MTU 12 V 4000 C13 Operating Instructions Manual Download Page 97

Page: 97 / 163

7.7 Injection Valve / Injector

7.7.1 Injector – Replacement

Special tools, Material, Spare parts

Designation / Use

Part No.

Qty.

Injector

(→ Spare Parts Catalog)

Replacing injector

Remove injector and install new injector (→ Page 98).

M015695/03E 2013-03

| Task Description | 97

TIM-ID: 0000000022 - 013

Summary of Contents for 12 V 4000 C13

Page 1: ...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...

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

Page 3: ...manual mode 52 4 5 After shutting down the engine 53 4 6 Plant cleaning 54 5 Maintenance 5 1 Maintenance task reference table QL1 55 6 Troubleshooting 6 1 Troubleshooting 56 6 2 Fault messages of the...

Page 4: ...ck 132 7 16 2 Charge air coolant Change 133 7 16 3 Draining charge air coolant 134 7 16 4 Charge air coolant Filling 135 7 16 5 Charge air coolant pump Checking pressure relief port 138 7 17 Belt Driv...

Page 5: ...ion approved by the manufacturer in writ ing including engine control parameters In compliance with all safety instructions and in adherence to all warning notices in this manual In accordance with th...

Page 6: ...ular must be read and understood This is particularly important in the case of personnel who only occasionally perform work on or around the product This personnel must be instructed repeatedly Person...

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: ...e is to be moved together with the generator the transport locking device for the generator must also be installed 4 Always use the screws supplied with or installed in the transport locking device to...

Page 9: ...alternately to specified tightening torque Name Size Type Lubricant Value Standard Screw M10 Tightening torque Engine oil 30 Nm 3 Nm 6 Fit locknut 2 of screw 1 on plate 6 and secure Removing the tran...

Page 10: ...ked with the transportation lock in place Make sure that the transportation lock on the generator is also removed 3 The transportation lock must always be refitted on the engine according to the instr...

Page 11: ...ner 2 together with screw 4 and washer 3 through the opening in the fly wheel housing 5 Note Tighten screw 4 in three steps 6 Tighten screw 4 on each side alternately to specified tightening torque Na...

Page 12: ...ts and monitoring units must be permanently observed with re gard to present operating status violation of limit values and warning or alarm messages Malfunctions and emergency stop The procedures for...

Page 13: ...llium containing pinion Do not blow out the interior of the flywheel housing or the starter with compressed air Clean the flywheel housing inside with a class H dust extraction device as an additional...

Page 14: ...roduct beforehand Hydraulic installation and removal Check the function and safe operating condition of tools and fixtures to be used Use only the specified devices for hydraulic removal installation...

Page 15: ...cy stop feature Store spare parts properly prior to replacement i e protect them against moisture in particular Pack defective electronic components and assemblies in a suitable manner when dispatched...

Page 16: ...emission regulations Emission control units systems may only be maintained exchanged or repaired if the components used for this purpose are approved by the manu facturer Noncompliance with these gui...

Page 17: ...ine 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 safety data sheet for all materials When carryi...

Page 18: ...event of a situation involving potential danger Consequences Minor or moderate injuries Remedial action NOTICE In the event of a situation involving potentially adverse effects on the product Consequ...

Page 19: ...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 20: ...neck 16 Fuel filter head 17 Engine governor 18 HP fuel pump 19 Automatic oil filter 20 Engine mounting support 21 Gear train 22 Vibration damper 23 Battery charging generator 24 Fan drive Engine model...

Page 21: ...4 8 A bank op tional only for 16 V 3 Injectors Y39 1 to Y39 6 A bank 4 ADEC ECU 7 5 B34 fuel pressure after fil ter 6 B48 fuel pressure in com mon rail 7 M8 HP fuel pump actua tor The injectors are un...

Page 22: ...sure af ter filter 4 B33 fuel temperature in common rail 5 B01 camshaft speed 6 B48 fuel pressure in com mon rail 7 B43 charge air coolant pressure 8 B26 charge air coolant temperature 9 B06 engine co...

Page 23: ...V 3 B44 turbocharger speed 4 B03 intake air tempera ture 5 B16 coolant pressure 6 B10 charge air pressure 7 B09 charge air tempera ture The injectors are underneath the cylinder head covers of the cy...

Page 24: ...1 B13 crankshaft speed 24 General Information M015695 03E 2013 03 TIM ID 0000012925 002...

