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1 Safety

1.1 Important provisions for all products

Nameplate

The product is identified by nameplate, model designation or serial number and must match with the infor-
mation on the title page of this manual.

Nameplate, model designation or serial number can be found on the product.

All EU-certified engines delivered by MTU come with a second nameplate. When operating the machine in the
EU: The second nameplate must be affixed in a prominent position as described in the accompanying specifi-
cations.

General information

This product may pose a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Noncompliance with the safety instructions and warning notices

Emission regulations and emission labels

Responsibility for compliance with emission regulations

Modification or removal of any mechanical/electronic components or the installation of additional compo-
nents including the execution of calibration processes 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 components used for this purpose are approved by the manufacturer.

Noncompliance with these regulations will invalidate the design type approval issued by the emissions regu-
lation authorities. The manufacturer does not accept any liability for violations of the emission regulations.
The maintenance schedules of the manufacturer must be observed over the entire life cycle of the product.

Replacing components with emission labels

On all MTU engines fitted with emission labels, these labels must remain on the engine throughout its opera-
tional life.

Engines used exclusively in land-based, military applications other than by US government agencies are ex-
cepted from this proviso.

Please note the following when replacing components with emission labels:
• The relevant emission labels must be affixed to the spare part.
• Do not transfer the emission labels from the replaced part to the spare part.
• Remove the emission labels from the replaced part and destroy them.

M015565/03E 2016-02

| Safety | 5

TIM-ID: 0000040530 - 008

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Содержание 20V4000GX2

Страница 1: ...Operating Instructions Diesel Engine 20V4000Gx2 M015565 03E...

Страница 2: ...kW cyl 50 Hz 3C restricted operation ICXN 20V4000G62 137 0 kW cyl 60 Hz 3C restricted operation ICXN 20V4000G62 133 5 kW cyl 50 Hz 3D emergency power fuel stop power IFN 20V4000G62 150 5 kW cyl 60 Hz...

Страница 3: ...ng the engine into operation after scheduled out of service period 44 5 3 Engine Starting in manual mode test run 45 5 4 Starting the engine in emergency situations override mode 46 5 5 Operational mo...

Страница 4: ...lling 114 8 15 5 Engine coolant pump Relief bore check 116 8 16 Low Temperature Circuit 117 8 16 1 Charge air coolant Level check 117 8 16 2 Charge air coolant Change 118 8 16 3 Charge air coolant dra...

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 M015565 03E 2016 02 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: ...or 6 Raise and lower the engine generator slowly Do not allow hoist slings or chains to contact the engine generator or any of their component parts Adjust lifting gear as necessary 7 For special pack...

Страница 17: ...lifting devices and appliances Never stand beneath a suspended load 1 Max admissible diagonal pull 10 2 Center of gravity Take note of the engine center of gravity See Installation Arrangement drawin...

Страница 18: ...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 installed 4 A...

Страница 19: ...the ring gear 4 Screw in screw 1 in bores of retainer 3 until retainer 3 is locked in position Note Screw 1 must be tightened stepwise and alternately on both sides of the flywheel housing 5 Tighten...

Страница 20: ...ys use the screws supplied with the or removed from the guard plates and engine mounting brackets to secure them on the en gine 1 Install engine mounting brackets 2 on both sides with guard plates 1 w...

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: ...ylinder 16 Cylinder head 17 Crankcase and add on com ponents 18 Fuel prefilter 19 HP fuel pump 20 Gear train 21 Lube oil filter 22 Crank drive 23 Battery charging generator 24 Coolant system KGS Free...

Страница 23: ...5 25 Charge air coolant temperature C 55 55 Raw water inlet temperature C Barometric pressure mbar 1000 1000 Site altitude above sea level m 100 100 Power related data power ratings are net brake powe...

Страница 24: ...ndividual cylinder heads X X Cylinder liners wet replaceable X X Number of inlet valves per cylinder 2 2 Number of exhaust valves per cylinder 2 2 Standard housing connecting flange engine main PTO SA...

Страница 25: ...rm R bar 4 5 4 5 Lube oil pressure before engine shutdown L bar 4 0 4 0 Fuel system Engine model Unit 20V4000 G62 20V4000 G82 Fuel pressure at engine inlet connection during engine start min admissibl...

Страница 26: ...rating inclinations L Liter 340 340 Weight Engine model Unit 20V4000 G62 20V4000 G82 Engine weight dry basic engine configuration in accord ance with scope of delivery specifications R kg 9450 9450 So...

