Operating Instructions Diesel engine 12 V 4000 C13, C13R, C13L 12 V 4000 C23, C23R 16 V 4000 C13, C13R, C13L 16 V 4000 C23, C23R M015695/03E
Printed in Germany © 2013 Copyright MTU Friedrichshafen GmbH This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, microfilming and storage or processing on electronic systems including data bases and online services.
Table of Contents 1 Safety 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.
7.12.1 Starter – Condition check 109 7.13 Lube Oil System, Lube Oil Circuit 110 7.13.1 7.13.2 7.13.3 7.13.4 Checking engine oil level Checking engine oil level Engine oil – Change Engine oil – Sample extraction and analysis 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 Centrifugal oil filter – Cleaning and filtersleeve replacement 7.15 Coolant Circuit, General, High-Temperature Circuit 7.15.1 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 Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10-60 Nm F30452769 1 Torque wrench, 60-320 Nm F30452768 1 Engine oil Transport locking device Note: The locking device on both ends protects the crankshaft bearings from shocks and vibration damage during engine transport. For installation and removal of the transport locking device, follow the instructions below: 1. 2. 3. 4. 5. 6.
2. 3. Screw locknut (2) onto screw (1) up to the end of the thread. The long end of holder (3) must face downwards. Push holder (3) through the plate openings (6). Note: 4. The holders (3) must lock the flywheel only, not the ring gear. Install screw (1) into the bore of holder (1) until the holder (1) is locked in position. Note: 5. Tighten screw (1) alternately on both sides of the flywheel housing. Tighten screw (1) alternately to specified tightening torque. 6.
1.5 Crankshaft transportation lock – For transport with flangemounted generator Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10-60 Nm F30452769 1 Ratchet F30027340 1 Engine oil Transportation lock Note: The transportation lock on the engine protects the crankshaft bearings from potential damage caused by shocks and vibration when transporting the genset. For installation and removal of the transportation lock, follow the instructions below: 1. 2. 3.
3. Turn crankshaft to bring cylinder A1 to TDC position. 4. Check the threads on both sides of the flywheel (1) for ease of movement. Fit retainer (2) together with screw (4) and washer (3) through the opening in the flywheel housing (5). 5. Tighten screw (4) in three steps. Tighten screw (4) on each side alternately to specified tightening torque. Name Size Type Lubricant Value/Standard Screw M10 Tightening torque (Engine oil) 50 Nm +5 Nm TIM-ID: 0000040647 - 002 Note: 6.
1.6 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.
1.7 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.
1.8 Fire prevention and environmental protection, fluids and lubricants, auxiliary 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 soaking 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 lead-containing compounds, avoid direct contact to the skin and 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.
1.9 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). 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. Other components are numbered in the same way, i.e. starting with No. 1 on driving end.
2.
2.3 Sensors and actuators – Overview Illustration also applies to 16V 4000 Cx3 engines 1 B07 (lube oil temperature) 2 Sensors for cylinder exhaust temperature B4.1 through B4.8 (A-bank) (optional only for 16 V) 3 Injectors Y39.1 to Y39.6 (A-bank) 4 ADEC (ECU 7) 5 B34 (fuel pressure after filter) 6 B48 (fuel pressure in common rail) 7 M8 (HP fuel pump actuator) TIM-ID: 0000012925 - 002 The injectors are underneath the cylinder head covers of the cylinder.
4 B33 (fuel temperature in common rail) 5 B01 (camshaft speed) 6 B48 (fuel pressure in common rail) 7 B43 (charge-air coolant pressure) 8 B26 (charge-air coolant temperature) 9 B06 (engine coolant temperature) TIM-ID: 0000012925 - 002 1 B50 (crankcase pressure) 2 B05.
1 Injectors Y39.11 to Y39.16 (B-bank) 2 Sensors for cylinder exhaust temperature B4.11 through B4.18 (B-bank) (optional only for 16 V) 3 B44 (turbocharger speed) 4 B03 (intake air temperature) 5 B16 (coolant pressure) 6 B10 (charge-air pressure) 7 B09 (charge-air temperature) TIM-ID: 0000012925 - 002 The injectors are underneath the cylinder head covers of the cylinder. Injector replacement and necessary activities (→ Page 97).
TIM-ID: 0000012925 - 002 1 B13 (crankshaft speed) 24 | General Information | M015695/03E 2013-03
3 Technical Data 3.1 12/16 V 4000 C13/13R/13L engine data: Application group 5A, optimized fuel consumption Explanation: DL BL A G R L N X Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated, without change (e.g.
GENERAL CONDITIONS (for maximum power) Number of cylinders 12V 12V 12V 16V 16V 16V Intake depression A (new filter) mbar 30 30 30 30 30 30 Intake depression, max. L mbar 50 50 50 50 50 50 Exhaust overpres- A sure mbar 65 65 65 65 65 65 Exhaust overpres- L sure, max.
COMBUSTION AIR / EXHAUST GAS Number of cylinders Charge-air pressure before cylinder R Exhaust tempera- R ture after turbocharger 12V 12V 12V 16V 16V 16V bar abs 2.2 2.4 2.5 2.3 2.5 2.6 2.7 2.
Number of cylinders 12V 12V 12V 16V 16V 16V Coolant antifreeze L content, max. % 50 50 50 50 50 50 Charge-air temperature after intercooler, max.