Page 25: ...13L 16V 4000C13 R 16V 4000C13 16V 4000C13L Application group 5A 5A 5A 5A 5A 5A Intake air temper ature C 25 25 25 25 25 25 Charge air cool ant temperature C 45 45 45 45 45 45 Raw water inlet temperatu...

Page 26: ...er of cylin ders 12V 12V 12V 16V 16V 16V Lube oil con sumption after 100 h runtime B hourly fuel con sumption R of B 0 3 0 3 0 3 0 3 0 3 0 3 MODEL RELATED DATA basic design Number of cylin ders 12V 12...

Page 27: ...tempera ture after engine shutdown L C 104 104 104 104 104 104 Coolant antifreeze content max L 50 50 50 50 50 50 Coolant pump in let pressure max L bar 2 5 2 5 2 5 2 5 2 5 2 5 Thermostat Starts to o...

Page 28: ...ube oil operating temperature be fore engine from R C 92 92 92 92 92 92 Lube oil operating temperature be fore engine to R C 95 95 95 95 95 95 Lube oil tempera ture before en gine alarm R C 97 97 97 9...

Page 29: ...s 12V 12V 12V 16V 16V 16V Coolant preheat ing preheating temperature min R C 40 40 40 40 40 40 INCLINATIONS STANDARD OIL SYSTEM reference waterline Number of cylin ders 12V 12V 12V 16V 16V 16V Longitu...

Page 30: ...210 210 Oil pan capacity at dipstick mark max standard oil system op tion max operat ing inclinations L Liters 190 190 190 240 240 240 WEIGHTS basic design dry engine Number of cylin ders 12V 12V 12V...

Page 31: ...e noise filter BL free field sound pres sure level Lp 1m distance ISO 6798 R dB A 103 104 105 105 108 108 Engine surface noise with attenu ated intake noise filter BL sound power level LW ISO 6798 R d...

Page 32: ...5 25 25 Charge air cool ant temperature C 45 45 45 45 45 45 Raw water inlet temperature C Barometric pres sure mbar 1000 1000 1000 1000 1000 1000 Site altitude above sea level m 100 100 100 100 100 10...

Page 33: ...uel con sumption R of B 0 3 0 3 0 3 0 3 0 3 0 3 MODEL RELATED DATA basic design Number of cylin ders 12V 12V 12V 16V 16V 16V Number of cylin ders 12 12 12 16 16 16 Cylinder arrange ment V angle degree...

Page 34: ...tempera ture after engine shutdown L C 104 104 104 104 104 104 Coolant antifreeze content max L 50 50 50 50 50 50 Coolant pump in let pressure max L bar 2 5 2 5 2 5 2 5 2 5 2 5 Thermostat Starts to o...

Page 35: ...ube oil operating temperature be fore engine from R C 92 92 92 92 92 92 Lube oil operating temperature be fore engine to R C 95 95 95 95 95 95 Lube oil tempera ture before en gine alarm R C 97 97 97 9...

Page 36: ...s 12V 12V 12V 16V 16V 16V Coolant preheat ing preheating temperature min R C 40 40 40 40 40 40 INCLINATIONS STANDARD OIL SYSTEM reference waterline Number of cylin ders 12V 12V 12V 16V 16V 16V Longitu...

Page 37: ...210 210 Oil pan capacity at dipstick mark max standard oil system op tion max operat ing inclinations L Liters 190 190 190 240 240 240 WEIGHTS basic design dry engine Number of cylin ders 12V 12V 12V...

Page 38: ...e noise filter BL free field sound pres sure level Lp 1m distance ISO 6798 R dB A 103 105 106 107 106 109 Engine surface noise with attenu ated intake noise filter BL sound power level LW ISO 6798 R d...

Page 39: ...100 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 12V 12V 16V 16V Rated engine speed A rpm 1800 1800 1900 1800 1900 1800 Net brake power w o fan fuel sto...

Page 40: ...to cooling equipment A C 100 100 100 100 Coolant temperature after engine warning R C 102 102 102 102 Coolant temperature after engine shut down L C 104 104 104 104 Coolant antifreeze content max L 50...

Page 41: ...tion max when engine is starting L bar 1 5 1 5 1 5 1 5 GENERAL OPERATING DATA Number of cylinders 12V 12V 16V 16V Coolant preheating preheating tempera ture min R C 40 40 40 40 INCLINATIONS STANDARD O...

