MTU 12V4000S83 Operating Instructions Manual Download

Page: 78 / 140

7.6.2 Injector – Removal and installation

Preconditions

☑

Engine is stopped and starting disabled.

Special tools, Material, Spare parts

Designation / Use

Part No.

Qty.

Installation/removal tool

F6789889

Milling cutter

F30452739

Torque wrench, 0.5-5 Nm

0015384230

Torque wrench, 10-60 Nm

F30452769

Ratchet

F30027340

Torque wrench, 60-320 Nm

F30452768

Ratchet

F30027341

Assembly paste (Optimoly Paste White T)

40477

Grease (Kluthe Hakuform 30-11C/Emulgier)

X00059351

Engine oil
O-ring

(→ Spare Parts Catalog)

WARNING

Fuels are combustible.

Risk of fire and explosion!

• Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.

Preparatory steps

Shut off fuel supply to engine.

Remove cylinder head cover (→ Page 75).

Removing injector

Disconnect connectors on injector.

78 | Task Description | MS150026/02E 2013-11

TIM-ID: 0000000925 - 011

Summary of Contents for 12V4000S83

Page 1: ...Operating Instructions Diesel engine 12 V 4000 S83 16 V 4000 S83 MS150026 02E...

Page 2: ...s protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of MTU Friedrichshafen GmbH This restriction also applies to copyright distribu...

Page 3: ...forming test run 60 7 1 2 Engine Barring manually 61 7 1 3 Engine Barring with starting system 63 7 2 Cylinder Liner 64 7 2 1 Cylinder liner Endoscopic examination 64 7 2 2 Instructions and comments o...

Page 4: ...rging Generator 117 7 17 1 Battery charging generator Check 117 7 17 2 Battery charging generator drive Drive belt tension adjustment 118 7 17 3 Battery charging generator drive Drive belt replacement...

Page 5: ...nfiguration approved by the manufacturer in writ ing including engine control parameters In compliance with all safety regulations and in adherence with all warning notices in this manual In accordanc...

Page 6: ...rk on or around the product This personnel must be instructed repeatedly Personnel requirements All work on the product shall be carried out by trained and qualified personnel only Training at the Tra...

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

Page 8: ...on both sides 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 4 Always use the screws su...

Page 9: ...wrench to the specified tightening torque 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 transportation...

Page 10: ...50 Nm 25 Nm 2 Screw locknut 2 onto screws 3 up to the end of the thread 3 Fit the retainers 8 through the openings of plate 1 and fasten with screw 3 4 Tighten screws 3 alternately with torque wrench...

Page 11: ...h the consequences of any operations performed During operation the display instruments and monitoring units must be permanently observed with re gard to present operating status violation of limit va...

Page 12: ...work Do not blow out the interior of the flywheel housing or the starter with compressed air Clean the flywheel housing inside with a class H dust extraction device Observe the safety data sheet Safe...

Page 13: ...ct beforehand Hydraulic installation and removal Check satisfactory function and safe operating condition of tools jigs and fixtures to be used Use only the specified jigs and fixtures for hydraulic r...

Page 14: ...stop feature Store spare parts properly prior to replacement i e protect them against moisture in particular Pack defective electronic components and assemblies in a suitable manner when dispatched f...

Page 15: ...roduct are prohibited by emission regulations Emission control units systems may only be maintained exchanged or repaired if the components used for this purpose are approved by the manu facturer Nonc...

Page 16: ...y line or before device or tool is to be replaced Carry out leak test in accordance with the specifications Paints and varnishes Observe the relevant safety data sheet for all materials When painting...

Page 17: ...event of a situation involving potential danger Consequences Minor or moderate injuries Remedial action NOTICE In the event of a situation involving potentially adverse effects on the product Conseque...

Page 18: ...ders on the left hand side of the engine and the letter B 3 to refer to the cylinders on the right hand side The cylinders of each bank are numbered consecutively starting with No 1 at the driving end...

