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MTU 20 V 4000 C22, Operating Instructions Manual

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MTU 20 V 4000 C22 Operating Instructions Manual Download Page 135

9 Appendix B

9.1 Special Tools

Air filter

Part No.:
Qty.:

Used in:

 

7.11.2 Air filter – Replacement (→ Page 92)

Coolant filter

Part No.:
Qty.:

Used in:

 

7.15.7 Coolant filter – Replacement (→ Page 112)

Diaphragm

Part No.:
Qty.:

Used in:

 

7.3.1 Crankcase breather – Oil separator replacement, diaphragm check and replace‐

ment (→ Page 63)

Drive belt

Part No.:
Qty.:

Used in:

 

7.18.5 Battery-charging generator drive – Drive belt replacement (→ Page 124)

Qty.:

Used in:

 

7.19.2 Fan drive – Drive belt replacement (→ Page 127)

Easy-change filter

Part No.:
Qty.:

Used in:

 

7.9.1 Fuel filter – Replacement (→ Page 86)

Filter element

Part No.:
Qty.:

Used in:

 

7.3.1 Crankcase breather – Oil separator replacement, diaphragm check and replace‐

ment (→ Page 63)

Qty.:

Used in:

 

7.3.3 Crankcase breather – Filter element replacement (→ Page 66)

Filter sleeve

Part No.:
Qty.:

Used in:

 

7.14.3 Centrifugal oil filter – Cleaning and filter-sleeve replacement (→ Page 103)

M015675/05E 2011-10 | Appendix B | 135

DCL-ID: 0000014250 - 001

Summary of Contents for 20 V 4000 C22

Page 1: ...Operating Instructions Diesel engine 20 V 4000 C22 M015675 05E...

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

Page 3: ...portant Please complete and return the Commissioning Note card below to MTU Friedrichshafen GmbH The Commissioning Note information serves as a basis for the contractually agreed logistic support war...

Page 4: ......

Page 5: ...1 6 2 ECU 4 alarms 44 7 Task Description 7 1 Engine 56 7 1 1 Engine Barring manually 56 7 1 2 Engine Barring with starting system 58 7 2 Cylinder Liner 59 7 2 1 Cylinder liner Endoscopic examination 5...

Page 6: ...ant Change 114 7 16 3 Charge air coolant Draining 115 7 16 4 Charge air coolant system Filling 116 7 16 5 Charge air coolant pump Relief bore check 118 7 17 Belt Drive 119 7 17 1 Drive belt Condition...

Page 7: ...other use is considered improper use The engine manufacturer accepts no liability whatsoever for resultant damage or injury in such case The responsibility is borne by the user alone Correct use also...

Page 8: ...accessible to operating maintenance repair and transport personnel at all times Use the manual as a basis for instructing personnel on engine operation and repair In particular person nel must have r...

Page 9: ...en specially wrapped in aluminum 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 t...

Page 10: ...ng the engine is allowed only with the transport locking device removed Make sure that the transport locking device of the generator is removed Prior to every unit transport this transport locking dev...

Page 11: ...removed Turn crankshaft to bring cylinder A1 in TDC position Check the threads on both sides of the flywheel 1 for ease of movement Install retainer 2 with screw 4 and washer 3 through the opening in...

Page 12: ...ing units must be permanently observed with re gard to present operating status violation of limit values and warning or alarm messages The following steps must be taken if a malfunction of the system...

Page 13: ...ry danger to life Allow the engine to cool down before opening the crankcase Avoid open flames electrical sparks and ignition sources Safety instructions u Before starting maintenance work allow the e...

Page 14: ...t all mounts and dampers are correctly installed Ensure that all fuel injection and pressurized oil lines are installed with enough space to prevent con tact with other components Do not place fuel or...

Page 15: ...nager or supervisor Before work is carried out on the assemblies the power supply to the relevant areas must be switched off Do not damage wiring during the removal work When reinstalling ensure that...

Page 16: ...ohibited by emission regulations Emission control units systems may only be main tained exchanged or repaired if the components used for this purpose are approved by MTU Noncom pliance with these guid...

Page 17: ...danger class AI AII and B out of containers results in a risk of explosion Forcing compressed air into thin walled containers e g containers made of tin plastic and glass for drying purposes or to ch...

