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6 Maintenance

6.1 Maintenance task reference table [QL1]

The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Mainte-
nance Schedule is a stand-alone publication.

The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance
Schedule.

Task

Item

Maintenance tasks

Option

WM00296

ENGINE, GENERAL

Carry out test run, minimum duration: until steady-state temperature is
reached, no less than 1/3 load (monthly)

WM00222

COOLANT CIRCUIT GENERAL, IF
APPLICABLE HIGH-TEMPERA-
TURE CIRCUIT

Check function of preheater and inspect for leaks

X

WM00067

OIL FILTRATION/COOLING

Replace oil filter at each oil change or when the time limit (years) is reached, at
the latest

WM00148

COOLANT CIRCUIT GENERAL, IF
APPLICABLE HIGH-TEMPERA-
TURE CIRCUIT

Replace thermostat of preheater (electric)

X

WM00297

FUEL INJECTOR

Replace rings

WM00289

ENGINE, GENERAL

Check engine for abnormal running noises, exhaust gas color and vibrations

WM00288

ENGINE, GENERAL

Check relief bore of coolant pump

(→ Page 168)
(→ Page 192)

WM00285

ENGINE, GENERAL

Check engine oil level

WM00286

ENGINE, GENERAL

Visually inspect engine for leaks and general condition

WM00287

ENGINE, GENERAL

Check maintenance indicator on air filter

WM00063

OIL FILTRATION/COOLING

Centrifugal oil filter, automatic: Measure thickness of oil residue layer, clean,
replace paper element; accomplish at each engine oil change at the latest

X

WM00069

LUBE OIL PUMP WITH DRIVE

Inspect pump visually

X

WM00136

ENGINE MOUNTING

Check securing screws for firm seating

X

WM00050

ENGINE MOUNTING

Check general condition of rubber mounts (visual inspection)

X

WM00086

FUEL FILTER

Replace easy-change fuel filter

WM00085

FUEL FILTER

Additional fuel filter, replace easy-change fuel filter

X

WM00170

BATTERY-CHARGING GENERA-
TOR

Check condition of belt and replace as necessary. Adjust belt tension

X

(→ Page 193)
(→ Page 195)
(→ Page 194)

WM00124

EXPANSION TANK

Replace valve cover

X

WM00076

121, 369

Replace air filter

WM00098

CYLINDER HEAD

Measure valve protrusion

WM00094

VALVE DRIVE

Check valve clearance, adjust as necessary. ATTENTION! Initial setting after
1,000 operating hours and every overhaul of cylinder heads after 1,000 operat-
ing hours

WM00119

CRANKCASE BREATHER

Replace filter or filter element

X

WM00106

CRANKCASE BREATHER

Replace oil separator

X

WM00110

CRANKCASE

Perform endoscopic examination of cylinder liner

WM00089

FUEL INJECTOR

Reset drift compensation (CDC) parameter

WM00090

FUEL INJECTOR

Replace fuel injection valve/injector

WM00040

COOLANT CIRCUIT GENERAL, IF
APPLICABLE HIGH-TEMPERA-
TURE CIRCUIT

Overhaul preheater

X

WM00189

ENGINE MOUNTING

Check general condition of resilient generator mounts (visual inspection)

X

WM00188

ENGINE MOUNTING

Check generator mount securing screws for firm seating

X

WM00216

FUEL SUPPLY SYSTEM

Check reading on vacuum gauge

X

MS15058/04E 2018-12

| Maintenance | 59

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Содержание 20V4000G44F

Страница 1: ...Operating Instructions Diesel Engine 20V4000G44F 20V4000G44LF 20V4000G94F 20V4000G94LF MS15058 04E...

Страница 2: ...er haul 30 000 h to 24 000 h 3B 8 000 h or 18 years 3D 3E Table 1 Applicability 2018 Copyright MTU Friedrichshafen GmbH This publication is protected by copyright and may not be used in any way whethe...

Страница 3: ...an enclosed area vent the exhaust to the outside x Do not modify or tamper with the exhaust system x Do not idle the engine except as necessary WA WAR W W W W W W W W W W W W W W W W W W W W W W W W W...

Страница 4: ......

Страница 5: ...monitoring 51 5 7 Emergency engine start Override mode 52 5 8 Engine Stopping in Manual mode test run 53 5 9 Emergency engine stop 55 5 10 After stopping the engine Engine remains ready for operation...

Страница 6: ...ater Overview 171 8 14 8 Preheater Overhaul 172 8 14 9 Preheater Function and leak check 173 8 14 10 Preheater Heating element and housing check 174 8 14 11 Preheater Solenoid switch replacement 177 8...

Страница 7: ...ns Emission related components must only be serviced ex changed or repaired if the components used for this purpose are approved by the manufacturer Noncompliance with these specifications will invali...

Страница 8: ...sed military applications other than by US government agen cies Please note the following when replacing components with emission labels The relevant emission labels must be affixed to the spare part...

Страница 9: ...ponents have hot surfaces e g exhaust system exhaust turbo chargers exhaust aftertreatment system engine oil system cooling system which can cause injury to per sons who approach or touch them danger...

Страница 10: ...a safe shutdown of fuel injection takes place on a diverse redundant path and thus results in engine standstill Through an ap propriate design of the engine generator set or whole plant the operator o...

Страница 11: ...lfills the conditions for such use and approval has been granted The section below applies to applications deployed in regions under the jurisdiction of the EPA Use of EPA Tier 2 and Tier 3 certified...

Страница 12: ...lified personnel only Training at the Training Center of the manufacturer Qualified personnel from the areas mechanical engineering plant construction and electrical engineering and also for work with...

Страница 13: ...battery terminals generator terminals or cables against accidental contact Check that all connections have been correctly allocated e g polarity fuel line reduction agent line supply return Immediatel...

Страница 14: ...ids and lubricants immediately or soak up with a suitable binding agent Operation of electrical equipment When electrical equipment is in operation certain components of these appliances are electrica...

Страница 15: ...e fitted Attach Do not operate sign in the operating area or to control equipment Disconnect the battery cables or actuate the battery isolating switch if fitted Lock circuit breakers Before starting...

Страница 16: ...ent contact with other components Do not place fuel or oil lines near hot components Miscellaneous Sufficient ventilation must be guaranteed during the work Wear a breathing mask offering protection a...

