Operating Instructions Diesel engine 20 V 4000 C22 M015675/05E
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Commissioning Note Important Please complete and return the “Commissioning Note” card below to MTU Friedrichshafen GmbH. The Commissioning Note information serves as a basis for the contractually agreed logistic support (war‐ ranty, spare parts, etc.).
Table of Contents 1 Safety 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.
7.11.3 Air filter element – Removal and installation 7.11.4 Service indicator - Signal ring position check 93 94 7.12 Starting Equipment 95 7.13 Lube Oil System, Lube Oil Circuit 96 7.12.1 Starter – Condition check 7.13.1 Engine oil level – Check 7.13.2 Engine oil – Change 7.14 Oil Filtration / Cooling 7.14.1 Automatic oil filter – Filter candles replacement 7.14.2 Oil indicator filter – Check 7.14.3 Centrifugal oil filter – Cleaning and filtersleeve replacement 7.
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.
1.2 Personnel and organizational requirements Personnel requirements Work on the engine must only be carried out by appropriately qualified and instructed personnel. Observe the minimum legal age. Responsibilities of the operating, maintenance and repair personnel must be specified by the operating company. Organizational measures This publication must be issued to all personnel involved in operation, maintenance, repair or transporta‐ tion.
1.3 Transport Transport Always use the lifting eyes on the engine and generator/gearbox when transporting gensets. Always use the lifting eyes on the engine when transporting an engine separately. Only use transport and lifting devices approved by MTU. Transport the engine/genset in the installation position only, maximum admissible inclination is 10°. Remove any loose parts on the genset.
1.4 Crankshaft transport locking device – For transport with flanged-on generator Transport This locking device protects the crankshaft bearings from shocks and vibration damage during unit trans‐ port. For removal of the transport locking device follow the following instructions: • The transport locking device should remain installed as long as possible during unit installation in or‐ der to avoid damage. • Starting or barring the engine is allowed only with the transport locking device removed.
Fitting the transport locking device on driving end (KS) TIM-ID: 0000004012 - 001 • Remove protective cover from flywheel housing (5). Keep guard plate and screws on the engine. They must be reinstalled when the transport locking de‐ vice has been removed. • Turn crankshaft to bring cylinder A1 in TDC position. • Check the threads on both sides of the flywheel (1) for ease of movement. • Install retainer (2) with screw (4) and washer (3) through the opening in the flywheel housing (5) .
1.5 Safety regulations for startup and operation Safety requirements for initial operation Prior to initial operation of the unit, install the assembly or unit according to the specifications and check the installation according to the MTU specifications. Before putting the device or plant into operation, always ensure: • that all maintenance and repair work is completed, • that all loose parts have been removed from rotating machine components, • that nobody is in the danger area of moving machine parts.
1.6 Explosion hazard when removing inspection port cover on engine DANGER Explosion hazard due to oil vapors. Risk of serious injury – danger to life! • Allow the engine to cool down before opening the crankcase! • Avoid open flames, electrical sparks and ignition sources. Safety instructions Before starting maintenance work, allow the engine to cool down for at least 10 min. (danger of explosion due to oil vapors).
1.7 Safety precautions when working on the engine • Maintenance and repair work may only be carried out by authorized, qualified personnel. • Allow the engine to cool down before commencing maintenance work (oil vapors present a risk of ex‐ plosion). • Before starting work, relieve pressure in systems and compressed-air lines which are to be opened. • Take special care when removing ventilation or plug screws from engine. Cover the screw or plug with a rag to prevent fluids escaping under pressure.
If welding has to be carried out on components (e.g. exhaust manifold), these components must first be removed from the engine. Hydraulic installation and removal Check the tools and devices to be used for perfect operation and safe condition. Only use the specified devices for force-fitting/removing parts. Observe the maximum press-on pressure for the device for force-fitting/removing parts. Do not attempt to bend or exert force on H.P. lines.
1.8 Fluids and lubricants, fire prevention and environmental protection Fire prevention Correct fuel or oil leaks immediately. Quantities of oil or fuel on hot components can cause fires – there‐ fore always keep the engine in a clean condition. Do not leave cloths soaked with fluids and lubricants lying on or near the assembly or plant. Do not store inflammable material near the assembly or plant. Do not weld pipes and components carrying oil or fuel. Before welding, clean with a nonflammable fluid.
Lead • When working with lead or lead-containing compounds, avoid direct contact to the skin and do not inhale lead vapors. • Prevent the buildup of white powder of lead. • Switch on fume extraction system.
1.9 Conventions for safety instructions in the text DANGER WARNING CAUTION Note: In the event of immediate danger. Consequences: Death or serious injury • Remedial action In the event of potentially dangerous situations. Consequences: Death or serious injury • Remedial action In the event of dangerous situations.
2 General Information 2.1 Engine side and cylinder designations Engine sides are always designated as viewed from the driving end (KS). The cylinders of the left engine side are designated "A" and those of the right side "B" (as per DIN ISO 1204). The cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end of the engine. Other components are numbered in the same way, i.e. starting with No. 1 on driving end.
2.
4 5 6 7 Intercooler Flywheel Charge-air coolant outlet Engine coolant inlet 8 9 10 11 Oil pan Oil dipstick Oil filler neck Starter (B side) TIM-ID: 0000002072 - 002 1 Engine lifting eye 2 Cylinder head cover / cyl‐ inder head 3 Oil heat exchanger M015675/05E 2011-10 | General Information | 21
1 Air supply downstream of intercooler (A side) 2 Exhaust system connec‐ tion (A side) 3 Exhaust turbocharger (A side) 4 Combustion air inlet (A side) 5 Crankcase breather 6 Combustion air inlet (B side) 7 Exhaust turbocharger (B side) 8 Exhaust system connec‐ tion (B side) 9 Air supply before inter‐ cooler (B side) Engine model designation Key to the engine model designation 20V 4000 C22 Number of cylinders V Cylinder arrangement: V engine 4000 Series C Application: Construction and Industrial, mo
2.3 Sensors, actuators and injectors – Overview 1 B07 (T-Lube oil) 2 Injectors Y39.1 to Y39.10 (A side cylinders) 3 B34 (P-Fuel after filter) 4 B48 (P-Fuel) 5 B33 (T-Fuel) TIM-ID: 0000012921 - 002 The injectors are underneath the cylinder head covers of the cylinder. Injector replacement and necessa‐ ry activities (→ Page 78).
