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MTU 20V4000GX2 Operating Instructions Manual

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Operating Instructions

Diesel Engine
20V4000Gx2
M015565/03E

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Summary of Contents for MTU 20V4000GX2

  • Page 1: Operating Instructions

    Operating Instructions Diesel Engine 20V4000Gx2 M015565/03E...
  • Page 2 All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen GmbH reserves the right to change, delete or supplement the information provided as and when required.

  • Page 3: Table Of Contents

    Table of Contents 1 Safety 5.4 Starting the engine in emergency situations (override mode) 1.1 Important provisions for all products 5.5 Operational monitoring 1.2 Correct use for all products 5.6 Engine – Stopping in manual mode (test 1.3 Personnel and organizational requirements run) 1.4 Safety regulations for startup and operation 5.7 Engine –...
  • Page 4 8.15.1 Engine coolant – Level check 8.15.2 Engine coolant – Change 9.1 Abbreviations 8.15.3 Engine coolant – Draining 9.2 MTU Contact/Service Partners 8.15.4 Engine coolant – Filling 8.15.5 Engine coolant pump – Relief bore check 10 Appendix B 8.16 Low-Temperature Circuit 10.1 Special Tools...

  • Page 5: Safety

    The maintenance schedules of the manufacturer must be observed over the entire life cycle of the product. Replacing components with emission labels On all MTU engines fitted with emission labels, these labels must remain on the engine throughout its opera- tional life.

  • Page 6: Correct Use For All Products

    • With preservation approved by the manufacturer in accordance with the (→ Preservation and Represerva- tion Specifications of the manufacturer) • With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU con- tact/Service partner) • In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (in- cluding engine control/parameters) •...

  • Page 7: Personnel And Organizational Requirements

    1.3 Personnel and organizational requirements Organizational measures of the user/manufacturer This manual must be issued to all personnel involved in operation, maintenance, repair, assembly, installa- tion, or transportation. Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance, repair, assembly, installation, and transport personnel at all times.

  • Page 8: Safety Regulations For Startup And Operation

    1.4 Safety regulations for startup and operation Safety regulations for startup Install the product correctly and carry out acceptance in accordance with the manufacturer's specifications before putting the product into service. All necessary approvals must be granted by the relevant authorities and all requirements for initial startup must be fulfilled.
  • Page 9 Follow the applicable warning instructions pertaining to such devices. M015565/03E 2016-02 | Safety | 9...

  • Page 10: Safety Precautions When Working On The Engine

    1.5 Safety precautions when working on the engine 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 to less than 50 °C (risk of explosion for oil vapors, fluids and lubricants, risk of burning).
  • Page 11 Never bend lines and avoid damaging lines, particularly the fuel lines. Ensure that all retainers and dampers are installed correctly. Ensure that O-rings are not installed in a slanted/twisted condition. Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent contact with other components.
  • Page 12 During hydraulic installation/removal of components, ensure that no persons are in the direct vicinity of the component being pressed. Working with batteries Observe the safety instructions of the battery manufacturer when working with batteries. Gases released from the battery are explosive. Avoid sparks and naked flames. Do not allow battery acids to come into contact with skin or clothing.

  • Page 13: Fire Prevention And Environmental Protection, Fluids And Lubricants, Auxiliary Materials

    The safety data sheet may be obtained from the relevant manufacturer or from MTU. Take special care when using hot, chilled or caustic materials.

  • Page 14: Compressed Air

    Compressed air Observe special safety precautions when working with compressed air: • Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of con- tainers, risks causing an explosion. • Wear goggles when blowing dirt off workpieces or blowing away swarf. •...

  • Page 15: Standards For Safety Notices In The Text

    1.7 Standards for safety notices in the text DANGER In the event of immediate danger. Consequences: Death, serious or permanent injury! • Remedial action. WARNING In the event of a situation involving potential danger. Consequences: Death, serious or permanent injury! •...

