MTU 12 V 2000 P12 Betriebsanleitung

Operating InstructionsDiesel engine12 V 2000 P1216 V 2000 P12MS150025/02E

Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Pack de‐fective electronic components and assemblie

Removing injection pump1. Mark installation position of injection pump.2. Disconnect wiring (1) from injection pump.3. Remove fuel line (2).4. Unscrew

8. Install injection pump, observing marked in‐stallation position.9. Install securing screws of injection pumpand tighten with torque wrench to speci

7.6 Injection Valve / Injector7.6.1 Injector – ReplacementSpecial tools, Material, Spare partsDesignation / Use Part No. Qty.Injector(→ Spare Parts Ca

7.6.2 Injector – Removal and installationPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignation / Use

Removing fuel injector1. Remove leak-off-fuel lines.2. Remove fuel line (3).3. Remove thrust screw (2).4. Pull off pressure pipe neck (1).5. Extract f

Installing fuel injector1. Remove all covers before installation.2. Clean sealing surface on cylinder head andprotective sleeve.3. Coat sealing ring (

7.7 Fuel System7.7.1 Fuel pressure relief valve – ReplacementPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare par

Fuel pressure relief valve –Replacement, variant B1. Close fuel supply.2. Remove fuel line (7).3. Remove banjo screw (4).4. Remove sealing rings (5).5

7.7.2 Fuel – DrainingPreconditions☑ Engine is stopped and starting disabled.WARNINGFuels are combustible.Risk of fire and explosion!• Avoid open flame

7.7.3 Fuel system – VentingFuel system – Venting1. Bar engine with starting system (→ Page 85).2. Repeat procedure 2 to 3 times, the fuel system is au

1.5 Fire prevention and environmental protection, auxiliarymaterials, fluids and lubricantsFire preventionRectify any fuel or oil leaks immediately; e

7.8 Fuel Filter7.8.1 Fuel filter – ReplacementSpecial tools, Material, Spare partsDesignation / Use Part No. Qty.Filter wrenchF30379104 1Diesel fuelEa

1. Stop engine (→ Page 55) and disable engine start.2. Cut out the filter to be replaced.3. Remove cut-out easy-change filter using the filter wrench.

7.8.2 Fuel prefilter cleaningPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignation / Use Part No. Qty

7.8.3 Fuel prefilter – Differential pressure gauge check and adjustmentDANGERUnguarded rotating and moving engine components.Risk of serious injury –

7.8.4 Fuel prefilter – DrainingPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignation / Use Part No. Q

7.8.5 Fuel prefilter – FlushingSpecial tools, Material, Spare partsDesignation / Use Part No. Qty.FuelGasket(→ Spare Parts Catalog)DANGERUnguarded rot

2. Open threaded vent plug (5) of filter to beflushed.3. Unlock drain valve (6) by pressing valvetoggle, open it and drain fuel.Result: Fuel flows fro

7.8.6 Fuel prefilter – Filter element replacementPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignatio

2. Open threaded vent plug (5) of contaminat‐ed filter.3. Unlock drain valve (6) by pressing toggleand open it.4. Drain water and dirt from filter.5.

7.9 Charge-Air Cooling General, Left-Hand Side7.9.1 Intercooler – Checking condensate drains for coolant discharge andobstructionsPreconditions☑ Engin

Lead• Adopt suitable measures to avoid the formation of lead dust.• Switch on extraction system.• When working with lead or lead-containing compounds,

7.10 Air Filter7.10.1 Air filter – ReplacementPreconditions☑ Engine is stopped and starting disabled.Replace air filter, carry out work in accordance

7.11 Air Intake7.11.1 Service indicator – Signal ring position checkPreconditions☑ Engine is stopped and starting disabled.Checking signal ring positi

7.12 Starting Equipment7.12.1 Starter – Condition checkPreconditions☑ Engine is stopped and starting disabled.Checking starter condition1. Check secur

7.13 Lube Oil System, Lube Oil Circuit7.13.1 Engine oil – Level checkPreconditions☑ Engine is stopped and starting disabled.Oil level check prior to e

7.13.2 Engine oil – ChangePreconditions☑ Engine is stopped and starting disabled.☑ Engine is at operating temperature.☑ MTU Fluids and Lubricants Spec

