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MTU 12V4000C Series, Operating Instructions Manual

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MTU 12V4000C Series Operating Instructions Manual Download Page 153

10 Appendix B

10.1 Special Tools

Adapter

Part No.:

F6558528

Qty.:
Used in:

1 
8.1.1 Engine – Barring manually (→ Page 75)

Barring tool

Part No.:

F6555766

Qty.:
Used in:

1 
8.1.1 Engine – Barring manually (→ Page 75)

Qty.:
Used in:

1 
8.2.1 Cylinder liner – Endoscopic examination (→ Page 77)

Crossbeam

Part No.:

T80091826

Qty.:
Used in:

1 
2.1 Transportation (→ Page 17)

MS150049/04E 2017-04

| Appendix B | 153

DCL-ID: 0000017488 - 006

Summary of Contents for 12V4000C Series

Page 1: ...Operating Instructions Diesel Engine 12V4000Cxyz 16V4000Cxyz MS150049 04E...

Page 2: ...tinuous operation variable 16V4000C20R 117 kW cyl 5B Continuous operation variable 16V4000C21 117 kW cyl 5B Continuous operation variable 16V4000C21L 126 kW cyl 5B Continuous operation variable 16V400...

Page 3: ...wn the engine 50 5 7 Plant Cleaning 51 6 Maintenance 6 1 Maintenance task reference table QL1 52 7 Troubleshooting 7 1 Troubleshooting 53 7 2 Fault messages from DDEC engine governor 56 8 Task Descrip...

Page 4: ...ump Relief bore check 132 8 17 Engine Mounting Support 133 8 17 1 Engine mounting Check 133 8 17 2 Securing screws Check for firm seating 134 8 18 Belt Drive 135 8 18 1 Drive belt Condition check 135...

Page 5: ...the execution of calibration processes that might affect the emission characteristics of the product are prohibited by emission regulations Emission control units systems may only be maintained ex ch...

Page 6: ...regard to the specified tightening torques With the exclusive use of technical personnel trained in commissioning operation maintenance and re pair By contracting only workshops authorized by the man...

Page 7: ...se personnel must be instructed repeatedly Personnel requirements All work on the product must be carried out by trained instructed and qualified personnel only Training at the Training Center of the...

Page 8: ...rminals or cables against accidental contact Check that all connections have been correctly allocated e g polarity direction Immediately after putting the product into operation make sure that all con...

Page 9: ...quipment is in operation certain components of these appliances are electrically live Follow the applicable operating and safety instructions when operating the devices and heed warnings at all times...

Page 10: ...g work on CaPoS if used Switch of the charging system DC DC converter Discharge the UltraCap modules using the appropriate discharger Short circuit the UltraCap modules with a suitable wire jumper Clo...

Page 11: ...d V belts must not be painted Only install them after painting the engine or mask them prior to painting The following applies to starters with copper beryllium alloy pinions Wear a respirator mask fi...

Page 12: ...en working on batteries Gases released from the battery are explosive Avoid sparks and naked flames Do not allow battery acids to come into contact with skin or clothing Wear protective clothing goggl...

Page 13: ...ified personnel only Follow the safety in structions in the manufacturer s user manual when working with laser equipment Wear special laser safety glasses when working with laser equipment danger of c...

Page 14: ...per sonal protective equipment when handling components Noise Wear ear protectors in work areas with a sound pressure level in excess of 85dB A Noise can lead to an increased risk of accident if acous...

Page 15: ...ray stands provided with fume extraction systems ensure that the area is well ventilated Make sure that neighboring work areas are not impaired Avoid open flames in the vicinity No smoking Observe fir...

Page 16: ...NOTICE In the event of a situation involving potentially adverse effects on the product Consequences Material damage Remedial action Additional product information Warning notices 1 This manual with...

Page 17: ...Raise and lower the system engine generator slowly Do not allow hoist slings or chains to contact the sys tem engine generator or any of their component parts Readjust lifting tackle as necessary 7 Fo...

Page 18: ...a suspended load Applies also to 16V4000Cx0 16V4000Cx1 1 Max permissible diagonal pull 10 2 Center of gravity Take note of the engine center of gravity Refer to the installation arrangement drawings f...

Page 19: ...s must be in stalled 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 22 4 Always use...

