MTU 12 V 4000 C10 Operating Instructions Manual Download

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Operating Instructions

Diesel engine

12 V 4000 C10, C10R, C11, C11R

12 V 4000 C20, C20R, C21, C21R

16 V 4000 C10, C11, C11R

16 V 4000 C20, C20R, C21, C21L

MS150049/02E

Summary of Contents for 12 V 4000 C10

Page 1: ...Operating Instructions Diesel engine 12 V 4000 C10 C10R C11 C11R 12 V 4000 C20 C20R C21 C21R 16 V 4000 C10 C11 C11R 16 V 4000 C20 C20R C21 C21L MS150049 02E...

Page 2: ...ten permission of MTU Friedrichshafen GmbH This restriction also applies to copyright distribution translation micro filming and storage or processing on electronic systems including data bases and on...

Page 3: ...anual mode 42 4 4 Operational checks 43 4 5 Stopping the engine in manual mode 44 4 6 After stopping the engine 45 4 7 Plant cleaning 46 5 Maintenance 5 1 Maintenance task reference table QL1 47 6 Tro...

Page 4: ...l check 120 7 16 2 Charge air coolant Change 121 7 16 3 Charge air coolant Drainage 122 7 16 4 Charge air coolant Filling 123 7 16 5 Charge air coolant pump Relief bore check 126 7 17 Engine Mounting...

Page 5: ...approved by MTU in writing engine and engine control parameters In compliance with all safety instructions and in adherence to all warning notices in these Operating Instructions In compliance with t...

Page 6: ...personnel who only occasionally perform work on or around the engine or plant This personnel must be instructed repeatedly For the identification and layout of the spare parts during maintenance or re...

Page 7: ...ecial packaging with aluminium foil Suspend the engine genset by the lifting eyes on the bearing pedestal or transport by means of handling equipment forklift truck capable of bearing the load Fit the...

Page 8: ...ides must be installed according to the instructions 3 If the engine is to be moved together with the generator the transport locking device for the generator must also be installed Page 11 4 Always u...

Page 9: ...cified tightening torque using the torque wrench Name Size Type Lubricant Value Standard Nut M24 Tightening torque Engine oil 100Nm 10Nm 4 Secure with nut 3 5 Mark the engine as Fitted with transport...

Page 10: ...l 250Nm 25Nm 2 Screw locknut 2 onto screws 3 up to the end of the thread 3 Insert holder 8 through opening in plate 1 and secure with screw 3 4 Tighten screws 3 alternately with torque wrench to the s...

Page 11: ...and gener ator according to the instructions 3 Always use the screws supplied with or installed in the transport locking device to secure it on the en gine 4 Starting or barring the engine is allowed...

Page 12: ...screws with washers on engine and screw back in when the transport locking de vice has been removed 6 Place screw 6 in the recess of holder 3 and insert through the opening at the flywheel housing 1 S...

Page 13: ...play instruments and monitoring units must be permanently observed with re gard to present operating status violation of limit values and warning or alarm messages Engine malfunctions and engine emerg...

Page 14: ...dust extraction de vice as an additional measure Safety regulations during maintenance and repair work Take special care when removing ventilation or plug screws from the engine or plant Cover the sc...

Page 15: ...es Observe the max permissible push on pressure specified for the equipment Do not attempt to bend or apply force to lines Before starting work pay attention to the following Vent the hydraulic instal...

Page 16: ...ial laser protection goggles Heavily focused ra diation Laser equipment must be fitted with the protective devices necessary for safe operation according to type and application For conducting light b...

Page 17: ...ne are prohibited by emission regulations Emission control units systems may only be main tained exchanged or repaired if the components used for this purpose are approved by MTU or equiva lent compon...

Page 18: ...equipment is disconnected from the supply line or before the equipment or tool is to be replaced Carry out leak test in accordance with the specifications Paints and lacquers Observe the relevant saf...

Page 19: ...ion involving potentially adverse effects on the product Consequences Material damage Remedial action Additional product information Note This manual contains highlighted safety messages in accordance...

Page 20: ...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...

Page 21: ...ocharger 8 Combustion air inlet 9 Charge air cooler 10 Charge air line 11 Starter 12 Engine governor 13 Easy change fuel filter 14 Oil filter 15 Air conditioning com pressor drive 16 HP pump 17 Engine...