Страница 17: ...d the pipework at the relevant designated points For hydraulic installation screw on the jig with the piston retracted For hydraulic removal screw on the jig with the piston extended For a hydraulic i...

Страница 18: ...properly prior to replacement i e protect them against moisture in particular Package faulty electronic components or assemblies properly before dispatching for repair Moisture proof Shock proof Wrap...

Страница 19: ...Ensure that suitable extinguishing agents fire extinguishers are always available and that staff are familiar with their correct handling A fire can result in the creation of toxic substances Always w...

Страница 20: ...tands provided with fume extraction systems ensure that the area is well ventilated Make sure that neighboring work areas are not adversely affected Avoid open flames in the surrounding area No smokin...

Страница 21: ...Consequences Material damage Remedial action Additional product information Warning notices 1 This manual with all safety instructions and warning notices must be issued to all personnel involved in...

Страница 22: ...rts on engine generator 6 Raise and lower engine generator slowly Do not allow hoist slings or chains to contact engine generator or any of their component parts Adjust lifting gear as necessary 7 For...

Страница 23: ...quipment e g protective helmet safety shoes 1 Max admissible diagonal pull 10 2 Center of gravity A 1880 mm B 1434 2 mm C 12 4 mm D 1318 mm E 932 mm Take note of the engine center of gravity Refer to...

Страница 24: ...must be reinstalled on both engine sides accord ing to the instructions 3 If the engine is to be moved together with the generator the transport locking device for the generator must also be installe...

Страница 25: ...the ring gear 4 Screw in screw 1 in bores of holder 3 until holder 3 is locked in position Note Screw 1 must be tightened stepwise and alternately on both sides of the flywheel housing 5 Tighten scre...

Страница 26: ...om the guard plates and engine supports to secure them on the engine u Install engine supports 2 on both sides with guard plates 1 washers 3 and screws 4 and tighten to specified tightening torque tig...

Страница 27: ...port locking device must be installed on all resilient mounts according to the instructions before transporting Removing engine mount trans portation locks 1 Slacken nuts 2 2 Undo nut 3 and unscrew an...

Страница 28: ...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 29: ...urbocharger 3 Crankcase breather 4 Coolant pipework 5 Engine mounting 6 Charge air pipework 7 Cylinder head 8 Cylinder head cover 9 Engine Control Unit ECU 10 Starter 11 Flywheel MS15058 04E 2018 12 G...

Страница 30: ...14 HP fuel pump 15 Vibration damper 16 Coolant distribution housing 17 LT thermostat housing 18 HT thermostat housing Engine model designation Key to the engine model designation 20V4000Gx4F LF 20 Num...

Страница 31: ...erter bleeder flap 3 K39A1 K39A10 injector cylinder A1 A10 4 B34 3 fuel pressure before intermediate filter 5 B48 1 HP pressure sensor A side 6 B34 1 fuel pressure after filter 7 B9 charge air tempera...

Страница 32: ...e sensor 4 B5 1 lube oil pressure sen sor after filter 5 B1 camshaft speed sensor 6 M8 HP fuel pump restric tor 7 B54 pressure sensor lube oil replenishment pump 8 B26 charge air coolant temperature s...

Страница 33: ...expansion tank 2 XF533 HT coolant level sensor remote expansion tank 3 K39B1 K39B10 injector cylinder B1 B10 4 B48 2 HP pressure sensor B side 5 B10 charge air pressure sensor MS15058 04E 2018 12 Gene...

Страница 34: ...1 B13 crankshaft speed sen sor 1 M46 diverter bleeder flap 2 B44 exhaust turbocharger speed sensor 32 General Information MS15058 04E 2018 12 TIM ID 0000068639 004...

Страница 35: ...nce 10 Value not adequately verified tolerance 5 ID Product type Application Speed List perform ance 1 20V4000G44F Power generation 3B continuous opera tion variable load ICXN 1500 rpm 50 Hz 2807 kW 3...

Страница 36: ...500 1500 Continuous power ISO 3046 10 overload pos sible power range DIN 6280 ISO 8528 A kW 2807 2807 2807 3007 3007 3007 Site conditions for max power ID 1 2 3 4 5 6 Intake depression new filter A mb...

Страница 37: ...ction of rotation c c w facing driving end X X X X X X Number of cylinders 20 20 20 20 20 20 Cylinder arrangement V angle Degrees 90 90 90 90 90 90 Bore mm 170 170 170 170 170 170 Stroke mm 210 210 21...

Страница 38: ...it 1 L C 75 0 75 0 75 0 75 0 75 0 75 0 Coolant temperature be fore intercooler limit 2 L C 78 0 78 0 78 0 78 0 78 0 78 0 Coolant antifreeze con tent max L 50 50 0 50 50 50 50 Lube oil system ID 1 2 3...

Страница 39: ...g inclina tions L Liters 270 270 270 270 270 270 Oil pan capacity at dip stick mark max stand ard oil system option max operating inclina tions L Liters 315 315 315 315 315 315 Weights main dimensions...

Страница 40: ...ound power level Lp 1 m distance ISO 6798 2 dB A tolerance R dB A 111 111 111 109 109 109 Engine surface noise with attenuated intake noise filter DL sound power level LW ISO 6798 2 db A tolerance R d...

Страница 41: ...ation Speed List perform ance 1 20V4000G94F Power generation 3D standby power fuel stop power IFN 1500 rpm 50 Hz 3088 kW 4141 bhp Ref 25 C 45 C EPA Nonroad T2 Com pliant 2 20V4000G94F Power generation...

Страница 42: ...0 30 30 30 Exhaust gas overpressure A mbar 30 30 30 Exhaust gas overpressure total pressure referenced to atmosphere A mbar 30 30 30 30 30 30 Exhaust gas overpres sure max total pressure referenced to...

Страница 43: ...4 77 4 77 Total displacement Liters 95 4 95 4 95 4 95 4 95 4 95 4 Compression ratio 16 4 16 4 16 4 16 4 16 4 16 4 Air exhaust gas ID 1 2 3 4 5 6 Combustion air volumet ric flow BL R m s 4 5 4 3 4 5 4...

Страница 44: ...ic L rpm 1613 1613 1613 1613 1613 1613 Limit speed for overspeed message emergency shutdown L rpm 1950 1950 1950 1950 1950 1950 Limit speed for overspeed message L rpm 1950 1950 1950 1950 1950 1950 Fi...

