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MTU 12 V 4000 S83L, Operating Instructions Manual

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MTU 12 V 4000 S83L Operating Instructions Manual Download Page 135

Ratchet with extension

Part No.:

F30006212

Qty.:
Used in:

1 
7.1.1 Cranking engine manually (→ Page 59)

Qty.:
Used in:

1 
7.2.1 Cylinder liner – Endoscopic examination
(→ Page 63)

Steam jet cleaner

Part No.:

-

Qty.:
Used in:

1 
4.7 Plant cleaning (→ Page 35)

Torque wrench, 0.5-5 Nm

Part No.:

0015384230

Qty.:
Used in:

1 
7.6.2 Injector – Removal and installation (→ Page 77)

Torque wrench, 10-60 Nm

Part No.:

F30452769

Qty.:
Used in:

1 
7.6.2 Injector – Removal and installation (→ Page 77)

Qty.:
Used in:

1 
7.18.2 Battery-charging generator drive – Drive belt
tension adjustment (→ Page 118)

Qty.:
Used in:

1 
7.18.3 Battery-charging generator drive – Drive belt re-
placement (→ Page 119)

MS150027/02E 2013-02

| Appendix B | 135

DCL-ID: 0000005665 - 003

Summary of Contents for 12 V 4000 S83L

Page 1: ...Operating Instructions Diesel engine 12 V 4000 S83L 16 V 4000 S83L MS150027 02E...

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: ...9 7 1 2 Engine Barring with starting system 61 7 1 3 Engine Test run 62 7 2 Cylinder Liner 63 7 2 1 Cylinder liner Endoscopic examination 63 7 2 2 Instructions and comments on endoscopic and visual ex...

Page 4: ...coolant pump Checking pressure relief port 115 7 17 Belt Drive 116 7 17 1 Drive belt Condition check 116 7 18 Battery Charging Generator 117 7 18 1 Battery charging generator Check 117 7 18 2 Battery...

Page 5: ...on 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 the...

Page 6: ...lar 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 Personn...

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: ...with the transport locking device removed If the gener ator transmission is already mounted on the engine ensure that the transport locking device of the generator transmission is also removed Prior...

Page 9: ...Use torque wrench to tighten nut 8 to the specified tightening torque 100 Nm 10 Nm Lubricant Engine oil Secure with nut 3 Mark the engine as Fitted with transport locking device Transport locking devi...

Page 10: ...the specified tightening torque 250 Nm 25 Nm Lubricant Engine oil Screw on nuts 6 up to the end of the threads of screws 5 Fit holders 4 through the openings in plates 1 on both sides and lock in pos...

Page 11: ...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 12: ...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 13: ...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 14: ...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 guid...

Page 15: ...ne 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 carryin...

Page 16: ...on involving potentially adverse effects on the product Consequences Material damage Remedial action Additional product information Note This manual contains highlighted safety warnings in accordance...

Page 17: ...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 18: ...ernor 12 Fuel filter 13 Cylinder head 14 HP fuel pump 15 Automatic oil filter safety oil filter is optional 16 Coolant filter 17 Fan drive 18 Centrifugal oil filter KGS Engine free end Engine model de...

Page 19: ...r filter XY44 solenoid valve fan coupling 3 B05 lube oil pressure 4 B44 turbocharger speed 5 Injectors Y39 1 to Y39 6 A bank 6 Engine governor 7 B34 fuel pressure after fil ter 8 F46 Leak fuel level m...

Page 20: ...3 fuel temperature in common rail 4 B48 fuel pressure in com mon rail 5 B01 camshaft speed 6 B43 charge air coolant pressure 7 B26 charge air coolant temperature 8 B06 coolant temperature 20 General I...

Page 21: ...re 3 B10 charge air pressure 4 XM2 Oil priming pump 5 B09 charge air tempera ture The injectors are located below the cylinder head covers Injector replacement and required procedure Page 76 MS150027...

Page 22: ...1 B13 crankshaft speed 22 General Information MS150027 02E 2013 02 TIM ID 0000012926 002...

Page 23: ...tric pressure mbar 1000 1000 Site altitude above sea level m 100 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 12V 16 V Rated engine speed A rpm 1900 190...

Page 24: ...2 2 COMBUSTION AIR EXHAUST GAS Number of cylinders 12V 16 V Charge air pressure before cylin der R bar abs 3 2 3 5 Exhaust temperature after turbo charger R C 495 515 COOLANT SYSTEM HT circuit Number...

Page 25: ...l operating temperature before engine to R C 99 99 Lube oil temperature before en gine alarm R C 101 101 Lube oil temperature before en gine shutdown L C 103 103 Lube oil operating pressure be fore en...

Page 26: ...ers 214 Oil pan capacity at dipstick mark min standard oil system Op tion max operating inclinations L liters 124 Oil pan capacity at dipstick mark max standard oil system Op tion max operating inclin...

