Operating Instructions Diesel engine 20V 4000 C22 M015675/06E
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Table of Contents 1 Safety 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 Important provisions for all products Personnel and organizational requirements Transport Crankshaft transport locking device – For transport with flanged-on generator Safety regulations for startup and operation Safety regulations for maintenance and repair work Fire prevention and environmental protection, consumable fluids and materials Standards for safety notices in the text 7.1.
7.13 Lube Oil System, Lube Oil Circuit 7.13.1 Checking engine oil level 7.13.2 Engine oil – Change 7.14 Oil Filtration / Cooling 7.14.1 Automatic oil filter – Oil filter candles replacement 7.14.2 Oil indicator filter – Cleaning and check 7.14.3 Cleaning centrifugal oil filter and replacing filter sleeve 7.15 Coolant Circuit, General, High-Temperature Circuit 7.15.1 7.15.2 7.15.3 7.15.4 7.15.
1 Safety 1.1 Important provisions for all products Nameplate The product is identified by nameplate, model designation or serial number and must match with the information on the title page of this manual. Nameplate, model designation or serial number can be found on the product.
1.2 Personnel and organizational requirements Organizational measures of the operator This manual must be issued to all personnel involved in operation, maintenance, repair or transportation. Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance, repair and transport personnel at all times.
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. The engine/genset must only be transported in installation position: maximum permissible diagonal pull 10°. Remove any loose parts on the genset. Raise the engine/genset slowly.
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 transport. 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 order 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 device 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 regulations for startup Install the product correctly and carry out acceptance in accordance the manufacturer's specifications before putting the product into service. Before the product is put into operation for the first time, all official authorizations must be available and commissioning preconditions met.
1.6 Safety regulations for maintenance and repair work Safety regulations prior to maintenance and repair work Have maintenance or repair work carried out by qualified and authorized personnel only. Allow the product to cool down to less than 50°C before starting maintenance work (risk of explosion of oil vapors, fluids and lubricants, risk of burning). Before starting work, relieve pressure in systems and compressed-air lines which are to be opened.
Ensure particular cleanness during maintenance and repair work on the product. After completion of maintenance and repair work, make sure that no loose objects are in/on the product (e.g. cloths and cable ties) Safety regulations after completion of maintenance and repair work Before barring, make sure that nobody is standing in the danger zone of the product.
Working on electrical and electronic assemblies Always obtain the permission of the person in charge before commencing maintenance and repair work or switching off any part of the electronic system required to do so. De-energize the appropriate areas prior to working on assemblies. Do not damage cabling during removal work. When reinstalling ensure that wiring is not damaged during operation by contact with sharp objects, by rubbing against other components or by a hot surface.
1.7 Fire prevention and environmental protection, consumable fluids and materials Fire prevention Rectify any fuel or oil leaks immediately. Oil or fuel on hot components can cause fires – therefore always keep the product in a clean condition. Do not leave cloths saturated with fluids and lubricants on the product. Do not store combustible materials near the product. Do not carry out welding work on pipes and components carrying oil or fuel. Before welding, clean with a nonflammable fluid.
Lead • Adopt suitable measures to avoid the formation of lead dust. • Switch on extraction system. • When working with lead or pastes that contain lead, avoid direct contact with the skin. Do not inhale lead vapors. • Wash hands after contact with lead or lead-containing substances. Compressed air Observe special safety precautions when working with compressed air: • Unauthorized use of compressed air, e.g.
1.8 Standards for safety notices in the text DANGER WARNING CAUTION NOTICE In the event of immediate danger. Consequences: Death, serious or permanent injury. • Remedial action In the event of a situation involving potential danger. Consequences: Death, serious or permanent injury. • Remedial action In the event of a situation involving potential danger. Consequences: Minor or moderate injuries. • Remedial action In the event of a situation involving potentially adverse effects on the product.
2 General Information 2.1 Engine side and cylinder designations Engine sides are always designated as viewed from the driving end (KS) (4). For designation of the cylinders (to DIN ISO 1204) the letter "A" (1) is used to refer to the cylinders on the left-hand side of the engine and the letter "B" (3) to refer to the cylinders on the right-hand side. The cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end. The numbering of other engine components also starts with no.
2.
5 6 7 8 Flywheel Charge-air coolant outlet Engine coolant inlet Oil pan 9 Oil dipstick 10 Oil filler neck 11 Starter (B side) TIM-ID: 0000002072 - 002 1 Engine lifting eye 2 Cylinder head cover / cylinder head 3 Oil heat exchanger 4 Intercooler M015675/06E 2013-04 | General Information | 19
1 Air supply downstream of intercooler (A side) 2 Exhaust system connection (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 connection (B side) 9 Air supply before intercooler (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, mobile
2.3 Sensors and actuators – 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 - 003 The injectors are underneath the cylinder head covers of the cylinder. Injector replacement and necessary activities (→ Page 77).
3 B10 (P-Charge Air) 4 B09 (T-Charge Air) 1 B44 (N-Turbocharger) 2 B03 (T-Intake Air) TIM-ID: 0000012921 - 003 1 Injectors Y39.11 to Y39.