Page 20: ...fied torque using a torque wrench Name Size Type Lubricant Value Standard Nut M24 Tightening torque Engine oil 100 Nm 10 Nm 4 Secure with nut 3 5 Mark the engine as Fitted with transport locking devic...

Page 21: ...oil 250 Nm 25 Nm 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 to specified torque us...

Page 22: ...and generator according to the instructions 3 Always use the screws supplied with or installed in the transport locking device to secure it on the engine 4 Starting or barring the engine is allowed on...

Page 23: ...crews with washers on engine and screw back in when the transport locking device has been removed 6 Place screw 6 in the recess of holder 3 and insert through the opening at the flywheel housing 1 Sec...

Page 24: ...nated in accordance with DIN ISO 1204 as viewed from driving end 4 For cylinder designation in accordance with DIN ISO 1204 the letter Ax refers to the cylinders on the left hand side of the engine 1...

Page 25: ...t pipe bellows 6 Turbocharger 7 Combustion air inlet 8 Intercooler 9 Crankcase breather 10 Charge air line 11 Electric starter 12 Crankcase 13 Engine governor 14 Easy change fuel filter 15 Cylinder he...

Page 26: ...pstick 12 Oil filler neck 13 Oil pan 14 Carbon brushes 15 Flywheel 16 Flywheel housing Engine model designation Explanation of engine model designation 12 16V4000Cxyz 12 16 Number of cylinders V Cylin...

Page 27: ...rankshaft speed 3 Charge air temperature 4 Charge air pressure The injectors are underneath the cylinder head covers of the cylinder Injector replacement and necessary activities Page 96 MS150049 04E...

Page 28: ...temperature 4 HP fuel 5 Intercooler coolant pressure 6 Engine coolant pressure 1 Intercooler coolant temper ature 2 Crankcase pressure 3 Lube oil temperature 4 Lube oil pressure 28 General Information...

Page 29: ...erance 10 Value not adequately verified tolerance 5 ID Product type Application Engine speed List perform ance 1 12V4000C11 T1237K11 110 2 Industrial vehicle main drive 5A continuous opera tion unrest...

Page 30: ...tal displacement Liters 48 80 48 80 48 80 48 80 Number of inlet valves per cylinder 2 2 2 2 Number of exhaust valves per cylinder 2 2 2 2 Combustion air exhaust gas ID 1 2 3 4 Charge air pressure befo...

Page 31: ...s 33 33 33 33 Engine oil max R Liters 198 198 198 198 Weights ID 1 2 3 4 Engine weight dry basic engine configu ration acc to scope of delivery specifica tion R kg 6044 6044 6044 6044 Sound Number of...

Page 32: ...t adequately verified tolerance 10 Value not adequately verified tolerance 5 ID Product type Application Engine speed List perform ance 1 16V4000C11 T1637K11 110 3 Industrial vehicle main drive 5A con...

Page 33: ...nder 2 2 2 Number of exhaust valves per cylinder 2 2 2 Combustion air exhaust gas ID 1 2 3 Charge air pressure before cylinder R bar 2 0 2 1 1 95 Exhaust gas temperature R C 377 377 376 Coolant system...

Page 34: ...e side R Liters 42 42 42 Engine oil max R Liters 230 230 230 Weights ID 1 2 3 Engine weight dry basic engine configuration acc to scope of delivery specification R kg 7083 7083 7083 Sound ID 1 2 3 Uns...

Page 35: ...verified tolerance 5 ID Product type Application Engine speed List perform ance 1 12V4000C21 T1237K11 109 9 Industrial vehicle main drive 5A continuous opera tion unrestricted 5B continuous opera tio...

Page 36: ...al displacement Liters 48 80 48 80 48 80 48 80 Number of inlet valves per cylinder 2 2 2 2 Number of exhaust valves per cylinder 2 2 2 2 Combustion air exhaust gas ID 1 2 3 4 Charge air pressure befor...

Page 37: ...e R Liters 33 33 33 33 Engine oil max R Liters 198 198 198 Weights ID 1 2 3 4 Engine weight dry basic engine configu ration acc to scope of delivery specifica tion R kg 6044 6044 6044 6044 Sound ID 1...