7.14 Oil Filtration / Cooling7.14.1 Engine oil filter – ReplacementSpecial tools, Material, Spare partsDesignation / Use Part No. Qty.Filter wrenchF30

Oil filter replacement with theengine runningA Filter in operation (normal position)B Filter switched offNote: When changing filters during engine ope

7.15 Coolant Circuit, General, High-Temperature Circuit7.15.1 Drain and venting pointsTop view1 Engine coolant vent 2 Engine coolant ventMS150025/02E

Left side1 Engine coolant drainplug2 Engine coolant drainplug128 | Task Description | MS150025/02E 2012-10TIM-ID: 0000006688 - 001

Right side1 Engine oil drainplug (heat exchanger)2 Engine coolant drainplugMS150025/02E 2012-10 | Task Description | 129TIM-ID: 0000006688 - 001

1.6 Standards for safety messages in the textDANGERIn the event of immediate danger.Consequences: Death or serious injury• Remedial actionWARNINGIn th

Driving end (KS)1 Engine coolant drainplug2 Intercooler drain 3 Engine oil drain plug130 | Task Description | MS150025/02E 2012-10TIM-ID: 0000006688 -

7.15.2 Engine coolant – Level checkPreconditions☑ Engine is stopped and starting disabled.☑ MTU Fluids and Lubricants Specifications (A001061/..) are

7.15.3 Engine coolant – ChangeSpecial tools, Material, Spare partsDesignation / Use Part No. Qty.CoolantEngine coolant – Change1. Drain engine coolant

7.15.4 Engine coolant – DrainingPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignation / Use Part No.

7.15.5 Engine coolant – FillingPreconditions☑ Engine is stopped and starting disabled.☑ MTU Fluids and Lubricants Specifications (A001061/..) are avai

Final steps1. Start the engine and operate it at idle speed for some minutes.2. Check coolant level (→ Page 131), top up with coolant if required.MS15

7.15.6 Coolant pump – Relief bore checkDANGERUnguarded rotating and moving engine components.Risk of serious injury – danger to life!• Take special ca

7.16 Low-Temperature Circuit7.16.1 Charge-air coolant – FillingPreconditions☑ Engine is stopped and starting disabled.☑ MTU Fluids and Lubricants Spec

Charge-air coolant – Filling1. Fill treated coolant through filling line or through filler neck of coolant expansion tank until coolant levelreaches m

7.16.2 Charge-air coolant – DrainingPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignation / Use Part

1.7 ATEX precautions (if applicable)The following additional precautions must be taken to comply with the requirements of the ATEXexplosion protection

7.16.3 Charge-air coolant – ChangeSpecial tools, Material, Spare partsDesignation / Use Part No. Qty.CoolantCharge-air coolant – Change1. Drain charge

7.16.4 Charge-air coolant – Level checkPreconditions☑ Engine is stopped and starting disabled.☑ MTU Fluids and Lubricants Specifications (A001061/..)

7.17 Belt Drive7.17.1 Drive belt – Condition checkPreconditions☑ Engine is stopped and starting disabled.☑ Guard is removed.Item Findings TaskDrive be

7.18 Engine Mounting / Support7.18.1 Engine mounts – Resilient elements checkPreconditions☑ Engine is stopped and starting disabled.☑ Engine is filled

7.19 Wiring (General) for Engine/Gearbox/Unit7.19.1 Engine wiring – CheckPreconditions☑ Engine is stopped and starting disabled.Special tools, Materia

7.20 Accessories for (Electronic) Engine Governor / ControlSystem7.20.1 Engine governor and connectors – CleaningPreconditions☑ Engine is stopped and

7.20.2 Engine monitoring unit and connectors – CleaningPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesi

7.20.3 Checking engine control unit plug connectionsPreconditions☑ Engine shut down and starting disabled.Special tools, Material, Spare partsDesignat

7.20.4 Engine monitoring unit – Plug connection checkPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesign

7.20.5 Engine control unit – Removal and installationPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesign

2 General Information2.1 Engine side and cylinder designationsEngine sides are always designated as viewed from the driving end (KS).The cylinders of

5. Disconnect ground strap from engine con‐trol unit grounding stud (7).6. If the screws (4) are easily accessible:1. Remove screws (4).2. Remove engi

7.21 Emergency Instrumentation (Local Operating Panel)7.21.1 LOP – Visual inspectionPreconditions☑ Engine is stopped and starting disabled.Preparatory