TIM-ID: 0000012921 - 003 1 B13 (N-Crankshaft) 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.
Number of cylinders 20V 4000 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 starting), min. admissible L bar - 0.1 Fuel pressure at supply connection to engine (when engine is starting), max. admissible L bar 1.5 Fuel pressure before injection pump, from (H.P. pump) R bar 5.0 Fuel pressure before injection pump, to (H.P.
ACOUSTICS Number of cylinders 16 R db(A) 118 Engine surface noise with attenuated, BL, intake noise (filter) (free-field sound- R pressure level Lp, 1m distance, ISO 6798) db(A) 108 TIM-ID: 0000002640 - 001 Exhaust noise, unsilenced, BL, (free-field sound-pressure level Lp, 1m distance, ISO 6798) M015675/06E 2013-04 | Technical Data | 27
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-of-service 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) Action Engine Depreserve (→ MTU Fluids and Lubricants Specifications A001061/..). Valve gear Lubricate valve gear (→ Page 68). Lube oil system Check engine oil level (→ Page 94). Fuel system Vent (→ Page 83).
4.2 Putting the engine into operation after scheduled out-ofservice-period Preconditions ☑Engine is stopped and starting disabled. Startup Action Lube oil system Check engine oil level (→ Page 94). Coolant circuit Check engine coolant level (→ Page 103); Check charge-air coolant level (→ Page 111). Coolant circuit Preheat coolant with coolant preheating unit (if applicable). Engine control system Put into operation.
4.3 Engine – Starting in manual mode Preconditions ☑Engine is not under load. ☑External start interlock is not activated. DANGER WARNING Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in. • Before cranking the engine with starter system, make sure that there are no persons in the engine's danger zone. A high level of noise is produced when the engine is running. Risk of damage to hearing. • Wear ear defenders.
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 Task Code Control and display panels Check indicated operating parameters (speed, temperatures, pressures). Engine oil Check engine oil level (→ Page 94).
4.5 Engine – Stopping in manual mode Preconditions ☑Engine is not under load. ☑Engine is running in manual mode. NOTICE Stopping the engine when it is running at full load subjects it to extreme thermal and mechanical stresses. Overheating of and, therefore, damage to components is possible. • Before shutting down the engine, allow it to idle until the engine temperatures decrease and constant levels are indicated. Preparation Item Measure Engine Operate engine at idling speed for approx. 5 minutes.
4.6 After shutting down the engine Preconditions ☑MTU Corrosion-proofing and Reproofing Regulations (A001070/..) are available. After shutting down the engine Item Action Coolant system Drain coolant (→ Page 105), (→ Page 113), if: • freezing temperatures are expected and the engine is to remain out of service for an extended period, but engine coolant has no antifreeze additive; • coolant is not preheated; • antifreeze concentration is 50 % and outside temperature is below -40 °C. Switch off.
4.7 Cleaning the plant Preconditions ☑Engine shut down and secured against being restarted. ☑Power supply not connected. Special tools, Material, Spare parts Designation / Use Part No. Qty. Steam jet cleaner - 1 30390 1 Cleaning agent (Hakupur 312) WARNING WARNING NOTICE Compressed air gun ejects a jet of pressurized air. Risk of injury to eyes and damage to hearing, risk of rupturing internal organs. • Never direct air jet at people. • Always wear safety goggles/face mask and ear defenders.
5 Maintenance 5.1 Maintenance Schedule 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. TIM-ID: 0000033894 - 002 The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule. Task Measures W0500 Check engine oil level. (→ Page 94) W0501 Visually inspect engine for leaks and general condition.
6 Troubleshooting 6.1 Troubleshooting Engine does not turn over when starter is operated Component Cause Action Battery Discharged or defective Charge or replace (see manufacturer's documentation). Cable connections defective Check if cable connections are properly secured (see manufacturer's documentation). Starter Engine wiring or starter faulty Check if cable connections are properly secured, contact Service. Engine wiring Faulty Check (→ Page 128).
Engine speed not steady Component Cause Action Fuel injection system Injector defective Replace (→ Page 77). Speed sensor Defective Notify Service. Fuel system Air in fuel system Bleed fuel system (→ Page 83). Engine Control Unit Defective Notify Service. Charge air temperature too high Component Cause Action Engine coolant Incorrect coolant concentration Check (MTU test kit). Intercooler Dirty Notify Service.
Cause Action Drain water from fuel prefilter. Intercooler Leaking Notify 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 016 L2 P-LUBE OIL Lube-oil pressure too low (2nd limit) Automatic engine shutdown. Task 1. Check engine-oil level and top up, if required; (→ Page 94); 2. Try to re-start the engine (→ Page 32). 3. Contact Service. 023 L1 COOLANT LEVEL Coolant level too low. Alarm Check coolant level in expansion appears together with No. tank. 24. 024 L2 COOLANT LEVEL Coolant level too low. Alarm Check coolant level in expansion appears together with No. tank. 23.
Fault code Alarm text Meaning Task 065 L1 P-FUEL Fuel supply pressure too low (1st limit) 1. Check fuel lines for leaks; re- pair defective lines. 2. Clean fuel prefilter 3. Flush fuel prefilter 4. Replace filter element of fuel prefilter. 5. Fuel filter replacement (→ Page 84). 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; re- pair defective lines. 2. Clean fuel prefilter 3. Flush fuel prefilter 4.