Page 27: ...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 MS15...

Page 28: ...dimensions Engine Main dimensions Length A 12V approx 2490 mm Length A 16V approx 2960 mm Width B 12V 16V approx 1449 mm Height C 12V 16V approx 1871 mm 28 Technical Data MS150027 02E 2013 02 TIM ID...

Page 29: ...Oil lubrication system Check engine oil level Page 90 Crank engine using starting system Page 61 Fuel prefilter Fill with fuel if fitted Coolant system If engine has been out of service for more than...

Page 30: ...ne is stopped and starting disabled Putting into operation Item Task Lube oil system Check engine oil level Page 90 Coolant system Check engine coolant level Page 101 Check charge air coolant level Pa...

Page 31: ...or starting the engine make sure that nobody is in the danger zone WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors Preparation Item Task Operating mode switch if fitt...

Page 32: ...ion Check engine for abnormal running noises exhaust color and vibrations Air filter Check signal ring position of service indicator on air filter if fitted Battery charging generator Check battery ch...

Page 33: ...f overheating damage to components Before stopping the engine operate it at idle speed until operating temperatures decrease and stable values are indicated Preparation Item Task Engine Allow engine t...

Page 34: ...of service for an extended period but engine coolant has no antifreeze addi tive coolant is not preheated antifreeze concentration is 50 and outside temperature is below 40 C Engine control system Swi...

Page 35: ...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 Instruc...

Page 36: ...pressure gauge of fuel prefilter Page 32 W0525 Check battery charging generator for contamination clean as necessary Page 117 W1001 Replace fuel filter or fuel filter element Page 83 W1006 Replace fue...

Page 37: ...entation Engine governor Plug in connections are loose Check plug in connections Page 126 Engine Running gear blocked engine cannot be barred manually Contact Service Engine turns but does not fire Co...

Page 38: ...n Check MTU test kit Charge air cooler Contaminated Contact Service Engine room Air intake temperature too high Check fans and air supply ventilation ducts Charge air pressure too low Component Probab...

Page 39: ...arger cylinder head piston rings cylinder liner Defective Contact Service Exhaust gas white Component Probable Cause Task Engine Not at operating temperature Run engine to reach operating tempera ture...

Page 40: ...tion Meaning EC ECU code Fault message from ECU 7 engine manage ment control unit AL AL Alert message from the SAM RL Redundancy Lost Redundant backup CAN CAN 2 not send ing any data fault DL Default...

Page 41: ...n Engine must not be restarted risk of engine damage notify Service 2 0100 92 2 019 HI T Exhaust A Exhaust temperature bank A too high 1st limit 1 Check wiring Page 124 2 Contact Service 2 0126 93 1 0...

Page 42: ...ndary turbo charger too high cylinder charge limited to fixed amount 1 Reduce power 2 Contact Service 2 3013 91 2 038 AL TC Synchro Fault Synchronization error be tween turbochargers 1 and 2 1 Reduce...

Page 43: ...Allow the engine to cool down 2 Contact Service 3 Check engine cool ant radiator clean if dirty 4 Restart engine Page 31 2 0120 93 2 081 AL System Leaking Pressure gradient in fuel rail is too low whe...

Page 44: ...preheater unit 2 1090 92 1 095 AL Oil Priming Fault Alarm configuration oil pri ming fault Check oil priming system 2 1090 92 0 102 AL Consumption Meter Defective Indication of fuel consump tion is i...

Page 45: ...SUPPLY A D converter supply volt age too low Replace Engine Control Unit 147 AD TEST1 ECU DEFEC TIVE Electronics defective auto matic engine shutdown Replace Engine Control Unit 148 L1 AD TEST2 SUPPLY...

Page 46: ...ng inter ference on the bus Notify Service Check CAN bus for short circuit rectify short circuit as nec essary Check shielding improve shielding as neces sary 2 0500 68 6 187 AL CAN1 Error Passive CAN...

Page 47: ...B10 defective short circuit or wiring break Check sensor and wiring replace as necessary Fault is cleared when en gine restarted 1 8004 56 6 211 SD P Lube Oil Sensor B05 defective engine oil pressure...

Page 48: ...9 AL Stop Camshaft Sen sor Fault Crankshaft speed and cam shaft speed sensors defec tive 1 Check wiring 2 Contact Service Check sensor 1 8004 56 2 230 Crankshaft sensor fault Sensor B13 defective cran...

Page 49: ...ircuit or wire break Check wiring re place as necessary Fault is cleared when engine re started 2 8006 58 8 270 SD Frequency Input Frequency setting sensor fault 1 Check wiring 2 Contact Service check...

Page 50: ...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 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...