Checking threaded connections1. Check all connected cables to verify thatthe two securing elements (1) are engagedon the lugs (2) so that the respecti

Performing lamp test1. Connect battery in accordance with batterymanufacturer's instructions.2. Switch master power switch to ON.3. Switch on eng

7.21.2 LOP – Test proceduresPreconditions☑ Engine is stopped and starting disabled.Preparatory steps1. Connect battery in accordance with batterymanuf

Overspeed test with the engine atstandstillNote: Overspeed test with the engine at standstillcan only be carried out if the engine isequipped with Eng

8 Engine Governor Assignment and Circuitry8.1 Engine Governor8.1.1 Engine governor channel circuitryEngine governor channel circuitryBinary inputs BE1

Current input IUE 11 Current source, voltage source2 Engine Control Unit ECU 4FunctionFunction SourceAcquisition of a current signal (4 to 20 mA). -Me

Pulse measuring inputs KW 1 and NW 11 Inductive sensor2 Engine Control Unit ECU 4Channel Function SensorKW1 Measuring of crankshaft angleand crankshaf

Temperature inputs TE 1 to TE 91 Engine Control Unit ECU 4Function SensorTemperature measuring Temperature-dependent resistor Pt100/Pt1000(exhaust gas

2.2 Engine layoutIllustrations are also applicable to 16 V1 Exhaust outlet2 Exhaust turbocharger3 Intercooler4 Air intake connection5 Crankcase ventil

Measuring channel specificationMeasuring range Sensor-dependentOutput signal UO0.5 to 4.5 VDCSensor supply 5 V ± 250 mVPressure measuring input HP pum

Transistor outputs TAA 1 to TAA 61 Engine Control Unit ECU 4FunctionFunction SensorSwitching output PlantChannel specificationChannel TAA1 to TAA6 pos

FunctionFunction SensorOutput voltage 0 to 10 V, e.g. for display instru‐mentsPlantChannel specificationOutput voltage UO = 0 to 10 VOutput current lO

Function SensorSwitching output EngineSolenoid valve outputs MVA 1 to MVA 201 Engine Control Unit ECU 4Function SensorInjector control Injection solen

Channel specificationPhysical level ISO 11 898CAN specification Version 2.0 AData format MTU-specificTerminator In connector (no bus disruption when c

8.1.2 MDEC governor assignmentScope of deliveryIncluded in the scope of delivery are:• SAM• W004 MDEC connector X1 10 m long (15 m and 25 m available

TAA3 Combined alarm All warning messages (Limit1) are indicated hereas a combined alarm.TAA4 n > 300 Indication of engine speed > 300 rpm.TAA5 S

8.2 Connector Assignment8.2.1 Connector pin assignmentConnector pin assignmentConnector X1, view to socketConnector X1Connector type VPT 06 GSE 22–55

Channel Signal Pin CommentsUA4 OUT Z 0 V to 10 V/ 8 mAUA4 GND YBE1 +IN h U < 4 V = low / U > 8 V= highBE1 -IN g Electrically isolatedBE2 +IN x U

Channel Signal Pin CommentsTAA6 GND K (Plant supply, coil instru‐ments FZ)CAN1 HIGH G Electrically isolatedCAN1 LOW FCAN1 GND ECAN2 HIGH C Electricall

1 Starter 2 Charge-air coolant pumpEngine model designationKey to the engine model designation 12/16V 2000 Px212/16 Number of cylindersV Cylinder arra

Channel Signal Pin CommentsTE7 IN w 0 V to 5 V/ internal 2 k0pullup to 5 V_TE_BUFTE7 GND xTE8 IN t 0 V to 5 V/ internal 2 k0pullup to 5 V_TE_BUFTE8 GN

Channel Signal Pin CommentsNSE2 IN q 0 V to 5 V/ internal 47k5pullup to 5 V_TE_BUFNSE2 GND VKW +IN m U < 0 V = low / U > 400mV = highKW -IN SNW

Channel Signal Pin CommentsTE3 IN b 0 V to 5 V/ internal 2 k0pullup to 5 V_TE_BUFTE3 GND cTE4 IN U 0 V to 5 V/ internal 2 k0pullup to 5 V_TE_BUFTE4 GN

Connector X4, view to socketConnector X4Connector type VPT 06 GSE 21–41 PWTarget Engine wiring harness (solenoid valves)Pin assignmentChannel Signal P