Page 19: ...11 Engine governor 12 Fuel filter 13 Cylinder head 14 HP fuel pump 15 Automatic oil filter safety oil filter is optional 17 Fan drive 18 Centrifugal oil filter KGS Engine free end Engine model designa...

Page 20: ...ter filter XY44 solenoid valve fan coupling 3 B05 lube oil pressure 4 B44 turbocharger speed 5 Injectors Y39 1 to Y39 6 A bank 6 Engine governor 7 B34 fuel pressure after fil ter 8 F46 leak fuel level...

Page 21: ...3 fuel temperature in common rail 4 B48 fuel pressure in com mon rail 5 B01 camshaft speed 6 B43 charge air coolant pressure 7 B26 charge air coolant temperature 8 B06 coolant temperature MS150026 02E...

Page 22: ...e 3 B10 charge air pressure 4 XM2 oil priming pump 5 B09 charge air tempera ture The injectors are located below the cylinder head covers Injector replacement and necessary activities Page 77 22 Gener...

Page 23: ...1 B13 crankshaft speed MS150026 02E 2013 11 General Information 23 TIM ID 0000012926 003...

Page 24: ...Barometric pressure mbar 1000 1000 Site altitude above sea level M 100 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 12V 16V Rated engine speed A rpm 190...

Page 25: ...cyl inder 2 2 COMBUSTION AIR EXHAUST GAS Number of cylinders 12V 16V Charge air pressure before cylin der r bar abs 3 2 3 5 Exhaust temperature after turbo charger r C 475 490 COOLANT SYSTEM HT circu...

Page 26: ...ing temperature before engine to r C 99 99 Lube oil temperature before en gine alarm r C 101 101 Lube oil temperature before en gine shutdown L C 103 103 Lube oil operating pressure be fore engine to...

Page 27: ...ters 214 Oil pan capacity dipstick mark min standard oil system de sign max operating inclinations L Liters 124 Oil pan capacity dipstick mark max standard oil system de sign max operating inclination...

Page 28: ...g order 8V A1 B4 A4 A2 B3 A3 B2 B1 12V A1 B5 A5 B3 A3 B6 A6 B2 A2 B4 A4 B1 16 V A1 A7 B4 B6 A4 B8 A2 A8 B3 B5 A3 A5 B2 A6 B1 B7 20 V A1 B5 A8 B7 A5 B2 A7 B10 A2 B3 A10 B6 A3 B4 A6 B9 A4 B1 A9 B8 28 Te...

Page 29: ...Main dimensions Engine model Length A Width B Height C 12 V 4000 S83 approx 2490 mm approx 1449 mm approx 1871 mm 16 V 4000 S83 approx 2960 mm approx 1449 mm approx 1871 mm MS150026 02E 2013 11 Techni...

Page 30: ...Oil lubrication system Check engine oil level Page 88 Crank engine using starting system Page 63 Fuel prefilter Fill with fuel if fitted Coolant system If engine has been out of service for more than...

Page 31: ...Startup Item Action Lube oil system Check engine oil level Page 88 Coolant circuit Check engine coolant level Page 101 Check charge air coolant level Page 114 Coolant circuit Preheat coolant with cool...

Page 32: ...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 33: ...y for leaks and general condition Check engine for abnormal running noises exhaust color and vibrations Air filter Check signal ring position of service indicator on air filter if fitted Battery charg...

Page 34: ...fore 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 35: ...o remain out of service for an extended period and engine coolant has no antifreeze additive the coolant is not maintained at a suitable temperature antifreeze concentration is 40 and outside temperat...

Page 36: ...ressed air gun directly 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 environmenta...

Page 37: ...ce fuel filter or fuel filter element Page 84 W1006 Replace injectors Page 77 W1008 Replace engine oil filter at each oil change or when the time limit years is reached at the latest Page 93 Page 92 W...

Page 38: ...ssibly loose u Perform visual inspection see manufacturer s documentation Connectors on engine governor possibly loose u Check plug connections Page 127 Running gear blocked engine cannot be barred ma...

