MTU 20V4000C55 Operating Instructions Manual Download Page 22

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3.2 Engine overview

Engine overview, free end

1 Oil heat exchanger
2 Crankcase breather
3 Exhaust outlet
4 Engine governor ECU9
5 Additional fuel filter

6 Fuel priming pump
7 Fuel filter
8 Indicator filter
9 HP fuel pump

10 Engine mounting

11 Automatic oil filter
12 Fan drive
13 Fan clutch
14 Centrifugal oil filter

22 | General Information | MS15043/00E 2016-04

TIM-ID: 0000067971 - 001

Summary of Contents for 20V4000C55

Page 1: ...Operating Instructions Diesel engine 20V4000C55 20V4000C65 Application group 5B MS15043 00E...

Page 2: ...r in whole or in part without the prior writ ten consent of MTU Friedrichshafen GmbH This particularly applies to its reproduction distribution editing translation micro filming and storage or process...

Page 3: ...78 8 1 1 Engine Barring manually 78 8 1 2 Engine Cranking on starting system 81 8 1 3 Engine Test run 83 8 2 Cylinder Liner 84 8 2 1 Cylinder liner Endoscopic examination 84 8 2 2 Instructions and com...

Page 4: ...ator drive Drive belt replacement 150 8 18 Fan Drive 151 8 18 1 Fan drive Drive belt tension check adjustment 151 8 18 2 Fan drive belt Replacement 154 8 19 Engine Mounting Support 156 8 19 1 Engine m...

Page 5: ...cesses that might affect the emission characteristics of the product are prohibited by emission regulations Emission control units systems may only be maintained ex changed or repaired if the componen...

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

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

Page 8: ...e product into operation make sure that all control and display instruments as well as the signaling and alarm systems work properly Smoking is prohibited in the area of the product Safety regulations...

Page 9: ...Follow the applicable warning instructions pertaining to such devices MS15043 00E 2016 04 Safety 9 TIM ID 0000040533 012...

Page 10: ...V belts must not be painted They may only be installed after painting the engine or must be covered before painting work is carried out The following applies to starters with copper beryllium alloy p...

Page 11: ...g in its vicinity Before starting welding work Switch off the power supply master switch Disconnect the battery cables or actuate the battery isolating switch Separate the electrical ground of electro...

Page 12: ...h sharp edges Chafing on components Contact with hot surfaces Do not secure cables on lines carrying fluids Do not use cable straps to secure cables Always use connector pliers to tighten union nuts o...

Page 13: ...ully with its handling Noise Noise can lead to an increased risk of accidents if acoustic signals warning shouts or sounds indicating dan ger are drowned Wear ear protectors in workplaces with a sound...

Page 14: ...rrying out painting work outside the spray stands provided with fume extraction systems ensure that the area is well ventilated Make sure that neighboring work areas are not adversely affected There m...

Page 15: ...n NOTICE In the event of a situation involving potentially adverse effects on the product Consequences Material damage Remedial action Additional product information Warning notices 1 This manual with...

Page 16: ...lter 6 Raise and lower the system engine generator diesel particulate filter slowly Do not allow hoist slings or chains to contact the system engine generator diesel particulate filter or any of their...

Page 17: ...and appliances Never stand beneath a suspended load 1 Center of gravity Take note of the engine center of gravity Refer to the installation arrangement drawings for details of the center of gravity of...

Page 18: ...the transport locking device removed If the generator gearbox is installed ensure that the transport locking device of the generator gearbox is removed Prior to transport of the engine always install...

Page 19: ...pport 1 with washer 7 and nut 8 and tighten nut 8 with torque wrench to the specified tightening torque Name Size Type Lubricant Value Standard Nut M24 Tightening torque Engine oil 100 Nm 10 Nm 4 Secu...

Page 20: ...ighten 3 Install retainer 3 in opening on flywheel housing on both sides with screw 4 and washers 5 Note Ensure retainer is seated flush arrow 4 Tighten screws 4 with torque wrench to specified tighte...

Page 21: ...gnated in accordance with DIN ISO 1204 as viewed from driving end 4 For cylinder designation in accordance with DIN ISO 1204 the letter Ax refers to the cylinders on the left hand side of the engine 1...

Page 22: ...xhaust outlet 4 Engine governor ECU9 5 Additional fuel filter 6 Fuel priming pump 7 Fuel filter 8 Indicator filter 9 HP fuel pump 10 Engine mounting 11 Automatic oil filter 12 Fan drive 13 Fan clutch...

Page 23: ...pump 9 Oil pan 10 Engine lifting equipment 11 Oil dipstick 12 Oil filler neck 13 Starter 14 PTO flange 15 Flywheel housing 16 Intercooler high pressure Engine model designation Explanation of engine m...

Page 24: ...control valve 3 B5 1 Lube oil pressure af ter filter 4 B33 Fuel temperature 5 B48 Fuel pressure 6 B13 Crankshaft speed 7 B1 Camshaft speed 8 B43 Intercooler coolant pressure 9 B26 Intercooler coolant...

Page 25: ...14 A19 Electronic engine la bel 15 F57 Charge air coolant lev el 16 F70 Water in fuel prefilter 17 F33 Engine coolant level 18 B34 3 Fuel pressure be fore supplementary filter 19 B34 2 Fuel pressure...

Page 26: ...Y39 Injector 5 Y39 Injector 6 Y39 Injector 7 Y39 Injector 8 Y39 Injector 9 Y39 Injector 10 B16 Engine coolant pres sure 11 Y39 Injector 12 Y39 Injector 13 B10 2 Charge air pressure B 26 General Inform...

Page 27: ...1 NOx Lambda A side 4 B89 Lambda 5 B7 Lube oil temperature 6 B91 3 Exhaust gas Lamb da pressure 7 B88 2 NOx Lambda B side 8 B44 2 Turbocharger B speed 9 B90 Intake air humidity pressure temperature M...

Page 28: ...product Actual value must be greater than specified value Actual value must be less than specified value Unspecific value tolerance 10 Unspecific value tolerance 5 ID Product type Application Engine s...

