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MTU 20 V 4000 C22 Operating instructions

1. CICK TLR 7 i p fhe pE J 4 e E I I amp i AEs A Ee 00001518 1 B44 N Turbocharger 2 BO3 T Intake Air 22 General Information M015675 06E 2013 04 TIMID 00000 12921 003 IU U TIMAD 00000 12921 003 00001519 1 B13 N Crankshaft i 00001520 1 B50 P Crankcase 4 BO1 N Camshaft 7 BO6 T Coolant 2 F25 P Lube Oil Diff after 5 B43 P Coolant Intercool Filter er 3 BO5 P Lube Oil 6 B26 T Coolant Intercool er M015675 06E 2013 04 General Information 23 3 Technical Data 3 1 20V 4000 C22 engine data Explanation DL Ref value Continuous power CP BL Ref value Fuel stop power FSP Design value Guaranteed value Guideline value Limit value up to which the engine can be operated without change e g of power setting
2. Part No F30452739 Qty 1 Used in 7 7 2 Injector Removal and installation gt Page 78 MTU test kit Part No 5605892099 00 Qty 1 Used in 7 15 6 Engine coolant Sample extraction and analysis gt Page 109 Optibell 2 belt tension tester Part No Y4345711 Qty 1 Used in 7 20 1 Fan drive Drive belt tension check adjust ment gt Page 125 138 AppendixB M015675 06E 2013 04 DCL ID 0000014250 002 DCL ID 0000014250 002 Ratchet Part No F30027340 Qty 1 Used in 7 3 1 Crankcase breather Oil separator element re placement diaphragm check and replacement gt Page 59 Ratchet with extension Part No F30006212 Qty 1 Used in 7 1 1 Engine Barring manually gt Page 52 Qty 1 Used in 7 2 1 Endoscopically examining cylinder liner gt Page 55 Slotted screwdriver Part No F30452578 S Qty 1 Used in 7 7 2 Injector Removal and installation gt Page 78 Socket wrench Part No F30039526 Qty 1 MA Used in 7 5 2 Valve clearance Check and adjustment gt Page 69 M015675 06E 2013 04 AppendixB 139 Socket wrench Part No Qty eae Used in CUD Steam jet cleaner Part No Qty Used in Torque wrench 10 60 Nm Part No Qty Used in Torque wrench 60 320 Nm Part
3. 01801221 6 Use torque wrench to tighten the screws of cover 4 to the specified torque Screw Tightening torque Engine oil 10 Nm 2 Nm 7 Check diaphragms in further oil separators in the same way 60 Task Description M015675 06E 2013 04 TIM 4D 0000000017 008 TIMAD 00000035 10 006 7 3 2 Crankcase breather Cleaning Special tools Material Spare parts Cleaner Snow White 11 0 40460 1 Cleaner Hakupur 312 30390 1 Compressed air gun ejects a jet of pressurized air Risk of injury to eyes and damage to hearing risk of rupturing internal organs A e Never direct air jet at people e Always wear safety goggles face mask and ear defenders A NOTICE Note Cleaner is extremely caustic Risk of injury and suffocation e Avoid contact with eyes and skin e Do not inhale vapors and smoke e Do not eat drink smoke when working with cleaner e Wear protective clothing gloves and goggles safety mask e Take measures against electrostatic charging Cleaning agents should not be left to take effect for too long Damage to components is possible e Observe manufacturer s instructions Clean crankcase breather Protect rubber and synthetic components from oil and fuel never treat with organic detergents Wipe with a dry cloth only Clean all metallic parts with cleaner Snow White 11 0 then rinse with cleaner Hakupur 312 Blow down all parts with compressed air M015675 06E 2
4. 00000595a Always use the lifting eyes on the engine and generator gearbox when transporting gensets Always use the lifting eyes on the engine when transporting an engine separately Only use transport and lifting devices approved by MTU The engine genset must only be transported in installation position maximum permissible diagonal pull 10 Remove any loose parts on the genset Raise the engine genset slowly The lifting ropes or chains must not make contact with the engine or its components Readjust lifting device as necessary Pay attention to the center of gravity of the engine genset For special packaging with aluminium foil Suspend the engine genset by the lifting eyes on the bearing pedestal or transport by means of handling equipment forklift truck capable of bearing the load Fit the crankshaft transportation lock on the engine and fit the engine mount locking devices prior to transport Secure the engine genset such as to preclude tipping during transport Secure such as to preclude slip ping and tipping when driving up or down inclines and ramps Placement after transport Place the engine genset on a firm flat surface only Make sure that the consistency and load bearing capacity of the ground or support surface is adequate Never set an engine down on the oil pan unless expressively authorized to do so by MTU on a case to case basis M015675 06E 2013 04 Safety 7 1 4 Crankshaft transp
5. Check wiring Contact Service Ry os Check wiring Contact Service N Check wiring Contact Service P Check wiring Contact Service PN ck Check wiring Contact Service lei ei Check wiring Contact Service PJ Check wiring Contact Service fom Check wiring 2 Contact Service TIM AD 0000003161 001 TIMAD 0000003161 001 215 216 219 220 226 BLY 230 231 232 240 245 246 266 301 302 303 304 305 306 307 308 309 SD P RAIL FUEL SD T LUBE OIL SD T INTAKE AIR SD COOLANT LEVEL SD P OILFILTER DIFF SD WATER IN FUEL SD ENG SPEED SEN SORS SD CRANKSHAFT SPEED SD CAMSHAFT SPEED SD ETC SPEED 11 SD P FUEL SD POWER SUPPLY SD T ELECTRONIC SD SPEED DEMAND AN TIMING CYLINDER A1 TIMING CYLINDER A2 TIMING CYLINDER A3 TIMING CYLINDER A4 TIMING CYLINDER A5 TIMING CYLINDER A6 TIMING CYLINDER A7 TIMING CYLINDER A8 TIMING CYLINDER A9 Sensor defect common rail pressure HP controller in emergency mode Sensor defect lube oil tem perature Sensor defect intake air temperature Sensor defect coolant level Sensor defect lube oil pres sure differential Sensor defect water in fuel prefilter Sensor defect crankshaft speed and sensor defect camshaft speed Sensor defect crankshaft speed Sensor defect camshaft spe
6. 1 87 l x X A6 B6 Al x x B6 AS x jes ee B5 Ad 1 1 B4 M x x X B4 l x X A3 B3 BI x B3 a2 x X Bo Ad B2 I x X m f1 Al B1 I KS KS 05500147a TIMID 0000004355 001 TIMAD 0000004355 001 Adjusting valve clearance Release locknut 1 Insert feeler gauge between valve bridge and rocker arm Using Allen key set adjusting screw 2 so that the specified valve clearance is provid ed Feeler gauge must just pass through the gap Tighten locknut 1 to 90 9 Nm holding adjusting screw 2 firm Replace or rectify adjusting screws and or locknuts which do not move freely Check valve clearance Final steps Remove barring tool gt Page 52 Install cylinder head cover gt Page 74 05500035a M015675 06E 2013 04 Task Description 73 7 9 3 Cylinder head cover Removal and installation Preconditions V Engine is stopped and starting disabled Special tools Material Spare parts Gasket gt Spare Parts Catalog Removing cylinder head cover 1 Clean very dirty cylinder head covers prior to removal 2 Remove screws 3 Remove cylinder head cover with gasket from cylinder head 05500273b Installing cylinder head cover Clean mating face Check condition of gasket replace if necessary Place gasket and cylinder head cover
7. SD P LUBE OIL SD P COOLANT SD P COOLANT IN TERC SD P CRANKCASE Module in maintenance pre dictor either defective or missing Maintenance predictor no more activated EEPROM write limit reached At least one device not de tected on Default CAN bus At least one device not de tected on Redundant CAN bus Error during loading of CAN project design data into ECU Error during project design data download in EEPROMs Error during CAN initializa tion Severe fault on Default CAN bus automatic change over to Redundant CAN bus Light fault on Default CAN bus e g short time over load Severe fault on Redundant CAN bus Automatic change over to Default CAN bus Light fault on Redundant CAN bus e g short time overload Sensor defect coolant tem perature Sensor defect fuel tempera ture Sensor defect charge air temperature Sensor defect charge air coolant temperature Sensor defect charge air pressure Sensor defect lube oil pres sure Sensor defect coolant pres sure Sensor defect intercooler coolant pressure Sensor defect crankcase pressure Contact Service Contact Service Contact Service 1 Check wiring CAN bus 2 Contact Service 1 Check wiring CAN bus 2 Contact Service Contact Service Contact Service Contact Service Contact Service none Contact Service none Check wiring Contact Service M
8. 33 4 5 Engine Stopping in manual mode Preconditions V Engine is not under load V Engine is running in manual mode NOTICE i Stopping the engine when it is running at full load subjects it to extreme thermal and mechanical stresses Overheating of and therefore damage to components is possible e Before shutting down the engine allow it to idle until the engine temperatures decrease and constant levels are indicated Preparation Engine Operate engine at idling speed for approx 5 minutes Stop engine Switch cabinet operator Press stop button station etc depending on e Automatic stopping sequence is executed manufacturer 34 Operation M015675 06E 2013 04 TIM AD 0000002291 005 TIMAD 0000002321 003 4 6 After shutting down the engine Preconditions M MTU Corrosion proofing and Reproofing Regulations A00 1070 are available After shutting down the engine Coolant system Drain coolant gt Page 105 gt Page 113 if e freezing temperatures are expected and the engine is to remain out of service for an extended period but engine coolant has no antifreeze additive coolant is not preheated antifreeze concentration is 50 and outside temperature is below 40 C Engine control system Switch off Air intake and exhaust sys Out of service period gt 1 week tem Seal off engine s intake and exhaust systems Out of service period gt 1 month Corrosion proof engine
9. C Coolant temperature after engine alarm Rje o 97 Coolant temperature after engine shutdown e je 89 Coolant antifreeze content max permissible e A A E e C e COOLING SYSTEM LT circuit Number of cylinders 20V 4000 Coolant temperature at engine outlet to cooling equipment rec 8 Coolant temperature before intercooler with max 40 antifreeze Thermostat starstoopen RY Thermostat fully open Roe fae LUBE OIL SYSTEM Number of cylinders 20V 4000 Lube oil operating temperature before engine from R Lube oil operating temp before engine to R Lube oil operating pressure before engine measuring block R M015675 06E 2013 04 Technical Data 25 Number of cylinders Lube oil pressure before engine alarm VA e000 Lube oil pressure before engine shutdown FUEL SYSTEM Number of cylinders Fuel pressure at supply connection to engine when engine is start ing min admissible Fuel pressure at supply connection to engine when engine is start ing max admissible Fuel pressure before injection pump from H P pump Fuel pressure before injection pump to H P pump Fuel pressure before injection pump min H P pump GENERAL OPERATING DATA Number of cylinders Coolant temperature before full load operation recommended min for standby plants with coolant preheating at least preheating tem perature INCLINATIONS STANDARD OIL SYSTEM Ref waterline Num
10. e Do not take any action or e carry out a further endoscopic examination as part of maintenance work or e contact Service cylinder liner must be replaced iS Final steps 1 Refit injector gt Page 78 2 Install cylinder head cover gt Page 74 56 Task Description M015675 06E 2013 04 TIM D 0000003304 005 TIMAD 0000003285 003 1 2 2 Instructions and comments on endoscopic and visual examination of cylinder liners Terms used for endoscopic examination Use the terms listed below to describe the condition of the cylinder liner surface in the endoscopic ex amination report Findings Light scoring Single scores Scored area Smoothened area Polished area Discoloration Corrosion fields spots Black lines Discolorations Heat Minor dirt scores can occur during the assembly of a new engine honing prod ucts particles broken off burrs Removed cylinders clearly exhibit such scoring on the running surface under endoscope magnification Cannot be felt with the fingernail Findings not critical Clearly visible scores caused by hard particles They usually start in the TDC area and cross through the honing pattern in the direction of stroke Findings not critical These areas consist of scores of different lengths and depths next to one anoth er In most cases they are found at the 6 o clock and 12 o clock positions inlet exhaust along the transverse engine axis Findings no
11. e Twist the cables when attaching e Ensure that the cables do not touch any components NOTICE Removal of all injectors Damage to component e Ensure that the high pressure fuel accumulator is secured on the engine through two HP lines Preparatory steps 1 Close off fuel supply to engine 2 Remove cylinder head cover gt Page 74 78 Task Description M015675 06E 2013 04 TIM AD 0000000952 010 TIMAD 0000000952 010 Remove injector Note Always replace the first and last injectors of one engine side first Replace the inner injectors only after the installation of the outer injectors on this engine side is com pleted 1 Release the cable terminal threaded con nection arrows on the injector and re move cable terminals 07500033b 2 Remove screw 2 and take off hold down W ORE clamp 1 el GERE 3 Remove high pressure fuel line 5 IN SW SS Nee g 4 Install installation removal device on the cylinder head 5 Remove injector with installation removal device 6 Remove the installation removal device 07500211a M015675 06E 2013 04 Task Description 79 Remove sealing ring 1 from injector or use a self made hook to take it out of the cylinder head Remove O rings 2 from injector Cover all connections and installation bores or seal with suitable plugs Install injector Prior to installation remove all blanking plugs Co
12. 7 1 1 Engine Barring manually gt Page 52 Belt tension tester Part No Y4345711 Qty 1 Used in 7 19 5 Battery charging generator drive Drive belt tension check gt Page 123 Connector pliers Part No 0135315483 Qty 1 Used in 7 1 2 Engine Barring with starting system gt Page 54 Qty 1 Used in 7 22 2 Checking engine control unit plug connections gt Page 130 Connector pliers Part No F30017884 Qty 1 Used in 7 22 1 Engine governor and connectors Cleaning gt Page 129 136 AppendixB M015675 06E 2013 04 DCL ID 0000014250 002 DCL ID 0000014250 002 Cranking tool Part No F6555766 Qty 1 Used in 7 2 1 Endoscopically examining cylinder liner gt Page 55 Endoscope Part No Y20097353 Qty 1 Used in 7 2 1 Endoscopically examining cylinder liner gt Page 55 Feeler gauge Part No Y20010128 Qty 1 Used in 7 5 2 Valve clearance Check and adjustment gt Page 69 Filter wrench Part No F30379 104 Qty 1 Used in 7 9 1 Fuel filter Replacement gt Page 84 Qty 1 Used in 7 9 4 Auxiliary fuel filter Replacement gt Page 87 Qty 1 Used in 7 15 7 Engine coolant filter Replacement gt Page 110 M015675 06E 2013 04 AppendixB 137 Installation and removal tool for injector Part No F6790161 Qty 1 Used in 7 7 2 Injector Removal and installation gt Page 78 Milling cutter
13. 8 Appendix A 8 1 8 2 Abbreviations MTU contact persons service partners 9 Appendix B 9 1 92 Special Tools Index 118 119 120 121 122 123 124 125 125 127 128 128 129 129 130 131 134 135 143 DCL ID 0000014250 002 TIMAD 0000040530 001 1 1 Safety Important provisions for all products Nameplate The product is identified by nameplate model designation or serial number and must match with the information on the title page of this manual Nameplate model designation or serial number can be found on the product General information This product may pose a risk of injury or damage in the following cases e Incorrect use e Operation maintenance and repair by unqualified personnel e Modifications or conversions e Noncompliance with the safety instructions and warning notices Correct use The product is intended exclusively for the application specified in the contract or defined at the time of delivery This means that the equipment must be operated e Within the permissible operating parameters in accordance with the gt product data e With fluids and lubricants approved by the manufacturer in accordance with the gt Fluids and Lubri cants Specifications of the manufacturer e With spare parts approved by the manufacturer in accordance with the gt applicable Spare Parts Catalog e In the original as delivered configuration or in a configuration approved by
14. Oil separator element replacement diaphragm check and replacement Preconditions MW Engine is stopped and starting disabled Special tools Material Spare parts Designation Use Qty Torque wrench 6 50 Nm F30027336 1 Ratchet F30027340 1 Engine oil Filter element gt Spare Parts Catalog Diaphragm gt Spare Parts Catalog Gasket gt Spare Parts Catalog WARNING l WARNING Hot oil A a eam Oil can contain combustion residues which are harmful to health Risk of injury and poisoning e Wear protective clothing gloves and goggles safety mask e Avoid contact with skin e Do not inhale oil vapor Replacing oil separator element Remove cover 2 with O ring 3 Remove filter element 1 from housing 4 Insert new filter element in housing 4 Install cover 2 with new O ring 01801220 Use torque wrench to tighten the screws of cover 2 to the specified torque Screw Tightening torque Engine oil 10 Nm 2 Nm Replace further oil separator elements in the same way M015675 06E 2013 04 Task Description 59 Checking diaphragm 1 Remove cover 4 2 Remove spring 5 gasket 2 and dia phragm 3 3 Check diaphragm 3 for damage fit new diaphragm if used one is damaged lt q 4 Install diaphragm 3 on housing 1 je 5 Install new seal 2 and spring 5 together A with cover 4
15. Preconditions WM Engine shut down and starting disabled Special tools Material Spare parts Loctite 270 Carbon brush Replace carbon brush Loosen screw 5 Disconnect cable 6 from screw 5 Loosen screws 3 Remove screws 2 Remove carbon brush 1 from grounding device 4 Fit new carbon brush 1 in grounding de vice 4 Tighten screws 2 by hand Insert screws 3 as far as the stop and tighten screws lightly Tighten screws 2 Apply Loctite 270 only to threads Secure cable 6 with screw 5 40083 gt Spare Parts Catalog 2 03500563a M015675 06E 2013 04 Task Description 67 7 5 Valve Drive 7 5 1 Valve gear Lubrication Preconditions V Engine is stopped and starting disabled Special tools Material Spare parts Engine oil Valve gear Lubrication 1 Remove cylinder head covers gt Page 74 2 Fill oil chambers of rocker arms and adjust ing screws with oil 3 Install cylinder head covers gt Page 74 68 Task Description M015675 06E 2013 04 ao GS A j 05500353a TIM AD 0000004337 004 TIMAD 0000004355 001 7 5 2 Valve clearance Check and adjustment Preconditions WM Engine is stopped and starting disabled W Engine coolant temperature is max 40 C W Valves are closed Special tools Material Spare parts Feeler gauge Y20010128 1 Torque wrench 60 320 Nm F30047446 1 Socket wrench F30039526