Page 39: ...e air temperature too high Cause Corrective action Engine coolant treatment incorrect u Check MTU test kit Intercooler clogged u Contact Service Engine room Air intake temperature too high u Check fan...

Page 40: ...cylinder head piston rings 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 Fuel...

Page 41: ...Description Meaning EC ECU code Fault message from ECU 7 engine governor AL AL Alarm message from the SAM RL Redundancy Lost Redundant CAN CAN 2 not sending any data fault DL Default Lost Default CAN...

Page 42: ...Engine must not be restarted risk of engine damage contact Service 2 0100 92 2 019 HI T Exhaust A Exhaust temperature bank A too high 1st limit 1 Check wiring Page 124 2 Contact Service 2 0126 93 1 02...

Page 43: ...ary turbo charger too high Fuel injec tion limited to fixed amount 1 Reduce power 2 Contact Service 2 3013 91 2 038 AL TC Synchro Fault Synchronization error be tween turbochargers 1 and 2 1 Reduce po...

Page 44: ...wn 1 Allow the engine to cool down 2 Contact Service 3 Check engine cool ant cooler clean if dirty 4 Restart engine Page 32 2 0120 93 2 081 AL Rail Leakage Pressure gradient in fuel rail is too low wh...

Page 45: ...preheater unit 2 1090 92 1 095 AL Prelubrication Fault Alarm configuration oil pri ming fault Check oil priming system 2 1090 92 0 102 AL Fuel Cons Counter Defect Indication of fuel consump tion is in...

Page 46: ...EST1 SUPPLY A D converter supply volt age too low Replace engine governor 147 AD TEST1 ECU DEFECT Electronics defective auto matic engine shutdown Replace engine governor 148 L1 AD TEST2 SUPPLY A D co...

Page 47: ...inter ference on the bus Contact Service Check CAN bus for short circuit rectify short circuit as nec essary Check shielding improve shielding as neces sary 2 0500 68 6 187 AL CAN1 Error Passive CAN 1...

Page 48: ...B10 defective short circuit or wiring break Check sensor and wiring replace as necessary Fault is cleared when en gine restarted 1 8004 56 6 211 SD P Lube Oil Sensor B05 defective engine oil pressure...

Page 49: ...9 AL Stop Camshaft Sen sor Defect Crankshaft speed and cam shaft speed sensors defec tive 1 Check wiring 2 Contact Service Check sensor 1 8004 56 2 230 SD Crankshaft Speed Sensor B13 defective crank s...

Page 50: ...cuit or wire break Check wiring re place as necessary Fault is cleared when engine re started 2 8006 58 8 270 SD Frequency Input Frequency setting sensor fault 1 Check wiring 2 Contact Service check s...

Page 51: ...solenoid valve 10 1 Check solenoid valve 2 Contact Service 1 8004 52 0 322 1 8004 52 1 323 1 8004 52 2 324 1 8004 52 3 325 1 8004 52 4 326 1 8004 52 5 327 1 8004 52 6 328 1 8004 52 7 329 1 8004 52 8...

Page 52: ...oid valve 2 Contact Service 1 8004 54 0 342 1 8004 54 1 343 1 8004 54 2 344 1 8004 54 3 345 1 8004 54 4 346 1 8004 54 5 347 1 8004 54 6 348 1 8004 54 7 349 1 8004 54 8 350 1 8004 54 9 351 OPEN_LOAD CY...

Page 53: ...iring 2 Attempt to re start engine 1 8004 56 0 365 AL Stop MV Wiring Ground Alarm configuration Injector wiring fault If bit 1 1020 021 output stage failure shut down engine is set engine is also shut...

Page 54: ...iminary warning backup coolant temperature reading too high 1 Check wiring 2 Contact Service 2 0129 93 1 393 SS T Coolant Redundant Alarm configuration limit 1 Main warning backup cool ant temperature...

Page 55: ...6 63 0 406 AL Open Load Digital In put 7 Alarm configuration wire break at digital input 7 wir ing defective or no resist ance across switch 1 Check wiring 2 Contact Service Check input of tar get dev...