Channel Signal Pin CommentsMV11 LOW R Bank 2MV12 HIGH P 24 V / 20 AMV12 LOW N Bank 2MV13 HIGH i 24 V / 20 AMV13 LOW h Bank 2MV14 HIGH g 24 V / 20 AMV1

Channel Signal Pin CommentsPOWER +24 V A Usupp = 24 V / 30 APOWER +24 V DPOWER GND BPOWER GND CPOWER GND EConnector X6, view to socketConnector X6Conn

9 Appendix A9.1 AbbreviationsAbbre‐viationMeaning ExplanationA/D Analog/Digital Transformer: transforms sensor voltages into nu‐meric valuesADEC Advan

Abbre‐viationMeaning ExplanationEMU Engine Monitoring UnitETK Ersatzteilkatalog Spare Parts Catalog (SPC)EUI Electronic Unit InjectorFPS Fuel Pressure

Abbre‐viationMeaning ExplanationSEL Stop engine light 1st function: Warning lamp (stop engine and rectifyfault)2nd function: Read out fault codesSID S

9.2 MTU contact persons/service partnersOur worldwide sales network with its subsidiaries, sales offices, representatives and customer servicecenters

2.3 Use1 Service and AutomationModule (SAM)2 Peripheral InterfaceModule 601 (option)3 Peripheral InterfaceModule 602 (option)4 CAN bus5 Engine with ge

10 Appendix B10.1 Special ToolsBarring tool for 12V enginesPart No.: F6558556Qty.:Used in:1 7.1.1 Engine – Barring manually (→ Page 84)Barring tool fo

Crowfoot wrench, 19 mmPart No.: F30027424Qty.:Used in:1 7.5.2 Injection pump – Removal and installation (→Page 99)Qty.:Used in:1 7.6.2 Injector – Remo

Feeler gaugePart No.: Y20010128Qty.:Used in:1 7.4.1 Valve clearance – Check and adjustment (→ Page95)Filter wrenchPart No.: F30379104Qty.:Used in:1 7.

RatchetPart No.: F30027340Qty.:Used in:1 7.4.2 Cylinder head cover – Removal and installation (→Page 97)Ratchet adapterPart No.: F30027340Qty.:Used in

Steam jet cleanerPart No.: -Qty.:Used in:1 4.11 Plant cleaning (→ Page 59)Torque wrench, 0.5–5 NmPart No.: 0015384230Qty.:Used in:1 7.5.2 Injection pu

Torque wrench, 6-50 NmPart No.: F30027336Qty.:Used in:1 7.3.2 Crankcase breather – Oil separator element re‐placement, diaphragm check and replacement

10.2 Index12/16 V 2000 P12 engine data  38AAbbreviations 176After stopping the engine – Engine remains ready for op‐eration 57After stopping the engin

Injection pump– Replacement  98Injection pump – Removal and installation 99Injector– Replacement  102Injector – Removal and installation 103Intercoole

Features• Electronic engine governing and control.• Monitoring of inadmissible engine operating states.• Display of fault messages and fault codes.• C

Printed in Germany© 2012 Copyright MTU Friedrichshafen GmbHThis Publication is protected by copyright and may not be used in any way whether in whole

Design of Engine Control System ECS-51 Engine with generator2 Engine interface3 Power supply +Ub4 Signal connection to theMCS devices and thehigher-le

Basic scope of Monitoring and Control System MCS-51 Monitoring and ControlSystem MCS-52 Power supply +Ub3 Signal connection toECS devices4 System boun

Service and Automation Module (SAM)1 Module cassette, slotsfor additional I/O PIMcards2 Compact flash memorycard3 Display for fault codesand minidialo

Customer interface• 24 binary outputs• 3 PWM outputs• 8 display outputs• 28 channel binary input• 10 analog inputs (e.g. PT100, 4–20 mA, 0-10 V, etc.)