Страница 45: ...0050 10050 10050 10050 10050 10050 Acoustics ID 1 2 3 4 5 6 Exhaust noise unsilenced BL free field sound pressure level Lp 1 m distance ISO 6798 3 dB A tolerance R dB A 121 120 121 122 121 122 Exhaust...

Страница 46: ...4 3 Firing order Number of cylinders Firing order 20V A1 B5 A8 B7 A5 B2 A7 B10 A2 B3 A10 B6 A3 B4 A6 B9 A4 B1 A9 B8 44 Technical Data MS15058 04E 2018 12 TIM ID 0000035068 003...

Страница 47: ...4 4 Engine Main dimensions Engine model Length A Width B Height C 20V4000Gx4F LF 3478 3 mm 1699 2 mm 2251 9 mm MS15058 04E 2018 12 Technical Data 45 TIM ID 0000068643 003...

Страница 48: ...econds at a pressure of at least 0 3 bar Only for engines without oil priming pump Crank engine on starting system without injecting fuel Page 90 Fuel prefilter Fill with fuel Page 136 Page 138 Fuel p...

Страница 49: ...circuit Check engine coolant level Page 160 Check charge air coolant level Page 183 Coolant circuit Heat engine coolant with coolant preheater Fuel prefilter Drain water Page 129 Page 131 Monitoring...

Страница 50: ...dentified or eliminated contact Service Preparation Item Action Operating mode switch if fitted Change to manual mode Preheating pump if fitted Switch on Starting the engine Item Action Control cabine...

Страница 51: ...ified or eliminated contact Service Note If an engine has been shutdown by a fault red alarm the engine may only be re started when the fault has been identified and eliminated Procedure following an...

Страница 52: ...when a pushbutton is provided Safety system Override Item Action Switchgear cabinet control panel etc depending on manufacturer Activate pushbutton for Override input of the ECU Certain shutdown crit...

Страница 53: ...arger turbine housings may be red hot If the maximum exhaust temperatures are not exceeded no restrictions in en gine operation are required Check for abnormal running noises and vibration Fuel prefil...

Страница 54: ...ms will be disregarded Severe material damage Initiate emergency start only in emergency situations Preparation Item Action Operating mode selector switch Change to Override mode Manual mode if applic...

Страница 55: ...to extreme thermal and mechanical stress es Overheating of and therefore damage to components is possible Before shutting down the engine allow it to idle until the engine temperatures decrease and co...

Страница 56: ...After engine shutdown Item Action Coolant circulating pump Allow to run on for sufficient time after stopping 54 Operation MS15058 04E 2018 12 TIM ID 0000002285 006...

Страница 57: ...subjects the engine system to an extremely high load Risk of overheating damage to components Trigger an emergency stop only in emergency situations Emergency engine stop Item Action Emergency stop pu...

Страница 58: ...he engine Engine remains ready for operation After stopping the engine Item Action Engine generator pump control Select operating mode e g MANUAL AUTOMATIC OPERATION 56 Operation MS15058 04E 2018 12 T...

Страница 59: ...to the coolant the engine room is not heated the coolant is not kept at a suitable temperature the antifreeze concentration is insufficient for the engine room tempera ture antifreeze concentration is...

Страница 60: ...r gun directly at seals or electronic components such as connectors or ECUs Cleaning the plant 1 Carry out plant cleaning only in areas where an appropriate oil separator is provided environmental pro...

Страница 61: ...engine oil change at the latest X Page 158 WM00069 LUBE OIL PUMP WITH DRIVE Inspect pump visually X Page 156 WM00136 ENGINE MOUNTING Check securing screws for firm seating X Page 197 WM00050 ENGINE MO...

Страница 62: ...Page 129 Page 131 WM00214 FUEL SUPPLY SYSTEM Replace filter element X Page 136 Page 138 WM00228 FUEL PIPEWORK FROM PUMP TO FILTER Check cooler elements for external contamination and leak tightness X...

Страница 63: ...inspection manufacturer s documentation Engine governor Plug in connections loose u Check plug in connections Page 207 Running gear blocked engine cannot be barred manually u Contact Service Engine tu...

Страница 64: ...ure too high Cause Corrective action Engine coolant treatment incorrect u Check MTU test kit Intercooler dirty u Contact Service Engine room Air intake temperature too high u Check fans and intake exh...

Страница 65: ...ngs or cylinder liner defective u Contact Service White exhaust gas Cause Corrective action Engine is not at operating temperature u Run engine to reach operating temperature Water in fuel u Check fue...

Страница 66: ...2 Check fuel recooling system if applicable 3 Contact Service 5 HI T Charge Air Cause Corrective action The charge air temperature at sensor B9 has violated limit value 1 Charge air temperature is too...

Страница 67: ...e lube oil pressure is too low 1 Check engine oil level Page 153 2 Contact Service 23 LO Coolant Level Cause Corrective action Coolant level in HT circuit at switch B533 is too low 1 Check engine cool...

Страница 68: ...too high Cause Fault or malfunction of another exhaust turbocharger 1 Reduce power 2 Contact Service 32 SS ETC1 Overspeed Cause Corrective action The speed of the A side LP turbocharger at sensor B44...

Страница 69: ...l Page 160 3 Contact Service 59 SS T Coolant L3 Cause Corrective action The coolant temperature at sensor B6 has violated limit value 3 Coolant temperature is too high 1 Check operation of cooler and...

Страница 70: ...lant side 3 Check engine coolant level Page 160 4 Contact Service 68 SS T Coolant Cause Corrective action The coolant temperature at sensor B6 has violated limit value 2 Coolant temperature is too hig...

Страница 71: ...e 92 SS Starter Speed Not Reached Cause Corrective action Engine speed has not reached the specified speed threshold within the specified time 1 Check pressure supply plant of starter 2 Check for addi...

Страница 72: ...e 207 3 Check battery charging generator 4 Contact Service 321 AL Wiring Cylinder A1 Cause Corrective action Short circuit fault in the injector wiring for cylinder A1 or injector faulty 1 Check wirin...

Страница 73: ...rrective action Short circuit fault in the injector wiring for cylinder A8 or injector faulty 1 Check wiring of affected injector Page 196 2 Replace injector Page 110 3 Contact Service 329 AL Wiring C...

Страница 74: ...ve action Short circuit fault in the injector wiring for cylinder B5 or injector faulty 1 Check wiring of affected injector Page 196 2 Replace injector Page 110 3 Contact Service 336 AL Wiring Cylinde...