Alarm text Meaning 090 IDLE SPEED LOW Idle speed not reached with- Note further alarms. in a specified period; Termination of starting procedure. 091 RUN UP SPEED LOW Run-up speed not reached within a specified period; Termination of starting procedure. Note further alarms. 092 START SPEED LOW Starter speed not reached within a specified period; Termination of starting procedure. Note further alarms. 093 PREHEAT TEMP.
Fault code Alarm text Meaning Task Automatic engine shutdown (depending on project design). 122 L1 T-ELECTRONIC Temperature in ECU housing too high (1st limit) 1. Improve engine room ventila- tion. 2. Reduce engine power. 134 15V POS ECU DEFECT Electronic equipment defec- Contact Service. tive; Automatic engine shutdown. 136 15V NEG ECU DEFECT Electronic equipment defec- Contact Service. tive; Automatic engine shutdown. 137 L1 5V BUFFER TEST Power supply for pressure sensors defective 1.
Fault code Alarm text Meaning 170 MI MODULE FAIL Module in maintenance pre- Contact Service. dictor either defective or missing. 171 MI NOT ACTIVE Maintenance predictor no more activated 173 MODULE WRITE LIMIT EEPROM write limit reached. Contact Service. 180 CAN1 NODE LOST At least one device not detected on Default CAN bus. 1. Check wiring (CAN bus). 2. Contact Service. 181 CAN2 NODE LOST At least one device not detected on Redundant CAN bus. 1. Check wiring (CAN bus). 2. Contact Service.
TIM-ID: 0000003161 - 001 Fault code Alarm text Meaning Task 215 SD P-RAIL FUEL Sensor defect (common rail pressure); HP controller in emergency mode. 1. Check wiring. 2. Contact Service. 216 SD T-LUBE OIL Sensor defect (lube oil temperature) 1. Check wiring. 2. Contact Service. 219 SD T-INTAKE AIR Sensor defect (intake-air temperature) 1. Check wiring. 2. Contact Service. 220 SD COOLANT LEVEL Sensor defect (coolant level) 1. Check wiring. 2. Contact Service.
Alarm text Meaning Task 310 TIMING CYLINDER A10 Injection timing fault cylinder A10 If fault occurs repeatedly: Contact Service. 311 TIMING CYLINDER B1 Injection timing fault cylinder B1 If fault occurs repeatedly: Contact Service. 312 TIMING CYLINDER B2 Injection timing fault cylinder B2 If fault occurs repeatedly: Contact Service. 313 TIMING CYLINDER B3 Injection timing fault cylinder B3 If fault occurs repeatedly: Contact Service.
TIM-ID: 0000003161 - 001 Fault code Alarm text Meaning Task 330 WIRING CYLINDER A10 Faulty wiring to solenoid valve cylinder A10; Misfiring 1. Check wiring 2. Contact Service: 331 WIRING CYLINDER B1 Faulty wiring to solenoid valve cylinder B1; Misfiring 1. Check wiring. 2. Contact Service. 332 WIRING CYLINDER B2 Faulty wiring to solenoid valve cylinder B2; Misfiring 1. Check wiring. 2. Contact Service. 333 WIRING CYLINDER B3 Faulty wiring to solenoid valve cylinder B3; Misfiring 1.
Fault code Alarm text Meaning 347 OPEN_LOAD CYL. A7 Disconnection in wiring to solenoid valve cylinder A7; Misfiring 1. Check wiring. 2. Contact Service. 348 OPEN_LOAD CYL. A8 Disconnection in wiring to solenoid valve cylinder A8; Misfiring 1. Check wiring. 2. Contact Service. 349 OPEN_LOAD CYL. A9 Disconnection in wiring to solenoid valve cylinder A9; Misfiring 1. Check wiring. 2. Contact Service. 350 OPEN_LOAD CYL. A10 Disconnection in wiring to solenoid valve cylinder A10; Misfiring 1.
Fault code Alarm text Meaning Task 364 STOP POWER STAGE 2 Solenoid valve or wiring or ECU defective Automatic engine shutdown. 1. Check wiring. 2. Try to re-start the engine (→ Page 32). 3. Contact Service. 365 STOP SOLENOID-WIR- Solenoid-valve wiring faulty; ING Automatic engine shutdown. 1. Check wiring. 2. Try to re-start the engine (→ Page 32). 3. Contact Service. TRAN.OUT1 PLANT DEF Binary transistor output plant 1 defective Contact Service. 382 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 gear F6555766 1 Barring gear F6783293 1 Adapter F6558528 1 Ratchet with extension F30006212 1 Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in.
Barring engine manually (tool mounted underneath) 1. 2. 3. 4. TIM-ID: 0000002521 - 006 5. Remove grounding device or guard plate. Engage barring gear (2) in ring gear (1) and mount on flywheel housing. • For 12/16V engines, use barring gear F6555766 with adapter F6558528. • For 20V engines, use barring gear F6783293. Fit ratchet (3) onto barring gear (2). Rotate crankshaft in normal direction of engine rotation; apart from the normal compression resistance, there should be no resistance.