FUEL SYSTEM Number of cylinders 12V 12V 12V 16V 16V 16V Fuel pressure at engine inlet connection, min. (when engine is starting) L bar -0.1 -0.1 -0.1 -0.1 -0.1 -0.1 Fuel pressure at engine inlet connection, min. (when engine is running) L bar -0.3 -0.3 -0.3 -0.3 -0.3 -0.3 Fuel pressure at engine inlet connection, max. (when engine is starting) L bar 1.5 1.5 1.5 1.5 1.5 1.
CAPACITIES Number of cylinders 12V 12V 12V 16V 16V 16V Engine coolant, R engine side (without cooling equipment) Liters 212 212 212 260 260 260 Charge-air coolant, engine side R Liters 47 47 47 50 50 50 Engine oil on initial filling (standard oil system) (option: max. operating inclinations) R Liters 245 245 245 300 300 300 Oil pan capacity L at dipstick mark “min.” (standard oil system) (option: max.
Number of cylinders 12V 12V 12V 16V 16V 16V dB(A) 103 104 105 105 108 108 Engine surface R noise with attenuated intake noise (filter), BL (sound power level LW, ISO 6798) dB(A) 121 123 123 124 127 127 TIM-ID: 0000002875 - 002 Engine surface R noise with attenuated intake noise (filter), BL, (freefield sound-pressure level Lp, 1m distance, ISO 6798) M015695/03E 2013-03 | Technical Data | 31
3.2 12/16 V 4000 C13/13R/13L engine data: Application group 5A, optimized exhaust emissions (EPA Stage 2) Explanation: DL BL A G R L N X Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated, without change (e.g.
Number of cylinders 12V 12V 12V 16V 16V 16V Exhaust overpres- L sure, max. mbar 85 85 85 85 85 85 Fuel temperature at engine inlet connection R °C 25 25 25 25 25 25 Fuel temperature at engine inlet connection, max (w/o power reduction) L °C 60 60 60 60 60 60 12V 12V 12V 16V 16V 16V 0.3 0.3 0.3 0.3 0.3 0.
COMBUSTION AIR / EXHAUST GAS Number of cylinders Charge-air pressure before cylinder R Exhaust tempera- R ture after turbocharger 12V 12V 12V 16V 16V 16V bar abs 2.4 2.6 2.8 2.6 2.9 3.0 3.
Number of cylinders 12V 12V 12V 16V 16V 16V Coolant antifreeze L content, max. % 50 50 50 50 50 50 Charge-air temperature after intercooler, max.
FUEL SYSTEM Number of cylinders 12V 12V 12V 16V 16V 16V Fuel pressure at engine inlet connection, min. (when engine is starting) L bar -0.1 -0.1 -0.1 -0.1 -0.1 -0.1 Fuel pressure at engine inlet connection, min. (when engine is running) L bar -0.3 -0.3 -0.3 -0.3 -0.3 -0.3 Fuel pressure at engine inlet connection, max. (when engine is starting) L bar 1.5 1.5 1.5 1.5 1.5 1.
CAPACITIES Number of cylinders 12V 12V 12V 16V 16V 16V Engine coolant, R engine side (without cooling equipment) Liters 212 212 212 260 260 260 Charge-air coolant, engine side R Liters 47 47 47 50 50 50 Engine oil on initial filling (standard oil system) (option: max. operating inclinations) R Liters 245 245 245 300 300 300 Oil pan capacity L at dipstick mark “min.” (standard oil system) (option: max.
Number of cylinders 12V 12V 12V 16V 16V 16V dB(A) 103 105 106 107 106 109 Engine surface R noise with attenuated intake noise (filter), BL (sound power level LW, ISO 6798) dB(A) 122 124 124 126 125 127 TIM-ID: 0000002924 - 002 Engine surface R noise with attenuated intake noise (filter), BL, (freefield sound-pressure level Lp, 1m distance, ISO 6798) 38 | Technical Data | M015695/03E 2013-03
3.3 12/16 V 4000 C23/23R engine data: Application group 5B, optimized fuel consumption Explanation: DL BL A G R L N X Ref. value: Continuous power Ref. value: Fuel stop power 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 Number of cylinders 12V 12V 16V 16V 12 12 16 16 90 90 90 90 Cylinder arrangement: V angle degrees Bore mm 170 170 170 170 Stroke mm 210 210 210 210 Cylinder displacement Liters 4.77 4.77 4.77 4.77 Total displacement Liters 57.2 57.2 76.3 76.
LUBE OIL SYSTEM Number of cylinders 12V 12V 16V 16V Lube oil operating temperature before en- R gine, from °C 92 92 92 92 Lube oil operating temperature before en- R gine, to °C 95 95 95 95 Lube oil temperature before engine, alarm R °C 97 97 97 97 Lube oil temperature before engine, shutdown L °C 99 99 99 99 Lube oil operating pressure before engine (measurement block) R bar 6.4 6.4 5.0 5.0 Lube oil operating pressure (low idle) (meas. point: before engine) R bar 2.
Number of cylinders 12V 12V 16V 16V Oil pan capacity at dipstick mark “min.” L (standard oil system) (option: max. operating inclinations) Liters 150 150 210 210 Oil pan capacity at dipstick mark “max.” L (standard oil system) (option: max.
3.4 12/16 V 4000 C23/23R engine data: Application group 5B, optimized exhaust emissions (EPA Stage 2) Explanation: DL BL A G R L N X Ref. value: Continuous power Ref. value: Fuel stop power 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 Number of cylinders 12V 12V 16V 16V 12 12 16 16 90 90 90 90 Cylinder arrangement: V angle degrees Bore mm 170 170 170 170 Stroke mm 210 210 210 210 Cylinder displacement Liters 4.77 4.77 4.77 4.77 Total displacement Liters 57.2 57.2 76.3 76.