Page 42: ...s without coupling R kg 7000 7000 8100 8100 ACOUSTICS Number of cylinders 12V 12V 16V 16V Exhaust noise unsilenced BL free field sound pressure level Lp 1m distance ISO 6798 R dB A 107 108 110 111 Exh...

Page 43: ...100 100 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 12V 12V 16V 16V Rated engine speed A rpm 1800 1900 1800 1900 1800 1900 1800 Net brake power w o fan...

Page 44: ...ing equipment A C 100 100 100 100 Coolant temperature after engine warning R C 102 102 102 102 Coolant temperature after engine shut down L C 104 104 104 104 Coolant antifreeze content max L 50 50 50...

Page 45: ...e inlet connection min when engine is running L bar 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 GENERAL OPERATING DATA Number of cylinder...

Page 46: ...40 240 WEIGHTS basic design dry engine Number of cylinders 12V 12V 16V 16V Engine dry weight with attached standard accessories without coupling R kg 7000 7000 8100 8100 ACOUSTICS Number of cylinders...

Page 47: ...ng order 8V A1 B4 A4 A2 B3 A3 B2 B1 12V A1 B5 A5 B3 A3 B6 A6 B2 A2 B4 A4 B1 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 M015...

Page 48: ...e dimensions Main engine dimensions Length A 12V approx 2810 mm Length A 16V approx 3280 mm Width B 12V 16V approx 1585 mm Height C 12V 16V approx 2027 mm 48 Technical Data M015695 03E 2013 03 TIM ID...

Page 49: ...Oil lubrication system Check engine oil level Page 110 Crank engine using starting system Page 80 Fuel prefilter Fill with fuel if fitted Coolant system If engine has been out of service for more than...

Page 50: ...Startup Item 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 coo...

Page 51: ...protectors 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 to...

Page 52: ...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 53: ...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 Engine control system Swi...

Page 54: ...cleaning 1 Carry out plant cleaning only in areas where an appropriate oil separator is provided environmental protection 2 Prior to putting the cleaning unit into operation read the Operating Instru...

Page 55: ...e gage of fuel pre filter W0525 Check battery charging generator for contamination clean as necessary Page 142 W1001 Replace fuel filter or fuel filter element Page 104 W1006 Replace fuel injectors Pa...

Page 56: ...ice Engine turns over when started but does not fire Component Cause Action Starter Lacks power battery discharged or de fective Charge or replace battery see manufac turer s documentation Engine wiri...

Page 57: ...efective Notify Service Coolant leakage from intercooler Component Cause Action Intercooler Leaking significant coolant loss Notify Service Black smoke from exhaust Component Cause Action Air supply A...

Page 58: ...Component Cause Action Drain water from fuel prefilter Intercooler Leaking Notify Service 58 Troubleshooting M015695 03E 2013 03 TIM ID 0000002541 002...

Page 59: ...igh Contact Service 2 0122 93 1 004 SS T Fuel Main warning Fuel tempera ture too high engine shut down Contact Service 2 0122 93 2 005 HI T Charge Air Preliminary warning Charge air temperature too hi...

Page 60: ...92 1 024 SS Coolant Level Coolant level too low 2nd limit value Check coolant level in expansion tank Page 122 2 0152 91 2 025 HI P Diff Lube Oil Oil filter differential pressure too high 1st limit va...

Page 61: ...wer 2 0125 93 1 052 SS T Lube Oil Lube oil temperature too high 2nd limit value 1 Reduce power 2 Check engine oil level Page 110 2 0125 93 2 057 LO P Coolant Coolant pressure too low 1st limit value C...

Page 62: ...usted to wards late suction restrictor of HP fuel block jamming or HP fuel control block wiring faulty Contact Service 2 0104 93 1 083 LO P Fuel Common Rail Rail pressure reference val ue DBR fuel lim...

Page 63: ...Service 1 8004 62 4 104 AL Eng Hours Counter Defect Checksum error of the hour meter in the EDM EEPROM 1 Contact Service 18004 623 118 LO ECU Supply Voltage Supply voltage too low 1st limit value Chec...

Page 64: ...149 AD TEST2 ECU DEFECT Internal electronic fault au tomatic engine shutdown Replace ECU 150 L1 AD TEST3 SUPPLY Internal electronic fault au tomatic engine shutdown Replace ECU 151 AD TEST3 ECU DEFECT...