7.1.2 Engine – Barring with starting system Special tools, Material, Spare parts Designation / Use Connector pliers DANGER Part No. Qty. 0135315483 1 Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in. • Before cranking the engine, make sure that there are no persons in the engine's danger zone. • After finishing work on the engine, make sure that all safety devices are put back in place and all tools removed from the engine.
7.2 Cylinder Liner 7.2.1 Endoscopically examining cylinder liner Preconditions ☑Engine shut down and secured against being restarted. Special tools, Material, Spare parts Designation / Use Part No. Qty. Cranking tool F6555766 1 Ratchet with extension F30006212 1 Endoscope Y20097353 1 Preparatory steps 1. 2. Remove cylinder head cover (→ Page 74). Remove injector (→ Page 78). Positioning crankshaft at BDC 1. 2.
1. 2. 3. Compile endoscopy report with the aid of the table. Use technical terms for description of the liner surface (→ Page 57). 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 Refit injector (→ Page 78). Install cylinder head cover (→ Page 74). TIM-ID: 0000003304 - 005 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 examination report. Findings Measure Light scoring Minor dirt scores can occur during the assembly of a new engine (honing products, particles, broken-off burrs). Removed cylinders clearly exhibit such scoring on the running surface under endoscope magnification.
Findings Measure Liners with heat discoloration starting in the TDC-ring 1 have to be replaced. Seizures, Seizure marks Seizure marks are of irregular circumferential length and depth. Can be caused by either the piston skirt or the piston crown. Material deposits on the liner (smears) show heavy discoloration and scoring. Replace liner. Evaluation of findings and further measures TIM-ID: 0000003285 - 003 The findings in the start phase of oxidation discoloration and heat discoloration are similar.
7.3 Crankcase Breather 7.3.1 Crankcase breather – Oil separator element 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, 6-50 Nm F30027336 1 Ratchet F30027340 1 Engine oil Filter element (→ Spare Parts Catalog) Diaphragm (→ Spare Parts Catalog) Gasket (→ Spare Parts Catalog) Hot oil. Oil can contain combustion residues which are harmful to health.
Checking diaphragm 1. 2. 3. 4. 5. 6. Remove cover (4). Remove spring (5), gasket (2) and diaphragm (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). Use torque wrench to tighten the screws of cover (4) to the specified torque. Name Screw Type Lubricant Value/Standard Tightening torque (Engine oil) 10 Nm −2 Nm Check diaphragms in further oil separators in the same way.
7.3.2 Crankcase breather – Cleaning Special tools, Material, Spare parts Designation / Use WARNING WARNING NOTICE Part No. Qty. Cleaner (Snow-White 11-0) 40460 1 Cleaner (Hakupur 312) 30390 1 Compressed air gun ejects a jet of pressurized air. Risk of injury to eyes and damage to hearing, risk of rupturing internal organs. • Never direct air jet at people. • Always wear safety goggles/face mask and ear defenders. Cleaner is extremely caustic.
7.3.3 Crankcase breather (open-circuit crankcase ventilation) – Filter element cleaning Preconditions ☑Engine is stopped and starting disabled. WARNING NOTICE Compressed air gun ejects a jet of pressurized air. Risk of injury to eyes and damage to hearing, risk of rupturing internal organs. • Never direct air jet at people. • Always wear safety goggles/face mask and ear defenders. Cleaning agents should not be left to take effect for too long. Damage to components is possible.
7.3.4 Crankcase breather – Filter element replacement Preconditions ☑Engine shut down and starting disabled. Special tools, Material, Spare parts Designation / Use Torque wrench, 10-60Nm Engine oil Filter insert WARNING Part No. Qty. F30452769 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. 8. Clean filter externally. Release vent hose on oil separator cover (1) and remove. Remove oil separator cover (1). Loosen clamp (5). Clean or replace filter element (2) (→ Page 61). Insert new sealing ring (3). Install cleaned or new filter element (2) with filter holder (5). Mount oil separator cover (1). 9. Tighten nut of clamp (4) with torque wrench to specified tightening torque. 3. 4. 5. 6. 7.
7.4 Running Gear 7.4.1 Grounding device – Carbon brush check Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Cold cleaner (Hakutex 60) 50602 Carbon brush WARNING NOTICE Qty. (→ Spare Parts Catalog) Compressed air gun ejects a jet of pressurized air. Risk of injury to eyes and damage to hearing, risk of rupturing internal organs. • Never direct air jet at people. • Always wear safety goggles/face mask and ear defenders.
Cleaning running surface on adapter 1. 2. 3. Clean running surface of carbon brushes on adapter with cold cleaner. Remove stubborn deposits with soft brush. Blow out adapter with compressed air. Installing grounding device Check mounting surface on flywheel housing for cleanness. Install grounding device on flywheel housing and secure with screws. TIM-ID: 0000033357 - 005 1. 2.
