MTU 20 V 4000 M93 Operating Instructions Manual Download Page 123

Page: 123 / 200

7.5 Injection Valve / Injector

7.5.1 Injector – Replacement

Special tools, Material, Spare parts

Designation / Use

Part No.

Qty.

Injector

(→ Spare Parts Catalog)

Replacing injector

Remove injector and install new injector (→ Page 124).

MS150048/04E 2013-07 | Task Description | 123

TIM-ID: 0000000022 - 013

Summary of Contents for 20 V 4000 M93

Page 1: ...Operating Instructions Diesel Engine 20 V 4000 M93 x MS150048 04E...

Page 2: ...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 distribut...

Page 3: ...rt up 61 4 8 Fuel treatment system Putting into operation 62 4 9 Fuel treatment system Switching on 65 4 10 Engine emergency stop at BlueLine automation system control stand 66 4 11 Coupling Engaging...

Page 4: ...and analysis 164 7 15 Raw Water Pump with Connections 165 7 15 1 Raw water pump Relief bore check 165 7 16 Battery Charging Generator 166 7 16 1 Battery charging generator drive Coupling condition ch...

Page 5: ...on approved by the manufacturer in writ ing including engine control parameters In compliance with all safety instructions and in adherence to all warning notices in this manual In accordance with the...

Page 6: ...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: ...ts and monitoring units must be permanently observed with re gard to present operating status violation of limit values and warning or alarm messages Malfunctions and emergency stop The procedures for...

Page 8: ...llium containing pinion Do not blow out the interior of the flywheel housing or the starter with compressed air Clean the flywheel housing inside with a class H dust extraction device as an additional...

Page 9: ...product beforehand Hydraulic installation and removal Check the function and safe operating condition of tools and fixtures to be used Use only the specified devices for hydraulic removal installation...

Page 10: ...cy stop feature Store spare parts properly prior to replacement i e protect them against moisture in particular Pack defective electronic components and assemblies in a suitable manner when dispatched...

Page 11: ...ics of the product 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 f...

Page 12: ...e supply 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 pa...

Page 13: ...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 14: ...trans port pallet or transport with equipment for heavy loads forklift truck Install the crankshaft locking device and the locking screws for the engine mounts prior to engine trans portation Secure t...

Page 15: ...on both 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 installed 4 Always use the screws s...

Page 16: ...t the ring gear 4 Turn screw 1 in bores of holder 3 until holder 3 is secured Note The screw 1 must be tightened alternately on both sides of the flywheel housing 5 Tighten screw 1 to specified tighte...

Page 17: ...ays use the screws supplied with the or removed from the guard plates and engine mounting brackets to secure them on the engine 1 Install engine mounting brackets 2 on both sides with guard plates 1 w...

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: ...equential turbocharging with internal engine coolant controlled charge air cooling The right hand ex haust turbocharger is cut in and cut out on 12V and 16V engines with electronically controlled hydr...

Page 20: ...also integrated in the engine wiring har ness Functions ECU supply EMU supply Plant signals ECU7 connector X1 Bus interface 2x MCS5 CAN CAN dialog output 1xMCS5 CAN Emergency stop ECU and EMU Electric...

Page 21: ...arms when limits are violated Pushbuttons for menu control and dimming unit Combined control and display elements for local engine gear control Flashing light and horn for combined alarm in engine roo...

Page 22: ...line from fuel filter head 1 Fuel line to HP pump Lube oil system oil lines with oil pressure 1 8 bar 1 Parting line ETC oil supply free end 22 General Information MS150048 04E 2013 07 TIM ID 00000100...

Page 23: ...1 Parting line ETC oil supply driving end 1 Oil line on equipment carrier 1 Oil supply to HP pump MS150048 04E 2013 07 General Information 23 TIM ID 0000010057 003...

Page 24: ...1 Oil supply to flap control free end 1 ETC oil supply on main oil gallery 1 Switching cylinder air flap A2 24 General Information MS150048 04E 2013 07 TIM ID 0000010057 003...

Page 25: ...A2 3 T piece flap control 1 Connection oil line to turbocharger B1 2 Switching cylinder exhaust flap tur bocharger B1 3 T piece flap control turbocharger B1 1 Switching cylinder air flap turbo charger...

Page 26: ...p turbo charger B2 4 T piece flap control turbocharger B2 1 Flap control distributor Special connections In case of leakage the following connection types are spray protected even without a cover and...

Page 27: ...has to pass the thread The pressure is so greatly reduced by this and the faulty sealing ring 1 that any leakage is not under pressure Plug in pipe connection b The sleeve 3 covers the joint to preve...

Page 28: ...ea 20 Leak fuel connection The HP fuel line is sealed by the thrust ring 8 If leakage in the area of the thrust ring 8 or the HP line 5 occurs the emerging fuel is routed to the leakage chamber The le...