Страница 27: ...20V4000 G62 20V4000 G42 20V4000 G82 Application group 3B 3B 3B 3B 3B 3B Intake air tempera ture C 25 25 25 25 25 25 Charge air coolant temperature C 55 55 55 55 55 55 Raw water inlet tem perature C B...

Страница 28: ...ting method Four stroke cycle diesel single action X X X X X X Combustion method direct fuel injection X X X X X X Cooling method con ditioned water X X X X X X Direction of rotation c c w facing driv...

Страница 29: ...ooling equipment A C 95 95 95 95 95 95 Coolant temperature after engine warning R C 97 97 97 97 97 97 Coolant temperature after engine shut down L C 99 99 99 99 99 99 Coolant antifreeze content max pe...

Страница 30: ...ure be fore engine shut down L bar 4 0 4 0 4 0 4 0 4 0 4 0 Fuel system Engine model Unit 20V4000 G22 20V4000 G62 20V4000 G22 20V4000 G62 20V4000 G42 20V4000 G82 Fuel pressure at en gine inlet connecti...

Страница 31: ...245 245 Oil pan capacity dip stick mark max standard oil system design max operat ing inclinations L Liter 340 340 340 340 340 340 Weight Engine model Unit 20V4000 G22 20V4000 G62 20V4000 G22 20V4000...

Страница 32: ...coolant temperature C 55 55 55 55 Raw water inlet temperature C Barometric pressure mbar 1000 1000 1000 1000 Site altitude above sea level m 100 100 100 100 Power related data power ratings are net br...

Страница 33: ...1 89 81 89 81 Compression ratio 15 5 15 5 15 5 15 5 Cylinder heads Individual cylinder heads X X X X Cylinder liners wet replaceable X X X X Number of inlet valves per cylinder 2 2 2 2 Number of exhau...

Страница 34: ...ating temperature be fore engine from R C 85 85 85 85 Lube oil operating temperature be fore engine to R C 95 95 95 95 Lube oil temperature before engine alarm R C 95 95 95 95 Lube oil temperature bef...

Страница 35: ...andard oil system design max operating inclinations R Liter 340 340 340 340 Oil pan capacity dipstick mark min standard oil system design max operating inclinations L Liter 245 245 245 245 Oil pan cap...

Страница 36: ...perature C 55 55 55 55 Raw water inlet temperature C Barometric pressure mbar 1000 1000 1000 1000 Site altitude above sea level m 100 100 100 100 Power related data power ratings are net brake power a...

Страница 37: ...1 89 81 89 81 Compression ratio 15 5 15 5 15 5 15 5 Cylinder heads Individual cylinder heads X X X X Cylinder liners wet replaceable X X X X Number of inlet valves per cylinder 2 2 2 2 Number of exhau...

Страница 38: ...ating temperature be fore engine from R C 85 85 86 86 Lube oil operating temperature be fore engine to R C 95 95 95 95 Lube oil temperature before engine alarm R C 95 95 95 95 Lube oil temperature bef...

Страница 39: ...tandard oil system design max operating inclinations R Liter 340 340 340 340 Oil pan capacity dipstick mark min standard oil system design max operating inclinations L Liter 245 245 245 245 Oil pan ca...

Страница 40: ...4 5 Final compression pressure Final compression pressure Final compression pressure at 120 rpm 24 bar to 28 bar 40 Technical Data M015565 03E 2016 02 TIM ID 0000002820 001...

Страница 41: ...4 6 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 M015565 03E 2016 02 Technical Data 41 TIM ID 0000035068 002...

Страница 42: ...n engine dimensions Main engine dimensions Engine model Length A Width B Height C 20V4000G22 42 62 82 Approx 3520 mm Approx 1480 mm Approx 2390 mm 42 Technical Data M015565 03E 2016 02 TIM ID 00000021...

Страница 43: ...er Fill with fuel Page 98 Fuel prefilter pressure gage Align adjustable pointer with position of pressure indicator Page 94 Fuel system Vent Page 91 Coolant circuit Change engine coolant if engine has...

Страница 44: ...105 Cooling system Check engine coolant level Page 111 Check charge air coolant level Page 117 Cooling system Preheat coolant with preheating unit Fuel prefilter Drain Page 95 Monitoring equipment Ca...

Страница 45: ...rting the engine Item Action Control cabinet control pan el etc depending on manu facturer If coolant temperature is 40 C with preheating system or 10 C 60 Hz generator without preheater 5 C 50 Hz gen...