Page 56: ...t 1 Aux 1 input signal above below limit 2 depending on configuration Determine cause of limit violation and rectify fault 2 0160 92 2 428 L1 T Aux 1 Alarm configuration limit 1 preliminary warning Au...

Page 57: ...limit violation and rectify fault 2 8006 65 1 460 AL EMU Exhaust High Alarm configuration limit EMU exhaust temperature too high 1 Check wiring 2 Contact Service 2 8006 65 2 461 AL EMU Exhaust Low Al...

Page 58: ...ecessary Fault is cleared when en gine restarted 1 8004 58 7 471 SD Suction Throttle SD alarm configuration suc tion throttle control defec tive short circuit or wire break Check sensor and wiring rep...

Page 59: ...n RED combined alarm from plant Check other fault messages 2 8006 00 2 480 Lim Ext PlantEngine Prot bin Alarm configuration limit in put signal above below limit depending on configuration Determine c...

Page 60: ...en gine s danger zone WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Engine Performing test run 1 Start engine Page 32 2 Perform test run a...

Page 61: ...fore cranking the engine with starter system make sure that there are no persons in the en gine s danger zone Barring engine manually tool mounted on side 1 Remove guard plate 2 Engage barring gear 2...

Page 62: ...e barring gear F6555766 with adapter F6558528 For 20V engines use barring gear F6783293 3 Fit ratchet 3 onto barring gear 2 4 Rotate crankshaft in normal direction of en gine rotation apart from the n...

Page 63: ...ce and all tools removed from the engine Barring engine with starting system 1 Release latch of connector X4 2 Remove connector from engine governor 3 Bar engine in unloaded condition Press START butt...

Page 64: ...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 65: ...pending 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 P...

Page 66: ...20 of the entire piston running surface covers more than 30 of the circumference and extends over more than 50 of piston stroke is wider than 15 mm over the entire piston stroke Discoloration This is...

Page 67: ...w heavy discoloration and scoring Replace liner Evaluation of findings and further measures The findings in the start phase of oxidation discoloration and heat discoloration are similar Thorough inves...

Page 68: ...residues which are harmful to health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Replacing oil separator 1 Rem...

Page 69: ...hragm 3 on housing 1 5 Install new seal 2 and spring 5 together with cover 4 6 Use torque wrench to tighten the screws of cover 4 to the specified torque Name Size Type Lubricant Value Standard Screw...

Page 70: ...are parts Designation Use Part No Qty Engine oil Valve gear Lubrication 1 Remove cylinder head covers Page 75 2 Fill oil chambers of valve bridges with oil 3 Fill oil chambers of rocker arms and adjus...

Page 71: ...Y20098771 1 Torque wrench 60 320 Nm F30452768 1 Socket wrench 24 mm F30039526 1 Engine oil Preparatory steps 1 Remove cylinder head cover Page 75 2 Install barring device Page 61 Note The OT mark if f...

Page 72: ...ram for 8V engines Two crankshaft positions Diagram for 12V engines Two crankshaft positions Diagram for 16V engines Two crankshaft positions 72 Task Description MS150026 02E 2013 11 TIM ID 0000000922...

Page 73: ...clearances 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 feel...

Page 74: ...ze Type Lubricant Value Standard Locknut M16 x 1 5 Tightening torque Engine oil 90 Nm 9 Nm 6 Replace or rectify adjusting screws and or locknuts which do not move freely 7 Check valve clearance Final...

Page 75: ...er head covers 1 prior to removal 2 Remove screws 3 4 with washers 2 5 3 Take off cylinder head cover 1 with O ring 6 from cylinder head 7 Installing cylinder head cover 1 Clean mounting surface 2 Che...

Page 76: ...G Oils oil vapors are combustible explosive Risk of fire and explosion Avoid open flames electric sparks and ignition sources Do not smoke NOTICE HP fuel pump not filled with engine oil Damage to comp...

Page 77: ...lacement Special tools Material Spare parts Designation Use Part No Qty Injector Spare Parts Catalog Injector Replacement u Remove injector and install new one Page 78 MS150026 02E 2013 11 Task Descri...