Page 29: ...er hour L of B 0 2 4 Model related data basic design ID 1 Uncooled exhaust lines X Exhaust piping liquid cooled Number of cylinders 20 Cylinder arrangement V angle Degrees 90 Bore mm 170 Stroke mm 210...

Page 30: ...rature R C 10 Side condition to case A lube oil viscosity R SAE 15 W Minimum idling speed A rpm 600 16 Inclinations for standard oil system reference waterline ID 1 Longitudinal inclination continuous...

Page 31: ...ue tolerance 10 Unspecific value tolerance 5 ID Product type Application Engine speed Listed power 1 20V4000C65 Industrial vehicle main drive 5B continuous opera tion variable 1800 rpm 3000 kW 4023 bh...

Page 32: ...nt V angle Degrees 90 Bore mm 170 Stroke mm 210 Displacement cylinder Liter 4 77 Displacement total Liter 95 4 Compression ratio 15 5 Number of inlet valves per cylinder 2 Number of exhaust valves per...

Page 33: ...coolant temperature R C 10 Side condition to case A Lube oil temperature R C 10 Side condition to case A lube oil viscosity R SAE 15 W Minimum idling speed A rpm 600 16 Inclinations for standard oil s...

Page 34: ...d BL free field sound pressure level Lp 1 m dis tance ISO 6798 3 dB A tolerance R dB A 119 Exhaust noise unsilenced BL sound power level LW ISO 6798 3 dB A tol erance R dB A 132 34 Technical Data MS15...

Page 35: ...4 3 Firing order Number of cylinders Firing order 20 V A1 B5 A8 B7 A5 B2 A7 B10 A2 B3 A10 B6 A3 B4 A6 B9 A4 B1 A9 B8 MS15043 00E 2016 04 Technical Data 35 TIM ID 0000035068 002...

Page 36: ...in dimensions Item Dimensions Total length A approx 3954 mm Width B approx 1635 mm Height C approx 1996 mm Height D approx 2229 mm Length E approx 870 mm 36 Technical Data MS15043 00E 2016 04 TIM ID 0...

Page 37: ...s Page 93 Lube oil system Check engine oil level Page 120 Bar engine using starting system Page 81 Fuel prefilter Fill with fuel if fitted Coolant circuit If engine has been out of service for more th...

Page 38: ...ngine into operation Check the components carrying air and exhaust for corrosion Do not put the engine in operation if corrosion was detected Putting into operation Item Measure Engine oil system Chec...

Page 39: ...operation Visually inspect engine for leaks and general condition Check engine for abnormal running noises exhaust color and vibrations Air filter Check signal ring position of maintenance indicator...

Page 40: ...ng 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 Me...

Page 41: ...efore damage to components is possible Before shutting down the engine allow it to idle until the engine temperatures decrease and constant levels are indicated Preparation Item Measure Engine Operate...

Page 42: ...eriod but engine coolant has no antifreeze additive the engine room is not heated the coolant is not kept at a suitable temperature the antifreeze concentration is insufficient for the engine room tem...

Page 43: ...ectly at seals or electronic components such as connectors or ECUs Plant Cleaning 1 Carry out plant cleaning only in areas where an appropriate oil separator is provided environmental protec tion 2 Pr...

Page 44: ...ge 101 W1008 X Replace engine oil filter when changing engine oil or when the interval years is reached at the latest W1009 Measure thickness of oil residue layer clean out and replace filter sleeve t...

Page 45: ...erator Page 149 W1817 Check coupling rods of EGR flaps for clearance Page 113 W1864 X Check and clean oil indicator filter Page 127 W1940 Replace auxiliary PTO of battery charging generator Page 150 T...

Page 46: ...Check plug in connections Page 162 Barring tool installed u Remove barring tool Page 78 Running gear blocked engine cannot be barred manually u Contact Service Engine transport locking device install...

Page 47: ...Contact Service Speed demand setting does not match rated speed u Correct speed demand setting Engine alarm involving power reduction signaled u Rectify cause of engine alarm Rated speed limited by th...

Page 48: ...engine oil in the engine u Drain engine oil Page 121 Oil separator of crankcase breather contaminated u Replace filter Page 88 Exhaust turbocharger cylinder head piston rings or cylinder liner defecti...

Page 49: ...Contact Service 5 HI T Charge Air Cause Corrective action The charge air temperature at sensor B9 has exceeded limit value 1 Charge air temperature too high 1 Reduce power 2 Check whether alarms 9 and...

Page 50: ...oo low 1 Check engine oil level Page 119 2 Contact Service 23 LO Coolant Level Cause Corrective action Coolant level at switch F33 is too low 1 Check engine coolant level Page 131 2 Check relief bore...

Page 51: ...speed is too high Cause Defect or malfunction of another turbocharger 1 Reduce power 2 Contact Service 32 SS ETC1 Overspeed Cause Corrective action The speed of the LP turbocharger A side at sensor B4...

Page 52: ...of cooler and fan plant side 3 Check engine coolant level Page 131 4 Contact Service 52 SS T Lube Oil Cause Corrective action The lube oil temperature at sensor B7 has exceeded limit value 2 Lube oil...

Page 53: ...SS P Fuel Cause Corrective action The fuel pressure at sensor B34 1 has undershot limit value 2 Fuel pressure is too low 1 Replace additional fuel filter Page 109 2 Replace fuel filter Page 108 3 Repl...

Page 54: ...y Page 171 4 Check for additional messages 5 Contact Service 91 SS Release Speed Not Reached Cause Corrective action Engine speed has not reached starter disengagement speed within the specified time...

Page 55: ...Page 162 3 Check battery charging generator Page 149 4 Contact Service 121 HIHI ECU Power Supply Voltage Cause Corrective action The supply voltage of the ECU has exceeded the specified limit value 2...

Page 56: ...ir Cause Corrective action The charge air temperature sensor B9 A side supplies incorrect signal or no signal 1 Check engine wiring Page 158 2 Contact Service 205 SD T Coolant Intercooler Cause Correc...