Page 38: ...Product type Application Engine speed List perform ance 1 16V4000C21 T1637K11 108 5 Industrial vehicle main drive 5A continuous opera tion unrestricted 5B continuous opera tion variable 1900 rpm 1864...

Page 39: ...arrangement V angle Degrees 90 90 90 90 90 Bore mm 165 165 165 165 165 Stroke mm 190 190 190 190 190 Displacement of a cylin der Liters 4 1 4 1 4 1 4 1 4 1 Total displacement Liters 65 0 65 0 65 0 65...

Page 40: ...ne side without cooling equipment R Liters 164 164 164 164 Charge air coolant engine side R Liters 42 42 42 42 Engine oil max R Liters 230 230 230 Weights ID 1 2 3 4 5 Engine weight dry basic engine c...

Page 41: ...er than the specified value Actual value must be less than the specified value Value not adequately verified tolerance 10 Value not adequately verified tolerance 5 ID Product type Application Engine s...

Page 42: ...sure max R bar Thermostat Starts to open R C 77 Thermostat Fully open R C 87 Lube oil system ID 1 Lube oil operating pressure upstream of engine from R bar 5 0 Fuel system ID 1 Fuel temperature before...

Page 43: ...ng order 8V A1 B4 A4 A2 B3 A3 B2 B1 12V A1 B2 A5 B4 A3 B1 A6 B5 A2 B3 A4 B6 16V A1 A7 B4 B6 A4 B8 A2 A8 B3 B5 A3 A5 B2 A6 B1 B7 20V A1 B5 A8 B7 A5 B2 A7 B10 A2 B3 A10 B6 A3 B4 A6 B9 A4 B1 A9 B8 MS1500...

Page 44: ...nsions Engine model Length A Width B Height C 12V4000Cxyz approx 2540 mm approx 1630 mm approx 2050 mm 16V4000Cxyz approx 3010 mm approx 1630 mm approx 2050 mm 44 Technical Data MS150049 04E 2017 04 T...

Page 45: ...ations A001070 Valve drive Lubricate valve gear every 6 months Page 87 Lube oil system Check engine oil level Page 108 Crank engine on starting system Page 76 Fuel system Vent Page 102 Coolant circuit...

Page 46: ...ngine into operation Check the components carrying air and exhaust for corrosion Do not put the engine in operation if corrosion was detected Putting into operation Item Measure Engine oil system Chec...

Page 47: ...g Risk of damage to hearing Wear ear protectors Preparation Item Measure Operating mode switch if applicable Switch to manual mode Coolant preheating unit if applicable Switch ON Start engine Item Mea...

Page 48: ...speed temperature pressures Engine oil Check engine oil level Page 108 Engine operation Visually inspect engine and attached components for condition and leaks Check for abnormal running noise exhaus...

Page 49: ...efore damage to components is possible Before shutting down the engine allow it to idle until the engine temperatures decrease and constant levels are indicated Preparation Item Measure Engine Operate...

Page 50: ...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 51: ...ctly at seals or electronic components such as connectors or ECUs Plant Cleaning 1 Carry out plant cleaning only in areas where an appropriate oil separator is provided environmental protec tion 2 Pri...

Page 52: ...tors Page 96 W1008 Replace engine oil filter when changing engine oil or when the interval years is reached at the latest Page 113 W1009 X Measure thickness of oil residue layer clean replace filter s...

Page 53: ...ngine turns but does not fire Cause Corrective action Poor rotation by starter Battery low or faulty u Charge or replace battery manufacturer s documentation Engine wiring faulty u Check Page 145 Air...

Page 54: ...tamination indicator Page 107 Intercooler contaminated u Contact Service Exhaust turbocharger defective u Contact Service Coolant leaks at intercooler Cause Corrective action Intercooler leaky major c...

Page 55: ...ctive action Engine is not at operating temperature u Warm up Fuel system Water in fuel u Drain fuel prefilter Check fuel system Intercooler leaking u Contact Service MS150049 04E 2017 04 Troubleshoot...

Page 56: ...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 a pause of approx 3 seconds on changing between active and inactive code...

Page 57: ...unit e g injectors FMI Failure Mode Identifier Information about the type of fault which has occurred FMI 0 Measured value above limit value monitoring of TOO HIGH example Coolant temperature FMI 1 Me...