  • Page 16: Transport

    Set the system down 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 the engine down on its oil pan unless expressly authorized to do so by MTU. 16 | Transport | M015565/03E 2016-02...

  • Page 17: Lifting Requirements

    2.2 Lifting requirements Lifting requirements DANGER Suspended load. Danger to life! • Use appropriate lifting devices and appliances. • Never stand beneath a suspended load. 1 Max. admissible diagonal 2 Center of gravity pull 10° Take note of the engine center of gravity See Installation/Arrangement drawings for details on engine center of gravity.

  • Page 18: Crankshaft Transport Locking Device

    2.3 Crankshaft transport locking device Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10–60 Nm F30452769 Torque wrench, 60–320 Nm F30452768 Engine oil Transport locking devices Note: The transport locking device on both sides protects the crankshaft bearings from shocks and vibration dam- age during engine transport.
  • Page 19 Installing the transport locking device on driving end (KS) Note: Install plate (6) on the upper part of the openings only. Secure the plates (6) with screws (4) and washers (5) at the lateral openings on both sides of the flywheel housing and tighten to the specified tightening torque.
  • Page 20 Installing guard plates and en- gine mounting brackets (if appli- cable) on driving end (KS) Note: Always use the screws supplied with the or removed from the guard plates and engine mounting brackets to secure them on the en- gine. Install engine mounting brackets (2) on both sides with guard plates (1) washers (3), and screws (4).

  • Page 21: General Information

    3 General Information 3.1 Engine side and cylinder designations 1 Left engine side (A-side) 3 Right engine side (B-side) 2 Engine free end in accord- 4 Engine driving end in ac- ance with DIN ISO 1204 cordance with (KGS = Kupplungsgegen- DIN ISO 1204 (KS = Kup- seite) plungsseite)

  • Page 22: Engine Overview

    3.2 Engine overview 1 Oil cooler 10 Coolant lines 19 HP fuel pump 2 Crankcase breather 11 Flywheel 20 Gear train 3 Coolant lines 12 Starter 21 Lube oil filter 4 Exhaust system 13 Engine mounting 22 Crank drive 5 Exhaust turbocharger 14 Air supply 23 Battery-charging generator 6 Air intake...

  • Page 23: Technical Data

    4 Technical Data 4.1 20V4000 continuous operation, unrestricted 3A, optimized fuel consumption G62, emissions-optimized (EPA) G82 Explanation Abbr. Meaning Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated, without change (e.g. of power settings). Not yet defined value Not applicable Applicable...
  • Page 24 Model related data (basic design) Engine model Unit 20V4000 20V4000 Engine with exhaust turbocharging (ETC) and charge-air cooling (CAC) Uncooled exhaust lines Operating method: Four-stroke cycle, diesel, single-ac- tion Combustion method: direct fuel injection Cooling method: conditioned water Direction of rotation: c.c.w. (facing driving end) Number of cylinders Cylinder arrangement: V-angle degrees...
  • Page 25 Coolant system (LT) Engine model Unit 20V4000 20V4000 Coolant temperature before intercooler (at engine inlet °C from cooling equipment) Coolant antifreeze content, max. permissible Pressure loss in the external cooling system, max. per- missible Lube oil system Engine model Unit 20V4000 20V4000 Lube oil operating temperature before engine, from...
  • Page 26 Engine model Unit 20V4000 20V4000 Oil change quantity max. (standard oil system) (design: Liter max. operating inclinations) Oil pan capacity dipstick mark min. (standard oil sys- Liter tem) (design: max. operating inclinations) Oil pan capacity dipstick mark max. (standard oil sys- Liter tem) (design: max.

