1.1 Engine Barring manually
Preconditions
Engine is stopped and starting disabled.
Qty. 1 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.
Result: 4.
6.1.2
DANGER
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.
6.1.3
DANGER
WARNING
Engine noise above 85 dB (A). Risk of damage to hearing! Wear ear protectors.
Preparatory steps
1. 2. Remove cylinder head cover ( Page 78). Remove injector ( Page 85).
Dark areas with even or varying degrees of discoloration Beginning and end of the discoloration are not sharply defined and do not cover the entire stroke area Dark areas in the upper section of the cooling bore, remaining cir cumference without objections Piston rings without objections
On the entire circumference, apart from light areas of discoloration Cylinder liner must be re (that do not impair operation) clearly darker stripes that start at the placed; Service must be con top piston ring tacted Heat discoloration in the direction of stroke and honing pattern dam age Heat discoloration of piston rings 1. 2. 3. Compile endoscopy report using the table. Use technical terms for description of the liner surface ( Page 70). Depending on findings: do not take any action or carry out a further endoscopic examination as part of maintenance work or contact Service; cylinder liner must be replaced.
Final steps
1. 2. Install injector ( Page 85). Install cylinder head cover ( Page 78).
6.2.2
Measure 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 becoming more visible from the second TDC-ring 2 onwards and less pro nounced from TDC-ring 1. The honing pattern is usually no longer visible and displays a clearly defined (straight) edge to the undisturbed surface. The dam aged surface is usually discolored. The circumferential length varies. Liners with burn marks, or heat discoloration, starting in TDC ring 1 have to be replaced.
Irregular circumference lengths and depths. Can be caused either by the pis ton skirt or the piston crown. Material deposits on the liner (smear), heavy dis coloration. Severe, visible scoring. Replace liner.
Part No. F30027336 F30027340 ( Spare Parts Catalog) ( Spare Parts Catalog) ( Spare Parts Catalog)
Qty. 1 1
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 Screw Size Type Tightening torque Lubricant (Engine oil) Value/Standard 10 Nm 2 Nm
6.
Checking diaphragm
1. 2. 3. 4. 5. 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).
6.
Use torque wrench to tighten the screws of cover (4) to the specified torque. Name Screw Size Type Tightening torque Lubricant (Engine oil) Value/Standard 10 Nm 2 Nm
7.
6.3.2
WARNING
Fuels are combustible. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke. Compressed air Risk of injury! Do not direct compressed-air jet at persons. Wear protective goggles / safety mask and ear protectors. Excessive reaction time of cleaning agents on components. Damage to component! Observe manufacturer's instructions. Wear protective clothing, gloves, and goggles / safety mask.
WARNING
CAUTION
Preparatory steps
1. 2. 3. Remove cylinder head cover ( Page 78). Install barring device ( Page 65). Bar engine with barring device in engine di rection of rotation until TDC pointer and TDC mark on the flywheel are aligned.
2. 3.
4. 5.
4.
Tighten locknut (1) with torque wrench to the specified tightening torque while holding adjusting screw (2) firmly with screw driver. Name Locknut Size M12 x 1 Type Tightening torque Lubricant (Engine oil) Value/Standard 50 Nm
5. Result:
Insert feeler gauge between valve bridge and rocker arm to verify that the gauge just passes through the gap. If not, adjust valve clearance.
Final steps
1. 2. 3. Remove barring device ( Page 65). Install cylinder head cover ( Page 78). Install end cover.
6.4.2
Preparatory steps
1. 2. On cylinder head covers with crankcase breather: Loosen clamps. Slide rubber sleeves onto the pipe.
Final steps
1. 2. Slide rubber sleeves onto the relevant pipe connection. Tighten all clamps.
Part No. F30026582 F30027340 F30006234 F30027424 F30027425 0015384230 X00058060 ( Spare Parts Catalog) ( Spare Parts Catalog) ( Spare Parts Catalog)
Qty. 1 1 1 1 1 1 1
Unguarded rotating and moving engine components. Risk of serious injury Danger to life! Before barring the engine, ensure that nobody is in the danger zone.
WARNING
Fuels are combustible. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke.
Preparatory steps
1. 2. 3. 4.
TIM-ID: 0000000021 - 002
Shut off fuel supply line before fuel filter. Drain fuel ( Page 96). Remove engine governor, if required ( Page 142). Remove charge-air manifolds and take off seals (only on engines with air-to-air charge-air cooling).
5. 6. 7. 8.
8.
9.
Install securing screws of injection pump and tighten with torque wrench to the specified torque. Name Screw Size M10 Type Tightening torque Lubricant (Engine oil) Value/Standard 60 Nm +12 Nm
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. Install fuel line (3). Observe the inscription on the union nuts (2, 4). Tighten union nuts (2, 4) marked with 35 +3 Nm (see arrow) with torque wrench to the specified tighten ing torque. Name Union nut Size M14 Type Tightening torque Lubricant (Engine oil) Value/Standard 35 Nm +3 Nm
13.
Tighten union nuts (2, 4) marked with 30 +3 Nm (see arrow) with torque wrench to the specified tighten ing torque. Name Union nut Size M14 Type Tightening torque Lubricant (Engine oil) Value/Standard 30 Nm +3 Nm
14. 15.