16. exhaust pipes Charge air pressure too low Air supply Air filter clogged Clean Intercooler Dirty Notify Service Turbocharger Defective Notify Service Coolant leakage from intercooler Intercooler Leaking significant coolant loss Notify Service Black smoke from exhaust Air supply Air filter clogged Clean Fuel injection system Injector defective Replace gt Page 77 Engine Overloaded Notify Service Blue smoke from exhaust Engine oil Too much oil in engine Drain engine oil gt Page 95 Oil separator on crankcase venting sys Replace gt Page 59 tem dirty Turbocharger cylinder Defective Notify Service head piston rings cyl inder liner White smoke from exhaust Engine Not at operating temperature Run engine to reach operating tempera ture Fuel system Water in fuel Check fuel system at fuel prefilter M015675 06E 2013 04 Troubleshooting 39 Drain water from fuel prefilter Intercooler Leaking Notify Service 40 Troubleshooting M015675 06E 2013 04 TIM AD 0000002541 002 TIMAD 0000003161 001 6 2 ECU 4 alarms Faults in the overall system are indicated as a four digit code on the PIM display The fault code num bers are generated by the ECU 51700056a The four digit code consists of one letter and three figures e The letter encodes when the fault occurred the last time A currently present B within the last operating hour C one to four
17. gt MTU Corrosion proofing and Reproofing Regula tions A001070 M015675 06E 2013 04 Operation 35 4 7 Cleaning the plant Preconditions V Engine shut down and secured against being restarted Power supply not connected Special tools Material Spare parts Steam jet cleaner z 1 Cleaning agent Hakupur 312 30390 1 WARNING A WARNING A NOTICE NOTICE Note Compressed air gun ejects a jet of pressurized air Risk of injury to eyes and damage to hearing risk of rupturing internal organs e Never direct air jet at people e Always wear safety goggles face mask and ear defenders Steam jet cleaner ejects jet of pressurized water Risk of injury to eyes and scalding e Never direct water jet at people e Wear protective clothing protective gloves and safety goggles face mask Cleaning agents should not be left to take effect for too long Damage to components is possible e Observe manufacturer s instructions Blowing down product with compressed air Entry of dirt and damage to components is possible e Do not aim compressed air gun directly at seals or electronic components such as connectors or ECUs Cleaning the system Carry out system cleaning only in areas where an appropriate oil separator is provided environmental protection Before starting to use the pressure steam jet washer read the Operating Instructions for the appliance observe the safety precautions If cleaning
18. 0000002204 002 TIMAD 0000002683 005 42 Putting the engine into operation after scheduled out of service period Preconditions WM Engine is stopped and starting disabled Startup Lube oil system Check engine oil level gt Page 94 Coolant circuit Check engine coolant level gt Page 103 Check charge air coolant level gt Page 111 Coolant circuit Preheat coolant with coolant preheating unit if applicable Engine control system Put into operation M015675 06E 2013 04 Operation 31 4 3 Engine Starting in manual mode 7 DANGER A Preconditions V Engine is not under load W External start interlock is not activated Rotating and moving engine parts Risk of crushing danger of parts of the body being caught or pulled in e Before cranking the engine with starter system make sure that there are no persons in the en gine s danger zone C warne A high level of noise is produced when the engine is running Risk of damage to hearing e Wear ear defenders Preparation Operating mode switch if Switch to manual mode applicable Coolant preheating unit if Switch ON applicable Start engine Switchgear cabinet opera 1 If no coolant preheater is fitted make sure that the coolant tempera tor station etc depending ture is gt 40 C on manufacturer 2 Press start button e Automatic starting procedure is performed e E
19. 001 Charge air coolant system Fill ing Pour treated coolant via the filling point on the coolant line from and to the intercooler and via the filler neck of the expansion tank until coolant is visible at the marking plate Install plugs with new sealing rings at the filling points Check proper condition of breather valve clean sealing faces if required Set breather valve onto filler neck and close it Final steps 20300087a Start the engine and operate it at idle speed for some minutes Check coolant level gt Page 111 M015675 06E 2013 04 Task Description 115 7 16 5 Charge air coolant pump Checking pressure relief port DANGER Rotating and moving engine parts Risk of crushing danger of parts of the body being caught or pulled in A e Only run the engine at low power Keep away from the engine s danger zone ss A high level of noise is produced when the engine is running Risk of damage to hearing A e Wear ear defenders Charge air coolant pump Checking pressure relief port Check pressure relief port for oil and cool ant discharge 2 Shut down engine gt Page 34 and secure against being restarted observe general Maintenance and Repair safety instruc tions 3 Clean the pressure relief port with a wire if it is dirty e Permissible coolant discharge rate up to 10 drops per hour e Permissible oil discharge rate up to 5 drops hour 4 If discha
20. 1 Allen key F30002817 1 Torque wrench 10 60 Nm F30510423 1 Socket wrench F30039518 1 Preparatory steps 1 Remove cylinder head cover gt Page 74 2 Install barring tool gt Page 52 3 Rotate crankshaft with barring tool in en gine direction of rotation until marking OT A1 and pointer are aligned 05500088a M015675 06E 2013 04 Task Description 69 Checking valve bridge balance X Valve bridge with guide Y Flying valve bridge 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 gauge to determine the distance between valve bridge and rocker arm 70 Task Description M015675 06E 2013 04 04100134a TIMID 0000004355 001 TIMAD 0000004355 001 Note Insert feeler gauge with determined value between valve bridge and valve stem end A At the opposite valve stem end B a feeler gauge thicker by 0 05 mm should not fit otherwise adjust valve bridge balance Adjusting valve bridge balance Not applicable for engines with flying valve bridge Hold valve bridge 1 firmly in position with open end spanner and release locknut 2 Use feeler gauge to determine the distance between valve bridge and rocker arm Place one feeler gauge of the determined value each between valve bridge and the two valve stem ends A and B Turn adjusting screw so
21. 1 Engine oil Coolant filter gt Spare Parts Catalog WARNING Coolant is hot and under pressure Risk of injury and scalding A e Let the engine cool down e Wear protective clothing gloves and goggles safety mask Engine coolant filter Replace ment 1 Close shutoff cocks 1 2 Remove engine coolant filter 2 with filter wrench 3 Clean the sealing surface on the connect ing piece 4 Coat gasket on new engine coolant filter with engine oil 5 Screw on engine coolant filter and tighten hand tight 6 Open shutoff cocks 1 20200470b 110 Task Description M015675 06E 2013 04 TIM 4D 0000006858 009 TIMAD 0000000042 007 7 10 7 16 1 WARNING A gi Low Temperature Circuit Charge air coolant Level check Preconditions MW Engine is stopped and starting disabled Coolant is hot and under pressure Risk of injury and scalding e Let the engine cool down M MTU Fluids and Lubricants Specifications A001061 are available e Wear protective clothing gloves and goggles safety mask Checking charge air coolant lev el at filler neck Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to escape Continue to turn breather valve counter clockwise and remove Check coolant level coolant must be visi ble at marking plate Top up coolant if necessary gt Page 114 Check proper condition of
22. 10 Open bleed screw 1 or 2 on filter to be drained Open drain valve 6 or 7 Drain water and dirt from the filter until clean fuel emerges Close drain valve 6 or 7 Open fuel return line 3 or 10 Open fuel inlet 4 or 9 Close bleed screw 1 or 2 on filter to be drained when clean fuel emerges 08000086b M015675 06E 2013 04 Task Description 85 7 9 3 Edge type fuel filter Draining WARNING A or Preconditions W Engine is stopped and starting disabled Special tools Material Spare parts Diesel fuel Sealing ring Fuels are combustible Risk of fire and explosion e Avoid open flames electrical sparks and ignition sources e Do not smoke Edge type fuel filter Draining Rotate edge type filter 2 with handle 1 clockwise several times Do not apply force when rotating handle Close fuel supply Remove drain plug 3 from edge type filter 2 Drain water and contaminants through drain plug opening 3 until pure fuel emerges from filter Fit drain plug 3 with new sealing ring and screw in Open fuel supply 86 Task Description M015675 06E 2013 04 gt Spare Parts Catalog 08000087a TIM AD 0000004952 001 TIMAD 0000043567 001 7 9 4 WARNING A NOTICE Auxiliary fuel filter Replacement Preconditions MW Engine is stopped and starting disabled Special tools Material Spare parts Filt
23. 122 Tighten locknut 2 Tighten screws 1 Install guard cover Check belt tension after 30 minutes and again after 8 hours engine runtime iS 0 OO ON 21300042b 124 Task Description M015675 06E 2013 04 TIM D 0000000965 001 TIMAD 0000040744 001 7 20 7 20 1 f 2 Result Fan Drive Fan drive Drive belt tension check adjustment Preconditions MW Engine is stopped and starting disabled Special tools Material Spare parts Y4345711 1 Optibell 2 belt tension tester Preparatory steps Remove protective cover Check belt condition visually gt Page 118 For drive belt replacement gt Page 127 Checking V belt tension Rock ford S270 fan clutch Switch on belt tension tester Hold measuring tip of belt tension tester over belt drive Tap drive belt arrow with a suitable tool Hold belt tension tester over belt drive until the measured value is indicated Initial assembly at MTU Initial operation with fan None 60 Hz 1 Hz 52 Hz 1 Hz M015675 06E 2013 04 Task Description 125 Checking V belt tension Rock ford 370 fan clutch Switch on belt tension tester Hold measuring tip of belt tension tester over belt drive Tap drive belt arrow with a suitable tool ie Po Hold belt tension tester over belt drive until the measured value is indicated Initial assembly at MTU Initial operation with fan 36 Hz 5 H
24. 2 OVERSPEED 1 ETC 2 CHARGER 2 OVERSPEED 2 L1 T LUBE OIL L2 T LUBE OIL L1 T INTAKE AIR L2 T INTAKE AIR L1 P COOLANT L2 P COOLANT L1 P INTERCOOLER L2 P INTERCOOLER L1 P Crankcase L2 P Crankcase Lube oil pressure too low 2nd limit Automatic engine shutdown Coolant level too low Alarm appears together with No 24 Coolant level too low Alarm appears together with No 23 Oil filter pressure differential too high Engine overspeed Automat ic engine shutdown ETC 1 overspeed 1st lim it ETC 1 overspeed 2nd lim it ETC 2 overspeed 1st lim it ETC 2 overspeed 2nd lim it Lube oil temperature too high 1st limit Lube oil temperature too high 2nd limit Intake air temperature too high 1st limit Intake air temperature too high 2nd limit Coolant pressure too low 1st limit Coolant pressure too low 2nd limit Charge air coolant pressure too low 1st limit Charge air coolant pressure too low 2nd limit Crankcase pressure too high 1st limit Crankcase pressure too high 2nd limit 1 Check engine oil level and top up if required gt Page 94 2 Try to re start the engine gt Page 32 3 Contact Service Check coolant level in expansion tank Check coolant level in expansion tank Check oil filter 1 Acknowledge alarm 2 Try to re start the engine gt Page 32 3 Contact Se
25. CYLINDER A10 WIRING CYLINDER B1 WIRING CYLINDER B2 WIRING CYLINDER B3 WIRING CYLINDER B4 WIRING CYLINDER B5 WIRING CYLINDER B6 WIRING CYLINDER B7 WIRING CYLINDER B8 WIRING CYLINDER B9 WIRING CYLINDER B10 OPEN_LOAD CYL A1 OPEN_LOAD CYL A2 OPEN_LOAD CYL A3 OPEN_LOAD CYL A4 OPEN_LOAD CYL A5 OPEN_LOAD CYL A6 Faulty wiring to solenoid valve cylinder A10 Misfiring Faulty wiring to solenoid valve cylinder B1 Misfiring Faulty wiring to solenoid valve cylinder B2 Misfiring Faulty wiring to solenoid valve cylinder B3 Misfiring Faulty wiring to solenoid valve cylinder B4 Misfiring Faulty wiring to solenoid valve cylinder B5 Misfiring Faulty wiring to solenoid valve cylinder B6 Misfiring Faulty wiring to solenoid valve cylinder B7 Misfiring Faulty wiring to solenoid valve cylinder B8 Misfiring Faulty wiring to solenoid valve cylinder B9 Misfiring Faulty wiring to solenoid valve cylinder B10 Misfiring Disconnection in wiring to solenoid valve cylinder A1 Misfiring Disconnection in wiring to solenoid valve cylinder A2 Misfiring Disconnection in wiring to solenoid valve cylinder A3 Misfiring Disconnection in wiring to solenoid valve cylinder A4 Misfiring Disconnection in wiring to solenoid valve cylinder A5 Misfiring Disconnection in wiring to solenoid valve cylinder A6 Misfiring M015675 06E 2013 04 Troubleshoot
26. No Qty Used in 140 AppendixB M015675 06E 2013 04 F30039518 1 7 5 2 Valve clearance Check and adjustment gt Page 69 1 4 7 Cleaning the plant gt Page 36 F305 10423 1 7 5 2 Valve clearance Check and adjustment gt Page 69 F30047446 1 7 5 2 Valve clearance Check and adjustment gt Page 69 DCL ID 0000014250 002 DCL ID 0000014250 002 Torque wrench 10 60Nm Part No F30452769 Qty 1 Used in 7 3 4 Crankcase breather Filter element replacement gt Page 63 Torque wrench 10 60 Nm Part No F30452769 Qty 1 Used in 7 7 2 Injector Removal and installation gt Page 78 Torque wrench 4 20 Nm Part No F30044239 Qty 1 Used in 7 7 2 Injector Removal and installation gt Page 78 Torque wrench 6 to 50 Nm Part No F30027336 Qty 1 Used in 7 14 3 Cleaning centrifugal oil filter and replacing filter sleeve gt Page 101 M015675 06E 2013 04 AppendixB 141 Torque wrench 6 50 Nm Part No F30027336 Qty 1 Used in 7 3 1 Crankcase breather Oil separator element re placement diaphragm check and replacement gt Page 59 Torque wrench 60 320 Nm Part No F30452768 Qty 1 Used in 7 7 2 Injector Removal and installation gt Page 78 142 AppendixB M015675 06E 2013 04 DCL ID 0000014250 002 DCL ID 0000014250 002 9 2 Index Numerics 20V 4000 C22 engine data 24 A
27. Not yet defined value Not applicable X Applicable Z2Zr anaop gt 1 Reference Conditions Engine model VA 000 aU group se a Charge air coolant temperature feo Barometie pressure ema w Site altitude above sea level im 00 POWER RELATED DATA power ratings are net brake power to ISO 3046 Number of cylinders 20V 4000 Engine rated speed Engine rated speed speed 1800 Net brake power without fan A fom fuel stop power ISO 3046 GENERAL CONDITIONS for maximum power Number of cylinders PAO 0100 Intake air es new filter mbar o s Ce a Co ar Fucltenpertue at engine sumy cometon k CONSUMPTION Number of cylinders i 4000 Specific fuel consumption be 100 BL 5 EN 590 42 8MJ kg e g kWh Lube oil consumption after 100 h operation average B fuel con of B 3 sumption per hour 24 Technical Data M015675 06E 2013 04 TIM 4D 0000002640 001 TIMAD 0000002640 001 MODEL RELATED DATA basic design Number of cylinders 20V 4000 Number of cylinders _ 20 Cylinder configuration V angle degrees 90 Bre Sm stoke im C O SS ce A A C A A Ce A A COMBUSTION AIR EXHAUST GAS Number of cylinders 20V 4000 Charge air pressure before cylinder R barabs 8 4 Exhaust temperature after turbocharger R je 420 COOLING SYSTEM HT circuit Number of cylinders PAO ar 0010 Coolant temperature at engine outlet to cooling equipment
28. Q il indicator filter Check 99 Cleaning 99 Operational checks 33 P Putting into operation Preparation after extended out of service periods gt 3 months 30 Putting the engine into operation Preparation after scheduled out of service period 31 S Safety notices standards 16 Safety regulation Environmental protection 14 144 AppendixB M015675 06E 2013 04 Safety regulations Consumables 14 Fire prevention 14 Fluids and lubricants 14 Important provisions 5 Maintenance work 11 Operation 10 Organizational requirements 6 Personnel requirements 6 Repair work 11 Safety notices standards 16 Startup 10 Sensors and actuators Overview 21 Service indicator Signal ring position check 92 Service partners 134 Spare parts service 134 Starter Condition check 93 System Cleaning 36 E Transport 7 Troubleshooting 38 V Valve clearance Check and adjustment 69 Valve gear Lubrication 68 DCL ID 0000014250 002
29. breather valve clean sealing faces if required Fit breather valve and close it L Hs J r 2 01400308b Checking charge air coolant level by means of level sensor Switch on engine control system and check display coolant level is automatically monitored by engine control system Top up coolant if necessary gt Page 114 M015675 06E 2013 04 Task Description 111 7 16 2 Charge air coolant Change Special tools Material Spare parts Coolant Charge air coolant Change 1 Drain charge air coolant gt Page 113 2 Fill with charge air coolant gt Page 114 112 Task Description M015675 06E 2013 04 TIM 4D 0000000041 011 TIMAD 0000007021 001 7 16 3 Charge air coolant Draining WARNING A Preconditions WM Engine is stopped and starting disabled Special tools Material Spare parts Designation Use Sealing ring Coolant is hot and under pressure Risk of injury and scalding e Let the engine cool down e Wear protective clothing gloves and goggles safety mask Charge air coolant Draining Provide an appropriate container to drain the coolant into Turn breather valve of filler neck on coolant expansion tank counterclockwise to first stop and allow pressure to escape Continue to turn breather valve counter clockwise and remove Draw off precipitated corrosion inhibitor oil from the expansion tank through fil