2 B16 (P-Coolant) 3 B10 (P-Charge Air) 1 B44 (N-Turbocharger) 2 B03 (T-Intake Air) 4 B09 (T-Charge Air) TIM-ID: 0000012921 - 002 1 Injectors Y39.11 to Y39.
TIM-ID: 0000012921 - 002 1 B13 (N-Crankshaft) M015675/05E 2011-10 | General Information | 25
4 B01 (N-Camshaft) 5 B43 (P-Coolant Intercool‐ er) 6 B26 (T-Coolant Intercool‐ er) 7 B06 (T-Coolant) TIM-ID: 0000012921 - 002 1 B50 (P-Crankcase) 2 F25 (P-Lube Oil Diff.
3 Technical Data 3.1 20V 4000 C22 engine data Explanation: DL BL A G R L N X Ref. value: Continuous power (CP) Ref. value: Fuel stop power (FSP) Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated, without change (e.g.
MODEL-RELATED DATA (basic design) Number of cylinders 20V 4000 Number of cylinders 20 Cylinder configuration: V angle degrees 90 Bore mm 165 Stroke mm 210 Cylinder displacement liter 4.49 Total displacement liter 89.81 Number of inlet valves, per cylinder 2 Number of exhaust valves, per cylinder 2 COMBUSTION AIR / EXHAUST GAS Number of cylinders 20V 4000 Charge-air pressure before cylinder R bar abs 3.
LUBE OIL SYSTEM Number of cylinders 20V 4000 Lube oil operating temperature before engine, from R °C 86 Lube oil operating temp. before engine, to R °C 95 Lube oil operating pressure before engine (measuring block) R bar 5.3 Lube oil pressure before engine, alarm R bar 4.5 Lube oil pressure before engine, shutdown L bar 3.9 FUEL SYSTEM Number of cylinders 20V 4000 Fuel pressure at supply connection to engine (when engine is start‐ L ing), min. admissible bar - 0.
CAPACITIES Number of cylinders 20V 4000 Engine coolant capacity (without cooling equipment) R liter 205 Engine oil capacity, initial filling (standard oil system) (Option: max. operating inclinations) R liter 390 Oil pan capacity, dipstick mark min. (standard oil system) (Option: max. operating inclinations) L liter 340 Oil pan capacity, dipstick mark max. (standard oil system) (Option: max.
3.
3.3 Main engine dimensions Main engine dimensions approx. 3630 mm Width (B) approx. 1450 mm Height (C) approx.
4 Operation 4.1 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 into operation after long out-of-service periods (>3 months) Item Action Engine Depreserve (→ MTU Fluids and Lubricants Specifications A001061/..). Valve gear Lubricate valve gear (→ Page 70). Lube oil system Check engine oil level (→ Page 96).
4.2 Putting the engine into operation after scheduled out-ofservice-period Preconditions ☑ Engine is stopped and starting disabled. Startup Item Action Lube oil system Check engine oil level (→ Page 96). Coolant circuit Check engine coolant level (→ Page 105); Check charge-air coolant level (→ Page 113). Preheat coolant with coolant preheating unit (if applicable). Engine control system Put into operation.
4.3 Engine – Start in manual mode Preconditions ☑ Engine with no load. ☑ External start interlock is not activated. DANGER WARNING Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Before barring or starting the engine, make sure that nobody is in the danger zone. Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. Preparation Item Measure Operating mode switch (if applicable) Switch to manual mode.
4.4 Operational checks DANGER WARNING Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. Operational checks Item Task Control and dis‐ play panels Check indicated operating parameters (speed, temperatures, pressures). Engine oil Check engine oil level (→ Page 96).
4.5 Engine – Shutdown in manual mode Preconditions ☑ Engine is not under load ☑ Engine in manual mode CAUTION Stopping the engine when it is running at full load causes extreme stress to the engine. Risk of overheating, damage to components! • Before stopping the engine, operate it at idle speed until operating temperatures decrease and stable values are indicated. Preparation Item Measure Engine Operate engine at idling speed for approx. 5 minutes.
4.6 After stopping the engine Preconditions ☑ MTU Fluids and Lubricants Specification (A001061/..) is available. After stopping the engine Item Task Coolant circuit Drain coolant (→ Page 107)(→ Page 115)if freezing temperatures are ex‐ pected and: • the engine is to remain out of service for an extended period and cool‐ ant has no antifreeze additive; • the coolant is not maintained at a suitable temperature; • antifreeze concentration is 50 % and outside temperature is below -40°C.
4.7 Plant – Cleaning Preconditions ☑ Engine is stopped and starting disabled. ☑ Operating voltage is not applied. Special tools, Material, Spare parts Designation / Use Part No. Qty. Steam jet cleaner - 1 30390 1 Cleaner (Hakupur 312) WARNING WARNING CAUTION Note: Compressed air Risk of injury! • Do not direct compressed-air jet at persons. • Wear protective goggles / safety mask and ear protectors. Water jet. Risk of injury and scalding! • Do not direct water jet at persons.
5 Maintenance 5.1 Maintenance task reference table [QL1] The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Maintenance Schedule is a stand-alone publication.
6 Troubleshooting 6.1 Troubleshooting Engine does not turn when starter is actuated Component Probable Cause Task Battery Low or defective Charge or replace (see manufacturer's documentation). Cable connections defective Check if cable connections are proper‐ ly secured (see manufacturer's docu‐ mentation). Starter Engine wiring or starter defective Check if cable connections are proper‐ ly secured, contact Service. Engine wiring Defective Check (→ Page 128).