Page 57: ...Service 214 SD P Crankcase Cause Corrective action The crankcase pressure sensor B50 supplies incorrect signal or no signal 1 Check engine wiring Page 158 2 Contact Service 215 SD P HD Cause Correctiv...

Page 58: ...P Fuel before Filter Cause Corrective action The fuel pressure sensor before main fuel filter B34 2 supplies incorrect signal or no signal 1 Check engine wiring Page 158 2 Contact Service 229 AL Stop...

Page 59: ...l pressure sensor after main fuel filter B34 1 supplies incorrect signal or no signal 1 Check engine wiring Page 158 2 Contact Service 266 SD Speed Demand Cause Corrective action Signal of analog spee...

Page 60: ...ective action Short circuit fault in injector wiring cylinder A6 or injector faulty 1 Check wiring of relevant injector Page 158 2 Replace injector Page 101 3 Contact Service 327 AL Wiring Cylinder A7...

Page 61: ...rective action Short circuit fault in injector wiring cylinder B3 or injector faulty 1 Check wiring of relevant injector Page 158 2 Replace injector Page 101 3 Contact Service 334 AL Wiring Cylinder B...

Page 62: ...rt circuit fault in injector wiring cylinder B10 or injector faulty 1 Check wiring of relevant injector Page 158 2 Replace injector Page 101 3 Contact Service 341 AL Open Load Cylinder A1 Cause Correc...

Page 63: ...inder A8 1 Check wiring of relevant injector Page 158 2 Contact Service 348 AL Open Load Cylinder A9 Cause Corrective action Disruption fault in injector wiring to cylinder A9 1 Check wiring of releva...

Page 64: ...er B6 1 Check wiring of relevant injector Page 158 2 Contact Service 357 AL Open Load Cylinder B7 Cause Corrective action Disruption fault in injector wiring cylinder B7 1 Check wiring of relevant inj...

Page 65: ...re in the intercooler at sensor B43 has undershot limit value 2 The charge air coolant pressure is too low 1 Check relief bore of charge air coolant pump Page 148 2 Check intercooler for coolant disch...

Page 66: ...harger 1 Reduce power 2 Contact Service 536 AL Wiring PWM_CM1 Cause Corrective action The M8 HP fuel control block of the HP fuel pump can not be activated 1 Check engine wiring Page 158 2 Contact Ser...

Page 67: ...s not match the engine number saved in the ECU 1 Check engine wiring Page 158 2 Contact Service 616 AL EIL Error Cause Corrective action ECU can not detect EIL u Contact Service 625 SD P Fuel bef Add...

Page 68: ...ration of dispenser flap Page 113 Page 159 2 Contact Service 633 SD P Ambient Air HDT2800 Cause Corrective action The air pressure sensor B90 supplies incorrect signal or no signal 1 Check engine wiri...

Page 69: ...LT coolant inlet temperature is too high in relation to the ambient air temperature 1 Check cooler plant side for contamination 2 Check operation of fan plant side 3 Contact Service 745 AL Emission F...

Page 70: ...Check NOx sensor and replace as necessary Page 164 3 Contact Service 872 AL EGR FlpA Wear Limit3 Cause Corrective action Fast reference run of EGR shutoff flap M53 faulty executed after every ECU rest...

Page 71: ...s flap M52 is fully open 1 Check operation of bypass flap Page 113 Page 159 2 Contact Service 957 AL p5 ctrlvar max BOI min active Cause Corrective action Emission related alarm The charge air pressur...

Page 72: ...operation of bypass flap Page 113 Page 159 2 Contact Service 961 AL NOx p5 max BOI min active Cause Corrective action Emission related alarm This fault is a strong indication of serious soot contamin...

Page 73: ...L CAN3 Bus Off Cause Corrective action The first engine CAN CAN 3 for engine side sensor actuator system is disrupted or faulty 1 Check engine wiring Page 158 2 Contact Service 975 AL CAN3 Error Passi...

Page 74: ...lap Egr A Targetposition Cause Corrective action The servomotor of the EGR shutoff flap M53 has not reached the target position within the specified time u Contact Service 1103 AL Flap BypassA Communi...

Page 75: ...t air pressure sensor integrated in the ECU have exceeded limit value 1 The intake air differential pressure is too high 1 Check air filter plant side for contamination 2 Contact Service 1116 AL Diffe...

Page 76: ...ssions too high The NOx emissions from the engine have exceeded limit value 1 cumulatively u Contact Service 1172 AL Inplausible NOx High Limit2 Cause Corrective action NOx emissions too high The NOx...

Page 77: ...nce run of EGR dispenser flap M55 faulty executed after every ECU restart Limit value 2 1 Check state of charge of batteries plant side 2 Check operation of dispenser flap Page 113 Page 159 3 Contact...

Page 78: ...Barring device F6798050 1 Ratchet with extension F30006212 1 DANGER Rotating and moving engine parts Risk of crushing danger of parts of the body being caught or pulled in Before cranking the engine...

Page 79: ...f working steps Barring engine manually instal lation on lower side 1 Remove grounding device or guard panel Note Use barring device F6783293 2 Engage barring device 2 with ring gear 3 and mount on fl...

Page 80: ...uence of working steps Barring engine manually at equipment carrier Note Use barring device F6798050 Further installation options on equipment carrier arrows 1 Engage barring device 1 with ring gear a...

Page 81: ...cleanliness prior to installation assembly and clean if necessary Engine Control Unit without pro tective cover 1 Dry clean Engine Control Unit and connectors thoroughly 2 Press end of unlocking clip...

Page 82: ...sary remove strip 4 and replace self adhesive gaskets 5 6 Install strip 4 7 Tighten screws 6 to specified torque using a torque wrench Name Size Type Lubricant Value Standard Screw M6 Tightening torqu...

Page 83: ...re are no persons in the engine s danger zone WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Engine Test run 1 Start engine Page 40 2 Perfo...