Страница 75: ...ion Disruption fault in injector wiring for cylinder A2 1 Check wiring of affected injector Page 196 2 Contact Service 343 AL Open Load Cylinder A3 Cause Corrective action Disruption fault in injector...

Страница 76: ...nder A10 1 Check wiring of affected injector Page 196 2 Contact Service 351 AL Open Load Cylinder B1 Cause Corrective action Disruption fault in injector wiring to cylinder B1 1 Check wiring of affect...

Страница 77: ...oad Cylinder B9 Cause Corrective action Disruption fault in injector wiring to cylinder B9 1 Check wiring of affected injector Page 196 2 Contact Service 360 AL Open Load Cylinder B10 Cause Corrective...

Страница 78: ...can not be activated 1 Check engine cabling Page 196 2 Contact Service 608 AL Wiring PWM_CM6 Cause Corrective action Open circuit or short circuit in wiring to fan oil priming pump M2 1 Check engine...

Страница 79: ...e critical upper limit value 1 Check sensor B33 replace if required 2 Contact Service 833 AL Emission Warning Cause Corrective action Emission fault summary alarm 1 Check for additional messages 2 Con...

Страница 80: ...r within the set time u Contact Service 956 AL p5 ctrlvar limit min active Cause Corrective action The charge air pressure regulator attempts to adjust its set value but has reached its lower limit Th...

Страница 81: ...on reached its maximum drift limit u Schedule an injector replacement 1035 AL Inj Drift Limit 1 Cyl A4 Cause Corrective action The drift correction for energization start and duration of injector A4 h...

Страница 82: ...n reached its maximum drift limit u Schedule an injector replacement 1041 AL Inj Drift Limit 1 Cyl A10 Cause Corrective action The drift correction for energization start and duration of injector A10...

Страница 83: ...on reached its maximum drift limit u Schedule an injector replacement 1047 AL Inj Drift Limit 1 Cyl B6 Cause Corrective action The drift correction for energization start and duration of injector B6 h...

Страница 84: ...mit 2 The injector has reached its maximum drift limit u Replace injector Page 110 1053 AL Inj Drift Limit 2 Cyl A2 Cause Corrective action The drift correction for energization start and duration of...

Страница 85: ...has reached its maximum drift limit u Replace injector Page 110 1059 AL Inj Drift Limit 2 Cyl A8 Cause Corrective action The drift correction for energization start and duration of injector A8 has vio...

Страница 86: ...ector has reached its maximum drift limit u Replace injector Page 110 1065 AL Inj Drift Limit 2 Cyl B4 Cause Corrective action The drift correction for energization start and duration of injector B4 h...

Страница 87: ...9 has violated limit 2 The injector has soon reached its maximum drift limit u Replace injector Page 110 1071 AL Inj Drift Limit 2 Cyl B10 Cause Corrective action The drift correction for energization...

Страница 88: ...ons too high The NOx emissions from the engine have violated limit value 2 cumulatively u Contact Service 1173 AL Implausible NOx Low Limit2 Cause Corrective action NOx emissions too low Cumulative NO...

Страница 89: ...de 2 Check plug connections to Engine Control Unit Page 207 3 Contact Service 1377 AL Refdrive Impossibl Eng Op Point Cause Corrective action Homing of one or more flaps before engine start was not co...

Страница 90: ...tchet 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 with starter system make sure...

Страница 91: ...sistance other than compression resist ance must be encountered 4 Rotate crankshaft in engine direction of rota tion Result If the resistance exceeds the normal com pression resistance contact Service...

Страница 92: ...age 46 Before starting the engine in a contingency situation to maintain operation of a leaking intercooler Page 143 Cranking engine on starting system Note The engine must not start and no fuel may b...

Страница 93: ...poisoning and suffocation Keep the engine room well ventilated at all times Repair leaking exhaust pipework immediately WARNING A high level of noise is produced when the engine is running Risk of hea...

Страница 94: ...n 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 low...

Страница 95: ...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 96: ...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 may be interru...

Страница 97: ...ks are similar A thorough investigation and compliance with the above evaluation criteria allow an unambiguous evaluation To avoid unnecessary disassembly work it is recommended that another inspectio...

Страница 98: ...substances which are harmful to health Risk of injury and poisoning Allow the product to cool to below 50 C before beginning work Wear protective clothing protective gloves and goggles safety mask Av...

Страница 99: ...s hot Oil can contain residue substances which are harmful to health Risk of injury and poisoning Allow the product to cool to below 50 C before beginning work Wear protective clothing protective glov...

Страница 100: ...ing ring and cover 1 10 Screw on new nut 2 with new washers and use torque wrench to tighten nut 2 to specified tightening torque Name Size Type Lubricant Value Standard Nut Tightening torque 10 Nm 2...

Страница 101: ...0 mm Y20000918 1 Measuring jig 2 optional Y4350010 1 Preparatory steps 1 Remove cylinder head covers Page 107 2 Remove guard plate and install barring tool Page 88 3 Turn crankshaft in direction of ro...

Страница 102: ...r head 3 4 Turn measuring unit screws 1 into the threads provided for the cylinder head cover and tighten to specified torque using a torque wrench Name Size Type Lubricant Value Standard Screw M10 Ti...

Страница 103: ...sured value is 95 8 mm 5 Install valve bridge 6 Adjust valve clearance Page 104 Step 2 optional Measure valve protrusion at the valve stem with measuring jig 2 1 Check TDC position of piston in cylind...

Страница 104: ...bricant Value Standard Screw M10 Tightening torque 20 Nm 6 Determine the values with all dial gages The valve protrusion value must be 2 mm Have the affected cylinder head replaced by expert personnel...

Страница 105: ...rts Designation Use Part No Qty Engine oil Valve gear Lubrication 1 Remove cylinder head covers Page 107 2 Fill oil chambers of valve bridges with oil 3 Fill oil chambers of rocker arms and adjusting...

Страница 106: ...320 Nm F30452768 1 Socket wrench 24 mm F30039526 1 Ratchet bit F30027341 1 Engine oil Preparatory steps 1 Remove cylinder head cover Page 107 2 Install barring device Page 88 Note Pointer 1 is locate...

Страница 107: ...re under load on cylinder A1 the piston is in overlap TDC 2 Check valve clearance with cold engine Inlet valves long rocker arm 0 2 mm 0 05 mm Exhaust valves short rocker arm 0 5 0 05 mm 3 Check all v...