LUBE OIL SYSTEM Number of cylinders 12V 12V 16V 16V Lube oil operating temperature before en- R gine, from °C 92 92 92 92 Lube oil operating temperature before en- R gine, to °C 95 96 95 96 95 95 Lube oil temperature before engine, alarm R °C 97 98 97 98 97 97 Lube oil temperature before engine, shutdown L °C 99 100 99 100 99 99 Lube oil operating pressure before engine (measurement block) R bar 6.4 6.2 6.4 6.9 5.0 5.0 Lube oil operating pressure (low idle) (meas.
CAPACITIES Number of cylinders 12V 12V 16V 16V Engine coolant, engine side (without cooling equipment) R Liters 212 212 260 260 Charge-air coolant, engine side R Liters 47 47 50 50 Engine oil on initial filling (standard oil sys- R tem) (option: max. operating inclinations) Liters 245 245 300 300 Oil pan capacity at dipstick mark “min.” L (standard oil system) (option: max. operating inclinations) Liters 150 150 210 210 Oil pan capacity at dipstick mark “max.
3.
3.6 Main engine dimensions Main engine dimensions approx. 2810 mm Length (A) 16V approx. 3280 mm Width (B) 12V, 16V approx. 1585 mm Height (C) 12V, 16V approx.
4 Operation 4.1 Preparations for recommissioning the engine after extended out-of-service periods (>3 months) Preconditions ☑Engine shut down and secured against being restarted. ☑MTU Corrosion-proofing and Reproofing Regulations (A001070/..) are available. Recommissioning after long out-of-service periods (>3 months) Action Engine Remove corrosion-proofing (→ MTU Corrosion-proofing and Reproofing Regulations A001070/..). Valve gear Lubricate valve gear every ≥ 6 months (→ Page 90).
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 110). Coolant circuit Check engine coolant level (→ Page 122); Check charge-air coolant level (→ Page 132). Coolant circuit Preheat coolant with coolant preheating unit (if applicable). Engine control system Put into operation.
4.3 Starting the engine in manual mode Preconditions ☑Engine is not under 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 Action Operating mode switch (if applicable) Switch to manual mode.
4.4 Stopping the engine in manual mode Preconditions ☑Engine is not under load. ☑Engine is running 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 Action Engine Operate engine at idling speed for approx. 5 minutes.
4.5 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 124), (→ Page 134), 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.
4.6 Plant cleaning Preconditions ☑Engine is stopped and starting disabled. ☑Operating voltage is not present. Special tools, Material, Spare parts Designation / Use Part No. Qty. Steam jet cleaner - 1 30390 1 Cleaner (Hakupur 312) WARNING WARNING CAUTION NOTICE 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. The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule. Task Maintenance tasks W0500 Check oil level with dipstick. Check oil level at sight glass. (→ Page 110) (→ Page 111) 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 149).
Engine speed not steady Component Cause Action Fuel injection system Injector defective Replace (→ Page 97). Speed sensor Defective Notify Service. Fuel system Air in fuel system Bleed fuel system (→ Page 103). 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 Fault messages of the engine governor ADEC (ECU 7) for series 4000 C&I engines The fault code numbers are generated by the Engine Control Unit an transmitted to the display. The fault code (1) comprises three digits. Fault messages can also be caused by faulty sensors/actuators. Contact Service to have sensors/ actuators checked and replaced as necessary if the troubleshooting measures listed in the table below prove unsuccessful. The table below lists possible fault codes: Fault code No.
Action SS P-Lube Oil Oil pressure too low (2nd limit value), automatic engine shutdown. 1. Check oil level, top up as necessary(→ Page 110). 2. Attempt to restart engine (→ Page 51). 2.0100.92 2 HI T-Exhaust A Exhaust temperature bank A to high (1st limit value). 1. Check cabling(→ Page 149) ; 2.0126.93 2. Contact Service. 1 SS T-Exhaust A Exhaust temperature bank A to high (2nd limit value). 1. Check cabling(→ Page 149) ; 2.0126.93 2. Contact Service.
Fault code No. Full designation Meaning 036 HI ETC2 Overspeed Alarm configuration limit value 1; preliminary warning: Speed of secondary turbo1. Reduce power. charger too high. 2. Contact Service. 2.3013.93 1 SS ETC2 Overspeed Alarm configuration limit value 2; main warning: Speed of secondary turbocharger too high. Fuel limitation to a 1. Reduce power. fixed value. 2. Contact Service. 2.3013.91 2 038 AL ETC Synchro Fault Synchronization error between exhaust turbocharger 1 and 2. 1.
Meaning 067 Coolant temperature too high (1st limit value). Reduce power. 2.0120.93 1 SS T-Coolant Coolant temperature too high (2nd limit value), automatic engine shutdown. 1. Allow the engine to cool down; 2. Contact Service. 3. Check engine coolant cooler, clean if dirty. 4. Restart engine (→ Page 51). 2.0120.93 2 081 AL System Leaky Pressure gradient in rail is too low during starting or too high during stopping; (HP system leaky, air in system). Contact Service. 1.8004.
Fault code No. Full designation Meaning 092 SS No Starter Speed Alarm configuration limit value; Starter speed was not attained; Termination of starting sequence; Starter rotates too slowly or does not rotate at all. Contact Service. 2.1090.92 3 SS T-Preheat Alarm configuration limit value 2; Main warning: Preheating temperature too low; coolant temperature too low for engine start; engine start interlock active. Check preheater. 2.1090.