Страница 46: ...ontrol cabinet Actuate switch button for ECU override input Control cabinet Automatic starting procedure is performed any safety functions and alarms leading to engine shutdown are disregarded Engine...

Страница 47: ...s in en gine operation are required Check for abnormal running noises and vibration HP pump Check relief bore Page 84 Fuel prefilter Check reading on differential pressure gage to ensure that maximum...

Страница 48: ...After the generator breaker if provided has been opened allow the engine to cool down by running it idle for approx 5 minutes Preparing a pump drive diesel mechanical diesel electric Item Action Engin...

Страница 49: ...from LOP Item Action Emergency stop pushbutton Press pushbutton Engine is stopped by disconnecting the power supply to the ECU Signaling e g by horn flashing lamp is tripped After emergency engine sto...

Страница 50: ...o 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 51: ...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 52: ...ne for abnormal running noises exhaust color and vibrations Page 47 W0507 X Drain water and contaminants from fuel prefilter Page 47 W0508 X Check reading on differential pressure gage of fuel prefilt...

Страница 53: ...nspection manufacturer s documentation Engine governor Plug in connections loose u Check plug in connections Page 130 Running gear blocked engine cannot be barred manually u Contact Service Engine tur...

Страница 54: ...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 exhaust li...

Страница 55: ...inder head piston rings 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...

Страница 56: ...ontact Service to have the sensors actuators checked and if required re placed Fault code Alarm text Meaning Task 005 L1 T CHARGE AIR Charge air temperature too high 1st limit value Reduce power Chang...

Страница 57: ...uel supply pressure too low 2nd limit value 1 Check fuel lines for leaks repair defec tive lines 2 Clean fuel prefilter Page 93 3 Flush fuel prefilter Page 96 4 Replace filter element of fuel prefilte...

Страница 58: ...r ing point which is read via CAN bus 080 L Bin EXTERN 4 Alarm from external binary channel 4 Depending on the corresponding measur ing point which is read via CAN bus 081 RAIL LEAKAGE HP fuel system...

Страница 59: ...ID Check sum error of hour meter data in IDM If fault occurs repeatedly Contact Service 106 ERR REC1 NOT VALID Check sum error of fault mem ory in EDM redundant data re cord 1 If fault occurs repeated...

Страница 60: ...low Contact Service 147 AD TEST1 ECU DEFECT Electronic equipment defective automatic engine shutdown Contact Service 148 L1 AD TEST2 SUP PLY A D converter supply voltage too low Contact Service 149 AD...

Страница 61: ...ensor defect charge air cool ant temperature 1 Check wiring 2 Contact Service 208 SD P CHARGE AIR Sensor defect charge air pres sure 1 Check wiring 2 Contact Service 211 SD P LUBE OIL Sensor defect lu...

Страница 62: ...efective CAN P EXTERN 1 Contact Service 274 SD P EXTERN 2 External device defective CAN P EXTERN 2 Contact Service 275 SD EXT COOLANT LEVEL External coolant level monitor ing defective CAN Contact Ser...

Страница 63: ...ault cylinder B6 If fault occurs repeatedly Contact Service 317 TIMING CYLINDER B7 Injection timing fault cylinder B7 If fault occurs repeatedly Contact Service 318 TIMING CYLINDER B8 Injection timing...

Страница 64: ...ring to solenoid valve cylinder B4 Misfiring 1 Check wiring 2 Contact Service 335 WIRING CYLINDER B5 Faulty wiring to solenoid valve cylinder B5 Misfiring 1 Check wiring 2 Contact Service 336 WIRING C...

Страница 65: ...on in wiring to sole noid valve cylinder A10 Misfiring 1 Check wiring 2 Contact Service 351 OPEN_LOAD CYL B1 Disconnection in wiring to sole noid valve cylinder B1 Misfiring 1 Check wiring 2 Contact S...

Страница 66: ...2 Solenoid valve or wiring or en gine governor defective automatic engine shutdown 1 Check wiring 2 Try to re start the engine Page 45 3 Contact Service 365 STOP MV WIRING Solenoid valve wiring faulty...

Страница 67: ...ing engine parts Risk of crushing danger of parts of the body being caught or pulled in Before barring the engine make sure that there are no persons in the engine s danger zone After finishing work o...

Страница 68: ...to barring device 2 Note No resistance 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 press...

Страница 69: ...place and all tools are removed from the engine Cranking engine on starting sys tem 1 Disengage bayonet union nut 4 of connec tor X4 on Engine Control Unit using pipe gripping pliers 2 and disconnect...