Page 29: ...tic oil filter 12 HP fuel pump 13 Fuel filter 14 Centrifugal oil filter s 15 Coolant cooler Engine model designation Key to the engine model designations 20V 4000 Mxyz 20 Number of cylinders V Cylinde...

Page 30: ...2 lube oil pressure af ter filter 12 B34 2 fuel pressure be fore filter 13 B34 1 fuel pressure after filter 14 B5 3 lube oil pressure be fore filter 15 B48 fuel pressure in com mon rail 16 B4 B10 exha...

Page 31: ...ng tem perature 10 B57 2 main bearing tem perature 11 B57 3 main bearing tem perature 12 B57 4 main bearing tem perature 13 B57 5 main bearing tem perature 14 B57 6 main bearing tem perature 15 B57 7...

Page 32: ...uel level 2 B33 fuel temperature 3 B1 camshaft speed 4 B54 oil refill pump pres sure 5 B6 2 coolant tempera ture 6 B6 coolant temperature 7 Connector XD1 Dialog unit 32 General Information MS150048 04...

Page 33: ...10 spray oil temp conrod bearing 9 B77 B9 spray oil temp conrod bearing 10 B77 B8 spray oil temp conrod bearing 11 B77 B7 spray oil temp conrod bearing 12 B77 B6 spray oil temp conrod bearing 13 B77 B...

Page 34: ...20 V 4000 M driving end 1 B13 2 crankshaft speed 2 B13 crankshaft speed 3 S37 2 safety switch 4 S37 1 safety switch 34 General Information MS150048 04E 2013 07 TIM ID 0000034733 003...

Page 35: ...temperature B9 Charge air temperature B10 Charge air pressure B13 Crankshaft speed B16 Coolant pressure B21 Raw water pressure B33 Fuel temperature B34 1 Fuel pressure after filter B34 2 Fuel pressur...

Page 36: ...rnor ECU 7 E4 X KF thermostat heating Y39A1 to Y39AX Injectors engine side A Y39B1 to Y39BX Injectors engine side B Designation Connection assignment Adaption X1 Engine Control Unit ECU X3 Engine Cont...

Page 37: ...1 7 B7 8 B10 9 B34 2 10 XY27 11 B34 1 12 B48 13 B4 23 14 F46 15 B33 16 B1 17 B4 21 18 XG03 19 B5 3 20 M8 21 X2 22 X37 23 XF33 24 B6 25 B44 4 26 B16 27 B4 24 28 B4 22 29 B49 30 Y26 31 B44 2 32 B9 33 B...

Page 38: ...3 4 Y39A4 5 Y39A5 6 Y39A6 7 Y39A7 8 Y39A8 9 Y39A9 10 Y39A10 11 X4 12 E4 1 13 E4 2 14 E4 3 15 E4 4 16 E4 5 17 Y39B9 18 Y39B10 19 Y39B8 20 Y39B7 21 Y39B6 22 Y39B5 23 Y39B4 24 Y39B3 25 Y39B2 26 Y39B1 38...

Page 39: ...Engine wiring harness for EIM 1 XD1 2 X1 3 X3 4 X52 5 XY1 6 X11 7 XB19 8 X37 MS150048 04E 2013 07 General Information 39 TIM ID 0000034732 002...

Page 40: ...Engine wiring harness for electric starter 1 EIM terminals 2 Fuse F1 3 Starter terminals 40 General Information MS150048 04E 2013 07 TIM ID 0000034732 002...

Page 41: ...3 Application group 1DS Intake air temperature C 25 Raw water inlet temperature C 25 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake po...

Page 42: ...oil operating pressure low idle measuring point before engine R bar 2 0 FUEL SYSTEM Number of cylinders 20 Fuel pressure at engine inlet connection min during engine start L bar 0 1 Fuel pressure at...

Page 43: ...engine side with cooling system R Liters 440 Engine oil on initial filling standard oil system Option max operating inclina tions R Liters 365 Oil change quantity max standard oil system Option max op...

Page 44: ...25 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 20 Rated engine speed A rpm 2100 Fuel stop...

Page 45: ...Fuel pressure at engine inlet connection max during engine start L bar 1 5 Fuel supply rate max R liters min 30 GENERAL OPERATING DATA Number of cylinders 20 Firing speed from R rpm 80 Firing speed t...

Page 46: ...tem Option max operating incli nations R Liters 320 Oil pan capacity at dipstick mark min standard oil system Option max operating inclinations L Liters 255 Oil pan capacity at dipstick mark max stand...

Page 47: ...inlet temperature C 25 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 20 Rated engine speed...

Page 48: ...Fuel pressure at engine inlet connection max during engine start L bar 1 5 Fuel supply rate max R liters min 30 GENERAL OPERATING DATA Number of cylinders 20 Firing speed from R rpm 80 Firing speed t...

Page 49: ...Liters 320 Oil pan capacity at dipstick mark min standard oil system Option max operating inclinations L Liters 255 Oil pan capacity at dipstick mark max standard oil system Option max operating incli...