Meaning Action 139 L1 TE BUFFER TEST Supply voltage of temperature sensors faulty. Contact Service.Check sensors;Replace ECU. - TE BUF. ECU DEFECT Supply voltage of temperature sensors faulty. Contact Service.Check sensors;Replace ECU. - BANK1 ECU DEFECT Power output stage for solenoid valve activation on bank 1 faulty; engine does not start. Replace ECU. - 144 BANK2 ECU DEFECT Power output stage for solenoid valve activation on bank 2 faulty; engine does not start. Replace ECU.
Fault code No. Full designation Meaning Action Related parameter No. 183 AL CAN No PU-Data Alarm configuration; The selected CAN mode initializes communication by means of the PU data module. However, the necessary PU data module is not present or is invalid. Contact Service. 2.0500.68 3 AL CAN PU Data Flash Error Alarm configuration; A programming error occurred when attempting to copy a received PU data module into the Flash module. Contact Service. 2.0500.
Related parameter No. Fault code No. Full designation Meaning Action 202 SD T-Fuel Sensor B33 defective (fuel temperature). 1. Check cabling. 2. Replace if neces- 1.8004.57 sary. 2 203 SD T-Charge Air 1. Check cabling. Sensor B09 faulty (charge-air 2. Replace if neces- 1.8004.57 temperature) A side. sary. 1 204 Sensor defective B26 (charge air coolant temperaSD T-Coolant Intercooler ture). SD T-Exhaust A 1. Check cabling Sensor B4.21 faulty (exhaust 2. Replace if neces- 1.8004.
Fault code No. Full designation Meaning Action SD Diff Lube Oil Sensor F25 faulty (lube oil differential pressure). 1. Check sensor and wiring. 2. Replace if necessary. Error cleared after restarting the en1.8004.58 gine. 5 222 SD Leak-Fuel Level 1. Check sensor and wiring. 2. Replace if necessary. 1.8004.58 Sensor F46 faulty (leak fuel). 3. Contact Service. 2 223 SD Intercooler Coolant Level 1. Check sensor Sensor F57 defective (charge and wiring. air coolant level). 2. Contact Service.
Meaning Action 245 SD ECU Supply Voltage Sensor fault (ECU operating voltage). Replace ECU. 2.8006589 SD Speed Setting 1. Check cabling. 2. Check speed set- 2.8006.58 External speed setting faulty. ting. 6 SD Loadp. Analog Filt. SD alarm configuration; Filtered analog signal of load pulse missing; short circuit or wire break. Check cabling, replace as necessary. Error cleared after restarting the en2.8006.58 gine. 8 Frequency setting sensor faulty. 1. Check cabling. 2. Contact Service.
TIM-ID: 0000033662 - 001 Fault code No. Full designation Meaning Action Related parameter No. 315 - - - 1.8004.51 4 316 - - - 1.8004.51 5 317 - - - 1.8004.51 6 318 - - - 1.8004.51 7 319 - - - 1.8004.51 8 320 - - - 1.8004.51 9 321 WIRING CYLINDER(A1A10) Wiring bank 1 (solenoid valve 1) ... Wiring bank 1 (solenoid valve 10) 1. Check solenoid valve. 2. Contact Service. 1.8004.52 0 322 - - - 1.8004.52 1 323 - - - 1.8004.52 2 324 - - - 1.8004.
Meaning Action 337 - - - 1.8004.53 6 338 - - - 1.8004.53 7 339 - - - 1.8004.53 8 340 - - - 1.8004.53 9 341 OPEN_LOAD CYL.(A1A10) Open Load Bank 1 (solenoid 1. Check solenoid valve 1) ... Open Load Bank 1 valve. (solenoid valve 10) 2. Contact Service. 1.8004.54 0 342 - - - 1.8004.54 1 343 - - - 1.8004.54 2 344 - - - 1.8004.54 3 345 - - - 1.8004.54 4 346 - - - 1.8004.54 5 347 - - - 1.8004.54 6 348 - - - 1.8004.54 7 349 - - - 1.8004.
Fault code No. Full designation Meaning Action Related parameter No. 359 - - - 1.8004.55 8 360 - - - 1.8004.55 9 361 Alarm configuration; Internal electronic fault (electronics possibly faulty: start ITS).Check additional messages if ITS indicates diagno- 1. Check solenoid AL Injector Power Stage sis "Electronics OK" (e.g. ca- valve cabling. Low bling faulty). 2. Replace ECU. 1.8004.49 6 362 Alarm configuration; Internal electronic fault (electronics possibly faulty: start ITS).
Meaning Action 382 AL Wiring TOP 2 Alarm configuration; Short circuit or wire break on transistor output, plant-side 2 (TOP 2). Check cabling to plant. 2.8006.63 9 AL Wiring TOP 3 Alarm configuration; Short circuit or wire break on transistor output, plant-side 3 (TOP 3). Check cabling to plant. 2.8006.64 0 AL Wiring TOP 4 Alarm configuration; Short circuit or wire break on transistor output, plant-side 4 (TOP 4). Check cabling to plant. 2.8006.64 1 AL MCR exceeded 1.
Fault code No. Full designation Action 402 Alarm configuration; Line disruption on digital input 3; CaAL Open Load Digital In- bling faulty or no resistance put 3 over switch. 1. Check cabling. 2. Contact Service.; Check input of tar- 2.8006.62 get device. 7 403 Alarm configuration; Line disruption on digital input 4; CaAL Open Load Digital In- bling faulty or no resistance put 4 over switch. 1. Check cabling. 2. Contact Service.; Check input of tar- 2.8006.62 get device.
