MTU 12V4000G34F Operating Instructions Manual Download Page 134

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9.6 Injector

9.6.1 Injector – Replacement

Special tools, Material, Spare parts

Designation / Use

Part No.

Qty.

Injector

(→ Spare Parts Catalog)

Injector – Replacement

Remove injector and install new one (→ Page 135).

134 | Injector | MS15060/01E 2018-12

TIM-ID: 0000042329 - 002

Summary of Contents for 12V4000G34F

Page 1: ...Operating Instructions Diesel Engine 12V4000G34F 12V4000G94F 16V4000G34F 16V4000G94F MS15060 01E...

Page 2: ...uls 8 000 h or 18 years Table 1 Applicability 2018 Copyright MTU Friedrichshafen GmbH This publication is protected by copyright and may not be used in any way whether in whole or in part without the...

Page 3: ...ors Overview 67 6 Operation 6 1 Putting the engine into operation after extended out of service periods 3 months 71 6 2 Putting into operation after scheduled out of service period 72 6 3 Starting the...

Page 4: ...3 Engine coolant Draining 186 9 14 4 Engine coolant Filling 188 9 14 5 Engine coolant pump Relief bore check 192 9 14 6 Engine coolant Sample extraction and analysis 193 9 14 7 Preheater Overview 195...

Page 5: ...ns Emission related components must only be serviced ex changed or repaired if the components used for this purpose are approved by the manufacturer Noncompliance with these specifications will invali...

Page 6: ...sed military applications other than by US government agen cies Please note the following when replacing components with emission labels The relevant emission labels must be affixed to the spare part...

Page 7: ...ponents have hot surfaces e g exhaust system exhaust turbo chargers exhaust aftertreatment system engine oil system cooling system which can cause injury to per sons who approach or touch them danger...

Page 8: ...a safe shutdown of fuel injection takes place on a diverse redundant path and thus results in engine standstill Through an ap propriate design of the engine generator set or whole plant the operator o...

Page 9: ...lfills the conditions for such use and approval has been granted The section below applies to applications deployed in regions under the jurisdiction of the EPA Use of EPA Tier 2 and Tier 3 certified...

Page 10: ...lified personnel only Training at the Training Center of the manufacturer Qualified personnel from the areas mechanical engineering plant construction and electrical engineering and also for work with...

Page 11: ...battery terminals generator terminals or cables against accidental contact Check that all connections have been correctly allocated e g polarity fuel line reduction agent line supply return Immediatel...

Page 12: ...ids and lubricants immediately or soak up with a suitable binding agent Operation of electrical equipment When electrical equipment is in operation certain components of these appliances are electrica...

Page 13: ...e fitted Attach Do not operate sign in the operating area or to control equipment Disconnect the battery cables or actuate the battery isolating switch if fitted Lock circuit breakers Before starting...

Page 14: ...ent contact with other components Do not place fuel or oil lines near hot components Miscellaneous Sufficient ventilation must be guaranteed during the work Wear a breathing mask offering protection a...

Page 15: ...d the pipework at the relevant designated points For hydraulic installation screw on the jig with the piston retracted For hydraulic removal screw on the jig with the piston extended For a hydraulic i...

Page 16: ...properly prior to replacement i e protect them against moisture in particular Package faulty electronic components or assemblies properly before dispatching for repair Moisture proof Shock proof Wrap...

Page 17: ...Ensure that suitable extinguishing agents fire extinguishers are always available and that staff are familiar with their correct handling A fire can result in the creation of toxic substances Always w...

Page 18: ...tands provided with fume extraction systems ensure that the area is well ventilated Make sure that neighboring work areas are not adversely affected Avoid open flames in the surrounding area No smokin...

Page 19: ...Consequences Material damage Remedial action Additional product information Warning notices 1 This manual with all safety instructions and warning notices must be issued to all personnel involved in...

Page 20: ...rts on engine generator 6 Raise and lower engine generator slowly Do not allow hoist slings or chains to contact engine generator or any of their component parts Adjust lifting gear as necessary 7 For...

Page 21: ...nal protective equipment e g protective helmet safety shoes 1 Max admissible diagonal pull 10 2 Center of gravity 3 Engine lifting eye Take note of the engine center of gravity Refer to the installati...

Page 22: ...must be reinstalled on both engine sides accord ing 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 installe...

Page 23: ...the ring gear 4 Screw in screw 1 in bores of holder 3 until holder 3 is locked in position Note Screw 1 must be tightened stepwise and alternately on both sides of the flywheel housing 5 Tighten scre...

Page 24: ...om the guard plates and engine supports to secure them on the engine u Install engine supports 2 on both sides with guard plates 1 washers 3 and screws 4 and tighten to specified tightening torque tig...

Page 25: ...port locking device must be installed on all resilient mounts according to the instructions before transporting Removing engine mount trans portation locks 1 Slacken nuts 2 2 Undo nut 3 and unscrew an...

Page 26: ...gnated 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 27: ...ted value 5 tolerance ID Product type Application Speed List perform ance 1 12V4000G34F Power generation 3E standby power overload capability ac cording to ICXN 1500 rpm 50 Hz 1755 kW 2353 bhp Ref 25...

Page 28: ...55 1755 Fuel stop power ISO 3046 A kW 1930 1930 1930 General conditions for maximum power ID 1 2 3 4 5 6 Intake depression new filter A mbar 15 15 15 15 15 15 Intake depression max L mbar 50 50 50 50...

Page 29: ...X X Cooling method treated water X X X X X X Direction of rotation c c w viewed on driving end X X X X X X Number of cylinders 12 12 12 12 12 12 Cylinder arrangement Vee angle Degrees 90 90 90 90 90 9...

Page 30: ...perature at engine connection outlet to cooling equipment R C 63 63 63 63 63 63 Coolant temperature be fore intercooler limit 1 L C 75 75 75 75 75 75 Coolant temperature be fore intercooler limit 2 L...

Page 31: ...a tions L Liters 160 160 160 160 160 160 Oil pan capacity at dip stick mark max stand ard oil system option max operating inclina tions L Liters 200 200 200 200 200 200 Masses main dimensions ID 1 2 3...

Page 32: ...ngine surface noise with attenuated intake noise filter DL sound power level LW ISO 6798 2 dB A tolerance R dB A 123 123 123 Engine surface noise with attenuated intake noise filter BL free field soun...

Page 33: ...form ance 1 16V4000G34F Power generation 3E standby power overload capability ac cording to ICXN 1500 rpm 50 Hz 2170 kW 2910 bhp Ref 25 C 55 C Optimized fuel con sumption 2 16V4000G34F Power generatio...

Page 34: ...15 Intake depression max L mbar 50 50 50 30 30 30 Exhaust gas overpressure total pressure referenced to atmosphere A mbar 30 30 30 30 30 30 Exhaust gas overpres sure max total pressure referenced to...