Page 50: ...25 Barometric pressure mbar 1000 Site altitude above sea level m 100 POWER RELATED DATA power ratings are net brake power as per ISO 3046 Number of cylinders 20 Rated engine speed A rpm 2100 Fuel sto...

Page 51: ...Fuel pressure at engine inlet connection max during engine start L bar 1 5 Fuel supply rate max R liters min 30 GENERAL OPERATING DATA Number of cylinders 20 Firing speed from R rpm 80 Firing speed t...

Page 52: ...Liters 320 Oil pan capacity at dipstick mark min standard oil system Option max operating inclinations L Liters 255 Oil pan capacity at dipstick mark max standard oil system Option max operating incli...

Page 53: ...Width B Height C 12 V 4000 M73 93 L approx 2991 mm approx 1463 mm approx 2368 mm 16 V 4000 M73 93 L approx 3583 mm approx 1463 mm approx 2368 mm 20 V 4000 M73 93 L approx 4192 mm approx 1484 mm appro...

Page 54: ...3 6 Firing order Firing order Num ber of cylin ders Firing order 20 V A1 B5 A8 B7 A5 B2 A7 B10 A2 B3 A10 B6 A3 B4 A6 B9 A4 B1 A9 B8 54 Technical Data MS150048 04E 2013 07 TIM ID 0000035068 001...

Page 55: ...4 Operation 4 1 Controls Automation system controls Refer to automation system operating instructions MS150048 04E 2013 07 Operation 55 TIM ID 0000016959 003...

Page 56: ...bove waterline Fill with water approx 3 4 liters Coolant circuit If engine is out of service for more than one year change coolant Page 157 Coolant circuit Check coolant level Page 156 Coolant circuit...

Page 57: ...required Coolant circuit Check coolant level Page 156 Coolant circuit Heat coolant with coolant preheating unit Engine control system Switch master switch to ON Press illuminated pushbutton READY FOR...

Page 58: ...sons in the en gine s danger zone WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors The engine can be started from the following points Item A...

Page 59: ...running noises and vibration Check exhaust color Page 79 Air filter Check signal ring position of service indicator Page 142 Replace air filter Page 140 if the signal ring is completely visible in th...

Page 60: ...eks Tasks after extended out of service periods 3 weeks Note Operate fuel treatment system for at least 5 minutes 1 Start up fuel treatment system Page 62 2 Shut down fuel treatment system Page 74 60...

Page 61: ...ves 4 Switch on fuel treatment system Page 65 5 Check direction of rotation of pump 6 Vent bypass and fuel lines of the system a Open ball valve for pressure tank b Open ball valve for overflow tank c...

Page 62: ...ic water drain 18 Water level electrode 19 Ball valve sample extrac tion inlet 20 Switchgear cabinet 21 Pump 22 Coarse filter 23 Fuel supply from tank 24 Tank Switching on fuel treatment system 1 Swit...

Page 63: ...ball valve 5 at inlet to fuel treatment system Result The pressure upstream of the fuel treatment system increases until the overflow valve at the pump unit opens and fuel flows through bypass 3 and...

Page 64: ...y pump draws fuel via bypass 2 directly from tank 24 5 Check suction pressure at the engine mounted fuel delivery pump Note If the suction pressure is within the permissible limits and engine operatio...

Page 65: ...re switching on ensure that all housings are closed Before switching on ensure that no work is in progress anywhere on the entire system Fuel treatment system Switching on 1 Carry out checks prior to...

Page 66: ...the engine plant Risk of overheating damage to components Initiate emergency stop only in emergency situations Engine emergency stop at BlueLine automation system Item Measure Engine Emergency stop a...

Page 67: ...button flashes Coupling is engaged After receiving the feedback signal from coupling the COUPLING IN button is illuminated brightly Engaging coupling in ahead direction with reversing gearbox FPP WJ...

Page 68: ...OUPLING OUT button flashes Coupling is disengaged After receiving the feedback signal from coupling the COUPLING OUT button is illuminated brightly Disengaging coupling with reversing gearbox FPP WJ I...

Page 69: ...long Follow instructions of the waterjet manufacturer Flushing with reversing gearbox and flushing mode Item Measure LOP Press FLUSH illuminated pushbutton and keep pressed Page 55 FLUSH pushbutton f...

Page 70: ...engine at idle speed for at least 10 minutes until engine temperatures have dropped and constant values are displayed Stopping the engine from LOP Item Measure LOP Disengage gearbox Page 55 LOP Opera...

Page 71: ...Before shutting down disengage gear and run the engine at idle speed for at least 10 minutes until engine temperatures have dropped and constant values are displayed Stopping the engine at the BlueLi...

Page 72: ...nnecting the power supply to the ECU On engines with emergency air shutoff flaps flaps close EMERGENCY STOP illuminated pushbutton flashes Horn flashing lamp etc are tripped After emergency stop from...