Meaning Action 415 Alarm configuration limit value 1; Preliminary warning: Coolant pressure in interTop up coolant LO P-Coolant Intercooler cooler too low. (→ Page 135). 2.0107.92 1 416 Alarm configuration limit value 2; Main warning: Coolant pressure in intercooler too Top up coolant SS P-Coolant Intercooler low. engine shutdown. (→ Page 135). 2.0107.92 2 417 420 421 428 440 442 444 445 448 Check sensor and cabling, replace as necessary.Error cleared after re1.8004.59 starting the engine.
Fault code No. Full designation Meaning 449 SS P-Charge Air Alarm configuration limit value 2; Main warning: Chargeair pressure too high. Contact Service. SD Feed Signal Percent Check signal transmitter and cabling, replace as necessaSD alarm configuration; Input ry. signal for initial/final torque Error cleared after faulty; Short circuit or wire restarting the en2.8006.59 break gine. 2 450 454 455 456 460 461 TIM-ID: 0000033662 - 001 462 463 464 Action Related parameter No.
Fault code No. Full designation Meaning 465 SD P-AUX 2 Check pressure transmitter and caSD alarm configuration; Ana- bling, replace as log input signal for Aux 2 necessary.Error pressure faulty; Short circuit cleared after re1.8004.58 or wire break starting the engine. 8 SD T-AUX 2 Check temperature sensor and cabling, SD alarm configuration; Ana- replace as necessalog input signal for Aux 2 ry. Error cleared aftemperature faulty; Short cir- ter restarting the 1.8004.58 cuit or wire break engine.
Fault code No. Full designation Meaning Action Related parameter No. 476 Alarm configuration; Initialization error of crash recordAL Crash Rec. Init. Error er. 478 AL Comb. Alarm Yellow (Plant) Alarm configuration; Combined alarm YELLOW from plant. Note further fault messages. 2.8006.00 1 479 AL Comb. Alarm Red (Plant) Alarm configuration; Combined alarm RED from plant. Note further fault messages. 2.8006.00 2 AL Lim Ext.
7 Task Description 7.1 Engine 7.1.1 Cranking engine manually Preconditions ☑Engine shut down and secured against being restarted. Special tools, Material, Spare parts Designation / Use DANGER Part No. Qty. Cranking tool F6555766 1 Cranking tool F6783293 1 Adapter F6558528 1 Ratchet with extension 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.
Cranking engine manually (tool mounted underneath) 1. 2. 3. 4. TIM-ID: 0000002521 - 005 5. Remove grounding device or guard plate. Engage cranking tool (2) in ring gear (1) and mount on flywheel housing. • For 12/16V engines, use cranking tool F6555766 with adapter F6558528. • For 20V engines, use cranking tool F6783293. Fit ratchet (3) onto cranking tool (2). Rotate crankshaft in normal direction of engine rotation; apart from the normal compression resistance, there should be no resistance.
7.1.2 DANGER Engine – Barring with starting system 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. 5. TIM-ID: 0000000918 - 004 6. Release latch of connector X4. Remove connector from engine governor.
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. Qty. Barring device F6555766 1 Ratchet with extension F30006212 1 Endoscope Y20097353 1 Preparatory steps 1. 2. Remove cylinder head cover (→ Page 95). Remove injector (→ Page 98). Positioning crankshaft at BDC 1. 2.
1. 2. 3. Compile endoscopy report using the table. Use technical terms for description of the liner surface (→ Page 83). 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 Install injector (→ Page 98). Install cylinder head cover (→ Page 95). TIM-ID: 0000003304 - 004 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.
7.4 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 Risk of injury! • Do not direct compressed-air jet at persons. • Wear protective goggles / safety mask and ear protectors. Unsuitable cleaning tools. Damage to component! • Observe manufacturer's instructions.
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 - 004 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. 3. TIM-ID: 0000000921 - 010 4. Remove cylinder head covers (→ Page 95). Fill oil chambers of valve bridges with oil. Fill oil chambers of rocker arms and adjusting screws with oil. Install cylinder head covers (→ Page 95).
7.5.2 Valve clearance – Check and adjustment Preconditions ☑Engine shut down 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 Y20098771 1 Torque wrench, 60-320 Nm F30452768 1 Box wrench socket, 24 mm F30039526 1 Engine oil Preparatory steps Remove cylinder head cover (→ Page 95). Install barring device (→ Page 78). 3.
4. Rotate crankshaft with barring device in direction of engine rotation until the "OT-A1" marking and pointer are aligned.
Diagram for 16V engines (two crankshaft positions) Diagram for 20V engines (two crankshaft positions) Checking valve clearance at two crankshaft positions 1. TIM-ID: 0000000922 - 010 2. 3. 4. 5. Check TDC position of piston in cylinder A1: • If the rocker arms are unloaded on cylinder A1, the piston is in firing TDC. • If the rocker arms are under load on cylinder A1, the piston is in overlap TDC. Check valve clearance with cold engine: • Inlet (long rocker arm) = 0.2 mm ±0.
Adjusting valve clearance 1. 2. 3. 4. 5. 6. 7. Release locknut (1). Insert feeler gauge (3) between valve bridge and rocker arm. Use Allen key to set adjusting screw (2) so that the specified valve clearance is established. Feeler gauge (3) must just pass through gap. Tighten locknut (1) with torque wrench to the specified tightening torque, holding the adjusting screw (2) to prevent it from turning. Name Size Type Lubricant Value/Standard Locknut M16 x 1.