Страница 70: ...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 45 2 Perfo...

Страница 71: ...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 72: ...Depending 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 73: ...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 74: ...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 75: ...il Filter element Spare Parts Catalog O ring Spare Parts Catalog WARNING Hot oil Oil can contain combustion residues which are harmful to health Risk of injury and poisoning Wear protective clothing g...

Страница 76: ...with new O ring 6 Tighten screws of cover tighten to specified torque using a torque wrench Name Size Type Lubricant Value Standard Screw Tightening torque Engine oil 6 Nm 2 Nm 7 Replace other oil sep...

Страница 77: ...al 2 Undo screws 1 and remove with wash ers 2 3 Remove cylinder head cover 3 with gas ket 4 from cylinder head 4 Remove other cylinder head covers in the same way Installing cylinder head cover 1 Clea...

Страница 78: ...nder head covers Page 77 2 Fill oil chambers of valve bridges with oil 3 Fill oil chambers of rocker arms and adjusting screws with oil 4 Install cylinder head covers Page 77 Lubricating valve gear fl...

Страница 79: ...r gage Y20098771 1 Torque wrench 10 60 Nm F30452769 1 Torque wrench 60 320 Nm F30452768 1 Ring socket wrench F30039518 1 Engine oil Preparatory steps 1 Remove cylinder head cover Page 77 2 Install bar...

Страница 80: ...ridge Note Not applicable for engines with flying valve bridge 1 Prior to adjusting valve clearance check valve bridge balance on all valve bridges 2 Use feeler gage to determine clearance be tween va...

Страница 81: ...ith open end wrench and release locknut 2 2 Use feeler gage to determine clearance be tween valve bridge and rocker arm 3 Place one feeler gage of the determined val ue each between valve bridge and t...

Страница 82: ...doing Name Size Type Lubricant Value Standard Nut M 16 x 1 5 Preload torque Engine oil 35 Nm 5 Nm 8 Recheck valve bridge balance Checking valve clearance at two crankshaft positions Item Explanation...

Страница 83: ...arm 5 If the deviation from the specified value exceeds 0 1 mm adjust valve clearance Adjusting valve clearance 1 Release locknut 1 2 Insert feeler gage between valve bridge and rocker arm 3 Turn adj...

Страница 84: ...Only run the engine at low power Keep away from the engine s danger zone WARNING High level of engine noise when the engine is running Risk of damage to hearing Wear ear protectors Checking HP fuel pu...

Страница 85: ...r 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 86 M015565 03E 2016 02 Injecto...

Страница 86: ...X00067260 1 Engine oil WARNING Fuels are combustible and explosive Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Wear protective clothing protective...

Страница 87: ...side is completed 1 Release the cable terminal threaded connec tion arrowed on the injector and remove ca ble terminals 2 Remove screw 2 and take off hold down clamp 1 3 Remove HP fuel line 5 4 Instal...

Страница 88: ...nozzle retaining nut 3 Fit new O rings on injector and apply assem bly compound 4 Fit new sealing ring with assembly compound on injector pay attention to installation posi tion of sealing ring 5 Cle...

Страница 89: ...fied initial tightening torque using a torque wrench Name Size Type Lubricant Value Standard Screw M12 Preload torque Engine oil 5 Nm to 10 Nm 13 Fit O rings 4 and 6 on HP fuel line 5 and coat with as...

Страница 90: ...ench Name Size Type Lubricant Value Standard Union nut Tightening torque 120 Nm 10 Nm 18 Twist cable several times 19 Insert cable lugs arrowed underneath the screws on the injector and tighten screws...

Страница 91: ...otective clothing protective gloves and safety glasses facial protection Venting LP fuel system 1 Loosen flushing return line of HP pump at connection 1 2 Unlock fuel priming pump 2 screw out han dle...

Страница 92: ...l sparks and ignition sources Do not smoke Wear protective clothing protective gloves and safety glasses facial protection Fuel filter Replacement 1 Remove easy change filter using filter wrench 2 Cle...

Страница 93: ...safety glasses facial protection Cleaning fuel prefilter 1 Close fuel supply 2 Remove nuts from filter head 3 Unscrew filter bowl and drain fuel into a suit able container 4 Remove securing nut for fi...

Страница 94: ...r of dif ferential pressure gage 1 After installation of a new filter element Align adjustable pointer 2 with pressure indicat ing pointer 3 of pressure gage 1 2 Verify that differential pressure is w...