Page 65: ...disruption or CAN station missing Contact Serv ice Check that at least one CAN sta tion is available Check cabling as necessary Check shielding improve shielding as neces sary 2 0500 68 7 188 AL CAN2...

Page 66: ...e engine 1 8004 56 6 211 SD P Lube Oil Sensor B05 defective lube oil pressure 1 Check cabling 2 Replace if neces sary 1 8004 56 3 212 SD P Coolant Sensor B16 defective cool ant pressure 1 Check cablin...

Page 67: ...SD crankshaft Sensor B13 faulty crank shaft speed 1 Check sensor and wiring 2 Contact Service 1 8004 49 8 231 SD camshaft Sensor B1 faulty camshaft speed 1 Check sensor and wiring 2 Contact Service 1...

Page 68: ...g sensor faulty 1 Check cabling 2 Contact Service Check setpoint speed transmitter 2 8006 59 0 301 TIMING CYLINDER A1 A10 Timing bank 1 solenoid valve 1 Timing bank 1 solenoid valve 10 Replace injecto...

Page 69: ...id valve 2 Contact Service 1 8004 52 0 322 1 8004 52 1 323 1 8004 52 2 324 1 8004 52 3 325 1 8004 52 4 326 1 8004 52 5 327 1 8004 52 6 328 1 8004 52 7 329 1 8004 52 8 330 1 8004 52 9 331 WIRING CYLIND...

Page 70: ...4 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 54 8 350 1 8004 54 9 351 OPEN_LOAD CYL B1 B10 Open Load Bank 2 solenoi...

Page 71: ...bit 1 1020 021 Power Stage Failure Stop Engine is set engine will be shut down as additional measure 1 Short circuit of positive connection of one or more injectors to ground 2 Short circuit of negati...

Page 72: ...wn 1 Check sensor and wiring 2 Contact Service 2 0129 93 2 394 LO P Lube Oil Redun dant Alarm configuration limit val ue 1 Preliminary warning Redundant lube oil pressure reading too low 1 Check senso...

Page 73: ...et device 2 8006 63 1 407 AL Open Load Digital In put 8 Alarm configuration Line dis ruption on digital input 8 wiring defective or no resist ance through the switch 1 Check cabling 2 Contact Service...

Page 74: ...cause of limit value violation and rectify fault 2 0160 92 2 428 L1 T Aux 1 Alarm configuration limit val ue 1 Preliminary warning Temperature signal of Aux 1 has exceeded not attained limit value 1 d...

Page 75: ...Input signal of Aux 1 plant side has exceeded not attained limit value 2 depending on config uration Determine cause of limit value violation and rectify fault 2 8006 65 1 460 AL Exhaust EMU High Alar...

Page 76: ...rans mitter and cabling replace as necessa ry Error cleared af ter restarting the engine 1 8004 59 0 470 SD T ECU SD alarm configuration Tem perature sensor for ECU faul ty Short circuit or wire break...

Page 77: ...ined alarm YELLOW from plant Note further fault messages 2 8006 00 1 479 AL Comb Alarm Red Plant Alarm configuration Com bined alarm RED from plant Note further fault messages 2 8006 00 2 480 AL Lim E...

Page 78: ...f serious injury Danger to life Before barring the engine ensure that nobody is in the danger zone Cranking engine manually tool mounted on side 1 Remove guard plate 2 Engage cranking tool 2 in ring g...

Page 79: ...cranking tool F6555766 with adapter F6558528 For 20V engines use cranking tool F6783293 3 Fit ratchet 3 onto cranking tool 2 4 Rotate crankshaft in normal direction of en gine rotation apart from the...

Page 80: ...emoved from the engine Engine Barring with starting system 1 Release latch of connector X4 2 Remove connector from engine governor 3 Bar engine in unloaded condition Press START button 4 Let the crank...

Page 81: ...ring 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 b...

Page 82: ...3 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 inject...

Page 83: ...n 20 of the entire piston running surface covers more than 30 of the circumference and extends over more than 50 of piston stroke is wider than 15 mm over the entire piston stroke Discoloration This i...

Page 84: ...ow heavy discoloration and scoring Replace liner Evaluation of findings and further measures The findings in the start phase of oxidation discoloration and heat discoloration are similar Thorough inve...

Page 85: ...residues which are harmful to health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Replacing oil separator elemen...