Component Probable Cause Task Engine wiring Defective Check (→ Page 128). Engine Overloaded Contact Service. Engine speed not steady Component Probable Cause Task Fuel injection equip‐ ment Injector defective Replace (→ Page 78). Speed sensor Defective Contact Service. Fuel system Not vented Vent fuel system (→ Page 85). Engine governor Defective Contact Service.
Exhaust gas white Component Probable Cause Task Engine Not at operating temperature Run engine to reach operating temper‐ ature. Fuel system Water in fuel Check fuel system on fuel prefilter. Drain fuel prefilter Leaking Contact Service.
6.2 ECU 4 alarms Faults in the overall system are indicated as a four-digit code on the PIM display. The fault code numbers are generated by the ECU. The four-digit code consists of one letter and three figures: • The letter encodes when the fault occurred the last time: A = currently present B = within the last operating hour C = one to four operating hours ago D = four to twelve operating hours ago Alarms that occurred more than twelve hours ago are deleted automatically.
Fault code Alarm text Meaning Task 016 L2 P-LUBE OIL Lube-oil pressure too low (2nd limit) TIM-ID: 0000003161 - 001 Automatic engine shut‐ down. 1. Check engine-oil level and top up, if required; (→ Page 96); 2. Try to re-start the engine (→ Page 35). 3. Contact Service. 023 L1 COOLANT LEVEL Coolant level too low. Alarm appears together with No. 24. Check coolant level in expansion tank. 024 L2 COOLANT LEVEL Coolant level too low. Alarm appears together with No. 23.
Fault code Alarm text Meaning 065 L1 P-FUEL Fuel supply pressure too low (1st limit) 1. Check fuel lines for leaks; repair defective lines. 2. Clean fuel prefilter 3. Flush fuel prefilter 4. Replace filter element of fuel prefilter. 5. Fuel filter replacement (→ Page 86). 6. If fault is not rectified: Contact Service. 066 L2 P-FUEL Fuel supply pressure too low (2nd limit) 1. Check fuel lines for leaks; repair defective lines. 2. Clean fuel prefilter 3. Flush fuel prefilter 4.
Fault code Alarm text Meaning Task 089 ENGINE SPEED LOW Engine speed lower than 200 rpm; Re-start the engine (→ Page 35). Automatic engine shut‐ down. 090 IDLE SPEED LOW Idle speed not reached within a specified period; Note further alarms. Termination of starting pro‐ cedure. 091 RUN UP SPEED LOW Run-up speed not reached Note further alarms. within a specified period; Termination of starting pro‐ cedure.
Fault code Alarm text Meaning Task 119 L2 SUPPLY VOLT. LOW Supply voltage too low (2nd limit) Check ECU supply voltage. 120 L1 SUPPLY VOLT. HIGH Supply voltage too high (1st limit) Check ECU supply voltage. 121 L2 SUPPLY VOLT. HIGH Supply voltage too high (2nd limit); Check ECU supply voltage. Automatic engine shut‐ down (depending on project design).
Fault code Alarm text Meaning Task 147 AD-TEST1 ECU DE‐ Electronic equipment de‐ FECT fective; Contact Service. Automatic engine shut‐ down. 148 L1 AD-TEST2 SUP‐ PLY A/D-converter supply volt‐ age too low. 149 AD-TEST2 ECU DE‐ Electronic equipment de‐ FECT fective; Contact Service. Contact Service. Automatic engine shut‐ down. 150 L1 AD-TEST3 SUP‐ PLY A/D-converter supply volt‐ age too low. 151 AD-TEST3 ECU DE‐ Electronic equipment de‐ FECT fective; Contact Service. Contact Service.
Fault code Alarm text Meaning Task 189 CAN2 ERROR PAS‐ SIVE Light fault on Redundant CAN bus (e.g. short-time overload) (none) 201 SD T-COOLANT Sensor defect (coolant temperature) 1. Check wiring. 2. Contact Service. 202 SD T-FUEL Sensor defect (fuel temper‐ ature) 1. Check wiring. 2. Contact Service. 203 SD T-CHARGE AIR Sensor defect (charge-air temperature) 1. Check wiring. 2. Contact Service. 205 SD T-COOLANT IN‐ TERC. Sensor defect (charge-air coolant temperature) 1. Check wiring.
TIM-ID: 0000003161 - 001 Fault code Alarm text Meaning Task 246 SD T-ELECTRONIC Sensor defect (temperature Contact Service. in ECU) 266 SD SPEED DE‐ MAND AN. Sensor defect (analog speed demand) 301 TIMING CYLINDER A1 Injection timing fault cylin‐ der A1 If fault occurs repeatedly: Contact Service. 302 TIMING CYLINDER A2 Injection timing fault cylin‐ der A2 If fault occurs repeatedly: Contact Service.
Fault code Alarm text Meaning 322 WIRING CYLINDER A2 Faulty wiring to solenoid valve cylinder A2; Task 1. Check wiring. 2. Contact Service. Misfiring 323 WIRING CYLINDER A3 Faulty wiring to solenoid valve cylinder A3; 1. Check wiring. 2. Contact Service. Misfiring 324 WIRING CYLINDER A4 Faulty wiring to solenoid valve cylinder A4; 1. Check wiring. 2. Contact Service. Misfiring 325 WIRING CYLINDER A5 Faulty wiring to solenoid valve cylinder A5; 1. Check wiring. 2. Contact Service.
Fault code Alarm text Meaning Task 337 WIRING CYLINDER B7 Faulty wiring to solenoid valve cylinder B7; 1. Check wiring. 2. Contact Service. Misfiring 338 WIRING CYLINDER B8 Faulty wiring to solenoid valve cylinder B8; 1. Check wiring. 2. Contact Service. Misfiring 339 WIRING CYLINDER B9 Faulty wiring to solenoid valve cylinder B9; 1. Check wiring. 2. Contact Service. Misfiring 340 WIRING CYLINDER B10 Faulty wiring to solenoid valve cylinder B10; 1. Check wiring. 2. Contact Service.
