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Task Description

6.3

Crankcase Ventilation

6.3.1

Crankcase breather – Oil separator replacement, diaphragm
check and replacement

Preconditions

• Engine is stopped and starting disabled.

Special tools

Designation / Use

Part No.

Qty.

Torque wrench 6-50 Nm

F30027336

Spare parts

Designation / Use

Part No.

Qty.

Filter element
Diaphragm
Seal

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 not inhale oil vapor.

Replacing oil separator

1. Remove cover (2) with O-ring (3).
2. Remove filter element (1) from housing (4).
3. Insert new filter element in housing (4).
4. Fit cover (2) with new O-ring.
5. Use torque wrench to tighten the screws of

cover (2) to specified torque 10 Nm -2 Nm.

6. Replace further oil separator elements in the

same way.

M015715/00E 06-08

Содержание 20 V 4000 G23

Страница 1: ...EDG TRAINING MANUAL JOB 6608 REV 0 2 Engine 2 1 MTU Manual 2 2 P ID 2 2 1 Lube Oil System 2 2 2 Fuel System 2 2 3 Cooling System...

Страница 2: ...Technical Publication Diesel Engine 20 V 4000 G23 20 V 4000 G43 20 V 4000 G63 20 V 4000 G83 Operating Instructions M015715 00E...

Страница 3: ...l entretien et de la conduite Modifications r serv es Impreso en Alemania 2006 Copyright MTU Friedrichshafen GmbH Esta publicaci n se encuentra protegida en toda su extensi n por los derechos de auto...

Страница 4: ...base pour l assistance en exploitation contractuelle garantie rechanges etc Rogamos separen la tarjeta Aviso de puesta en servicio y la devuelvan rellenada a MTU Friedrichshafen GmbH Las informaciones...

Страница 5: ...ta en servicio Messa in servizio il Data da coloca o em servi o Eingebaut in Installation site Lieu de montage Lugar de montaje Installato Incorporado em Schiffstyp Schiffshersteller Vessel type class...

Страница 6: ...fuel consumption 21 2 6 2 20V 4000 Gx3 engine data Standby operation 3D optimized exhaust emissions EPA stage 2 28 2 6 3 20V 4000 Gx3 engine data Continuous operation variable 3B optimized fuel consu...

Страница 7: ...101 6 4 1 Valve gear Lubrication 101 6 4 2 Valve clearance Check and adjustment 102 6 4 3 Cylinder head cover Remove and install 105 6 5 Fuel Injector 106 6 5 1 Injector replacement 106 6 5 2 Injecto...

Страница 8: ...lant Sample extraction and analysis 141 6 15 LT Circuit 142 6 15 1 Charge air coolant change 142 6 15 2 Charge air coolant Filling 143 6 15 3 Charge air coolant Draining 145 6 15 4 Charge air coolant...

Страница 9: ...04 Table of Contents M015715 00E 06 08 MTU...

Страница 10: ...the application specified in the contract or defined at the time of delivery Any other use is considered improper use The manufacturer will accept no liability for any resultant damage The responsibil...

Страница 11: ...d in operation maintenance repair or transportation The personnel must be instructed on engine operation and repair by means of this publication and in particular the safety instructions must be expla...

Страница 12: ...nsporting the engine it is imperative to install transportation locking devices for crankshaft and engine mounts Secure the engine against tilting during transportation The engine must be especially s...

Страница 13: ...s or cables Inadequate protection of electrical components can lead to electric shocks and serious injuries When the engine is running never release coolant oil fuel compressed air or hydraulic lines...

Страница 14: ...ounted units Never use the engine as a ground connection This prevents the welding current passing through the engine resulting in burnt scorched bearings sliding surfaces and tooth flanks which may l...

Страница 15: ...o properly support the wires For this purpose no cable binders must be used as during maintenance and or repair work the binders can be removed but not installed a second time Spare parts shall be pro...

Страница 16: ...s governing the use of materials that may affect water quality is applicable which means work must only be carried out by authorized specialist companies MTU is such a company Auxiliary materials Use...

Страница 17: ...set to permitted pressure must form an intermediate connection Hose coupling and connections must be securely attached Always wear protective goggles when blowing off tools or chips The snout of the...

Страница 18: ...ions Consequences Slight injury or material damage Preventive measures Note This Publication contains especially emphasized safety instructions in accordance with the American standard ANSI Z535 which...

Страница 19: ...14 Safety M015715 00E 06 08 MTU...

Страница 20: ...tem high pressure 080 Fuel system low pressure 100 Exhaust turbocharger 110 Intercooler 120 Air intake air supply 140 Exhaust system 170 Starting equipment 180 Lube oil system lube oil circuit 200 Coo...