Install injection pump wiring (1). Use torque wrench to tighten screws to the specified tightening torque. Name Screw Size Type Tightening torque Lubricant (Engine oil) Value/Standard 1.5 Nm 0.2 Nm
Final steps
1. 2. 3. 4. 5. 6. 7. 8. Remove barring device ( Page 65). Clean mating faces on cylinder head and charge-air manifold. Check gaskets for damage and replace them, if required. Coat gaskets with grease and place onto cylinder head. Install charge-air manifolds. Install engine governor ( Page 142). Open fuel supply line. Vent fuel system ( Page 98)
6.5.2
Qty. 1
Fuels are combustible. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke. Component is hot. Risk of burning! Wear protective gloves.
WARNING
3. 4. 5.
6.5.3
8.
Insert screw for cabling in injection pump and use torque wrench to tighten to specified tightening tor que . Name Screw Size Type Tightening torque Lubricant Value/Standard 1 Nm 0.2 Nm
Replacing injector
u Remove injector and install new injector ( Page 85).
6.6.2
Part No. F30377999 F30378207 F30026582 F30027340 F30006234 F30025897 F30027424 F30027425 F30011450 X00029933 ( Spare Parts Catalog) ( Spare Parts Catalog) ( Spare Parts Catalog)
Qty. 1 1 1 1 1 1 1 1 1 1
Fuels are combustible. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke. Compressed air Risk of injury! Do not direct compressed-air jet at persons. Wear protective goggles / safety mask and ear protectors.
WARNING
Preparatory steps
1. 2. 3. 4. 5. Shut off fuel supply line before fuel filter. Drain fuel ( Page 96). Remove engine governor, if required ( Page 142). Remove charge-air manifolds and take off seals (only on engines with air-to-air charge-air cooling). Remove cylinder head cover ( Page 78).
Removing injector
1. 2. 3. 4. 5. Disconnect leak-off fuel line from cylinder head. Disconnect fuel line (1). Remove thrust screw (2). Pull off pressure pipe neck (3). Extract fuel from the exposed bores using the suction device.
6. 7. 8. 9. 10. 11.
Remove screw (2). Take off clamp (1). Screw impact extractor into injector. Remove injector using the impact extractor. Remove injector sealing ring using a selfmade hook. Seal all openings with appropriate covers after removal.
Installing injector
1. 2. 3. 4. 5. Result: 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 transversal axis of the engine. The pin is engaged in the groove of the clamp (4). Install clamp (4) with screw (5), positioning it correctly. The pin is engaged in the groove of the clamp. Forked clamp end is engaged in the cov er recess. Tighten screw (5) of the clamp by hand. Injector can still be rotated. Blow out fuel line (2) and pressure pipe neck (5) with compressed air. Coat sealing ring with grease and fit onto pressure pipe neck (5). Coat the tape of the pressure pipe neck (5) with engine oil. Insert pressure pipe neck (5) into cylinder head until the sealing ring is in contact with the cylinder head. Fully press in pressure pipe neck (5) by hand.
6. Result:
13.
Tighten thrust screw (4) with torque wrench to the specified tightening torque. Name Thrust screw Size Type Lubricant (Engine oil) Value/Standard 40 Nm 5 Nm M22 x 1.5 Tightening torque
14.
TIM-ID: 0000000023 - 001
Use torque wrench to tighten screw for clamp at injector to the specified tightening torque. Name Screw Size M10 Type Tightening torque Lubricant (Engine oil) Value/Standard 50 Nm
15. 16.
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. Connect fuel line (2).
Note: 17.
Observe the inscription on the union nuts (1, 3). Tighten union nuts (1, 3) marked with 35 +3 Nm (see arrows) with torque wrench to the specified tight ening torque. Name Union nut Size M14 Type Tightening torque Lubricant (Engine oil) Value/Standard 35 Nm +3 Nm
18.
Tighten union nuts (1, 3) marked with 30 +3 Nm (see arrows) with torque wrench to the specified tight ening torque. Name Union nut Size M14 Type Tightening torque Lubricant (Engine oil) Value/Standard 30 Nm +3 Nm
19.
Final steps
1. 2. 3. 4. 5. 6. 7. 8. Install cylinder head cover ( Page 78). Clean mating faces on cylinder head and charge-air manifold. Check gaskets for damage and replace them, if required. Coat gaskets with grease and place onto cylinder head. Install charge-air manifolds. Install engine governor ( Page 142). Open fuel supply line. Vent fuel system ( Page 98)
6.6.3
Injector Removal
Preconditions
Preparatory steps have been carried out.
Qty. 1
Fuels are combustible. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke.
Injector Removal
1. 2. Remove screw (1). Remove clamp (2).
3. 4. 5.
Screw impact extractor into injector. Remove injector using the impact extractor. Remove sealing rings.
6.6.4
Injector Installation
Special tools, Material, Spare parts
Designation / Use Engine barring device Grease (Kluthe Hakuform 30-10/Emulgier) Engine oil Sealing ring Copper sealing ring Part No. F6557929 X00029933 ( Spare Parts Catalog) ( Spare Parts Catalog) Qty. 1 1
WARNING
Fuels are combustible. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke. Contamination of components. Damage to component! Observe manufacturer's instructions. Check components for special cleanness.