Page 35: ...4 77 4 77 4 77 4 77 Total displacement Liters 76 3 76 3 76 3 76 3 76 3 76 3 Compression ratio 16 4 16 4 16 4 16 4 16 4 16 4 Air exhaust gas ID 1 2 3 4 5 6 Combustion air volumet ric flow DL R m s 2 7...

Page 36: ...ore engine limit 1 L C 99 99 99 99 99 99 Lube oil temperature be fore engine limit 2 L C 101 101 101 101 101 101 General operating data ID 1 2 3 4 5 6 High idling speed max static L rpm 1650 1650 1650...

Page 37: ...ic engine configuration acc to scope of delivery spec ification R kg 8052 8052 8052 8052 8052 8052 Acoustics ID 1 2 3 4 5 6 Exhaust noise unsilenced DL free field sound pressure level Lp 1 m distance...

Page 38: ...Engine surface noise with attenuated intake noise filter BL free field sound pressure level Lp 1 m distance ISO 6798 2 dB A tolerance R dB A 108 108 108 Engine surface noise with attenuated intake no...

Page 39: ...ing order Firing order Number of cylinders Firing order 12V A1 B5 A5 B3 A3 B6 A6 B2 A2 B4 A4 B1 16V A1 A7 B4 B6 A4 B8 A2 A8 B3 B5 A3 A5 B2 A6 B1 B7 MS15060 01E 2018 12 Technical Data 39 TIM ID 0000062...

Page 40: ...idth B Height C 12V4000Gx4F with 2 cylinder HP pump 2433 4 mm 1660 5 mm 2176 5 mm 12V4000Gx4F with 4 cylinder HP pump 2495 0 mm 1660 5 mm 2176 5 mm 16V4000Gx4F with 4 cylinder HP pump 2981 6 mm 1660 5...

Page 41: ...similarly to the 16V model 1 Wastegate 2 LT thermostat housing 3 HT thermostat housing 4 Engine lifting eye 5 Engine mounting 6 Crankcase 7 Starter 8 Flywheel 9 Engine governor 10 Intercooler Engine...

Page 42: ...with engine governor ECU 9 Common rail injection with up to 1800 bar injection pressure atomizes the fuel very finely to optimize com bustion As a result fuel consumption is improved and particle and...

Page 43: ...cooling Dual cooling system LT Low temperature circuit with coolant for charge air cooling HT High temperature circuit with coolant for engine cooling and engine oil heat exchanger Separate pumps for...

Page 44: ...case and coolant distribution housing are installed on the face at the free end KGS The flywheel housing is located on the driving end KS The cylinder heads and engine lifting points are mounted left...

Page 45: ...and camshaft 15 bearings are inside the crankcase The crankcase incorporates bores to route lube oil and engine coolant lines 2 4 6 7 and for the cylin der liners 5 The oil pan 11 serves as a lube oil...

Page 46: ...t pump Gear train The gear train comprises the drive and idler gears installed in the gearcase Technical data Gears with straight toothing Benefits Low wear power transmission Low maintenance No axial...

Page 47: ...on damper and pistons Carefully matched components ensure maximum performance and minimum wear Technical data Piston Aluminum solid skirt piston with integrated cooling duct Two compression rings one...

Page 48: ...ption Function The forces generated in the combustion chambers of the cylinders are transmitted from the pistons 3 and conrods 4 to the crankshaft 2 The crankshaft transforms these forces into a rotar...

Page 49: ...from the crank case Fuel is supplied to the injectors by the HP fuel pump via a common pressure accumulator Fuel flows to through HP lines to the injectors Technical data Individual cylinder heads Two...

Page 50: ...g an air fuel mixture which ignites sponta neously under compression When the exhaust valves 9 open exhaust gas created by the combustion process flows via the outlet duct to the exhaust manifold lead...

Page 51: ...ft supports with the rocker arms are mounted on the cylinder heads Technical data Centrally arranged camshaft lubrication of sleeve bearings from the crankcase The drive gear of the camshaft is direct...

Page 52: ...camshaft to actuate the valves is transferred by swing followers 3 4 pushrods 6 and rocker arms 8 11 onto the valve bridges 13 of the intake and exhaust valves The valves open against spring pressure...

Page 53: ...uel system with Common Rail injection The fuel system consists of a low pressure system and a high pressure system Common Rail system The Common Rail system is controlled by the engine governor Inject...

Page 54: ...lled in the injectors 1 and controlled by the engine electronics The fuel quantity required for the injection process and to maintain the system pressure of up to 1800 bar is preset by a restrictor va...

Page 55: ...ng end KS and on top of the en gine The high power and load application requirements of these engine make wide ranging performance maps necessary Continuous improvement of charge air and exhaust syste...

Page 56: ...via the exhaust outlet 5 and the exhaust gas system Charge air system From the compressor wheel which is arranged on the same shaft of the rotor assembly air is drawn in from the outside via air filt...

Page 57: ...kshaft axial bearings 22 Crankshaft support bearing driving end 23 Mechanical coupling op tion 24 Camshaft bearing 25 Spray nozzles for piston cooling oil P Pressure measuring point T Temperature meas...

Page 58: ...r head 19 Camshaft bearings 24 Crankshaft support bearing driving end 22 Crankshaft thrust bearings 21 Exhaust turbocharger bearings 1 The lube oil pump 11 is a gear pump It is driven by the crankshaf...

Page 59: ...nt expansion tank HT 15 Engine coolant pump 16 Engine coolant drain plug 17 Restrictor 18 Lube oil heat exchanger 19 Crankcase 20 Engine coolant preheater in let 21 Coolant manifold 22 Intercooler 23...

Page 60: ...coolant chambers and bores of the cylinder heads The coolant then flows to the thermostat 7 via the coolant collecting lines 1 on the left and right The thermostat 7 diverts the engine coolant to the...

Page 61: ...nt coming from the charge air coolant cooler flows to the charge air coolant pump 5 When the engine is cold the thermostat routes the charge air coolant directly to the charge air coolant pump 5 The r...

Page 62: ...uel return line between the engine and the fuel tank Uncombusted heated fuel a flows through the fuel inlet 5 into the heat exchanger 4 which is made of heat resistant aluminum Air b drawn through an...

Page 63: ...l 85 dB A 89 dB A Maximum operating temperature 130 C 266 F 130 C 266 F Cooler for 16 20V engines Frequency 50 Hz 60 Hz Maximum spec heat dissipation 0 37 kW K 0 41 kW K Air flow 2250 m3 h 2700 m3 h S...

Page 64: ...of the engine The engine management system controls e g the injection timing injection duration and the resulting injec tion quantity for each ignition and for each cylinder It controls among other t...