Page 51: ...oid valve 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 54 8 350 1 8004 54 9 351 OPEN_LOAD CY...

Page 52: ...t ITS 1 Check wiring 2 Attempt to re start engine 1 8004 56 0 365 AL Stop SV Wiring Ground Alarm configuration Injector wiring fault If bit 1 1020 021 output stage failure shut down engine is set engi...

Page 53: ...reliminary warning backup coolant temperature reading too high 1 Check wiring 2 Contact Service 2 0129 93 1 393 SS T Coolant Backup Alarm configuration limit 1 Main warning backup cool ant temperature...

Page 54: ...006 63 0 406 AL Open Load Digital In put 7 Alarm configuration wire break at digital input 7 wir ing defective or no resist ance across switch 1 Check wiring 2 Contact Service Check input of tar get d...

Page 55: ...1 Aux 1 input signal above below limit 2 depending on configuration Determine cause of limit violation and rectify fault 2 0160 92 2 428 L1 T Aux 1 Alarm configuration limit 1 preliminary warning Aux...

Page 56: ...limit violation and rectify fault 2 8006 65 1 460 AL EMU Exhaust High Alarm configuration limit EMU exhaust temperature too high 1 Check wiring 2 Contact Service 2 8006 65 2 461 AL EMU Exhaust Low Al...

Page 57: ...necessary Fault is cleared when en gine restarted 1 8004 58 7 471 SD Intake Throttle SD alarm configuration in take throttle control defec tive short circuit or wire break Check sensor and wiring rep...

Page 58: ...ation RED combined alert from plant Check other fault messages 2 8006 00 2 480 AL Lim Ext Plant Bin Alarm configuration limit in put signal above below limit depending on configuration Determine cause...

Page 59: ...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 60: ...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 61: ...moved 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 cranks...

Page 62: ...WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors Perform engine test run 1 Start engine Page 31 2 Perform test run not below 1 3 load and at least until steady state te...

Page 63: ...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 bo...

Page 64: ...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 65: ...liner It appears rather darker within the honed struc ture in contrast to the bright metallic running surface The honing pattern is undis turbed Discolorations extend in stroke direction and may be i...

Page 66: ...ation are similar A thorough investigation and compliance with the above evaluation criteria allow an unambiguous evaluation To avoid unnecessary disassembly work it is recommended that another inspec...

Page 67: ...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 1 Rem...

Page 68: ...hragm 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 Screw...

Page 69: ...are parts Designation Use Part No Qty Engine oil Valve gear Lubrication 1 Remove cylinder head covers Page 74 2 Fill oil chambers of valve bridges with oil 3 Fill oil chambers of rocker arms and adjus...

Page 70: ...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 7...

Page 71: ...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 MS150027 02E 2013 02 T...

Page 72: ...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 73: ...t 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 oi...

Page 74: ...r 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 Chec...

Page 75: ...ors are combustible explosive Risk of fire and explosion Avoid open flames electric sparks and ignition sources Do not smoke CAUTION Fuel system high pressure pump not filled with engine oil Damage to...

Page 76: ...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 77 76 Task Description MS...

Page 77: ...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 78: ...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 79: ...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 80: ...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 81: ...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 82: ...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 83: ...on 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 84: ...ng 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 85: ...aterial Spare parts Designation Use Part No Qty Air filter Spare Parts Catalog Air filter Replacement 1 Remove air filter and install new one Page 86 2 Reset signal ring of service indicator Page 89 M...

Page 86: ...ng air fil ter element 1 Release latches 9 2 Remove dust bowl 8 and partition 7 3 Remove collar nut 6 4 Screw off air filter element 4 5 Clean housing 3 and dust bowl 8 6 Check seal 5 for damage and c...

Page 87: ...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 124 MS150027 02E...

Page 88: ...ring Wear ear protectors Emergency air shutoff flaps Electric control check 1 Start engine Page 31 2 Activate the appropriate function to trigger emergency air shutoff flaps depending on installation...

Page 89: ...Checking signal ring position 1 If the signal ring is completely visible in the control window 2 replace air filter Page 85 2 After installation of new filter press reset button 1 Result Engaged pist...

Page 90: ...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 91: ...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 92: ...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 fil...

Page 93: ...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 94: ...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 sk...

Page 95: ...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 96: ...rking steps 2 Additionally the following instructions are to be observed Replace all sealing elements Coat O rings with grease Insert O rings in grooves Observe position of cylinder screw to elongated...

Page 97: ...ealth Risk 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 compresse...

Page 98: ...rt Cleaning strainer 1 Wash strainer 5 with cleaning agent 2 Remove stubborn deposits with soft brush 3 Blow out strainer 5 with compressed air from inside Installing strainer 1 Coat square section ri...