CAUTION
Injector Installation
1. 2. 3. 4. 5. Use engine barring device to turn engine several times to blow out remaining fuel. Coat sealing ring (2) with grease. Wind sealing ring (2) on to injector (3). Fix copper sealing ring (1) with grease on injector (3). Press injector (3) by hand into cylinder head, in doing so make sure that the pin in the injector (3) is at 11 o'clock position to the engine's longitudinal axis.
6. Result: 7. Result:
Attach clamp (2) in correct position. Pin (1) is in recess of clamp (2). Fork of clamp (2) engages in end cover fixation. Insert screw (3) by hand. Injector can still be turned.
Part No. F30026582 F30027340 F30006234 F30025897 F30027424 F30027425 F30011450 X00029933 ( Spare Parts Catalog) ( Spare Parts Catalog)
Qty. 1 1 1 1 1 1 1 1
Fuels are combustible. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke. Compressed air Risk of injury! Do not direct compressed-air jet at persons. Wear protective goggles / safety mask and ear protectors.
WARNING
Preparatory steps
1. 2. 3. 4.
TIM-ID: 0000000024 - 001
Shut off fuel supply line before fuel filter. Drain fuel ( Page 96). Remove engine governor, if required ( Page 142). Remove charge-air manifolds and take off seals (only on engines with air-to-air charge-air cooling).
9.
Tighten thrust screw (4) with torque wrench to the specified tightening torque. Name Thrust screw Size Type Lubricant (Engine oil) Value/Standard 40 Nm 5 Nm M22 x 1.5 Tightening torque
Connect fuel line (2). Observe the inscription on the union nuts (1, 3). Tighten union nuts (1, 3) marked with 35 +3 Nm (see arrows) with torque wrench to the specified tight ening torque. Name Union nut Size M14 Type Tightening torque Lubricant (Engine oil) Value/Standard 35 Nm +3 Nm
12.
Tighten union nuts (1, 3) marked with 30 +3 Nm (see arrows) with torque wrench to the specified tight ening torque. Name Union nut Size M14 Type Tightening torque Lubricant (Engine oil) Value/Standard 30 Nm +3 Nm
Final steps
1. 2. 3. 4. 5. 6. 7. Clean mating faces on cylinder head and charge-air manifold. Check gaskets for damage and replace them, if required. Coat gaskets with grease and place onto cylinder head. Install charge-air manifolds. Install engine governor ( Page 142). Open fuel supply line. Vent fuel system ( Page 98)
TIM-ID: 0000000024 - 001
6.7.2
Part No. ( Spare Parts Catalog) ( Spare Parts Catalog) ( Spare Parts Catalog)
Qty.
Fuels are combustible. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke.
6.7.3
Fuel Draining
Preconditions
Engine is stopped and starting disabled.
Qty. 1 1
Fuels are combustible. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke.
Fuel Draining
1. Loosen nut (arrow) on banjo union.
2. 3.
Disconnect fuel line on non-return valve (ar row). Remove non-return valve and collet emerg ing fuel in a suitable container.
4.
If fuel no longer emerges, install non-return valve and tighten with torque wrench to the specified tighten ing torque. Name Non-return valve Size Type Tightening torque Lubricant (Engine oil) Value/Standard 10 Nm +1 Nm
5. 6.
6.7.4
Part No.
Qty.
Fuels are combustible. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke.
2. 3. 4.
Loosen nut (arrow) on banjo union. Operate the pump with the handle until bub ble-free fuel emerges. Tighten nut on banjo union.
5. 6. 7.
Loosen banjo screw (arrow). Operate the pump with the handle until bub ble-free fuel emerges. Tighten banjo screw.
8. 9. 10.
Loosen union nut of fuel return line. Loosen non-return valve (arrow). Operate the pump with the handle until bub ble-free fuel emerges.
11.
Use torque wrench to non-return valve to the specified tightening torque. Name Non-return valve Size Type Tightening torque Lubricant (Engine oil) Value/Standard 10 Nm +1 Nm
12. 13.
Tighten union nut of fuel return line. Lock fuel priming pump, screw in handle.
Qty. 1
Fuels are combustible. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke.
6.8.2
Qty.
Fuels are combustible. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke.
6.8.3
DANGER
WARNING
Engine noise above 85 dB (A). Risk of damage to hearing! Wear ear protectors.
6.8.4
Qty.
Fuels are combustible. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke.
2. 3. 4. 5. 6.
TIM-ID: 0000004929 - 003
7. 8. 9. 10. 11.
Open threaded vent plug (5) of filter to be drained. Unlock drain valve (6) by pressing toggle and open it. Drain water and contaminants from filter un til pure fuel emerges. Close drain valve (6). Remove screws for cover and take off cov er (2). Fill filter housing with clean fuel. Place new gasket in cover (2). Fit cover with gasket and secure it with screws. Cut in the cut-out filter again. Close threaded vent plug (5) when fuel emerges.
6.8.5
DANGER
Unguarded rotating and moving engine components. Risk of serious injury danger to life! Take special care when working on a running engine.
WARNING
Fuels are combustible. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke. Engine noise above 85 dB (A). Risk of damage to hearing! Wear ear protectors.
WARNING
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).
6.8.6
Qty.
Fuels are combustible. Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke.
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). Fit cover with gasket and secure it with screws. Cut in the cut-out filter again. Close threaded vent plug (5) when fuel emerges. Adjust the differential pressure gauge ( Page 102).