Fault code Alarm text Meaning 351 OPEN_LOAD CYL. B1 Disconnection in wiring to solenoid valve cylinder B1; Task 1. Check wiring. 2. Contact Service. Misfiring 352 OPEN_LOAD CYL. B2 Disconnection in wiring to solenoid valve cylinder B2; 1. Check wiring. 2. Contact Service. Misfiring 353 OPEN_LOAD CYL. B3 Disconnection in wiring to solenoid valve cylinder B3; 1. Check wiring. 2. Contact Service. Misfiring 354 OPEN_LOAD CYL. B4 Disconnection in wiring to solenoid valve cylinder B4; 1.
Fault code Alarm text Meaning Task 365 STOP SOLENOIDWIRING Solenoid-valve wiring faul‐ ty; Automatic engine shut‐ down. 1. Check wiring. 2. Try to re-start the engine (→ Page 35). 3. Contact Service. TRAN.OUT1 PLANT DEF Binary transistor output plant 1 defective Contact Service. 382 TRAN.OUT2 PLANT DEF Binary transistor output plant 2 defective Contact Service. 383 TRAN.OUT3 PLANT DEF Binary transistor output plant 3 defective Contact Service. 384 TRAN.
7 Task Description 7.1 Engine 7.1.1 Engine – Barring manually Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use DANGER Part No. Qty. Barring device F6555766 1 Barring device F6783293 1 Adapter F6558528 1 Ratchet F30006212 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.
Barring engine manually (installation on lower side) 1. 2. 3. 4. TIM-ID: 0000002521 - 004 5. Remove grounding device or guard plate. Engage barring device (2) with ring gear (1) and mount on flywheel housing. • For 12/16V engines, use barring device F6555766 with adapter F6558528. • For 20V engines, use barring de‐ vice F6783293. Set ratchet (3) onto barring device (2). Rotate crankshaft in engine direction of ro‐ tation. Apart from the normal compression resistance, there should be no resistance.
7.1.2 Engine – Barring with starting system Special tools, Material, Spare parts DANGER Designation / Use Part No. Qty. Connector pliers 0135315483 1 Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • before barring or starting the engine, ensure that nobody is in the danger zone. • After working on the engine, check that all protective devices have been reinstalled and all tools removed from the engine. Engine – Barring with starting system 1. 2. 3. 4.
7.2 Cylinder Liner 7.2.1 Cylinder liner – Endoscopic examination Preconditions ☑ Engine is stopped and starting disabled Special tools, Material, Spare parts Designation / Use Part No. Endoscope Qty. Y20097353 Preparatory steps 1. 2. Remove cylinder head cover (→ Page 76). Remove injector (→ Page 79). Positioning crankshaft at BDC 1. 2. Using barring device, turn crankshaft until crankshaft journal of the cylinder to be tested has reached BDC.
Final steps Install injector (→ Page 79). Install cylinder head cover (→ Page 76). TIM-ID: 0000003304 - 003 1. 2.
7.2.2 Instructions and comments on endoscopic and visual examination of cylinder liners Terms used for endoscopic examination Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic exami‐ nation report. Findings Measure Light scoring Minor dirt scores can occur during the assembly of a new engine (honing prod‐ ucts, particles, broken-off burrs). Removed cylinders clearly exhibit such scor‐ ing on the running surface under endoscope magnification.
Findings Measure Discolorations (Heat) These are caused by a disturbance 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 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.
7.3 Crankcase Breather 7.3.1 Crankcase breather – Oil separator replacement, diaphragm check and replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use WARNING Part No. Qty. Torque wrench, 6 to 50 Nm F30027336 1 Ratchet F30027340 1 Engine oil Filter element (→ Spare Parts Catalog) Diaphragm (→ Spare Parts Catalog) Seal (→ Spare Parts Catalog) Hot oil. Oil can contain combustion residues which are harmful to health.
Crankcase breather – Replacing filter element (variant B) 1. 2. 3. 4. Remove cover (2) with O-ring (3). Remove filter element (1) from housing (4). Insert new filter element in housing (4). Install cover (2) with new O-ring. 5. Use torque wrench to tighten the screws of cover (2) to the specified torque. Name Size Screw 6. Type Lubricant Value/Standard Tightening torque (Engine oil) 6 Nm +2 Nm Replace further oil separator elements in the same way. Checking diaphragm (variant B) 3. 4. 5. 6.
7.3.2 Crankcase breather – Cleaning Special tools, Material, Spare parts Designation / Use WARNING WARNING CAUTION Part No. Qty. Cleaner (Snow-White 11-0) 40460 1 Cleaner (Hakupur 312) 30390 1 Compressed air Risk of injury! • Do not direct compressed-air jet at persons. • Wear protective goggles / safety mask and ear protectors. Cleaner is extremely caustic. Risk of injury and suffocation! • Avoid contact with eyes and skin. • Do not inhale vapors and smoke.
7.3.3 Crankcase breather – Filter element replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Torque wrench 10-60 Nm Filter element WARNING Part No. Qty. F30510423 1 (→ Spare Parts Catalog) Hot oil. Oil can contain combustion residues which are harmful to health. Risk of injury and poisoning! • Wear protective clothing, gloves, and goggles / safety mask. • Avoid contact with skin. • Do not inhale oil vapor.
Crankcase breather (open-circuit crankcase ventilation) – Filter element cleaning or replacement 1. 2. 3. 4. 5. 6. 7. 8. TIM-ID: 0000003532 - 001 9. 10. 11. Clean filter (6) outside. Undo clamp (2) and screw (7). Pull hose (1) off cover (3). Loosen clamp (5). Remove cover (3). Clean filter element (4) (→ Page 65) or re‐ place. Fit cover (3). Use torque wrench to tighten clamp (5) to specified torque 12 Nm to 14 Nm. Push hose (1) onto cover (3). Tighten clamp (2) and screw (7).