Страница 108: ...t pass through the gap 4 Pull feeler gauge 3 between valve bridge and rocker arm Note Hold adjusting screw 2 firmly in position 5 Tighten lock nut 1 to specified tightening torque using a torque wrenc...

Страница 109: ...3 4 with washers 2 5 3 Take off cylinder head cover with O ring 6 from cylinder head 7 Installing cylinder head cover 1 Clean installation surface 2 Check O ring 6 for damage replace as necessary 3 Co...

Страница 110: ...y through swallowing risk of poisoning through inhalation irritation to eyes and skin Seek medical attention immediately do not induce vomiting Do not inhale vapors or mist Wear protective clothing pr...

Страница 111: ...box 2 Use fuel suction device to fill HP pump with 2 liters of clean engine oil 3 Screw in union 1 and use torque wrench to tighten to specified tightening torque Name Size Type Lubricant Value Standa...

Страница 112: ...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 117 110 Injector MS15058 04E 20...

Страница 113: ...plosion Avoid open flames electrical sparks and ignition sources Do not smoke Wear protective clothing protective gloves and safety glasses facial protection WARNING Liquid or gaseous media e g fuel a...

Страница 114: ...tion of components Damage to component Observe manufacturer s instructions Check components for special cleanliness Nameplate u The nameplate contains the following infor mation 1 DMC Data Matrix Code...

Страница 115: ...1 5 Install installation removal jig on the cylinder head 6 Remove injector with installation removal jig 7 Remove the installation removal jig 8 Remove sealing ring 4 from injector or use a self made...

Страница 116: ...Note Only remove plug from injector just before assembling the adapter 2 Remove plug 3 Clean sealing face on cylinder head and pro tective sleeve by removing carbon deposits with a milling cutter 4 F...

Страница 117: ...me Size Type Lubricant Value Standard Screw M12 Tightening torque Engine oil 100 Nm 10 Nm 17 Use a torque wrench and long socket to tighten adapter 3 to specified tightening torque Name Size Type Lubr...

Страница 118: ...not reset drift correction CDC after re in stalling a used injector 23 After fitting new injectors Page 117 Final steps 1 Install cylinder head cover Page 107 2 Open fuel supply to engine 116 Injector...

Страница 119: ...ia e g fuel or ether Risk of fatal injury through swallowing risk of poisoning through inhalation irritation to eyes and skin Seek medical attention immediately do not induce vomiting Do not inhale va...

Страница 120: ...MC Data Matrix Code 2 L Orange part number 3 MTU part number 4 IIG code Initial Injector Equalization 5 EMI ID code 6 Serial number 7 Date of manufacture Preparatory steps 1 Allow HP system to cool do...

Страница 121: ...6 Install installation removal jig on the cylinder head 7 Remove injector with installation removal jig 8 Remove the installation removal jig 9 Remove sealing ring 2 from injector 1 or use a self made...

Страница 122: ...ylinder head and pro tective sleeve by removing carbon deposits with a milling cutter 4 Coat damper ring 2 with Assembly com pound Molykote P 37 5 Coat O rings 3 and 5 with Assembly com pound Kluthe H...

Страница 123: ...pe Lubricant Value Standard Screw M12 Tightening torque Engine oil 100 Nm 10 Nm 17 Use a torque wrench and long socket to tighten adapter 3 to specified tightening torque Name Size Type Lubricant Valu...

Страница 124: ...eset the emission certification becomes invalid u Reset drift compensation CDC using DiaSys and enter injector code IIG Dialog system DiaSys E531920 If DiaSys is not available contact Service Final st...

Страница 125: ...e g fuel are poisonous Escaping vapors of highly volatile media e g fuel or ether Risk of fatal injury through swallowing risk of poisoning through inhalation irritation to eyes and skin Seek medical...

Страница 126: ...vent screw to specified tightening torque Name Size Type Lubricant Value Standard Screw A F9 Tightening torque 6 Nm 2 Nm 6 Continue to operate the pump until resistance is noticeable at least 50 time...

Страница 127: ...h swallowing risk of poisoning through inhalation irritation to eyes and skin Seek medical attention immediately do not induce vomiting Do not inhale vapors or smoke Wear protective clothing protectiv...

Страница 128: ...ing risk of poisoning through inhalation irritation to eyes and skin Seek medical attention immediately do not induce vomiting Do not inhale vapors or smoke Wear protective clothing protective gloves...

Страница 129: ...engine room well ventilated at all times Pressure ratios Note If the fuel prefilter is above the full level of the fuel tank during engine operation the fuel pressure in the filter is lower than ambi...

Страница 130: ...to heavy duty fuel prefilters Fuel prefilter non switchable u Drain water and contaminants from fuel prefilter Page 129 Fuel prefilter switchable u Drain water and contaminants from fuel prefilter Pag...

Страница 131: ...engine room well ventilated at all times WARNING Exhaust gases are harmful to health and may cause cancer Risk of poisoning and suffocation Keep the engine room well ventilated at all times Repair lea...

Страница 132: ...Vent fuel prefilter Page 141 Draining fuel prefilter in case of high pressure version B Note The fuel prefilter can be drained during engine operation or with the engine at a standstill 1 Provide a s...

Страница 133: ...d soap Keep the engine room well ventilated at all times WARNING Exhaust gases are harmful to health and may cause cancer Risk of poisoning and suffocation Keep the engine room well ventilated at all...

Страница 134: ...ilter module 2 is cut out 3 Open threaded vent plug 1 of filter to be serviced 4 Open drain plug 1 5 Allow water to drain until fuel emerges 6 Close drain plug 2 again 7 Drain the second filter on the...

Страница 135: ...chover during engine operation and at engine stand still 1 Provide a suitable container to collect the water 2 Take care when opening drain plug 1 be cause fuel or water can spurt out 3 Allow water to...

Страница 136: ...eading at low pressure gauge 3 Red zone 1 1 0 bar to 0 4 bar low pressure Green zone 2 0 4 bar to 0 5 bar nor mal operation 2 Switch over the fuel prefilter or replace a fil ter element Page 138 when...

Страница 137: ...riptions also apply to heavy duty fuel prefilters Fuel prefilter non switchable u Fuel prefilter replace filter element Page 136 Fuel prefilter switchable u Fuel prefilter replace filter element Page...