Qty.
Compressed air Risk of injury! Do not direct compressed-air jet at persons. Wear protective goggles / safety mask and ear protectors.
6.10.2
Variant A
1. 2. 3. 4. 5. Release clamp (2). Remove air filter (3) and clamp (2) from flange of intake housing (1). Verify that there are no objects in the flange of the intake housing (1) and clean it. Place new air filter (3) with clamp (2) onto intake housing (1). Tighten clamp (2).
Variant B
1. 2. 3. 4. 5. 6. Release latches (1). Remove cover (2). Remove filter insert (3) and filter ele ment (4). Wipe out filter housing (5) and cover (2) with moist cloth. Insert new filter element (4) and filter in sert (3). For installation, follow reverse sequence of working steps.
2. Result:
WARNING
Engine noise above 85 dB (A). Risk of damage to hearing! Wear ear protectors.
6.13.2
Qty.
Hot oil. Oil can contain combustion residues which are harmful to health. Risk of injury and poisoning! Wear protective clothing, gloves, and goggles / safety mask. Avoid contact with skin. Do not inhale oil vapor.
Oil change without semirotary hand pump: Draining oil at drain plug on oil pan
1. 2. 3. 4. Provide a suitable container to collect the oil. Remove drain plug and drain oil. Install drain plug with new sealing ring. Replace engine oil filter ( Page 115).
Qty. 1
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.
Part No.
Qty.
Coolant is hot and under pressure. Risk of injury and scalding! Let the engine cool down. Wear protective clothing, gloves, and goggles / safety mask. Engine noise above 85 dB (A). Risk of damage to hearing! Wear ear protectors.
WARNING
CAUTION
Cold coolant in hot engine can cause thermal stress. Formation of cracks in components! Fill / top up coolant only into cold engine.
Preparatory steps
1. 2. Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to escape. Continue to turn breather valve counter clockwise and remove.
Final steps
1. 2. Start the engine and operate it at idle speed for some minutes. Check coolant level ( Page 120), top up with coolant if required.
6.15.2
Qty.
Coolant is hot and under pressure. Risk of injury and scalding! Let the engine cool down. Wear protective clothing, gloves, and goggles / safety mask.
Preparatory steps
1. 2. Provide an appropriate container to drain the coolant into. Switch off preheating unit.
5. 6.
6.15.3
6.15.4
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.
6.15.5
DANGER
WARNING
Engine noise above 85 dB (A). Risk of damage to hearing! Wear ear protectors.
Qty.
Coolant is hot and under pressure. Risk of injury and scalding! Let the engine cool down. Wear protective clothing, gloves, and goggles / safety mask. Engine noise above 85 dB (A). Risk of damage to hearing! Wear ear protectors.
WARNING
CAUTION
Cold coolant in hot engine can cause thermal stress. Formation of cracks in components! Fill / top up coolant only into cold engine.
Preparatory steps
1. 2. 3. Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to escape. Continue to turn breather valve counter clockwise and remove. Remove plug screw from filling point on coolant line to intercooler.
Final steps
1. 2. Start the engine and operate it at idle speed for some minutes. Check coolant level ( Page 126).
6.16.2
Qty.
Coolant is hot and under pressure. Risk of injury and scalding! Let the engine cool down. Wear protective clothing, gloves, and goggles / safety mask.
6. 7.
6.16.3
6.16.4
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.
6.17.2
WARNING
Compressed air Risk of injury! Do not direct compressed-air jet at persons. Wear protective goggles / safety mask and ear protectors. Chemical substances in cleaners. Risk of irritation and chemical burns! Always obey manufacturer's instructions before use!
WARNING
CAUTION
Excessive reaction time of cleaning agents on components. Damage to component! Observe manufacturer's instructions. Wear protective clothing, gloves, and goggles / safety mask. Unsuitable cleaning tool. Damage to component! Observe manufacturer's instructions. Use appropriate cleaning tool.
CAUTION
Findings Singular cracks Belt is oily, shows signs of over heating Cracks on entire circumference Chunking
6.18.2
4.
8.
Install protective cover. Setting (new drive belt) Setting (used drive belt) 450 N - 50 N 350 N - 50 N
3.
Tighten screw (2) with torque wrench to the specified tightening torque. Name Screw Size M12 Type Tightening torque Lubricant (Engine oil) Value/Standard 40 Nm +4 Nm
4. 5. 6.
Tighten screw (3). Check drive belt tension. Install protective cover.
6.18.3
8.
Tighten securing screw (2) with torque wrench to the specified tightening torque. Name Screw Size M12 Type Tightening torque Lubricant (Engine oil) Value/Standard 40 Nm + 4 Nm
9. 10. 11.
Tighten securing screw (3). Install drive belt for fan drive ( Page 136). Install protective cover.
Preparatory steps
1. 2. Remove screws from protective cover. Remove protective cover.
Place belt-tension tester onto drive midway between the belt pulleys (arrow). Press button uniformly against drive belt surface until spring disengagement can be heard and felt. Do not press any further, otherwise the reading is not exact. Take off belt-tension tester without chang ing the position of the indication arm. Read off measured value at the intersection of indication arm and KG scale.
6.
If the measured value deviates from the specified setting, readjust belt tension. Setting (new drive belt) Setting (used drive belt) 660 N 510 N
6.