30. level coolant must be visible at marker plate 2 Top up engine coolant if necessary gt Page 106 Check and clean breather valve 4 Place breather valve on filler neck and close o L Jif J r arn 2 01400308b Checking engine coolant level via level sensor 1 Switch on engine control system and check readings on the display 2 Top up engine coolant if necessary gt Page 106 M015675 06E 2013 04 Task Description 103 7 15 2 Engine coolant Change Special tools Material Spare parts Coolant Engine coolant change 1 Drain engine coolant gt Page 105 2 Fill with engine coolant gt Page 106 104 Task Description M015675 06E 2013 04 TIM D 0000000036 031 TIMAD 0000000936 005 7 15 3 Engine coolant Draining f wanno A D Preconditions WM Engine is stopped and starting disabled _ Coolant is hot and under pressure Risk of injury and scalding e Let the engine cool down e Wear protective clothing gloves and goggles safety mask Preparatory steps Provide a suitable receptacle to catch the coolant Switch off preheating unit Engine coolant Draining Turn breather valve of filler neck on coolant expansion tank counterclockwise to first stop and allow pressure to escape Continue to turn breather valve counterclockwise and remove Draw off separated corrosion inhibitor oil in expansion tank through the fi
31. max marks If necessary top up to max mark gt Page 95 Insert oil dipstick into guide tube and push fully home 94 Task Description M015675 06E 2013 04 TIMID 0000006 161 004 TIMAD 0000006151 001 7 13 2 Engine oil Change WARNING A FOI Preconditions WM Engine is stopped and starting disabled M Engine is at operating temperature M MTU Fluids and Lubricants Specification A001061 is available Special tools Material Spare parts Engine oil Sealing ring gt Spare Parts Catalog Hot oil Oil can contain combustion residues which are harmful to health Risk of injury and poisoning e Wear protective clothing gloves and goggles safety mask e Avoid contact with skin e Do not inhale oil vapor Procedure without pump Draining oil at drain plug on oil pan Provide a suitable container in which to collect the oil Remove drain plug and drain oil Install drain plug with new sealing ring Procedure with pump Oil extraction Provide a suitable container in which to collect the oil Extract all oil from oil pan using the pump Filling with new oil Open cover of filler neck Pour oil in at filler neck up to max mark at oil dipstick Close cover of filler neck Check engine oil level gt Page 94 After oil change bar engine with starting system gt Page 54 18000022a M015675 06E 2013 04 Task Description 95 7 14 Oil Filtration Cool
32. max permissible push on pressure specified for the equipment Do not attempt to bend or apply force to lines Before starting work pay attention to the following e Vent the hydraulic installation removal tool the pumps and the lines at the relevant points for the equipment to be used e g open vent plugs pump until bubble free air emerges close vent plugs e For hydraulic installation screw on the tool with the piston retracted e For hydraulic removal screw on the tool with the piston extended For a hydraulic installation removal tool with central expansion pressure supply screw spindle into shaft end until correct sealing is established During hydraulic installation and removal ensure that nobody is standing in the immediate vicinity of the component to be installed removed Working with batteries Observe the safety instructions of the battery manufacturer when working with batteries Gases emanating from the battery are explosive Avoid sparks and naked flames Do not allow electrolyte to come in contact with skin or clothing Wear protective clothing and protective gloves Never place tools on the battery Before connecting the cable to the battery check the battery polarity Battery pole reversal may lead to injury through the sudden discharge of acid or bursting of the battery body M015675 06E 2013 04 TIMID 0000040535 001 TIMAD 0000040535 001 Working on electrical and electronic assemblies Always
33. obtain the permission of the person in charge before commencing maintenance and repair work or switching off any part of the electronic system required to do so De energize the appropriate areas prior to working on assemblies Do not damage cabling during removal work When reinstalling ensure that wiring is not damaged dur ing operation by contact with sharp objects by rubbing against other components or by a hot surface Do not secure cables on lines carrying fluids Do not use cable binders to secure cables Always use connector pliers to tighten union nuts on connectors Subject the device as well as the product to a function check on completion of all repair work In partic ular check the function of the engine emergency stop feature Store spare parts properly prior to replacement i e protect them against moisture in particular Pack defective electronic components and assemblies in a suitable manner when dispatched for repair i e protected in particular against moisture and impact and wrapped in antistatic foil if necessary Working with laser equipment When working with laser equipment always wear special laser protection goggles hazard due to heavi ly focused radiation Laser equipment must be fitted with the protective devices necessary for safe operation according to type and application For conducting light beam procedures and measurement work only the following laser devices must be used e Laser devices o
34. on the left hand side of the engine and the letter B 3 to refer to the cylinders on the right hand side The cylinders of each bank are numbered consecutively starting with No 1 at the driving end The numbering of other engine components also starts with no 1 at the driving end 00001555 1 Left hand side of engine 3 Right hand side of engine 2 Auxiliary PTO end 4 Main PTO end M015675 06E 2013 04 General Information 17 2 2 Engine layout 00001513 1 Centrifugal oil filter 6 Engine coolant outlet 2 Engine lifting eye 7 Starter A side 3 Fan drive 8 Engine Control Unit ECU 4 4 Drive belt 9 Fuel priming pump 5 Charge air coolant inlet 10 Fuel filter easy change fil ter 18 General Information M015675 06E 2013 04 11 Crankcase 12 HP fuel pump 13 Engine oil filter automatic filter TIM AD 0000002072 002 TIMAD 0000002072 002 e See ies eRe eee es Hea y jl d ieee QOODOODCUHOVSeI OQOODOUS00UDO0000 DOCSOUUOUSoY aioe onto aS 00001514
35. on cylinder head Install cylinder head cover we SS 74 Task Description M015675 06E 2013 04 TIM AD 0000000923 006 TIMAD 0000001640 012 7 6 Injection Pump HP Pump 7 6 1 WARNING A WARNING A NOTICE HP pump Filling with engine oil Preconditions WM Engine is stopped and starting disabled Special tools Material Spare parts Engine oil Fuels are combustible Risk of fire and explosion e Avoid open flames electrical sparks and ignition sources e Do not smoke Oils oil vapors are combustible explosive Risk of fire and explosion e Avoid open flames electric sparks and ignition sources e Do not smoke HP fuel pump not filled with engine oil Damage to components major material damage e Ensure that th HP fuel pump is filled with engine oil before it is installed or put into operation Filling HP pump Remove plug screw 1 Use pump oiler to fill HP pump with engine oil until engine oil emerges Install plug screw 1 07300740a M015675 06E 2013 04 Task Description 75 7 6 2 HP pump Relief bore check Rotating and moving engine parts Risk of crushing danger of parts of the body being caught or pulled in A e Only run the engine at low power Keep away from the engine s danger zone A high level of noise is produced when the engine is running Risk of damage to hearing A e Wear ear defenders HP pump Relief bore check Check reli
36. operating hours ago D four to twelve operating hours ago Alarms that occurred more than twelve hours ago are deleted automatically e The three figures encode the fault itself as listed in the table below Alarms can also be caused by defective sensors actuators If troubleshooting in accordance with the following table is not successful contact Service to have the sensors actuators checked and if re quired replaced 003 004 005 006 009 010 015 L1 T FUEL E2 FUEE L1 T CHARGE AIR L2 T CHARGE AIR L1 T INTERCOOLER L2 T INTERCOOLER L1 P LUBE OIL Fuel temperature too high Reduce power 1st limit Fuel temperature too high Reduce power 2nd limit Charge air temperature too Reduce power high 1st limit Charge air temperature too Reduce power high 2nd limit Charge air coolant tempera Reduce power ture too high 1st limit Charge air coolant tempera Reduce power ture too high 2nd limit Lube oil pressure too low Check engine oil level and top up if 1st limit required gt Page 94 M015675 06E 2013 04 Troubleshooting 41 Aarm tx 016 023 024 025 030 031 032 036 037 051 052 053 054 057 058 059 060 063 064 42 Troubleshooting M015675 06E 2013 04 L2 P LUBE OIL L1 COOLANT LEVEL L2 COOLANT LEVEL L1 P OILFILTER DIFF ENGINE OVERSPEED ETC CHARGER 1 OVERSPEED 1 ETC CHARGER 1 OVERSPEED 2 ETC 2 CHARGER
37. pair defective lines Clean fuel prefilter Flush fuel prefilter Replace filter element of fuel prefilter Fuel filter replacement gt Page 84 If fault is not rectified Contact Service Check fuel lines for leaks re pair defective lines Clean fuel prefilter Flush fuel prefilter Replace filter element of fuel prefilter Fuel filter replacement gt Page 84 If fault is not rectified Contact Service Reduce power Allow the engine to cool down Check coolant cooler elements etc and clean contaminated parts see manufacturer s docu mentation Re start the engine gt Page 32 If fault occurs repeatedly Con tact Service Contact Service Contact Service Contact Service Check fuel prefilter Re start the engine gt Page 32 M015675 06E 2013 04 Troubleshooting 43 Aarm tx IDLE SPEED LOW 091 RUN UP SPEED LOW 092 START SPEED LOW 093 PREHEAT TEMP LIM IT2 094 PREHEAT TEMP LIM IT1 100 EDM NOT VALID 101 IDM NOT VALID 102 INVALID FUEL CONS 1 103 INVALID FUEL CONS 2 104 OP HOURS 1 NOT VALID 105 OP HOURS2 NOT VALID 106 ERR REC1 NOT VALID 107 ERR REC2 NOT VALID 118 L1 SUPPLY VOLT LOW 119 L2 SUPPLY VOLT LOW 120 L1 SUPPLY VOLT HIGH 121 L2 SUPPLY VOLT HIGH 44 Troubleshooting M015675 06E 2013 04 Idle speed not reached with in a specified period Termination of starting pro cedure Run up
38. that both feeler gauges can be just pulled through Hold adjusting screw securely in position with Allen key and fit locknut by hand on valve bridge Replace or rectify adjusting screws which do not move freely a 04100133a 04100132a M015675 06E 2013 04 Task Description 71 Tighten locknut 2 to 35 Nm 5 Nm hold ing valve bridge 1 in position with open end spanner Check valve bridge balance again Adjust valve bridge balance at two crank shaft positions according to the following diagram Checking valve clearance at two crankshaft positions Check TDC position of piston in cylinder Al e f the rocker arms are unloaded on cylin der A1 the piston is in firing TDC e If the rocker arms are loaded on cylinder A1 the piston is in overlap TDC Check valve clearance with cold engine e Inlet valves long rocker arm 0 2 mm e Exhaust valves short rocker arm 0 5 mm Check all valve clearances at two crank shaft positions firing and overlap TDC for cylinder A1 as per diagram Use feeler gauge to determine the distance between valve bridge and rocker arm If the deviation from the reference value exceeds 0 1 mm adjust valve clearance 72 Task Description M015675 06E 2013 04 05500087a 1 2 x l A10 X B10 AW x 1 B10 ag p 1 Bo AG y x X Bg X Aa x B8 A8 BB AT x X B7 ay
39. the manufacturer in writ ing including engine control parameters e In compliance with all safety instructions and in adherence to all warning notices in this manual e In accordance with the maintenance requirements over the entire service life of the product gt Main tenance Schedule e In compliance with the maintenance and repair instructions contained in this manual in particular with regard to the specified tightening torques e With the exclusive use of technical personnel trained in commissioning operation maintenance and repair e By contracting only workshops authorized by the manufacturer to carry out repair and overhaul Any other use is considered improper use and increases the risk of personnel injury or material damage in product operation The manufacturer will accept no liability for such damage Modifications or conversions Unauthorized modifications to the product compromise safety The manufacturer will accept no liability or warranty claims for any damage caused by unauthorized modifications or conversions Spare parts Only genuine spare parts must be used to replace components or assemblies The manufacturer will accept no liability or warranty claims for any damage caused by the use of other spare parts M015675 06E 2013 04 Safety 5 L2 6 Safety Personnel and organizational requirements Organizational measures of the operator This manual must be issued to all personnel involved in operation ma
40. tor 3 Clean connector housings connector sock et housings 1 and all contacts with iso propyl alcohol When connectors sockets and all contacts are dry Fit connectors and check governor connections gt Page 130 F30017884 1 X00058037 1 50800100b 50800101b M015675 06E 2013 04 Task Description 129 7 22 2 Checking engine control unit plug connections Preconditions V Engine shut down and starting disabled Special tools Material Spare parts Connector pliers 0135315483 1 Checking engine control unit plug connections 1 Use connector pliers 3 to make certain that all plug in connections on engine con trol unit are securely seated 2 Tighten loose bayonet couplings 2 with connector pliers 3 by turning them clock wise until they latch into place 3 Make sure that unassigned sockets are closed off with cover caps 4 Contact Service if bayonet union nut is de fective 50800102a 130 Task Description M015675 06E 2013 04 TIM AD 0000000949 003 TIMAD 0000000858 011 8 Appendix A 8 1 Abbreviations Abbre Meaning Explanation viation A D ADEC AFRS AGR AL ANSI ATL ATS BR BV CAN CDC CEL CKT CLS CM CPS CR CTS DDEC DDL DDR Dia Sys DIN DL DOC DPF DT ECM ECU Analog Digital Advanced Diesel Engine Controller Air Filter Restriction Sensor Abgasruckfuhrung Alarm American National Standa
41. volt age too low Electronic equipment defec tive Automatic engine shutdown A D converter supply volt age too low Electronic equipment defec tive Automatic engine shutdown A D converter supply volt age too low Electronic equipment defec tive Automatic engine shutdown 1 2 Improve engine room ventila tion Reduce engine power Contact Service Contact Service i N k N 3 Disconnect connectors X2 and X3 from ECU If alarm does not disappear Contact Service Check wiring pressure sen sors Contact Service Disconnect connectors X2 and X3 from ECU If alarm does not disappear Contact Service Check wiring pressure sen sors Contact Service Contact Service Contact Service Contact Service Contact Service Contact Service Contact Service Contact Service Contact Service Contact Service Contact Service Contact Service M015675 06E 2013 04 Troubleshooting 45 Aarm tx 170 173 180 181 183 184 185 186 187 188 189 46 Troubleshooting M015675 06E 2013 04 MI MODULE FAIL MI NOT ACTIVE MODULE WRITE LIMIT CAN1 NODE LOST CAN2 NODE LOST CAN NO PU DATA CAN PU DATA EE FAIL CAN LESS MAILBOX ES CAN 1 BUS OFF CAN 1 ERROR PAS SIVE CAN2 BUS OFF CAN2 ERROR PAS SIVE SD T COOLANT SD T FUEL SD T CHARGE AIR SD T COOLANT IN TERC SD P CHARGE AIR
42. wrench Screw M12 Tightening torque 100 Nm 10 Nm M015675 06E 2013 04 Task Description 81 16 17 18 19 Tighten union nut of adapter limiting valve with torque wrench to the specified tightening torque Union nut Tightening torque 140 Nm 10 Nm Tighten union nut of adapter injector with torque wrench to the specified tightening torque Union nut Tightening torque 120 Nm 10 Nm Twist cable several times 07500033b Insert cable lugs arrows underneath the screws on the injector and tighten screws with torque wrench to the specified tightening torque Screw Tightening torque 1 5 Nm Final steps Install cylinder head cover gt Page 74 Open up fuel supply to engine 82 Task Description M015675 06E 2013 04 TIM AD 0000000952 010 TIMAD 0000004709 006 7 8 Fuel System 7 8 1 Fuel system Venting Preconditions MW Engine is stopped and starting disabled Special tools Material Spare parts Designation Use Diesel fuel A Fuels are combustible Risk of fire and explosion e Avoid open flames electrical sparks and ignition sources e Do not smoke Venting LP fuel system Open vent plug 1 Unlock fuel priming pump 2 screw out handle by turning it counterclockwise Operate the pump with the handle 2 until bubble free fuel emerges from the vent plug 1 Close vent plug 1 Screw in handle by turning it clockwise Verify that fuel p
43. 00000938 008 7 15 6 Engine coolant Sample extraction and analysis Preconditions M MTU Fluids and Lubricants Specifications A001061 are available Special tools Material Spare parts MTU test kit Rotating and moving engine parts A WARNING A Coolant is hot and under pressure Risk of injury and scalding e Let the engine cool down 5605892099 00 1 Risk of crushing danger of parts of the body being caught or pulled in e Only run the engine at low power Keep away from the engine s danger zone e Wear protective clothing gloves and goggles safety mask Risk of damage to hearing e Wear ear defenders Engine coolant Sample extrac tion and analysis With the engine running open drain valve 1 Flush sample extraction point by draining approx 1 liter coolant Drain approx 1 liter coolant into a clean container Close drain valve 1 Using the equipment and chemicals in the MTU test kit examine coolant for e Antifreeze concentration e Corrosion inhibitor concentration e pH value For engine coolant changing intervals gt MTU Fluids and Lubricants Specifica tions A001061 A high level of noise is produced when the engine is running 20202577 M015675 06E 2013 04 Task Description 109 7 15 7 Engine coolant filter Replacement Preconditions V Engine is stopped and starting disabled Special tools Material Spare parts Filter wrench F30379 104