Page 84: ...en 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 lo...

Page 85: ...epending on findings Do not take any action or carry out a further endoscopic examination as part of maintenance work or contact Service cylinder liner must be replaced Final steps 1 Install injector...

Page 86: ...ound 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...

Page 87: ...ation are similar A thorough inves tigation and compliance with the above evaluation criteria allow an unambiguous evaluation To avoid unnec essary disassembly work it is recommended that another insp...

Page 88: ...g WARNING Engine oil is hot Engine oil can contain combustion residues which are harmful to health Risk of injury and poisoning Allow the engine to cool to below 50 C before beginning work Wear protec...

Page 89: ...ing ring and cover 1 10 Screw on new nut 2 with new washers and tighten nut 2 to specified torque using a torque wrench Name Size Type Lubricant Value Standard Nut Tightening torque 10 Nm 2 Nm 11 Repl...

Page 90: ...ck components for special cleanliness Replacing auxiliary PTO for gen eral purposes 1 Remove auxiliary PTO 1 by loosening screws 2 on the gearcase 2 Before installing the new PTO thoroughly clean the...

Page 91: ...uxiliary PTO 2 with O ring 1 6 Install new auxiliary PTO 2 with new O ring 1 7 Install screws 8 with washers 7 8 Install retainers 3 4 with screws 5 6 9 Tighten screws 5 6 8 crosswise 10 Install drive...

Page 92: ...abled 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 150 Drive belt C Chunking Drive belt B...

Page 93: ...parts Designation Use Part No Qty Engine oil Valve gear Lubrication 1 Remove cylinder head upper section Page 99 2 Fill oil chambers of valve bridges with oil 3 Fill oil chambers of rocker arms and a...

Page 94: ...shaft with barring device in en gine direction of rotation until marking OT and pointer are aligned Valve protrusion Measurement 1 Check TDC position of piston in cylinder A1 If rocker arms on cylinde...

Page 95: ...lue for a new cylinder head 93 8 mm Admissible wear 2 mm If the measured value is 95 8 mm have the relevant cylinder head replaced by specialist personnel ahead of schedule 5 Install valve bridge 6 Ad...

Page 96: ...e Y20098771 1 Valve setting gage Y4349603 1 Angular screw driver F30002815 1 Torque wrench 60 320 Nm F30452768 1 Socket wrench 24 mm F30039526 1 Engine oil Preparatory steps 1 Remove cylinder head upp...

Page 97: ...TDC If rocker arms on cylinder A1 are loaded the piston is in overlap TDC 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...

Page 98: ...t just pass through the gap 4 Pull valve adjusting gage 3 between valve bridge and rocker arm 5 Tighten locknut 1 to specified torque using a torque wrench holding the adjusting screw 2 to prevent it...

Page 99: ...Parts Catalog Removing cylinder head cover 1 Clean very dirty cylinder head cover upper section 2 prior to removal 2 Remove screws 4 5 with washers 3 6 3 Remove cylinder head cover upper sec tion 2 wi...

Page 100: ...sitioned correctly 6 Screw in ESD connector 8 in cylinder head cover lower section 7 and tighten to specified torque using a torque wrench Name Size Type Lubricant Value Standard Nut Tightening torque...

Page 101: ...Replacement Special tools Material Spare parts Designation Use Part No Qty Injector Spare Parts Catalog Injector Replacement u Remove injector and install new one Page 102 MS15043 00E 2016 04 Injecto...

Page 102: ...els are combustible and explosive Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Wear protective clothing protective gloves and safety glasses facial...

Page 103: ...2 Unscrew union nuts 2 5 and remove HP line 3 from rail 4 and cylinder head Note When the adapter is unscrewed the stored volume of the injector is emptied 3 Provide suitable container to collect esc...

Page 104: ...plug for HP line until directly before assembly of the adapter 1 Prior to installation remove plug 2 Coat injector with assembly paste at the seat of the nozzle retaining nut Note A new sealing ring i...

Page 105: ...and screw head mating face and thread of screw 2 with engine oil 9 Insert screw 2 and tighten hand tight Note Ensure immaculate cleanliness 10 Coat thread and sealing cone of adapter 1 with engine oil...

Page 106: ...Engine oil 40 Nm 5 Nm 17 Release union nuts 2 5 on HP line 3 approx 45 angle of rotation while counterholding adapter 1 in relation to injector 18 Tighten union nuts 2 5 on HP line 3 without interrupt...

Page 107: ...g 2 and connect a suitable hose 2 Provide suitable container to collect escaping fuel 3 Follow the procedure described here to oper ate the hand pump a Hold sleeve 2 firmly Turn handle 1 counterclockw...

Page 108: ...es Do not smoke Wear protective clothing protective gloves and safety glasses facial protection Fuel filter Replacement 1 Provide suitable container to collect escaping fuel 2 Remove easy change filte...

Page 109: ...t smoke Wear protective clothing protective gloves and safety glasses facial protection Additional fuel filter Replace ment 1 Provide suitable container to collect escaping fuel 2 Remove easy change f...

Page 110: ...ondensation contains acid Risk of chemical burns Wear protective goggles Wear protective gloves Charge air cooler leak check 1 With the engine at standstill open the plug screws in the charge air elbo...

Page 111: ...e 2 Does the label on the engine match the label document in the Business Portal Equipment 3 Check emission label for intactness 4 Check content of emission label for complete readability 5 Does the e...

Page 112: ...8 11 2 Exhaust flaps Overview 1 EGR shutoff flap 2 Donor cylinder flap 1 Bypass flap 112 Exhaust Gas Recirculation MS15043 00E 2016 04 TIM ID 0000060173 001...

Page 113: ...ass and EGR flap mechanical Note For installation position of exhaust flaps refer to overview Page 112 1 Remove guard plates of exhaust flaps Page 115 2 Check operability and ease of movement of coupl...

Page 114: ...1 by moving it at the specified points arrows and make sure that there is no excessive play Result Replace coupling rod 1 if it is jamming slug gish or features excessive play Page 115 114 Exhaust Gas...