If the measured value deviates from the specified setting, readjust belt tension. Setting (new drive belt) Setting (used drive belt) 670 N - 50 N 570 N - 50 N
6.
Tighten screw (3) with torque wrench to the specified tightening torque. Name Screw Size M12 Type Tightening torque Lubricant (Engine oil) Value/Standard 100 Nm
TIM-ID: 0000000045 - 001
4.
Tighten screws (1, 4) with torque wrench to the specified tightening torque. Name Screw Size M12 Type Tightening torque Lubricant (Engine oil) Value/Standard 69 Nm
5.
Final steps
1. 2. Install protective cover. Fit screws and tighten.
6.19.2
Preparatory steps
1. 2. Remove protective cover from radiator. Remove fan.
Note: 5. 6. 7.
Note: 4. 5. 6.
Final steps
1. 2. Install fan. Install protective cover.
6.20 Cabling
6.20.1 Engine wiring Check
Preconditions
Engine is stopped and starting disabled.
6. Note: 7. 8.
6.20.2
No. 1 2 3 4 5 6 7 8
Monitoring of Charge-air pressure Charge-air temperature Camshaft speed Crankshaft speed Coolant temperature Fuel temperature Lube oil pressure Lube oil temperature
Always use test connectors to enter the connectors. Never use test leads for this purpose.Otherwise the contacts could be bent.
6.21.2
Note:
Always use test connectors to enter the connectors. Never use test leads for this purpose.Otherwise the contacts could be bent.
6.21.3
CAUTION
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.
7 Appendix A
7.1 Abbreviations
Abbreviation A/D ADEC AFRS ANSI ATL ATS BR BV CAN CDC CEL Meaning Analog/Digital Advanced Diesel Engine Controller Air Filter Restriction Sensor American National Standards Institute Abgasturbolader Air Temperature Sensor Baureihe Betriebsstoffvorschrift Controller Area Network Calibration Drift Compensation Stop Engine Light Series MTU Fluids and Lubricants Specifications, Publication No. A01061/.. Data bus system, bus standard Setting of drift compensation in engine gov ernor with DiaSys 1st function: Warning lamp (rectify fault as soon as possible) 2nd function: Read out fault codes CKT CLS CPS CTS DDEC DDL DDR DIN DL DOC
TIM-ID: 0000000858 - 009
Explanation Transformer: transforms sensor voltages into numeric values Engine management system Association of American standardization or ganizations Exhaust turbocharger (ETC)
Circuit Coolant Level Sensor Coolant Pressure Sensor Coolant Temperature Sensor Detroit Diesel Electronic Controls Diagnostic Data Link Diagnostic Data Reader Deutsches Institut fr Normung e. V. Default Lost Diesel Oxidation Catalyst Diesel Particulate Filter Diagnostic Tool Electronic Control Module Engine Control Unit Engine Data Module Electrically Erasable Programmable Read Only Memory Electronic Foot Pedal Assembly MS15018/01E 2012-05 | Appendix A | 143 Diagnostic unit Electronic control unit of the DDEC system Engine governor Memory module for engine data Monitors coolant level Monitors coolant pressure Monitors coolant temperature Engine control system made by Detroit Die sel Diagnostic lines Diagnostic unit At the same time identifier of German stand ards (DIN = Deutsche Industrie-Norm) Alarm: Default CAN bus failure Oxidation catalyst upstream of the diesel particulate filter
Abbreviation EGR EMU ETK EUI FPS FRS FTS FWCP GND HD HI HIHI HT IDM INJ ISO KGS KS LED LO LOLO LSG N/A LP OEM OI OLS OPS OTS OT PAN PIM PWM P-xyz RL
Meaning Exhaust Gas Recirculation Engine Monitoring Unit Ersatzteilkatalog Electronic Unit Injector Fuel Pressure Sensor Fuel - Differential Pressure Sensor Fuel Temperature Sensor Fire Water Control Panel Ground Hochdruck High High High High Temperature Interface Data Module Injector International Organization for Stand ardization Kraftgegenseite Kraftseite Light Emitting Diode Low Low Low Limiting Speed Governor Not Applicable Low Pressure Original Equipment Manufacturer Optimized Idle Oil Level Sensor Oil Pressure Sensor Oil Temperature Sensor Oberer Totpunkt Panel Peripheral Interface Module Modulated signal Pressure-xyz Redundancy Lost
Explanation
Spare Parts Catalog (SPC) Monitors fuel pressure Monitors fuel temperature Control cabinet High Pressure (HP) Alarm: Measured value exceeds 1st maxi mum limit Alarm: Measured value exceeds 2nd maxi mum limit value Memory module for interface data International umbrella organization for all na tional standardization institutes Engine free end in accordance with DIN ISO 1204 Engine driving end in accordance with DIN ISO 1204 Alarm: Measured value lower than 1st mini mum limit value Alarm: Measured value lower than 2nd mini mum limit value
Monitors oil level Monitors oil temperature Top Dead Center (TDC) Control panel
TIM-ID: 0000000858 - 009