44. 013 04 Task Description 61 7 3 3 Crankcase breather open circuit crankcase ventilation Filter element cleaning Preconditions V Engine is stopped and starting disabled WARNING i Compressed air gun ejects a jet of pressurized air Risk of injury to eyes and damage to hearing risk of rupturing internal organs A e Never direct air jet at people e Always wear Safety goggles face mask and ear defenders Cleaning agents should not be left to take effect for too long Damage to components is possible in e Observe manufacturer s instructions Clean filter element Remove filter element gt Page 59 Clean filter element with cleaning agent Remove cleaner Blow out filter element thoroughly with compressed air Install filter element gt Page 59 oI iS 62 Task Description M015675 06E 2013 04 TIM D 0000003508 004 TIMAD 0000003532 003 7 3 4 Crankcase breather Filter element replacement WARNING A OF Ol ee IS Preconditions MW Engine shut down and starting disabled Special tools Material Spare parts Torque wrench 10 60Nm Engine oil Filter insert Hot oil F30452769 1 gt Spare Parts Catalog Oil can contain combustion residues which are harmful to health Risk of injury and poisoning e Wear protective clothing gloves and goggles safety mask e Avoid contact with skin e Do not inhale oil vapor Crankcase breather closed cir cuit crankcase
45. 2 Putting the engine into operation after scheduled out of service period 4 3 Engine Starting in manual mode 4 4 Operational checks 4 5 Engine Stopping in manual mode 4 6 After shutting down the engine 4 7 Cleaning the plant 5 Maintenance 5 1 Maintenance Schedule task reference table QL1 6 Troubleshooting 6 1 Troubleshooting 6 2 ECU 4 alarms 7 Task Description 7 1 Engine 7 1 1 Engine Barring manually 11 14 16 17 18 21 24 28 29 30 31 32 33 34 35 36 37 38 41 52 52 7 1 2 Engine Barring with starting system 7 2 Cylinder Liner 7 2 1 Endoscopically examining cylinder liner 7 2 2 Instructions and comments on endoscopic and visual examination of cylinder liners 7 3 Crankcase Breather 7 3 1 Crankcase breather Oil separator element replacement diaphragm check and replacement 7 3 2 Crankcase breather Cleaning 7 3 3 Crankcase breather open circuit crankcase ventilation Filter element cleaning 7 3 4 Crankcase breather Filter element replacement 7 4 Running Gear 74 1 Grounding device Carbon brush check 7 4 2 Grounding device Carbon brush replacement 7 5 Valve Drive 7 5 1 Valve gear Lubrication 7 5 2 Valve clearance Check and adjustment 7 5 3 Cylinder head cover Removal and installation 7 6 Injection Pump HP Pump 7 6 1 HP pump Filling with engine oil 7 6 2 HP pump Relief bore check 7 7 Injection Valve Injector 7 7 1 Injecto
46. 3 to the specified torque using torque wrench Nut Tightening torque 35 Nm to 45 Nm 17 Place rotor 11 in housing 12 and check for ease of movement 18 Check sealing ring 13 fit new one if necessary 19 Fit sealing ring 13 on housing 12 20 Fit cover 1 21 Tighten cover screw 2 by hand 22 Fit clamp 14 and tighten to the specified torque using torque wrench Clamp Tightening torque 8 Nm to 10 Nm 23 Tighten cover screw 2 to the specified torque using torque wrench Screw Tightening torque 5 Nm to 7 Nm 102 Task Description M015675 06E 2013 04 TIMAD 0000000934 012 TIMAD 0000000937 012 7 15 Coolant Circuit General High Temperature Circuit 7 15 WARNING A 1 Engine coolant Level check Preconditions WM Engine is stopped and starting disabled Coolant is hot and under pressure Risk of injury and scalding e Let the engine cool down M MTU Fluids and Lubricants Specifications A001061 are available e Wear protective clothing gloves and goggles safety mask Checking engine coolant level at filler neck 1 Turn breather valve on coolant expansion tank counterclockwise to the first stop and allow pressure to escape 2 Continue to turn breather valve counterclockwise and remove 3 Check engine coolant level coolant must be visible at the bottom edge of the filler neck s cast eye Checking engine coolant level at remote cooler 1 Check engine coolant
47. 5 A3 A5 B2 A6 B 1 B7 A1 B5 A8 B7 A5 B2 A7 B 10 A2 B3 A 1 0 B6 A3 B4 A6 B9 A4 B 1 A9 B8 28 Technical Data M015675 06E 2013 04 TIM AD 0000002794 004 TIMAD 0000002137 001 3 3 Main engine dimensions Main engine dimensions me 2 00000317a Length A approx 3630 mm Width B approx 1450 mm Height C approx 2252 mm M015675 06E 2013 04 Technical Data 29 4 Operation 4 1 Putting the engine into operation after extended out of service periods gt 3 months Preconditions MW Engine is stopped and starting disabled M MTU Fluids and Lubricants Specifications A001061 are available Putting into operation after long out of service periods gt 3 months Engine Valve gear Lube oil system Fuel system Coolant circuit Coolant circuit Coolant circuit Engine governor Engine control system ECS 30 Operation M015675 06E 2013 04 Depreserve gt MTU Fluids and Lubricants Specifications A001061 Lubricate valve gear gt Page 68 Check engine oil level gt Page 94 Vent gt Page 83 If engine is out of service for more than one year change engine coolant gt Page 104 Change charge air coolant gt Page 112 Check engine coolant level gt Page 103 Check charge air coolant level gt Page 111 Preheat coolant with coolant preheating unit if provided Check plug in connections gt Page 130 Switch ON TIM AD
48. Abbreviations 131 After shutting down the engine 35 Air filter Replacement 90 Air filter element Cleaning 89 Removal and installation 91 Automatic oil filter Oil filter candles replacement 96 Auxiliary fuel filter Replacement 87 B Battery charging generator Check 120 Battery charging generator Removal 119 C Centrifugal oil filter Cleaning 101 Charge air coolant Change 12 Levelcheck 111 Charge air coolant level Check 111 Charge air coolant pump Checking pressure relief port 116 Charge air coolant system Filling 114 Charge air coolant Draining 113 Connectors Cleaning 129 Contact persons 134 Change 104 112 Sample extraction and analysis 109 Coolant filter Replacement 110 Coolant charge air Levelcheck 111 Crankcase breather Filter element replacement 63 Cleaning 61 Diaphragm check 59 Oil separator element replacement 59 Crankcase breather open circuit crankcase ventilation Filter element cleaning 62 Crankshaft transport locking device For transport with flanged on generator 8 Cylinder Designation 17 Cylinder head cover Removal and installation 74 Cylinder liner Endoscopic examination 55 D Designations Engine sides and cylinders 17 Drive belt Check condition 118 Dust bowl Cleaning 89 E ECU 4 alarms 41 Edge type fuel filter Draining 86 Engine Barring manually 52 Startingin manual m
49. BDC Insert endoscope into cylinder liner through injector socket Endoscopically examining cylinder liner e Thin carbon coating around carbon scraper ring No action required e Slight localized additive deposits at top edge e Localized polished areas at bottom edge e Ring of carbon around entire circumference between top piston ring and bottom edge of carbon scraper ring First signs of marks left by top piston ring Light traces around circumference Faultless even honing pattern First signs of marks left by lower cooling bores e Wear pattern appears darker e Dark areas with even or varying degrees of discoloration Further endoscopic examina e Beginning and end of the discoloration are not sharply defined and tion required as part of mainte do not cover the entire stroke length nance work e Dark areas in the upper section of the cooling bore remaining cir cumference cannot be faulted Piston rings cannot be faulted e Around the entire circumference as well as areas of pale discolora Cylinder liner must be replaced tion not such as to impair operation clearly darker stripes that contact Service start at the top piston ring Heat discoloration in the direction of stroke and honing pattern damage Heat discoloration of piston rings M015675 06E 2013 04 Task Description 55 1 Compile endoscopy report with the aid of the table Use technical terms for description of the liner surface gt Page 57 3 Depending on findings
50. Engine lifting eye 2 Cylinder head cover cyl inder head 3 Oil heat exchanger 4 Intercooler 5 Flywheel 6 Charge air coolant outlet 7 Engine coolant inlet 8 Oil pan 9 Oil dipstick 10 Oil filler neck 11 Starter B side M015675 06E 2013 04 General Information 19 7 7 7 ror 5 a era oP io a O h g i 9 n EA o i q PAm pW Ls n JUE ae g 3 s ih y e Ar T Lg ee a j e T I Sig DE I H J B ai ay ail es ne j A be 00001515 1 Air supply downstream of 4 Combustion air inlet A 7 Exhaust turbocharger B intercooler A side side side 2 Exhaust system connec 5 Crankcase breather 8 Exhaust system connec tion A side 6 Combusti
51. Operating Instructions Diesel engine 20V 4000 C22 M015675 06E Printed in Germany 2013 Copyright MTU Friedrichshafen GmbH This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of MTU Friedrichshafen GmbH This restriction also applies to copyright distribution translation mi crofilming and storage or processing on electronic systems including data bases and online services This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage during operation Subject to alterations and amendments DCL ID 0000014250 002 Table of Contents 1 Safety 1 1 Important provisions for all products 1 2 Personnel and organizational requirements 1 3 Transport 1 4 Crankshaft transport locking device For transport with flanged on generator 1 5 Safety regulations for startup and operation 1 6 Safety regulations for maintenance and repair work 1 7 Fire prevention and environmental protection consumable fluids and materials 1 8 Standards for safety notices in the text 2 General Information 2 1 Engine side and cylinder designations 2 2 Engine layout 2 3 Sensors and actuators Overview 3 Technical Data 3 1 20V 4000 C22 engine data 3 2 Firing order 3 3 Main engine dimensions 4 Operation 4 1 Putting the engine into operation after extended out of service periods gt 3 months 4
52. ads on both sides of the flywheel 1 for ease of movement Install retainer 2 with screw 4 and washer 3 through the opening in the flywheel housing 5 Lubricant engine oil Tighten screw 4 in three steps Tightening torque 50 5 Nm Mark the engine as Fitted with transportation locking device M015675 06E 2013 04 Safety 9 1 3 10 Safety Safety regulations for startup and operation Safety regulations for startup Install the product correctly and carry out acceptance in accordance the manufacturer s specifications before putting the product into service Before the product is put into operation for the first time all official authorizations must be available and commissioning preconditions met When putting the product into operation always ensure e that all maintenance and repair work has been completed e that all loose parts have been removed from rotating machine components e that no one is present in the danger zone of rotating machine components Immediately after putting the product into operation make sure that all control and display instruments as well as the signaling and alarm systems work properly Safety regulations for equipment operation The operator must be familiar with the control and display elements The operator must be familiar with the consequences of any operations performed During operation the display instruments and monitoring units must be permanently observed with re gar
53. akutex 60 50602 Carbon brush gt Spare Parts Catalog Compressed air gun ejects a jet of pressurized air Risk of injury to eyes and damage to hearing risk of rupturing internal organs e Never direct air jet at people e Always wear safety goggles face mask and ear defenders Inappropriate cleaning tool Risk of damage to component e Observe manufacturer s instructions e Use appropriate cleaning tool Remove grounding assembly Remove screws 1 with washers Remove grounding device 2 from flywheel housing 3 03500562a Checking grounding device Carbon brush Damaged Fit new part gt Page 67 Wear limit 45 mm new condition Fit new part gt Page 67 60 mm Press carbon brush against spring pressure Spring broken damaged Fit new part gt Page 67 Running surface on adapter contaminated corroded Clean M015675 06E 2013 04 Task Description 65 Cleaning running surface on adapter 1 Clean running surface of carbon brushes on adapter with cold cleaner h Remove stubborn deposits with soft brush 3 Blow out adapter with compressed air Installing grounding device 1 Check mounting surface on flywheel housing for cleanness 2 Install grounding device on flywheel housing and secure with screws 66 Task Description M015675 06E 2013 04 TIM 4D 0000033357 005 TIMAD 0000033339 002 7 4 2 oe eS D N Note 10 Grounding device Carbon brush replacement
54. and sealing ring depending on degree of gt See manufacturer s docu contamination when the limit years is reached at the latest mentation W1207 Check valve clearance adjust as necessary ATTENTION First gt Page 69 adjustment after 1000 operating hours W1463 Check general condition of engine mounting visual inspection gt Page 117 W1481 Replace supplementary fuel filter or filter element of supple gt Page 87 mentary fuel filter W1697 Check carbon brushes on flywheel replace if necessary gt Page 65 W1698_ Replace carbon brushes on flywheel gt Page 67 W1716 Clean generator gt Page 121 Table 1 Maintenance Schedule task reference table QL 1 M015675 06E 2013 04 Maintenance 37 6 Troubleshooting 6 1 Troubleshooting Engine does not turn over when starter is operated Battery Discharged or defective Charge or replace see manufacturer s documentation Cable connections defective Check if cable connections are properly secured see manufacturer s documen tation Starter Engine wiring or starter faulty Check if cable connections are properly secured contact Service Engine wiring Faulty Check gt Page 128 Engine alternator Assemblies or connectors possibly loose Perform visual inspection see manufac control system turer s documentation Engine Control Unit Electrical connections may be loose Check electrical connections gt Page 130 Engine Jammed can
55. at injector with assembly paste in the area of the nozzle retaining nut Fit new O rings on injector and coat with grease Fit new sealing ring with grease on injector observe installation position of sealing ring Clean sealing face on cylinder head and protective sleeve with milling cutter Insert injector into cylinder head making sure that the HP line connections are aligned correctly Push in the injector using the installation removal device Remove the installation removal device 80 Task Description M015675 06E 2013 04 07500032b 04000047a 07500211a TIMID 0000000952 010 TIMAD 0000000952 010 9 13 14 Use slotted screwdriver to check thrust ring at both line ends for secure seating 07700369a Tighten loose thrust ring to the specified tightening torque Thrust ring Tightening torque 5 Nm to 10 Nm Coat screw head mating face 2 and thread with engine oil Q Lp cy S 07500011 Fit hold down clamp 1 in correct position by hand Tighten screw 2 with torque wrench to the speci fied initial tightening torque Screw M12 Preload torque Engine oil 5 Nm to 10 Nm Fit O rings 4 and 6 on high pressure fuel line 5 and coat with grease Tighten high pressure fuel line 5 to the specified initial tightening torque HP line Preload torque Engine oil 5 Nm to 10 Nm Tighten screw 2 to specified torque using a torque
56. austic substances When using flammable materials prevent them coming into contact with ignition sources and do not smoke Used oil Used oil contains combustion residues that are harmful to health Rub barrier cream into hands Wash hands after contact with used oil M015675 06E 2013 04 TIM AD 0000040536 003 TIMAD 0000040536 003 Lead Adopt suitable measures to avoid the formation of lead dust Switch on extraction system When working with lead or pastes that contain lead avoid direct contact with the skin Do not inhale lead vapors Wash hands after contact with lead or lead containing substances Compressed air Observe special safety precautions when working with compressed air Unauthorized use of compressed air e g forcing flammable liquids hazard class Al All and B out of containers risks causing an explosion Wear goggles when blowing dirt off components or blowing away swarf Blowing compressed air into thin walled containers e g containers made of sheet metal plastic or glass for drying purposes or to check for leaks risks bursting them Pay special attention to the pressure in the compressed air system or pressure vessel Assemblies or products to be connected must either be designed for that pressure or if the permis sible pressure is lower than the system pressure a pressure reducing valve and safety valve set to the permissible pressure must be connected between the assemblies products a
57. ber of cylinders Longitudinal inclination continuous max driving end down Option max operating inclinations Longitudinal inclination continuous max driving end up Option max operating inclinations Longitudinal inclination temporary max driving end up Option max operating inclinations CAPACITIES Number of cylinders Engine coolant capacity without cooling equipment Engine oil capacity initial filling standard oil system Option max operating inclinations Oil pan capacity dipstick mark min standard oil system Option max operating inclinations Oil pan capacity dipstick mark max standard oil system Option max operating inclinations WEIGHTS MAIN DIMENSIONS Number of cylinders Engine weight dry basic engine configuration 26 Technical Data M015675 06E 2013 04 VA 01010 PAO e000 10 L degrees 10 PA e000 VA E0010 a o s TIM 4D 0000002640 001 TIMAD 0000002640 001 ACOUSTICS Number of cylinders Exhaust noise unsilenced BL free field sound pressure level Lp 1m dis db A tance ISO 6798 Engine surface noise with attenuated BL intake noise filter free field sound db A pressure level Lp 1m distance ISO 6798 M015675 06E 2013 04 Technical Data 27 3 2 Firing order Firing order Number of cylin Firing order ders A1 B4 A4 A2 B3 A3 B2 B 1 A1 B2 A5 B4 A3 B 1 A6 B5 A2 B3 A4 B6 A1 A7 B4 B6 A4 B8 A2 A8 B3 B
58. ct with skin e Do not inhale oil vapor Compressed air gun ejects a jet of pressurized air Risk of injury to eyes and damage to hearing risk of rupturing internal organs e Never direct air jet at people e Always wear safety goggles face mask and ear defenders M015675 06E 2013 04 Task Description 101 Cleaning centrifugal oil filter and replacing filter sleeve 1 Remove clamp 14 2 Undo cover screw 2 and take off cov er 1 3 Carefully lift rotor 11 allow oil to drain and remove from housing 4 Holding the rotor 11 firmly release rotor cover nut 3 5 Take off rotor cover 4 6 Remove filter sleeve 6 7 Measure thickness of oil residues on filter sleeve 6 Result If the oil residues exceed the maximum lay er thickness of 45 mm shorten the service _ Sae interval 8 Dismantle rotor tube 7 conical disk 8 18300068b and rotor base 10 9 Wash rotor cover 4 rotor tube 7 conical disk 8 and rotor base 10 with cold cleaner 10 Blow out with compressed air 11 Check sealing ring 9 fit new one if neces sary 12 Assemble rotor tube 7 conical disk 8 and rotor base 10 together 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 neces sary 15 Mount rotor cover 4 and sealing ring 5 16 Tighten rotor cover nut