Page 99: ...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 100: ...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 101: ...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 102: ...e Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant Change 1 Drain engine coolant Page 103 2 Fill with engine coolant Page 105 102 Task Description MS150027 02E 201...

Page 103: ...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 104: ...ase 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 104 T...

Page 105: ...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 106: ...se c Repeat the steps from Start engine Step 7 until no more coolant has to be added d Disconnect pump and hose Filling coolant through filler neck 1 Alternatively Fill in coolant through filler neck...

Page 107: ...p Checking pressure relief port 1 Check pressure relief port for oil and cool ant discharge 2 Shut down engine Page 33 and secure against being restarted observe general Maintenance and Repair safety...

Page 108: ...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 109: ...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 wi...

Page 110: ...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 visi ble at marking plate 4...

Page 111: ...ecial tools Material Spare parts Designation Use Part No Qty Coolant Charge air coolant Change 1 Drain charge air coolant Page 112 2 Fill with charge air coolant Page 113 MS150027 02E 2013 02 Task Des...

Page 112: ...Turn breather valve 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 segregated c...

Page 113: ...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 cool...

Page 114: ...Repeat the 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 expan...

Page 115: ...pump Checking pressure relief port 1 Check pressure relief port for oil and cool ant discharge 2 Shut down engine Page 33 and secure against being restarted observe general Maintenance and Repair saf...

Page 116: ...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 119 Drive belt B Cracks on entire...

Page 117: ...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 Note D...

Page 118: ...pecified 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 119: ...pter or box wrench on screw 1 and press belt tensioner in the di rection indicated by the arrow as far as it will go 4 Tighten screw 3 5 Remove the used drive belt 6 Fit new drive belt 7 Slacken screw...

Page 120: ...ition visually Page 116 Result For drive belt replacement Page 122 Checking V belt tension Rock ford S270 fan clutch 1 Switch on belt tension tester 2 Hold measuring tip of belt tension tester over be...

Page 121: ...z 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 screws...

Page 122: ...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 123: ...gine mounting Check Engine mounting Check Item Findings Action Visually inspect mounts Damage Brittleness Deformation Crack formation Swelling visible Replace contact Service MS150027 02E 2013 02 Task...

Page 124: ...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 125: ...leaning 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 ille...

Page 126: ...isabled 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 sea...

Page 127: ...sible 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 control system ma...

Page 128: ...ith DIN ISO 1204 LED Light Emitting Diode LO Low Alarm Measured value lower than 1st minimum limit value LOLO Low Low Alarm Measured value lower than 2nd minimum lim it value LSG Limiting Speed Govern...

Page 129: ...TD Transmitter Deviation Alarm Deviation in transmitter values TPS Throttle Position Sensor TRS Timing Reference Sensor T xyz Temperature xyz Temperature measuring point xyz specifies the measuring p...

Page 130: ...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 131: ...ngine manually Page 59 Barring device Part No F6555766 Qty Used in 1 7 2 1 Cylinder liner Endoscopic examination Page 63 Box wrench socket 24 mm Part No F30039526 Qty Used in 1 7 4 2 Valve clearance C...

Page 132: ...783293 Qty Used in 1 7 1 1 Cranking engine manually Page 59 Endoscope Part No Y20097353 Qty Used in 1 7 2 1 Cylinder liner Endoscopic examination Page 63 Feeler gauge Part No Y20098771 Qty Used in 1 7...

Page 133: ...Used in 1 7 6 2 Injector Removal and installation Page 77 Milling cutter Part No F30452739 Qty Used in 1 7 6 2 Injector Removal and installation Page 77 MTU test kit Part No 5605892099 00 Qty Used in...

Page 134: ...ing generator drive Drive belt tension adjustment Page 118 Qty Used in 1 7 18 3 Battery charging generator drive Drive belt re placement Page 119 Ratchet Part No F30027341 Qty Used in 1 7 6 2 Injector...

Page 135: ...ench 0 5 5 Nm Part No 0015384230 Qty Used in 1 7 6 2 Injector Removal and installation Page 77 Torque wrench 10 60 Nm Part No F30452769 Qty Used in 1 7 6 2 Injector Removal and installation Page 77 Qt...

Page 136: ...1 7 14 3 Centrifugal oil filter Cleaning and filter sleeve replacement Page 99 Torque wrench 60 320 Nm Part No F30452768 Qty Used in 1 7 4 2 Valve clearance Check and adjustment Page 70 Qty Used in 1...

Page 137: ...copic examination 63 Instructions and comments on endoscopic and visual examination 65 D Drive belt Condition check 116 E Emergency air shutoff flaps Electric control check 88 Engine Barring with star...

Page 138: ...months 29 S Safety instructions Conventions 16 Safety regulation Environmental protection 14 Safety regulations Auxiliary materials 14 Fire prevention 14 Fluids and lubricants 14 Important provisions...

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