Page 78: ...e wrench 60 320 Nm F30452768 1 Ratchet F30027341 1 Assembly paste Optimoly Paste White T 40477 1 Grease Kluthe Hakuform 30 11C Emulgier X00059351 1 Engine oil O ring Spare Parts Catalog WARNING Fuels...

Page 79: ...emove injector with installation removal tool 7 Remove installation removal tool 8 Remove sealing ring 4 from injector or use a self made hook to take it out of the cylinder head 9 Remove O rings 3 O...

Page 80: ...installation position of seal ing ring 4 Fit new O rings 3 included in the scope of supply of the injector O ring 2 and damping ring 1 onto the injector and coat with grease 5 Remove oil carbon from...

Page 81: ...d torque Engine oil 5 Nm to 10 Nm 13 Tighten screw 2 with torque wrench to the specified tightening torque Name Size Type Lubricant Value Standard Screw M12 Tightening torque 100 Nm 10 Nm 14 Tighten a...

Page 82: ...will void the emissions certification 18 Reset drift compensation CDC with Dia Sys E531920 If DiaSys is not available contact Service Final steps 1 Install cylinder head cover Page 75 2 Open fuel supp...

Page 83: ...trical sparks and ignition sources Do not smoke Venting LP fuel system 1 Open vent plug 1 2 Unlock fuel priming pump 2 screw out handle by turning it counterclockwise 3 Operate the pump with the handl...

Page 84: ...on Avoid open flames electrical sparks and ignition sources Do not smoke Fuel filter Replacement 1 Remove easy change filter using filter wrench 2 Clean sealing face on filter head 3 Apply a thin coat...

Page 85: ...air jet at people Always wear safety goggles face mask and ear defenders Intercooler Checking conden sate drain for coolant leakage and obstructions 1 With the engine running check if air es capes fro...

Page 86: ...heck Preconditions Engine is stopped and starting disabled Checking starter condition 1 Check securing screws of starter for secure seating and tighten if required 2 Check wiring Page 124 86 Task Desc...

Page 87: ...gine is running Risk of damage to hearing Wear ear protectors Emergency air shutoff flaps Electric control check 1 Start engine Page 32 2 Activate the appropriate function to trigger emergency air shu...

Page 88: ...p Checking 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 in...

Page 89: ...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 collect the engine oil 2 R...

Page 90: ...ers 4 Install drain screws s with new sealing ring 5 Tighten drain screws 2 and 3 with torque wrench to the specified torque Name Size Type Lubricant Value Standard Screw M26 x 1 5 Tightening torque E...

Page 91: ...ng Wear protective clothing 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 of damage to hearing Wear...

Page 92: ...g gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Engine oil filter Replacement 1 Remove engine oil filter using filter wrench 2 Clean sealing surface on connecting piec...

Page 93: ...Parts Catalog Oil filter candles Spare Parts Catalog WARNING Hot oil Oil can contain combustion residues which are harmful to health Risk of injury and poisoning Wear protective clothing gloves and go...

Page 94: ...Take off spring washer and washer 5 Remove screw 4 6 Remove flushing arm 5 from screen plate 6 7 Turn filter insert upside down and use ap propriate tool to push out filter candles 1 8 Turn filter in...

Page 95: ...orque using a torque wrench Name Size Type Lubricant Value Standard Nut Tightening torque Engine oil 80 Nm 15 Install spinner 1 with spring 16 Tighten screw 2 to specified torque using a torque wrench...

Page 96: ...3 Install oil filter cover 1 4 Install nuts 2 of oil filter cover 1 96 Task Description MS150026 02E 2013 11 TIM ID 0000006401 008...

Page 97: ...ve clothing gloves and goggles safety mask 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...

Page 98: ...w part Cleaning strainer 1 Wash strainer 5 with cleaner 2 Remove stubborn deposits with soft brush 3 Blow out strainer 5 with compressed air from inside Installing strainer 1 Coat square section ring...