7.4 Running Gear 7.4.1 Grounding device – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Removing grounding device 1. 2. 3. 4. Clean grounding device (2) prior to remov‐ al. Remove screws (1). Remove screws (3) from grounding device (2). Remove grounding device (2). Installing grounding device Install grounding device (2) with screws (3) on belt pulley. Install screws (1) and tighten. TIM-ID: 0000003983 - 001 1. 2.
7.4.2 Grounding device – Replacement Special tools, Material, Spare parts Designation / Use Part No. Grounding device (→ Spare Parts Catalog) Qty. Remove grounding device and install new one .
7.5 Valve Drive 7.5.1 Valve gear – Lubrication Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil Lubricating valve gear 1. 2. TIM-ID: 0000004337 - 003 3. Remove cylinder head covers (→ Page 76). Fill oil chambers of rocker arms and adjust‐ ing screws with oil. Install cylinder head covers (→ Page 76).
7.5.2 Valve clearance – Check and adjustment Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine coolant temperature is max. 40 °C. ☑ Valves are closed. Special tools, Material, Spare parts Designation / Use Part No. Qty. Feeler gauge Y20010128 1 Torque wrench 60-320 Nm F30047446 1 Socket wrench F30039526 1 Allen key F30002817 1 Torque wrench 10-60 Nm F30510423 1 Socket wrench F30039518 1 Preparatory steps Remove cylinder head cover (→ Page 76).
Checking valve-bridge balance X Valve bridge with guide Y Flying valve bridge Note: 1. TIM-ID: 0000004355 - 001 2. Not applicable for engines with flying valve bridge. Prior to adjusting valve clearance, check valve-bridge balance on all valve bridges. Use feeler gauge to determine the distance between valve bridge and rocker arm.
3. TIM-ID: 0000004355 - 001 4. Insert feeler gauge with determined value between valve bridge and valve-stem end (A). At the opposite valve-stem end (B), a feeler gauge thicker by 0.05 mm should not fit, otherwise adjust valve bridge balance.
Adjusting valve-bridge balance Note: 1. 2. 3. 4. 5. 6. 7. Use feeler gauge to determine the distance between valve bridge and rocker arm. Place one feeler gauge (of the determined value) each between valve bridge and the two valve-stem ends (A) and (B). Turn adjusting screw so that both feeler gauges can be just pulled through. Hold adjusting screw securely in position with Allen key and fit locknut by hand on valve bridge. Replace or rectify adjusting screws which do not move freely.
Checking valve clearance at two crankshaft positions 1. 2. 3. 4. 5. Check TDC position of piston in cylinder A1: • If the rocker arms are unloaded on cylin‐ der A1, the piston is in firing TDC. • If the rocker arms are loaded on cylinder A1, the piston is in overlap TDC. Check valve clearance with cold engine: • Inlet valves (long rocker arm) = 0.2 mm • Exhaust valves (short rocker arm) = 0.
7.5.3 Cylinder head cover – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Gasket Part No. Qty. (→ Spare Parts Catalog) Removing cylinder head cover 1. 2. 3. Clean cylinder head covers prior to removal if they are heavily soiled. Undo and remove screws. Remove cylinder head cover with gasket from cylinder head. Installing cylinder head cover Clean mating faces. Check condition of gasket, replace if necessary.
7.6 Injection Pump / HP Pump 7.6.1 DANGER WARNING HP fuel pump – Relief bore check Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. HP fuel pump – Relief bore check 1. 2. TIM-ID: 0000004531 - 002 3. Visually inspect relief bore (1) for fuel dis‐ charge.
7.7 Injection Valve / Injector 7.7.1 Injector – Replacement Special tools, Material, Spare parts Designation / Use Injector Part No. Qty. (→ Spare Parts Catalog) Remove injector and install new injector.
7.7.2 Injector – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Installation and removal tool for injector F6790161 1 Milling cutter F30452739 1 Slotted nut screwdriver F30452578 1 Torque wrench, 0.
Removing injector Note: 1. 2. 3. 4. 5. Remove screw (2) and take off hold-down clamp (1). Remove high-pressure fuel line (5). Install installation/removal jig on cylinder head. Remove injector with installation/removal jig. Remove installation/removal jig. TIM-ID: 0000000952 - 003 6. Always replace the first and last injectors of one engine side first. Replace the inner in‐ jectors only after the installation of the outer injectors on this engine side is completed.
7. TIM-ID: 0000000952 - 003 8. 9. Remove sealing ring (1) from injector or use a self-made wire hook to extract it from the cylinder head. Remove O-rings (2) from injector. Cover all connections and bores, or seal with suitable plugs.
Installing injector 1. 2. 3. 4. 5. 6. 7. 8. Clean sealing surface on cylinder head and protective sleeve with milling cutter. Insert injector into cylinder head ensuring that the HP line connection is aligned cor‐ rectly. Press in injector with installation/removal jig. Remove installation/removal jig. Use slotted screwdriver to check thrust ring at both line ends for secure seating. TIM-ID: 0000000952 - 003 9. Remove all plugs before installing.
10. Tighten loose thrust ring to the specified tightening torque. Name Size Thrust ring Lubricant Tightening torque Value/Standard 5 Nm to 10 Nm 11. Coat screw head mating face (2) and thread with engine oil. 12. Place hold-down clamp (1) in correct installation position. Tighten screw (2) with torque wrench to the specified initial tightening torque. Name Size Type Lubricant Value/Standard Screw M12 Preload torque (Engine oil) 5 Nm to 10 Nm 13.
18. Twist cable several times. 19. Insert cable terminals (arrowed) underneath screws on injector and tighten screws to specified torque using a torque wrench. Name Size Screw Type Tightening torque Lubricant Value/Standard 1.5 Nm Final steps Install cylinder head cover (→ Page 76). Open up fuel supply to engine. TIM-ID: 0000000952 - 003 1. 2.