Pressure measuring point, xyz specifies the measuring point designation Alarm: Redundant CAN bus failure
Explanation U.S. standardization organization Alarm: Sensor failure 1st function: Warning lamp (stop engine and rectify fault) 2nd function: Read out fault codes
SID SRS SS TBS TCI TCO TD TPS TRS T-xyz UT VNT VSG VSS WZK
System Identifier Synchronous Reference Sensor Safety System Turbocharger Boost Sensor Turbo Compressor Inlet Turbo Compressor Outlet Transmitter Deviation Throttle Position Sensor Timing Reference Sensor Temperature-xyz Unterer Totpunkt Variable Nozzle Turbine Variable-Speed Governor Vehicle Speed Sensor Werkzeugkatalog Tool Catalog (TC) Temperature measuring point, xyz specifies the measuring point designation Bottom Dead Center (BDC) Alarm: Deviation in transmitter values TDC cylinder 1 Safety system alarm Monitors charge-air pressure
Local support
Experienced and qualified specialists place their knowledge and expertise at your disposal. For locally available support, go to the MTU Internet site: http://www.mtu-online.com
24h hotline
With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist you - either during operation, for preventive maintenance, corrective work in case of malfunction or changed operating conditions, or for spare parts supply. Your contact at Headquarters: Service-support@mtu-online.com
8 Appendix B
8.1 Special Tools
Adapter Part No.: Qty.: Used in: Qty.: Used in: Qty.: Used in: F30006234 1 6.5.1 Injection pump Removal and installation ( Page 79) 1 6.6.2 Injector Removal and installation ( Page 85) 1 6.7.1 Fuel injection line Pressure pipe neck replace ment ( Page 93)
Barring device Part No.: Qty.: Used in: Barring device for 12V engines Part No.: Qty.: Used in: F6558556 1 6.1.1 Engine Barring manually ( Page 65) F6557929 1 6.5.3 Injection pump Installation ( Page 83)
Barring device for 16V, 18V engines Part No.: Qty.: Used in:
DCL-ID: 0000019467 - 003
Belt tension tester Part No.: Qty.: Used in: 5505890119/00 1 6.19.1 Fan drive Drive-belt check and adjustment ( Page 133)
Belt-tension tester Part No.: Qty.: Used in: Y20097429 1 6.18.2 Battery-charging generator drive Drive-belt check and adjustment ( Page 130)
Box wrench, 17 mm Part No.: Qty.: Used in: F30028341 1 6.7.3 Fuel Draining ( Page 96)
Crowfoot wrench, 19 mm Part No.: Qty.: Used in: Qty.: Used in: Qty.: Used in: F30027424 1 6.5.1 Injection pump Removal and installation ( Page 79)
DCL-ID: 0000019467 - 003
1 6.6.2 Injector Removal and installation ( Page 85) 1 6.7.1 Fuel injection line Pressure pipe neck replace ment ( Page 93)
Crowfoot wrench, 22 mm Part No.: Qty.: Used in: Qty.: Used in: Qty.: Used in: F30027425 1 6.5.1 Injection pump Removal and installation ( Page 79) 1 6.6.2 Injector Removal and installation ( Page 85) 1 6.7.1 Fuel injection line Pressure pipe neck replace ment ( Page 93)
Double box wrench Part No.: Qty.: Used in: Qty.: Used in: F30011450 1 6.6.2 Injector Removal and installation ( Page 85) 1 6.7.1 Fuel injection line Pressure pipe neck replace ment ( Page 93)
Engine barring device Part No.: Qty.: Used in: Qty.: Used in: Feeler gauge Part No.: Qty.: Used in: Y4342013 1 6.4.1 Valve clearance Check and adjustment ( Page 75) F6557929 1 6.5.2 Injection pump Removal ( Page 82) 1 6.6.4 Injector Installation ( Page 91)
Filter wrench Part No.: Qty.: Used in: Qty.: Used in: F30379104 1 6.8.1 Fuel filter Replacement ( Page 100) 1 6.14.1 Engine oil filter Replacement ( Page 115)
Fuel suction device Part No.: Qty.: Used in: F30378207 1 6.6.2 Injector Removal and installation ( Page 85)
Impact extractor Part No.: Qty.: Used in: Qty.: Used in: F30377999 1 6.6.2 Injector Removal and installation ( Page 85) 1 6.6.3 Injector Removal ( Page 89)
Ratchet Part No.: Qty.: Used in: Qty.: Used in: F30027340 1 6.4.1 Valve clearance Check and adjustment ( Page 75)
DCL-ID: 0000019467 - 003
Ratchet adapter Part No.: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: F30027340 1 6.3.1 Crankcase breather Oil separator element re placement, diaphragm check and replacement ( Page 72) 1 6.5.1 Injection pump Removal and installation ( Page 79) 1 6.6.2 Injector Removal and installation ( Page 85) 1 6.7.1 Fuel injection line Pressure pipe neck replace ment ( Page 93) 1 6.18.2 Battery-charging generator drive Drive-belt check and adjustment ( Page 130) 1 6.18.3 Battery-charging generator drive Drive belt re placement ( Page 132) 1 6.19.1 Fan drive Drive-belt check and adjustment ( Page 133)
Ratchet adapter, " Part No.: Qty.: Used in: F30450902 1 6.5.3 Injection pump Installation ( Page 83)
Socket wrench, 19 mm Part No.: Qty.: Used in: Qty.: Used in: F30025897 1 6.6.2 Injector Removal and installation ( Page 85) 1 6.7.1 Fuel injection line Pressure pipe neck replace ment ( Page 93)