Page 73: ...t a suitable temperature the antifreeze concentration is insufficient for the engine room tem perature antifreeze concentration is 50 and engine room temperature is be low 40 C Raw water Drain If free...

Page 74: ...inet until water discharge from the outlet stops 2 Switch off fuel treatment system 3 Close ball valve at the inlet to the fuel treatment system 4 Close ball valve at the outlet of the fuel treatment...

Page 75: ...im compressed 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 envir...

Page 76: ...differential pressure gauge of fuel prefilter Page 59 W1001 Replace fuel filter or fuel filter element Page 129 W1005 Replace air filter Page 140 W1006 Replace fuel injection valves injectors Page 12...

Page 77: ...k general condition of engine mounting visual inspection Page 167 W1713 Injector Reset drift correction CDC param eters Page 175 Table 2 Maintenance schedule task reference table QL1 MS150048 04E 2013...

Page 78: ...ped with an overload protection If the maximum permissible current consumption is exceeded e g in case of a blockage or dry running the motor protection relay triggers and the pump is switched off u R...

Page 79: ...ode u Check fuse replace if required and re start the system by actuating the key switch Running gear blocked engine cannot be barred manually u Contact Service Engine turns but does not fire Cause Co...

Page 80: ...ndicator Page 142 Intercooler clogged u Contact Service Exhaust turbocharger defective u Contact Service Coolant leaks at intercooler Cause Corrective action Intercooler leaky major coolant discharge...

Page 81: ...st gas Cause Corrective action Engine is not at operating temperature u Run engine to reach operating temperature Intercooler leaky u Contact Service MS150048 04E 2013 07 Troubleshooting 81 TIM ID 000...

Page 82: ...1 comprises 3 digits Fault messages may also be caused by faulty sensors actuators Contact Service to have sensors actuators tested and replaced as necessary if troubleshooting as described in the ta...

Page 83: ...ilure ZKP Number 18 004 204 Cause Corrective action ETC2 could not be cut in 1 Reduce power 2 Contact Service 81 AL Rail Leakage ZKP Number 18 004 046 Cause Corrective action Pressure gradient in rail...

Page 84: ...lace as necessary 2 Error cleared after restarting the engine 202 SD T Fuel ZKP Number 18 004 572 Cause Corrective action Coolant temperature sensor faulty Short circuit or wire break 1 Check sensor a...

Page 85: ...ng B4 22 replace as necessary 208 SD P Charge Air ZKP Number 18 004 566 Cause Corrective action Charge air pressure sensor faulty Short circuit or wire break 1 Check sensor and cabling B10 replace as...

Page 86: ...sensor and cabling B48 replace as necessary 2 Error cleared after restarting the engine 216 SD T Lube Oil ZKP Number 18 004 575 Cause Corrective action Lube oil temperature sensor faulty Short circui...

Page 87: ...cleared after restarting the engine 227 SD P Lube Oil before Filter ZKP Number 18 004 620 Cause Corrective action Sensor for lube oil pressure before filter faulty Short circuit or wire break 1 Check...

Page 88: ...Error cleared after restarting the engine 233 SD Charger 2 Speed ZKP Number 13 011 129 Cause Corrective action Speed sensor of secondary turbocharger faulty Short circuit or wire break 1 Check sensor...

Page 89: ...ant lube oil pressure sensor faulty Short circuit or wire break 1 Check sensor and cabling replace as necessary 2 Error cleared after restarting the engine 301 AL Timing Cylinder A1 ZKP Number 18 004...

Page 90: ...ctive action Time of flight measuring fault of injector in cylinder A5 Time of flight measured value extremely low or extremely high u If alarm occurs frequently replace solenoid valve of injector 306...

Page 91: ...Cause Corrective action Time of flight measuring fault of injector in cylinder A10 Time of flight measured value extremely low or extremely high u If alarm occurs frequently replace solenoid valve of...

Page 92: ...Corrective action Time of flight measuring fault of injector B5 Time of flight measured value extremely low or extremely high u If alarm occurs frequently replace solenoid valve of injector 316 AL Ti...

Page 93: ...ult of injector B10 Time of flight measured value extremely low or extremely high u If alarm occurs frequently replace solenoid valve of injector 321 AL Wiring Cylinder A1 ZKP Number 18 004 520 Cause...

Page 94: ...by injector replacement 2 Error cleared after restarting the engine 326 AL Wiring Cylinder A6 ZKP Number 18 004 525 Cause Corrective action Short circuit in injector cabling to cylinder A6 Result Mis...

Page 95: ...g by injector replacement 2 Error cleared after restarting the engine 332 AL Wiring Cylinder B2 ZKP Number 18 004 531 Cause Corrective action Cabling fault in injector cabling to cylinder B2 Result Mi...

Page 96: ...by injector replacement 2 Error cleared after restarting the engine 338 AL Wiring Cylinder B8 ZKP Number 18 004 537 Cause Corrective action Cabling fault in injector cabling to cylinder B8 Result Misf...