7.8 Fuel System 7.8.1 Fuel system – Venting Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Venting LP fuel system 1. 2. 3. 4. 5. TIM-ID: 0000004707 - 002 6. Loosen flushing/return line of HP pump at connection (1). Unlock fuel priming pump (2), screw out handle.
7.9 Fuel Filter 7.9.1 Fuel filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Filter wrench Engine oil Easy-change filter WARNING Part No. Qty. F30379104 1 (→ Spare Parts Catalog) Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Replacing fuel filter 1. 2. 3. 4. TIM-ID: 0000000927 - 003 5. 6.
7.9.2 Edge-type fuel filter – Draining Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Diesel fuel Sealing ring WARNING Qty. (→ Spare Parts Catalog) Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Edge-type fuel filter – Draining 1. 2. 3. 4. 5. 6. TIM-ID: 0000004952 - 001 7. Rotate edge-type filter (2) with handle (1) clockwise several times.
7.9.3 Fuel prefilter – Draining Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Draining fuel prefilter 1. 2. 3. 4. TIM-ID: 0000004930 - 002 5. 6. 7. 8. Shut down the filter unit (5/8) to be changed at valves (3) and (4) or (9) and (10).
7.10 Charge-Air Cooling 7.10.1 DANGER WARNING WARNING Intercooler – Check drain for coolant leakage and obstruction Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. Compressed air Risk of injury! • Do not direct compressed-air jet at persons. • Wear protective goggles / safety mask and ear protectors.
7.11 Air Filter 7.11.1 Air filter element and dust bowl – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Seal WARNING Part No. Qty. (→ Spare Parts Catalog) Compressed air Risk of injury! • Do not direct compressed-air jet at persons. • Wear protective goggles / safety mask and ear protectors. Air filter element – Cleaning Note: 1. 2. 3. Note: 4. 5. Debris particles must not enter the intake system. Clean dust bowl.
Visual inspection 1. TIM-ID: 0000005423 - 002 2. Use inspection lamp to check cleaned filter element for damage. Fit new filter element if old one is damaged (→ Page 92).
7.11.2 Air filter – Replacement Special tools, Material, Spare parts Designation / Use Air filter Part No. Qty. (→ Spare Parts Catalog) Remove air filter and install new one . u (→ Page 93) Reset signal ring of service indicator .
7.11.3 Air filter element – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Seal Part No. Qty. (→ Spare Parts Catalog) Air filter element – Removal and installation 1. 2. 3. 4. 5. 6. 7. 8. TIM-ID: 0000005455 - 002 9. Release latches (9). Remove dust bowl (8) and partition (7). Remove collar nut (6). Screw off air filter element (4). Clean housing (3) and dust bowl (8).
7.11.4 Service indicator - Signal ring position check Preconditions ☑ Engine is stopped and starting disabled. Checking signal ring position 1. 2. TIM-ID: 0000005484 - 004 Result: If the signal ring is completely visible in the control window (2), replace air filter (→ Page 92). After installation of new filter, press reset button (1). Engaged piston with signal ring moves back to initial position.
7.12 Starting Equipment 7.12.1 Starter – Condition check Preconditions ☑ Engine is stopped and starting disabled. Checking starter condition Check securing screws of starter for secure seating and tighten if required. Check wiring (→ Page 128). TIM-ID: 0000000905 - 009 1. 2.
7.13 Lube Oil System, Lube Oil Circuit 7.13.1 Engine oil level – Check Checking engine oil level prior to engine start 1. 2. Note: 3. 4. 5. Withdraw oil dipstick from guide tube and wipe it. Insert dipstick into guide tube up to the stop, withdraw after approx. 10 seconds. Check oil level on oil dipstick side marked "5 Min. after Stop". After extended out-of-service periods, the oil level may be up to 2 cm above the "max." mark.
7.13.2 Engine oil – Change Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine is at operating temperature. ☑ MTU Fluids and Lubricants Specification (A001061/..) is available. Special tools, Material, Spare parts Designation / Use Part No. Engine oil Sealing ring WARNING Qty. (→ Spare Parts Catalog) Hot oil. Oil can contain combustion residues which are harmful to health. Risk of injury and poisoning! • Wear protective clothing, gloves, and goggles / safety mask.
7.14 Oil Filtration / Cooling 7.14.1 Automatic oil filter – Filter candles replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Grease (Kluthe Hakuform 30-10/Emulgier) WARNING Qty. X00029933 1 Engine oil O-ring (→ Spare Parts Catalog) Oil filter candles (→ Spare Parts Catalog) Hot oil. Oil can contain combustion residues which are harmful to health.
Oil filter candles – Removal 1. 2. Remove nuts (2) from oil filter cover (1). Remove oil filter cover. 3. 4. Withdraw filter insert (1). Remove O-ring. Remove screw (2). Withdraw spinner (1) with spring. Remove nut (3). Take off spring washer and washer. Remove screw (4). Remove flushing arm (5) from screen plate (6). TIM-ID: 0000006401 - 002 5. 6. 7. 8. 9. 10.
11. 12. Turn filter insert upside down and use ap‐ propriate tool to push out filter candles (1). Turn filter insert by 180°and insert new filter candles (1) with chamfer facing downwards. Oil filter candles – Installation For installation follow reverse sequence of working steps. In addition, the following work must be performed: • Replace all sealing elements with new parts. • Coat O-rings with grease. • Insert O-rings in grooves.
7.14.2 Oil indicator filter – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use WARNING WARNING CAUTION Part No. Strainer (→ Spare Parts Catalog) Square-section ring (→ Spare Parts Catalog) O-ring (→ Spare Parts Catalog) 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.
Checking strainer Item Findings Task Strainer Metallic residues • • • • Strainer Damaged Replace Square-section ring Damaged Replace O-ring Damaged Replace Clean Monitor engine operation Check strainer daily Contact Service. Cleaning strainer 1. 2. 3. Wash strainer (5) with cleaner. Remove stubborn deposits with soft brush. Blow out strainer (5) with compressed air from inside. Installing strainer Coat square-section ring (4) on strainer (5) with engine oil and install strainer (5).