Grounding1 PIM2 SAM3 Engine governor4 Battery5 To engine sensors6 Generating set7 Equipotential bondingstrip8 Grounding9 Equipotential bondingstrip10

2.4 ECS-5 – Use of devicesEngine governorCentral control and monitoring device for the engine• Communication with other devices and higher-level syste

Hardware structureItem. Name Meaning1 Cover –2 Housing –3 Rating plate Part and serial numberData record and engine number4 Screws –5 Connector X6 Con

Operating voltage Rated voltage: 24 VDCContinuous voltage:16.5 VDC to 32 VDCTemporarily restricted operation:11 VDC to 36 VDCResidual ripple: Max. 8 V

2.5 MDEC – FunctionsControl functionsFollowing engine functions are controlled:• Engine start• Engine stop• Emergency start• Restart response• Sequenc

Override (safety system bypass)The “Override” feature is used to bypass safety functions tripped by limit value violations or sensor faultsand to bypa

Table of Contents1 Safety1.1 Important provisions for all MTU engines orsystems 51.2 Personnel and organizational requirements 61.3 Transport 71.4 Saf

Speed - injection controlFunctions of the closed-loop engine speed control integrated in the engine governor:• Maintaining the desired engine speed un

Switching to an external speed setting takes place automatically once the nominal speed has beenreached.The following speed setting variants are possi

Fault messages are stored in two memories:• Chronological memoryThe fault message numbers are stored in a ring memory in chronological order of their

2.6 Peripheral Interface Modules (PIMs)PIMs for use with processor printed circuit board MPU 23 and MPU 27PIM design1 Module cassette 12 Basic module

The following information is transmitted via the optional interface modules PIM 601 and PIM 602:• Analog operational data• Analog limit values• Status

2.7 Printed circuit board SCB 3Purpose and designDesign1 Component side2 Soldering side3 Top view4 LED (red) “Printed circuitboard RESET”5 LED (green)

Function1 Transmission channel 1 2 Connector 3 Module housing withSCB 3SCB 3 is equipped with two serial transmission channels routed to the terminal

Connection terminal Namen03 Channel 1: O2 of RS422 interfacen04 Channel 2: O2 of RS422 interfacen05 Channel 1: Ground (GND) of RS422 interfacen06 Chan

3 Technical Data3.1 12/16 V 2000 P12 engine dataExplanation:DL Ref. value: Continuous powerBL Ref. value: Fuel stop powerA Design valueG Guaranteed va

Number of cylinders 12 16Cylinder displacement liter 1.99 1.99Total displacement liter 23.88 31.84Compression ratio 16 16Number of inlet valves per cy

7.7.3 Fuel system – Venting 1097.8 Fuel Filter 1107.8.1 Fuel filter – Replacement 1107.8.2 Fuel prefilter cleaning 1127.8.3 Fuel prefilter – Different

GENERAL OPERATING DATANumber of cylinders 12 16Cold start capability: air temperature without starting aid, with‐out preheating) - (case A)R °C 0** 0*

3.2 Firing orderFiring order12 V A1-B2-A5-B4-A3-B1-A6-B5-A2-B3-A4-B616 V A1-B5-A3-A5-B2-B8-A2-A8-B3-A7-B4-B6-A4-A6-B1-B7MS150025/02E 2012-10 | Technic

3.3 Engine – Main dimensionsEngine – Main dimensionsEngine model 12 V 2000 Px2 16 V 2000 Px2Length (A) approx. 2165 mm approx. 2505 mmWidth (B) approx

3.4 SAMUse/application• Installation in enclosed control cabinets.• Suitable for mounting on mounting rails (rail installation) or for installation wi

Term Unit ValueAmbient temperature: °C -40 – +70 with circulating ambient air.Storage temperature: °C -40 - +100Relative humidity % 5 – 97, no condens

Electrical requirementsTerm Unit ValueOperating voltage: V 24, -30 % to +30 % (+16.8 – +32)Permissible residual ripple less than 5% acc. to STA‐NAG 10

TerminalsTerm Unit ValueTerminal strip modules: WAGO spring terminalsCurrent-carrying capacity (at 70°C):A 10 per contactRated voltage: V 250Rated sur

3.5 SCB 3 – Technical dataTerm Unit ValueDimensions (H x W x D) mm 59 x 63 x 15Weight kg 0.036Input voltage VDC +5 (±5 %) from processor printed circu

4 Operation4.1 LOP – ControlsLOP – ControlsItem Color Inscription Meaning / Function1 White F1 Function keys for operating the screen.Functions vary a

Item Color Inscription Meaning / Function8 White DIMMER ↓ Holding down the key decreases LCD background illumina‐tion.9 White LAMP TEST Pressing the k

1 Safety1.1 Important provisions for all MTU engines or systemsNameplateEngine identification is provided by the engine serial number on the nameplate