7.5.3 Cylinder head cover – Removal and installation Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Grease (Kluthe Hakuform 30-10/Emulgier) O-ring Part No. Qty. X00029933 1 (→ Spare Parts Catalog) Removing cylinder head cover 1. 2. 3. Clean very dirty cylinder head covers (1) prior to removal. Remove screws (3, 4) with washers (2, 5). Take off cylinder head cover (1) with Oring (6) from cylinder head (7).
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.
7.7 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 98).
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/removal tool F6789889 1 Milling cutter F30452739 1 Torque wrench, 0.
2. 3. Note: 4. 5. 6. 7. 8. 9. 10. The injector accumulator will be emptied when removing the adapter. Remove adapter (3). Remove screw (2) and take off hold-down clamp (1). Install installation/removal tool on cylinder head. Remove injector with installation/removal tool. Remove installation/removal tool. Remove sealing ring (4) from injector or use a self-made hook to take it out of the cylinder head. Remove O-rings (3), O-ring (2) and damper ring (1) from injector.
Installing injector 1. 2. 3. 4. 5. 6. 7. Fit new O-rings (3) (included in the scope of supply of the injector), O-ring (2) and damping ring (1) onto the injector and coat with grease. Remove oil carbon from sealing face on cylinder head and protective sleeve with milling cutter. Insert injector into cylinder head, ensuring that the HP line adapter is correctly aligned. Use installation/removal tool to press in injector. Remove installation/removal tool. TIM-ID: 0000000925 - 008 8.
9. 10. Note: 11. 12. Coat screw head mating face (2) and thread with engine oil. Fit hold-down clamp (1) in the correct position and use torque wrench to tighten screw (2) to the specified initial tightening torque. Name Size Type Lubricant Value/Standard Screw M12 Preload torque (Engine oil) 5 Nm to 10 Nm Ensure special cleanness. Coat thread and sealing cone of adapter (3) with engine oil. Install adapter (3) and use torque wrench to tighten to the specified initial tightening torque.
18. Mount double-walled HP line (5) and use torque wrench to tighten to the specified torque. Tightening sequence: 1 Adapter (4) 2 Rail (6) Name Size Union nut / thrust screw 19. Note: 20. Type Tightening torque Lubricant Value/Standard 40 Nm + 5 Nm Fit cable connector onto injector. Failure to reset drift compensation (CDC) will void the emissions certification. Reset drift compensation (CDC) with DiaSys® (→ E531920/...). If DiaSys® is not available, contact Service.
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 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. Preparatory steps 1. 2. Shut off fuel supply to the engine. Provide suitable container to collect escaping fuel. Fuel prefilter – Draining 1. 2. 3. 4. 5. Open vent plug (1). Open drain valve (2).
7.10 Charge-Air Cooling 7.10.1 DANGER WARNING WARNING Intercooler – Checking condensate drain for coolant discharge and obstructions 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 Intake 7.11.1 Service indicator – Signal ring position check Preconditions ☑Engine is stopped and starting disabled. Checking signal ring position 1. 2. TIM-ID: 0000030654 - 002 Result: If the signal ring is completely visible in the control window (2), replace air filter. 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 149). 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 Checking engine oil level Preconditions ☑Engine shut down and secured against being restarted. Checking engine oil level at oil sight glass 1. TIM-ID: 0000030329 - 002 2. The oil level (2) can be checked visually in advance at the oil sight glass (1). A correct reading of the engine oil level is only possible with the oil dipstick (→ Page 110).
7.13.3 Engine oil – Change Preconditions ☑Engine shut down and starting disabled. ☑Engine is at operating temperature. ☑MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 40-200Nm F30027337 1 Ratchet adapter F30027341 1 Engine oil Sealing ring WARNING (→ Spare Parts Catalog) Hot oil. Oil can contain combustion residues which are harmful to health.
5. Tighten drain screws (2) and (3) with torque wrench to the specified torque. Name Size Type Lubricant Value/Standard Screw M26 x 1.5 Tightening torque (Engine oil) 100Nm +10Nm Filling with new engine oil 1. 2. TIM-ID: 0000006152 - 008 3. 4. Open cover on filler neck. Pour oil in at filler neck up to "max." mark at oil dipstick. Close cap on filler neck. Check engine oil level (→ Page 110).
7.13.4 Engine oil – 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. Hot oil. Oil can contain combustion residues which are harmful to health.
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. X00058060 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. Pull out oil filter element (1). Remove O-ring. 5. 6. 7. 8. 9. 10. Remove screw (2). Pull out 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: 0000029294 - 007 12.
Installing oil filter candles Install in reverse order of removal. Additionally, the following instructions are to be observed: • Replace all seals with new parts • Coat O-rings with grease • Insert O-rings in grooves • Pay attention to installation position of fillister-head screw to slot in shaft. TIM-ID: 0000029294 - 007 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 Action 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 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 1. 2. 16. Remove clamp (14). Release 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 maximum layer thickness of oil residues exceeds 45 mm, shorten maintenance 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 124). Fill with engine coolant (→ Page 126). TIM-ID: 0000000036 - 030 1. 2.
7.15.3 Draining engine coolant Preconditions ☑Engine shut down and secured against being restarted. 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. Have a suitable container ready to catch the coolant. Switch off preheating unit. Draining engine coolant 1. 2. 3.