Page 58: ...vel top up if required Page 116 3 Check cooler for dirt 4 Check cabling 5 Contact Service 16 111 5 Sensor Top up coolant in put voltage too high 1 Check cabling 2 Contact Service 17 51 3 Throttle sens...

Page 59: ...eck cabling 2 Contact Service 28 172 4 Air temperature sensor in put voltage too low 1 Check cabling 2 Contact Service 29 351 4 Circuit exhaust turbocharger inlet temperature defective low version 33...

Page 60: ...h 1 Check cabling 2 Contact Service 37 95 3 Fuel differential pressure sensor input voltage too high 1 Check cabling 2 Contact Service 38 18 4 Fuel pressure sensor upper level input voltage too low 1...

Page 61: ...eck coolant condition Page 123 2 Check coolant level top up if required Page 126 3 Check intercooler for contami nation 4 Contact Service 44 105 0 Inlet elbow temperature too high 1 Check contaminatio...

Page 62: ...igh Contact Service 48 18 1 High range Fuel pressure too low 1 Check fuel prefilter 2 Check fuel filter Page 103 3 Fill tank as necessary 4 Contact Service 48 94 1 Fuel pressure too low 1 Check fuel p...

Page 63: ...2 Nonvolatile check sum error Contact Service 53 253 12 EEPROM write error Contact Service 53 253 13 Out of calibrated range Contact Service 54 84 12 Vehicle s speed sensor de fect 1 Check cabling 2...

Page 64: ...it plus X3 Contact Service 62 54 4 Auxiliary output 6 open cir cuit X3 Contact Service 62 54 7 Auxiliary output 6 mechani cal system does not respond correctly X3 Contact Service 62 55 3 Auxiliary out...

Page 65: ...urbocharger speed sensor input signal faulty ir regular period Contact Service 65 51 0 Throttle position above nor mal range Contact Service 65 51 1 Throttle position below nor mal range Contact Servi...

Page 66: ...to ground Contact Service 71 xxx 1 Reaction time injection noz zle xxx too short Contact Service 72 84 0 Vehicle s speed too high Contact Service 72 84 11 Vehicle s speed too high ab solute Contact S...

Page 67: ...rsion 29 0 or later Contact Service 75 232 0 Sensor supply voltage too high Contact Service 76 121 0 Engine overspeed with ex haust brake Contact Service 77 3 0 Cylinder head temperature too high Cont...

Page 68: ...ice 77 171 0 Outside temperature too high Contact Service 77 171 1 Outside temperature too low Contact Service 77 172 1 Intake air temperature too low Contact Service 77 174 0 Fuel temperature too hig...

Page 69: ...EGR temperature too high version 33 0 or later Contact Service 81 129 3 Exhaust duct temperature 1 sensor voltage too high ver sion 32 0 or later Contact Service 81 130 3 Exhaust duct temperature 2 s...

Page 70: ...igh version 32 0 or later Contact Service 81 144 3 Exhaust duct temperature 16 sensor voltage too high version 32 0 or later Contact Service 81 154 3 EGR temperature input volt age too high Contact Se...

Page 71: ...t temperature 6 sensor voltage too low ver sion 32 0 or later Contact Service 82 135 4 Exhaust duct temperature 7 sensor voltage too low ver sion 32 0 or later Contact Service 82 136 4 Exhaust duct te...

Page 72: ...8 2 Contact Service 83 101 0 Crankcase pressure too high Contact Service 83 153 0 Crankcase pressure too high version 27 0 or later Contact Service 83 173 0 Exhaust temperature too high Contact Servic...

Page 73: ...ntact Service 83 141 0 Exhaust duct temperature 13 sensor voltage too high version 32 0 or later Contact Service 83 142 0 Exhaust duct temperature 14 sensor voltage too high version 32 0 or later Cont...

Page 74: ...ltage too low Contact Service 88 20 1 High range coolant pressure too low Contact Service 88 109 1 Coolant pressure too low Contact Service 89 95 0 Fuel differential pressure too high Contact Service...

Page 75: ...being caught up or drawn in Ensure that all personnel is clear of the danger zone before cranking the engine on the starter Barring engine manually lateral installation 1 Remove guard plate 2 Engage b...