Page 22: ...mp 12 Inspection port cover 13 Oil filler neck 14 Oil pan 15 Crankcase 16 Flywheel housing 17 Flywheel 18 Charge air line 19 Charge air cooler Engine model designation Key to the engine model designat...

Page 23: ...er ature 2 Crankshaft speed 3 Charge air temperature 4 Charge air pressure The injectors are underneath the cylinder head covers of the cylinder Injector replacement and necessa ry activities Page 91...

Page 24: ...1 Camshaft speed 2 Fuel pressure LP 3 Fuel temperature 4 Fuel high pressure 5 Charge air coolant pres sure 6 Engine coolant pressure 24 General Information MS150049 02E 2012 11 TIM ID 0000008365 002...

Page 25: ...1 Lube oil temperature 2 Lube oil pressure 3 Crankcase pressure 4 Charge air coolant tem perature MS150049 02E 2012 11 General Information 25 TIM ID 0000008365 002...

Page 26: ...0R 12V 4000 C11 12V 4000 C11R Application group 5A 5B 5A 5B 5A 5B 5A 5B Intake air temperature C 25 25 25 25 Barometric pressure mbar 1000 1000 1000 1000 Site altitude above sea level m 100 100 100 10...

Page 27: ...utlet to cooling equipment A C 90 95 95 Coolant pump inlet pressure max R C 1 5 1 5 1 5 Thermostat Starts to open R 76 76 76 Thermostat Fully open R bar 87 87 87 LUBE OIL SYSTEM Number of cylinders 12...

Page 28: ...NOISE Number of cylinders 12 12 12 12 Unsilenced exhaust noise at 1m dis tance R dB A 108 110 108 28 Technical Data MS150049 02E 2012 11 TIM ID 0000040201 001...

Page 29: ...4000 C11 16 V 4000 C11R Application group 5A 5B 5A 5B 5A 5B Intake air temperature C 25 25 25 Barometric pressure mbar 1000 1000 1000 Site altitude above sea level m 100 100 100 POWER RELATED DATA po...

Page 30: ...oling equipment A C 95 95 95 Coolant pump inlet pressure max R C 1 5 1 5 1 5 Thermostat Starts to open R 76 76 76 Thermostat Fully open R bar 87 87 87 LUBE OIL SYSTEM Number of cylinders 16 16 16 Lube...

Page 31: ...NOISE Number of cylinders 16 16 16 Unsilenced exhaust noise at 1m distance R dB A 108 110 108 MS150049 02E 2012 11 Technical Data 31 TIM ID 0000040208 001...

Page 32: ...12V 4000 C21R Application group 5A 5B 5A 5B 5A 5B 5A 5B Intake air temperature C 25 25 25 25 Barometric pressure mbar 1000 1000 1000 1000 Site altitude above sea level m 100 100 100 100 POWER RELATED...

Page 33: ...tlet to cooling equipment A C 92 95 95 Coolant pump inlet pressure max R C 1 5 1 5 1 5 Thermostat Starts to open R 76 76 76 Thermostat Fully open R bar 87 87 87 LUBE OIL SYSTEM Number of cylinders 12...

Page 34: ...NOISE Number of cylinders 12 12 12 12 Unsilenced exhaust noise at 1m dis tance R dB A 108 110 108 34 Technical Data MS150049 02E 2012 11 TIM ID 0000040210 001...

Page 35: ...V 4000 C21L Application group 5A 5B 5A 5B 5A 5B 5A 5B Intake air temperature C 25 25 25 25 Barometric pressure mbar 1000 1000 1000 1000 Site altitude above sea level m 100 100 100 100 POWER RELATED D...

Page 36: ...et to cooling equipment A C 92 95 95 Coolant pump inlet pressure max R C 1 5 1 5 1 5 Thermostat Starts to open R 76 76 76 Thermostat Fully open R bar 87 87 87 LUBE OIL SYSTEM Number of cylinders 16 16...

Page 37: ...NOISE Number of cylinders 16 16 16 16 Unsilenced exhaust noise at 1m dis tance R dB A 108 112 114 MS150049 02E 2012 11 Technical Data 37 TIM ID 0000040213 001...