7.4.2 Grounding device – Carbon brush replacement Preconditions ☑Engine shut down and starting disabled. Special tools, Material, Spare parts Designation / Use Loctite 270 Carbon brush Part No. Qty. 40083 (→ Spare Parts Catalog) 2 Replace carbon brush 1. 2. 3. 4. 5. 6. 7. 8. 9. Apply Loctite 270 only to threads. Secure cable (6) with screw (5). TIM-ID: 0000033339 - 002 Note: 10. Loosen screw (5). Disconnect cable (6) from screw (5). Loosen screws (3). Remove screws (2).
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 Valve gear – Lubrication 1. 2. TIM-ID: 0000004337 - 004 3. Remove cylinder head covers (→ Page 74). Fill oil chambers of rocker arms and adjusting screws with oil. Install cylinder head covers (→ Page 74).
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 74).
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. 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. TIM-ID: 0000004355 - 001 5. 6. Not applicable for engines with flying valve bridge. Hold valve bridge (1) firmly in position with open-end spanner and release locknut (2).
7. 8. 9. Tighten locknut (2) to 35 Nm +5 Nm, holding valve bridge (1) in position with openend spanner. Check valve bridge balance again. Adjust valve-bridge balance at two crankshaft positions according to the following diagram. Checking valve clearance at two crankshaft positions 1. 2. 3. 4. TIM-ID: 0000004355 - 001 5. Check TDC position of piston in cylinder A1: • If the rocker arms are unloaded on cylinder A1, the piston is in firing TDC.
Adjusting valve clearance 1. 2. 3. 4. 5. 6. 7. Release locknut (1). Insert feeler gauge between valve bridge and rocker arm. Using Allen key, set adjusting screw (2) so that the specified valve clearance is provided. Feeler gauge must just pass through the gap. Tighten locknut (1) to 90 +9 Nm, holding adjusting screw (2) firm. Replace or rectify adjusting screws and/or locknuts which do not move freely. Check valve clearance. Final steps Remove barring tool (→ Page 52).
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 very dirty cylinder head covers prior to removal. Remove screws. Remove cylinder head cover with gasket from cylinder head. Installing cylinder head cover Clean mating face. Check condition of gasket, replace if necessary.
7.6 Injection Pump / HP Pump 7.6.1 HP pump – Filling with engine oil Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil WARNING WARNING NOTICE Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Oils/oil vapors are combustible/explosive. Risk of fire and explosion! • Avoid open flames, electric sparks and ignition sources. • Do not smoke.
7.6.2 DANGER WARNING HP pump – Relief bore check Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in. • Only run the engine at low power. Keep away from the engine's danger zone. A high level of noise is produced when the engine is running. Risk of damage to hearing. • Wear ear defenders. HP pump – Relief bore check 1. 2. TIM-ID: 0000000924 - 007 3. Check relief bore for oil and fuel discharge by visual inspection.
7.7 Injection Valve / Injector 7.7.1 Injector – Replacement Special tools, Material, Spare parts Designation / Use Part No. Injector Qty. (→ Spare Parts Catalog) Replacing injector Remove injector and install new injector (→ Page 78).
7.7.2 Injector – Removal and installation Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty.
Remove 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 device on the cylinder head. Remove injector with installation/removal device. Remove the installation/removal device. TIM-ID: 0000000952 - 010 6. Always replace the first and last injectors of one engine side first. Replace the inner injectors only after the installation of the outer injectors on this engine side is completed.
7. 8. 9. Remove sealing ring (1) from injector or use a self-made hook to take it out of the cylinder head. Remove O-rings (2) from injector. Cover all connections and installation bores, or seal with suitable plugs. Install injector 1. 2. 3. 4. 5. 6. 7. Clean sealing face on cylinder head and protective sleeve with milling cutter. Insert injector into cylinder head, making sure that the HP line connections are aligned correctly. Push in the injector using the installation/ removal device.
9. 10. Use slotted screwdriver to check thrust ring at both line ends for secure seating. Tighten loose thrust ring to the specified tightening torque. Name Size TIM-ID: 0000000952 - 010 Thrust ring Type Lubricant Tightening torque Value/Standard 5 Nm to 10 Nm 11. Coat screw head mating face (2) and thread with engine oil. 12. Fit hold-down clamp (1) in correct position by hand. Tighten screw (2) with torque wrench to the specified initial tightening torque.
16. Tighten union nut of adapter (limiting valve) with torque wrench to the specified tightening torque. Name Size Union nut 17. Type Lubricant Tightening torque Value/Standard 140 Nm + 10 Nm Tighten union nut of adapter (injector) with torque wrench to the specified tightening torque. Name Size Union nut Type Lubricant Tightening torque Value/Standard 120 Nm +10 Nm 18. Twist cable several times. 19.
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. TIM-ID: 0000004709 - 006 4. 5. 6. Open vent plug (1). Unlock fuel priming pump (2), screw out handle by turning it counterclockwise.
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. Fuel filter – Replacement 1. 2. 3. 4. 5. TIM-ID: 0000000927 - 006 6.
7.9.2 Draining fuel prefilter Preconditions ☑Engine shut down and secured against being restarted. 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 - 003 5. 6. 7. 8. Shut off the filter unit (5/8) to be changed at valves (3) and (4) or (9) and (10).