Page 86: ...aphragm 3 on housing 1 5 Install new seal 2 and spring 5 together with cover 4 6 Use torque wrench to tighten the screws of cover 4 to the specified torque Name Size Type Lubricant Value Standard Scre...

Page 87: ...OTICE Unsuitable cleaning tools Damage to component Observe manufacturer s instructions Use appropriate cleaning tool Remove grounding assembly 1 Remove screws 1 with washers 2 Remove grounding device...

Page 88: ...er 2 Remove stubborn deposits with soft brush 3 Blow out adapter with compressed air Installing grounding device 1 Check mounting surface on flywheel housing for cleanness 2 Install grounding device o...

Page 89: ...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...

Page 90: ...pare parts Designation Use Part No Qty Engine oil Valve gear Lubrication 1 Remove cylinder head covers Page 95 2 Fill oil chambers of valve bridges with oil 3 Fill oil chambers of rocker arms and adju...

Page 91: ...pare 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 1 Remove cylinder head cover Page 9...

Page 92: ...in di rection of engine rotation until the OT A1 marking and pointer are aligned Diagram for 8V engines two crankshaft positions Diagram for 12V engines two crankshaft positions 92 Task Description M0...

Page 93: ...DC 2 Check valve clearance with cold engine Inlet long rocker arm 0 2 mm 0 05 mm Exhaust short rocker arm 0 5 mm 0 05 mm 3 Check all valve clearances in two crankshaft positions firing TDC and overlap...

Page 94: ...ut 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 5 Tightening torque Engine o...

Page 95: ...er head covers 1 prior to removal 2 Remove screws 3 4 with washers 2 5 3 Take off cylinder head cover 1 with O ring 6 from cylinder head 7 Installing cylinder head cover 1 Clean mounting surface 2 Che...

Page 96: ...NG Oils oil vapors are combustible explosive Risk of fire and explosion Avoid open flames electric sparks and ignition sources Do not smoke NOTICE HP fuel pump not filled with engine oil Damage to com...

Page 97: ...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 98 M015695 03E 2013 03 Ta...

Page 98: ...wrench 60 320 Nm F30452768 1 Ratchet F30027341 1 Assembly paste Optimoly Paste White T 40477 1 Grease Kluthe Hakuform 30 10 Emulgier X00029933 1 Engine oil O ring Spare Parts Catalog WARNING Fuels are...

Page 99: ...cylinder head 7 Remove injector with installation removal tool 8 Remove installation removal tool 9 Remove sealing ring 4 from injector or use a self made hook to take it out of the cylinder head 10...

Page 100: ...nstallation position of seal ing ring 4 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 5 Remove oil carbon from se...

Page 101: ...h torque wrench to the specified tightening torque Name Size Type Lubricant Value Standard Screw M12 Tightening torque 100 Nm 10 Nm 14 Tighten adapter 3 with torque wrench to the specified tightening...

Page 102: ...rew Tightening torque 40 Nm 5 Nm 19 Fit cable connector onto injector Note Failure to reset drift compensation CDC will void the emissions certification 20 Reset drift compensation CDC with Dia Sys E5...

Page 103: ...trical sparks and ignition sources Do not smoke Venting LP fuel system 1 Open vent plug 1 2 Unlock fuel priming pump 2 screw out handle by turning it counterclockwise 3 Operate the pump with the handl...

Page 104: ...n Avoid open flames electrical sparks and ignition sources Do not smoke Fuel filter Replacement 1 Remove easy change filter using filter wrench 2 Clean sealing face on filter head 3 Apply a thin coat...

Page 105: ...urces Do not smoke Draining fuel prefilter 1 Shut off the filter unit 5 8 to be changed at valves 3 and 4 or 9 and 10 2 Open bleed screw 1 or 2 on filter to be drained 3 Open drain valve 6 or 7 4 Drai...

Page 106: ...lames electrical sparks and ignition sources Do not smoke Preparatory steps 1 Shut off fuel supply to the engine 2 Provide suitable container to collect escaping fuel Fuel prefilter Draining 1 Open ve...

Page 107: ...ing conden sate drain for coolant discharge and obstructions 1 With the engine running check that air blows out of the condensate drain hole s on the left and right sides of the engine at the main PTO...

Page 108: ...disabled Checking signal ring position 1 If the signal ring is completely visible in the control window 2 replace air filter 2 After installation of new filter press reset button 1 Result Engaged pist...