59. cts a jet of pressurized air Risk of injury to eyes and damage to hearing risk of rupturing internal organs e Never direct air jet at people e Always wear safety goggles face mask and ear defenders Clean air filter element Clean paper filter element dry only Open air filter and remove filter element gt Page 91 Check gasket for damage and cleanness replace if necessary Clean all sealing and contact surfaces Debris particles must not enter the intake system Clean dust bowl if available Blow out filter element with compressed air max 3 bar from the inside out until no more dust is blown out Fit new filter element if old one is heavily contaminated or damaged gt Page 90 Visual inspection Use inspection lamp to check cleaned filter element for damage Fit new filter element if old one is damaged gt Page 90 01000492a 01000493a M015675 06E 2013 04 Task Description 89 7 11 2 Air filter Replacement Special tools Material Spare parts Air filter gt Spare Parts Catalog Air filter Replacement 1 Remove air filter and install new one gt Page 91 2 Reset signal ring of service indicator gt Page 92 90 Task Description M015675 06E 2013 04 TIM 4D 0000000903 004 TIMAD 0000005455 003 7 11 3 Os On oN 2 Air filter element Removal and installation optional Preconditions MW Engine is stopped and starting disabl
60. d to present operating status violation of limit values and warning or alarm messages Malfunctions and emergency stop The procedures for cases of emergency in particular emergency stop must be practiced regularly The following steps must be taken if a malfunction of the system is recognized or reported by the sys tem e Inform supervisor s in charge e Analyze the message e f required carry out emergency operations e g emergency stop Operation The following conditions must be fulfilled before starting the product e Wear ear protection e Ensure that the engine room is well ventilated e Do not inhale the exhaust gases of the product e Ensure that the exhaust system is free of leaks and that the gases are discharged to atmosphere e Mop up any leaked or spilt fluids and lubricants immediately or soak up with a suitable binding agent e Protect battery terminals generator terminals or cables against accidental contact Operation of electrical equipment When electrical equipment is in operation certain components of these appliances are electrically live Observe the safety instructions for these devices M015675 06E 2013 04 TIM D 0000040533 001 TIMAD 0000040535 001 1 6 safety regulations for maintenance and repair work Safety regulations prior to maintenance and repair work Have maintenance or repair work carried out by qualified and authorized personnel only Allow the product to cool down
61. disassem bling it Remove screws 1 Take off cover 2 with O ring 3 Take strainer 5 from filter housing 18300256b M015675 06E 2013 04 Task Description 99 Checking strainer a Emane faensen Strainer Metallic residues e Clean e Monitor engine operation e Check strainer daily e Contact Service Strainer Damaged Fit new part Square section ring Damaged Fit new part O ring Damaged Fit new part Cleaning strainer Wash strainer 5 with cleaner Remove stubborn deposits with soft brush Blow out strainer 5 with compressed air from inside Installing strainer Coat square section ring 4 on strainer 5 with engine oil and install strainer 5 Coat O ring 3 with engine oil and fit in filter housing Fit cover 2 and secure with screws 1 and washers 100 Task Description M015675 06E 2013 04 TIM AD 0000006402 005 TIMAD 0000000934 012 7 14 3 WARNING WARNING A Cleaning centrifugal oil filter and replacing filter sleeve Preconditions Mi Engine shut down and secured against being restarted Special tools Material Spare parts Torque wrench 6 to 50 Nm F30027336 1 Cold cleaner Hakutex 60 X00056750 1 Filter sleeve gt Spare Parts Catalog Sealing ring gt Spare Parts Catalog Hot oil Oil can contain combustion residues which are harmful to health Risk of injury and poisoning e Wear protective clothing gloves and goggles safety mask e Avoid conta
62. e TIM AD 0000003161 001 TIMAD 0000003161 001 365 382 383 384 385 386 STOP POWER STAGE 2 STOP SOLENOID WIR ING TRAN OUT1 PLANT DEF TRAN OUT2 PLANT DEF TRAN OUT3 PLANT DEF TRAN OUT4 PLANT DEF TRAN OUT 5 PLANT DEF TRAN OUT 6 PLANT DEF Solenoid valve or wiring or ECU defective Automatic engine shutdown Solenoid valve wiring faulty Automatic engine shutdown Binary transistor output plant 1 defective Binary transistor output plant 2 defective Binary transistor output plant 3 defective Binary transistor output plant 4 defective Binary transistor output plant 5 defective Binary transistor output plant 6 defective 1 Check wiring 2 Try to re start the engine gt Page 32 3 Contact Service 1 Check wiring 2 Try to re start the engine gt Page 32 3 Contact Service Contact Service Contact Service Contact Service Contact Service Contact Service Contact Service M015675 06E 2013 04 Troubleshooting 51 7 fal 7 1 1 DANGER A Task Description Engine Engine Barring manually Preconditions W Engine is stopped and starting disabled Special tools Material Spare parts Barring gear Barring gear Adapter Ratchet with extension Rotating and moving engine parts F6555766 F6783293 F6558528 1 1 1 F300062 12 1 Risk of crushing danger of parts of the body being caught or pulled in e Before c
63. ed Special tools Material Spare parts Gasket Removing and installing air fil ter element Release latches 9 Remove dust bowl 8 and partition 7 Remove collar nut 6 Screw off air filter element 4 Clean housing 3 and dust bowl 8 Check seal 5 for damage and cleanness replace if necessary Clean all sealing and contact surfaces Fit partition 7 and dust bowl 8 according to marking Secure dust bowl 8 with latches 9 gt Spare Parts Catalog 01000491a M015675 06E 2013 04 Task Description 91 7 11 4 Service indicator Signal ring position check optional Preconditions V Engine is stopped and starting disabled Checking signal ring position 1 If the signal ring is completely visible in the control window 2 replace air filter gt Page 90 2 After installation of new filter press reset button 1 Result Engaged piston with signal ring moves back to initial position 08401046 92 Task Description M015675 06E 2013 04 TIMID 0000005484 008 TIMAD 0000000905 017 alh 7 12 1 Starting Equipment Starter Condition check Preconditions MW Engine is stopped and starting disabled Checking starter condition Check securing screws of starter for secure seating and tighten if required Check wiring gt Page 128 M015675 06E 2013 04 Task Description 93 7 13 FAG Note Lube Oil System Lube Oil Circu
64. ed Sensor defect turbocharger speed Sensor defect fuel pres sure Sensor defect ECU operat ing voltage Sensor defect temperature in ECU Sensor defect analog speed demand Injection timing fault cylin der Al Injection timing fault cylin der A2 Injection timing fault cylin der A3 Injection timing fault cylin der A4 Injection timing fault cylin der A5 Injection timing fault cylin der A6 Injection timing fault cylin der A7 Injection timing fault cylin der A8 Injection timing fault cylin der A9 1 Check wiring 2 Contact Service Check wiring Contact Service p9 i Check wiring Contact Service M Check wiring Contact Service pJ i Check wiring Contact Service MI k Check wiring Contact Service e ND Check wiring Contact Service N Check wiring Contact Service p3 k Check wiring Contact Service MI k Check wiring Contact Service ND 1 Check wiring 2 Contact Service Contact Service Contact Service 1 Check speed transmitter 2 Check wiring 3 Contact Service If fault occurs repeatedly Contact Service If fault occurs repeatedly Contact Service If fault occurs repeatedly Contact Service If fault occurs repeatedly Contact Service If fault occurs repeatedly Contact Service If fault occurs repeatedly Contact Service If fault occurs repeatedly Contac
65. ef bore for oil and fuel discharge by visual inspection 2 If relief bore is contaminated stop the en gine disable engine start and clean relief bore 3 Note the following in case of fluid dis charge e Heavy discharge means continuous dis charge of fluids leakage Contact Serv ice e Minor discharge of fluids up to 10 drops per day is normal moistening and not considered a leakage 07300450b 76 Task Description M015675 06E 2013 04 TIM AD 0000000924 007 TIMAD 0000000022 013 Tf 7 7 1 Injection Valve Injector Injector Replacement Special tools Material Spare parts Injector gt Spare Parts Catalog Replacing injector Remove injector and install new injector gt Page 78 M015675 06E 2013 04 Task Description 77 7 7 2 Injector Removal and installation Preconditions MW Engine is stopped and starting disabled Special tools Material Spare parts Installation and removal tool for injector F6790161 1 Milling cutter F30452739 1 Slotted screwdriver F30452578 1 Torque wrench 4 20 Nm F30044239 1 Torque wrench 10 60 Nm F30452769 1 Torque wrench 60 320 Nm F30452768 1 Assembly paste Optimoly Paste White T 40477 1 Grease Kluthe Hakuform 30 10 emulsifier X00029933 1 Engine oil Fuels are combustible Risk of fire and explosion A e Avoid open flames electrical sparks and ignition sources e Do not smoke Cable damage during operation Fire hazard
66. elt condition visually gt Page 118 02800042a Checking drive belt tension 1 Fit measuring head 2 on belt tension tester 3 and hit drive belt 1 with a suitable tool 2 Hold belt tension tester over belt drive until the measured value is displayed For specifications refer to table below Application Value for new drive belt Value for used drive belt Series 4000 92 Hz to 96 Hz 80 Hz to 84 Hz 3 Ifthe measured values deviate from the specifications above adjust drive belt tension gt Page 122 M015675 06E 2013 04 Task Description 123 7 19 6 Battery charging generator drive Drive belt replacement Preconditions V Engine is stopped and starting disabled Special tools Material Spare parts Drive belt gt Spare Parts Catalog Note In the event of drive belt failure during engine operation fit a new drive belt as quickly as possible Non compliance with these instructions may lead to severe consequential damage to drive unit and gear train 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 cover Loosen locknut 2 and screws 1 3 Release drive belt with tensioning nut 3 and take off belt 4 Clean belt pulleys Fit new drive belt Tension drive belt with tensioning nut 3 and check belt tension gt Page
67. er wrench Engine oil Easy change filter Fuels are flammable and explosive Danger to life Risk of burns F30379 104 1 gt Spare Parts Catalog 2 e Avoid naked flames electrical sparks and ignition sources e Do not smoke e Wear protective clothing protective gloves and goggles safety mask Fuels are flammable and explosive Risk of severe component damage and other severe damage e Avoid naked flames electrical sparks and ignition sources e Do not smoke Replacing auxiliary fuel filter Provide suitable container to collect escap ing fuel 2 Close fuel feed with stopcock 1 Remove easy change filter 3 with filter wrench 4 Clean sealing surface on filter head 2 5 Coat gasket on easy change filter 3 slight ly with engine oil arrow 6 Screw on easy change filter 3 by hand un til the seal makes contact with the filter head and tighten manually Replace further easy change filters in the same way 8 Open stopcock 1 9 Vent fuel system gt Page 83 08301004 M015675 06E 2013 04 Task Description 87 7 10 Charge Air Cooling 7 10 1 Intercooler Check water drain for coolant leakage and absence of restrictions DANGER Rotating and moving engine parts Risk of crushing danger of parts of the body being caught or pulled in A e Only run the engine at low power Keep away from the engine s danger zone A high level of noise is produced when the eng
68. f classes 1 2 or 3A e Laser devices of class 3B which have maximum output in the visible wavelength range 400 to 700 nm a maximum output of 5 mW and in which the beam axis and surface are designed to prevent any risk to the eyes M015675 06E 2013 04 Safety 13 1 7 14 Safety Fire prevention and environmental protection consumable fluids and materials Fire prevention Rectify any fuel or oil leaks immediately Oil or fuel on hot components can cause fires therefore al ways keep the product in a clean condition Do not leave cloths saturated with fluids and lubricants on the product Do not store combustible materials near the product Do not carry out welding work on pipes and components carrying oil or fuel Before welding clean with a nonflammable fluid When starting the engine with an external power source connect the ground lead last and remove it first To avoid sparks in the vicinity of the battery connect the ground lead from the external power source to the ground lead of the engine or to the ground terminal of the starter Always keep suitable firefighting equipment fire extinguishers at hand and familiarize yourself with their use Noise Noise can lead to an increased risk of accidents if it makes it more difficult to hear audible signals warning calls or noises indicating danger Wear ear defenders in work areas with a sound pressure level in excess of 85dB A Environmental protection and disp
69. ght or pulled in A e Before cranking the engine make sure that there are no persons in the engine s danger zone e After finishing work on the engine make sure that all safety devices are put back in place and all tools removed from the engine Barring engine with starting sys tem 1 Disengage the bayonet coupling 4 of con nector X4 with connector pliers 2 and withdraw connector 3 from engine gover nor 2 Bar engine in unloaded condition Press START button 3 Let the crankshaft rotate until oil pressure is indicated 4 Engine start is automatically interrupted when specified starting period is expired If necessary re start the engine after approx 20 seconds 5 Plug connector X4 3 and use connector pliers 2 to secure the bayonet cou pling 4 by turning it clockwise until it latches into place 50800020a 54 Task Description M015675 06E 2013 04 TIM D 0000000950 003 TIMAD 0000003304 005 7 2 7 2 1 Cylinder Liner Endoscopically examining cylinder liner Preconditions M Engine shut down and secured against being restarted Special tools Material Spare parts Cranking tool F6555766 1 Ratchet with extension F30006212 1 Endoscope Y20097353 1 Preparatory steps Remove cylinder head cover gt Page 74 Remove injector gt Page 78 Positioning crankshaft at BDC Using cranking tool turn crankshaft until crankpin of the cylinder to be tested has reached
70. inder A9 2 Contact Service Misfiring Disconnection in wiring to 1 Check wiring solenoid valve cylinder A10 2 Contact Service Misfiring Disconnection in wiring to 1 Check wiring solenoid valve cylinder B1 2 Contact Service Misfiring Disconnection in wiring to 1 Check wiring solenoid valve cylinder B2 2 Contact Service Misfiring Disconnection in wiring to 1 Check wiring solenoid valve cylinder B3 2 Contact Service Misfiring Disconnection in wiring to 1 Check wiring solenoid valve cylinder B4 2 Contact Service Misfiring Disconnection in wiring to 1 Check wiring solenoid valve cylinder B5 2 Contact Service Misfiring Disconnection in wiring to 1 Check wiring solenoid valve cylinder B 2 Contact Service Misfiring Disconnection in wiring to 1 Check wiring solenoid valve cylinder B7 2 Contact Service Misfiring Disconnection in wiring to 1 Check wiring solenoid valve cylinder B8 2 Contact Service Misfiring Disconnection in wiring to 1 Check wiring solenoid valve cylinder B9 2 Contact Service Misfiring Disconnection in wiring to 1 Check wiring solenoid valve cylinder B10 2 Contact Service Misfiring Defect in ECU solenoid valve power stage Defect in ECU solenoid valve power stage Contact Service Contact Service Solenoid valve or wiring or 1 Check wiring ECU defective 2 Try to re start the engine Automatic engine shutdown gt Page 32 3 Contact Servic
71. ine coolant Filling n f n a oN SS ga 09 09 Gq ca 15 5 Engine coolant pump Checking pressure relief port 15 6 Engine coolant Sample extraction and analysis 7 15 7 Engine coolant filter Replacement a Low Temperature Circuit 7 16 1 Charge air coolant Level check 7 16 2 Charge air coolant Change 7 16 3 Charge air coolant Draining 7 16 4 Charge air coolant system Filling 7 16 5 Charge air coolant pump Checking pressure relief port Engine Mounting Support 7 17 1 Engine mounting Check Belt Drive 94 94 95 96 96 99 101 103 103 104 105 106 108 109 o e U Ne kel 7 19 7 20 7 21 7 22 7 18 1 Drive belt Check condition Battery Charging Generator 19 1 Battery charging generator Removal 19 2 Battery charging generator Check 19 3 Generator Cleaning 19 4 Battery charging generator drive Drive belt tension adjustment 7 19 5 Battery charging generator drive Drive belt tension check 7 19 6 Battery charging generator drive Drive belt replacement Fan Drive 7 20 1 Fan drive Drive belt tension check adjustment 7 20 2 Fan drive Drive belt replacement Wiring General for Engine Gearbox Unit 7 21 1 Engine wiring Check Accessories for Electronic Engine Governor Control System 7 22 1 Engine governor and connectors Cleaning 7 22 2 Checking engine control unit plug connections
72. ine is running Risk of damage to hearing A e Wear ear defenders Compressed air gun ejects a jet of pressurized air Risk of injury to eyes and damage to hearing risk of rupturing internal organs A e Never direct air jet at people e Always wear safety goggles face mask and ear defenders Intercooler Check water drain for coolant leakage and absence n of restrictions N A Eoc 1 With the engine running check the drain l Ed bore s on the right and left of the engine for emerging air at driving end If no air escapes e Clean drain bore s e Blow out with compressed air l 2 Ifa large amount of coolant is continuously l Cy ke discharged the intercooler is leaking Con tact Service i 11100023b Emergency measures prior to engine start with a leaking intercooler Remove injectors gt Page 78 Bar engine manually gt Page 52 Bar engine with starting system to blow out combustion chambers gt Page 54 Install injectors gt Page 78 TO 88 Task Description M015675 06E 2013 04 TIM D 0000000955 004 TIMAD 0000005423 005 7 11 Air Filter gt Spare Parts Catalog 7 11 1 Air filter element and dust bowl optional Cleaning Preconditions A Engine is stopped and starting disabled Special tools Material Spare parts Gasket A Note Note gi Compressed air gun eje