7.9.3 Edge-type fuel filter – Draining Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Diesel fuel Sealing ring WARNING Part No. 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.
7.9.4 Auxiliary fuel filter – Replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. F30379104 1 (→ Spare Parts Catalog) 2 Filter wrench Engine oil Easy-change filter WARNING NOTICE Fuels are flammable and explosive. Danger to life! Risk of burns! • Avoid naked flames, electrical sparks and ignition sources. • Do not smoke. • Wear protective clothing, protective gloves, and goggles / safety mask.
7.10 Charge-Air Cooling 7.10.1 DANGER WARNING WARNING Intercooler – Check water drain for coolant leakage and absence of restrictions Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in. • Only run the engine at low power. Keep away from the engine's danger zone. A high level of noise is produced when the engine is running. Risk of damage to hearing. • Wear ear defenders. Compressed air gun ejects a jet of pressurized air.
7.11 Air Filter 7.11.1 Air filter element and dust bowl (optional) – Cleaning Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Gasket WARNING Part No. Qty. (→ Spare Parts Catalog) Compressed air gun ejects a jet of pressurized air. Risk of injury to eyes and damage to hearing, risk of rupturing internal organs. • Never direct air jet at people. • Always wear safety goggles/face mask and ear defenders. Clean air filter element Note: 1. 2.
7.11.2 Air filter – Replacement Special tools, Material, Spare parts Designation / Use Air filter Part No. Qty. (→ Spare Parts Catalog) Air filter – Replacement Remove air filter and install new one (→ Page 91). Reset signal ring of service indicator (→ Page 92). TIM-ID: 0000000903 - 004 1. 2.
7.11.3 Air filter element – Removal and installation (optional) Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Gasket Part No. Qty. (→ Spare Parts Catalog) Removing and installing air filter element 1. 2. 3. 4. 5. 6. 7. 8. TIM-ID: 0000005455 - 003 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 (optional) Preconditions ☑Engine is stopped and starting disabled. Checking signal ring position 1. 2. TIM-ID: 0000005484 - 008 Result: If the signal ring is completely visible in the control window (2), replace air filter (→ Page 90). 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 - 017 1. 2.
7.13 Lube Oil System, Lube Oil Circuit 7.13.1 Checking engine oil level Checking oil level before starting engine 1. 2. Note: 3. 4. 5. Withdraw oil dipstick from guide tube and wipe it clean. Insert dipstick into guide tube and push fully home, 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 – Oil filter candles replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Grease (Kluthe Hakuform 30-10/Emulgier) WARNING NOTICE Part No. 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.
3. 4. Withdraw oil filter element (1). Remove O-ring. 5. 6. 7. 8. 9. 10. Remove screw (2). Withdraw plastic spinner (1) with spring. Remove nut (3). Take off spring washer and washer. Remove screw (4). Remove flushing arm (5) from screen plate (6). 11. Turn filter element by 180° and use appropriate tool to push out filter candles (1). Turn filter insert by 180° and insert new filter candles (1) with chamfer facing downwards. TIM-ID: 0000006401 - 006 12.
Installing oil filter candles For installation follow reverse sequence of working steps. Additionally, the following instructions are to be observed: • Replace all sealing elements. • Coat O-rings with grease. • Insert O-rings in grooves. • Observe position of cylinder screw to elongated hole on shaft. TIM-ID: 0000006401 - 006 1. 2.
7.14.2 Oil indicator filter – Cleaning and check Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use WARNING WARNING NOTICE Part No. Qty. Cleaner (Snow-White 11-0) 40460 1 Cleaner (Hakupur 312) 30390 1 Engine oil Strainer (→ Spare Parts Catalog) Square-section ring (→ Spare Parts Catalog) O-ring (→ Spare Parts Catalog) Hot oil. Oil can contain combustion residues which are harmful to health.
Checking strainer Item Findings Measure Strainer Metallic residues • • • • Strainer Damaged Fit new part Square-section ring Damaged Fit new part O-ring Damaged Fit new part 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.
7.14.3 Cleaning centrifugal oil filter and replacing filter sleeve Preconditions ☑Engine shut down and secured against being restarted. Special tools, Material, Spare parts Designation / Use WARNING Qty. Torque wrench, 6 to 50 Nm F30027336 1 Cold cleaner (Hakutex 60) X00056750 1 Filter sleeve (→ Spare Parts Catalog) Sealing ring (→ Spare Parts Catalog) Hot oil. Oil can contain combustion residues which are harmful to health.
Cleaning centrifugal oil filter and replacing filter sleeve 15. Remove clamp (14). Undo cover screw (2) and take off cover (1). Carefully lift rotor (11), allow oil to drain and remove from housing. Holding the rotor (11) firmly, release rotor cover nut (3). Take off rotor cover (4). Remove filter sleeve (6). Measure thickness of oil residues on filter sleeve (6). If the oil residues exceed the maximum layer thickness of 45 mm, shorten the service interval.
7.15 Coolant Circuit, General, High-Temperature Circuit 7.15.1 Engine 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 engine coolant level at filler neck: 1. 2. 3.