Page 76: ...nk angle sensor for injection timing of any cylinder Page 27 For this purpose unlock latch 4 3 Crank engine in unloaded state Press START pushbutton Note Interrupt engine start after maximum ten sec o...

Page 77: ...top piston 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...

Page 78: ...epending 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 injector...

Page 79: ...on the running surface and show local removal of the honing pat tern Grooves from the honing process are not visible any more New cylinder liners must be fitted in the following cases Polished area co...

Page 80: ...rting in the TDC ring 1 have to be replaced Seizure marks scuffing Seizure marks are of irregular circumferential length and depth Can be caused by either the piston skirt or the piston crown Material...

Page 81: ...to cool to below 50 C before beginning work Wear protective clothing protective gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Crankcase breather closed cir cuit crankc...

Page 82: ...age 83 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 Use torque wrench to tighten nut of clamp 4 to specified tightening to...

Page 83: ...air jet at people Always wear safety goggles face mask and ear defenders NOTICE Cleaning agents should not be left to take effect for too long Damage to components is possible Observe manufacturer s i...

Page 84: ...jet of pressurized air Risk of injury to eyes and damage to hearing risk of rupturing internal organs Never direct air jet at people Always wear safety goggles face mask and ear defenders NOTICE Inap...

Page 85: ...ng surface of carbon brushes on adapter with cold cleaner 2 Remove stubborn deposits with soft brush 3 Blow out adapter with compressed air Installing grounding device 1 Remove dirt from flywheel hous...

Page 86: ...on brush 6 on adapter 2 7 Tighten screws 4 and 5 finger tight 8 Turn screws 3 and 7 as far as the stop and tighten lightly 9 Tighten screws 4 and 5 to specified torque using a torque wrench Name Size...

Page 87: ...Spare parts Designation Use Part No Qty Engine oil Valve gear Lubrication 1 Remove cylinder head covers Page 94 2 Fill oil chambers of valve bridges with oil 3 Fill oil chambers of rocker arms and ad...

Page 88: ...ion using barring tool until OT marking 1 and pointer 2 are aligned Measuring valve protrusion 1 Check TDC position of piston in cylinder A1 If rocker arms on cylinder A1 are unloaded the piston is in...

Page 89: ...ble wear 2 mm If the measured value is 95 8 mm have the relevant cylinder head replaced by specialist personnel ahead of schedule 5 Install valve bridge 6 Adjusting valve clearance Page 90 Final steps...

Page 90: ...s Designation Use Part No Qty Feeler gage Y20098771 1 Torque wrench 60 320 Nm F30452768 1 Socket box wrench F30039526 1 Engine oil Preparatory steps 1 Remove cylinder head cover Page 94 2 Install barr...

Page 91: ...agram for 8V engines two crankshaft positions Diagram for 12V engines two crankshaft positions Diagram for 16V engines two crankshaft positions MS150049 04E 2017 04 Valve Drive 91 TIM ID 0000004357 00...

Page 92: ...ces in two crankshaft positions firing TDC and overlap TDC of cylinder A1 as per diagram 1 Cylinder A1 is in firing TDC 2 Cylinder A1 is in overlap TDC I Inlet valve X Exhaust valve 4 Use feeler gage...

Page 93: ...bricant Value Standard Nut M16 x 1 5 Tightening torque Engine oil 90 Nm 9 Nm man ual tightening 6 Replace or rectify adjusting screws and or locknuts which do not move freely 7 Check valve clearance F...

Page 94: ...o screws 1 and remove with wash ers 2 3 Remove cylinder head cover 3 with gas ket 4 from cylinder head 4 Remove other cylinder head covers in the same way Installing cylinder head cover 1 Clean mating...

Page 95: ...f damage to hearing Wear ear protectors HP fuel pump Relief bore check 1 Check relief bore for oil and fuel discharge by visual inspection 2 If relief bore is found dirty stop the engine disable engin...

Page 96: ...Replacement Special tools Material Spare parts Designation Use Part No Qty Injector Spare Parts Catalog Injector Replacement u Remove injector and install new one Page 97 96 Injector MS150049 04E 201...

Page 97: ...X00067260 1 Engine oil WARNING Fuels are combustible and explosive Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Wear protective clothing protective...