5. 6. 7. Open the drainage point on the main PTO end of the crankcase, on the left or right side (arrowed) and drain off the engine coolant. Close off all open drain points. Place pressure cap on filler neck and close. Concluding operations Switch on preheater.
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. Connect a suitable pump with a hose to drain valve at main PTO end (arrowed). 2. Open vent points on distributor, oil heat exchanger and exhaust turbochargers (arrows). Open drain valve and pump coolant into engine at 0.5 bar minimum. When coolant emerges from the vent points, close vent points one by one, proceeding from the lowest point upwards. Fill expansion tank until overflow edge is reached. Close drain valve.
Alternatively: Filling with coolant through filler neck 1. 2. 3. 4. 5. 6. 7. 8. 9. Open vent points on distributor, oil heat exchanger and exhaust turbochargers (arrows). Add coolant to expansion tank until the coolant level at top edge of filler neck remains constant. When coolant emerges from the vent points, close vent points one by one, proceeding from the lowest point upwards. Check proper condition of breather valve and clean sealing faces if required.
7.15.5 DANGER WARNING Engine coolant pump – Checking pressure relief port 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. Engine coolant pump – Checking pressure relief port 1. 2. 3. TIM-ID: 0000006798 - 005 4. Check pressure relief port for oil and coolant discharge.
7.15.6 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. Replacing engine coolant filter 1. 2. 3. 4. 5. TIM-ID: 0000006858 - 008 6.
7.15.7 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 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.
7.16 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 134). Fill with charge-air coolant (→ Page 135). TIM-ID: 0000000041 - 011 1. 2.
7.16.3 Draining charge-air coolant Preconditions ☑Engine shut down and secured against being restarted. Special tools, Material, Spare parts Designation / Use Sealing ring WARNING Part No. 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. Draining charge-air coolant 1. 2. 3. 4. 5. 6. 7.
7.16.4 Charge-air coolant – Filling Preconditions ☑Engine shut down and starting disabled. ☑MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Charge-air 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.
1. Connect appropriate pump with hose to a drain valve (arrow) or at the lowest point between engine and cooler. 2. Open vent point on charge-air cooler (arrow). Open drain valve and pump coolant into engine at 0.5 bar minimum. When coolant emerges from the vent point, close vent point. Fill expansion tank until overflow edge is reached. Close drain valve. Check proper condition of breather valve on coolant expansion tank, clean sealing faces if required. Fit breather valve and close it.
Alternatively: Filling with coolant through filler neck 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Open vent point on charge-air cooler (arrow). Top up engine coolant via filler neck on coolant expansion tank until coolant level remains constant in sight glass at max. mark. When coolant emerges from the vent point, close vent point. Check proper condition of breather valve on coolant expansion tank, clean sealing faces if required. Mount breather valve and turn until the first stop. Start engine (→ Page 51).
7.16.5 DANGER WARNING Charge-air coolant pump – Checking pressure relief port 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 – Checking pressure relief port 1. 2. 3. TIM-ID: 0000007040 - 002 4. Check pressure relief port for oil and coolant discharge.
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 Alternator – Removing and refitting Preconditions ☑Engine shut down and secured against being restarted. Special tools, Material, Spare parts Designation / Use WARNING Part No. Qty. Torque wrench, 20-100 Nm F30026582 1 Ratchet adapter F30027340 1 Heavy object. Risk of crushing! • Use appropriate lifting devices and appliances. Removing alternator 1. 2. 3. Remove protective cover. Mark electrical leads on alternator for identification and disconnect.
8. 9. 10. 11. Unscrew bolts (arrowed). Remove alternator (1). Clean alternator (1) thoroughly (→ Page 142). Refit alternator (1) in reverse order of removal. Tensioning drive belt 1. 2. Result: 3. TIM-ID: 0000007425 - 006 4. 5. 6. Fit drive belt. Slacken bolt (2) by half a turn. Belt tensioner moves against the drive belt and tensions it. Tighten bolt (2) to specified torque using a torque wrench.
7.18.2 Battery-charging generator – Check Preconditions ☑Engine shut down 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. Checking battery-charging generator Item Findings Measure Ventilation area (arrow) Clean None Ventilation area (arrow) Contaminated Clean Cleaning battery-charging generator Dry-clean battery-charging generator only.
7.18.3 Battery-charging generator drive – Drive belt tension adjustment Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use WARNING Part No. Qty. Torque wrench, 60-320 Nm F30452768 1 Ratchet F30027341 1 Torque wrench, 10-60 Nm F30452769 1 Ratchet F30027340 1 Spring/circlip/tensioning roller preload. Risk of injury! • Only use specified tool and equipment. Adjusting belt tension 1. 2. Result: TIM-ID: 0000000945 - 007 3. 4. 5.
7.18.4 Battery-charging generator – Drive belt and belt tensioner replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use WARNING Part No. Qty. Torque wrench, 20-100Nm F30026582 1 Ratchet adapter F30027340 1 Drive belt (→ Spare Parts Catalog) Belt tensioner (→ Spare Parts Catalog) 1 Heavy object. Risk of crushing! • Use appropriate lifting devices and appliances. Replacing drive belt and belt tensioner 1.
Install protective cover. Readjust belt tension after 30 minutes and again after 8 hours engine runtime (→ Page 143). TIM-ID: 0000007421 - 007 4. 5.
7.19 Fan Drive 7.19.1 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 139). For drive belt replacement (→ Page 148). 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 1. 2. TIM-ID: 0000040744 - 001 3. 4. Release screws (2) until fan clutch can be moved.