Страница 21: ...ngine model designation Key to the engine model designation 20V 4000 Gx3 20 Number of cylinders V Cylinder arrangement V engine 4000 Series G Application x Application segment 2 4 6 8 3 Design index M...

Страница 22: ...end KS The cylinders of the left engine side are designated 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...

Страница 23: ...18 Product Summary 2 3 Main Engine Dimensions 2 3 1 Main engine dimensions Main engine dimensions Length A approx 3520 mm Width B approx 1620 mm Height C approx 2490 mm M015715 00E 06 08 MTU...

Страница 24: ...iring Order 2 4 1 Firing order Firing order 12V A1 B5 A5 B3 A3 B6 A6 B2 A2 B4 A4 B1 16 V A1 A7 B4 B6 A4 B8 A2 A8 B3 B5 A3 A5 B2 A6 B1 B7 20V A1 B5 A8 B7 A5 B2 A7 B10 A2 B3 A10 B6 A3 B4 A6 B9 A4 B1 A9...

Страница 25: ...20 Product Summary 2 5 Final Compression Pressure 2 5 1 Final compression pressure Final compression pressure Final compression pressure at 120 rpm 24 bar to 28 bar M015715 00E 06 08 MTU...

Страница 26: ...gine model 20V 4000 G23 20V 4000 G43 20V 4000 G63 20V 4000 G63L 20V 4000 G83 20V 4000 G83L Application group 3D 3D 3D 3D 3D 3D Intake air temperature C 25 25 25 25 25 25 Charge air coolant temperature...

Страница 27: ...g ETC and charge air cooling CAC X X X X X X Exhaust piping non cooled X X X X X X Working method four cycle diesel single acting X X X X X X Combustion method Direct fuel injection X X X X X X Coolin...

Страница 28: ...OMBUSTION AIR EXHAUST GAS Number of cylinders 20 20 20 20 20 20 Charge air pressure before cylinder BL R bar abs 2 5 3 1 2 7 2 9 3 3 3 6 COOLANT SYSTEM HT circuit Number of cylinders 20 20 20 20 20 20...

Страница 29: ...20 20 20 20 Lube oil operating temperature before engine from R C 88 88 88 88 88 88 Lube oil operating temperature before engine to R C 98 98 98 98 98 98 Lube oil temperature before engine alarm R C 9...

Страница 30: ...nection max during engine starting L bar 1 5 1 5 1 5 1 5 1 5 1 5 GENERAL OPERATING DATA Number of cylinders 20 20 20 20 20 20 Cold start capability Air temperature w o start aid w o preheating case A...

Страница 31: ...390 390 Oil change quantity max standard oil system Option max operating inclinations R liters Oil pan capacity at dipstick mark min standard oil system Option max operating inclinations L liters 245...

Страница 32: ...20 20 20 20 20 20 Exhaust noise unsilenced BL sound power level LW ISO 6798 R dB A 131 134 130 131 136 136 Engine surface noise with attenuated intake noise filter BL sound power level LW ISO 6798 R d...

Страница 33: ...Application group 3D 3D 3D Intake air temperature C 25 25 25 Charge air coolant temperature C 45 45 45 Raw water inlet temperature C Barometric pressure mbar 1000 1000 1000 Site altitude above sea le...

Страница 34: ...s 20 20 20 Cylinder arrangement V angle Degrees 90 90 90 Bore mm 170 170 170 Stroke mm 210 210 210 Displacement cylinder liters 4 77 4 77 4 77 Displacement total liters 95 4 95 4 95 4 Compression rati...

Страница 35: ...off engine cooling system max L bar 0 7 0 7 0 7 LUBE OIL SYSTEM Number of cylinders 20 20 20 Lube oil operating temperature before engine from R C 88 88 88 Lube oil operating temperature before engine...

Страница 36: ...linations R liters 390 390 390 Oil change quantity max standard oil system Option max operating inclinations R liters Oil pan capacity at dipstick mark min standard oil system Option max operating inc...

Страница 37: ...0 G43 20V 4000 G63 20V 4000 G63L 20V 4000 G83 20V 4000 G83L Application group 3B 3B 3B 3B 3B 3B Intake air temperature C 25 25 25 25 25 25 Charge air coolant temperature C 55 55 55 55 55 55 Raw water...

Страница 38: ...CAC X X X X X X Exhaust piping non cooled X X X X X X Working method four cycle diesel single acting X X X X X X Combustion method Direct fuel injection X X X X X X Cooling system conditioned water X...

Страница 39: ...S Number of cylinders 20 20 20 20 20 20 Charge air pressure before cylinder DL R bar abs 2 3 2 8 2 5 2 6 3 1 3 3 COOLANT SYSTEM HT circuit Number of cylinders 20 20 20 20 20 20 Coolant temperature at...