Page 97: ...g by injector replacement 2 Error clearance After each working cycle 344 AL Open Load Cylinder A4 ZKP Number 18 004 543 Cause Corrective action Disruption fault in injector cabling to cylinder A4 Resu...

Page 98: ...by injector replacement 2 Error clearance After each working cycle 350 AL Open Load Cylinder A10 ZKP Number 18 004 549 Cause Corrective action Disruption fault in injector cabling to cylinder A10 Res...

Page 99: ...g by injector replacement 2 Error clearance After each working cycle 356 AL Open Load Cylinder B6 ZKP Number 18 004 555 Cause Corrective action Disruption fault in injector cabling to cylinder B6 Resu...

Page 100: ...t 1 1020 021 Power Stage Failure Stop Engine is set engine will be shut down as additional measure u Start ITS If the ITS diagnosis result is electronics OK note further fault messages e g cabling fau...

Page 101: ...n transistor output 1 TO 1 1 Check charger valve cabling repair as necessary 2 Replace engine governor 372 AL Wiring TO 2 ZKP Number 18 004 635 Cause Corrective action Short circuit or wire break on t...

Page 102: ...Maximum deviation of lube oil pressure values from sensors 1 Check sensor and cabling replace as necessary 2 Contact Service 417 SD Level Water Fuel Prefilter ZKP Number 18 004 594 Cause Corrective a...

Page 103: ...y 1 Check signal transmitter and cabling replace as necessary 2 Replace engine governor 469 SD AUX 1 ZKP Number 18 004 590 Cause Corrective action Analog input signal for Aux 1 faulty Short circuit or...

Page 104: ...corder initialization error 1 Check setting with DiaSys 2 Contact Service 482 SD T Exhaust C ZKP Number 18 004 596 Cause Corrective action Exhaust temperature sensor on A side faulty Short circuit or...

Page 105: ...g consumer a wire break or a short circuit u Check connection between POM and starter 502 AL Open Load POM Alternator ZKP Number 14 500 902 Cause Corrective action Open load was detected at the connec...

Page 106: ...ss 519 Oillevel Calibration Error ZKP Number 10 158 921 Cause Corrective action Error when writing the calibration value into the Flash or SD memory of the level sensor associated PV AL Group 6 Mot Bi...

Page 107: ...e Oil Pan ZKP Number 10 137 900 Cause Corrective action Temperature sensor in oil pan defective Short circuit or wire break u Check sensor and cabling replace as necessary 582 AL Emergency Stop Failed...

Page 108: ...eck sensor and cabling replace as necessary 601 SD ETC1 ETC2 ZKP Number 13 011 227 Cause Corrective action SD ETC1 and ETC2 u Check sensor and cabling replace as necessary 625 SD P Fuel before Prefilt...

Page 109: ...gine s danger zone After finishing work on the engine make sure that all safety devices are put back in place and all tools removed from the engine Engine Barring manually 1 Remove guard plate Result...

Page 110: ...7 1 2 Engine Barring with starting system Barring using the automation system Refer to automation system operating instructions 110 Task Description MS150048 04E 2013 07 TIM ID 0000017532 003...

Page 111: ...s First signs of marks 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 n...

Page 112: ...Final steps 1 Install injector Page 124 2 Install cylinder head cover Page 120 112 Task Description MS150048 04E 2013 07 TIM ID 0000000015 014...

Page 113: ...nd the liner It appears rather darker within the honed struc ture in contrast to the bright metallic running surface The honing pattern is undis turbed Discolorations extend in stroke direction and ma...

Page 114: ...tion 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 inspect...

Page 115: ...re parts Designation Use Part No Qty Engine oil Valve gear Lubrication 1 Remove cylinder head covers Page 120 2 Fill oil chambers of valve bridges with oil 3 Fill oil chambers of rocker arms and adjus...

Page 116: ...re parts Designation Use Part No Qty Feeler gauge Y20098771 1 Torque wrench 60 320 Nm F30452768 1 Box wrench socket 24 mm F30039526 1 Engine oil Preparatory steps 1 Remove cylinder head cover Page 120...

Page 117: ...n di rection of engine rotation until the OT A1 marking and pointer are aligned Diagram for 8V engines two crankshaft positions Diagram for 12V engines two crankshaft positions MS150048 04E 2013 07 Ta...

Page 118: ...C 2 Check valve clearance with cold engine Inlet long rocker arm 0 2 mm 0 05 mm Exhaust short rocker arm 0 5 mm 0 05 mm 3 Check all valve clearances in two crankshaft positions firing TDC and overlap...

Page 119: ...1 with torque wrench to the specified tightening torque holding the adjusting screw 2 to prevent it from turning Name Size Type Lubricant Value Standard Locknut M16 x 1 5 Tightening torque Engine oil...

Page 120: ...r head covers 1 prior to removal 2 Remove screws 3 4 with washers 2 5 3 Take off cylinder head cover 1 with O ring 6 from cylinder head 7 Installing cylinder head cover 1 Clean mounting surface 2 Chec...