  • Page 27: 20V4000 Continuous Operation, Variable 3B, Optimized Fuel Consumption G22/G62, Emissions-Optimized ("Ta-Luft") G22/G62, Emissions-Optimized (Epa)

    4.2 20V4000 continuous operation, variable 3B, optimized fuel consumption G22/G62, emissions-optimized (“TA-Luft”) G22/ G62, emissions-optimized (EPA) G42/G82 Explanation Abbr. Meaning Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated, without change (e.g. of power settings). Not yet defined value Not applicable Applicable...
  • Page 28 General conditions (for maximum power) Engine model Unit 20V4000 20V4000 20V4000 20V4000 20V4000 20V4000 Intake air depression mbar (new filter) (design) Intake air depression mbar (limit value) Exhaust backpres- mbar sure (design) Exhaust backpres- mbar sure (limit value) Model related data (basic design) Engine model Unit 20V4000...
  • Page 29 Engine model Unit 20V4000 20V4000 20V4000 20V4000 20V4000 20V4000 Standard housing connecting flange (engine main PTO) Flywheel interface DISC 21" 21" 21" 21" 21" 21" Air / exhaust gas Engine model Unit 20V4000 20V4000 20V4000 20V4000 20V4000 20V4000 Charge air pressure bar abs before cylinder (abs.), DL...
  • Page 30 Lube oil system Engine model Unit 20V4000 20V4000 20V4000 20V4000 20V4000 20V4000 Lube oil operating °C temperature before engine, from Lube oil operating °C temperature before engine, to Lube-oil temperature °C before engine, alarm Lube-oil temperature °C before engine, shut- down Lube oil operating pressure before en-...
  • Page 31 Oil and coolant capacity Engine model Unit 20V4000 20V4000 20V4000 20V4000 20V4000 20V4000 Engine coolant ca- Liter pacity, engine side (without cooling equipment) Charge-air coolant, Liter engine side Engine oil capacity, Liter initial filling (stand- ard oil system) (de- sign: max. operating inclinations) Oil change quantity Liter...

  • Page 32: 20V4000 Continuous Operation, Restricted 3C, Optimized Fuel Consumption G22/G62, Emissions-Optimized ("Ta-Luft")

    4.3 20V4000 continuous operation, restricted 3C, optimized fuel consumption G22/G62, emissions-optimized (“TA-Luft”) G22/G62 Explanation Abbr. Meaning Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated, without change (e.g. of power settings). Not yet defined value Not applicable Applicable...
  • Page 33 Model related data (basic design) Engine model Unit 20V4000 20V4000 20V4000 20V4000 Engine with exhaust turbocharging (ETC) and charge-air cooling (CAC) Uncooled exhaust lines Operating method: Four-stroke cy- cle, diesel, single-action Combustion method: direct fuel in- jection Cooling method: conditioned water Direction of rotation: c.c.w.
  • Page 34 Engine model Unit 20V4000 20V4000 20V4000 20V4000 Coolant antifreeze content, max. permissible Pressure loss in the external cooling system, max. permissible Coolant system (LT) Engine model Unit 20V4000 20V4000 20V4000 20V4000 Coolant temperature before inter- °C cooler (at engine inlet from cooling equipment) Coolant antifreeze content, max.
  • Page 35 General operating data Engine model Unit 20V4000 20V4000 20V4000 20V4000 Cold start capability: air temperature °C (w/o start aid, w/o preheating) (case A) Coolant preheating: preheating tem- °C perature (min.) Firing speed, from Firing speed, to Oil and coolant capacity Engine model Unit 20V4000...

  • Page 36: 20V4000 Standby Power 3D, Optimized Fuel Consumption G22/G62, Emissions-Optimized (Epa)