Страница 95: ...ing fuel prefilter 1 Left filter cut in 2 Right filter cut in 1 Switch off filter to be drained 2 Open threaded vent plug 5 of the filter to be drained 3 Unlock drain valve 6 by pressing toggle and op...

Страница 96: ...parks and ignition sources Do not smoke Wear protective clothing protective gloves and safety glasses facial protection WARNING Liquid or gaseous media e g fuel are poisonous Escaping vapors of highly...

Страница 97: ...tered side flushing the filter deposits down wards out of the filter 4 Close threaded vent plug 5 and drain valve 6 Fuel prefilter Filling with fuel 1 Remove screws securing cover and take off cover 2...

Страница 98: ...og Gasket Spare Parts Catalog WARNING Fuels are combustible and explosive Risk of fire and explosion Avoid open flames electrical sparks and ignition sources Do not smoke Wear protective clothing prot...

Страница 99: ...ove spring housing 4 and filter ele ment 3 8 Insert new filter element 3 and spring hous ing 4 9 Fill filter housing with clean fuel 10 Place new gasket in cover 2 11 Fit cover with gasket and secure...

Страница 100: ...direct air jet at people Always wear safety goggles face mask and ear defenders Intercooler Check water drain for coolant leakage and absence of restrictions 1 With the engine running check the drain...

Страница 101: ...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 102 2 Reset signal ring of service indicator Page 1...

Страница 102: ...lla tion 1 Loosen clamp 2 2 Remove air filter 1 and clamp 2 from con necting flange of intake housing 3 3 Verify that there are no objects in the flange of the intake housing 3 and clean it 4 Place ne...

Страница 103: ...sabled Checking signal ring position 1 If the signal ring is completely visible in the control window 2 replace air filter Page 101 2 After installation of new filter press reset button 1 Result Engag...

Страница 104: ...em make sure that there 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 Air starter Manual operat...

Страница 105: ...the oil level may be up to 2 cm above mark 1 This may be caused e g by oil from oil filters and heat ex changer flowing back into the oil pan 3 The oil level must reach mark 1 or exceed mark 1 by up...

Страница 106: ...Avoid contact with skin Do not inhale oil vapor Oil change without semirotary hand pump Draining oil at drain plug s on oil pan 1 Provide a suitable container in which to collect the engine oil 2 Remo...

Страница 107: ...l drain plug s with new sealing ring 5 Tighten drain screws 2 and 3 to specified torque using a torque wrench Name Size Type Lubricant Value Standard Screw M26 x 1 5 Tightening torque Engine oil 100 N...

Страница 108: ...ing Wear protective clothing gloves and goggles safety mask Avoid contact with skin Do not inhale oil vapor Engine oil filter Replacement 1 Unscrew engine oil filter with filter wrench 2 Clean sealing...

Страница 109: ...ring Spare Parts Catalog WARNING Hot oil Oil can contain combustion residues which are harmful to health Risk of injury and poisoning Wear protective clothing gloves and goggles safety mask Avoid con...

Страница 110: ...rotor base 10 with sealing ring 9 13 Insert new filter sleeve 6 in rotor tube 7 with the smooth paper surface facing the wall 14 Check sealing ring 5 fit new one if necessa ry 15 Mount rotor cover 4 w...

Страница 111: ...o 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 engine coolant level at remote cooler Note Engi...

Страница 112: ...Material Spare parts Designation Use Part No Qty Coolant Engine coolant change 1 Drain engine coolant Page 113 2 Fill with engine coolant Page 114 112 Coolant Circuit General High Temperature Circuit...

Страница 113: ...f filler neck on coolant expansion tank counterclockwise to first stop and allow pressure to escape 2 Continue to turn breather valve counterclockwise and remove 3 Draw off separated corrosion inhibit...

Страница 114: ...ne 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 top up coolant only into...

Страница 115: ...ngine with out load stop engine Page 48 11 Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to escape 12 Continue to turn breather valve counterclock...

Страница 116: ...protectors Checking engine coolant pump relief bore 1 Check relief bore for oil and coolant dis charge 2 Shut down engine Page 48 and disable engine start observe general safety instruc tions in Maint...

Страница 117: ...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 118: ...al tools Material Spare parts Designation Use Part No Qty Coolant Charge air coolant Change 1 Drain charge air coolant Page 119 2 Fill with charge air coolant Page 120 118 Low Temperature Circuit M015...