Page 121: ...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 122: ...e s danger zone WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors HP pump Relief bore check 1 Visually inspect relief bore 1 for fuel dis char...

Page 123: ...or Replacement Special tools Material Spare parts Designation Use Part No Qty Injector Spare Parts Catalog Replacing injector u Remove injector and install new injector Page 124 MS150048 04E 2013 07 T...

Page 124: ...wrench 60 320 Nm F30452768 1 Ratchet F30027341 1 Assembly paste Optimoly Paste White T 40477 1 Grease Kluthe Hakuform 30 10 Emulgier X00029933 1 Engine oil O ring Spare Parts Catalog WARNING Fuels ar...

Page 125: ...r head 7 Remove injector with installation removal tool 8 Remove installation removal tool 9 Remove sealing ring 4 from injector or use a self made hook to take it out of the cylinder head 10 Remove O...

Page 126: ...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 127: ...h torque wrench to the specified tightening torque Name Size Type Lubricant Value Standard Screw M12 Tightening torque 100 Nm 10 Nm 14 Tighten adapter 3 with torque wrench to the specified tightening...

Page 128: ...screw Tightening torque 40 Nm 5 Nm 19 Fit connectors on injector Note Failure to reset drift compensation CDC will void the emissions certification 20 Reset drift compensation CDC with Dia Sys E531920...

Page 129: ...in Only run the engine at low power Keep away from the engine s danger zone WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not sm...

Page 130: ...three way cock to operating position both filters cut in 8 Replace further fuel filters in the same way 9 Vent fuel system 1 Fuel filter replacement with the engine running 1 Cut out the filter to be...

Page 131: ...differential pressure gauge 1 When installing the new filter element align adjustable pointer 2 with pressure indicating pointer 3 of pressure gauge 1 2 Check differential pressure Checking differenti...

Page 132: ...drained 1 Left filter cut in 2 Right filter cut in 2 Open threaded vent plug 5 of filter to be drained 3 Unlock drain valve 6 by pressing toggle and open it 4 Drain water and contaminants from filter...

Page 133: ...at low power Keep away from the engine s danger zone WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke WARNING High level...

Page 134: ...efilter Filling with fuel 1 Stop engine Page 70 and disable engine start 2 Remove screws securing the cover and take off cover 2 3 Fill filter housing with clean fuel 4 Place new gasket in cover 2 5 F...

Page 135: ...Diesel fuel Filter element Spare Parts Catalog Gasket Spare Parts Catalog WARNING Fuels are combustible Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke...

Page 136: ...7 Remove spring housing 4 and filter ele ment 3 8 Insert new filter element 3 and spring housing 4 9 Fill filter housing with clean fuel 10 Place new gasket in cover 2 11 Fit cover with gasket and se...

Page 137: ...llation of electric lines Damage to component Note down line assignment to connections before removal NOTICE Inappropriate cleaning tool Risk of damage to component Observe manufacturer s instructions...

Page 138: ...intake 2 Install exhaust flap with actuators 3 Install exhaust system after exhaust turbocharger 4 Install air filter Page 141 5 Fill with engine coolant Page 159 138 Task Description MS150048 04E 201...

Page 139: ...ans Never direct air jet at people Always wear safety goggles face mask and ear defenders Checking intercooler water drain for coolant discharge and obstruction 1 With the engine running check the dra...

Page 140: ...e parts Designation Use Part No Qty Air filter Spare Parts Catalog Replacing the air filter 1 Remove old air filter and install new air filter Page 141 2 Reset signal ring of contamination indicator P...

Page 141: ...2 Remove air filter 1 and clamp 2 from connecting flange of intake housing 3 3 Verify that there are no objects in the con necting flange of the intake housing 3 and clean it 4 Place new air filter 1...

Page 142: ...isabled Checking signal ring position 1 If the signal ring is completely visible in the control window 2 replace air filter Page 140 2 After installation of new filter press reset button 1 Result Enga...

Page 143: ...eck 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 174 MS150048 04E...

Page 144: ...or heat exchanger back to the oil pan 3 The oil level must reach mark 1 or exceed mark 1 by up to 2 cm 4 Top up with oil to mark 1 as necessary Page 145 5 Insert dipstick into guide tube up to the st...

Page 145: ...ot inhale oil vapor Oil change without semirotary hand pump Draining oil via drain plug s on oil pan 1 Provide a suitable container to collect the oil 2 Remove drain plug s and drain oil 3 Install dra...

Page 146: ...Tightening torque 100 Nm 10Nm Filling with new oil 1 Open cover 1 on filler neck 2 Pour oil in at filler neck up to max mark at oil dipstick 3 Close cover 1 on filler neck 4 Check engine oil level Pag...

Page 147: ...ning 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 Wea...

Page 148: ...Parts Catalog WARNING Hot oil Oil can contain combustion residues which are harmful to health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with sk...