Page 98: ...side is completed 1 Release the cable terminal threaded connec tion arrowed on the injector and remove ca ble terminals 2 Remove screw 2 and take off hold down clamp 1 3 Remove HP fuel line 5 4 Instal...

Page 99: ...nozzle retaining nut 3 Fit new O rings on injector and apply assem bly compound 4 Fit new sealing ring with assembly compound on injector pay attention to installation posi tion of sealing ring 5 Clea...

Page 100: ...ied initial tightening torque using a torque wrench Name Size Type Lubricant Value Standard Screw M12 Preload torque Engine oil 5 Nm to 10 Nm 13 Fit O rings 4 and 6 on HP fuel line 5 and coat with ass...

Page 101: ...nch Name Size Type Lubricant Value Standard Union nut Tightening torque 120 Nm 10 Nm 18 Twist cable several times 19 Insert cable lugs arrowed underneath the screws on the injector and tighten screws...

Page 102: ...ses facial protection LP fuel system Venting 1 Connect 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...

Page 103: ...media e g fuel or ether Risk of fatal injury through swallowing risk of poisoning through inhalation irritation to eyes and skin Seek medical attention immediately do not induce vomiting Do not inhale...

Page 104: ...et at people Always wear safety goggles face mask and ear defenders Charge air cooler checking wa ter drain for coolant leakage and obstruction 1 With the engine running verify that air emerges from t...

Page 105: ...ck 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 145 MS150049 04E 2...

Page 106: ...Checking filling level and condi tion of system Note After two successive starting attempts with cold start system try to start the engine again after 10 minutes only If the next two staring trials fa...

Page 107: ...8 12 Air Intake 8 12 1 Service indicator Check See manufacturer s documentation MS150049 04E 2017 04 Air Intake 107 TIM ID 0000005482 004...

Page 108: ...engine oil level with the engine running 1 After the engine has run for approx 10 minutes at a constant speed of 900 rpm remove oil dipstick from guide tube and wipe it 2 Insert dipstick into guide t...

Page 109: ...d Checking engine oil level at oil sight glass 1 The oil level 2 can be checked visually in ad vance at the oil sight glass 1 2 A correct reading of the engine oil level is on ly possible with the oil...

Page 110: ...hing protective gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Procedure without pump Draining oil at drain plug s on oil pan 1 Provide a suitable container in which to...

Page 111: ...all drain plug s with new sealing ring 5 use torque wrench to tighten drain plugs 2 and 3 to specified tightening torque Name Size Type Lubricant Value Standard Screw M26 x 1 5 Tightening torque Engin...

Page 112: ...ore beginning work Wear protective clothing protective gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING High level of engine noise when the engine is running Risk...

Page 113: ...lothing protective gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Engine oil filter Replacement 1 Use filter wrench to remove engine oil filter 2 Clean sealing surface...

Page 114: ...rts Catalog Sealing ring Spare Parts Catalog WARNING Oil is hot Oil can contain residue substances which are harmful to health Risk of injury and poisoning Allow the product to cool to below 50 C befo...

Page 115: ...o lower rotor 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 rotor cap 8 14 Check sealing ring 11 replace if n...

Page 116: ...to turn cap counterclockwise and remove 3 Check engine coolant level engine coolant must be visible at bottom edge of cast in eye of filler neck Checking coolant level at exter nal cooler Note Engine...

Page 117: ...level at sight glass 1 Check coolant level coolant level must be between min and max mark 2 Top up coolant if necessary Page 120 MS150049 04E 2017 04 Coolant Circuit General High Temperature Circuit 1...

Page 118: ...Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 119 2 Fill with engine coolant Page 120 118 Coolant Circuit General High Temperature Circuit...

Page 119: ...rosion inhibitor oil in expansion tank through the filler neck 4 Open drain valves and or drain plugs and drain coolant at the following points Elbow of HT engine coolant pump Crankcase left and right...

Page 120: ...cool down Wear protective clothing gloves and goggles safety mask NOTICE Cold coolant in hot engine can cause thermal stress Possible formation of cracks in the engine Fill top up coolant only into co...

Page 121: ...ngine 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 engine coolant via filler neck on expansion t...