4.2 Putting the engine into operation after extended out-of-service-periods (>3 months)Preconditions☑ Engine is stopped and starting disabled.☑ MTU

4.3 Putting the engine into operation after scheduled out-of-service-periodPreconditions☑ Engine is stopped and starting disabled.Putting the engine i

4.4 Start engine in manual mode (testing mode)Preconditions☑ Generator (if provided) not connected to network.☑ External start interlock is not activa

4.5 Safety system – OverrideCAUTIONSafety functions and engine shutdown alarms will be disregarded.Serious damage to plant!• Initiate emergency start

4.6 Operational checksDANGERUnguarded rotating and moving engine components.Risk of serious injury – danger to life!• Take special care when working o

4.7 Stop engine in manual mode (testing mode)Preconditions☑ Generator (if provided) not connected to network.☑ Engine is running in manual mode.CAUTIO

4.8 Emergency stopCAUTIONAn emergency stop causes extreme stress to the engine.Risk of overheating, damage to components!• Initiate emergency stop onl

4.9 After stopping the engine – Engine remains ready foroperationAfter stopping the engineItem ActionEngine/generator/pumpcontrolSelect operating mode

4.10 After stopping the engine – putting the engine out of servicePreconditions☑ MTU-Preservation and Represervation Specifications (A001070/..) are a

4.11 Plant cleaningPreconditions☑ Engine is stopped and starting disabled.☑ Operating voltage is not present.Special tools, Material, Spare partsDesig

1.2 Personnel and organizational requirementsOrganizational measures of the operatorThis publication must be issued to all personnel involved in opera

5 Maintenance5.1 Maintenance task reference table [QL1]The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. T

6 Troubleshooting6.1 TroubleshootingEngine does not turn when starter is actuatedComponent Cause MeasureBattery Flat or defective Charge or replace (s

Engine does not reach rated speedComponent Cause MeasureFuel supply Fuel inlet blocked Completely open shutoff valve up‐stream of fuel prefilter.Fuel

Black exhaust gasComponent Cause MeasureAir supply Air filter clogged Check signal ring position of contami‐nation indicator (→ Page 121).Fuel injecti

6.2 Fault indication on printed circuit board SAMThe structure of the display (1) is as follows:• First line• Fault indication• # (2) = Alarm is no lo

SE No. Fault message text11 I/O-Module Slot4 Defect12 Serial Connection Lost13 CAN Bus- 3 Error/Bus Defec14 CAN Bus- 3 Overrun15 S/A Bus Faulty16 PAN

Fault code Fault message Meaning Action023 L1 COOLANT LEVEL Coolant level too low(1st limit value)Check coolant level in expansiontank (→ Engine opera

Fault code Fault message Meaning Action067 L1 T-COOLANT Coolant temperature toohigh (1st limit value);Reduce power.068 L2 T-COOLANT Coolant temperatur

Fault code Fault message Meaning Action122 L1 T-ELECTRONIC Temperature in ECU hous‐ing too high (1st limit value)1. Improve engine room ventila‐tion.2

Fault code Fault message Meaning Action187 CAN 1 ERROR PAS‐SIVECAN 1 in Error-Passivestate, minor bus disruptionor missing CAN node .Contact Service.•

1.3 TransportTransportLift the engine only with the lifting eyes provided.Use only the transport and lifting equipment approved by MTU.Take note of th

Fault code Fault message Meaning Action216 SD T-LUBE OIL Sensor B07 faulty (lube oiltemperature).1. Check cabling (→ Engine oper‐ating instructions);

Fault code Fault message Meaning Action267 SD SP. DEM. TESTBENCHExternal test bench speedsetting faulty.Check potentiometer and cabling(→ Engine oper

Fault code Fault message Meaning Action373 TRAN.OUT3 EN‐GINE DEFBinary transistor output en‐gine 3 faulty.-374 TRAN.OUT4 EN‐GINE DEFBinary transistor

6.3 ECU alarmsThe ECU generates alarms which are indicated in different ways depending on the equipment configura‐tion:• as four-digit code on a PIM•

FaultcodeAlarm text Meaning Task016 L2 P-LUBE OIL Lube-oil pressure too low (2ndlimit)automatic engine shutdown1. Check engine-oil level and top up, i