Page 18: ...es Minor injury or material damage Remedial action Note This manual contains highlighted safety warnings in accordance with the US ANSI Z535 standard which begin with one of the signal words listed ab...

Page 19: ...ted A and those of the right side B as per DIN ISO 1204 The cylinders of each bank are numbered consecutively starting with No 1 at the driving end of the engine Other components are numbered in the s...

Page 20: ...lt 5 Charge air coolant inlet 6 Engine coolant outlet 7 Starter A side 8 Engine Control Unit ECU 4 9 Fuel priming pump 10 Fuel filter easy change filter 11 Crankcase 12 HP fuel pump 13 Engine oil filt...

Page 21: ...r cyl inder head 3 Oil heat exchanger 4 Intercooler 5 Flywheel 6 Charge air coolant outlet 7 Engine coolant inlet 8 Oil pan 9 Oil dipstick 10 Oil filler neck 11 Starter B side M015675 05E 2011 10 Gene...

Page 22: ...Exhaust turbocharger B side 8 Exhaust system connec tion B side 9 Air supply before inter cooler B side Engine model designation Key to the engine model designation 20V 4000 C22 20 Number of cylinders...

Page 23: ...Y39 1 to Y39 10 A side cylinders 3 B34 P Fuel after filter 4 B48 P Fuel 5 B33 T Fuel The injectors are underneath the cylinder head covers of the cylinder Injector replacement and necessa ry activitie...

Page 24: ...Injectors Y39 11 to Y39 20 B side cylinders 2 B16 P Coolant 3 B10 P Charge Air 4 B09 T Charge Air 1 B44 N Turbocharger 2 B03 T Intake Air 24 General Information M015675 05E 2011 10 TIM ID 0000012921 0...

Page 25: ...1 B13 N Crankshaft M015675 05E 2011 10 General Information 25 TIM ID 0000012921 002...

Page 26: ...case 2 F25 P Lube Oil Diff after Filter 3 B05 P Lube Oil 4 B01 N Camshaft 5 B43 P Coolant Intercool er 6 B26 T Coolant Intercool er 7 B06 T Coolant 26 General Information M015675 05E 2011 10 TIM ID 00...

Page 27: ...00 POWER RELATED DATA power ratings are net brake power to ISO 3046 Number of cylinders 20V 4000 Engine rated speed A rpm 1800 Net brake power without fan fuel stop power ISO 3046 A kW 2720 GENERAL CO...

Page 28: ...t temperature after engine alarm R C 97 Coolant temperature after engine shutdown L C 99 Coolant antifreeze content max permissible L 50 Coolant pump inlet pressure min L bar 0 2 Coolant pump inlet pr...

Page 29: ...from H P pump R bar 5 0 Fuel pressure before injection pump to H P pump R bar 8 1 Fuel pressure before injection pump min H P pump R bar 5 0 GENERAL OPERATING DATA Number of cylinders 20V 4000 Coolant...

Page 30: ...pacity dipstick mark max standard oil system Option max operating inclinations L liter 245 WEIGHTS MAIN DIMENSIONS Number of cylinders 20V 4000 Engine weight dry basic engine configuration R kg 9865 A...

Page 31: ...ng order 8V A1 B4 A4 A2 B3 A3 B2 B1 12V A1 B2 A5 B4 A3 B1 A6 B5 A2 B3 A4 B6 16 V A1 A7 B4 B6 A4 B8 A2 A8 B3 B5 A3 A5 B2 A6 B1 B7 20 V A1 B5 A8 B7 A5 B2 A7 B10 A2 B3 A10 B6 A3 B4 A6 B9 A4 B1 A9 B8 M015...

Page 32: ...3 3 Main engine dimensions Main engine dimensions Length A approx 3630 mm Width B approx 1450 mm Height C approx 2252 mm 32 Technical Data M015675 05E 2011 10 TIM ID 0000002137 001...

Page 33: ...061 Valve gear Lubricate valve gear Page 70 Lube oil system Check engine oil level Page 96 Fuel system Vent Page 85 Coolant circuit If engine is out of service for more than one year change engine coo...

Page 34: ...Startup Item Action Lube oil system Check engine oil level Page 96 Coolant circuit Check engine coolant level Page 105 Check charge air coolant level Page 113 Coolant circuit Preheat coolant with cool...