Страница 119: ...breather valve of filler neck on coolant expansion tank counterclockwise to first stop and allow pressure to escape 3 Continue to turn breather valve counterclock wise and remove 4 Draw off precipita...

Страница 120: ...k of damage to hearing Wear ear protectors NOTICE Cold coolant in hot engine can cause thermal stress Possible formation of cracks in the engine Fill top up coolant only into cold engine Preparatory s...

Страница 121: ...t the marker plate 2 Install plug screws of filling points with new sealing rings 3 Check proper condition of breather valve clean sealing faces if required 4 Position breather valve on filler neck an...

Страница 122: ...aring Wear ear protectors Charge air coolant pump Re lief bore check 1 Check relief bore for oil and coolant dis charge 2 Shut down engine Page 48 and disable engine start observe general safety instr...

Страница 123: ...sabled 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 126 Drive belt C Chunking Drive belt...

Страница 124: ...tions Engine is stopped and starting disabled Adjusting belt tension 1 Loosen locknut 2 and screws 1 2 Tension drive belt with tensioning nut 3 and check belt tension Page 125 3 Tighten locknut 2 4 Ti...

Страница 125: ...ve belt tension 1 Fit sensor head on belt tension tester and tap drive belt with a suitable tool 2 Hold belt tension tester over belt drive until the measured value is displayed For specifications ref...

Страница 126: ...since pretension by the drive belt is no longer provided Therefore engine operation without drive belt connection is not allowed Battery charging generator drive Drive belt replacement 1 Remove guard...

Страница 127: ...silient mounts 1 Wipe rubber surface with dry cloth do not use organic detergents 2 Visually inspect resilient mounts for cracks and deformation 3 Have cracked mounts replaced contact Serv ice Checkin...

Страница 128: ...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 129: ...ohol 2 Remove dirt on surface of connectors 1 sockets and shrink pieces 2 using isopropyl alcohol 3 Check legibility of cable labels Clean or re place illegible labels Cleaning severely contaminated c...

Страница 130: ...k that all plug connections on the En gine Control Unit are properly seated using pipe gripping pliers 3 2 Tighten loose bayonet union nuts 2 with pipe gripping pliers 3 by turning them clock wise unt...

Страница 131: ...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 132: ...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 133: ...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 134: ...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 135: ...ty Used in 1 8 2 1 Cylinder liner Endoscopic examination Page 71 Belt tension tester Part No Y4345711 Qty Used in 1 8 18 2 Battery charging generator drive Drive belt con dition check Page 125 Crossbe...

Страница 136: ...r Endoscopic examination Page 71 Feeler gage Part No Y20098771 Qty Used in 1 8 4 3 Valve clearance Check and adjustment Page 79 Filter wrench Part No F30379104 Qty Used in 1 8 8 1 Fuel filter Replacem...

Страница 137: ...utter Part No F30452739 Qty Used in 1 8 6 2 Injector Removal and installation Page 86 Pipe gripping pliers Part No F30017884 Qty Used in 1 8 1 2 Engine Cranking on starting system Page 69 Qty Used in...

Страница 138: ...in 1 8 13 2 Engine oil Change Page 106 Ratchet with extension Part No F30006212 Qty Used in 1 8 1 1 Engine Barring manually Page 67 Qty Used in 1 8 2 1 Cylinder liner Endoscopic examination Page 71 Ri...

Страница 139: ...age 18 Qty Used in 1 8 4 3 Valve clearance Check and adjustment Page 79 Qty Used in 1 8 6 2 Injector Removal and installation Page 86 Qty Used in 1 8 14 2 Centrifugal oil filter Cleaning and filter sl...

Страница 140: ...t transport locking device Page 18 Qty Used in 1 8 4 3 Valve clearance Check and adjustment Page 79 Qty Used in 1 8 6 2 Injector Removal and installation Page 86 Qty Used in 1 8 13 2 Engine oil Change...

Страница 141: ...examination 71 Instructions and comments on endoscopic and visual examination 73 D Differential pressure gage Adjustment Fuel prefilter 94 Check Fuel prefilter 94 Dimensions Engine 42 Drive belt Condi...

Страница 142: ...s 134 O Oil separator element Replacement Crankcase breather 75 Operational monitoring 47 Overview Engine 22 P Plant Cleaning 51 Preparation Putting the engine into operation after extended out of ser...

Страница 143: ...V Valve clearance Adjustment 79 Check 79 Valve gear Lubrication 78 M015565 03E 2016 02 Index 143 DCL ID 0000034750 001...

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