7.14.3 Centrifugal oil filter – Cleaning and filter-sleeve replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use WARNING Qty. Torque wrench, 6-50 Nm F30027336 1 Cold cleaner (Hakutex 60) X00056750 1 Filter sleeve (→ Spare Parts Catalog) Sealing ring (→ Spare Parts Catalog) Sealing ring (→ Spare Parts Catalog) Hot oil. Oil can contain combustion residues which are harmful to health.
Centrifugal oil filter – Cleaning and filter-sleeve replacement 16. Remove clamp (3). Release cover screw (1) and take off cover (2). Carefully lift rotor (6), allow oil to drain and remove from housing. Holding the rotor (6) firmly, release rotor cover nut (7). Take off rotor cover (8). Remove filter sleeve (10). Measure thickness of oil residues on filter sleeve (10). If maximum layer thickness of oil residues exceeds 45 mm, shorten maintenance in‐ terval.
7.15 Coolant Circuit, General, High-Temperature Circuit 7.15.1 Coolant – Level check Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask. Checking coolant level at filler neck: 1. 2. 3.
7.15.2 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine coolant Drain engine coolant. u (→ Page 107) Fill with engine coolant.
7.15.3 Engine coolant – Draining Preconditions ☑ Engine is stopped and starting disabled. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask. Preparatory steps 1. 2. Provide an appropriate container to drain the coolant into. Switch off preheating unit. Engine coolant – Draining 1. 2. 3. 4. TIM-ID: 0000000936 - 003 5. 6.
7.15.4 Engine coolant – Filling Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine coolant WARNING CAUTION Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask. Cold coolant in hot engine can cause thermal stress.
Filling coolant with pump 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Connect appropriate pump with hose to drain valve. Open drain valve and pump coolant into en‐ gine at 0.5 bar minimum. Fill expansion tank until overflow edge is reached. Close drain valve. Check proper condition of breather valve, clean sealing faces if required. Set breather valve onto filler neck and close it. Start engine (→ Page 35). After the engine has run at unloaded condi‐ tion for 10 seconds, stop engine (→ Page 37).
7.15.5 DANGER WARNING Engine coolant pump – Relief bore check Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. Checking relief bore on engine coolant pump 1. 2. 3. TIM-ID: 0000000961 - 006 4. Check relief bore for oil and coolant dis‐ charge.
7.15.6 Coolant – Sample extraction and analysis Preconditions ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use MTU test kit DANGER WARNING WARNING Part No. Qty. 5605892099/00 1 Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down.
7.15.7 Coolant filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use WARNING Part No. Qty. Filter wrench F30379104 1 Engine oil Coolant filter (→ Spare Parts Catalog) Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask. Coolant filter – Replacement 1. 2. 3. 4. 5. TIM-ID: 0000006858 - 006 6.
7.16 Low-Temperature Circuit 7.16.1 Charge-air coolant – Level check Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask. Checking charge-air coolant level at filler neck: 1. 2. 3. 4. 5. 6.
7.16.2 Charge-air coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Charge-air coolant Drain charge-air coolant. u (→ Page 115) Fill with charge-air coolant.
7.16.3 Charge-air coolant – Draining Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Sealing ring WARNING Qty. (→ Spare Parts Catalog) Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask. Charge-air coolant – Draining 1. 2. 3. 4. 5. 6. 7. Drain residual coolant at intercooler, left and right side.
7.16.4 Charge-air coolant system – Filling Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specification (A001061/..) is available. Special tools, Material, Spare parts WARNING CAUTION Designation / Use Part No. Charge-air coolant Sealing ring (→ Spare Parts Catalog) Qty. Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. Cold coolant in hot engine can cause thermal stress.
Charge-air coolant system – Filling 1. 2. 3. 4. Pour treated coolant via the filling point on the coolant line from and to the intercooler and via the filler neck of the expansion tank until coolant is visible at the marking plate. Install plugs with new sealing rings at the filling points. Check proper condition of breather valve, clean sealing faces if required. Set breather valve onto filler neck and close it. Final steps Start the engine and operate it at idle speed for some minutes.
7.16.5 DANGER WARNING Charge-air coolant pump – Relief bore check Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. Charge-air coolant pump – Relief bore check 1. 2. 3. TIM-ID: 0000000964 - 003 4. Check relief bore for oil and coolant dis‐ charge.
7.17 Belt Drive 7.17.1 Drive belt – Condition check Preconditions ☑ Engine is stopped and starting disabled. ☑ Guard is removed.
7.18 Battery-Charging Generator 7.18.1 Battery-charging generator – Removal Preconditions ☑ Engine is stopped and starting disabled WARNING Heavy object. Risk of crushing! • Use appropriate lifting devices and appliances. Battery-charging generator – Removal 1. 2. 3. 4. 5. 6. 7. 8. TIM-ID: 0000007379 - 001 9. 10. Remove guard cover. Label and disconnect electrical cables on battery-charging generator. Protect all cables against damage. Undo nut (3).
7.18.2 Battery-charging generator – Check Preconditions ☑ Engine is stopped and starting disabled. WARNING Compressed air Risk of injury! • Do not direct compressed-air jet at persons. • Wear protective goggles / safety mask and ear protectors. Battery-charging generator check Item Diagnosis Task Ventilation area (arrow) Clean None Ventilation area (arrow) Dirty Clean Battery-charging generator cleaning Dry-clean battery-charging generator only.
7.18.3 Battery-charging generator drive – Drive belt tension adjustment Preconditions ☑ Engine is stopped and starting disabled. Adjusting belt tension 1. 2. TIM-ID: 0000000944 - 001 3. 4. 5. Loosen locknut (2) and screws (1). Tension drive belt with tensioning nut (3) and check belt tension (→ Page 123). Tighten locknut (2). Tighten screws (1). Install guard cover.