Page 35: ...otectors Preparation Item Measure Operating mode switch if applicable Switch to manual mode Coolant preheating unit if applicable Switch on Starting the engine Item Measure Switch cabinet operator sta...

Page 36: ...aks and gen eral condition Check engine for abnormal running nois es exhaust color and vibrations Page 41 W0501 W0506 Battery charging generator Check battery charging generator for contamination clea...

Page 37: ...onents Before stopping the engine operate it at idle speed until operating temperatures decrease and stable values are indicated Preparation Item Measure Engine Operate engine at idling speed for appr...

Page 38: ...e for an extended period and cool ant has no antifreeze additive the coolant is not maintained at a suitable temperature antifreeze concentration is 50 and outside temperature is below 40 C Engine con...

Page 39: ...sensors with compressed air Plant Cleaning 1 Carry out plant cleaning only in areas where an appropriate oil separator is provided environmental pro tection 2 Prior to putting the cleaning unit into...

Page 40: ...ation clean if necessary Page 121 W1001 Replace fuel filter or fuel filter element Page 86 W1002 Check valve clearance Page 71 W1003 Check drive belt condition and tension replace as necessary Page 11...

Page 41: ...d engine cannot be barred manually Contact Service Engine turns but does not fire Component Probable Cause Task Starter Poor rotation by starter Battery low or defective Charge or replace battery see...

Page 42: ...Charge air pressure too low Component Probable Cause Task Air supply Air filter clogged Clean Intercooler Contaminated Contact Service Exhaust turbocharger Defective Contact Service Coolant leaks on i...

Page 43: ...e Not at operating temperature Run engine to reach operating temper ature Fuel system Water in fuel Check fuel system on fuel prefilter Drain fuel prefilter Intercooler Leaking Contact Service M015675...

Page 44: ...bleshooting in accordance with the following table is not successful contact Service to have the sensors actuators checked and if re quired replaced Fault code Alarm text Meaning Task 003 L1 T FUEL Fu...

Page 45: ...2 CHARGER 2 OVERSPEED 1 ETC 2 overspeed 1st limit Contact Service 037 ETC 2 CHARGER 2 OVERSPEED 2 ETC 2 overspeed 2nd limit Contact Service 051 L1 T LUBE OIL Lube oil temperature too high 1st limit R...

Page 46: ...h 2nd limit Automatic engine shut down 1 Allow the engine to cool down 2 Check coolant cooler elements etc and clean contaminated parts see manufacturer s docu mentation 3 Re start the engine Page 35...

Page 47: ...oc umentation 100 EDM NOT VALID Check sum error of meas uring point data in EDM If fault occurs repeatedly Contact Service 101 IDM NOT VALID Check sum error of meas uring point data in IDM If fault oc...

Page 48: ...sure sensors defective 1 Disconnect connectors X2 and X3 from ECU If alarm does not disappear Contact Service 2 Check wiring pressure sen sors 3 Contact Service 138 SENSORPOWER DEFECT Power supply for...

Page 49: ...OM write limit reached Contact Service 180 CAN1 NODE LOST At least one device not de tected on Default CAN bus 1 Check wiring CAN bus 2 Contact Service 181 CAN2 NODE LOST At least one device not de te...

Page 50: ...defect common rail pressure HP controller in emergency mode 1 Check wiring 2 Contact Service 216 SD T LUBE OIL Sensor defect lube oil temperature 1 Check wiring 2 Contact Service 219 SD T INTAKE AIR...

Page 51: ...edly Contact Service 310 TIMING CYLINDER A10 Injection timing fault cylin der A10 If fault occurs repeatedly Contact Service 311 TIMING CYLINDER B1 Injection timing fault cylin der B1 If fault occurs...

Page 52: ...Check wiring 2 Contact Service 329 WIRING CYLINDER A9 Faulty wiring to solenoid valve cylinder A9 Misfiring 1 Check wiring 2 Contact Service 330 WIRING CYLINDER A10 Faulty wiring to solenoid valve cyl...

Page 53: ...solenoid valve cylinder A3 Misfiring 1 Check wiring 2 Contact Service 344 OPEN_LOAD CYL A4 Disconnection in wiring to solenoid valve cylinder A4 Misfiring 1 Check wiring 2 Contact Service 345 OPEN_LO...