Page 122: ...r protectors Engine coolant pump Relief bore check 1 Check relief bore for oil and coolant dis charge Permissible coolant discharge up to 10 drops per hour Permissible oil discharge up to 5 drops per...

Page 123: ...ty mask WARNING Coolant contains antifreeze and is toxic Risk of poisoning and slipping Avoid contact with eyes and skin Do not inhale vapors or mist wear breathing protection Do not eat drink smoke w...

Page 124: ...Nm 5 Using the equipment and chemicals from the MTU test kit examine coolant for antifreeze concentration Amount of corrosion protection oil pH value 6 For engine coolant change intervals refer to MT...

Page 125: ...steps u Switch off preheating unit Breather valve Replacement Note Pictorial schematic Design may deviate 1 Turn breather valve 1 on coolant expansion tank counterclockwise until the first stop and r...

Page 126: ...stop and allow pressure to escape 2 Continue to turn cap counterclockwise and remove Note Charge air coolant must be visible at marker plate 3 Check charge air coolant level 4 Top up charge air coolan...

Page 127: ...al tools Material Spare parts Designation Use Part No Qty Coolant Charge air coolant Change 1 Drain charge air coolant Page 128 2 Fill with charge air coolant Page 129 MS150049 04E 2017 04 Low Tempera...

Page 128: ...oolant expansion tank counterclockwise until the first stop and al low pressure to escape 3 Continue to turn breather valve counterclock wise and remove 4 Draw off separated corrosion inhibitor oil in...

Page 129: ...ressure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask NOTICE Cold coolant in hot engine can cause thermal stress Possible formation of cr...

Page 130: ...tart engine Page 47 10 After 10 seconds of running the engine with out load shut down the engine Page 49 11 Turn pressure cap of coolant expansion tank counterclockwise until the first stop and al low...

Page 131: ...ry 7 Position pressure cap on the filler neck and close to the first stop 8 Start engine Page 47 9 After 10 seconds of running the engine with out load shut down the engine Page 49 10 Turn pressure ca...

Page 132: ...aring Wear ear protectors Charge air coolant pump Re lief bore check 1 Check relief bore for oil and coolant dis charge 2 Stop engine Page 49 and disable engine start observe general safety instructio...

Page 133: ...mounting Check Engine mounting Check Item Findings Action Visually inspect resilient mounts Damage Brittleness Deformation Crack formation Swelling Replace contact Service MS150049 04E 2017 04 Engine...

Page 134: ...is stopped and starting disabled Checking securing screws for firm seating 1 Check securing screws 1 on fan housing 2 for firm seating 2 Tighten loose threaded connections using a torque wrench 134 E...

Page 135: ...Protective cover is removed Drive belt Condition check Item Findings Measure Drive belt A Singular cracks None Drive belt B Cracks on entire circumference Replace Page 139 Drive belt C Chunking Drive...

Page 136: ...ons 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 3 Che...

Page 137: ...ders Checking battery charging generator Item Findings Measure Ventilation areas arrows Clean None Ventilation areas arrows Contaminated Clean Cleaning battery charging generator Note Dry clean batter...

Page 138: ...ttery charging generator and remove 3 Protect all cables from damage 4 Slacken screws 2 and 3 by half a turn 5 Mount socket or box wrench on screw 4 and press belt tensioner in direction of arrow as f...

Page 139: ...bility Risk of crushing body or limbs Use appropriate lifting gear and appliances Wear safety shoes Replacing drive belt and belt tensioner 1 Remove protective cover 2 Slacken screws 2 and 3 by half a...

Page 140: ...sioned Risk of hands being crushed Lock belt tensioner in position Only use specified tools and devices Adjusting belt tension 1 Remove protective cover 2 Slacken screws 1 and 2 by half a turn Result...

Page 141: ...on adjustment UPC 0K601A0515 UPC 06K01 2233 UPC 06K01B0324 47 Hz 3 Hz 64 Hz 1 Hz 56 Hz 1 Hz UPC 0K601A0515 UPC 06K01 2233 X00027176 46 Hz 3 Hz 62 Hz 1 Hz 55 Hz 1 Hz UPC 0K601A0515 UPC 06K01 2264 UPC 0...