Page 38: ...g order 8V A1 B4 A4 A2 B3 A3 B2 B1 12V A1 B2 A5 B4 A3 B1 A6 B5 A2 B3 A4 B6 16 V A1 A7 B4 B6 A4 B8 A2 A8 B3 B5 A3 A5 B2 A6 B1 B7 20 V A1 B5 A8 B7 A5 B2 A7 B10 A2 B3 A10 B6 A3 B4 A6 B9 A4 B1 A9 B8 38 Te...

Page 39: ...ions Engine model Length A Width B Height C 12 V 4000 Cxy approx 2540 mm approx 1620 mm approx 1990 mm 16 V 4000 Cxy approx 3010 mm approx 1620 mm approx 1990 mm MS150049 02E 2012 11 Technical Data 39...

Page 40: ...ons A001061 Valve gear Lubricate valve gear every 6 months Page 84 Lube oil system Check engine oil level Page 103 Bar engine with startingsystem Page 73 Fuel system Vent Page 97 Coolant circuit If en...

Page 41: ...tartup Item Action Lube oil system Check engine oil level Page 103 Coolant circuit Check engine coolant level Page 112 Check charge air coolant level Page 120 Coolant circuit Preheat coolant with cool...

Page 42: ...rotectors Preparation Item Action Operating mode switch if applicable Switch to manual mode Coolant preheating unit if applicable Switch ON Starting the engine Item Action Switchgear cabinet opera tor...

Page 43: ...display panels Check readings of operational data speed temperature pressures Engine operation Visually inspect engine and attached components for condition and leaks Check for abnormal running noise...

Page 44: ...age 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 spee...

Page 45: ...for an extended period but engine coolant has no antifreeze additive the coolant is not maintained at a suitable temperature antifreeze concentration is 50 and outside temperature is below 40 C Engine...

Page 46: ...cleaning 1 Carry out plant cleaning only in areas where an appropriate oil separator is provided environmental pro tection 2 Prior to putting the cleaning unit into operation read the Operating Instru...

Page 47: ...r contamination clean as necessary Page 130 W1001 Replace fuel filter or fuel filter element Page 98 W1003 Check belt condition and tension replace if necessary Page 128 W1006 Replace fuel injectors P...

Page 48: ...enance tasks W1698 X Replace carbon brushes at flywheel Page 83 W1716 Cleaning battery charging generator Page 131 Table 1 Maintenance task reference table QL1 48 Maintenance MS150049 02E 2012 11 TIM...

Page 49: ...nnot be barred manually Contact Service Engine turns but does not fire Component Cause Action Starter Poor rotation by starter Battery low or faulty Charge or replace battery see manu facturer s docum...

Page 50: ...nated Contact Service Engine room Air intake temperature too high Check fans and intake exhaust lines Charge air pressure too low Component Cause Action Air supply Air filter clogged Check signal ring...

Page 51: ...t turbocharg er cylinder head pis ton rings cylinder lin er Faulty Contact Service White exhaust gas Component Cause Action Engine Not at operating temperature Run engine to reach operating temper atu...

Page 52: ...lamp flashes Flashing phase 1 Flashing phase 2 Flashing phase 1 Flashing phase 2 2 x flash 3 x flash 3 x flash 4 x flash There is a pause lasting 0 5 seconds between flashing phases 1 and 2 There is...

Page 53: ...PID 192 253 Variable SID Subsystem Identification Character Information about the source of fault messages from subordinate systems which may be replaced as a unit e g injectors FMI Failure Mode Ident...

Page 54: ...ature sensor inter cooler input voltage too low 1 Check cabling 2 Contact Service 15 110 4 Coolant temperature sen sor input voltage too low 1 Check cabling 2 Contact Service 15 175 4 Oil temperature...

Page 55: ...65 4 Oxygen concentration cir cuit input voltage too low 1 Check cabling 2 Contact Service 25 Reserved for No Codes No troubleshooting 26 25 11 Aux shutdown 1 active Contact Service 26 61 11 Aux shutd...