Страница 40: ...20 20 20 20 Lube oil operating temperature before engine from R C 88 88 88 88 88 88 Lube oil operating temperature before engine to R C 98 98 98 98 98 98 Lube oil temperature before engine alarm R C 9...

Страница 41: ...nection max during engine starting L bar 1 5 1 5 1 5 1 5 1 5 1 5 GENERAL OPERATING DATA Number of cylinders 20 20 20 20 20 20 Cold start capability Air temperature w o start aid w o preheating case A...

Страница 42: ...390 390 Oil change quantity max standard oil system Option max operating inclinations R liter Oil pan capacity at dipstick mark min standard oil system Option max operating inclinations L liter 245 24...

Страница 43: ...20 20 20 20 20 20 Exhaust noise unsilenced DL sound power level LW ISO 6798 R dB A 130 133 131 132 134 136 Engine surface noise with attenuated intake noise filter DL sound power level LW ISO 6798 R d...

Страница 44: ...B Intake air temperature C 25 25 25 Charge air coolant temperature C 45 45 45 Raw water inlet temperature C Barometric pressure mbar 1000 1000 1000 Site altitude above sea level m 100 100 100 POWER RE...

Страница 45: ...20 20 20 Cylinder arrangement V angle degrees 90 90 90 Bore mm 170 170 170 Stroke mm 210 210 210 Displacement per cylinder liter 4 77 4 77 4 77 Total displacement liter 95 4 95 4 95 4 Compression rat...

Страница 46: ...off engine cooling system max L bar 0 7 0 7 0 7 LUBE OIL SYSTEM Number of cylinders 20 20 20 Lube oil operating temperature before engine from R C 88 88 88 Lube oil operating temperature before engine...

Страница 47: ...clinations R liter 390 390 390 Oil change quantity max standard oil system Option max operating inclinations R liter Oil pan capacity at dipstick mark min standard oil system Option max operating incl...

Страница 48: ...3B Intake air temperature C 25 25 25 Charge air coolant temperature C 55 55 55 Raw water inlet temperature C Barometric pressure mbar 1000 1000 1000 Site altitude above sea level m 100 100 100 POWER...

Страница 49: ...20 20 20 Cylinder arrangement V angle degrees 90 90 90 Bore mm 170 170 170 Stroke mm 210 210 210 Displacement per cylinder liter 4 77 4 77 4 77 Total displacement liter 95 4 95 4 95 4 Compression rat...

Страница 50: ...off engine cooling system max L bar 0 7 0 7 0 7 LUBE OIL SYSTEM Number of cylinders 20 20 20 Lube oil operating temperature before engine from R C 88 88 88 Lube oil operating temperature before engine...

Страница 51: ...clinations R liter 390 390 390 Oil change quantity max standard oil system Option max operating inclinations R liter Oil pan capacity at dipstick mark min standard oil system Option max operating incl...

Страница 52: ...e oil level Page 130 Fuel prefilter Prime Page 119 Fuel prefilter pressure gauge Align adjustable pointer with position of pressure indicator Page 114 Coolant circuit If engine is out of service for m...

Страница 53: ...m Check oil level Page 130 Cooling system Check engine coolant level Page 139 Check charge air coolant level Page 146 Cooling system Preheat coolant with preheating unit Fuel prefilter Drain Page 115...

Страница 54: ...t control panel etc depending on manufacturer If coolant temperature is 40 C with preheating pump or 10 C 60 Hz generator without preheating pump or 5 C 50 Hz generator without preheating pump Press s...

Страница 55: ...utton for override input of ECU Switching cabinet control panel etc depending on manufacturer Press start button Automatic starting procedure is performed All safety functions are deactivated and engi...

Страница 56: ...are within the limit restricted engine operation is not required Check for abnormal running noises and vibration Fuel prefilter Check if suction side pressure indicated at the fuel prefilter pressure...

Страница 57: ...le speed until operating temperatures decrease and stable values are indicated Preparation Item Task Engine After the generator circuit breaker has been opened allow the engine to cool down by running...

Страница 58: ...tuations Emergency stop from LOP Item Task EMERGENCY STOP button Press Engine is stopped by switching off power supply to ECU Signalization e g by horn flashing lamp is released After emergency stop f...

Страница 59: ...8 After stopping the engine engine remains ready for operation After stopping the engine Item Task Engine generator control system Select operating mode e g MANUAL OPERATION AUTOMATIC OPERATION M01571...

Страница 60: ...antifreeze additive the engine room is not heated the coolant is not maintained at a suitable temperature the antifreeze concentration is insufficient for the engine room temperature antifreeze conce...

Страница 61: ...56 Operation M015715 00E 06 08 MTU...