73. ing 7 14 1 Automatic oil filter Oil filter candles replacement Preconditions V Engine is stopped and starting disabled Special tools Material Spare parts Grease Kluthe Hakuform 30 10 Emulgier X00029933 1 Engine oil O ring gt Spare Parts Catalog Oil filter candles gt Spare Parts Catalog ball Hot oil Oil can contain combustion residues which are harmful to health A Risk of injury and poisoning e Wear protective clothing gloves and goggles safety mask e Avoid contact with skin e Do not inhale oil vapor Contamination of components Damage to component e Observe manufacturer s instructions e Check components for special cleanliness Removing oil filter candles 1 Remove nuts 2 from oil filter cover 1 2 Remove oil filter cover 1 18300161 96 Task Description M015675 06E 2013 04 TIM AD 0000006401 006 TIMAD 0000006401 006 3 4 O CO N Withdraw oil filter element 1 Remove O ring Remove screw 2 Withdraw plastic spinner 1 with spring Remove nut 3 Take off spring washer and washer Remove screw 4 Remove flushing arm 5 from screen plate 6 Turn filter element by 180 and use appro priate tool to push out filter candles 1 Turn filter insert by 180 and insert new fil ter candles 1 with chamfer facing down wards 18300162b 18300262b 18300166b M015675 06E 2013 04 Task Desc
74. ing 49 N PI k BJ M PJ k Ss p3 PI k P3 i M N e 2 i Check wiring Contact Service Check wiring Contact Service Check wiring Contact Service Check wiring Contact Service Check wiring Contact Service Check wiring Contact Service Check wiring Contact Service Check wiring Contact Service Check wiring Contact Service Check wiring Contact Service Check wiring Contact Service Check wiring Contact Service Check wiring Contact Service Check wiring Contact Service Check wiring Contact Service Check wiring Contact Service Aarm tx OPEN_LOAD CYL A7 348 OPEN_LOAD CYL A8 349 OPEN_LOAD CYL A9 350 OPEN_LOAD CYL A10 351 OPEN_LOAD CYL B1 352 OPEN_LOAD CYL B2 353 OPEN_LOAD CYL B3 354 OPEN_LOAD CYL B4 355 OPEN_LOAD CYL B5 356 OPEN_LOAD CYL B6 3S7 OPEN_LOAD CYL B7 358 OPEN_LOAD CYL B8 359 OPEN_LOAD CYL B9 360 OPEN_LOAD CYL B10 361 POWER STAGE FAIL 1 362 POWER STAGE FAIL 2 363 STOP POWER STAGE 1 50 Troubleshooting M015675 06E 2013 04 Disconnection in wiring to solenoid valve cylinder A7 1 Check wiring 2 Contact Service Misfiring Disconnection in wiring to 1 Check wiring solenoid valve cylinder A8 2 Contact Service Misfiring Disconnection in wiring to 1 Check wiring solenoid valve cyl
75. intenance repair or transporta tion Keep this manual handy in the vicinity of the product such that it is accessible to operating mainte nance repair and transport personnel at all times Use this manual as a basis for instructing personnel on product operation and repair whereby the safe ty relevant instructions in particular must be read and understood This is particularly important in the case of personnel who only occasionally perform work on or around the product This personnel must be instructed repeatedly Personnel requirements All work on the product shall be carried out by trained and qualified personnel only e Training at the Training Center of the manufacturer e Qualified personnel specialized in mechanical and plant engineering The operator must define the responsibilities of the personnel involved in operation maintenance re pair and transport Working clothes and personal protective equipment Wear proper protective clothing for all work When working always wear the necessary personal protective equipment e g ear protectors protec tive gloves goggles breathing protection Observe the information on personal protective equipment in the respective activity description M015675 06E 2013 04 TIM AD 0000040531 002 TIMAD 0000002618 006 1 3 Transport Transport
76. it Checking engine oil level Checking oil level before start ing engine Withdraw oil dipstick from guide tube and wipe it clean Insert dipstick into guide tube and push fully home withdraw after approx 10 sec onds Check oil level on oil dipstick side marked 5 Min after Stop After extended out of service periods the oil level may be up to 2 cm above the max mark This might be caused by en gine oil flowing from oil filter and heat ex changer back into the oil pan The oil level must reach the max mark or exceed it by up to 2 cm If necessary top up to max mark 48000109b gt Page 95 Insert oil dipstick into guide tube and push fully home Checking engine oil level with the engine running After the engine has run for approx 10 minutes at a constant speed of 900 rpm withdraw oil dipstick from guide tube and wipe it Insert dipstick into guide tube and push fully home withdraw after approx 10 seconds Check oil level on the dipstick side marked IDLE Oil level must not be lower than the add mark If necessary top up to max mark gt Page 95 Checking oil level after engine has been shut down 5 minutes after stopping the engine remove oil dipstick from the guide tube and wipe it Insert dipstick into guide tube and push fully home withdraw after approx 10 seconds Check oil level on oil dipstick side marked 5 Min after Stop Oil level must be between add and
77. ith a number of black lines around the running surface have limited service life and should be replaced These are caused by a disturbance in the liner ring tribosystem Usually they run over the whole ring travel area TDC BDC starting at the first TDC ring and becoming more visible from the second TDC ring onwards and less pronounced from TDC ring 1 The honing pattern is usually no longer visible and displays a clearly defined straight edge to the undisturbed surface The damaged surface is usually discolored The circumferential length varies M015675 06E 2013 04 Task Description 57 Liners with heat discoloration starting in the TDC ring 1 have to be replaced Seizures Seizure marks Seizure marks are of irregular circumferential length and depth Can be caused by either the piston skirt or the piston crown Material deposits on the liner smears show heavy discoloration and scoring Replace liner Evaluation of findings and further measures The findings in the start phase of oxidation discoloration and heat discoloration are similar Thorough investigation and compliance with the above evaluation criteria allows a definite evaluation To avoid unnecessary disassembly work it is recommended that another inspection be carried out after further operation of the engine 58 Task Description M015675 06E 2013 04 TIM 4D 0000003285 003 TIMAD 0000000017 008 7 3 Crankcase Breather 7 3 1 Crankcase breather
78. k of injury and suffocation e Avoid contact with eyes and skin e Do not inhale vapors and smoke e Do not eat drink smoke when working with cleaner e Wear protective clothing gloves and goggles safety mask e Take measures against electrostatic charging Cleaning agents should not be left to take effect for too long Damage to components is possible e Observe manufacturer s instructions Clean generator Clean generator with compressed air only do not use any liquids in cleaning process Clean all metallic parts with cleaner Snow White 11 0 then rinse with cleaner Hakupur 312 Blow off all components thoroughly with compressed air M015675 06E 2013 04 Task Description 121 7 19 4 Battery charging generator drive Drive belt tension adjustment Preconditions MW 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 gt Page 123 3 Tighten locknut 2 4 Tighten screws 1 5 Install guard cover 122 Task Description M015675 06E 2013 04 21300042b TIM D 0000000944 001 TIMAD 0000000946 001 7 19 5 Battery charging generator drive Drive belt tension check Preconditions WM Engine is stopped and starting disabled Special tools Material Spare parts Belt tension tester Y4345711 1 Preparatory steps 1 Remove guard cover 2 Check b
79. ler neck Open drain valve or plug screw and drain coolant at the LT coolant pump Drain residual coolant at intercooler left and right side Close all drain valves and install drain plugs with new sealing rings Close breather valve of filler neck gt Spare Parts Catalog RS iy O oy ce l Q TAA a S OSS i 20300048a 20300088a M015675 06E 2013 04 Task Description 113 7 16 4 Charge air coolant system Filling Preconditions V Engine is stopped and starting disabled Special tools Material Spare parts WM MTU Fluids and Lubricants Specification A001061 is available Charge air coolant Sealing ring WARNING Engine noise above 85 dB A Risk of damage to hearing e Wear ear protectors CAUTION f Cold coolant in hot engine can cause thermal stress Formation of cracks in components A e Fill top up coolant only into cold engine gt Spare Parts Catalog Preparatory steps Turn breather valve of filler neck on coolant expansion tank counterclockwise to first stop and allow pressure to escape 2 Continue to turn breather valve counter clockwise and remove 3 Remove plugs from filling points on the coolant lines from and to the intercooler 20800016a 114 Task Description M015675 06E 2013 04 TIM 4D 0000007011 001 TIMAD 0000007011
80. ller neck Open drain valves and or drain plugs and drain coolant at the following points e at HT coolant pump elbow e on crankcase left and right sides e at preheating unit Close all open drain points Position breather valve on filler neck and close M015675 06E 2013 04 Task Description 105 7 15 4 Engine coolant Filling Preconditions MW Engine is stopped and starting disabled M MTU Fluids and Lubricants Specifications A001061 are available Special tools Material Spare parts Engine coolant WARNING Coolant is hot and under pressure Risk of injury and scalding A e Let the engine cool down e Wear protective clothing gloves and goggles safety mask i Cold coolant in hot engine can cause thermal stress Possible formation of cracks in the engine g e Fill top up coolant only into cold engine Preparatory steps 1 Turn breather valve of filler neck on coolant expansion tank counterclockwise to first stop and allow pressure to escape 2 Continue to turn breather valve counter clockwise and remove 20800016b 106 Task Description M015675 06E 2013 04 TIM AD 00000067 15 003 TIMAD 00000067 15 003 pols OMe Goh Filling with coolant using a pump Connect appropriate pump with hose to drain valve Open drain valve and pump coolant into en gine at 0 5 bar minimum Fill expansion tank until overflow edge is reached Close drain va
81. lter Diesel particulate filter Diagnostic unit Electronic control unit of the DDEC system Engine governor M015675 06E 2013 04 AppendixA 131 Abbre Meaning Explanation viation EDM EES PROM EFPA EGR EIL EMU ESCM ETK EUI FO FPS FRS FTS FWCP GND HD HP HI HIHI HT IDM INJ ISO KGS KS L1 L2 LED LLK LO LOLO LSG LSU LT MCR N A ND Engine Data Module Electrically Erasable Programmable Read Only Memory Electronic Foot Pedal Assembly Exhaust Gas Recirculation Engine Ident Label Engine Monitoring Unit Extreme Site Condition Management Ersatzteilkatalog Electronic Unit Injector Frequency Output Fuel Pressure Sensor Fuel Restriction Sensor Fuel Temperature Sensor Fire Water Control Panel Ground High pressure High High High High Temperature Interface Data Module Injector International Organization for Standardiza tion Kraftgegenseite Kraftseite Limit 1 Limit 2 Light Emitting Diode Ladeluftkthlung Low Low Low Maximum speed governor Lambda Sonde Universal Low Temperature Maximum Continuous Rating Not Applicable Niederdruck 132 Appendix A M015675 06E 2013 04 Memory module for engine data Electrically Erasable Programmable Read Only Mem ory Electronic Foot Pedal Assembly Exhaust gas recirculation Engine monitoring unit Power reduction in the case of extreme site condi tions Spare Parts Catalog Electronic Unit Inject
82. lve Check proper condition of breather valve and clean sealing faces if required Place breather valve on filler neck and close Start engine gt Page 32 After 10 seconds of running the engine without load shut down the engine gt Page 34 20200220b Turn breather valve of filler neck on coolant expansion tank counterclockwise to first stop and allow pressure to escape Continue to turn breather valve counter clockwise and remove Check coolant level gt Page 103 and top up engine coolant as required a Fill in coolant in expansion tank until the coolant level at top edge of filler neck remains constant b Place breather valve on filler neck and close c Repeat the steps from Start engine gt Step 7 until coolant is no longer needed to be topped up d Disconnect pump and hose Filling with coolant through filler neck Alternatively Fill in coolant in expansion tank via filler neck until coolant level at top edge of filler neck remains constant Check proper condition of breather valve and clean sealing faces if required Set breather valve onto filler neck and turn until the first stop Start engine gt Page 32 After 10 seconds of running the engine without load shut down the engine gt Page 34 Turn breather valve counterclockwise and remove Check coolant level gt Page 103 a
83. nd the system Hose couplings and connections must be securely attached Provide the snout of the air nozzle with a protective disk e g rubber disk First shut off compressed air lines before compressed air device is disconnected from the supply line or before device or tool is to be replaced Carry out leak test in accordance with the specifications Paints and varnishes Observe the relevant safety data sheet for all materials When painting in areas other than spray booths equipped with extractors ensure good ventilation Make sure that neighboring work areas are not adversely affected There must be no naked flames in the vicinity No smoking Observe fire prevention regulations Always wear a mask providing protection against paint and solvent vapors Liquid nitrogen Observe the relevant safety data sheet for all materials Store liquid nitrogen only in small quantities and always in regulation containers without gas tight caps Avoid body contact eyes hands Wear protective clothing protective gloves closed shoes and safety goggles Make sure that working area is well ventilated Avoid knocking or jolting the containers fixtures or workpieces in any way Acids alkalis urea solution AdBlue DEF Observe the relevant safety data sheet for all materials When working with acids and alkaline solutions wear goggles or face mask gloves and protective clothing Do not inhale vapors If urea solution is swall
84. nd top up engine coolant as required a Repeat the steps from Start engine gt Step 4 until coolant is no longer needed to be topped up b Check proper condition of breather valve and clean sealing faces if required c Place breather valve on filler neck and close Final steps Start the engine and run it without load for some minutes Check coolant level gt Page 103 and top up engine coolant as required M015675 06E 2013 04 Task Description 107 7 15 5 Engine coolant pump Checking pressure relief port Rotating and moving engine parts Risk of crushing danger of parts of the body being caught or pulled in A e Only run the engine at low power Keep away from the engine s danger zone A high level of noise is produced when the engine is running Risk of damage to hearing A e Wear ear defenders Engine coolant pump Checking pressure relief port Check pressure relief port for oil and cool ant discharge 2 Shut down engine gt Page 34 and secure against being restarted observe general Maintenance and Repair safety instruc tions 3 Clean the pressure relief port with a wire if it is dirty e Permissible coolant discharge rate up to 10 drops per hour e Permissible oil discharge rate up to 5 drops hour 4 If discharge exceeds the specified limits Contact Service 20200223b 108 Task Description M015675 06E 2013 04 TIM AD 0000000961 010 TIMAD 00
85. nder A4 Misfiring Faulty wiring to solenoid valve cylinder A5 Misfiring Faulty wiring to solenoid valve cylinder A6 Misfiring Faulty wiring to solenoid valve cylinder A7 Misfiring Faulty wiring to solenoid valve cylinder A8 Misfiring Faulty wiring to solenoid valve cylinder A9 Misfiring Service If fault occurs repeatedly Service If fault occurs repeatedly Service If fault occurs repeatedly Service If fault occurs repeatedly Service If fault occurs repeatedly Service If fault occurs repeatedly Service If fault occurs repeatedly Service If fault occurs repeatedly Service If fault occurs repeatedly Service If fault occurs repeatedly Service 1 Check wiring 2 Contact Service Check wiring 2 Contact Service Check wiring 2 Contact Service gt Check wiring 2 Contact Service Check wiring 2 Contact Service Check wiring 2 Contact Service Check wiring 2 Contact Service Check wiring 2 Contact Service Check wiring 2 Contact Service Contact Contact Contact Contact Contact Contact Contact Contact Contact Contact Contact TIM AD 0000003161 001 TIMAD 0000003161 001 Check wiring Contact Service 331 332 333 334 335 336 337 338 339 340 341 342 343 344 345 346 WIRING
86. ngine speed instrument indicates increasing speed e After the starting sequence is completed engine is running at idle speed 32 Operation M015675 06E 2013 04 TIM AD 0000002233 006 TIMAD 0000002262 001 44 DANGER A WARNING A Operational checks Unguarded rotating and moving engine components Risk of serious injury danger to life e Take special care when working on a running engine Engine noise above 85 dB A Risk of damage to hearing e Wear ear protectors Operational checks Control and dis Check indicated operating parameters play panels speed temperatures pressures Check engine oil level gt Page 94 W0500 Engine operation Check engine visually for leaks and general W0501 condition W0506 Check engine for abnormal running noises exhaust color and vibrations gt Page 38 Battery charging Check battery charging generator for con W0525 generator tamination clean as required gt Page 120 HP pump Check relief bore gt Page 76 W0504 Fuel prefilter Drain water and contaminants at drain W0507 cock on fuel prefilter if fitted gt Page 86 W0508 Check reading on vacuum gauge of fuel prefilter if fitted Intercooler Check condensate drain s for water dis W0502 charge and obstruction gt Page 88 HT cooling pump Check relief bore gt Page 108 W0505 LT cooling pump Check relief bore gt Page 116 W0505 M015675 06E 2013 04 Operation