Page 65: ...Internal ambient air sensor Lambda sensor recording 10 banks for multiple injection 5 fold Angle input OL detection adjustable hysteresis Fast data communication via RS485 SmartConnect Smaller housing...

Page 66: ...ating site e g altitude above sea level Engine monitoring for genset applications Engine speed Oil pressure Coolant temperature Intercooler coolant temperature Coolant level Intercooler coolant level...

Page 67: ...ion Monitors A19 EIL Engine Ident Label B5 1 Pressure sensor lube oil after filter B9 Charge air temperature sensor B34 1 Pressure sensor fuel after filter B38 Fuel inlet temperature sensor B48 1 HP f...

Page 68: ...or B48 2 HP fuel pressure sensor rail XB533 HT coolant level sensor remote expansion tank XB557 LT coolant level sensor remote expansion tank K39B1 K39B6 Injectors right engine side 68 Functional Desc...

Page 69: ...Designation Monitors B13 Crankshaft speed sensor MS15060 01E 2018 12 Functional Description 69 TIM ID 0000079214 003...

Page 70: ...before filter B6 Coolant temperature sensor B7 Lube oil temperature sensor B26 Charge air coolant temperature sensor B50 Crankcase pressure sensor XB54 Connector for optional oil refill pump Designat...

Page 71: ...filter Fill with fuel Page 165 Page 162 Fuel prefilter pressure gauge Check low pressure indicator on switchable fuel prefilter Page 160 Coolant circuit If engine is out of service for more than one y...

Page 72: ...circuit Check engine coolant level Page 184 Check charge air coolant level Page 207 Coolant circuit Heat engine coolant with coolant preheater Fuel prefilter Drain water Page 158 Page 155 Monitoring...

Page 73: ...dentified or eliminated contact Service Preparation Item Action Operating mode switch if fitted Change to manual mode Preheating pump if fitted Switch on Starting the engine Item Action Control cabine...

Page 74: ...ified or eliminated contact Service Note If an engine has been shutdown by a fault red alarm the engine may only be re started when the fault has been identified and eliminated Procedure following an...

Page 75: ...when a pushbutton is provided Safety system Override Item Action Switchgear cabinet control panel etc depending on manufacturer Activate pushbutton for Override input of the ECU Certain shutdown crit...

Page 76: ...arger turbine housings may be red hot If the maximum exhaust temperatures are not exceeded no restrictions in en gine operation are required Check for abnormal running noises and vibration Fuel prefil...

Page 77: ...ms will be disregarded Severe material damage Initiate emergency start only in emergency situations Preparation Item Action Operating mode selector switch Change to Override mode Manual mode if applic...

Page 78: ...unning at full load subjects it to extreme thermal and mechanical stress es Overheating of and therefore damage to components is possible Before shutting down the engine allow it to idle until the eng...

Page 79: ...subjects the engine system to an extremely high load Risk of overheating damage to components Trigger an emergency stop only in emergency situations Emergency engine stop Item Action Emergency stop pu...

Page 80: ...he engine Engine remains ready for operation After stopping the engine Item Action Engine generator pump control Select operating mode e g MANUAL AUTOMATIC OPERATION 80 Operation MS15060 01E 2018 12 T...

Page 81: ...to the coolant the engine room is not heated the coolant is not kept at a suitable temperature the antifreeze concentration is insufficient for the engine room tempera ture antifreeze concentration is...

Page 82: ...r gun directly at seals or electronic components such as connectors or ECUs Cleaning the plant 1 Carry out plant cleaning only in areas where an appropriate oil separator is provided environmental pro...

Page 83: ...ccomplish at each engine oil change at the latest X Page 182 WM00069 LUBE OIL PUMP WITH DRIVE Inspect pump visually X Page 180 WM00136 ENGINE MOUNTING Check securing screws for firm seating X Page 220...

Page 84: ...contaminants from fuel prefilter X Page 158 Page 155 WM00214 FUEL SUPPLY SYSTEM Replace filter element X Page 165 Page 162 WM00228 FUEL PIPEWORK FROM PUMP TO FILTER Check cooler elements for external...

Page 85: ...inspection manufacturer s documentation Engine governor Plug in connections loose u Check plug in connections Page 226 Running gear blocked engine cannot be barred manually u Contact Service Engine tu...

Page 86: ...ure too high Cause Corrective action Engine coolant treatment incorrect u Check MTU test kit Intercooler dirty u Contact Service Engine room Air intake temperature too high u Check fans and intake exh...

Page 87: ...ings or cylinder liner defective u Contact Service White exhaust gas Cause Corrective action Engine is not at operating temperature u Run engine to reach operating temperature Water in fuel u Check fu...

Page 88: ...2 Check fuel recooling system if applicable 3 Contact Service 5 HI T Charge Air Cause Corrective action The charge air temperature at sensor B9 has violated limit value 1 Charge air temperature is too...

Page 89: ...e lube oil pressure is too low 1 Check engine oil level Page 177 2 Contact Service 23 LO Coolant Level Cause Corrective action Coolant level in HT circuit at switch B533 is too low 1 Check engine cool...

Page 90: ...too high Cause Fault or malfunction of another exhaust turbocharger 1 Reduce power 2 Contact Service 32 SS ETC1 Overspeed Cause Corrective action The speed of the A side LP turbocharger at sensor B44...

Page 91: ...l Page 184 3 Contact Service 59 SS T Coolant L3 Cause Corrective action The coolant temperature at sensor B6 has violated limit value 3 Coolant temperature is too high 1 Check operation of cooler and...

Page 92: ...lant side 3 Check engine coolant level Page 184 4 Contact Service 68 SS T Coolant Cause Corrective action The coolant temperature at sensor B6 has violated limit value 2 Coolant temperature is too hig...

Page 93: ...e 92 SS Starter Speed Not Reached Cause Corrective action Engine speed has not reached the specified speed threshold within the specified time 1 Check pressure supply plant of starter 2 Check for addi...

Page 94: ...e 226 3 Check battery charging generator 4 Contact Service 321 AL Wiring Cylinder A1 Cause Corrective action Short circuit fault in the injector wiring for cylinder A1 or injector faulty 1 Check wirin...

Page 95: ...rrective action Short circuit fault in the injector wiring for cylinder A8 or injector faulty 1 Check wiring of affected injector Page 219 2 Replace injector Page 134 3 Contact Service 329 AL Wiring C...

Page 96: ...ve action Short circuit fault in the injector wiring for cylinder B5 or injector faulty 1 Check wiring of affected injector Page 219 2 Replace injector Page 134 3 Contact Service 336 AL Wiring Cylinde...

Page 97: ...ion Disruption fault in injector wiring for cylinder A2 1 Check wiring of affected injector Page 219 2 Contact Service 343 AL Open Load Cylinder A3 Cause Corrective action Disruption fault in injector...