Page 99: ...rts Catalog WARNING Hot oil Oil can contain combustion residues which are harmful to health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin...

Page 100: ...rotor base 10 with sealing ring 9 13 Insert new filter sleeve 6 in rotor tube 7 with the smooth paper surface facing the outer wall 14 Check sealing ring 5 fit new one if neces sary 15 Mount rotor co...

Page 101: ...first stop and allow pressure to escape 2 Continue to turn breather valve counterclockwise and remove 3 Check engine coolant level coolant must be visible at the bottom edge of the filler neck s cast...

Page 102: ...e Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 104 2 Fill with engine coolant Page 106 102 Task Description MS150026 02E 201...

Page 103: ...ear protectors Engine coolant pump Pressure relief port check 1 Check pressure relief port for oil and cool ant discharge 2 Shut down engine Page 34 and secure against being restarted observe general...

Page 104: ...ing unit Draining engine coolant 1 Turn pressure cap on coolant expansion tank counterclockwise until the first stop and allow pressure to escape 2 Continue to turn pressure cap counterclockwise and r...

Page 105: ...ase on the left or right side arrowed and drain off the engine coolant 6 Close off all open drain points 7 Place pressure cap on filler neck and close Concluding operations u Switch on preheater MS150...

Page 106: ...ng 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 co...

Page 107: ...se c Repeat the steps from Start engine Step 7 until no more coolant has to be added 12 Disconnect pump and hose Filling coolant through filler neck 1 Alternatively Fill in coolant through filler neck...

Page 108: ...n Wear protective clothing gloves and goggles safety mask WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Engine coolant Sample extrac tion...

Page 109: ...isk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Engine coolant filter Replace ment 1 Close shutoff cocks 1 2 Remove engine coolant filter 2...

Page 110: ...olant Change Special tools Material Spare parts Designation Use Part No Qty Coolant Charge air coolant Change 1 Drain charge air coolant Page 111 2 Fill with charge air coolant Page 112 110 Task Descr...

Page 111: ...sure cap on coolant expansion tank counterclockwise until the first stop and allow pressure to escape 3 Continue to turn pressure cap counter clockwise and remove 4 Draw off separated corrosion inhibi...

Page 112: ...alding 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 u...

Page 113: ...Set breather valve onto filler neck and close c Repeat the steps from Start engine Step 7 until no more coolant has to be added 12 Disconnect pump and hose Filling coolant through filler neck 1 Alter...

Page 114: ...clockwise to the first stop and allow pressure to escape 2 Continue to turn breather valve counter clockwise and remove 3 Check coolant level coolant must be visi ble at marking plate 4 Top up coolant...

Page 115: ...hearing Wear ear protectors Charge air coolant pump Relief bore check 1 Check relief bore for oil and coolant dis charge 2 Stop engine Page 34 and secure against being restarted observe general Maint...

Page 116: ...ed Guard is removed Drive belt Condition check Item Findings Action Drive belt A Singular cracks None Drive belt B Cracks on entire circumference Replace Page 119 Drive belt C Chunking Drive belt Belt...

Page 117: ...jet at people Always wear safety goggles face mask and ear defenders Battery charging generator Check Item Findings Action Ventilation area arrow Clean None Ventilation area arrow Contaminated Clean...

Page 118: ...pecified tool and equipment Adjusting belt tension 1 Remove protective cover 2 Slacken screws 1 and 2 by half a turn Result Belt tensioner moves against the drive belt and tensions it 3 Tighten screw...

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

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

Page 121: ...z 2 Hz 44 Hz 2 Hz Adjusting drive belt tension 1 Release screws 2 until fan clutch can be moved 2 Tighten stud 1 until the required frequen cy is achieved 3 For Rockford S270 fan clutch Tighten screws...

Page 122: ...elt Spare Parts Catalog Preparatory steps 1 Remove protective cover 2 Remove fan Replacing drive belt 1 Release screws 2 2 Slacken off stud 1 until drive belt can be removed 3 Clean belt pulleys 4 Fit...