Page 56: ...ing 2 Contact Service 32 239 3 CEL short circuit on battery circuit plus 1 Check cabling 2 Contact Service 32 239 4 CEL open circuit 1 Check cabling 2 Contact Service 33 102 3 Charge pressure sensor i...

Page 57: ...les do not re spond charge air pressure version 33 0 or later Contact Service 39 147 11 VNT nozzles at maximum exhaust brake operation version 33 0 or later Contact Service 39 147 12 VNT nozzles do no...

Page 58: ...e 112 3 Check cooler for dirt 4 Contact Service 44 172 0 Air inlet temperature too high 1 Check contamination indica tor signal ring position Page 102 2 Contact Service 44 175 0 Oil temperature too hi...

Page 59: ...ow 1 Check fuel prefilter 2 Check fuel filter Page 98 3 Fill tank as necessary 4 Contact Service 48 106 1 Air inlet pressure too low Contact Service 48 164 1 Injection control pressure too low Contact...

Page 60: ...e 54 84 12 Vehicle s speed sensor de fect 1 Check cabling 2 Contact Service 55 216 14 Fault in another control unit version 27 0 or later This fault is stored in conjunction with another fault in orde...

Page 61: ...X3 Contact Service 62 54 7 Auxiliary output 6 mechani cal system does not re spond correctly X3 Contact Service 62 55 3 Auxiliary output 7 short cir cuit on battery circuit plus Y3 Contact Service 62...

Page 62: ...3 0 Turbocharger speed too high Contact Service 64 103 8 Exhaust turbocharger speed sensor input signal faulty irregular period Contact Service 65 51 0 Throttle position above nor mal range Contact Se...

Page 63: ...rvice 68 230 5 Idle detection pedal travel sensor TPS fault in circuit circuit disrupted Contact Service 68 230 6 Idle detection pedal travel sensor TPS fault in circuit short circuit to ground Contac...

Page 64: ...round short circuit Contact Service 74 99 0 Oil filter badly clogged 1 Replace oil filter Page 107 2 Contact Service 75 168 0 ECM battery voltage too high Contact Service 75 214 0 Real time clock back...

Page 65: ...low Contact Service 77 108 0 Atmospheric pressure too high Contact Service 77 108 1 Atmospheric pressure too low Contact Service 77 109 0 Coolant pressure too high Contact Service 77 110 1 Coolant te...

Page 66: ...ure sen sor input voltage too high Contact Service 81 153 3 Crankcase pressure input voltage too high version 27 0 or later Contact Service 81 164 3 Injection control pressure sensor input voltage too...

Page 67: ...81 140 3 Exhaust duct temperature 12 sensor voltage too high version 32 0 or later Contact Service 81 141 3 Exhaust duct temperature 13 sensor voltage too high version 32 0 or later Contact Service 81...

Page 68: ...4 Exhaust duct temperature 3 sensor voltage too low version 32 0 or later Contact Service 82 132 4 Exhaust duct temperature 4 sensor voltage too low version 32 0 or later Contact Service 82 133 4 Exh...

Page 69: ...2 9 EGR temperature intelli gent sensor does not re spond version 33 0 or lat er Contact Service 82 412 12 EGR temperature intelli gent sensor failure version 33 0 or later Contact Service 83 73 0 Pum...

Page 70: ...32 0 or later Contact Service 83 138 0 Exhaust duct temperature 10 sensor voltage too high version 32 0 or later Contact Service 83 139 0 Exhaust duct temperature 11 sensor voltage too high version 3...

Page 71: ...ressure sen sor input voltage too high Contact Service 87 73 4 Pump pressure sensor in put voltage too low Contact Service 87 108 4 Atmospheric pressure sen sor input voltage too low Contact Service 8...

Page 72: ...Risk of serious injury Danger to life Before barring the engine ensure that nobody is in the danger zone Barring the engine manually 1 Remove guard plate 2 Install barring device 2 with adapter on the...

Page 73: ...ection timing of any cylinder Page 23 For this purpose unlock latch 4 3 Bar engine in unloaded condition Press START button Note Interrupt engine start after maximum ten seconds for thirty seconds to...

Page 74: ...ing and bottom edge of carbon scraper ring First signs of marks left by top piston ring Bright mark on entire circumference Faultless even honing pattern First signs of marks left by lower cooling bor...