Page 98: ...nder A10 1 Check wiring of affected injector Page 219 2 Contact Service 351 AL Open Load Cylinder B1 Cause Corrective action Disruption fault in injector wiring to cylinder B1 1 Check wiring of affect...

Page 99: ...oad Cylinder B9 Cause Corrective action Disruption fault in injector wiring to cylinder B9 1 Check wiring of affected injector Page 219 2 Contact Service 360 AL Open Load Cylinder B10 Cause Corrective...

Page 100: ...can not be activated 1 Check engine cabling Page 219 2 Contact Service 608 AL Wiring PWM_CM6 Cause Corrective action Open circuit or short circuit in wiring to fan oil priming pump M2 1 Check engine c...

Page 101: ...e critical upper limit value 1 Check sensor B33 replace if required 2 Contact Service 833 AL Emission Warning Cause Corrective action Emission fault summary alarm 1 Check for additional messages 2 Con...

Page 102: ...r within the set time u Contact Service 956 AL p5 ctrlvar limit min active Cause Corrective action The charge air pressure regulator attempts to adjust its set value but has reached its lower limit Th...

Page 103: ...n reached its maximum drift limit u Schedule an injector replacement 1035 AL Inj Drift Limit 1 Cyl A4 Cause Corrective action The drift correction for energization start and duration of injector A4 ha...

Page 104: ...reached its maximum drift limit u Schedule an injector replacement 1041 AL Inj Drift Limit 1 Cyl A10 Cause Corrective action The drift correction for energization start and duration of injector A10 h...

Page 105: ...n reached its maximum drift limit u Schedule an injector replacement 1047 AL Inj Drift Limit 1 Cyl B6 Cause Corrective action The drift correction for energization start and duration of injector B6 ha...

Page 106: ...it 2 The injector has reached its maximum drift limit u Replace injector Page 134 1053 AL Inj Drift Limit 2 Cyl A2 Cause Corrective action The drift correction for energization start and duration of i...

Page 107: ...as reached its maximum drift limit u Replace injector Page 134 1059 AL Inj Drift Limit 2 Cyl A8 Cause Corrective action The drift correction for energization start and duration of injector A8 has viol...

Page 108: ...ctor has reached its maximum drift limit u Replace injector Page 134 1065 AL Inj Drift Limit 2 Cyl B4 Cause Corrective action The drift correction for energization start and duration of injector B4 ha...

Page 109: ...has violated limit 2 The injector has soon reached its maximum drift limit u Replace injector Page 134 1071 AL Inj Drift Limit 2 Cyl B10 Cause Corrective action The drift correction for energization...

Page 110: ...ns too high The NOx emissions from the engine have violated limit value 2 cumulatively u Contact Service 1173 AL Implausible NOx Low Limit2 Cause Corrective action NOx emissions too low Cumulative NOx...

Page 111: ...de 2 Check plug connections to Engine Control Unit Page 226 3 Contact Service 1377 AL Refdrive Impossibl Eng Op Point Cause Corrective action Homing of one or more flaps before engine start was not co...

Page 112: ...chet with extension F30006212 1 DANGER Rotating and moving engine parts Risk of crushing danger of parts of the body being caught or pulled in Before cranking the engine with starter system make sure...

Page 113: ...sistance other than compression resist ance must be encountered 4 Rotate crankshaft in engine direction of rota tion Result If the resistance exceeds the normal com pression resistance contact Service...

Page 114: ...age 71 Before starting the engine in a contingency situation to maintain operation of a leaking intercooler Page 169 Cranking engine on starting system Note The engine must not start and no fuel may b...

Page 115: ...oisoning and suffocation Keep the engine room well ventilated at all times Repair leaking exhaust pipework immediately WARNING A high level of noise is produced when the engine is running Risk of hear...

Page 116: ...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 lowe...

Page 117: ...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 118: ...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 interrup...

Page 119: ...ks 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 inspectio...

Page 120: ...substances which are harmful to health Risk of injury and poisoning Allow the product to cool to below 50 C before beginning work Wear protective clothing protective gloves and goggles safety mask Av...

Page 121: ...mm Y20000918 1 Measuring jig 2 optional Y4350010 1 Preparatory steps 1 Remove cylinder head covers Page 130 2 Remove guard plate and install barring tool Page 112 3 Turn crankshaft in direction of ro...

Page 122: ...r head 3 4 Turn measuring unit screws 1 into the threads provided for the cylinder head cover and tighten to specified torque using a torque wrench Name Size Type Lubricant Value Standard Screw M10 Ti...

Page 123: ...sured value is 95 8 mm 5 Install valve bridge 6 Adjust valve clearance Page 126 Step 2 optional Measure valve protrusion at the valve stem with measuring jig 2 1 Check TDC position of piston in cylind...

Page 124: ...ricant Value Standard Screw M10 Tightening torque 20 Nm 6 Determine the values with all dial gages The valve protrusion value must be 2 mm Have the affected cylinder head replaced by expert personnel...

Page 125: ...rts Designation Use Part No Qty Engine oil Valve gear Lubrication 1 Remove cylinder head covers Page 130 2 Fill oil chambers of valve bridges with oil 3 Fill oil chambers of rocker arms and adjusting...

Page 126: ...r F30002815 1 Torque wrench 60 320 Nm F30452768 1 Socket wrench 24 mm F30039526 1 Engine oil Preparatory steps 1 Remove cylinder head covers Page 130 2 Remove guard plate and install barring tool Page...

Page 127: ...er of the flywheel 4 The additional OT A1 mark 1 if applicable on the outer perimeter of the flywheel must not be used for reference Diagram for 8V engines Two crankshaft positions Diagram for 12V eng...

Page 128: ...ance adjustment with cold engine Inlet valves long rocker arm 0 2 mm 0 05 mm Exhaust valves short rocker arm 0 5 mm 0 05 mm 3 Check all valve clearances in two crankshaft positions firing TDC and over...

Page 129: ...t just pass through the gap 4 Pass valve setting gauge 3 between valve bridge and rocker arm 5 Tighten locknut 1 to specified torque using a torque wrench holding the adjusting screw 2 in place to pre...

Page 130: ...3 4 with washers 2 5 3 Take off cylinder head cover with O ring 6 from cylinder head 7 Installing cylinder head cover 1 Clean installation surface 2 Check O ring 6 for damage replace as necessary 3 Co...

Page 131: ...of poisoning through inhalation irritation to eyes and skin Seek medical attention immediately do not induce vomiting Do not inhale vapors or smoke Wear protective clothing protective gloves and safet...

Page 132: ...ur cylinder HP pump u Undo nut 2 and remove oil line 1 from HP pump Filling HP pump two cylinder HP pump 1 Remove union 1 Note Excess engine oil runs into gear box 2 Use fuel suction pipe to fill HP p...