Torque wrench, 0.5-5 Nm Part No.: Qty.: Used in: 0015384230 1 6.5.1 Injection pump Removal and installation ( Page 79)
Torque wrench, 20-100 Nm Part No.: Qty.: Used in: Qty.: Used in: F30026582 1 6.4.1 Valve clearance Check and adjustment ( Page 75) 1 6.5.3 Injection pump Installation ( Page 83)
Torque wrench, 20-100 Nm Part No.: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: F30026582 1 6.5.1 Injection pump Removal and installation ( Page 79) 1 6.6.2 Injector Removal and installation ( Page 85) 1 6.7.1 Fuel injection line Pressure pipe neck replace ment ( Page 93) 1 6.18.2 Battery-charging generator drive Drive-belt check and adjustment ( Page 130) 1 6.18.3 Battery-charging generator drive Drive belt re placement ( Page 132) 1 6.19.1 Fan drive Drive-belt check and adjustment ( Page 133)
Torque wrench, 6-50 Nm Part No.: Qty.: Used in: F30027336 1 6.3.1 Crankcase breather Oil separator element re placement, diaphragm check and replacement ( Page 72)
Torque wrench, 8-40 Nm Part No.: Qty.: Used in: F30043446 1 6.4.2 Cylinder head cover Removal and installation ( Page 78)
Torque wrench, 8-40 Nm Part No.: Qty.: Used in: F30043446 1 6.7.3 Fuel Draining ( Page 96)
8.2 Consumables
Charge-air coolant Part No.: Qty.: Used in: Cleaner Part No.: Qty.: Used in: Coolant Part No.: Qty.: Used in: Diesel fuel Part No.: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Engine coolant Part No.: Qty.: Used in: Qty.: Used in: 6.15.1 Engine coolant Filling ( Page 116) 6.15.3 Engine coolant Change ( Page 119) 6.3.2 Crankcase breather Wire mesh cleaning ( Page 74) 6.8.1 Fuel filter Replacement ( Page 100) 6.8.2 Fuel prefilter cleaning ( Page 101) 6.8.4 Fuel prefilter Draining ( Page 103) 6.8.6 Fuel prefilter Filter element replacement ( Page 106) 6.16.3 Charge-air coolant Change ( Page 125) 6.3.2 Crankcase breather Wire mesh cleaning ( Page 74) 6.16.1 Charge-air coolant Filling ( Page 122)
Engine oil Part No.: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Engine oil Part No.: Qty.: Used in: Fuel Part No.:
DCL-ID: 0000019467 - 003
6.3.1 Crankcase breather Oil separator element replacement, diaphragm check and replacement ( Page 72) 6.4.1 Valve clearance Check and adjustment ( Page 75) 6.5.1 Injection pump Removal and installation ( Page 79) 6.6.2 Injector Removal and installation ( Page 85) 6.6.4 Injector Installation ( Page 91) 6.7.1 Fuel injection line Pressure pipe neck replacement ( Page 93) 6.7.3 Fuel Draining ( Page 96) 6.7.4 Fuel system Venting ( Page 98) 6.13.2 Engine oil Change ( Page 114) 6.14.1 Engine oil filter Replacement ( Page 115) 6.18.2 Battery-charging generator drive Drive-belt check and adjustment ( Page 130) 6.18.3 Battery-charging generator drive Drive belt replacement ( Page 132) 6.19.1 Fan drive Drive-belt check and adjustment ( Page 133)
Grease (Kluthe Hakuform 30-10/Emulgier) Part No.: Qty.: Used in: X00058060 1 6.5.1 Injection pump Removal and installation ( Page 79)
Grease (Kluthe Hakuform 30-10/Emulgier) Part No.: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Isopropyl alcohol Part No.: Qty.: Used in: Qty.: Used in: Petroleum jelly Part No.: Qty.: Used in: 6.3.2 Crankcase breather Wire mesh cleaning ( Page 74) X00058037 1 6.20.1 Engine wiring Check ( Page 138) 1 6.21.1 Engine governor and connectors Cleaning ( Page 140) X00029933 1 6.5.3 Injection pump Installation ( Page 83) 1 6.6.2 Injector Removal and installation ( Page 85) 1 6.6.4 Injector Installation ( Page 91) 1 6.7.1 Fuel injection line Pressure pipe neck replacement ( Page 93)
Copper sealing ring Part No.: Qty.: Used in: Diaphragm Part No.: Qty.: Used in: 6.3.1 Crankcase breather Oil separator element replacement, diaphragm check and replacement ( Page 72) 6.6.4 Injector Installation ( Page 91)
Drive belt Part No.: Qty.: Used in: Qty.: Used in: 6.18.3 Battery-charging generator drive Drive belt replacement ( Page 132) 6.19.2 Fan drive Drive belt replacement ( Page 136)
Easy-change filter Part No.: Qty.: Used in: Filter element Part No.: Qty.: Used in: Qty.: Used in: Qty.: Used in: Filter insert Part No.: Qty.: Used in: 6.10.1 Air filter Replacement ( Page 109) 6.3.1 Crankcase breather Oil separator element replacement, diaphragm check and replacement ( Page 72) 6.8.6 Fuel prefilter Filter element replacement ( Page 106)
DCL-ID: 0000019467 - 003