Page 75: ...Depending on findings Do not take any action or carry out a further endoscopic examination as part of maintenance work or contact Service cylinder liner must be replaced Final steps 1 Install injecto...

Page 76: ...Polished areas are on the running surface and show local removal of the hon ing pattern Grooves from the honing process are not visible any more New cylinder liners must be fitted in the following cas...

Page 77: ...ing 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 d...

Page 78: ...njury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Crankcase breather closed circuit crankcase ventilation Filter element repla...

Page 79: ...Page 80 6 Insert new sealing ring 3 7 Install cleaned or new filter element 2 with filter holder 5 8 Mount oil separator cover 1 9 Tighten nut of clamp 4 with torque wrench to specified tightening to...

Page 80: ...ear protectors CAUTION Excessive reaction time of cleaning agents on components Damage to component Observe manufacturer s instructions Wear protective clothing gloves and goggles safety mask Clean f...

Page 81: ...alog WARNING Compressed air Risk of injury Do not direct compressed air jet at persons Wear protective goggles safety mask and ear protectors CAUTION Unsuitable cleaning tool Damage to component Obser...

Page 82: ...on adapter contaminated corroded Clean Cleaning running surface on adapter 1 Clean running surface of carbon brushes on adapter with cold cleaner 2 Remove stubborn deposits with soft brush 3 Blow out...

Page 83: ...brush 1 Loosen screw 5 2 Disconnect cable 6 from screw 5 3 Loosen screws 3 4 Remove screws 2 5 Remove carbon brush 1 from grounding device 4 6 Fit new carbon brush 1 in grounding de vice 4 7 Tighten s...

Page 84: ...are parts Designation Use Part No Qty Engine oil Valve gear Lubrication 1 Remove cylinder head covers Page 89 2 Fill oil chambers of valve bridges with oil 3 Fill oil chambers of rocker arms and adjus...

Page 85: ...ignation Use Part No Qty Feeler gauge Y20098771 1 Torque wrench 60 320Nm F30452768 1 Socket box wrench F30039526 1 Engine oil Preparatory steps 1 Remove cylinder head cover Page 89 2 Install barring d...

Page 86: ...gram for 12V engines two crankshaft positions 1 Cylinder A1 is in firing TDC 2 Cylinder A1 is in overlap TDC I Inlet valve X Exhaust valve Diagram for 16V engines two crankshaft positions 1 Cylinder A...

Page 87: ...A1 as per diagram 4 Use feeler gauge to determine the distance between valve bridge and rocker arm 5 If the deviation from the set value exceeds 0 1mm adjust valve clearance Adjusting valve clearance...

Page 88: ...Final steps 1 Remove barring device Page 72 2 Install cylinder head cover Page 89 88 Task Description MS150049 02E 2012 11 TIM ID 0000004357 007...

Page 89: ...cylinder head cover 1 Clean very dirty cylinder head covers prior to removal 2 Remove screws 3 Remove cylinder head cover with gasket from cylinder head Installing cylinder head cover 1 Clean mating...

Page 90: ...ors HP pump Relief bore check 1 Check relief bore for oil and fuel discharge by visual inspection 2 If relief bore is contaminated stop the en gine disable engine start and clean relief bore 3 Note th...

Page 91: ...tor Replacement Special tools Material Spare parts Designation Use Part No Qty Injector Spare Parts Catalog Replacing injector u Remove injector and install new injector Page 92 MS150049 02E 2012 11 T...

Page 92: ...1 Grease Kluthe Hakuform 30 10 emulsifier X00029933 1 Engine oil WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke CAUTION...

Page 93: ...ted 1 Release the cable terminal threaded con nection arrows on the injector and remove cable terminals 2 Remove screw 2 and take off hold down clamp 1 3 Remove high pressure fuel line 5 4 Install ins...

Page 94: ...rea of the nozzle retaining nut 3 Fit new O rings on injector and coat with grease 4 Fit new sealing ring with grease on injector observe installation position of sealing ring 5 Clean sealing face on...

Page 95: ...ch to the specified initial tightening torque Name Size Type Lubricant Value Standard Screw M12 Preload torque Engine oil 5Nm to 10Nm 13 Fit O rings 4 and 6 on high pressure fuel line 5 and coat with...