Page 115: ...ing hands To carry out the teach in routine keep clear of the safety zone of the actuation mechanism in the intake and exhaust area Switch off the operating voltage of the engine governor before start...

Page 116: ...Name Size Type Lubricant Value Standard Nut Tightening torque Assembly paste Ul tra Therm MTU 16 Nm 2 Nm 3 Tighten washers and locknuts 3 to the specified tightening torque Name Size Type Lubricant Va...

Page 117: ...actuator output shaft 3 Remove coupling rod 4 and lever 1 4 Remove washers Installing coupling rod donor cylinder flap 1 Insert coupling rod 4 and washers 2 Tighten lever 1 with locknut 3 on output sh...

Page 118: ...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 158 118 Starting...

Page 119: ...opped and starting disabled Engine oil level check at sight glass 1 Make a preliminary visual check of oil lev el 2 at the sight glass 1 2 A proper engine oil level check must always be carried out us...

Page 120: ...ngine running 1 After the engine has run for approx 10 minutes at a constant speed of 600 to 900 rpm pull out oil dipstick from guide tube and wipe it 2 Insert dipstick into guide tube up to the stop...

Page 121: ...and poisoning Allow the engine to cool to below 50 C before beginning work Wear protective clothing protective gloves and safety glasses facial protection Avoid contact with skin Do not inhale oil va...

Page 122: ...ant Value Standard Screw M18x1 5 Tightening torque Engine oil 50 Nm 10 Nm 6 Screw in drain screws 2 4 and tighten to specified torque using a torque wrench Name Size Type Lubricant Value Standard Scre...

Page 123: ...before beginning work Wear protective clothing protective gloves and safety glasses facial protection Avoid contact with skin Do not inhale oil vapor WARNING High level of engine noise when the engine...

Page 124: ...an contain combustion residues which are harmful to health Risk of injury and poisoning Allow the engine to cool to below 50 C before beginning work Wear protective clothing protective gloves and safe...

Page 125: ...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 appropri ate tool to push out filter candles 1 12 Turn filter insert by 180...

Page 126: ...ly the following instructions are to be observed Replace all seals with new parts Apply assembly compound to O rings Insert O rings in grooves Observe position of fillister head screw to elongated hol...

Page 127: ...ake measures against electrostatic charging WARNING Engine oil is hot Engine oil can contain combustion residues which are harmful to health Risk of injury and poisoning Allow the engine to cool to be...

Page 128: ...aged Replace Square section ring Damaged Replace O ring Damaged Replace Cleaning strainer 1 Wash strainer 5 with cleaner 2 Remove stubborn deposits with soft brush 3 Blow out strainer 5 with compresse...

Page 129: ...Engine oil can contain combustion residues which are harmful to health Risk of injury and poisoning Allow the engine to cool to below 50 C before beginning work Wear protective clothing protective gl...

Page 130: ...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 as neces sary 15 Mount rotor cover 4 w...

Page 131: ...to turn cap counterclockwise and remove 3 Check engine coolant level engine coolant must be visible at bottom edge of cast in eye of filler neck Checking coolant level at exter nal cooler Note Engine...

Page 132: ...at sight glass 1 Check coolant level coolant level must be between min and max mark 2 Top up with treated coolant as necessary Page 136 132 Coolant Circuit General High Temperature Circuit MS15043 00E...

Page 133: ...Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 134 2 Fill with engine coolant Page 136 MS15043 00E 2016 04 Coolant Circuit General High Tem...

Page 134: ...coolant expansion tank counterclockwise until the first stop and allow pressure to escape 3 Continue to turn cover counterclockwise and remove 4 Extract remaining engine coolant in the coolant expansi...

Page 135: ...engine coolant pump with torque wrench to specified tightening torque Name Size Type Lubricant Value Standard Spindle 11 a f Tightening torque 12 Nm 2 Close all other open drain points 3 Put on fille...

Page 136: ...o cool down Wear protective clothing protective gloves and safety glasses facial protection NOTICE Cold coolant in hot engine can cause thermal stress Possible formation of cracks in the engine Fill t...

Page 137: ...cap and clean sealing faces if required 7 Put on filler neck cap and close it 8 Start engine Page 40 and shut down after 10 second of operation without load Page 40 9 Continue to turn cover counterclo...

Page 138: ...ntil first stop is reached 5 Start engine Page 40 and shut down after 10 second of operation without load Page 41 6 Turn cap counterclockwise and remove 7 Check engine coolant level Page 131 and top u...

Page 139: ...rotectors Checking engine coolant pump relief bore 1 Check relief bore arrow for oil and coolant discharge Note Observe general safety instructions for main tenance and repair work 2 Stop engine Page...

Page 140: ...teps u Switch off preheating unit Breather valve Replacement Note Pictorial schematic Design may deviate 1 Turn breather valve 1 on coolant expansion tank counterclockwise to the first stop and allow...

Page 141: ...stop and allow pressure to escape 2 Continue to turn cap counterclockwise and remove Note Charge air coolant must be visible at marker plate 3 Check charge air coolant level 4 Top up charge air coolan...

Page 142: ...al tools Material Spare parts Designation Use Part No Qty Coolant Charge air coolant Change 1 Drain charge air coolant Page 143 2 Fill with charge air coolant Page 145 142 Low Temperature Circuit MS15...

Page 143: ...ot and under pressure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask Draining charge air coolant 1 Provide a suitable container in which t...

Page 144: ...t at charge air cooler high pressure arrow Final steps 1 Close all drain valves and screw in drain plugs with new sealing rings 2 Put on filler neck cap and close it 144 Low Temperature Circuit MS1504...

Page 145: ...d scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask NOTICE Cold coolant in hot engine can cause thermal stress Possible formation of cracks in the engine Fill t...

Page 146: ...seconds of running the engine with out load shut down the engine Page 41 7 Turn cap counterclockwise and remove 8 Check charge air coolant level Page 141 and top up if required a Repeat the steps fro...