7.18.4 Battery-charging generator drive – Drive belt tension check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Belt tension tester Y4345711 1 Preparatory steps 1. 2. Remove guard cover. Check belt condition visually (→ Page 119). Checking drive belt tension 1. Fit measuring head (2) on belt-tension tester (3) and hit drive belt (1) with a suitable tool. 2.
7.18.5 Battery-charging generator drive – Drive belt replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Drive belt Note: Part No. Qty. (→ Spare Parts Catalog) In the event of drive belt failure during engine operation fit a new drive belt as quickly as possible. Non‐ compliance with these instructions may lead to severe consequential damage to drive unit and gear train, since pretension by the drive belt is no longer provided.
7.19 Fan Drive 7.19.1 Fan drive belt– Tension check / adjustment Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Optibell 2 belt tension tester Part No. Qty. Y4345711 1 Preparatory steps 1. 2. Result: Remove guard cover. Check belt condition visually (→ Page 119). If required, replace drive belt (→ Page 127). Checking Vee belt tension 1. 2. Switch on belt tension tester. Hold measuring tip of belt tension tester over belt drive.
Adjusting drive belt tension 1. 2. TIM-ID: 0000007438 - 001 3. Release screws (2) until fan coupling can be moved. Tighten stud (1) until the required frequency is achieved. Tighten screws (2) to 250 Nm ± 25 Nm.
7.19.2 Fan drive – Drive belt replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Drive belt Part No. Qty. (→ Spare Parts Catalog) Preparatory steps 1. 2. Remove protective cover. Remove fan. Replacing drive belt 1. 2. 3. 4. TIM-ID: 0000007457 - 003 5. Release screws (2). Slacken off stud (1) until drive belt can be removed. Clean belt pulleys. Fit new drive belt on belt pulleys, ensuring that it is not under tension.
7.20 Wiring (General) for Engine/Gearbox/Unit 7.20.1 Engine wiring – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol X00058037 1 Engine wiring – Check 1. 2. 3. 4. 5. 6. Close male connectors that are not plugged in with the protective cap supplied. Clean dirty connector housings, sockets and contacts with isopropyl alcohol. Ensure that all sensor connectors are securely engaged.
7.21 Accessories for (Electronic) Engine Governor / Control System 7.21.1 Engine control unit and connectors – Cleaning Preconditions ☑ Engine shut down and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Connector pliers 0135315483 1 Isopropyl alcohol 46181 1 Cleaning engine control unit and connectors 1. 2. 3. Remove heavy soiling from housing surface with isopropyl alcohol.
7.21.2 Engine governor plug-in connections – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Connector pliers 0135315483 1 Engine governor plug-in connections – Check 1. 2. 3. TIM-ID: 0000000949 - 002 4. Use connector pliers (3) to make certain that all plug-in connections on engine gov‐ ernor are securely seated.
8 Appendix A 8.
Abbreviation Meaning EGR Exhaust Gas Recirculation EMU Engine Monitoring Unit ETK Ersatzteilkatalog EUI Electronic Unit Injector FPS Fuel Pressure Sensor FRS Fuel - Differential Pressure Sensor FTS Fuel Temperature Sensor Monitors fuel temperature FWCP Fire Water Control Panel Control cabinet GND Ground HD Hochdruck High Pressure (HP) HI High Alarm: Measured value exceeds 1st maxi‐ mum limit HIHI High High Alarm: Measured value exceeds 2nd maxi‐ mum limit value HT High Temper
Abbreviation Meaning Explanation SAE Society of Automotive Engineers U.S.
8.2 MTU contacts/service partners Service Our worldwide sales network with its subsidiaries, sales offices, representatives and customer service centers ensures fast and direct support on site and the high availability of our products. Local support Experienced and qualified specialists place their knowledge and expertise at your disposal. For locally available support, go to the MTU internet site: http://www.mtu-online.
9 Appendix B 9.1 Special Tools Air filter Part No.: Qty.: Used in: 7.11.2 Air filter – Replacement (→ Page 92) Coolant filter Part No.: Qty.: Used in: 7.15.7 Coolant filter – Replacement (→ Page 112) Diaphragm Part No.: Qty.: Used in: 7.3.1 Crankcase breather – Oil separator replacement, diaphragm check and replace‐ ment (→ Page 63) Drive belt Part No.: Qty.: Used in: 7.18.5 Battery-charging generator drive – Drive belt replacement (→ Page 124) Qty.: Used in: 7.19.
Gasket Part No.: Qty.: Used in: 7.5.3 Cylinder head cover – Removal and installation (→ Page 76) Grounding device Part No.: Qty.: Used in: 7.4.2 Grounding device – Replacement (→ Page 69) Injector Part No.: Qty.: Used in: 7.7.1 Injector – Replacement (→ Page 78) O-ring Part No.: Qty.: Used in: 7.14.1 Automatic oil filter – Filter candles replacement (→ Page 98) Qty.: Used in: 7.14.2 Oil indicator filter – Check (→ Page 101) Oil filter candles Part No.: Qty.: Used in: 7.14.
Sealing ring Part No.: Qty.: Used in: 7.9.2 Edge-type fuel filter – Draining (→ Page 87) Qty.: Used in: 7.13.2 Engine oil – Change (→ Page 97) Qty.: Used in: 7.14.3 Centrifugal oil filter – Cleaning and filter-sleeve replacement (→ Page 103) Qty.: Used in: 7.14.3 Centrifugal oil filter – Cleaning and filter-sleeve replacement (→ Page 103) Qty.: Used in: 7.16.3 Charge-air coolant – Draining (→ Page 115) Qty.: Used in: 7.16.
9.
I Injector – Removal and installation 79 – Replacement 78 Inspection port cover – Explosion hazard 13 Instructions and comments on endoscopic and visual ex‐ amination of cylinder liners 61 Intercooler – Drain, coolant leakage 89 M Main engine dimensions 32 Maintenance and repair work – Safety requirements 14 MTU contact persons 134 O Oil indicator filter – Check 101 Operational checks 36 P Personnel and organizational requirements 8 Plant – Cleaning 39 Putting into operation – Preparation after extended out