Page 96: ...torque Name Size Type Lubricant Value Standard Union nut Tightening torque 120Nm 10Nm 18 Twist cable several times 19 Insert cable lugs arrows underneath the screws on the injector and tighten screws...

Page 97: ...filling device to connection 4 2 Disconnect return line at connection 1 3 Use hand pump to fill fuel system providing pressure of min 0 5 bar max 2 0 bar until fuel emerges without bubbles at connec...

Page 98: ...plosion Avoid open flames electrical sparks and ignition sources Do not smoke Replacing fuel filter 1 Remove easy change filter using the filter wrench 2 Clean sealing surface on filter head 3 Slightl...

Page 99: ...cking charge air cooler water drain for coolant leakage and absence of restrictions 1 With the engine running check the drain bore s on the right and left of the engine for emerging air at driving end...

Page 100: ...eck Preconditions Engine is stopped and starting disabled Checking starter condition 1 Check securing screws of starter for secure seating and tighten if required 2 Check wiring Page 140 100 Task Desc...

Page 101: ...cking filling level and condition of system Note After two successive starting trials with cold start system make next starting trial after 10 minutes only If the next two staring trials fail contact...

Page 102: ...7 12 Air Intake 7 12 1 Service indicator Check See manufacturer s documentation 102 Task Description MS150049 02E 2012 11 TIM ID 0000005482 003...

Page 103: ...or heat exchanger back to the oil pan 3 The oil level must reach mark 1 or exceed mark 1 by up to 2 cm 4 Top up with oil to mark 1 as necessary Page 104 5 Insert oil dipstick into guide tube up to the...

Page 104: ...ning oil at drain plug s on oil pan 1 Provide a suitable container in which to collect the engine oil 2 Remove drain plug s and drain engine oil 3 Install drain plug s with new sealing ring Procedure...

Page 105: ...Standard Screw M26 x 1 5 Tightening torque Engine oil 100Nm 10Nm Filling with new engine oil 1 Open cover on filler neck 2 Pour oil in at filler neck up to max mark at oil dipstick 3 Close cap on fill...

Page 106: ...protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors Engine oil Sample e...

Page 107: ...ety mask Avoid contact with skin Do not inhale oil vapor Replacing engine oil filter 1 Remove engine oil filter using the filter wrench 2 Clean the sealing surface on the connecting piece Note Use onl...

Page 108: ...ning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING Compressed air Risk of injury Do not direct compressed air jet at persons Wear prot...

Page 109: ...dings Action Strainer Metallic residues Clean Monitor engine operation Check strainer daily Contact Service Strainer Damaged Fit new part Square section ring Damaged Fit new part O ring Damaged Fit ne...

Page 110: ...Emulgier X00029933 1 Filter sleeve Spare Parts Catalog Sealing ring Spare Parts Catalog Sealing ring Spare Parts Catalog WARNING Hot oil Oil can contain combustion residues which are harmful to health...

Page 111: ...12 onto rotor lower sec tion 13 13 Insert new filter sleeve 9 with stiffener plate 10 into rotor cap 8 ensuring that smooth surface of filter sleeve 9 faces ro tor cap 8 14 Check sealing ring 11 repl...

Page 112: ...first stop and allow pressure to escape 2 Continue to turn breather valve counterclockwise and remove 3 Check engine coolant level coolant must be visible at the bottom edge of the filler neck s cast...

Page 113: ...e Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant Change 1 Drain engine coolant Page 114 2 Fill with engine coolant Page 115 MS150049 02E 2012 11 Task Description...

Page 114: ...f filler neck on coolant expansion tank counterclockwise to first stop and allow pres sure to escape 2 Continue to turn breather valve counterclockwise and remove 3 Draw off separated corrosion inhibi...

Page 115: ...ding Let the engine cool down Wear protective clothing gloves and goggles safety mask CAUTION Cold coolant in hot engine can cause thermal stress Formation of cracks in components Fill top up coolant...

Page 116: ...he steps from Start engine Step 7 until coolant is no longer needed to be topped up d Disconnect pump and hose Filling with coolant through filler neck 1 Alternatively Fill in coolant in expansion tan...