Page 147: ...kwise until the first stop and allow pressure to escape 11 Continue to turn cover counterclockwise and remove 12 Check charge air coolant level Page 141 and top up if required a Fill in coolant in exp...

Page 148: ...Checking charge air coolant pump relief bore 1 Check pressure relief port arrow for oil and coolant discharge Note Observe safety regulations when carrying out maintenance and repair work Page 10 2 S...

Page 149: ...sk and ear defenders Checking battery charging generator Item Findings Measure Ventilation areas arrows Clean None Ventilation areas arrows Contaminated Clean Cleaning battery charging generator Note...

Page 150: ...nsioner 5 continue to loosen screw 1 and allow belt tensioner 5 to move slowly downwards 5 Remove screw 1 with washer 2 and take off belt tensioner 5 6 Take off used drive belt 6 7 Fit new drive belt...

Page 151: ...t replacement Page 154 Version A fan drive with belt tensioning pulley Adjusting fan height 1 Release screws 2 but keep them in position 2 Relieve tensioning screw 1 and if necessa ry shift fan clutch...

Page 152: ...stment 36 Hz 3 Hz 48 Hz 1 Hz 42 Hz 1 Hz Drive belt Tension adjustment 1 Undo two hex nuts 3 2 Tension belt 1 by turning the pull rod 2 un til the required frequency Table 2 is at tained 3 Turn cranksh...

Page 153: ...ld belt tension tester over belt drive until the measured value is displayed Initial assembly at MTU Initial operation with fan Belt tension adjustment 36 Hz 3 Hz 49 Hz 1 Hz 44 Hz 1 Hz Drive belt Tens...

Page 154: ...two hex nuts 4 2 Increase the tensioning arm length by turning the pull rod 3 until the tensioning lever 6 can move freely 3 Turn tensioning lever 6 to the outside Note If necessary shift fan clutch...

Page 155: ...Nm 7 Nm Version B fan drive without belt tensioning pulley Replacing drive belt 1 Undo screws 2 2 Slacken off stud 1 until drive belt can be re moved 3 Clean belt pulleys 4 Fit new drive belt on belt...

Page 156: ...ype Lubricant Value Standard Screw M12x170 Control torque Engine oil 100 Nm 10 Nm 3 Version without fan drive Tighten loose screw connections 2 to specified torque using a torque wrench Name Size Type...

Page 157: ...tandard Screw M20x200 M20x180 Control torque Engine oil 500 Nm 50 Nm 7 Tighten loose screw connections 5 to specified torque using a torque wrench Name Size Type Lubricant Value Standard Screw M16x230...

Page 158: ...intact 4 Replace faulty cable clips 5 Check cable clamps for secure fit tighten loose clamps 6 Replace faulty cable clamps 7 Visually inspect the following electrical components for damage Connector...

Page 159: ...ngine to cool down to below 50 C before beginning work Wear suitable protective equipment thermal gloves Avoid unprotected contact with hot surfaces NOTICE Carry out the calibration learning run for a...

Page 160: ...minated by black ex haust Replace actuator Checking actuators with DiaSys Note For installation position of exhaust flaps refer to overview Page 112 1 Switch on ECU Note A learning run must not be car...

Page 161: ...dirt from housing surface 2 Use isopropyl alcohol to remove dirt from the connector and cable surfaces 3 Check legibility of cable labels Clean or replace illegible labels Heavily contaminated connec...

Page 162: ...The contacts in the plug connection can be bent Carry out check of plug connection only with test connectors Checking plug connections at engine governor 1 Check all plug connections for secure seati...

Page 163: ...tting parameters for drift correction CDC with DiaSys 1 Use DiaSys to reset the CDC parameters Dialog system DiaSys E531920 2 If no DiaSys is available contact Service Entering the codes for the injec...

Page 164: ...suitable protective equipment thermal gloves Avoid unprotected contact with hot surfaces NOTICE High voltage Risk of damage to components Switch off ignition before replacing components NOTICE Ceramic...

Page 165: ...orque max 12 Nm 2 Remove protective cap on thread of sensor 3 only just before installation Note Do not wipe off the thread lubricant applied by the manufacturer 3 Coat sensor 3 thread with specified...

Page 166: ...elow 50 C before beginning work Wear suitable protective equipment thermal gloves Avoid unprotected contact with hot surfaces NOTICE Ceramic cell breakage due to shock or impact Risk of damage to comp...

Page 167: ...pecified assembly compound as required 3 Screw in sensor by hand 4 Tighten nut 2 to specified torque using a torque wrench Name Size Type Lubricant Value Standard Nut M18 x 1 5 Tightening torque Assem...

Page 168: ...168 MS15043 00E 2016 04...

Page 169: ...9 Manufacturer s Documentation 9 1 Prefilter Installation Instructions 171 9 2 Prefilter Installation Operation 183 MS15043 00E 2016 04 Manufacturer s Documentation 169...

Page 170: ...170 Manufacturer s Documentation MS15043 00E 2016 04...

Page 171: ...lug Fitting E Priming Pump includes Isolators F Check Valve Extended G 2 Priming Pump Clamps and 4 Screws H 2 Priming Pump Hoses and 4 Fittings I Electric Heaters optional J Check Valve K Water In Fue...

Page 172: ...filter is used contaminants collect on the filter from the bottom up Fuel rises on the filter indicating remaining filter life Fuel level increases in clear cover As contaminants collect on the filter...

Page 173: ...quipped and place a suitable container under the fuel filters 2 Remove the primary fuel filter element assembly sedimenter and or water separator Drain the used element and dispose of it in an environ...

Page 174: ...o Injectors Rail On engine Filtration Low Pressure Pump High Pressure Pump Fuel Tank Figure 2 Industrial Pro Connections Note When the engine is shut off fuel levels may drop until the engine is resta...

Page 175: ...e sensor 3 with torque wrench to max 30 Nm 22 ft lbs tightening torque 3 Connect the F70 plug 1 of the WIF sensor harness 5 to the WIF sensor 3 and tighten the bayonet lock 2 1 2 3 4 Figure 3 WIF Sens...