Page 109: ...heck 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 149 M015695 03E...

Page 110: ...ngine oil level with the engine running 1 After the engine has run for approx 10 minutes at a constant speed of 900 rpm withdraw oil dipstick from guide tube and wipe it 2 Insert dipstick into guide t...

Page 111: ...restarted Checking engine oil level at oil sight glass 1 The oil level 2 can be checked visually in advance at the oil sight glass 1 2 A correct reading of the engine oil level is only possible with...

Page 112: ...ing 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 w...

Page 113: ...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 114: ...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 115: ...Parts Catalog WARNING Hot oil Oil can contain combustion residues which are harmful to health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with s...

Page 116: ...f spring washer and washer 9 Remove screw 4 10 Remove flushing arm 5 from screen plate 6 11 Turn filter element by 180 and use appro priate tool to push out filter candles 1 12 Turn filter insert by 1...

Page 117: ...ally 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...

Page 118: ...isk of injury and poisoning 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 j...

Page 119: ...w part Cleaning strainer 1 Wash strainer 5 with cleaner 2 Remove stubborn deposits with soft brush 3 Blow out strainer 5 with compressed air from inside Installing strainer 1 Coat square section ring...

Page 120: ...talog Sealing ring Spare Parts Catalog Sealing ring Spare Parts Catalog WARNING Hot oil Oil can contain combustion residues which are harmful to health Risk of injury and poisoning Wear protective clo...

Page 121: ...base 10 with sealing ring 9 14 Insert new filter sleeve 6 in rotor tube 7 with the smooth paper surface facing the wall 15 Check sealing ring 5 fit new one if neces sary 16 Mount rotor cover 4 with s...

Page 122: ...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 123: ...ge Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant Change 1 Drain engine coolant Page 124 2 Fill with engine coolant Page 126 M015695 03E 2013 03 Task Description...

Page 124: ...ing unit Draining engine coolant 1 Turn pressure cap on coolant expansion tank counterclockwise until the first stop and allow pressure to escape 2 Continue to turn pressure cap counterclockwise and r...

Page 125: ...case on the left or right side arrowed and drain off the engine coolant 6 Close off all open drain points 7 Place pressure cap on filler neck and close Concluding operations u Switch on preheater M015...

Page 126: ...lding Let the engine cool down Wear protective clothing gloves and goggles safety mask NOTICE Cold coolant in hot engine can cause thermal stress Formation of cracks in components Fill top up coolant...

Page 127: ...e breather valve on filler neck and close 9 Start engine Page 51 10 After running the engine for 10 seconds un der zero load stop engine Page 52 11 Turn breather valve of filler neck on coolant expans...

Page 128: ...nd turn until the first stop 6 Start engine Page 51 7 After running the engine for 10 seconds un der zero load stop engine Page 52 8 Turn breather valve counterclockwise and remove 9 Check coolant lev...

Page 129: ...p Checking pressure relief port 1 Check pressure relief port for oil and cool ant discharge 2 Shut down engine Page 52 and secure against being restarted observe general Maintenance and Repair safety...

Page 130: ...Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Replacing engine coolant filter 1 Close shutoff cocks 1 2 Remove engine coolant filter 2 w...

Page 131: ...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 extrac tion and analysis 1 With the engine ru...

Page 132: ...on 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 visi ble at marking plate 4...

Page 133: ...pecial tools Material Spare parts Designation Use Part No Qty Coolant Charge air coolant Change 1 Drain charge air coolant Page 134 2 Fill with charge air coolant Page 135 M015695 03E 2013 03 Task Des...

Page 134: ...ssure cap on coolant expansion tank counterclockwise until the first stop and allow pressure to escape 3 Continue to turn pressure cap counter clockwise and remove 4 Draw off separated corrosion inhib...

Page 135: ...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 components Fill top up...

Page 136: ...close it 9 Start engine Page 51 10 After 10 seconds of running the engine without load shut down the engine Page 52 11 Turn breather valve of coolant expansion tank counterclockwise until the first st...

Page 137: ...terclockwise until the first stop and allow pressure to escape 9 Continue to turn breather valve counter clockwise and remove 10 Check coolant level Page 132 and top up engine coolant as required a To...

Page 138: ...pump Checking pressure relief port 1 Check pressure relief port for oil and cool ant discharge 2 Shut down engine Page 52 and secure against being restarted observe general Maintenance and Repair saf...