Gasket Part No.: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Injector Part No.: Qty.: Used in: Oil filter Part No.: Qty.: Used in: 6.14.1 Engine oil filter Replacement ( Page 115) 6.6.1 Injector Replacement ( Page 84) 6.3.1 Crankcase breather Oil separator element replacement, diaphragm check and replacement ( Page 72) 6.4.2 Cylinder head cover Removal and installation ( Page 78) 6.8.4 Fuel prefilter Draining ( Page 103) 6.8.5 Fuel prefilter Flushing ( Page 104) 6.8.6 Fuel prefilter Filter element replacement ( Page 106)
Pressure pipe neck Part No.: Qty.: Used in: 6.7.1 Fuel injection line Pressure pipe neck replacement ( Page 93)
Pressure relief valve Part No.: Qty.: Used in: Seal Part No.: Qty.: Used in:
DCL-ID: 0000019467 - 003
6.7.2 Fuel pressure maintaining valve Removal and installation ( Page 95)
6.5.1 Injection pump Removal and installation ( Page 79) 6.6.2 Injector Removal and installation ( Page 85) 6.7.1 Fuel injection line Pressure pipe neck replacement ( Page 93)
Sealing ring Part No.: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: Qty.: Used in: 6.3.2 Crankcase breather Wire mesh cleaning ( Page 74) 6.5.1 Injection pump Removal and installation ( Page 79) 6.5.1 Injection pump Removal and installation ( Page 79) 6.5.3 Injection pump Installation ( Page 83) 6.5.3 Injection pump Installation ( Page 83) 6.6.2 Injector Removal and installation ( Page 85) 6.6.2 Injector Removal and installation ( Page 85) 6.6.4 Injector Installation ( Page 91) 6.7.2 Fuel pressure maintaining valve Removal and installation ( Page 95) 6.7.2 Fuel pressure maintaining valve Removal and installation ( Page 95) 6.8.2 Fuel prefilter cleaning ( Page 101) 6.9.1 Intercooler Checking condensate drains for coolant discharge and obstructions ( Page 108) 6.13.2 Engine oil Change ( Page 114) 6.15.2 Engine coolant Draining ( Page 118) 6.15.2 Engine coolant Draining ( Page 118) 6.16.1 Charge-air coolant Filling ( Page 122) 6.16.2 Charge-air coolant Draining ( Page 124) 6.16.2 Charge-air coolant Draining ( Page 124)
DCL-ID: 0000019467 - 003
8.4 Index
12/16/18 V 2000 Gx5 engine data, optimized fuel con sumption18 12/16/18 V 2000 Gx5-TB engine data, optimized fuel consumption22 A Abbreviations143 Actuators139 After stopping the engine Engine remains ready for op eration34 After stopping the engine putting the engine out of service35 Air filter Replacement 109 Air filter Removal and installation110 Air starter Manual operation 112 Auxiliary materials11 C Charge-air coolant Change 125 Level check 126 Charge-air coolant Draining 124 Filling 122 Charge-air coolant level Check 126 Connectors Cleaning 140 Contact persons146 Coolant Change 125 Charge-air Draining 124 Filling 122 Filling 116 Coolant - charge air Level check 126 Coolant level Check 120 Cooler Checking cooler elements externally for dirt127 Cooler Cleaning cooler elements128 Crankcase breather Diaphragm check 72 Oil separator element replacement 72 Crankcase breather Wire mesh cleaning74 Cylinder Designation 17 Cylinder head cover Removal and installation 78 Cylinder liner Endoscopic examination 68 Instructions and comments on endoscopic and visual examination 70 D Drive belt Condition check 129 E ECU 7 engine governor Removal and installation 142 Emergency stop33 Engine Main dimensions 16 Overview 14 Test run 67 Wiring check 138 Engine coolant Change 119 Draining 118 Filling 116 Engine coolant level Check 120 Engine governor Checking plug-in connections 141 Cleaning 140 Engine oil Change 114 Engine oil level Check 113 Engine sides Designation 17 Engine wiring Check 138 Environmental protection11 F Fan drive Drive belt replacement 136 Fault indication on SAM display Genset applications 40 Fire prevention11 Firing order26 Fluids and lubricants11 Fuel prefilter Flushing 104 Fuel prefilter Differential pressure gauge Check and adjustment 102 Draining 103 Filter element Replacement 106 Flushing 104 Fuel prefilter cleaning101 Fuel pressure maintaining valve Removal and installation 95 G General conditions5
H Hotline146 I Injection pump Installation 83 Removal 82 Removal and installation 79 Injector Installation 91 Removal 89 Replacement 84 Intercooler Condensate drains for coolant discharge Check 108 Condensate drains for obstructions Check 108 M Maintenance work Safety regulations 8 MTU contact persons146 O Operational checks31 P Personnel and organizational requirements6 Putting the engine into operation after extended out-ofservice periods (>3 months)27 Putting the engine into operation after scheduled out-ofservice-period 28 R Repair work Safety regulations 8 S Safety instructions13 Safety regulations8 Safety system Override 30 SAM Genset applications 40 Sensors139 Service partners146 Spare parts service146 Start engine in manual mode (testing mode)29 Stop engine in manual mode (testing mode)32 T Transport7 Troubleshooting37 V Valve clearance Adjustment 75 Check 75