Page 176: ...y Voltage 24V Maximum Current 6A 24V Recommended Fuse 10 Amp FUEL IN M12 X 1 5 6H THD DEUTSCH CONNECTOR DT04 2P FUEL OUT M12 X 1 5 6H THD A RED WIRE 24VDC B BLACK WIRE Figure 5 Priming Pump Electrical...

Page 177: ...bolts and straps 9 Remove primer pump Assembly 1 Install the new primer pump with fuel flow arrow aimed towards fuel outlet See Figure 7 FUEL OUT FUEL OUT Figure 7 Primer Pump 2 Install the primer pu...

Page 178: ...l be applied Note When wiring the electric preheater use a fuse NOT a circuit breaker With Relay B Key Controlled Circuit 25 A Fuse Battery Relay 85 86 87 30 51 Use a relay if the available keyed circ...

Page 179: ...element key is lined up with the keyway on the center boss of the housing and press the filter element into the housing Ensure the filter element is fully seated by firmly push ing on the end plate K...

Page 180: ...gs Every 12 Months Check all electrical connections for corrosion Check all fuel fittings for leaks Extreme winter or salt corrosion environments may require lubrication of the top collar threads with...

Page 181: ...7 7 7 0 4 2 1 1 3 8 3 2 2 0 0 5 0 8 4 P LAC E S MO U N TIN G B R AC K E T R E AR V IE W 5 5 2 1 4 2 5 4 4 1 2 2 7 6 8 9 6 6 6 0 1 6 7 6 1 2 P LAC E S 8 9 1 4 0 7 7 0 1 9 5 6 R 2 2 5 6 S LO T 1 2 P LAC...

Page 182: ...182 Manufacturer s Documentation MS15043 00E 2016 04 TIM ID 0000083486 002...

Page 183: ...9 2 Prefilter Installation Operation MS15043 00E 2016 04 Manufacturer s Documentation 183 TIM ID 0000098598 001...

Page 184: ...184 Manufacturer s Documentation MS15043 00E 2016 04 TIM ID 0000098598 001...

Page 185: ...MS15043 00E 2016 04 Manufacturer s Documentation 185 TIM ID 0000098598 001...

Page 186: ...186 Manufacturer s Documentation MS15043 00E 2016 04 TIM ID 0000098598 001...

Page 187: ...MS15043 00E 2016 04 Manufacturer s Documentation 187 TIM ID 0000098598 001...

Page 188: ...188 Manufacturer s Documentation MS15043 00E 2016 04 TIM ID 0000098598 001...

Page 189: ...MS15043 00E 2016 04 Manufacturer s Documentation 189 TIM ID 0000098598 001...

Page 190: ...190 Manufacturer s Documentation MS15043 00E 2016 04 TIM ID 0000098598 001...

Page 191: ...MS15043 00E 2016 04 Manufacturer s Documentation 191 TIM ID 0000098598 001...

Page 192: ...192 Manufacturer s Documentation MS15043 00E 2016 04 TIM ID 0000098598 001...

Page 193: ...MS15043 00E 2016 04 Manufacturer s Documentation 193 TIM ID 0000098598 001...

Page 194: ...194 Manufacturer s Documentation MS15043 00E 2016 04 TIM ID 0000098598 001...

Page 195: ...lamp rectify fault as soon as possible 2nd function Read out fault codes CKT Circuit CLS Coolant Level Sensor Monitors coolant level CM Current Measurement Current measured value CPS Coolant Pressure...

Page 196: ...ssure HI High Alarm Measured value exceeds 1st maximum limit HIHI High High Alarm Measured value exceeds 2nd maximum limit HT High Temperature IDM Interface Data Module Memory module for interface dat...

Page 197: ...ng lamp stop engine and rectify fault 2nd function Read out fault codes SID System Identifier SRS Synchronous Reference Sensor TDC cylinder 1 SS Safety System Security Shutdown Safety system alarm TBS...

Page 198: ...of a malfunction for information on changes in conditions of use and for supplying spare parts Your contact person in our Customer Assistance Center E mail info mtu online com Tel 49 7541 9077777 Fax...

Page 199: ...Unit B in2 645 16 mm2 ft2 0 0929 m2 yd2 0 8361 m2 stat mile2 2 59 km2 Unit B multiplied by factor Unit A mm2 0 00155 in2 m2 10 764 ft2 m2 1 1960 yd2 km2 0 3861 stat mile2 Volume Unit A multiplied by...

Page 200: ...t mile h mph 1 609 km h knot UK 1 852 km h Unit B multiplied by factor Unit B m s 3 281 ft s km h 0 6214 stat mile h mph km h 0 54 knot UK Mass Unit A multiplied by factor Unit B lb 0 4536 kg oz 28 35...

Page 201: ...95 bar lbf ft2 psf 47 88 Pa inHg 0 03386 bar inHg 345 3 kp m2 mmH2O Unit B multiplied by factor Unit A atm 760 mmHg atm 1 0133 bar atm 10332 kp m2 mmH2O atm 1 0332 kp cm2 at atm 14 696 lbf in2 psi bar...

Page 202: ...8598 kcal h lbf ft s 0 0018 HP Temperature Celsius Kelvin x C x 273 15 K x K x 273 15 C x F 5 9 x 32 C 5 9 x 32 273 15 K x R 5 4x C 5 4x 273 15 K Fahrenheit R aumur x C 9 5x 32 F 4 5x R x K 9 5 x 273...

Page 203: ...ngth class 8 8 surface finish bare metal phosphatized or galvanized and 10 9 surface finish bare metal or phosphatized The values in the table are based on a friction coefficient tot 0 125 Threads and...

Page 204: ...o Steel M A Nm Gray cast iron MA Nm Al alloy MA Nm M6 9 6 6 M8 11 9 10 M10 17 13 13 M12 27 23 18 M14 37 33 33 M16 55 45 MA tightening torques Tightening torques for setscrews and nuts made of stainles...