Page 133: ...mp 1 Remove union 1 Note Excess engine oil runs into gear box 2 Use fuel suction pipe to fill HP pump with 2 liters of clean engine oil 3 Screw in union 1 and use a torque wrench to tighten to specifi...

Page 134: ...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 135 134 Injector MS15060 01E 20...

Page 135: ...ia 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 va...

Page 136: ...MC Data Matrix Code 2 L Orange part number 3 MTU part number 4 IIG code Initial Injector Equalization 5 EMI ID code 6 Serial number 7 Date of manufacture Preparatory steps 1 Allow HP system to cool do...

Page 137: ...6 Install installation removal jig on the cylinder head 7 Remove injector with installation removal jig 8 Remove the installation removal jig 9 Remove sealing ring 2 from injector 1 or use a self made...

Page 138: ...ylinder head and pro tective sleeve by removing carbon deposits with a milling cutter 4 Coat damper ring 2 with Assembly com pound Molykote P 37 5 Coat O rings 3 and 5 with Assembly com pound Kluthe H...

Page 139: ...pe Lubricant Value Standard Screw M12 Tightening torque Engine oil 100 Nm 10 Nm 17 Use a torque wrench and long socket to tighten adapter 3 to specified tightening torque Name Size Type Lubricant Valu...

Page 140: ...eset the emission certification becomes invalid u Reset drift compensation CDC using DiaSys and enter injector code IIG Dialog system DiaSys E531920 If DiaSys is not available contact Service Final st...

Page 141: ...plosion Avoid open flames electrical sparks and ignition sources Do not smoke Wear protective clothing protective gloves and safety glasses facial protection WARNING Liquid or gaseous media e g fuel a...

Page 142: ...tion of components Damage to component Observe manufacturer s instructions Check components for special cleanliness Nameplate u The nameplate contains the following infor mation 1 DMC Data Matrix Code...

Page 143: ...1 5 Install installation removal jig on the cylinder head 6 Remove injector with installation removal jig 7 Remove the installation removal jig 8 Remove sealing ring 4 from injector or use a self made...

Page 144: ...Note Only remove plug from injector just before assembling the adapter 2 Remove plug 3 Clean sealing face on cylinder head and pro tective sleeve by removing carbon deposits with a milling cutter 4 F...

Page 145: ...me Size Type Lubricant Value Standard Screw M12 Tightening torque Engine oil 100 Nm 10 Nm 17 Use a torque wrench and long socket to tighten adapter 3 to specified tightening torque Name Size Type Lubr...

Page 146: ...not reset drift correction CDC after re in stalling a used injector 23 After fitting new injectors Page 135 Final steps 1 Install cylinder head cover Page 130 2 Open fuel supply to engine 146 Injector...

Page 147: ...e g fuel are poisonous Escaping vapors of highly volatile media e g fuel or ether Risk of fatal injury through swallowing risk of poisoning through inhalation irritation to eyes and skin Seek medical...

Page 148: ...vent screw to specified tightening torque Name Size Type Lubricant Value Standard Screw A F9 Tightening torque 6 Nm 2 Nm 6 Continue to operate the pump until resistance is noticeable at least 50 time...

Page 149: ...to eyes and skin Seek medical attention immediately do not induce vomiting Do not inhale vapors or smoke Wear protective clothing protective gloves and safety glasses If contact is made with skin was...

Page 150: ...avoid damage to cooling elements only aim water jet parallel to the cooling fins applying moderate pressure To improve the cleaning effect add a suitable degreasing agent to the water in accordance w...

Page 151: ...ors of highly volatile 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...

Page 152: ...h swallowing risk of poisoning through inhalation irritation to eyes and skin Seek medical attention immediately do not induce vomiting Do not inhale vapors or smoke Wear protective clothing protectiv...

Page 153: ...ing risk of poisoning through inhalation irritation to eyes and skin Seek medical attention immediately do not induce vomiting Do not inhale vapors or smoke Wear protective clothing protective gloves...

Page 154: ...engine room well ventilated at all times Pressure ratios Note If the fuel prefilter is above the full level of the fuel tank during engine operation the fuel pressure in the filter is lower than ambi...

Page 155: ...d soap Keep the engine room well ventilated at all times WARNING Exhaust gases are harmful to health and may cause cancer Risk of poisoning and suffocation Keep the engine room well ventilated at all...

Page 156: ...ilter module 2 is cut out 3 Open threaded vent plug 1 of filter to be serviced 4 Open drain plug 1 5 Allow water to drain until fuel emerges 6 Close drain plug 2 again 7 Drain the second filter on the...

Page 157: ...chover during engine operation and at engine stand still 1 Provide a suitable container to collect the water 2 Take care when opening drain plug 1 be cause fuel or water can spurt out 3 Allow water to...

Page 158: ...engine room well ventilated at all times WARNING Exhaust gases are harmful to health and may cause cancer Risk of poisoning and suffocation Keep the engine room well ventilated at all times Repair lea...

Page 159: ...Vent fuel prefilter Page 167 Draining fuel prefilter in case of high pressure version B Note The fuel prefilter can be drained during engine operation or with the engine at a standstill 1 Provide a s...

Page 160: ...eading at low pressure gauge 3 Red zone 1 1 0 bar to 0 4 bar low pressure Green zone 2 0 4 bar to 0 5 bar nor mal operation 2 Switch over the fuel prefilter or replace a fil ter element Page 162 when...

Page 161: ...riptions also apply to heavy duty fuel prefilters Fuel prefilter non switchable u Fuel prefilter replace filter element Page 165 Fuel prefilter switchable u Fuel prefilter replace filter element Page...

Page 162: ...es and skin Seek medical attention immediately do not induce vomiting Do not inhale vapors or smoke Wear protective clothing protective gloves and safety glasses If contact is made with skin wash off...

Page 163: ...is opened absolute cleanness is imperative Carefully extract the filter element straight up avoiding contact with the upper edge of the cylinder if at all possible to prevent contamination of the fuel...

Page 164: ...ible to prevent contamination of the fuel remaining in the filter housing 6 Unscrew filter cover 1 and withdraw with fil ter element 3 from filter housing 4 7 Unclip filter element 3 from filter cover...

Page 165: ...tion to eyes and skin Seek medical attention immediately do not induce vomiting Do not inhale vapors or smoke Wear protective clothing protective gloves and safety glasses If contact is made with skin...

Page 166: ...element 3 from filter housing 4 7 Unclip filter element 3 from filter cover 1 8 Install new O ring 2 on filter cover 1 9 Coat new O rings on filter cover and filter ele ment with fuel 10 Clip new filt...