Страница 138: ...tion to eyes and skin Seek medical attention immediately do not induce vomiting Do not inhale vapors or smoke Wear protective clothing protective gloves and safety glasses If contact is made with skin...

Страница 139: ...element 3 from filter housing 4 7 Unclip filter element 3 from filter cover 1 8 Install new O ring 2 on filter cover 1 9 Coat new O rings on filter cover and filter ele ment with fuel 10 Clip new filt...

Страница 140: ...yes and skin Seek medical attention immediately do not induce vomiting Do not inhale vapors or smoke Wear protective clothing protective gloves and safety glasses If contact is made with skin wash off...

Страница 141: ...is opened absolute cleanness is imperative Carefully extract the filter element straight up avoiding contact with the upper edge of the cylinder if at all possible to prevent contamination of the fuel...

Страница 142: ...ible to prevent contamination of the fuel remaining in the filter housing 6 Unscrew filter cover 1 and withdraw with fil ter element 3 from filter housing 4 7 Unclip filter element 3 from filter cover...

Страница 143: ...well ventilated at all times WARNING Exhaust gases are harmful to health and may cause cancer Risk of poisoning and suffocation Keep the engine room well ventilated at all times Repair leaking exhaust...

Страница 144: ...eaded vent plugs 2 3 Note Never actuate the handle with the threaded vent plugs closed 5 Move handle 1 of fuel priming pump back and screw in 6 Close threaded vent plugs 2 3 and tighten by hand Ventin...

Страница 145: ...direct air jet at people Always wear safety goggles face mask and hearing protection Intercooler Checking conden sate drain for coolant leak and obstruction 1 With the engine running verify that air e...

Страница 146: ...Material Spare parts Designation Use Part No Qty Air filter Spare Parts Catalog Air filter Replacement 1 Remove air filter and install new one Page 146 2 Reset signal ring of service indicator Page 1...

Страница 147: ...l Spare parts Designation Use Part No Qty Air filter Spare Parts Catalog Checking air filter 1 Check entire circumference of air filter for damage 2 Fit new air filter if damaged Page 144 MS15058 04E...

Страница 148: ...otective gloves safety goggles respiratory protection etc is to be used NOTICE Stepping or climbing on the genset to perform installation tasks is to be avoided Otherwise there is a risk of component...

Страница 149: ...the equipment always use suitable ladders or work platforms Use personal protective equipment WARNING Heavy part risk of falling or overturning due to lack of stability Risk of crushing body or limbs...

Страница 150: ...Remove cover 2 3 Remove filter insert 3 and filter element 4 4 Wipe out filter housing 5 and cover 2 with a damp cloth 5 Insert new filter element 4 and filter in sert 3 6 Assemble in reverse order 14...

Страница 151: ...rting disabled Checking signal ring position 1 When the yellow piston 2 has reached the red shaded Service lettering 3 replace air filter Page 144 2 After installation of new filter press reset button...

Страница 152: ...the product to cool to below 50 C before beginning work Wear protective clothing protective gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor NOTICE Inadequate oil pressu...

Страница 153: ...th un scheduled engine oil change 1 Provide a suitable container in which to col lect the engine oil 2 Remove drain plug 1 and drain engine oil from engine oil heat exchanger and from en gine oil filt...

Страница 154: ...ck engine oil level Page 153 Note Observe the following instructions to avoid engine damage Adequate oil pressure for an engine start is only provided when the quick start function is deactivated 5 Ma...

Страница 155: ...o 2 cm above mark 1 This may be caused e g by oil from oil filters and heat ex changers flowing back into the oil pan After extended standstill the oil level 2 cm above mark 2 is the minimum oil level...

Страница 156: ...t inhale oil vapor WARNING Exhaust gases are harmful to health and may cause cancer Risk of poisoning and suffocation Keep the engine room well ventilated at all times Repair leaking exhaust pipework...

Страница 157: ...the oil sludge 3 Drain approx 1 liter engine oil into a clean container 4 Close screw 1 and tighten to specified tightening torque Name Size Type Lubricant Value Standard Screw Tightening torque Engin...

Страница 158: ...ect oil priming pump and connections for firm seating and leaks Retighten loose threaded connections as necessary 2 Check leak telltale bore 2 for oil discharge Result If oil emerges the gear pump 1 u...

Страница 159: ...ick start function is deactivated before starting the engine For engines with lube oil priming pump Prime the engine for 20 seconds at a pressure of at least 0 3 bar Engine oil filter Replacement 1 Re...

Страница 160: ...k Avoid contact with skin Do not inhale oil vapor WARNING Compressed air gun ejects a jet of pressurized air Risk of injury to eyes and damage to hearing risk of rupturing internal organs Never direct...

Страница 161: ...eal ing ring 4 in rotor cover 3 Note Do not clamp rotor unit in a bench vise Use an oil filter wrench 5 Screw on rotor cover 3 by turning at hexa gon 6 Tighten rotor cover 3 with torque wrench to spec...

Страница 162: ...nd goggles safety mask Checking coolant level at re mote cooler 1 Check coolant level coolant must be visible at marking plate 2 Top up with treated coolant as necessary Page 164 3 Check and clean bre...

Страница 163: ...Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 162 2 Fill with engine coolant Page 164 MS15058 04E 2018 12 Coolant Circuit General High Tem...

Страница 164: ...les safety mask Wipe up escaped spilled coolant immediately Preparatory steps 1 Provide a suitable container to catch the coolant 2 Switch off preheater Draining engine coolant 1 Turn valve cover of c...

Страница 165: ...2 Close all other open drain points 3 Position valve cover on filler neck and close MS15058 04E 2018 12 Coolant Circuit General High Temperature Circuit 163 TIM ID 0000000960 005...

Страница 166: ...gloves and goggles safety mask WARNING A high level of noise is produced when the engine is running Risk of hearing loss Wear suitable hearing protection WARNING Coolant contains antifreeze and is to...

Страница 167: ...he first stop and release pressure 2 Continue to turn valve cover 1 counter clockwise and remove Variant 1 Filling with coolant from below using a pump 1 Open venting point on distributor arrow MS1505...

Страница 168: ...aces if required 8 Fit valve cover and close it 9 Start engine Page 48 10 After 10 seconds of running the engine with out load shut down the engine Page 53 11 Turn valve cover of coolant expansion tan...