Page 142: ...UPC 0K601A0605 UPC 06K01 2233 UPC 06K01B0325 47 Hz 3 Hz 59 Hz 1 Hz 52 Hz 1 Hz UPC 0K601A0605 UPC 06K01 2264 UPC 06K01B0326 41 Hz 3 Hz 52 Hz 1 Hz 45 Hz 1 Hz XS526220 00004 UPC 06K01 2264 XS526220 0000...

Page 143: ...e belt 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 re moved 3 Clean belt pulleys 4...

Page 144: ...Before 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 leak...

Page 145: ...intact 4 Replace faulty cable clips 5 Check cable clamps for secure fit tighten loose clamps 6 Replace faulty cable clamps 7 Visually inspect the following electrical components for damage Connector h...

Page 146: ...electrical sparks and ignition sources Wear goggles facial protection Only work in a well ventilated room Do not smoke DDEC and connectors Clean ing 1 Remove coarse dirt from housing surface us ing a...

Page 147: ...connectors 3 3 Remove covers 2 4 Clean connector housings connector socket housings and all contacts with isopropyl alco hol 5 When connectors sockets and all contacts are dry Install connectors and c...

Page 148: ...nnections 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 cov ering caps 2 5 I...

Page 149: ...amp rectify fault as soon as possible 2nd function Read out fault codes CKT Circuit CLS Coolant Level Sensor Monitors coolant level CM Current Measurement Current measured value CPS Coolant Pressure S...

Page 150: ...ssure HI High Alarm Measured value exceeds 1st maximum limit HIHI High High Alarm Measured value exceeds 2nd maximum limit HT High Temperature IDM Interface Data Module Memory module for interface dat...

Page 151: ...ng lamp stop engine and rectify fault 2nd function Read out fault codes SID System Identifier SRS Synchronous Reference Sensor TDC cylinder 1 SS Safety System Security Shutdown Safety system alarm TBS...

Page 152: ...of a malfunction for information on changes in conditions of use and for supplying spare parts Your contact person in our Customer Assistance Center E mail info mtu online com Tel 49 7541 9077777 Fax...

Page 153: ...manually Page 75 Barring tool Part No F6555766 Qty Used in 1 8 1 1 Engine Barring manually Page 75 Qty Used in 1 8 2 1 Cylinder liner Endoscopic examination Page 77 Crossbeam Part No T80091826 Qty Us...

Page 154: ...ty Used in 1 8 5 2 Valve protrusion Measurement Page 88 Endoscope Part No Y20097353 Qty Used in 1 8 2 1 Cylinder liner Endoscopic examination Page 77 Feeler gage Part No Y20098771 Qty Used in 1 8 5 3...

Page 155: ...8 14 1 Engine oil filter Replacement Page 113 Qty Used in 1 8 14 2 Centrifugal oil filter Cleaning and filter sleeve re placement Page 114 High pressure cleaner Part No Qty Used in 1 5 7 Plant Cleani...

Page 156: ...1 8 15 6 Engine coolant Sample extraction and analysis Page 123 Optibell 2 belt tension tester Part No Y4345711 Qty Used in 1 8 20 1 Fan drive Adjust and check drive belt tension Page 141 Ratchet bit...

Page 157: ...y charging generator Drive belt tension ad justment Page 140 Ratchet with extension Part No F30006212 Qty Used in 1 8 1 1 Engine Barring manually Page 75 Qty Used in 1 8 2 1 Cylinder liner Endoscopic...

Page 158: ...g device Page 19 Qty Used in 1 2 4 Crankshaft transport locking device For transport with flanged on generator Page 22 Qty Used in 1 8 3 1 Crankcase breather Filter element replacement Page 81 Qty Use...

Page 159: ...evice For transport with flanged on generator Page 22 Qty Used in 1 8 5 3 Valve clearance Check and adjustment Page 90 Qty Used in 1 8 7 2 Injector Removal and installation Page 97 Qty Used in 1 8 19...

Page 160: ...generator Removal assembly 22 Cylinder Designation 24 Cylinder head cover Installation 94 Removal 94 Cylinder liner Endoscopic examination 77 Cylinder liner Instructions and comments on endoscopic and...

Page 161: ...Putting into operation Preparation after scheduled out of service period 46 Putting the engine into operation after extended out of service periods 3 months 45 S Safety notices standards 16 Safety reg...

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