Page 149: ...f spring washer and washer 9 Remove screw 4 10 Remove flushing arm 5 from screen plate 6 11 Turn filter element by 180 and use appro priate tool to push out filter candles 1 12 Turn filter insert by 1...

Page 150: ...ally the following instructions are to be observed Replace all seals with new parts Coat O rings with grease Insert O rings in grooves Pay attention to installation position of fillister head screw to...

Page 151: ...ing 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 of ruptu...

Page 152: ...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 153: ...ts 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 154: ...sk 8 and rotor base 10 with sealing ring 9 13 Insert new filter sleeve 6 in rotor tube 7 with the smooth paper surface facing the wall 14 Check sealing ring 5 fit new one if neces sary 15 Mount rotor...

Page 155: ...14 Coolant Circuit General High Temperature Circuit 7 14 1 Ventilation points Coolant lines on exhaust turbocharger 1 Ventilation point MS150048 04E 2013 07 Task Description 155 TIM ID 0000014547 001...

Page 156: ...ure 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 eye Checking engine coolan...

Page 157: ...e Special tools Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 158 2 Fill with engine coolant Page 159 MS150048 04E 2013 07 Task Description...

Page 158: ...n expan sion tank counterclockwise to first stop and allow pressure to escape 2 Continue to turn breather valve counter clockwise and remove 3 Draw off precipitated corrosion inhibitor oil from the ex...

Page 159: ...NOTICE Cold coolant in hot engine can cause thermal stress Possible formation of cracks in the engine Fill top up coolant only into cold engine Preparatory steps 1 Turn breather valve of coolant expa...

Page 160: ...Filling with coolant using a pump 1 Connect appropriate pump with hose to fill ing connection arrow on A side or B side Alternatively 160 Task Description MS150048 04E 2013 07 TIM ID 0000006727 006...

Page 161: ...11 When coolant temperature is 40 C T Cool ant increase engine speed to 1 000 rpm for approx 2 minutes then reduce engine speed to idle speed 12 With the engine running idle top up with coolant until...

Page 162: ...el is at the overflow edge 9 When coolant temperature is 40 C T Coolant increase engine speed to 1 000 rpm for approx 2 mi nutes With the engine running idle top up with coolant until coolant level is...

Page 163: ...o hearing Wear ear protectors Engine coolant pump Relief bore check 1 Check relief bore for oil and coolant dis charge 2 Stop engine Page 58 and disable en gine start observe general safety instruc ti...

Page 164: ...ol down 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...

Page 165: ...Risk of damage to hearing Wear ear protectors Raw water pump relief bore check 1 Check relief bore for oil and raw water dis charge 2 Stop engine Page 58 and disable en gine start observe general safe...

Page 166: ...d and starting disabled Battery charging generator drive Coupling condition check 1 Remove protective cover 2 Check resilient coupling for cracks arrow and plastic deformation 3 In case of severe defo...

Page 167: ...gine mounting Check Engine mounting Check Item Findings Action Visually inspect mounts Damage Brittleness Deformation Crack formation Swelling visible Replace contact Service MS150048 04E 2013 07 Task...

Page 168: ...System 7 18 1 Water drain valve Check Water drain valve Check 1 Open water drain valve 2 Check water outlet for obstructions 3 Close water drain valve 168 Task Description MS150048 04E 2013 07 TIM ID...

Page 169: ...es Do not smoke Checking differential pressure gauge 1 Switch on fuel treatment system Page 65 2 Set the alarm points at the differential pressure gauge to zero Result Alarm is initiated with preset d...

Page 170: ...ect connector from water level probe 4 Immerse water level probe into a tank filled with water until water level reaches the thread 5 Switch system on Result Water drain valve opens 6 Leave water leve...

Page 171: ...ssure at the pressure gauge in the inlet to the fuel treatment system and note down 3 Checking pump pressure with reduced suction a Reduce suction pressure of pump to 0 8 bar with the shut off valve a...

Page 172: ...mponents and lines Damage to component Ensure that components lines are installed so that they are never under tension or strain Ensure correct installation position of components Coalescer filter ele...

Page 173: ...htening torque Engine oil 30 Nm 3 Nm 17 Fit gasket 10 18 Install cover 19 Install screws 1 washers 2 and nuts 9 20 Tighten nuts 9 21 Open ball valve at the inlet and outlet of the fuel treatment syste...

Page 174: ...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 175: ...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 176: ...alcohol 2 Remove dirt from the connector and cable surfaces with isopropyl alcohol 3 Check legibility of cable labels Clean or replace illegible labels Cleaning severely contaminated connectors on EM...

Page 177: ...ng 2 2 Check whether both switches 3 are actu ated 3 If switches 3 and or guard plate 1 with engine support 4 is are not installed Screw on guard plate 1 with engine support 4 Then screw on switch 3 e...

Page 178: ...om housing surface with isopropyl alcohol 2 Remove dirt from connector and cable surfaces with isopropyl alcohol 3 Check legibility of cable labels Clean or replace illegible labels Cleaning severely...