Page 139: ...led 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 144 Drive belt B Cracks on entir...

Page 140: ...G Heavy object Risk of crushing Use appropriate lifting devices and appliances Removing alternator 1 Remove protective cover 2 Mark electrical leads on alternator for identification and disconnect 3 P...

Page 141: ...3 Tighten bolt 2 to specified torque using a torque wrench Name Size Type Lubricant Value Standard Screw M10 Tightening torque 60 Nm 5 Nm 4 Tighten bolt 1 to specified tightening torque using a torque...

Page 142: ...otectors Checking battery charging generator Item Findings Measure Ventilation area arrow Clean None Ventilation area arrow Contaminated Clean Cleaning battery charging generator Note Dry clean batter...

Page 143: ...specified tool and 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...

Page 144: ...nd 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 Tighten screw 3 5 Remove drive belt 6 Screw on screw 2 and replace belt...

Page 145: ...4 Install protective cover 5 Readjust belt tension after 30 minutes and again after 8 hours engine runtime Page 143 M015695 03E 2013 03 Task Description 145 TIM ID 0000007421 007...

Page 146: ...dition visually Page 139 Result For drive belt replacement Page 148 Checking V belt tension Rock ford S270 fan clutch 1 Switch on belt tension tester 2 Hold measuring tip of belt tension tester over b...

Page 147: ...Hz 2 Hz 44 Hz 2 Hz Adjusting drive belt tension 1 Release screws 2 until fan clutch can be moved 2 Tighten stud 1 until the required frequen cy is achieved 3 For Rockford S270 fan clutch Tighten screw...

Page 148: ...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 149: ...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 150: ...Cleaning 1 Remove coarse dirt from housing surface with isopropyl alcohol 2 Remove dirt from connector and cable surfaces with isopropyl alcohol 3 Check legibility of cable labels Clean or replace ill...

Page 151: ...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 1 Check all plug connections for secure se...

Page 152: ...Calibration Drift Compensation Resets the drift correction with DiaSys in engine governor to ensure optimum emission and consump tion behavior CRC Cyclic Redundancy Control Check sum procedure to dete...

Page 153: ...Unit Module for monitoring control and plant related sys tem integration of peripheral components PDU Process Data Unit POM Power Output Module Module to control starter and battery charging gen erato...

Page 154: ...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 155: ...engine manually Page 78 Barring device Part No F6555766 Qty Used in 1 7 2 1 Cylinder liner Endoscopic examination Page 81 Box wrench socket 24 mm Part No F30039526 Qty Used in 1 7 5 2 Valve clearance...

Page 156: ...6783293 Qty Used in 1 7 1 1 Cranking engine manually Page 78 Endoscope Part No Y20097353 Qty Used in 1 7 2 1 Cylinder liner Endoscopic examination Page 81 Feeler gauge Part No Y20098771 Qty Used in 1...

Page 157: ...y Used in 1 7 7 2 Injector Removal and installation Page 98 Milling cutter Part No F30452739 Qty Used in 1 7 7 2 Injector Removal and installation Page 98 MTU test kit Part No 5605892099 00 Qty Used i...

Page 158: ...ement 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 3 Battery charging generator drive Drive belt tension adjustment Page 143...

Page 159: ...Used in 1 7 7 2 Injector Removal and installation Page 98 Torque wrench 10 60 Nm Part No F30452769 Qty Used in 1 1 4 Crankshaft transport locking device Page 8 Qty Used in 1 1 5 Crankshaft transportat...

Page 160: ...ing and refitting Page 140 Torque wrench 40 200Nm Part No F30027337 Qty Used in 1 7 13 3 Engine oil Change Page 112 Torque wrench 6 50 Nm Part No F30027336 Qty Used in 1 7 3 1 Crankcase breather Oil s...

Page 161: ...evice 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...

Page 162: ...hecking pressure relief port 129 138 Coolant charge air Level check 132 Crankcase breather Diaphragm check 85 Oil separator element replacement 85 Crankshaft transport locking device Installation 8 Re...

Page 163: ...tenance schedule Maintenance task reference table QL1 55 MTU contact persons 154 O Oil indicator filter Check 118 Cleaning 118 P Plant Cleaning 54 Putting the engine into operation Preparation after s...

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MTU 12 V 4000 C13, Operating Instructions Manual

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Summary of Contents for 12 V 4000 C13

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