87. not be cranked by hand Notify Service Engine turns over when started but does not fire Starter Lacks power battery discharged or de Charge or replace battery see manufac fective turer s documentation Engine wiring Faulty Check gt Page 128 Fuel system Air in fuel system Bleed fuel system gt Page 83 Engine Control Unit Faulty Notify Service Engine fires unevenly Fuel injection system Injector defective Replace gt Page 77 Engine wiring Faulty Check gt Page 128 Fuel system Air in fuel system Bleed fuel system gt Page 83 Engine Control Unit Faulty Notify Service Engine fails to reach rated speed Fuel supply Fuel prefilter clogged Replace Fuel filter clogged Replace gt Page 84 Air supply Air filter clogged Clean Fuel injection system Injector defective Replace gt Page 77 Engine wiring Faulty Check gt Page 128 Engine Overloaded Notify Service 38 Troubleshooting M015675 06E 2013 04 TIMAD 0000002541 002 TIMAD 0000002541 002 Engine speed not steady Fuel injection system Injector defective Replace gt Page 77 Speed sensor Defective Notify Service Fuel system Air in fuel system Bleed fuel system gt Page 83 Engine Control Unit Defective Notify Service Charge air temperature too high Engine coolant Incorrect coolant concentration Check MTU test kit Intercooler Dirty Notify Service Engine room Air intake temperature too high Check fans and air intake
88. ntilation or plug screws from the product Cover the screw or plug with a rag to prevent fluids escaping under pressure Take care when draining hot fluids and lubricants risk of burning Use only proper and calibrated tools Observe the specified tightening torques during assembly or dis assembly Carry out work only on assemblies or plants which are properly secured Never use lines for climbing Keep fuel injection lines and connections clean Always seal connections with caps or covers if a line is removed or opened Take care not to damage lines in particular fuel lines during maintenance and repair work Ensure that all retainers and dampers are installed correctly Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent contact with other components Do not place fuel or oil lines near hot components Do not touch elastomeric seals if they have carbonized or resinous appearance unless hands are prop erly protected Note cooling time for components which are heated for installation or removal risk of burning When working high on the equipment always use suitable ladders and work platforms Make sure com ponents or assemblies are placed on stable surfaces M015675 06E 2013 04 Safety 11 12 Safety Ensure particular cleanness during maintenance and repair work on the product After completion of maintenance and repair work make sure that no loose objects are in on
89. ode 32 Stopping in manual mode 34 Wiring check 128 Engine coolant Change 104 Draining 105 Filling 106 Levelcheck 103 Sample extraction and analysis 109 Engine coolant filter Replacement 110 Engine coolant pump Checking pressure relief port 108 Engine governor Cleaning 129 Engine layout 18 Engine mounting Check 117 Engine oil Centrifugal oil filter Cleaning 101 Filter sleeve Replacing 101 Engine oil level Checking 94 Engine oil Change 95 Engine sides Designation 17 Engine wiring Check 128 E Fan drive Drive beltreplacement 127 Drive belt tension check adjustment 125 Filter replacement Fuel 87 Filter sleeve Replacing 101 Firing order 28 M015675 06E 2013 04 AppendixB 143 Fuel filter Replacing 84 Fuel prefilter Draining 85 Fuel system Venting 83 G Generator Cleaning 121 Grounding device Carbon brush check 65 Grounding device Carbon brush replacement 67 H Hotline 134 HP pump Filling with engine oil 75 Relief bore check 76 I Injector Installation 78 Removal 78 Replacement 77 Instructions and comments on endoscopic and visual ex amination of cylinder liners 57 Intercooler Check water drain for coolant leakage and absence of restrictions 88 M Main engine dimensions 29 Maintenance Schedule Maintenance Schedule task reference table OL1 37 MTU contact persons 134 O
90. on air inlet B tion B side 3 Exhaust turbocharger A side 9 Air supply before intercool side er B side Engine model designation Key to the engine model designation 20V 4000 C22 2 Design index 20 General Information M015675 06E 2013 04 TIM D 0000002072 002 TIMAD 00000 12921 003 2 3 Sensors and actuators Overview 00001516 1 BO7 T Lube oil 2 Injectors Y39 1 to Y39 10 A side cylinders 3 B34 P Fuel after filter 5 B33 T Fuel 4 B48 P Fuel The injectors are underneath the cylinder head covers of the cylinder Injector replacement and neces sary activities gt Page 77 M015675 06E 2013 04 General Information 21 j ovine 7 oman arza vores oma ora pose orana J ee 3 a ale a a z Na Sab D a ae y d f d i d d mice eS b S Pla Wie A a a b 6 A a Tlo a SN ee ea ea A ee A etd el d Eg i f m f m ja m i a JOS 00001517 1 Injectors Y39 11 to 3 B10 P Charge Air Y39 20 B side cylinders 4 BO9 T Charge Air 2 B16 P Coolant ON je OOO I AARNA I i u CA i i
91. or Monitors fuel pressure Monitors fuel temperature Governor cabinet Alarm Measured value exceeds 1st maximum limit value Alarm Measured value exceeds 2nd maximum limit value High temperature Memory module for interface data International umbrella organization for all national standardization institutes Engine free end in accordance with DIN ISO 1204 Engine driving end in accordance with DIN ISO 1204 Limit value 1 Limit value 2 Light emitting diode Intercooler Alarm Measured value lower than 1st minimum limit value Alarm Measured value lower than 2nd minimum lim it value Universal lambda probe Low temperature Torque limiting curve Low pressure TIM 4D 0000000858 011 TIMAD 0000000858 011 Abbre Meaning Explanation viation NN NT OEM Ol OLS OPS OTS OT PAN PIM PWM P xyz RL SAE SD SEL SID SRS SS TBS TCI TCO TD TPS TRS T xyz U_PDU UDV UT VNT VSG VSS WZK ZKP Normal Null Niedertemperatur Original Equipment Manufacturer Optimized Idle Oil Level Sensor Oil pressure sensor Oil Temperature Sensor Oberer Totpunkt Panel Peripheral Interface Module Pulse Width Modulation Pressure xyz Redundancy Lost Society of Automotive Engineers Sensor Defect Stop EngineLlight System Identification Synchronous Reference Sensor Safety System Security Shutdown Turbocharger Boost Sensor Turbo Compressor Inlet Turbo Compressor Outlet Transmitter De
92. ort locking device For transport with flanged on generator Transport AAA VV 03600029a This locking device protects the crankshaft bearings from shocks and vibration damage during unit transport For removal of the transport locking device follow the following instructions e The transport locking device should remain installed as long as possible during unit installation in order to avoid damage Starting or barring the engine is allowed only with the transport locking device removed Make sure that the transport locking device of the generator is removed Prior to every unit transport this transport locking device must be reinstalled according to the in structions The transport locking device of the generator is also to be fitted Removing the transport locking device from driving end KS e Remove screw 4 on both sides Remove retainer 2 and washer 3 e Remove guard plate from flywheel housing Store the removed parts of the transport locking device carefully for possible reuse 8 Safety M015675 06E 2013 04 TIM 4D 0000004012 001 TIMAD 0000004012 001 Fitting the transport locking device on driving end KS Remove protective cover from flywheel housing 5 Keep guard plate and screws on the engine They must be reinstalled when the transport locking de vice has been removed Turn crankshaft to bring cylinder A1 in TDC position Check the thre
93. osal Modification or removal of any mechanical electronic components or the installation of additional com ponents 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 exchanged or repaired if the components used for this purpose are approved by the manu facturer Noncompliance with these guidelines will invalidate the design type approval issued by the emissions regulation 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 Dispose of used consumables and filters in accordance with local regulations Within the EU batteries can be returned free of charge to the manufacturer where they will be properly recycled Consumable fluids and materials The Fluids and Lubricants Specifications will be amended or supplemented as necessary Prior to opera tion make sure that the latest version is used The latest version can be found on the website on the Technical Info tab at http www mtu online com Consumable fluids and materials may also be hazardous or toxic When using fluids lubricants consum ables and other chemical substances follow the safety instructions that apply to the product Take spe cial care when using hot chilled or c
94. owed rinse out mouth and drink plenty of water If spilled onto clothing remove the affected clothing immediately After contact with skin rinse affected parts of the body with plenty of water Rinse eyes immediately with eyedrops or clean tap water Seek medical attention as soon as possi ble M015675 06E 2013 04 Safety 15 1 8 Standards for safety notices in the text DANGER A WARNING A CAUTION OTICE In the event of immediate danger Consequences Death serious or permanent injury e Remedial action In the event of a situation involving potential danger Consequences Death serious or permanent injury e Remedial action In the event of a situation involving potential danger Consequences Minor or moderate injuries e Remedial action In the event of a situation involving potentially adverse effects on the product Consequences Material damage e Remedial action e Additional product information Safety notices gt This manual with all safety instructions and safety notices must be issued to all personnel involved in operation maintenance repair or transportation 16 Safety M015675 06E 2013 04 TIM AD 0000040578 002 TIMAD 0000002185 012 2 General Information 2 1 Engine side and cylinder designations Engine sides are always designated as viewed from the driving end KS 4 For designation of the cylinders to DIN ISO 1204 the letter A 1 is used to refer to the cylinders
95. r Replacement 7 7 2 Injector Removal and installation m m 7 8 Fuel System 7 8 1 Fuel system Venting 7 9 Fuel Filter 7 9 1 Fuel filter Replacement 7 9 2 Draining fuel prefilter 7 9 3 Edge type fuel filter Draining 7 9 4 Auxiliary fuel filter Replacement 7 10 Charge Air Cooling 7 10 1 Intercooler Check water drain for coolant leakage and absence of restrictions 7 11 Air Filter 7 11 1 Air filter element and dust bowl optional Cleaning 7 11 2 Air filter Replacement 7 11 3 Air filter element Removal and installation optional 7 11 4 Service indicator Signal ring position check optional 7 12 Starting Equipment 7 12 1 Starter Condition check 54 55 55 57 59 59 61 62 74 75 75 76 77 71 78 83 83 84 84 85 86 87 88 88 89 89 90 91 92 93 93 M015675 06E 2013 04 Table of Contents 3 7 13 7 14 7 15 7 16 7 17 7 18 4 Table of Contents M015675 06E 2013 04 Lube Oil System Lube Oil Circuit 7 13 1 Checking engine oil level 7 13 2 Engine oil Change Oil Filtration Cooling 7 14 1 Automatic oil filter Oil filter candles replacement 14 2 Oil indicator filter Cleaning and check 7 14 3 Cleaning centrifugal oil filter and replacing filter sleeve N Coolant Circuit General High Temperature Circuit 15 1 Engine coolant Level check 15 2 Engine coolant Change 15 3 Engine coolant Draining n n n 15 4 Eng
96. r disposal For locally available support go to the MTU Internet site http www mtu online com 24h hotline With our 24h hotline and the outstanding flexibility of our service staff we are always ready to assist you either during operation for preventive maintenance corrective work in case of malfunction or changed operating conditions or for spare parts supply Your contact at Headquarters Service support mtu online com Spare parts service Fast simple and correct identification of spare parts for your drive system or vehicle fleet The right spare part at the right time at the right place With this aim in mind we can call on a globally networked spares logistics system a central warehouse at headquarters and on site stores at our subsidiary companies agencies and service workshops Your contact at Headquarters E mail spare parts mtu online com Phone 49 7541 908555 Fax 49 7541 908121 134 AppendixA M015675 06E 2013 04 TIM AD 0000000873 014 DCL ID 0000014250 002 9 Appendix B 9 1 Special Tools Adapter Part No F6558528 Qty 1 Used in 7 1 1 Engine Barring manually gt Page 52 Allen key Part No F30002817 Qty 1 Used in 7 5 2 Valve clearance Check and adjustment gt Page 69 Barring gear Part No F6555766 Qty 1 Used in 7 1 1 Engine Barring manually gt Page 52 M015675 06E 2013 04 AppendixB 135 Part No F6783293 Qty 1 Used in
97. ranking the engine with starter system make sure that there are no persons in the en gine s danger zone Barring engine manually tool mounted on side Remove guard plate Engage barring gear 2 in ring gear 3 and mount on flywheel housing e Use barring gear F6555766 Fit ratchet 1 onto barring gear 2 Rotate crankshaft in normal direction of en gine rotation apart from the normal com pression resistance there should be no re sistance Barring gear is removed by same procedure in reverse 52 Task Description M015675 06E 2013 04 00000225b TIMAD 0000002521 006 TIMAD 0000002521 006 oa Barring engine manually tool mounted underneath Remove grounding device or guard plate Engage barring gear 2 in ring gear 1 and mount on flywheel housing e For 12 16V engines use barring gear F6555766 with adapter F6558528 e For 20V engines use barring gear F6783293 Fit ratchet 3 onto barring gear 2 Rotate crankshaft in normal direction of en gine rotation apart from the normal com pression resistance there should be no re sistance Barring gear is removed by same procedure in reverse 00000720b M015675 06E 2013 04 Task Description 53 7 1 2 Engine Barring with starting system Special tools Material Spare parts Connector pliers 0135315483 1 Rotating and moving engine parts Risk of crushing danger of parts of the body being cau
98. rds Institute Abgasturbolader Abgasturboaufladung Air Temperature Sensor Baureihe Betriebsstoffvorschrift Controller Area Network Calibration Drift Compensation Stop engine light Circuit Coolant Level Sensor Current Measurement Coolant Pressure Sensor Common Rail Coolant Temperature Sensor Detroit Diesel Electronic Controls Diagnostic Data Link Diagnostic Data Reader Electronic dialog system Deutsches Institut f r Normung e V Default Lost Diesel Oxidation Catalyst Dieselpartikelfilter Diagnostic Tool Electronic Control Module Engine Control Unit Transformer transforms sensor voltages into numer ic values Engine management system Exhaust gas recirculation Association of American standardization organiza tions Exhaust turbocharger exhaust turbocharging Series Fluids and Lubricants Specifications MTU Publica tion No A01061 Data bus system bus standard Setting of drift compensation in engine governor with DiaSys 1st function Warning lamp rectify fault as soon as possible 2nd function Read out fault codes Monitors coolant level Current measured value Monitors coolant pressure Monitors coolant temperature Engine control system made by Detroit Diesel Diagnostic lines Diagnostic unit At the same time identifier of German standards DIN Deutsche Industrie Norm Alarm Default CAN bus failure Oxidation catalyst upstream of the diesel particulate fi
99. readed connections 2 Ensure that cables are fixed in their clamps and cannot swing freely 3 Check that cable clamps are firm tighten loose cable clamps 4 Replace faulty cable clamps 5 Visually inspect the following electrical line components for damage e Connector housing e Contacts e Sockets e Cables and terminals e Plug in contacts Result Contact Service if cable conductors are damaged Note Close male connectors that are not plugged in with the protective cap supplied 6 Clean dirty connector housings sockets and contacts using isopropyl alcohol 7 Ensure that all sensor connectors are securely engaged 128 Task Description M015675 06E 2013 04 TIM AD 0000000029 019 TIMAD 0000000948 011 fedh ye a Accessories for Electronic Engine Governor Control System Engine governor and connectors Cleaning Preconditions MW Engine is stopped and starting disabled Special tools Material Spare parts Connector pliers Isopropyl alcohol Engine governor and connectors Cleaning Remove coarse dirt from housing surface with isopropyl alcohol Remove dirt from surface of connec tors 1 connector sockets and shrink sleeves 2 using a cloth moistened with isopropyl alcohol Check legibility of cable labels Clean or re place illegible labels Cleaning severely contaminated connectors on engine governor Use connector pliers 2 to disengage bayo net union nut 4 and withdraw connec
100. rge exceeds the specified limits Contact Service 20300133b 116 Task Description M015675 06E 2013 04 TIM AD 0000000964 005 TIMAD 00000 15370 004 7 17 Engine Mounting Support 7 17 1 Engine mounting Check Engine mounting Check Visually inspect mounts Damage Brittleness Replace contact Service Deformation Crack formation Swelling visible M015675 06E 2013 04 Task Description 117 7 18 Belt Drive 7 18 1 Drive belt Check condition Preconditions V Engine is stopped and starting disabled W Protective cover is removed 21300116b Drive belt A Singular cracks None Drive belt Belt is oily shows signs of over Fit new part gt Page 124 heating Drive belt B Cracks on entire circumference Drive belt C Material broken out 118 Task Description M015675 06E 2013 04 TIM 4D 0000003740 003 TIMAD 0000007379 001 7 19 Battery Charging Generator 7 19 1 Battery charging generator Removal Preconditions WM Engine is stopped and starting disabled Heavy object Risk of crushing A e Use appropriate lifting devices and appliances Battery charging generator Re moval 1 Remove guard cover 2 Label and disconnect electrical cables on battery charging generator 3 Protect all cables against damage 4 Undo nut 3 5 Tilt battery charging generator 1 towards engine and remove V belt 5 6 Unscrew n