Page 179: ...ting disabled Checking EMU plug connections 1 Check both connectors on EMU 2 for firm seating Make sure that clips 3 are engag ed 2 Check screws 1 of cable clamps on EMU 2 for firm seating Make sure t...

Page 180: ...sabled Checking EIM plug connections 1 Check both Tyco plugs 62 pole 1 on EIM for firm seating Make sure that the clips 2 are engaged 2 Check screws 3 of cable clamps on EIM for firm seating Ensure th...

Page 181: ...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 182: ...overnor from engine 1 Note or mark assignment of cables and connectors 2 Remove all screws 2 3 Undo latches 3 of the connectors 4 Disconnect all connectors 5 Remove screws 1 6 Take off engine governor...

Page 183: ...ll screws 2 3 Undo clips 3 on connectors 4 Disconnect all connectors 5 Remove screws 1 6 Remove ECU 1 with EMU 4 Removing EMU 1 Unscrew screws on base of EMU 4 2 Remove EMU 4 from ECU 1 Installing EMU...

Page 184: ...When doing so observe correct assignment between cables and plugs 2 Check seal before installing Result Replace seal if porous or defective Downloading software 1 The new EIM still does not have appr...

Page 185: ...or operation 4 Application loader active 5 External RAM faulty 6 External FLASH faulty 7 No firmware 8 Application crashed Fuse lamp SILA A second indicator is the fuse lamp This is also integrated in...

Page 186: ...oring current path failed S8 10 Emergency stop current path failed 24V internal S9 11 ES pushbutton current path failed 24V external S10 12 Key switch current path failed S11 13 SDAF 1 2 current path...

Page 187: ...fuse S4 fail ure 1 2 second steps Note These bit sequences are transmitted constantly Information about the status of the current paths of the EIM is also provided in the CAN message Sta tus internal...

Page 188: ...1 Cleaning LOP 1 Wipe LCD display with dry cloth without applying excessive pressure 2 Remove dirt from keys using isopropyl alcohol 3 Remove heavy soiling from housing surface with isopropyl alcohol...

Page 189: ...e monitoring system EMU Engine Monitoring Unit Engine monitoring unit ETK Ersatzteilkatalog Spare Parts Catalog FPP Fixed Pitch Propeller Fixed pitch propeller GCU Gear Control Unit Gear control unit...

Page 190: ...System RL Redundancy Lost Alarm Redundant CAN bus failure SAE Society of Automotive Engineers U S standardization organization SAT Sea Acceptance Test SD Sensor Defect Alarm Sensor failure SDAF Shut D...

Page 191: ...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 192: ...Barring manually Page 109 Box wrench socket 24 mm Part No F30039526 Qty Used in 1 7 3 2 Valve clearance Check and adjustment Page 116 Feeler gauge Part No Y20098771 Qty Used in 1 7 3 2 Valve clearanc...

Page 193: ...r Removal and installation Page 124 MTU test kit Part No 5605892099 00 Qty Used in 1 7 12 3 Engine oil Sample extraction and analysis Page 147 Qty Used in 1 7 14 7 Engine coolant Sample extraction and...

Page 194: ...ector Removal and installation Page 124 Qty Used in 1 7 12 2 Engine oil Change Page 145 Ratchet Part No F30027339 Qty Used in 1 7 18 5 Coalescer filter element Replacement Page 172 Ratchet head with e...

Page 195: ...jet cleaner Part No Qty Used in 1 4 19 Plant Cleaning Page 75 Torque wrench Part No F30027337 Qty Used in 1 7 12 2 Engine oil Change Page 145 Torque wrench 0 5 5 Nm Part No 0015384230 Qty Used in 1 7...

Page 196: ...installation Page 124 Torque wrench 4 20 Nm Part No F30044239 Qty Used in 1 7 9 2 Air filter Removal and installation Page 141 Torque wrench 6 50 Nm Part No F30027336 Qty Used in 1 7 13 3 Centrifugal...

Page 197: ...haft transport locking device Page 15 Torque wrench 60 320 Nm Part No F30452768 Qty Used in 1 7 3 2 Valve clearance Check and adjustment Page 116 Qty Used in 1 7 5 2 Injector Removal and installation...

Page 198: ...rankshaft Transport locking device Removal installation 15 Cylinder Designation 18 Cylinder head cover Removal and installation 120 Cylinder liner Endoscopic examination 111 Instructions and comments...

Page 199: ...treatment system Putting into operation 62 Shutdown 74 Switching on 65 H Hotline 191 HP pump Filling with engine oil 121 Relief bore check 122 I Injector Removal and installation 124 Replacement 123...

Page 200: ...ners 191 Spare parts service 191 Starter Condition check 143 T Tasks After extended out of service periods 60 Tasks after extended out of service periods 3 weeks 60 transport 14 Transport locking devi...

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MTU 20 V 4000 M93, Operating Instructions Manual

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