Страница 62: ...be done action to be taken indicate the relevant maintenance item They serve as a reference for the scope of parts needed and also appear on the labels of the corresponding spare parts Preventive main...

Страница 63: ...oad factor 85 Load profile Load profile table application group 3A Power 110 100 Corresponding operating time 1 99 Load profile table application group 3B Power 110 100 70 Corresponding operating time...

Страница 64: ...7 500 8 000 8 500 9 000 9 500 10 000 10 500 Engine oil filter 2 Engine operation X Centrifugal oil filter 2 X X X X X X X X X X X X X X X X X X X X X Fuel filter 2 X X X X X X X X X X Valve gear X X...

Страница 65: ...000 21 500 Engine oil filter 2 Engine operation Centrifugal oil filter 2 X X X X X X X X X X X X X X X X X X X X X X Fuel filter 2 X X X X X X X X X X X Valve gear X X X X X X X Belt drive 2 X X X X X...

Страница 66: ...0 Engine oil filter 2 Engine operation Centrifugal oil filter 2 X X X X X X X X X X X X X X X X X Fuel filter 2 X X X X X X X X X Valve gear X X X X X X Belt drive 2 X X X X X X Air filter 3 X X X Fue...

Страница 67: ...000 9 500 10 000 10 500 Engine oil filter 2 Engine operation X Centrifugal oil filter 2 X X X X X X X X X X X X X X X X X X X X X Valve gear X X X X X X X X X X Fuel filter 2 X X X X X X X X X X Belt...

Страница 68: ...ne oil filter 2 Engine operation Centrifugal oil filter 2 X X X X X X X X X X X X X X X Valve gear X X X X X X X X Fuel filter 2 X X X X X X X X Belt drive 2 X X X X X Air filter 3 X X X Fuel injector...

Страница 69: ...00 8 500 9 000 Engine oil filter 2 Engine operation X Centrifugal oil filter 2 X X X X X X X X X X X X X X X X X X Valve gear X X X X X X X X X Fuel filter 2 X X X X X X X X X Belt drive 2 X X X X X X...

Страница 70: ...500 5 000 5 500 6 000 Engine oil filter 2 Engine operation X Centrifugal oil filter 2 X X X X X X X X X X X X Valve gear X X X X X X Fuel filter 2 X X X X X X Belt drive 2 X X X X X X Air filter 3 X...

Страница 71: ...W1002 QL1 Belt drive Check drive belt condition and tension replace if necessary Page 148 adjust belt tension Page 149 W1003 QL1 Air filter Replace air filter Page 122 W1005 QL1 Fuel injector Replace...

Страница 72: ...linder liners visually Workshop Manual W1063 QL4 Extended component maintenance Disassemble engine completely Inspect engine components acc to assembly instructions repair or replace as necessary Work...

Страница 73: ...68 Maintenance M015715 00E 06 08 MTU...

Страница 74: ...erform visual inspection see manufacturer s documentation ECU Plug in connections are loose Check plug in connections Page 153 Engine Running gear blocked engine cannot be barred manually Contact Serv...

Страница 75: ...ive Contact Service Fuel system Not vented Vent fuel system Page 111 ECU Defective Contact Service Charge air temperature too high Component Probable Cause Task Engine coolant Incorrect coolant concen...

Страница 76: ...sk Too much oil in engine Drain engine oil Page 128 Engine oil Oil separator of crankcase breather contaminated Replace Page 99 Exhaust turbocharger cylinder head piston rings cylinder liner Defective...

Страница 77: ...warning Fuel temperature too high Contact Service 2 0122 931 004 SS T Fuel Main warning Fuel temperature too high Engine stop Contact Service 2 0122 932 005 HI T Charge Air Preliminary warning Charge...

Страница 78: ...Coolant Level Alarm configuration limit value 1 Coolant level too low Check coolant level in expansion tank Page 139 2 0152 921 024 SS Coolant Level Alarm configuration limit value 2 Coolant level too...

Страница 79: ...ynchro Fault Synchronization error between ETCs 1 and 2 1 Reduce power 2 Contact Service 1 8004 205 039 AL ETC 2 cut in failure ETC2 failed to cut in 1 Reduce power 2 Contact Service 1 8004 204 044 L1...

Страница 80: ...pressure too low Engine stop 1 Check fuel lines for leaks 2 Clean fuel prefilter Page 113 3 Fuel prefilter Flushing Page 117 4 Replace filter element of fuel prefilter Page 119 5 Replace fuel filter P...

Страница 81: ...p Speed Alarm configuration limit value Runup speed was not attained Contact Service 2 1090 924 092 SS No Starter Speed Alarm configuration limit value Starter speed was not attained Termination of st...

