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1.3 Personnel and organizational requirements

Organizational measures of the user/manufacturer

This manual must be issued to all personnel involved in operation, maintenance, repair, assembly, installa-
tion, or transportation.

Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance,
repair, assembly, installation, and transport personnel at all times.

Personnel must receive instruction on product handling and maintenance based on this manual with a spe-
cial emphasis on safety requirements and warnings.

This is important in the case of personnel who only occasionally perform work on or around the product.
These 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 Training Center of the manufacturer
• Technical personnel from the areas mechanical engineering, plant construction, and electrical engineering

The operator must define the responsibilities of the personnel involved in operation, maintenance, repair, as-
sembly, installation, and transport in writing.

Personnel shall not report for duty under the influence of alcohol, drugs or strong medication.

Clothing and personal protective equipment

Always wear appropriate personal protective equipment, e.g. safety shoes, ear protectors, protective gloves,
goggles, breathing mask. Follow the instructions concerning personal protective equipment in the descrip-
tions of the individual activities.

MS15043/00E 2016-04

| Safety | 7

TIM-ID: 0000040531 - 008

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Содержание 20V4000C55

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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