Page 205: ...based on a friction coefficient tot 0 125 Threads and mating faces of screws and nuts must be coated with engine oil prior to assembly An assembly tolerance of 10 of the figures in the table is permit...

Page 206: ...ion when tightening MA tightening torques Tightening torques for plug screws to MTN 5183 1 standard This standard applies to plug screws to DIN 908 DIN 910 and DIN 7604 with threaded end to DIN 3852 F...

Page 207: ...ess Tightening torques for plug screws to DIN 908 DIN 910 and DIN 7604A with short threaded end Thread Screwed into Steel gray cast iron MA Nm AI alloy MA Nm M10 x 1 15 15 M12 x 1 5 25 25 M14 x 1 5 35...

Page 208: ...into Steel gray cast iron M A Nm Al alloy MA Nm M8 x 1 10 10 M22 x 1 5 80 65 M26 x 1 5 105 90 M30 x 1 5 130 130 M38 x 1 5 140 120 M45 x 1 5 160 140 MA tightening torques Tightening torques for banjo s...

Page 209: ...idable deviations during the tightening process Tightening torques for steel banjo screws Thread inserted in steel gray cast iron aluminum alloy MA Nm M8 x 1 10 M10 x 1 15 M12 x 1 5 20 M14 x 1 5 25 M1...

Page 210: ...nd oiled or galvanized Threads and mating faces beneath heads must be coated with engine oil prior to assembly An assembly tolerance of 10 of the figures in the table is permitted due to unavoidable d...

Page 211: ...e union nut firmly by hand noticeable increase in force it should be tightened another 1 4 turn 90 past this point Tightening torques for spigot unions with O ring to ISO 6149 2 Thread Torque Nm 10 M8...

Page 212: ...crew in valves see ISO 6149 47 and ISO 7789 Tightening torques for spigot unions with O ring to ISO 6149 3 Thread Torque Nm 10 M8 x 1 8 M10 x 1 15 M12 x 1 5 25 M14 x 1 5 35 M16 x 1 5 40 M18 x 1 5 45 M...

Page 213: ...S fittings In contrast to the instructions for pipe unions hose fittings with sealing heads and the matching adapters must be fitted and connected as follows Hose fitting forming metallic seal with un...

Page 214: ...5 x 2 35 290 M52 x 2 38 42 330 Sealing head with BSP union nut BSPP thread Torque Nm G1 4 20 G3 8 34 G1 2 60 G5 8 69 G3 4 115 G1 140 G1 1 4 210 G1 1 2 290 G2 400 SAE sealing cone with union nut JIC 37...

Page 215: ...Size Torque Nm 9 16 18 4 14 2 11 16 16 6 24 3 13 16 16 8 43 4 1 14 10 60 8 1 3 16 12 12 90 5 1 3 16 12 14 90 5 1 7 16 12 16 125 10 1 11 16 12 20 170 20 2 12 24 200 25 2 1 2 20 32 460 30 MS15043 00E 2...

Page 216: ...and adjustment Page 96 Barring device Part No F6555766 Qty Used in 1 8 1 1 Engine Barring manually Page 78 Qty Used in 1 8 2 1 Cylinder liner Endoscopic examination Page 84 Barring device Part No F678...

Page 217: ...8050 Qty Used in 1 8 1 1 Engine Barring manually Page 78 Belt tension tester optibelt TT3 Part No Y4345711 Qty Used in 1 8 18 1 Fan drive Drive belt tension check adjustment Page 151 Crossbeam Part No...

Page 218: ...Qty Used in 1 8 6 2 Valve protrusion Measurement Page 94 Endoscope Part No Y20097353 Qty Used in 1 8 2 1 Cylinder liner Endoscopic examination Page 84 Feeler gage Part No Y20098771 Qty Used in 1 8 6 3...

Page 219: ...e 109 High pressure cleaning unit Part No Qty Used in 1 5 7 Plant Cleaning Page 43 Installation removal jig Part No F6796646 Qty Used in 1 8 7 2 Injector Removal and installation Page 102 Milling cutt...

Page 220: ...upling rod replacement Page 115 Qty Used in 1 8 21 5 NOx sensor Replacement Page 164 Qty Used in 1 8 21 6 Lambda sensor Replacement Page 166 Ratchet adapter Part No F30027341 Qty Used in 1 8 13 3 Engi...

Page 221: ...9526 Qty Used in 1 8 6 3 Valve clearance Check and adjustment Page 96 Torque wrench 300 800 Nm Part No F30047798 Qty Used in 1 8 13 3 Engine oil Change Page 121 Qty Used in 1 8 19 1 Engine mounting Se...

Page 222: ...156 Qty Used in 1 8 21 5 NOx sensor Replacement Page 164 Qty Used in 1 8 21 6 Lambda sensor Replacement Page 166 Torque wrench 40 200 Nm Part No F30027337 Qty Used in 1 8 13 3 Engine oil Change Page 1...

Page 223: ...1 Fan drive Drive belt tension check adjustment Page 151 Qty Used in 8 18 2 Fan drive belt Replacement Page 154 Qty Used in 1 8 19 1 Engine mounting Securing screw check Page 156 Torque wrench 6 50 Nm...

Page 224: ...Check Exhaust flaps 113 Replacement Exhaust flaps 115 Cranking Engine On starting system 81 Crankshaft Transport locking device Installation 18 Removal 18 Cylinder Designation 21 Cylinder head cover...

Page 225: ...Replacement 108 Fuel system Venting 107 H Hotline 198 I IIG Input 163 Injector Replacement 101 Injector coding IIG Input 163 Injectors Installation 102 Removal 102 L Lambda sensor Replacement 166 Lif...

Page 226: ...NOx 164 Service partners 198 Spare parts service 198 Starter Condition check 118 Starting system Engine cranking 81 T Technical data 20V4000C55 28 20V4000C65 31 Tightening specifications Nuts 203 Scr...

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MTU 20V4000C55, Operating Instructions Manual

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