Страница 82: ...lty automatic engine shutdown Replace ECU 136 15V NEG ECU DEFECT Internal voltage 15 VDC missing automatic engine shutdown Contact Service 139 L1 TE BUFFER TEST Supply voltage of temperature sensors f...

Страница 83: ...ction to one node on CAN bus 1 failed Contact Service 2 0500 680 181 AL CAN2 Node Lost Alarm configuration Connection to one node on CAN bus 2 failed Contact Service 2 0500 681 182 AL CAN Wrong Parame...

Страница 84: ...a warning 1 Inspect CAN bus for short circuit and rectify short circuit as necessary 2 Check shielding improve as necessary 3 Contact Service 2 0500 689 190 AL EMU Parameter Not Supported Alarm config...

Страница 85: ...r restarting the engine 1 8004 566 211 SD P Lube Oil SD alarm configuration Lube oil pressure sensor faulty short circuit or wire break Check sensor and cabling B5 replace as necessary Error cleared a...

Страница 86: ...D alarm configuration Leak off fuel level sensor faulty short circuit or wire break Check sensor and cabling F46 replace as necessary Error cleared after restarting the engine 1 8004 582 223 SD Level...

Страница 87: ...culation SD alarm configuration Recirculation sensor faulty short circuit or wire break Check sensor and cabling B49 replace as necessary Error cleared after restarting the engine 1 8004 581 242 SD T...

Страница 88: ...506 308 AL Timing Cylinder A8 1 8004 507 309 AL Timing Cylinder A9 1 8004 508 310 AL Timing Cylinder A10 1 8004 509 311 AL Timing Cylinder B1 1 8004 510 312 AL Timing Cylinder B2 1 8004 511 313 AL Ti...

Страница 89: ...iring Cylinder A9 1 8004 528 330 AL Wiring Cylinder A10 1 8004 529 331 AL Wiring Cylinder B1 1 8004 530 332 AL Wiring Cylinder B2 1 8004 531 333 AL Wiring Cylinder B3 1 8004 532 334 AL Wiring Cylinder...

Страница 90: ...Cylinder A9 1 8004 548 350 AL Open Load Cylinder A10 1 8004 549 351 AL Open Load Cylinder B1 1 8004 550 352 AL Open Load Cylinder B2 1 8004 551 353 AL Open Load Cylinder B3 1 8004 552 354 AL Open Loa...

Страница 91: ...bit 1 1020 021 Power Stage Failure Stop Engine is set engine will be shut down as additional measure 1 Short circuit of positive connection of one or more injectors to ground 2 Short circuit of negati...

Страница 92: ...31 393 SS T Coolant Redundant Alarm configuration limit value 1 Main warning Redundant coolant temperature reading too high Engine stop 1 Check cabling and sensor 2 Contact Service 2 0129 932 394 LO P...

Страница 93: ...rm configuration Line disruption on digital input 6 Cabling faulty or no resistance over switch 1 Check cabling 2 Check input of target device 3 Contact Service 2 8006 630 406 AL Open Load Digital Inp...

Страница 94: ...lter SD alarm configuration Sensor for water level in fuel prefilter faulty short circuit or wire break Check sensor and cabling replace as necessary Error cleared after restarting the engine 1 8004 5...

Страница 95: ...attained limit value 1 depending on configuration Determine and rectify reason for limit value violation 2 0110 921 442 L2 P Aux 1 Alarm configuration limit value 2 Preliminary warning Pressure signa...

Страница 96: ...value too low 1 Check cabling 2 Contact Service 2 8006 653 462 AL Coolant EMU L1 Alarm configuration limit value EMU coolant temperature value too high low Check configuration with DiaSys 2 8006 654...

Страница 97: ...faulty short circuit or wire break Check sensor and cabling replace as necessary Error cleared after restarting the engine 1 8004 592 472 Al Stop SD Alarm configuration Engine shutdown since all shutd...

Страница 98: ...of serious injury danger to life Before barring the engine ensure that nobody is in the danger zone Engine Barring manually 1 Remove guard plate 2 Engage barring tool 2 with ring gear 3 and mount on...

Страница 99: ...es have been reinstalled and all tools removed from the engine Engine Barring with starting system 1 Release latch of connector X4 2 Disconnect connector from ECU 3 Bar engine in unloaded condition Pr...

Страница 100: ...rting the engine ensure that nobody is in the danger zone WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors Engine test run 1 Start engine Page 49 2 Perform test run at...

Страница 101: ...r cooling bores Running pattern seems darker No actions required Darker areas of even or varying color intensity Beginning and end of the discoloration are not sharply defined and do not cover the ent...

Страница 102: ...rature differences around the liner It appears rather darker within the honed structure in contrast to the bright metallic running surface The honing pattern is undisturbed Discolorations extend in st...