Page 54: ...wiring to solenoid valve cylinder B7 Misfiring 1 Check wiring 2 Contact Service 358 OPEN_LOAD CYL B8 Disconnection in wiring to solenoid valve cylinder B8 Misfiring 1 Check wiring 2 Contact Service 35...

Page 55: ...TRAN OUT2 PLANT DEF Binary transistor output plant 2 defective Contact Service 383 TRAN OUT3 PLANT DEF Binary transistor output plant 3 defective Contact Service 384 TRAN OUT4 PLANT DEF Binary transis...

Page 56: ...Danger to life Before barring the engine ensure that nobody is in the danger zone Barring engine manually lateral installation 1 Remove guard plate 2 Engage barring device 2 in ring gear 3 and install...

Page 57: ...barring device F6555766 with adapter F6558528 For 20V engines use barring de vice F6783293 3 Set ratchet 3 onto barring device 2 4 Rotate crankshaft in engine direction of ro tation Apart from the nor...

Page 58: ...e engine Engine Barring with starting system 1 Disengage the bayonet coupling 4 of con nector X4 with connector pliers 2 and withdraw connector 3 from engine gover nor 2 Bar engine in unloaded conditi...

Page 59: ...ks left by lower cooling bores Running pattern seems darker No action required Dark areas with even or varying degrees of discoloration Beginning and end of the discoloration are not sharply defined a...

Page 60: ...Final steps 1 Install injector Page 79 2 Install cylinder head cover Page 76 60 Task Description M015675 05E 2011 10 TIM ID 0000003304 003...

Page 61: ...Polished areas are on the running surface and show local removal of the hon ing pattern Grooves from the honing process are not visible any more New cylinder liners must be fitted in the following ca...

Page 62: ...ting in the TDC ring 1 have to be replaced Seizures Seizure marks Seizure marks are of irregular circumferential length and depth Can be caused by either the piston skirt or the piston crown Material...

Page 63: ...atalog 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 Do n...

Page 64: ...her oil separator elements in the same way Checking diaphragm variant B 1 Remove cover 4 2 Remove spring 5 seal 2 and diaphragm 3 3 Check diaphragm 3 for damage fit new diaphragm if used one is damage...

Page 65: ...en working with cleaner Wear protective clothing gloves and goggles safety mask Take measures against electrostatic charging CAUTION Excessive reaction time of cleaning agents on components Damage to...

Page 66: ...Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Crankcase breather closed circuit crankcase ventilation Filter element replacement 1 Loosen clam...

Page 67: ...e 1 off cover 3 4 Loosen clamp 5 5 Remove cover 3 6 Clean filter element 4 Page 65 or re place 7 Fit cover 3 8 Use torque wrench to tighten clamp 5 to specified torque 12 Nm to 14 Nm 9 Push hose 1 ont...

Page 68: ...grounding device 1 Clean grounding device 2 prior to remov al 2 Remove screws 1 3 Remove screws 3 from grounding device 2 4 Remove grounding device 2 Installing grounding device 1 Install grounding de...

Page 69: ...placement Special tools Material Spare parts Designation Use Part No Qty Grounding device Spare Parts Catalog Remove grounding device and install new one u Page 68 M015675 05E 2011 10 Task Description...

Page 70: ...pecial tools Material Spare parts Designation Use Part No Qty Engine oil Lubricating valve gear 1 Remove cylinder head covers Page 76 2 Fill oil chambers of rocker arms and adjust ing screws with oil...

Page 71: ...auge Y20010128 1 Torque wrench 60 320 Nm F30047446 1 Socket wrench F30039526 1 Allen key F30002817 1 Torque wrench 10 60 Nm F30510423 1 Socket wrench F30039518 1 Preparatory steps 1 Remove cylinder he...

Page 72: ...e Not applicable for engines with flying valve bridge 1 Prior to adjusting valve clearance check valve bridge balance on all valve bridges 2 Use feeler gauge to determine the distance between valve br...

Page 73: ...ed value between valve bridge and valve stem end A 4 At the opposite valve stem end B a feeler gauge thicker by 0 05 mm should not fit otherwise adjust valve bridge balance M015675 05E 2011 10 Task De...

Page 74: ...ve stem ends A and B 4 Turn adjusting screw so that both feeler gauges can be just pulled through 5 Hold adjusting screw securely in position with Allen key and fit locknut by hand on valve bridge 6 R...