101. riming pump 2 is locked Handle must be tightened 08000139b M015675 06E 2013 04 Task Description 83 7 9 Fuel Filter 7 9 1 Fuel filter Replacement Preconditions V Engine is stopped and starting disabled Special tools Material Spare parts Filter wrench F30379 104 1 Engine oil Easy change filter gt Spare Parts Catalog WARNING Fuels are combustible Risk of fire and explosion A e Avoid open flames electrical sparks and ignition sources e Do not smoke Fuel filter Replacement 1 Remove easy change filter using filter wrench Clean sealing face on filter head 3 Apply a thin coat of oil to the seal on the easy change filter arrowed 4 Screw on the easy change filter by hand until the seal is in contact and tighten hand tight 5 Replace the other easy change filters in the same way 6 Vent fuel system gt Page 83 iS 08300782 84 Task Description M015675 06E 2013 04 TIM AD 0000000927 006 TIMAD 0000004930 003 7 9 2 Draining fuel prefilter WARNING A gt CON OI Preconditions M Engine shut down and secured against being restarted Special tools Material Spare parts Diesel fuel Fuels are combustible Risk of fire and explosion e Avoid open flames electrical sparks and ignition sources e Do not smoke Draining fuel prefilter Shut off the filter unit 5 8 to be changed at valves 3 and 4 or 9 and
102. ription 97 Installing oil filter candles 1 For installation follow reverse sequence of working steps 2 Additionally the following instructions are to be observed e Replace all sealing elements e Coat O rings with grease e Insert O rings in grooves e Observe position of cylinder screw to elongated hole on shaft 98 Task Description M015675 06E 2013 04 TIM AD 0000006401 006 TIMAD 0000006402 005 7 14 2 WARNING WARNING NOTICE alma Oil indicator filter Cleaning and check Preconditions MW Engine is stopped and starting disabled Special tools Material Spare parts Cleaner Snow White 11 0 40460 1 Cleaner Hakupur 312 30390 1 Engine oil Strainer gt Spare Parts Catalog Square section ring gt Spare Parts Catalog O ring gt Spare Parts Catalog Hot oil Oil can contain combustion residues which are harmful to health Risk of injury and poisoning e Wear protective clothing gloves and goggles safety mask e Avoid contact with skin e Do not inhale oil vapor Compressed air gun ejects a jet of pressurized air Risk of injury to eyes and damage to hearing risk of rupturing internal organs e Never direct air jet at people e Always wear safety goggles face mask and ear defenders Inappropriate cleaning tool Risk of damage to component e Observe manufacturer s instructions e Use appropriate cleaning tool Removing strainer Clean oil indicator filter before
103. rvice Contact Service Contact Service Contact Service Contact Service Reduce power 1 Reduce power 2 If fault occurs repeatedly Con tact Service Reduce power Reduce power Check coolant circuit Check coolant circuit Check coolant circuit Check coolant circuit Check oil separator gt Page 59 Replace oil separator TIM 4D 0000003161 001 TIMAD 0000003161 001 066 067 068 081 082 083 087 089 L1 P FUEL L2 PAPEL L1 T COOLANT L2 T COOLANT RAIL LEAKAGE RAIL PRESSURE HIGH RAIL PRESSURE LOW L1 LEV WATER IN FUEL ENGINE SPEED LOW Fuel supply pressure too low 1st limit Fuel supply pressure too low 2nd limit Coolant temperature too high 1st limit Warning Coolant temperature too high 2nd limit Automatic engine shutdown HP fuel system leaking sys tem contains air Pressure in HP fuel system exceeds specified value Solenoid valve of HP fuel control block jamming or wiring to solenoid valve de fective Pressure in HP fuel system lower than the specified val ue HP fuel control block defec tive or system leaking NOTE With very large generators having a run out time of more than gt 20 sec this alarm is not a relevant fault Water level in fuel prefilter too high Engine speed lower than 200 rpm Automatic engine shutdown 1 w N o On wn ol oO il 2 3 4 Check fuel lines for leaks re
104. speed not reached within a specified period Termination of starting pro cedure Starter speed not reached within a specified period Termination of starting pro cedure Coolant preheating temper ature too low during starting 2nd limit Termination of starting pro cedure depending on project design Coolant preheating temper ature too low during starting 1st limit Check sum error of measur ing point data in EDM Check sum error of measur ing point data in IDM Check sum error of accumu lated fuel consumption data in EDM redundant data re cord 1 Check sum error of accumu lated fuel consumption data in EDM redundant data re cord 2 Check sum error of hour meter data in EDM Check sum error of hour meter data in IDM Check sum error of fault memory in EDM redundant data record 1 Check sum error of fault memory in EDM redundant data record 2 Supply voltage too low 1st limit Supply voltage too low 2nd limit Supply voltage too high 1st limit Supply voltage too high 2nd limit Note further alarms Note further alarms Note further alarms Check preheating pump preheating system see manufacturer s docu mentation Check preheating pump preheating system see manufacturer s docu mentation If fault occurs repeatedly Contact Service If fault occurs repeatedly Contact Service Contact Service Contact Service If fault occurs repeatedly Con
105. t Service If fault occurs repeatedly Contact Service If fault occurs repeatedly Contact Service M015675 06E 2013 04 Troubleshooting 47 Aarm tx If fault occurs repeatedly 310 311 312 313 314 315 316 317 318 319 320 321 322 323 324 325 326 S27 328 329 TIMING CYLINDER A10 TIMING CYLINDER B1 TIMING CYLINDER B2 TIMING CYLINDER B3 TIMING CYLINDER B4 TIMING CYLINDER B5 TIMING CYLINDER B6 TIMING CYLINDER B7 TIMING CYLINDER B8 TIMING CYLINDER B9 TIMING CYLINDER B10 WIRING CYLINDER A1 WIRING CYLINDER A2 WIRING CYLINDER A3 WIRING CYLINDER A4 WIRING CYLINDER A5 WIRING CYLINDER A6 WIRING CYLINDER A7 WIRING CYLINDER A8 WIRING CYLINDER A9 48 Troubleshooting M015675 06E 2013 04 Injection timing fault cylin der A10 Injection timing fault cylin der B1 Injection timing fault cylin der B2 Injection timing fault cylin der B3 Injection timing fault cylin der B4 Injection timing fault cylin der BS Injection timing fault cylin der B6 Injection timing fault cylin der B7 Injection timing fault cylin der B8 Injection timing fault cylin der B9 Injection timing fault cylin der B10 Faulty wiring to solenoid valve cylinder A1 Misfiring Faulty wiring to solenoid valve cylinder A2 Misfiring Faulty wiring to solenoid valve cylinder A3 Misfiring Faulty wiring to solenoid valve cyli
106. t critical Smoothened areas are changes to the running surface but almost the whole hon ing pattern is still visible Smoothened areas appear brighter and more brilliant than the surrounding running surface Findings not critical Polished areas are on the running surface and show local removal of the honing pattern Grooves from the honing process are not visible any more New cylinder liners must be fitted in the following cases Polished area covers more than 20 of the entire piston running surface covers more than 30 of the circumference and extends over more than 50 of piston stroke is wider than 15 mm over the entire piston stroke This is caused by oxidation surface discoloration through oil or fuel and temper ature differences around the liner It appears rather darker within the honed structure in contrast to the bright metallic running surface The honing pattern is undisturbed Discolorations extend in stroke direction and may be interrupted Findings not critical Corrosion fields spots result from water condensed water with the valves in the overlap open position They are clearly visible due to the dark color of the honing groove bottom This corrosion is not critical unless there is corrosion pitting Black lines are a step towards heat discoloration They are visible as a clear dis coloration from TDC to BDC in the running surface and the start of localized dam age to the honing pattern Cylinders w
107. tact Service If fault occurs repeatedly Contact Service If fault occurs repeatedly Contact Service If fault occurs repeatedly Contact Service Check ECU supply voltage Check ECU supply voltage Check ECU supply voltage Check ECU supply voltage If engine was stopped Start engine gt Page 32 TIM AD 0000003161 001 TIMAD 0000003161 001 122 134 136 137 138 139 140 142 144 145 146 147 148 149 150 151 L1 T ELECTRONIC 15V POS ECU DEFECT 15V NEG ECU DEFECT L1 5V BUFFER TEST SENSORPOWERDE FECT L1 TE BUFFER TEST TE BUF ECU DEFECT BANK1 ECU DEFECT BANK2 ECU DEFECT 15V_GOOD ECU DE FECT L1 AD TEST1 SUPPLY AD TEST1 ECU DE FECT L1 AD TEST2 SUPPLY AD TEST2 ECU DE FECT L1 AD TEST3 SUPPLY AD TEST3 ECU DE FECT Automatic engine shutdown depending on project de sign Temperature in ECU housing too high 1st limit Electronic equipment defec tive Automatic engine shutdown Electronic equipment defec tive Automatic engine shutdown Power supply for pressure sensors defective Power supply for pressure sensors defective Internal electronic fault temperature sensors Internal electronic fault temperature sensors Internal electronic fault Engine does not start Internal electronic fault Engine does not start Electronic equipment defec tive Automatic engine shutdown A D converter supply
108. the outside of the system with a pressure steam jet washer e The pressure of the high pressure jet cleaning jet must not exceed 50 bar e A minimum distance between spray nozzle and system of 1 m must be observed e The temperature of the cleaning agent must not exceed 80 C For external cleaning with high pressure jet use a flat mouth nozzle only Carry out external cleaning as follows a b c d Seal all openings in a suitable fashion Remove coarse dirt Spray on cleaner sparingly and leave it for 1 to 5 minutes Use the high pressure jet to remove the loosened dirt Never aim compressed air directly at electronic components e Dry engine 36 Operation M015675 06E 2013 04 TIM AD 00000 10171 026 TIMAD 0000033894 002 5 Maintenance 5 1 Maintenance Schedule task reference table QL1 The maintenance tasks and intervals for this product are defined in the Maintenance Schedule The Maintenance Schedule is a stand alone publication The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule Measures W 0506 Check engine for abnormal running noises exhaust color and gt Page 33 vibrations sleeve at every oil change at the latest Page 5 Page 170 W1046 Crankcase breather Replace filter or filter element gt Page 59 W1047 Check and clean oil indicator filter gt Page 99 W1164 Replace filter element
109. the product e g cloths and cable ties Safety regulations after completion of maintenance and repair work Before barring make sure that nobody is standing in the danger zone of the product Check that all guards have been reinstalled and that all tools and loose parts have been removed after working on the product in particular the barring tool Welding work Welding operations on the product or mounted units are not permitted Cover the product when welding in its vicinity Before starting welding work e Switch off the power supply master switch e Disconnect the battery e Separate the electrical ground of electronic equipment from the ground of the unit No other maintenance or repair work must be carried out in the vicinity of the product while welding is going on Risk of explosion or fire due to oil vapors and highly flammable fluids and lubricants Do not use product as ground terminal Never position the welding power supply cable adjacent to or crossing wiring harnesses of the product The welding current may otherwise induce an interference voltage in the wiring harnesses which could conceivably damage the electrical system Remove parts e g exhaust pipes which are to be welded from the product beforehand Hydraulic installation and removal Check the function and safe operating condition of tools and fixtures to be used Use only the specified devices for hydraulic removal installation procedures Observe the
110. to less than 50 C before starting maintenance work risk of explosion of oil vapors fluids and lubricants risk of burning Before starting work relieve pressure in systems and compressed air lines which are to be opened Use suitable containers of adequate capacity to catch fluids and lubricants When changing the oil or working on the fuel system ensure that the engine room is adequately venti lated Never carry out maintenance and repair work with the product in operation Carry out function checks on a product in operation only if expressly permitted to do so Secure the product against unintentional starting e g with start interlock Attach Do not operate sign in the operating area or to control equipment Disconnect the battery Lock circuit breakers Close the main valve on the compressed air system and vent the compressed air line when pneumatic starters are fitted Disconnect the control equipment from the product The following additional instructions apply to starters with beryllium copper pinion e Breathing protection of filter class P2 must be applied during maintenance work to avoid health haz ards caused by the beryllium containing pinion Do not blow out the interior of the flywheel housing or the starter with compressed air Clean the flywheel housing inside with a class H dust extraction device as an additional measure Safety regulations during maintenance and repair work Take special care when removing ve
111. ut 2 from stud 7 Unscrew bolts 4 and carefully remove battery charging generator with bracket and stud 8 Clean battery charging generator thorough ly gt Page 120 9 Assemble in reverse order 10 Adjust drive belt gt Page 122 3 21300106a M015675 06E 2013 04 Task Description 119 7 19 2 Battery charging generator Check WARNING A Note Preconditions V Engine is stopped and starting disabled Compressed air Risk of injury e Do not direct compressed air jet at persons e Wear protective goggles safety mask and ear protectors 21300106b Battery charging generator check a 0 Te Ventilation area arrow Clean None Ventilation area arrow Dirty Clean Battery charging generator cleaning Dry clean battery charging generator only Remove thick dirt from battery charging generator Blow out ventilation area arrow with compressed air until all dust is cleared 120 Task Description M015675 06E 2013 04 TIM AD 0000007377 001 TIMAD 0000007385 003 7 19 3 Generator Cleaning Special tools Material Spare parts Cleaner Snow White 1 1 0 40460 1 Cleaner Hakupur 312 30390 1 Compressed air gun ejects a jet of pressurized air Risk of injury to eyes and damage to hearing risk of rupturing internal organs A e Never direct air jet at people e Always wear safety goggles face mask and ear defenders A NOTICE Cleaner is extremely caustic Ris
112. ventilation Fil ter element replacement Loosen clamps 1 push rubber sleeves 2 over pipe 3 Release band clamp 4 with lever 6 Remove cover 7 Replace filter element 5 Fit cover 7 Operate lever 6 to tension clamping band 4 Push back rubber sleeve 2 and tighten clamp 1 Replace further filter elements in the same way 01800358b M015675 06E 2013 04 Task Description 63 Crankcase breather open circuit crankcase ventilation Filter el ement cleaning or replacement 1 Clean filter externally 2 Release vent hose on oil separator cov er 1 and remove 3 Remove oil separator cover 1 4 Loosen clamp 5 5 Clean or replace filter element 2 gt Page 61 6 Insert new sealing ring 3 7 Install cleaned or new filter element 2 with filter holder 5 8 Mount oil separator cover 1 01801233 9 Tighten nut of clamp 4 with torque wrench to specified tightening torque Tightening torque Engine oil 9Nm 1Nm 10 Push vent hose onto oil separator cover 3 and bolt on 11 Replace further filter elements 2 in the same way 64 Task Description M015675 06E 2013 04 TIM D 0000003532 003 TIMAD 0000033357 005 7 4 Running Gear 7 4 1 WARNING NOTICE Grounding device Carbon brush check Preconditions MW Engine is stopped and starting disabled Special tools Material Spare parts Cold cleaner H
113. viation Throttle Position Sensor Timing Reference Sensor Temperature xyz Voltage Power Driver Unit Uberdruckventil Unterer Totpunkt Variable Nozzle Turbine Variable Speed Governor Vehicle Speed Sensor Werkzeugkatalog Zuordnung Kategorie Parameter Reference surface for height above sea level Monitors oil level Monitors oil pressure Monitors oil temperature Top Dead Center Control panel Peripheral interface module Modulated signal Pressure measuring point xyz specifies the measur ing point designation Alarm Redundant CAN bus failure U S standardization organization Alarm Sensor failure 1st function Warning lamp stop engine and rectify fault 2nd function Read out fault codes OT cylinder 1 Safety system alarm Monitors charge air pressure Alarm Deviation in transmitter values Temperature measuring point xyz specifies the measuring point designation Solenoid valve output stage supply voltage Pressure relief valve Bottom Dead Center Tool Catalog A number assigned to a parameter describing func tion and allocation M015675 06E 2013 04 AppendixA 133 8 2 MTU contact persons service partners Our worldwide sales network with its subsidiaries sales offices representatives and customer service centers ensures fast and direct support on site and the high availability of our products Local support Experienced and qualified specialists place their knowledge and expertise at you
114. z 49 Hz 2 Hz 44 Hz 2 Hz QM 0 TER For Rockford S270 fan clutch Tighten screws 2 to specified tightening torque Screw M12x60 Tightening torque 100 Nm 10 Nm Adjusting drive belt tension Release screws 2 until fan clutch can be moved Tighten stud 1 until the required frequen cy is achieved 22100057b For Rockford S370 fan clutch Tighten screws 2 to specified tightening torque Screw M16x80 Tightening torque 270 Nm 10 Nm 126 Task Description M015675 06E 2013 04 TIM 4D 0000040744 001 TIMAD 0000007457 004 7 20 2 Fan drive Drive belt replacement Preconditions WM Engine is stopped and starting disabled Special tools Material Spare parts Drive belt gt Spare Parts Catalog Preparatory steps Remove protective cover Remove fan Replacing drive belt Release screws 2 Slacken off stud 1 until drive belt can be removed Clean belt pulleys Fit new drive belt on belt pulleys ensuring that it is not under tension Adjust belt tension gt Page 125 i 22100057b M015675 06E 2013 04 Task Description 127 7 21 Wiring General for Engine Gearbox Unit 7 21 1 Engine wiring Check Preconditions MW Engine is stopped and starting disabled Special tools Material Spare parts Isopropyl alcohol X00058037 1 Checking engine wiring 1 Check securing screws of cable clamps on engine and tighten loose th

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