Страница 103: ...n discoloration and heat discoloration are similar Thorough investigation and compliance with the above evaluation criteria allows a definite evaluation To avoid unnecessary disassembly work it is rec...

Страница 104: ...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 not inhale oil...

Страница 105: ...agm 3 for damage fit new diaphragm if used one is damaged 4 Mount diaphragm 3 on housing 1 5 Install new seal 2 and spring 5 together with cover 4 6 Use torque wrench to tighten the screws of cover 4...

Страница 106: ...starting disabled Material Designation Use Part No Qty Engine oil Valve gear Lubrication 1 Remove cylinder head covers Page 105 2 Fill oil chambers of valve bridges with oil 3 Fill oil chambers of roc...

Страница 107: ...ation Use Part No Qty Feeler gauge Y20010128 1 Torque wrench 60 320 Nm F30047446 1 Ring socket 24 mm F30039526 1 Preparatory steps 1 Remove cylinder head cover Page 105 2 Install barring tool Page 93...

Страница 108: ...rms are unloaded on cylinder A1 the piston is in firing TDC If the rocker arms are loaded on cylinder A1 the piston is in overlap TDC 2 Check valve clearance with cold engine Inlet valves long rocker...

Страница 109: ...so that the specified valve clearance is provided 4 Feeler gauge must just pass through the gap 5 Tighten locknut 1 to 90 9 Nm holding adjusting screw 2 firm 6 Replace or rectify adjusting screws and...

Страница 110: ...Designation Use Part No Qty Gasket Remove cylinder head cover 1 Clean very dirty cylinder head covers prior to removal 2 Remove screws 3 Remove cylinder head cover with gasket from cylinder head Insta...

Страница 111: ...106 Task Description 6 5 Fuel Injector 6 5 1 Injector replacement Spare parts Designation Use Part No Qty Injector Remove injector and install new one Page 107 M015715 00E 06 08 MTU...

Страница 112: ...10423 1 Socket wrench 17 mm F30025896 1 Socket wrench 19 mm F30025897 1 Torque wrench 60 320 Nm F30047446 1 Ratchet adapter F30027341 1 Material Designation Use Part No Qty Petroleum jelly WARNING Fue...

Страница 113: ...ve HP fuel line 4 Note The injector accumulator will be emptied when removing the adapter 4 Unscrew adapter 3 until only the last two to three courses of the thread are engaged 5 Allow the fuel to dra...

Страница 114: ...new O rings scope of supply of injector with petroleum jelly and fit on injector 3 Fit new sealing ring with petroleum jelly on injector observe installation position of sealing ring 4 Clean sealing s...

Страница 115: ...3 and use torque wrench to pretighten to between 5 Nm and 10 Nm 12 Tighten screw 2 and adapter 3 to specified tightening torque of 100 Nm 10 Nm using a torque wrench 13 Coat thread and sealing cone o...

Страница 116: ...id naked flames electrical sparks and ignition sources Do not smoke Venting LP fuel system 1 Open vent plug 1 2 Unlock fuel priming pump 2 screw out handle by turning it counterclockwise 3 Operate the...

Страница 117: ...esignation Use Part No Qty Easy change filter WARNING Fuels are combustible Risk of fire and explosion Avoid naked flames electrical sparks and ignition sources Do not smoke Fuel filter Replacement 1...

Страница 118: ...l prefilter cleaning 1 Shut off fuel supply 2 Remove nuts from filter head 3 Take off filter housing and drain fuel into appropriate container 4 Remove filter element securing nut and remove filter el...

Страница 119: ...erential pressure gauge 1 After installation of a new filter element align adjustable pointer 2 with pressure indicating pointer 3 of pressure gauge 1 2 Verify that differential pressure is within the...

Страница 120: ...stopped and starting disabled Material Designation Use Part No Qty Diesel fuel Spare parts Designation Use Part No Qty Gasket WARNING Fuels are combustible Risk of fire and explosion Avoid naked flame...

Страница 121: ...ssing toggle and open it 4 Drain water and contaminants from the filter until pure fuel emerges 5 Close drain cock 6 6 Remove screws securing the cover and take off cover 2 7 Fill filter housing with...

Страница 122: ...ed rotating and moving engine components Risk of serious injury danger to life Take special care when working on a running engine WARNING Fuels are combustible Risk of fire and explosion Avoid naked f...

Страница 123: ...the filter deposits downwards out of the filter 4 Close vent plug 5 and drain cock 6 Fuel prefilter filling fuel 1 Stop engine Page 52 and disable engine start 2 Remove screws securing the cover and...

Страница 124: ...stopped and starting disabled Material Designation Use Part No Qty Diesel fuel Spare parts Designation Use Part No Qty Filter element Gasket WARNING Fuels are combustible Risk of fire and explosion A...