Page 75: ...e to determine the distance between valve bridge and rocker arm 5 If the deviation from the reference value ex ceeds 0 1 mm adjust valve clearance Adjusting valve clearance 1 Release locknut 1 2 Inser...

Page 76: ...ad cover 1 Clean cylinder head covers prior to removal if they are heavily soiled 2 Undo and remove screws 3 Remove cylinder head cover with gasket from cylinder head Installing cylinder head cover 1...

Page 77: ...on a running engine WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors HP fuel pump Relief bore check 1 Visually inspect relief bore 1 for fuel dis charge 2 For double w...

Page 78: ...7 1 Injector Replacement Special tools Material Spare parts Designation Use Part No Qty Injector Spare Parts Catalog Remove injector and install new injector u Page 79 78 Task Description M015675 05E...

Page 79: ...T 40477 1 Grease Kluthe Hakuform 30 10 Emulgier X00029933 1 Engine oil WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke C...

Page 80: ...engine side is completed 1 Undo cable terminal screws arrowed on injector and remove cable terminals 2 Remove screw 2 and take off hold down clamp 1 3 Remove high pressure fuel line 5 4 Install instal...

Page 81: ...njector or use a self made wire hook to extract it from the cylinder head 8 Remove O rings 2 from injector 9 Cover all connections and bores or seal with suitable plugs M015675 05E 2011 10 Task Descri...

Page 82: ...llation position of seal ing ring 5 Clean sealing surface on cylinder head and protective sleeve with milling cutter 6 Insert injector into cylinder head ensuring that the HP line connection is aligne...

Page 83: ...ten high pressure fuel line 5 to the specified initial tightening torque Name Size Type Lubricant Value Standard HP line Preload torque Engine oil 5 Nm to 10 Nm 15 Tighten screw 2 to specified torque...

Page 84: ...injector and tighten screws to specified torque using a torque wrench Name Size Type Lubricant Value Standard Screw Tightening torque 1 5 Nm Final steps 1 Install cylinder head cover Page 76 2 Open up...

Page 85: ...on sources Do not smoke Venting LP fuel system 1 Loosen flushing return line of HP pump at connection 1 2 Unlock fuel priming pump 2 screw out handle 3 Operate the fuel priming pump 2 with the handle...

Page 86: ...f fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Replacing fuel filter 1 Remove easy change filter using filter wrench 2 Clean sealing surface on filter head...

Page 87: ...cal sparks and ignition sources Do not smoke Edge type fuel filter Draining 1 Rotate edge type filter 2 with handle 1 clockwise several times 2 Do not apply force when rotating handle 3 Close fuel sup...

Page 88: ...e Draining fuel prefilter 1 Shut down the filter unit 5 8 to be changed at valves 3 and 4 or 9 and 10 2 Open threaded vent plug 1 or 2 on filter to be drained 3 Open drain valve 6 or 7 4 Drain water a...

Page 89: ...ctors Intercooler Check drain for coolant leakage and obstruction 1 Verify that air emerges from condensate drain bore s on left and right engine sides at driving end when engine is running If no air...

Page 90: ...tors Air filter element Cleaning Note Clean paper filter element dry only 1 Open air filter and remove filter element Page 93 2 Check seal for damage and cleanness re place if necessary 3 Clean all ma...

Page 91: ...Visual inspection 1 Use inspection lamp to check cleaned filter element for damage 2 Fit new filter element if old one is damaged Page 92 M015675 05E 2011 10 Task Description 91 TIM ID 0000005423 002...

Page 92: ...ls Material Spare parts Designation Use Part No Qty Air filter Spare Parts Catalog Remove air filter and install new one u Page 93 Reset signal ring of service indicator u Page 94 92 Task Description...

Page 93: ...l and installation 1 Release latches 9 2 Remove dust bowl 8 and partition 7 3 Remove collar nut 6 4 Screw off air filter element 4 5 Clean housing 3 and dust bowl 8 6 Check seal 5 for damage and clean...

Page 94: ...cking signal ring position 1 If the signal ring is completely visible in the control window 2 replace air filter Page 92 2 After installation of new filter press reset button 1 Result Engaged piston w...

Page 95: ...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 128 M015675 05E...

Page 96: ...gine oil level with the engine running 1 After the engine has run for approx 10 minutes at a constant speed of 900 rpm withdraw oil dipstick from guide tube and wipe it 2 Insert dipstick into guide tu...