Page 167: ...well ventilated at all times WARNING Exhaust gases are harmful to health and may cause cancer Risk of poisoning and suffocation Keep the engine room well ventilated at all times Repair leaking exhaust...

Page 168: ...eaded vent plugs 2 3 Note Never actuate the handle with the threaded vent plugs closed 5 Move handle 1 of fuel priming pump back and screw in 6 Close threaded vent plugs 2 3 and tighten by hand Ventin...

Page 169: ...irect air jet at people Always wear safety goggles face mask and hearing protection Intercooler Checking conden sate drain for coolant leak and obstruction 1 With the engine running verify that air es...

Page 170: ...Material Spare parts Designation Use Part No Qty Air filter Spare Parts Catalog Air filter Replacement 1 Remove air filter and install new one Page 172 2 Reset signal ring of service indicator Page 1...

Page 171: ...l Spare parts Designation Use Part No Qty Air filter Spare Parts Catalog Checking air filter 1 Check entire circumference of air filter for damage 2 Fit new air filter if damaged Page 170 MS15060 01E...

Page 172: ...otective gloves safety goggles respiratory protection etc is to be used NOTICE Stepping or climbing on the genset to perform installation tasks is to be avoided Otherwise there is a risk of component...

Page 173: ...rting disabled Checking signal ring position 1 When the yellow piston 2 has reached the red shaded Service lettering 3 replace air filter Page 170 2 After installation of new filter press reset button...

Page 174: ...the product 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 NOTICE Inadequate oil pressu...

Page 175: ...th un scheduled engine oil change 1 Provide a suitable container in which to col lect the engine oil 2 Remove drain plug 1 and drain engine oil from engine oil heat exchanger and from en gine oil filt...

Page 176: ...ck engine oil level Page 177 Note Observe the following instructions to avoid engine damage Adequate oil pressure for an engine start is only provided when the quick start function is deactivated 5 Ma...

Page 177: ...o 2 cm above mark 1 This may be caused e g by oil from oil filters and heat ex changers flowing back into the oil pan After extended standstill the oil level 2 cm above mark 2 is the minimum oil level...

Page 178: ...re beginning work Wear protective clothing protective gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING A high level of noise is produced when the engine is runnin...

Page 179: ...Use equipment and chemicals in MTU test kit to analyze engine oil for Dispersancy spot test Water content Dilution by fuel MS15060 01E 2018 12 Lube Oil System Lube Oil Circuit 179 TIM ID 0000000932 01...

Page 180: ...ect oil priming pump and connections for firm seating and leaks Retighten loose threaded connections as necessary 2 Check leak telltale bore 2 for oil discharge Result If oil emerges the gear pump 1 u...

Page 181: ...ick start function is deactivated before starting the engine For engines with lube oil priming pump Prime the engine for 20 seconds at a pressure of at least 0 3 bar Engine oil filter Replacement 1 Re...

Page 182: ...k Avoid contact with skin Do not inhale oil vapor WARNING Compressed air gun ejects a jet of pressurized air Risk of injury to eyes and damage to hearing risk of rupturing internal organs Never direct...

Page 183: ...eal ing ring 4 in rotor cover 3 Note Do not clamp rotor unit in a bench vise Use an oil filter wrench 5 Screw on rotor cover 3 by turning at hexa gon 6 Tighten rotor cover 3 with torque wrench to spec...

Page 184: ...nd goggles safety mask Checking coolant level at re mote cooler 1 Check coolant level coolant must be visible at marking plate 2 Top up with treated coolant as necessary Page 188 3 Check and clean bre...

Page 185: ...Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 186 2 Fill with engine coolant Page 188 MS15060 01E 2018 12 Coolant Circuit General High Tem...

Page 186: ...wear breathing protection Do not eat drink smoke when working with antifreeze Wear protective clothing protective gloves and goggles safety mask Wipe up escaped spilled coolant immediately Preparatory...

Page 187: ...n valves to specified tightening torque Name Size Type Lubricant Value Standard Spindle A F11 Tightening torque 12 Nm 2 Close all remaining open drain points 3 Position valve cover on filler neck and...

Page 188: ...gloves and goggles safety mask WARNING A high level of noise is produced when the engine is running Risk of hearing loss Wear suitable hearing protection WARNING Coolant contains antifreeze and is to...

Page 189: ...he first stop and release pressure 2 Continue to turn valve cover 1 counter clockwise and remove Variant 1 Filling with coolant from below using a pump 1 Open venting point on distributor arrow MS1506...

Page 190: ...aces if required 8 Fit valve cover and close it 9 Start engine Page 73 10 After 10 seconds of running the engine with out load shut down the engine Page 78 11 Turn valve cover of coolant expansion tan...

Page 191: ...tank counterclockwise to the first stop and allow pressure to escape 9 Turn valve cover 1 counterclockwise and re move 10 Check coolant level Page 184 and top up with coolant through the filler neck...

Page 192: ...p the engine room well ventilated at all times Repair leaking exhaust pipework immediately WARNING A high level of noise is produced when the engine is running Risk of hearing loss Wear suitable heari...

Page 193: ...RNING 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 when workin...

Page 194: ...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 195: ...t 6 Intake 7 Safety thermostat 8 Housing cover 9 Pump Arrow Flow direction Variant Heating output Rated voltage Frequency Phases 1 9 kW 400 V 50 Hz 3 2 9 kW 480 V 60 Hz 3 3 12 kW 400 V 50 Hz 3 4 12 kW...

Page 196: ...protection Function check Note The preheater operates properly if the measured value of the coolant temperature is within the control range of the thermostat 1 Check coolant preheating temperature 2 C...

Page 197: ...onnected Replacing solenoid switch u Replace solenoid switch Page 201 Cleaning heating element and replacing gasket u Clean heating element and housing and check Page 198 Replacing thermostat u Replac...

Page 198: ...ssure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask WARNING Coolant contains antifreeze and is toxic Risk of poisoning and slipping Avoid...

Page 199: ...d or new heating element into housing 7 Install electrical part 2 and tighten screws 1 Installing coolant lines 1 Clean drain plug and screw in thread arrow at preheater 2 Coat drain plug with screw l...

Page 200: ...Final steps 1 Connect preheater power sources 2 Switch on preheater 200 Coolant Circuit General High Temperature Circuit MS15060 01E 2018 12 TIM ID 0000081913 004...

Page 201: ...jury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask WARNING Hot components surfaces Risk of burns Allow the engine to cool down to below 50 C before begi...

Page 202: ...noid switch off the rail 5 Fit a new solenoid switch on the rail and fully engage the spring clip 6 Connect up all wires as marked previously 7 Close the control box and tighten the screws Final steps...

Page 203: ...es Risk of burns Allow the engine to cool down to below 50 C before beginning work Wear suitable protective equipment thermal gloves Avoid unprotected contact with hot surfaces WARNING Coolant is hot...