Страница 125: ...ilter 5 Close drain cock 6 6 Remove screws securing the cover and take off cover 2 7 Remove spring 4 and filter element 3 8 Insert new filter element 3 and spring 4 9 Fill filter housing with clean fu...

Страница 126: ...ive goggles safety mask and ear protectors Intercooler Checking condensate drains for coolant discharge and obstructions 1 With the engine running verify that air emerges from the condensate drain s a...

Страница 127: ...tion 6 9 Air Filter 6 9 1 Air filter replacement Spare parts Designation Use Part No Qty Air filter Remove air filter and install new one Page 124 Reset signal ring of service indicator Page 125 M0157...

Страница 128: ...on 123 6 9 2 Air filter Check Spare parts Designation Use Part No Qty Air filter Air filter Check 1 Check entire circumference of air filter for damage 2 Fit new air filter if damaged Page 124 M015715...

Страница 129: ...abled Air filter removal and installation 1 Loosen clamp 2 2 Remove air filter 3 and clamp 2 from flange of intake housing 1 3 Verify that there are no objects in the flange of the intake housing 1 an...

Страница 130: ...ine is stopped and starting disabled Signal ring position check 1 If the signal ring is completely visible in the control window 2 replace air filter Page 122 2 After installation of new filter press...

Страница 131: ...o life Before barring or starting the engine ensure that nobody is in the danger zone WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors Air starter manual operation 1 Pr...

Страница 132: ...arter Condition check Preconditions Engine is stopped and starting disabled Starter Condition check 1 Check starter securing screws for secure seating 2 Tighten loose screw connections 3 Check wiring...

Страница 133: ...g ring 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...

Страница 134: ...ters at drain plug 3 approx 5 liters 4 Replace engine oil filter Page 132 5 Install drain plug s with new sealing ring 6 Tighten drain plugs 2 and 3 with torque wrench to the specified torque 100 Nm 1...

Страница 135: ...e g oil filter or heat exchanger back to the oil pan 3 The oil level must reach the mark 1 or exceed the mark 1 by up to 2 cm 4 If necessary top up to the mark 1 Page 128 5 Insert dipstick into guide...

Страница 136: ...nd poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors En...

Страница 137: ...e harmful to health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Engine oil filter Replacement 1 Remove oil filt...

Страница 138: ...le oil vapor WARNING Compressed air Risk of injury Do not direct compressed air jet at persons Wear protective goggles safety mask and ear protectors Centrifugal oil filter Cleaning and filter sleeve...

Страница 139: ...ce facing the wall 15 Check sealing ring 9 fit new one if necessary 16 Mount rotor cover 8 with sealing ring 9 17 Tighten rotor cover nut 7 with 35 Nm to 45 Nm 18 Place rotor 6 in housing 5 and check...

Страница 140: ...under pressure Risk of injury and scalding 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 cr...

Страница 141: ...o filler neck and close it 11 3 Repeat the steps from Start engine 7 until coolant is no longer needed to be topped up 11 4 Disconnect pump and hose Filling coolant through filler neck 1 Alternatively...

Страница 142: ...ine coolant Draining 1 Turn breather valve of coolant expansion tank counterclockwise until the first stop and allow pressure to escape 2 Continue to turn breather valve counterclockwise and remove 3...

Страница 143: ...138 Task Description 6 14 3 Engine coolant Change Material Designation Use Part No Qty Engine coolant Drain engine coolant Page 137 Fill engine coolant system Page 135 M015715 00E 06 08 MTU...

Страница 144: ...terclockwise to 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 eye...

Страница 145: ...k of damage to hearing Wear ear protectors Engine coolant pump Relief bore check 1 Check relief bore for oil and water discharge 2 Stop the engine Page 52 and disable engine start observe general safe...

Страница 146: ...et the engine cool down Wear protective clothing gloves and goggles safety mask WARNING Engine noise above 85 dB A Risk of damage to hearing Wear ear protectors Engine coolant Sample extraction and an...

Страница 147: ...Description 6 15 LT Circuit 6 15 1 Charge air coolant change Material Designation Use Part No Qty Coolant Drain charge air coolant system Page 145 Fill charge air coolant system Page 143 M015715 00E 0...

Страница 148: ...ure Risk of injury and scalding 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 comp...

Страница 149: ...er valve on filler neck and close 11 3 Repeat the steps from Start engine 7 until coolant is no longer needed to be topped up 11 4 Disconnect pump and hose Filling coolant through filler neck 1 Altern...

Страница 150: ...nt into 2 Turn breather valve of coolant expansion tank counterclockwise until the first stop and allow pressure to escape 3 Continue to turn breather valve counterclockwise and remove 4 Draw off segr...