Page 123: ...gine mounting Check Engine mounting Check Item Findings Action Visually inspect mounts Damage Brittleness Deformation Crack formation Swelling visible Replace contact Service MS150026 02E 2013 11 Task...

Page 124: ...swing freely 3 Check that cable clamps are firm tighten loose cable clamps 4 Replace faulty cable clamps 5 Visually inspect the following electrical line components for damage Connector housing Conta...

Page 125: ...parameters must be reset otherwise the emission certification of the engine is no longer ap plicable u Reset the CDC parameters with DiaSys Manufacturer s documentation Resetting CDC parameters DiaSy...

Page 126: ...face using a cloth moistened with isopropyl alcohol 2 Remove dirt from the connector and cable surfaces with isopropyl alcohol 3 Check legibility of cable labels Clean or replace illegible labels Clea...

Page 127: ...table test probe e g test prod 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 plu...

Page 128: ...as soon as possible 2nd function Read out fault codes CCT Circuit CLS Coolant level sensor Monitors coolant level CM Current Measurement Current measured value CPS Coolant pressure sensor Monitors co...

Page 129: ...ds 2nd maximum limit HT High Temperature IDM Interface Data Module Memory module for interface data IIG Initiale Injektorgleichstellung Initial input of injector code with DiaSys in engine governor IN...

Page 130: ...fault codes SID System Identifier SRS Synchronous Reference Sensor TDC cylinder 1 SS Safety System Security Shutdown Safety system alarm TBS Turbocharger Boost Sensor Monitors charge air pressure TCI...

Page 131: ...e work in case of malfunction or changed operating conditions or for spare parts supply Your contact person in our Customer Assistance Center E mail info mtu online com Tel 49 7541 9077777 Fax 49 7541...

Page 132: ...2 Engine Barring manually Page 61 Barring device Part No F6555766 Qty Used in 1 7 2 1 Cylinder liner Endoscopic examination Page 64 Barring gear Part No F6555766 Qty Used in 1 7 1 2 Engine Barring ma...

Page 133: ...Page 64 Feeler gauge Part No Y20098771 Qty Used in 1 7 4 2 Valve clearance Check and adjustment Page 71 Filter wrench Part No F30379104 Qty Used in 1 7 8 1 Fuel filter Replacement Page 84 Qty Used in...

Page 134: ...tallation Page 78 MTU test kit Part No 5605892099 00 Qty Used in 1 7 12 3 Engine oil Sample extraction and analysis Page 91 Qty Used in 1 7 14 6 Engine coolant Sample extraction and analysis Page 108...

Page 135: ...rive belt re placement Page 119 Ratchet Part No F30027341 Qty Used in 1 7 6 2 Injector Removal and installation Page 78 Qty Used in 1 7 17 2 Battery charging generator drive Drive belt tension adjustm...

Page 136: ...12 Qty Used in 1 7 1 2 Engine Barring manually Page 61 Qty Used in 1 7 2 1 Cylinder liner Endoscopic examination Page 64 Socket wrench 24 mm Part No F30039526 Qty Used in 1 7 4 2 Valve clearance Check...

Page 137: ...in 1 7 17 2 Battery charging generator drive Drive belt tension adjustment Page 118 Qty Used in 1 7 17 3 Battery charging generator drive Drive belt re placement Page 119 Torque wrench 40 200 Nm Part...

Page 138: ...Used in 1 7 6 2 Injector Removal and installation Page 78 Qty Used in 1 7 13 2 Automatic oil filter Filter candles replacement Page 93 Qty Used in 1 7 17 2 Battery charging generator drive Drive belt...

Page 139: ...ylinder head cover Removal and installation 75 Cylinder liner Endoscopic examination 64 D Designations Engine sides and cylinders 18 Drive belt Condition check 116 E Emergency air shutoff flaps Electr...

Page 140: ...rational checks 33 Overview Actuators 20 Sensors 20 P Plant Cleaning 36 Putting the engine into operation Preparation after scheduled out of service period 31 R Recommissioning Preparations for after...

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