FaultcodeAlarm text Meaning Task078 LIM INTER‐COOLER LEV.Alarm from external charge-aircoolant level monitoring(Depending on the corresponding meas‐ur

FaultcodeAlarm text Meaning Task106 ERR REC1 NOTVALIDCheck sum error of fault mem‐ory in EDM (redundant datarecord 1)If fault occurs repeatedly: Conta

FaultcodeAlarm text Meaning Task146 L1 AD-TEST1SUPPLYA/D-converter supply voltagetoo lowContact Service.147 AD-TEST1 ECUDEFECTElectronic equipment def

FaultcodeAlarm text Meaning Task201 SD T-COOLANT Sensor defect (coolant tem‐perature)1. Check wiring.2. Contact Service.202 SD T-FUEL Sensor defect (F

FaultcodeAlarm text Meaning Task274 SD P-EXTERN 2 External device defective(CAN P-EXTERN 2)Contact Service.275 SD EXT.COOL‐ANT LEVELExternal coolant-l

1.4 Safety regulations for maintenance and repair workSafety regulations prior to maintenance and repair workHave maintenance and repair work carried

FaultcodeAlarm text Meaning Task319 TIMING CYLIN‐DER B9Injection timing fault cylinderB9If fault occurs repeatedly: Contact Serv‐ice.320 TIMING CYLIN‐

FaultcodeAlarm text Meaning Task334 WIRING CYLIN‐DER B4Faulty wiring to solenoid valvecylinder B4;Misfiring1. Check wiring.2. Contact Service.335 WIRI

FaultcodeAlarm text Meaning Task348 OPEN_LOADCYL. A8Disconnection in wiring to sol‐enoid valve cylinder A8;Misfiring1. Check wiring.2. Contact Service

FaultcodeAlarm text Meaning Task363 STOP POWERSTAGE 1Solenoid valve or wiring orECU defectiveautomatic engine shutdown1. Check wiring.2. Try to re-sta

7 Task Description7.1 Engine7.1.1 Engine – Barring manuallyPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare parts

7.1.2 Engine – Barring with starting systemSpecial tools, Material, Spare partsDesignation / Use Part No. Qty.Connector pliers0135315483 1DANGERUnguar

7.1.3 Engine – Test runDANGERUnguarded rotating and moving engine components.Risk of serious injury – danger to life!• Before barring or starting the

7.2 Cylinder Liner7.2.1 Cylinder liner – Endoscopic examinationPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare p

Final steps1. Install injector (→ Page 103).2. Install cylinder head cover (→ Page 97).88 | Task Description | MS150025/02E 2012-10TIM-ID: 0000000015

7.2.2 Instructions and comments on endoscopic and visual examination of cylinderlinersTerms used for endoscopic examinationUse the terms listed below

Safety regulations after completion of maintenance and repair workBefore barring the engine, make sure that nobody is standing in the danger zone of t

Findings ActionBurn mark This is caused by a malfunction in the liner / ring tribosystem. Usually they runover the whole ring-travel area (TDC/BDC), s

7.3 Crankcase Breather7.3.1 Crankcase breather – Wire mesh cleaningPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spa

Crankcase breather – Wire meshcleaning1. Remove hose from oil separator hous‐ing (1).2. Remove cylinder head cover (5).3. Release screws (4), remove d

7.3.2 Crankcase breather – Oil separator element replacement, diaphragm checkand replacementPreconditions☑ Engine is stopped and starting disabled.Spe

Checking diaphragm1. Remove cover (4).2. Remove spring (5), gasket (2) and dia‐phragm (3).3. Check diaphragm (3) for damage, fit newdiaphragm if used

7.4 Valve Drive7.4.1 Valve clearance – Check and adjustmentPreconditions☑ Engine is stopped and starting disabled.☑ Engine coolant temperature is max.

Checking valve clearance at twocrankshaft positions1 Cylinder A1 is in firing TDC2 Cylinder A1 is in overlap TDCI Inlet valveX Exhaust valve1. Check T

7.4.2 Cylinder head cover – Removal and installationPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesigna

7.5 Injection Pump / HP Pump7.5.1 Injection pump – ReplacementSpecial tools, Material, Spare partsDesignation / Use Part No. Qty.Injection pump(→ Spar

7.5.2 Injection pump – Removal and installationPreconditions☑ Engine is stopped and starting disabled.Special tools, Material, Spare partsDesignation