Page 204: ...e 8 Fit cover and tighten screws Replacing control thermostat 1 Undo screws 1 on housing cover 2 of con trol thermostat and remove cover 2 Mark cables prior to disconnection 3 Disconnect wires 4 Remov...

Page 205: ...Final steps 1 Connect preheater to power supply 2 Switch on preheater MS15060 01E 2018 12 Coolant Circuit General High Temperature Circuit 205 TIM ID 0000081762 002...

Page 206: ...ety mask Preparatory steps u Switch off preheater Replacing valve cover Note Schematic diagram Design may deviate 1 Turn valve cover 1 on coolant expansion tank counterclockwise until the first stop a...

Page 207: ...and slipping Avoid contact with eyes and skin Do not inhale vapors or mist wear breathing protection Do not eat drink smoke when working with antifreeze Wear protective clothing protective gloves and...

Page 208: ...rge air coolant level is monitored automatically by the engine control system 1 Switch on engine control system and check readings on the display 2 Top up with charge air coolant as necessary Page 212...

Page 209: ...al tools Material Spare parts Designation Use Part No Qty Coolant Charge air coolant Change 1 Drain charge air coolant Page 210 2 Fill with charge air coolant Page 212 MS15060 01E 2018 12 Low Temperat...

Page 210: ...raining charge air coolant 1 Provide a suitable container to catch coolant 2 Turn valve cover on coolant expansion tank counterclockwise to first stop and release pressure 3 Continue to turn valve cov...

Page 211: ...fied tightening torque Name Size Type Lubricant Value Standard Spindle A F11 Tightening torque 12 Nm 9 Screw in drain screws on thermostat housing and intercooler with new sealing rings 10 Position va...

Page 212: ...lding 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 cracks in the engine Fill top up...

Page 213: ...e Page 73 10 After 10 seconds of running the engine with out load shut down the engine Page 78 11 Turn valve cover of coolant expansion tank counterclockwise until the first stop and al low pressure t...

Page 214: ...he engine Page 78 8 Turn valve cover of coolant expansion tank counterclockwise until the first stop and al low pressure to escape 9 Turn valve cover counterclockwise and re move 10 Check coolant leve...

Page 215: ...cation Keep the engine room well ventilated at all times Repair leaking exhaust pipework immediately WARNING A high level of noise is produced when the engine is running Risk of hearing loss Wear suit...

Page 216: ...onents Never operate the engine without protective covers or safety guards which meet applicable accident prevention regulations Ensure that the safety guards can prevent body parts from being drawn i...

Page 217: ...0 1 WARNING Belt tensioner spring is pretensioned Risk of hands being crushed Lock belt tensioner in position Only use specified tools and devices Adjusting belt tension 1 Slacken screws 1 and 2 by ha...

Page 218: ...belt replacement 1 Remove protective cover 2 Loosen screws 2 and 3 by half a turn 3 Mount socket or box wrench on screw 1 and press belt tensioner in direction of arrow as far as the stop 4 Tighten s...

Page 219: ...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...

Page 220: ...re tight 2 Use a torque wrench to tighten loose screw connections 1 to specified tightening torque Name Size Type Lubricant Value Standard Screw M20 Control torque Engine oil 500 Nm 50 Nm 3 Use a torq...

Page 221: ...fied tightening torque Name Size Type Lubricant Value Standard Screw M20 Control torque Engine oil 500 Nm 50 Nm 3 Use a torque wrench to tighten loose screw connections 3 to specified tightening torqu...

Page 222: ...tion of the mounts Cover engine mounts when working with fuel or oil Remove contaminations on the rubber mounts immediately with a dry cloth and degrease them Engine mounting Check Item Findings Actio...

Page 223: ...ll Risk of shorter service life or destruction of the mounts Cover engine mounts when working with fuel or oil Remove contaminations on the rubber mounts immediately with a dry cloth and degrease them...

Page 224: ...ing check Preconditions Engine is stopped and starting disabled Generator mounting securing screw firm seating check 1 Check securing screws for firm seating 2 Tighten loose screws 224 Engine Mounting...

Page 225: ...propyl alcohol to remove coarse dirt from housing surface 2 Use isopropyl alcohol to remove dirt from the connector and cable surfaces 3 Check legibility of cable labels Clean or replace illegible lab...

Page 226: ...The contacts in the plug connection can be bent Carry out check of plug connection only with test connectors Checking plug connections at engine governor 1 Check all plug connections for secure seati...

Page 227: ...ntrol Unit from engine 1 Note or mark assignment of cables and con nectors 2 Remove all screws 2 3 Undo latches 1 on connectors 4 Remove all male connectors 5 Remove screws 3 6 Take off Engine Control...

Page 228: ...CDC Resetting with DiaSys Note The engine will lose its emissions certification of the drift correction parameters CDC if not reset 1 Use DiaSys to reset the CDC parameters Dialog system DiaSys E5319...

Page 229: ...level sensor Monitors coolant level CM Current Measurement Current measured value CPS Coolant pressure sensor Monitors coolant pressure CR Common Rail CTS Coolant temperature sensor Monitors coolant...

Page 230: ...t HIHI High High Alarm Measured value exceeds 2nd maximum limit HT High Temperature IDM Interface Data Module Memory module for interface data IIG Initial injector equalization Initial input of inject...

Page 231: ...p 1st function Warning lamp stop engine and rectify fault 2nd function Read out fault codes SID System Identifier SPC Spare Parts Catalog SRS Synchronous Reference Sensor TDC cylinder 1 SS Safety Syst...

Page 232: ...Unit B in2 645 16 mm2 ft2 0 0929 m2 yd2 0 8361 m2 stat mile2 2 59 km2 Unit B multiplied by factor Unit A mm2 0 00155 in2 m2 10 764 ft2 m2 1 1960 yd2 km2 0 3861 stat mile2 Volume Unit A multiplied by...

Page 233: ...t mile h mph 1 609 km h knot UK 1 852 km h Unit B multiplied by factor Unit B m s 3 281 ft s km h 0 6214 stat mile h mph km h 0 54 knot UK Mass Unit A multiplied by factor Unit B lb 0 4536 kg oz 28 35...

Page 234: ...95 bar lbf ft2 psf 47 88 Pa inHg 0 03386 bar inHg 345 3 kp m2 mmH2O Unit B multiplied by factor Unit A atm 760 mmHg atm 1 0133 bar atm 10332 kp m2 mmH2O atm 1 0332 kp cm2 at atm 14 696 lbf in2 psi bar...

Page 235: ...8598 kcal h lbf ft s 0 0018 HP Temperature Celsius Kelvin x C x 273 15 K x K x 273 15 C x F 5 9 x 32 C 5 9 x 32 273 15 K x R 5 4x C 5 4x 273 15 K Fahrenheit R aumur x C 9 5x 32 F 4 5x R x K 9 5 x 273...