Page 97: ...ith skin Do not inhale oil vapor Procedure without pump Draining oil at drain plug on oil pan 1 Provide a suitable container in which to collect the oil 2 Remove drain plug and drain oil 3 Install dra...

Page 98: ...g Spare 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 glove...

Page 99: ...filter cover 3 Withdraw filter insert 1 4 Remove O ring 5 Remove screw 2 6 Withdraw spinner 1 with spring 7 Remove nut 3 8 Take off spring washer and washer 9 Remove screw 4 10 Remove flushing arm 5 f...

Page 100: ...Oil filter candles Installation 1 For installation follow reverse sequence of working steps 2 In addition the following work must be performed Replace all sealing elements with new parts Coat O rings...

Page 101: ...e clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING Compressed air Risk of injury Do not direct compressed air jet at persons Wear protective goggles safe...

Page 102: ...eaning 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 4 on stra...

Page 103: ...talog Sealing ring Spare Parts Catalog Sealing ring Spare Parts Catalog WARNING Hot oil Oil can contain combustion residues which are harmful to health Risk of injury and poisoning Wear protective clo...

Page 104: ...nd rotor base 14 with sealing ring 13 14 Insert new filter sleeve 10 in rotor tube 11 with the smooth paper surface facing the wall 15 Check sealing ring 9 fit new one if neces sary 16 Mount rotor cov...

Page 105: ...clockwise to the first stop and allow pressure to escape 2 Continue to turn breather valve counterclockwise and remove 3 Check coolant level coolant must be visible at the lower edge of the cast in ey...

Page 106: ...nt Change Special tools Material Spare parts Designation Use Part No Qty Engine coolant Drain engine coolant u Page 107 Fill with engine coolant u Page 108 106 Task Description M015675 05E 2011 10 TIM...

Page 107: ...urn breather valve of filler neck on coolant expansion tank counterclockwise to first stop and allow pressure to escape 2 Continue to turn breather valve counter clockwise and remove 3 Draw off separa...

Page 108: ...lding Let the engine cool down Wear protective clothing gloves and goggles safety mask CAUTION Cold coolant in hot engine can cause thermal stress Formation of cracks in components Fill top up coolant...

Page 109: ...peat the steps from Start engine Step 7 until coolant is no longer needed to be topped up d Disconnect pump and hose Filling coolant through filler neck 1 Alternatively Fill in coolant in expansion ta...

Page 110: ...g relief bore on engine coolant pump 1 Check relief bore for oil and coolant dis charge 2 Stop engine Page 37 and disable en gine start observe general safety instruc tions for maintenance and repair...

Page 111: ...wn Wear protective clothing gloves and goggles safety mask WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors Coolant Sample extraction and analysis 1 With the engine run...

Page 112: ...under pressure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Coolant filter Replacement 1 Close shut off cocks 1 2 Remove coolant filter...

Page 113: ...on tank counterclockwise to the first stop and allow pressure to escape 2 Continue to turn breather valve counter clockwise and remove 3 Check coolant level coolant must be visible at marking plate 4...

Page 114: ...hange Special tools Material Spare parts Designation Use Part No Qty Charge air coolant Drain charge air coolant u Page 115 Fill with charge air coolant u Page 116 114 Task Description M015675 05E 201...

Page 115: ...in the coolant into 2 Turn breather valve of filler neck on coolant expansion tank counterclockwise to first stop and allow pressure to escape 3 Continue to turn breather valve counter clockwise and r...

Page 116: ...e to hearing Wear ear protectors CAUTION Cold coolant in hot engine can cause thermal stress Formation of cracks in components Fill top up coolant only into cold engine Preparatory steps 1 Turn breath...

Page 117: ...s visible at the marking plate 2 Install plugs with new sealing rings at the filling points 3 Check proper condition of breather valve clean sealing faces if required 4 Set breather valve onto filler...

Page 118: ...ge air coolant pump Relief bore check 1 Check relief bore for oil and coolant dis charge 2 Stop engine Page 37 and disable en gine start observe general safety instruc tions for maintenance and repair...

Page 119: ...removed Item Findings Task Drive belt A Breaks in a few individual places None Drive belt Belt is oily shows signs of over heating Fit new belt Page 124 Drive belt B Breaks around the entire circum fe...