7.15.2 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change Drain engine coolant (→ Page 105). Fill with engine coolant (→ Page 106). TIM-ID: 0000000036 - 031 1. 2.
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 a suitable receptacle to catch the coolant. Switch off preheating unit. Engine coolant – Draining 1. 2. 3. 4.
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 NOTICE 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 with coolant using a 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 engine at 0.5 bar minimum. Fill expansion tank until overflow edge is reached. Close drain valve. Check proper condition of breather valve and clean sealing faces if required. Place breather valve on filler neck and close. Start engine (→ Page 32). After 10 seconds of running the engine without load, shut down the engine (→ Page 34).
7.15.5 DANGER WARNING Engine coolant pump – Checking pressure relief port Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in. • Only run the engine at low power. Keep away from the engine's danger zone. A high level of noise is produced when the engine is running. Risk of damage to hearing. • Wear ear defenders. Engine coolant pump – Checking pressure relief port 1. 2. 3. TIM-ID: 0000000961 - 010 4.
7.15.6 Engine 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 Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in. • Only run the engine at low power. Keep away from the engine's danger zone. Coolant is hot and under pressure.
7.15.7 Engine 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. Engine coolant filter – Replacement 1. 2. 3. 4. 5. TIM-ID: 0000006858 - 009 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. Coolant Charge-air coolant – Change Drain charge-air coolant (→ Page 113). Fill with charge-air coolant (→ Page 114). TIM-ID: 0000000041 - 011 1. 2.
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 – Checking pressure relief port Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in. • Only run the engine at low power. Keep away from the engine's danger zone. A high level of noise is produced when the engine is running. Risk of damage to hearing. • Wear ear defenders. Charge-air coolant pump – Checking pressure relief port 1. 2. 3. TIM-ID: 0000000964 - 005 4.
7.17 Engine Mounting / Support 7.17.1 Engine mounting – Check Engine mounting – Check Item Findings Visually inspect mounts. • • • • • Action Replace (contact Service).
7.18 Belt Drive 7.18.1 Drive belt – Check condition Preconditions ☑Engine is stopped and starting disabled.
7.19 Battery-Charging Generator 7.19.1 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).
7.19.2 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. Remove thick dirt from battery-charging generator.
7.19.3 Generator – Cleaning Special tools, Material, Spare parts Designation / Use WARNING WARNING NOTICE Part No. Qty. Cleaner (Snow-White 11-0) 40460 1 Cleaner (Hakupur 312) 30390 1 Compressed air gun ejects a jet of pressurized air. Risk of injury to eyes and damage to hearing, risk of rupturing internal organs. • Never direct air jet at people. • Always wear safety goggles/face mask and ear defenders. Cleaner is extremely caustic.
7.19.4 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.
7.19.5 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 118). Checking drive belt tension 1. Fit measuring head (2) on belt-tension tester (3) and hit drive belt (1) with a suitable tool. 2.
7.19.6 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. Noncompliance 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.
7.20 Fan Drive 7.20.1 Fan drive – 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 protective cover. Check belt condition visually (→ Page 118). For drive belt replacement (→ Page 127). Checking V-belt tension – Rockford S270 fan clutch 1. 2.
Checking V-belt tension – Rockford S370 fan clutch 1. 2. Switch on belt tension tester. Hold measuring tip of belt tension tester over belt drive. Tap drive belt (arrow) with a suitable tool. 3. Hold belt tension tester over belt drive until the measured value is indicated. Initial assembly at MTU Initial operation with fan Re-tensioning 36 Hz ±5 Hz 49 Hz ±2 Hz 44 Hz ±2 Hz Adjusting drive belt tension 2. 3. 4. Release screws (2) until fan clutch can be moved.
7.20.2 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 - 004 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.
7.21 Wiring (General) for Engine/Gearbox/Unit 7.21.1 Engine wiring – Check Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Isopropyl alcohol Part No. Qty. X00058037 1 Checking engine wiring 1. 2. 3. 4. 5. Result: Close male connectors that are not plugged in with the protective cap supplied. Clean dirty connector housings, sockets and contacts using isopropyl alcohol. Ensure that all sensor connectors are securely engaged.
7.22 Accessories for (Electronic) Engine Governor / Control System 7.22.1 Engine governor and connectors – Cleaning Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Connector pliers F30017884 1 Isopropyl alcohol X00058037 1 Engine governor and connectors – Cleaning 1. 2. 3. Remove coarse dirt from housing surface with isopropyl alcohol.
7.22.2 Checking engine control unit plug connections Preconditions ☑Engine shut down and starting disabled. Special tools, Material, Spare parts Designation / Use Connector pliers Part No. Qty. 0135315483 1 Checking engine control unit plug connections 1. 2. 3. TIM-ID: 0000000949 - 003 4. Use connector pliers (3) to make certain that all plug-in connections on engine control unit are securely seated.