Страница 169: ...tank counterclockwise to the first stop and allow pressure to escape 9 Turn valve cover 1 counterclockwise and re move 10 Check coolant level Page 160 and top up with coolant through the filler neck...

Страница 170: ...p the engine room well ventilated at all times Repair leaking exhaust pipework immediately WARNING A high level of noise is produced when the engine is running Risk of hearing loss Wear suitable heari...

Страница 171: ...RNING Coolant contains antifreeze and is toxic Risk of poisoning and slipping Avoid contact with eyes and skin Do not inhale vapors or mist wear breathing protection Do not eat drink smoke when workin...

Страница 172: ...Nm 5 Using the equipment and chemicals from the MTU test kit examine coolant for antifreeze concentration Amount of corrosion protection oil pH value 6 For engine coolant change intervals refer to MT...

Страница 173: ...t 6 Intake 7 Safety thermostat 8 Housing cover 9 Pump Arrow Flow direction Variant Heating output Rated voltage Frequency Phases 1 9 kW 400 V 50 Hz 3 2 9 kW 480 V 60 Hz 3 3 12 kW 400 V 50 Hz 3 4 12 kW...

Страница 174: ...onnected Replacing solenoid switch u Replace solenoid switch Page 177 Cleaning heating element and replacing gasket u Clean heating element and housing and check Page 174 Replacing thermostat u Replac...

Страница 175: ...protection Function check Note The preheater operates properly if the measured value of the coolant temperature is within the control range of the thermostat 1 Check coolant preheating temperature 2 C...

Страница 176: ...ssure Risk of injury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask WARNING Coolant contains antifreeze and is toxic Risk of poisoning and slipping Avoid...

Страница 177: ...d or new heating element into housing 7 Install electrical part 2 and tighten screws 1 Installing coolant lines 1 Clean drain plug and screw in thread arrow at preheater 2 Coat drain plug with screw l...

Страница 178: ...Final steps 1 Connect preheater power sources 2 Switch on preheater 176 Coolant Circuit General High Temperature Circuit MS15058 04E 2018 12 TIM ID 0000081913 004...

Страница 179: ...jury and scalding Let the engine cool down Wear protective clothing gloves and goggles safety mask WARNING Hot components surfaces Risk of burns Allow the engine to cool down to below 50 C before begi...

Страница 180: ...noid switch off the rail 5 Fit a new solenoid switch on the rail and fully engage the spring clip 6 Connect up all wires as marked previously 7 Close the control box and tighten the screws Final steps...

Страница 181: ...es Risk of burns Allow the engine to cool down to below 50 C before beginning work Wear suitable protective equipment thermal gloves Avoid unprotected contact with hot surfaces WARNING Coolant is hot...

Страница 182: ...e 8 Fit cover and tighten screws Replacing control thermostat 1 Undo screws 1 on housing cover 2 of con trol thermostat and remove cover 2 Mark cables prior to disconnection 3 Disconnect wires 4 Remov...

Страница 183: ...Final steps 1 Connect preheater to power supply 2 Switch on preheater MS15058 04E 2018 12 Coolant Circuit General High Temperature Circuit 181 TIM ID 0000081762 002...

Страница 184: ...ety mask Preparatory steps u Switch off preheater Replacing valve cover Note Schematic diagram Design may deviate 1 Turn valve cover 1 on coolant expansion tank counterclockwise until the first stop a...

Страница 185: ...and slipping Avoid contact with eyes and skin Do not inhale vapors or mist wear breathing protection Do not eat drink smoke when working with antifreeze Wear protective clothing protective gloves and...

Страница 186: ...rge air coolant level is monitored automatically by the engine control system 1 Switch on engine control system and check readings on the display 2 Top up with charge air coolant as necessary Page 188...

Страница 187: ...al tools Material Spare parts Designation Use Part No Qty Coolant Charge air coolant Change 1 Drain charge air coolant Page 186 2 Fill with charge air coolant Page 188 MS15058 04E 2018 12 Low Temperat...

Страница 188: ...th eyes and skin Do not inhale vapors or mist wear breathing protection Do not eat drink smoke when working with antifreeze Wear protective clothing protective gloves and goggles safety mask Wipe up e...

Страница 189: ...a torque wrench Name Size Type Lubricant Value Standard Spindle 11 A F Tightening torque 12 Nm 9 Close the remaining drain valves and screw in drain plugs with new sealing rings 10 Fit valve cover on...

Страница 190: ...rotective clothing gloves and goggles safety mask WARNING A high level of noise is produced when the engine is running Risk of hearing loss Wear suitable hearing protection WARNING Coolant contains an...

Страница 191: ...move Variant 1 Filling coolant with pump 1 Connect suitable pump with hose to drain valve 1 2 Loosen vent line union at distributor 1 3 Open drain valve and pump coolant into en gine at 0 5 bar minimu...

Страница 192: ...Check coolant level Page 183 and top up coolant as required a Fill in coolant in expansion tank until the coolant level at top edge of filler neck re mains constant b Fit valve cover on filler neck a...

Страница 193: ...scape 10 Turn valve cover counterclockwise and re move 11 Check coolant level Page 183 and top up with coolant through the filler neck if re quired a Fill in coolant in expansion tank until the coolan...

Страница 194: ...cation Keep the engine room well ventilated at all times Repair leaking exhaust pipework immediately WARNING A high level of noise is produced when the engine is running Risk of hearing loss Wear suit...

Страница 195: ...onents Never operate the engine without protective covers or safety guards which meet applicable accident prevention regulations Ensure that the safety guards can prevent body parts from being drawn i...

Страница 196: ...tensioner spring is pretensioned Risk of hands being crushed Lock belt tensioner in position Only use specified tools and devices Adjusting belt tension 1 Slacken screws 1 and 2 by half a turn Result...

Страница 197: ...belt replacement 1 Remove protective cover 2 Loosen screws 2 and 3 by half a turn 3 Mount socket or box wrench on screw 1 and press belt tensioner in direction of arrow as far as the stop 4 Tighten s...

Страница 198: ...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 199: ...re tight 2 Use a torque wrench to tighten loose screw connections 1 to specified tightening torque Name Size Type Lubricant Value Standard Screw M20 Control torque Engine oil 500 Nm 50 Nm 3 Use a torq...

Страница 200: ...fied tightening torque Name Size Type Lubricant Value Standard Screw M20 Control torque Engine oil 500 Nm 50 Nm 3 Use a torque wrench to tighten loose screw connections 3 to specified tightening torqu...