Page 120: ...and disconnect electrical cables on battery charging generator 3 Protect all cables against damage 4 Undo nut 3 5 Tilt battery charging generator 1 towards engine and remove V belt 5 6 Unscrew nut 2...

Page 121: ...ear protectors Battery charging generator check Item Diagnosis Task Ventilation area arrow Clean None Ventilation area arrow Dirty Clean Battery charging generator cleaning Note Dry clean battery cha...

Page 122: ...e is stopped and starting disabled Adjusting belt tension 1 Loosen locknut 2 and screws 1 2 Tension drive belt with tensioning nut 3 and check belt tension Page 123 3 Tighten locknut 2 4 Tighten screw...

Page 123: ...ng drive belt tension 1 Fit measuring head 2 on belt tension tester 3 and hit drive belt 1 with a suitable tool 2 Hold belt tension tester over belt drive until the measured value is displayed For spe...

Page 124: ...rain since pretension by the drive belt is no longer provided Therefore engine operation without drive belt connection is not allowed Battery charging generator drive Drive belt replacement 1 Remove g...

Page 125: ...n visually Page 119 Result If required replace drive belt Page 127 Checking Vee belt tension 1 Switch on belt tension tester 2 Hold measuring tip of belt tension tester over belt drive Tap drive belt...

Page 126: ...lt tension 1 Release screws 2 until fan coupling can be moved 2 Tighten stud 1 until the required frequency is achieved 3 Tighten screws 2 to 250 Nm 25 Nm 126 Task Description M015675 05E 2011 10 TIM...

Page 127: ...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 128: ...nnot swing freely 3 Check that cable ties are firm tighten loose cable ties 4 Replace faulty cable ties 5 Visually inspect the following electrical line components for damage connector housings contac...

Page 129: ...surface of connectors 1 connector sockets and shrink formed com ponents 2 using a cloth moistened with isopropyl alcohol 3 Check legibility of cable labels Clean or re place illegible labels Cleaning...

Page 130: ...nections Check 1 Use connector pliers 3 to make certain that all plug in connections on engine gov ernor are securely seated 2 Tighten loose bayonet couplings 2 with connector pliers 3 by turning them...

Page 131: ...odes CKT Circuit CLS Coolant Level Sensor Monitors coolant level CPS Coolant Pressure Sensor Monitors coolant pressure CTS Coolant Temperature Sensor Monitors coolant temperature DDEC Detroit Diesel E...

Page 132: ...all na tional standardization institutes KGS Kraftgegenseite Engine free end in accordance with DIN ISO 1204 KS Kraftseite Engine driving end in accordance with DIN ISO 1204 LED Light Emitting Diode L...

Page 133: ...alarm TBS Turbocharger Boost Sensor Monitors charge air pressure TCI Turbo Compressor Inlet TCO Turbo Compressor Outlet TD Transmitter Deviation Alarm Deviation in transmitter values TPS Throttle Posi...

Page 134: ...r during operation for preventive maintenance corrective work in case of malfunction or changed operating conditions or for spare parts supply Your contact at Headquarters Service support mtu online c...

Page 135: ...generator drive Drive belt replacement Page 124 Qty Used in 7 19 2 Fan drive Drive belt replacement Page 127 Easy change filter Part No Qty Used in 7 9 1 Fuel filter Replacement Page 86 Filter elemen...

Page 136: ...dles replacement Page 98 Qty Used in 7 14 2 Oil indicator filter Check Page 101 Oil filter candles Part No Qty Used in 7 14 1 Automatic oil filter Filter candles replacement Page 98 Seal Part No Qty U...

Page 137: ...Used in 7 14 3 Centrifugal oil filter Cleaning and filter sleeve replacement Page 103 Qty Used in 7 16 3 Charge air coolant Draining Page 115 Qty Used in 7 16 4 Charge air coolant system Filling Page...

Page 138: ...nerator 10 Cylinder head cover Removal and installation 76 Cylinder liner Endoscopic examination 59 D Drive belt Condition check 119 Dust bowl Cleaning 90 E ECU 4 alarms 44 Edge type fuel filter Drain...

Page 139: ...onal requirements 8 Plant Cleaning 39 Putting into operation Preparation after extended out of service periods 3 months 33 Putting the engine into operation Preparation after scheduled out of service...

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