Page 236: ...trength class 8 8 surface condition bare phosphatized or galvanized and 10 9 surface condition bare or phosphatized The values in the table are based on a friction coefficient tot 0 125 Threads and ma...

Page 237: ...to Steel M A Nm Gray cast iron MA Nm AI alloy MA Nm M6 9 6 6 M8 11 9 10 M10 17 13 13 M12 27 23 18 M14 37 33 33 M16 55 45 MA tightening torques Tightening torques for setscrews and nuts made of stainle...

Page 238: ...le are based on a friction coefficient tot 0 125 Threads and mating faces of screws and nuts must be coated with engine oil prior to assembly An assembly tolerance of 10 of the figures in the table is...

Page 239: ...n when tightening MA tightening torques Tightening torques for plug screws as per MTN 5183 1 standard This standard applies to plug screws to DIN 908 DIN 910 and DIN 7604 with threaded end to DIN 3852...

Page 240: ...ess Tightening torques for plug screws to DIN 908 DIN 910 and DIN 7604A with short threaded end Thread screwed into Steel gray cast iron MA Nm AI alloy MA Nm M10 x 1 15 15 M12 x 1 5 25 25 M14 x 1 5 35...

Page 241: ...Steel gray cast iron M A Nm AI alloy MA Nm M8 x 1 10 10 M22 x 1 5 80 65 M26 x 1 5 105 90 M30 x 1 5 130 130 M38 x 1 5 140 120 M45 x 1 5 160 140 MA tightening torques Tightening torque for banjo screws...

Page 242: ...iations during the tightening process Tightening torques for steel banjo screws Thread inserted in steel gray cast iron aluminum alloy MA Nm M8 x 1 10 M10 x 1 15 M12 x 1 5 20 M14 x 1 5 25 M16 x 1 5 25...

Page 243: ...ng and oiled or galvanized Threads and mating faces beneath heads must be coated with engine oil prior to assembly An assembly tolerance of 10 of the figures in the table is permitted due to unavoidab...

Page 244: ...tening the union nut firmly by hand noticeable increase in force it should be tightened another 1 4 turn 90 past this point Tightening torques for spigot unions with O ring to ISO 6149 2 Thread Torque...

Page 245: ...ew in valves see ISO 6149 47 and ISO 7789 Tightening torques for screwed plugs with O ring as per ISO 6149 3 Thread Torque Nm 10 M8 x 1 8 M10 x 1 15 M12 x 1 5 25 M14 x 1 5 35 M16 x 1 5 40 M18 x 1 5 45...

Page 246: ...to ORFS fittings In contrast to the instructions for pipe unions hose fittings with sealing heads and the matching adapters must be fitted and connected as follows Hose fitting metallic sealing with...

Page 247: ...5 x 2 35 290 M52 x 2 38 42 330 Sealing head with BSP union nut BSPP thread Torque Nm G1 4 20 G3 8 34 G1 2 60 G5 8 69 G3 4 115 G1 140 G1 1 4 210 G1 1 2 290 G2 400 SAE sealing cone with union nut JIC 37...

Page 248: ...Size Torque Nm 9 16 18 4 14 2 11 16 16 6 24 3 13 16 16 8 43 4 1 14 10 60 8 1 3 16 12 12 90 5 1 3 16 12 14 90 5 1 7 16 12 16 125 10 1 11 16 12 20 170 20 2 12 24 200 25 2 1 2 20 32 460 30 248 Appendix...

Page 249: ...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 250: ...nce Check and adjustment Page 126 Barring tool Part No F6555766 Qty Used in 1 9 1 1 Engine Barring manually Page 112 Qty Used in 1 9 2 1 Cylinder liner Endoscopic examination Page 116 Crossbeam Part N...

Page 251: ...Used in 1 9 4 1 Valve protrusion Measurement Page 121 Endoscope Part No Y20097353 Qty Used in 1 9 2 1 Cylinder liner Endoscopic examination Page 116 Feeler gauge Part No Y20098771 Qty Used in 1 9 4 3...

Page 252: ...e 181 Fuel suction pipe Part No F30378207 Qty Used in 1 9 5 1 HP fuel pump Filling with engine oil Page 131 High pressure cleaner Part No Qty Used in 1 6 12 Plant Cleaning Page 82 Installation removal...

Page 253: ...Milling cutter Part No F30452739 Qty Used in 1 9 6 2 Injector Removal and installation Page 135 Qty Used in 1 9 6 3 Injector rings Replacement Page 141 MTU test kit Part No F6798833 Qty Used in 1 9 1...

Page 254: ...Removal and installation Page 135 Qty Used in 1 9 6 3 Injector rings Replacement Page 141 Qty Used in 1 9 12 1 Engine oil Change Page 174 Qty Used in 1 9 17 1 Battery charging generator Drive belt ten...

Page 255: ...filter Cleaning and filter sleeve re placement Page 182 Qty Used in 1 9 17 1 Battery charging generator Drive belt tension ad justment Page 217 Qty Used in 1 9 17 2 Battery charging generator drive Dr...

Page 256: ...9 6 2 Injector Removal and installation Page 135 Qty Used in 1 9 6 3 Injector rings Replacement Page 141 Qty Used in 1 9 13 2 Centrifugal oil filter Cleaning and filter sleeve re placement Page 182 Qt...

Page 257: ...4 3 Valve clearance Check and adjustment Page 126 Qty Used in 1 9 6 2 Injector Removal and installation Page 135 Qty Used in 1 9 6 3 Injector rings Replacement Page 141 Qty Used in 1 9 12 1 Engine oil...

Page 258: ...Filter element replace ment Page 162 Qty Used in 1 9 8 9 Fuel prefilter non switchable Filter element re placement Page 165 Valve setting gauge Part No Y4349603 Qty Used in 1 9 4 3 Valve clearance Che...

Page 259: ...212 Coolant expansion tank Valve cover replacement 206 Cooling system 59 Crankcase 44 Crankcase breather Oil mist separator Replacement 120 Crankshaft Transport locking device Installation removal 22...

Page 260: ...Fuel filter Replacement 152 Fuel prefilter Draining Non switchable 158 Switchable 155 Filter element replacement 161 Non switchable 165 Switchable 162 Low pressure indicator check Switchable 160 Pres...

Page 261: ...onths 71 Putting the engine generator set into operation after scheduled out of service period 72 R Relief bore Check Engine coolant pump 192 Running gear 47 S Safety regulations Assembly work 13 Auxi...

Page 262: ...Valve protrusion Measurement 121 W Warning notices standards 19 262 Index MS15060 01E 2018 12 DCL ID 0000044539 002...

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MTU 12V4000G34F, Operating Instructions Manual

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