Страница 151: ...nsion tank counterclockwise to 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 marking plate 4 If...

Страница 152: ...of damage to hearing Wear ear protectors Charge air coolant pump Relief bore check 1 Check relief bore for oil and water discharge 2 Stop the engine Page 52 and disable engine start observe general sa...

Страница 153: ...ped and starting disabled Guard is removed Item Findings Task Drive belt A Breaks in a few individual places None Drive belt Belt is oily shows signs of overheating Drive belt B Breaks around the enti...

Страница 154: ...ing circlip tensioning roller preload Risk of injury Only use specified tool and equipment Adjusting belt tension 1 Remove guard cover 2 Slacken screws 1 and 2 by half a turn Result Belt tensioner mov...

Страница 155: ...cken screws 1 and 2 by half a turn 3 Place socket adapter or box wrench on screw 3 and press belt tensioner in the direction indicated by the arrow as far as it will go 4 Tighten screw 2 5 Remove the...

Страница 156: ...ten loose screw connections 2 Make certain that cables are securely seated in clamps and cannot move freely 3 Check cable binders for secure seating tighten loose cable binders 4 Replace defective cab...

Страница 157: ...ce using a cloth moistened 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 s...

Страница 158: ...Checking plug in connections Preconditions Engine is stopped and starting disabled ECU Checking plug in connections 1 Verify that all plug in connections are securely seated 2 Secure loose connectors...

Страница 159: ...154 Task Description M015715 00E 06 08 MTU...

Страница 160: ...Special Tools 155 7 Special Tools 7 1 Special tools Part No Designation Use Qty F6555766 Barring tool 1 F30006212 Ratchet 1 M015715 00E 06 08 MTU...

Страница 161: ...l Tools Part No Designation Use Qty Y20097353 Rigid endoscope 1 F30027336 Torque wrench 6 50 Nm 1 Y20010128 Feeler gauge 1 F30047446 Torque wrench 60 320 Nm 1 F30039526 Ring socket 24 mm 1 M015715 00E...

Страница 162: ...Special Tools 157 Part No Designation Use Qty F30510423 Torque wrench 10 60 Nm 1 F6784183 Puller 1 M015715 00E 06 08 MTU...

Страница 163: ...No Designation Use Qty F6784167 Press in tool 1 F30510423 Torque wrench 10 60 Nm 1 F30025896 Socket wrench 17 mm 1 F30025897 Socket wrench 19 mm 1 F30027341 Ratchet adapter 1 F30379104 Filter wrench 1...

Страница 164: ...Special Tools 159 Part No Designation Use Qty F30027337 Torque wrench 1 5605892099 00 MTU test kit 1 M015715 00E 06 08 MTU...

Страница 165: ...160 Special Tools M015715 00E 06 08 MTU...

Страница 166: ...Annex 161 8 Annex 8 1 Manufacturer s documentation See Manufacturer s documentation M015715 00E 06 08 MTU...

Страница 167: ...Annex 8 2 MTU contact person service partner You will find the MTU contact person service partner for your region at www mtu online com worldwide in the left hand navigation margin M015715 00E 06 08...

Страница 168: ...ant temperature DDEC Detroit Diesel Electronic Controls Engine control system made by Detroit Diesel DDL Diagnostic Data Link DDR Diagnostic Data Reader DIN Deutsches Institut f r Normung e V German S...

Страница 169: ...ght Emitting Diode LO LOW Alarm Measured value lower than 1st minimum limit LOLO Low Low Alarm Measured value lower than 2nd minimum limit LSG Limiting Speed Governor N A Not Applicable OEM Original E...

Страница 170: ...m is initiated by the safety system TBS Turbocharger Boost Sensor Monitors charge air pressure TC Tools Catalog TCI Turbo Compressor Inlet TCO Turbo Compressor Outlet TD Transmitter Deviation Alarm Se...

Страница 171: ...166 Annex M015715 00E 06 08 MTU...

Страница 172: ...t 149 Battery charging generator drive Drive belt replacement 150 Battery charging generator drive Drive belt tension adjustment 149 Belt Drive 148 Drive belt Condition check 148 C Cabling General for...

Страница 173: ...efilter cleaning 113 Fuel filter Replacement 112 Fuel Injector 106 Injector Removal and Installation 107 Injector replacement 106 Fuel prefilter differential pressure check and adjustment of gauge 114...

Страница 174: ...pping the engine in manual mode 52 T Technical Data 21 20V 4000 Gx3 engine data Continuous operation variable 3B optimized exhaust emissions EPA 39 20V 4000 Gx3 engine data Continuous operation variab...

Страница 175: ......

Страница 176: ...Demo version http www verypdf com...

Страница 177: ...Demo version http www verypdf com...

Страница 178: ...Demo version http www verypdf com...

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