Page 117: ...relief bore of engine coolant pump 1 Check relief bore for oil and coolant dis charge 2 Stop engine Page 44 and disable en gine start observe general safety instruc tions for maintenance and repair 3...

Page 118: ...er pressure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Replacing coolant filter 1 Close shutoff cocks 1 2 Remove coolant filter 2 with...

Page 119: ...protective clothing gloves and goggles safety mask WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors Engine coolant Sample extraction and analysis 1 With the engine run...

Page 120: ...n tank counterclockwise to the first stop and allow pressure to escape 2 Continue to turn breather valve counter clockwise and remove 3 Check coolant level coolant must be visible at marking plate 4 T...

Page 121: ...ecial tools Material Spare parts Designation Use Part No Qty Coolant Charge air coolant Change 1 Drain charge air coolant Page 122 2 Fill with charge air coolant Page 123 MS150049 02E 2012 11 Task Des...

Page 122: ...of coolant expansion tank counterclockwise until the first stop and allow pressure to escape 3 Continue to turn breather valve counter clockwise and remove 4 Draw off separated corrosion inhibitor oil...

Page 123: ...ure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask CAUTION Cold coolant in hot engine can cause thermal stress Formation of cracks in comp...

Page 124: ...ge 42 10 After 10 seconds of running the engine without load shut down the engine Page 44 11 Turn breather valve of coolant expansion tank counterclockwise to the first stop and allow pressure to esca...

Page 125: ...breather valve onto filler neck and turn to the first stop 8 Start engine Page 42 9 After 10 seconds of running the engine without load shut down the engine Page 44 10 Turn breather valve counterclock...

Page 126: ...g relief bore on charge air coolant pump 1 Check relief bore for oil and coolant dis charge 2 Stop engine Page 44 and disable en gine start observe general safety instruc tions for maintenance and rep...

Page 127: ...gine mounting Check Engine mounting Check Item Findings Action Visually inspect mounts Damage Brittleness Deformation Crack formation Swelling visible Replace contact Service MS150049 02E 2012 11 Task...

Page 128: ...ed Guard is removed Drive belt Condition check Item Findings Action Drive belt A Singular cracks None Drive belt Belt is oily shows signs of over heating Replace Page 133 Drive belt B Cracks on entire...

Page 129: ...nditions Engine shut down and starting disabled Battery charging generator Condition check 1 Check if securing screws of battery charging generator fit firmly 2 Tighten any loose threaded connections...

Page 130: ...tectors Checking battery charging generator Item Findings Measure Ventilation area arrow Clean None Ventilation area arrow Contaminated Clean Cleaning battery charging generator Note Dry clean battery...

Page 131: ...vy object Risk of crushing Use appropriate lifting devices and appliances Removing battery charging generator 1 Remove protective cover 2 Mark electric cables on battery charging generator and remove...

Page 132: ...ainst the drive belt and tensions it 3 Tighten screw 2 to specified torque using a torque wrench Name Size Type Lubricant Value Standard Screw M10x1 5 Tightening torque 60Nm 5Nm 4 Tighten screw 1 with...

Page 133: ...lt and belt tensioner 1 Remove protective cover 2 Slacken screws 2 and 3 by half a turn 3 Mount socket or box wrench on screw 1 and press belt tensioner in direction of ar row as far as the stop 4 Tig...

Page 134: ...h Name Size Type Lubricant Value Standard Screw M10x1 5 Tightening torque 42Nm 4 Install protective cover 5 Readjust belt tension after 30 minutes and again after 8 hours engine runtime Page 135 134 T...

Page 135: ...equipment Adjusting belt tension 1 Remove protective cover 2 Slacken screws 1 and 2 by half a turn Result Belt tensioner moves against the drive belt and tensions it 3 Tighten screw 2 to specified to...

Page 136: ...tion visually Page 128 Result Measure for drive replacement Page 138 Check V belt tension fan coupling Rockford S270 1 Switch on belt tension tester 2 Hold measuring tip of belt tension tester over be...

Page 137: ...can be moved 2 Tighten stud 1 until the required frequency is achieved 3 Tighten screws 2 to specified tightening torque Name Size Type Lubricant Value Standard Screw M12x60 Tightening torque 100Nm 10...