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 - 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.
7.20 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 Isopropyl alcohol Part No. Qty. 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 governor and connectors – Cleaning Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Isopropyl alcohol Note: Part No. Qty. X00058037 1 Always use test connectors to enter the connectors. Never use test leads for this purpose.Otherwise the contacts could be bent. Engine governor and connectors – Cleaning 1. 2. 3.
7.21.2 Engine governor plug connections – Check Preconditions ☑Engine is stopped and starting disabled. Note: Always use test plugs to check the connections. Never use test leads. Otherwise, the contacts might be bent. Engine governor plug connections – Check Check all plug connections for secure seating. Latch plugs if loose. TIM-ID: 0000000048 - 007 1. 2.
8 Appendix A 8.1 Abbreviations Abbre- Meaning viation Alternating Current AdBlue - Brand name given by the German automotive industry association (VDA) Urea solution with 32.
TIM-ID: 0000009959 - 008 Abbre- Meaning viation Explanation IIE Initial Injector Equalization Input of the injector code with DiaSys® in engine governor to ensure optimum emission and consumption behavior ISO International Organization for Standardization International umbrella organization for all national standardization institutes ITS Integrated Test System KGS Kraftgegenseite Engine free end in accordance with DIN ISO 1204 KS Kraftseite Engine driving end in accordance with DIN ISO 1204
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 Cranking engine manually (→ Page 78) Part No.: F6555766 Qty.: Used in: 1 7.2.1 Cylinder liner – Endoscopic examination (→ Page 81) Part No.: F30039526 Qty.: Used in: 1 7.5.
Cranking tool Part No.: F6555766 Qty.: Used in: 1 7.1.1 Cranking engine manually (→ Page 78) Part No.: F6783293 Qty.: Used in: 1 7.1.1 Cranking engine manually (→ Page 78) Part No.: Y20097353 Qty.: Used in: 1 7.2.1 Cylinder liner – Endoscopic examination (→ Page 81) Part No.: Y20098771 Qty.: Used in: 1 7.5.
Filter wrench Part No.: F30379104 Qty.: Used in: 1 7.9.1 Fuel filter – Replacement (→ Page 104) Qty.: Used in: 1 7.15.6 Engine coolant filter – Replacement (→ Page 130) Part No.: F6789889 Qty.: Used in: 1 7.7.2 Injector – Removal and installation (→ Page 98) Part No.: F30452739 Qty.: Used in: 1 7.7.2 Injector – Removal and installation (→ Page 98) Part No.: 5605892099/00 Qty.: Used in: 1 7.13.4 Engine oil – Sample extraction and analysis (→ Page 114) Qty.: Used in: 1 7.15.
Optibell 2 belt tension tester Part No.: Y4345711 Qty.: Used in: 1 7.19.1 Fan drive – Drive belt tension check / adjustment (→ Page 146) Part No.: F30027340 Qty.: Used in: 1 1.5 Crankshaft transportation lock – For transport with flange-mounted generator (→ Page 10) Qty.: Used in: 1 7.3.1 Crankcase breather – Oil separator element replacement, diaphragm check and replacement (→ Page 85) Qty.: Used in: 1 7.7.2 Injector – Removal and installation (→ Page 98) Qty.: Used in: 1 7.18.
Ratchet with extension Part No.: F30006212 Qty.: Used in: 1 7.1.1 Cranking engine manually (→ Page 78) Qty.: Used in: 1 7.2.1 Cylinder liner – Endoscopic examination (→ Page 81) Part No.: - Qty.: Used in: 1 4.6 Plant cleaning (→ Page 54) Part No.: 0015384230 Qty.: Used in: 1 7.7.2 Injector – Removal and installation (→ Page 98) Part No.: F30452769 Qty.: Used in: 1 1.4 Crankshaft transport locking device (→ Page 8) Qty.: Used in: 1 1.
Torque wrench, 20-100Nm Part No.: F30026582 Qty.: Used in: 1 7.18.4 Battery-charging generator – Drive belt and belt tensioner replacement (→ Page 144) Part No.: F30026582 Qty.: Used in: 1 7.18.1 Alternator – Removing and refitting (→ Page 140) Part No.: F30027337 Qty.: Used in: 1 7.13.3 Engine oil – Change (→ Page 112) Part No.: F30027336 Qty.: Used in: 1 7.3.1 Crankcase breather – Oil separator element replacement, diaphragm check and replacement (→ Page 85) Qty.: Used in: 1 7.14.
Torque wrench, 60-320 Nm F30452768 Qty.: Used in: 1 1.4 Crankshaft transport locking device (→ Page 8) Qty.: Used in: 1 7.5.2 Valve clearance – Check and adjustment (→ Page 91) Qty.: Used in: 1 7.7.2 Injector – Removal and installation (→ Page 98) Qty.: Used in: 1 7.18.3 Battery-charging generator drive – Drive belt tension adjustment (→ Page 143) DCL-ID: 0000013811 - 005 Part No.
9.
F R Fan drive – Drive belt replacement 148 – Drive belt tension check / adjustment 146 Fault messages of the engine governor ADEC (ECU 7) for series 4000 C&I engines 59 Filter – Automatic oil filter – Replacing filter candles 115 Filter sleeve – Replacement 120 Firing order 47 Fuel filter – Replacing 104 Fuel prefilter – Draining 105, 106 Fuel system – Venting 103 Recommissioning – Preparations for after long out-of-service periods (>3 months) 49 G Grounding device – Carbon brush check 87 Grounding devi