Страница 201: ...tion of the mounts Cover engine mounts when working with fuel or oil Remove contaminations on the rubber mounts immediately with a dry cloth and degrease them Engine mounting Check Item Findings Actio...

Страница 202: ...crew firm seating check Preconditions Engine is stopped and starting disabled Generator mounting securing screw firm seating check 1 Check securing screws for firm seating 2 Tighten loose screws 200 G...

Страница 203: ...well Risk of shorter service life or destruction of the mounts Cover engine mounts when working with fuel or oil Remove contaminations on the rubber mounts immediately with a dry cloth and degrease th...

Страница 204: ...aping vapors of highly volatile media e g fuel or ether Risk of fatal injury through swallowing risk of poisoning through inhalation irritation to eyes and skin Seek medical attention immediately do n...

Страница 205: ...on to eyes and skin Seek medical attention immediately do not induce vomiting Do not inhale vapors or smoke Wear protective clothing protective gloves and safety glasses If contact is made with skin w...

Страница 206: ...To avoid damage to cooling elements only aim water jet parallel to the cooling fins applying moderate pressure To improve the cleaning effect add a suitable degreasing agent to the water in accordance...

Страница 207: ...rameters CDC if not reset Parameters for drift correction CDC Resetting with DiaSys 1 Use DiaSys to reset the CDC parameters Dialog system DiaSys E531920 2 If no DiaSys is available contact Service En...

Страница 208: ...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 209: ...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 210: ...1 Note or mark assignment of cables and plugs 2 Remove all screws 2 3 Undo clips 3 on connectors 4 Remove all male connectors 5 Remove screws 1 6 Take off engine governor Installing engine governor on...

Страница 211: ...level sensor Monitors coolant level CM Current Measurement Current measured value CPS Coolant pressure sensor Monitors coolant pressure CR Common Rail CTS Coolant temperature sensor Monitors coolant t...

Страница 212: ...t HIHI High High Alarm Measured value exceeds 2nd maximum limit HT High Temperature IDM Interface Data Module Memory module for interface data IIG Initial injector equalization Initial input of inject...

Страница 213: ...p 1st function Warning lamp stop engine and rectify fault 2nd function Read out fault codes SID System Identifier SPC Spare Parts Catalog SRS Synchronous Reference Sensor TDC cylinder 1 SS Safety Syst...

Страница 214: ...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 215: ...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 216: ...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 217: ...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 218: ...trength class 8 8 surface condition bare phosphatized or galvanized and 10 9 surface condition bare or phosphatized The values in the table are based on a friction coefficient tot 0 125 Threads and ma...

Страница 219: ...to Steel M A Nm Gray cast iron MA Nm AI 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 stainle...

Страница 220: ...le are 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...

Страница 221: ...n when tightening MA tightening torques Tightening torques for plug screws as per MTN 5183 1 standard This standard applies to plug screws to DIN 908 DIN 910 and DIN 7604 with threaded end to DIN 3852...

Страница 222: ...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 223: ...Steel gray cast iron M A Nm AI 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 torque for banjo screws...

Страница 224: ...iations 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 M16 x 1 5 25...

Страница 225: ...ng and 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 unavoidab...

Страница 226: ...tening the 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...

Страница 227: ...ew in valves see ISO 6149 47 and ISO 7789 Tightening torques for screwed plugs with O ring as per 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...

Страница 228: ...to ORFS 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 metallic sealing with...

Страница 229: ...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 230: ...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 30 228 Appendix...

Страница 231: ...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 232: ...Engine Barring manually Page 88 Qty Used in 1 8 2 1 Cylinder liner Endoscopic examination Page 92 Crossbeam Part No T80091826 Qty Used in 1 2 1 Transport Page 20 Crossbeam Part No T80092360 Qty Used i...

Страница 233: ...tion Page 92 Feeler gage Part No Y20098771 Qty Used in 1 8 4 3 Valve clearance Check and adjustment Page 104 Filter wrench Part No F30379104 Qty Used in 1 8 8 1 Fuel filter Replacement Page 125 Qty Us...

Страница 234: ...in 1 5 12 Plant Cleaning Page 58 Installation removal jig Part No F6789889 Qty Used in 1 8 6 2 Injector rings Replacement Page 111 Qty Used in 1 8 6 3 Injector Removal and installation Page 117 Measur...

Страница 235: ...njector Removal and installation Page 117 MTU test kit Part No F6798833 Qty Used in 1 8 12 3 Engine oil Sample extraction and analysis Page 154 Qty Used in 1 8 14 6 Engine coolant Sample extraction an...

Страница 236: ...8 18 1 Engine mounting Checking securing screws for firm seating Page 197 Ratchet bit Part No F30027340 Qty Used in 1 8 6 2 Injector rings Replacement Page 111 Qty Used in 1 8 6 3 Injector Removal an...

Страница 237: ...ination Page 92 Socket wrench 24 mm Part No F30039526 Qty Used in 1 8 4 3 Valve clearance Check and adjustment Page 104 Torque screwdriver 1 5 Nm Part No F30452774 Qty Used in 1 8 6 2 Injector rings R...

Страница 238: ...sed in 1 8 13 2 Centrifugal oil filter Cleaning and filter sleeve re placement Page 158 Qty Used in 1 8 16 2 Battery charging generator Drive belt tension ad justment Page 194 Qty Used in 1 8 16 3 Bat...

Страница 239: ...y Used in 1 8 12 1 Engine oil Change Page 150 Qty Used in 1 8 13 2 Centrifugal oil filter Cleaning and filter sleeve re placement Page 158 Qty Used in 1 8 16 2 Battery charging generator Drive belt te...

Страница 240: ...over replacement 182 Crankcase breather Filter element replacement 97 Oil mist separator Replacement 96 Crankshaft Transport locking device Installation removal 22 Cylinder Designation 26 Cylinder hea...

Страница 241: ...on switchable 136 Switchable 138 Low pressure indicator check Switchable 134 Pressure ratios 127 Venting 141 Fuel system Venting 123 G Generator mounting Check 201 Securing screw firm seating check 20...

Страница 242: ...art up 11 Maintenance work 13 Operation 11 Organizational requirements 10 Personnel requirements 10 Repair work 13 Safety requirements Functional safety 7 Warning notices standards 19 Safety system Ov...

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