Page 138: ...elt Spare Parts Catalog Preparatory steps 1 Remove protective cover 2 Remove fan Replacing drive belt 1 Release screws 2 2 Slacken off stud 1 until drive belt can be removed 3 Clean belt pulleys 4 Fit...

Page 139: ...fore starting work release pressure from pipework Checking compressor 1 Check oil supply line 3 and connections for condition and leaks 2 Check coolant lines 1 and connections for condition and leaks...

Page 140: ...nnot swing freely 3 Check that cable ties are firm tighten loose cable ties 4 Replace faulty cable ties 5 Visually inspect the following electrical line components for damage connector housings contac...

Page 141: ...age Avoid open flames electrical sparks and ignition sources Wear goggles facial protection Only work in a well ventilated room Do not smoke DDEC and connectors Cleaning 1 Remove coarse dirt from hous...

Page 142: ...nec tors 1 2 Unscrew connectors 3 3 Remove covers 2 4 Clean connector housings connector sock et housings and all contacts with isopropyl alcohol 5 When connectors sockets and all contacts are dry Ins...

Page 143: ...Check all plug in connections on both sides of DDEC for secure seating 2 Slide connectors 1 on until they latch into position 3 Screw in connectors 3 securely 4 Seal non assigned connector bases with...

Page 144: ...s soon as possible 2nd function Read out fault codes CKT Circuit CLS Coolant level sensor CPS Coolant pressure sensor CTS Coolant temperature sensor DDEC Detroit Diesel Electronic Controls Engine cont...

Page 145: ...in accordance with DIN ISO 1204 KS Kraftseite Engine driving end in accordance with DIN ISO 1204 LED Light Emitting Diode LO Low Alarm Measured value lower than 1st minimum limit value LOLO Low Low A...

Page 146: ...air pressure TCI Turbo Compressor Inlet TCO Turbo Compressor Outlet TD Transmitter Deviation Alarm Deviation in transmitter values TPS Throttle Position Sensor TRS Timing Reference Sensor T xyz Temper...

Page 147: ...u either during operation for preventive maintenance corrective work in case of malfunction or changed operating conditions or for spare parts supply Your contact at Headquarters Service support mtu o...

Page 148: ...1 1 Engine Barring manually Page 72 Qty Used in 1 7 2 1 Cylinder liner Endoscopic examination Page 74 Cold cleaner Hakutex 60 Part No 50602 Qty Used in 7 4 1 Grounding device Check carbon brush Page...

Page 149: ...9 1 Fuel filter Replacement Page 98 Qty Used in 1 7 14 1 Engine oil filter Replacement Page 107 Qty Used in 1 7 14 3 Centrifugal oil filter Cleaning and filter sleeve replacement Page 110 Qty Used in...

Page 150: ...traction and analysis Page 106 Qty Used in 1 7 15 7 Engine coolant Sample extraction and analysis Page 119 Optibell 2 belt tension tester Part No Y4345711 Qty Used in 1 7 20 1 Fan drive Adjust and che...

Page 151: ...harging generator Drive belt and belt tensioner replacement Page 133 Qty Used in 1 7 19 5 Battery charging generator Drive belt tension adjustment Page 135 Ratchet with extension Part No F30006212 Qty...

Page 152: ...wrench 10 60Nm Part No F30452769 Qty Used in 1 1 4 Crankshaft transport locking device Page 8 Qty Used in 1 1 5 Crankshaft transport locking device For transport with flanged on generator Page 11 Qty...

Page 153: ...Used in 1 7 14 3 Centrifugal oil filter Cleaning and filter sleeve replacement Page 110 Torque wrench 60 320Nm Part No F30452768 Qty Used in 1 1 4 Crankshaft transport locking device Page 8 Qty Used i...

Page 154: ...assembly 11 Cylinder Designation 20 Cylinder head cover Removal and installation 89 Cylinder liner Endoscopic examination 74 D DDEC and connectors Cleaning 141 DDEC Checking plug in connections 143 D...

Page 155: ...l requirements 6 Plant Cleaning 46 Provisions 5 Putting the engine into operation Preparation after scheduled out of service period 41 Putting the engine into operation after extended out of service p...

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