8 Appendix A TIM-ID: 0000000858 - 011 8.
Abbre- Meaning viation Explanation EDM Engine Data Module Memory module for engine data EEPROM Electrically Erasable Programmable Read Only Memory Electrically Erasable Programmable Read Only Memory EFPA Electronic Foot Pedal Assembly Electronic Foot Pedal Assembly EGR Exhaust Gas Recirculation Exhaust gas recirculation EIL Engine Ident Label EMU Engine Monitoring Unit Engine monitoring unit ESCM Extreme Site Condition Management Power reduction in the case of extreme site conditions E
TIM-ID: 0000000858 - 011 Abbre- Meaning viation Explanation NN Normal Null Reference surface for height above sea level NT Niedertemperatur OEM Original Equipment Manufacturer OI Optimized Idle OLS Oil Level Sensor Monitors oil level OPS Oil pressure sensor Monitors oil pressure OTS Oil Temperature Sensor Monitors oil temperature OT Oberer Totpunkt Top Dead Center PAN Panel Control panel PIM Peripheral Interface Module Peripheral interface module PWM Pulse Width Modulation Mo
8.2 MTU contact persons/service partners 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 Adapter Part No.: F6558528 Qty.: Used in: 1 7.1.1 Engine – Barring manually (→ Page 52) Part No.: F30002817 Qty.: Used in: 1 7.5.2 Valve clearance – Check and adjustment (→ Page 69) Part No.: F6555766 Qty.: Used in: 1 7.1.
Barring gear Part No.: F6783293 Qty.: Used in: 1 7.1.1 Engine – Barring manually (→ Page 52) Part No.: Y4345711 Qty.: Used in: 1 7.19.5 Battery-charging generator drive – Drive belt tension check (→ Page 123) Part No.: 0135315483 Qty.: Used in: 1 7.1.2 Engine – Barring with starting system (→ Page 54) Qty.: Used in: 1 7.22.2 Checking engine control unit plug connections (→ Page 130) Part No.: F30017884 Qty.: Used in: 1 7.22.
Cranking tool Part No.: F6555766 Qty.: Used in: 1 7.2.1 Endoscopically examining cylinder liner (→ Page 55) Part No.: Y20097353 Qty.: Used in: 1 7.2.1 Endoscopically examining cylinder liner (→ Page 55) Part No.: Y20010128 Qty.: Used in: 1 7.5.2 Valve clearance – Check and adjustment (→ Page 69) Part No.: F30379104 Qty.: Used in: 1 7.9.1 Fuel filter – Replacement (→ Page 84) Qty.: Used in: 1 7.9.4 Auxiliary fuel filter – Replacement (→ Page 87) Qty.: Used in: 1 7.15.
Installation and removal tool for injector Part No.: F6790161 Qty.: Used in: 1 7.7.2 Injector – Removal and installation (→ Page 78) Part No.: F30452739 Qty.: Used in: 1 7.7.2 Injector – Removal and installation (→ Page 78) Part No.: 5605892099/00 Qty.: Used in: 1 7.15.6 Engine coolant – Sample extraction and analysis (→ Page 109) Milling cutter MTU test kit Optibell 2 belt tension tester Y4345711 Qty.: Used in: 1 7.20.
Ratchet Part No.: F30027340 Qty.: Used in: 1 7.3.1 Crankcase breather – Oil separator element replacement, diaphragm check and replacement (→ Page 59) Part No.: F30006212 Qty.: Used in: 1 7.1.1 Engine – Barring manually (→ Page 52) Qty.: Used in: 1 7.2.1 Endoscopically examining cylinder liner (→ Page 55) Part No.: F30452578 Qty.: Used in: 1 7.7.2 Injector – Removal and installation (→ Page 78) Part No.: F30039526 Qty.: Used in: 1 7.5.
Socket wrench Part No.: F30039518 Qty.: Used in: 1 7.5.2 Valve clearance – Check and adjustment (→ Page 69) Part No.: - Qty.: Used in: 1 4.7 Cleaning the plant (→ Page 36) Part No.: F30510423 Qty.: Used in: 1 7.5.2 Valve clearance – Check and adjustment (→ Page 69) Part No.: F30047446 Qty.: Used in: 1 7.5.
Torque wrench, 10-60Nm Part No.: F30452769 Qty.: Used in: 1 7.3.4 Crankcase breather – Filter element replacement (→ Page 63) Part No.: F30452769 Qty.: Used in: 1 7.7.2 Injector – Removal and installation (→ Page 78) Part No.: F30044239 Qty.: Used in: 1 7.7.2 Injector – Removal and installation (→ Page 78) Part No.: F30027336 Qty.: Used in: 1 7.14.
Torque wrench, 6-50 Nm Part No.: F30027336 Qty.: Used in: 1 7.3.1 Crankcase breather – Oil separator element replacement, diaphragm check and replacement (→ Page 59) Part No.: F30452768 Qty.: Used in: 1 7.7.
9.
Fuel filter – Replacing 84 Fuel prefilter – Draining 85 Fuel system – Venting 83 Safety regulations – Consumables 14 – Fire prevention 14 – Fluids and lubricants 14 – Important provisions 5 – Maintenance work 11 – Operation 10 – Organizational requirements 6 – Personnel requirements 6 – Repair work 11 – Safety notices, standards 16 – Startup 10 Sensors and actuators – Overview 21 Service indicator – Signal ring position check 92 Service partners 134 Spare parts service 134 Starter – Condition check 93 Syst