    4.4 20V4000 standby power 3D, optimized fuel consumption G22/G62, emissions-optimized (EPA) G42/G82 Explanation Abbr. Meaning Ref. value: Continuous power Ref. value: Fuel stop power Design value Guaranteed value Guideline value Limit value, up to which the engine can be operated, without change (e.g. of power settings). Not yet defined value Not applicable Applicable...
  • Page 37 Model related data (basic design) Engine model Unit 20V4000 20V4000 20V4000 20V4000 Engine with exhaust turbocharging (ETC) and charge-air cooling (CAC) Uncooled exhaust lines Operating method: Four-stroke cy- cle, diesel, single-action Combustion method: direct fuel in- jection Cooling method: conditioned water Direction of rotation: c.c.w.
  • Page 38 Engine model Unit 20V4000 20V4000 20V4000 20V4000 Coolant antifreeze content, max. permissible Pressure loss in the external cooling system, max. permissible Coolant system (LT) Engine model Unit 20V4000 20V4000 20V4000 20V4000 Coolant temperature before inter- °C cooler (at engine inlet from cooling equipment) Coolant antifreeze content, max.
  • Page 39 General operating data Engine model Unit 20V4000 20V4000 20V4000 20V4000 Cold start capability: air temperature °C (w/o start aid, w/o preheating) (case A) Coolant preheating: preheating tem- °C perature (min.) Firing speed, from Firing speed, to Oil and coolant capacity Engine model Unit 20V4000...

  • Page 40: Final Compression Pressure

    4.5 Final compression pressure Final compression pressure Final compression pressure at 120 rpm 24 bar to 28 bar 40 | Technical Data | M015565/03E 2016-02...

  • Page 41: Firing Order

    4.6 Firing order Number of Firing order cylinders 20 V A1-B5-A8-B7-A5-B2-A7-B10-A2-B3-A10-B6-A3-B4-A6-B9-A4-B1-A9-B8 M015565/03E 2016-02 | Technical Data | 41...

  • Page 42: Main Engine Dimensions

    4.7 Main engine dimensions Main engine dimensions Engine model Length (A) Width (B) Height (C) 20V4000G22/42/62/82 Approx. 3520 mm Approx. 1480 mm Approx. 2390 mm 42 | Technical Data | M015565/03E 2016-02...

  • Page 43: Operation

    5.1 Putting the engine into operation after extended out-of-service periods (>3 months) Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Preservation and Represervation Specifications A001070/.. are available. Putting the engine into operation after extended out-of-service-periods (>3 months) Item...

  • Page 44: Putting The Engine Into Operation After Scheduled Out-Of-Service-Period

    5.2 Putting the engine into operation after scheduled out-of- service-period Preconditions ☑ Engine is stopped and starting disabled. Putting the engine into operation Item Task Lube oil system Check oil level (→ Page 105); Cooling system Check engine coolant level (→ Page 111); Check charge-air coolant level (→...

  • Page 45: Engine - Starting In Manual Mode (Test Run)

    5.3 Engine – Starting in manual mode (test run) Preconditions ☑ Generator (if fitted) is not connected to network. ☑ External start interlock is not active. DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...

  • Page 46: Starting The Engine In Emergency Situations (Override Mode)

    5.4 Starting the engine in emergency situations (override mode) NOTICE Safety functions and engine shutdown alarms will be disregarded. Severe material damage! • Initiate emergency start only in emergency situations. Preparation Item Measure Operating mode switch Change to override mode (manual mode, if applicable). Starting the engine in emergency situations Item Measure...

  • Page 47: Operational Monitoring

    5.5 Operational monitoring DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running. Risk of damage to hearing! •...

  • Page 48: Engine - Stopping In Manual Mode (Test Run)

    5.6 Engine – Stopping in manual mode (test run) Preconditions ☑ Generator (if fitted) is not connected to network ☑ Engine in manual mode NOTICE Stopping the engine when it is running at full load subjects it to extreme thermal and mechanical stress- Overheating of and, therefore, damage to components is possible! •...

  • Page 49: Engine - Emergency Stop

    5.7 Engine – Emergency stop NOTICE An emergency stop subjects the engine system to an extremely high load. Risk of overheating, damage to components! • Trigger an emergency stop only in emergency situations. Emergency engine stop from LOP Item Action Emergency stop pushbutton Press pushbutton.

  • Page 50: After Stopping The Engine - Putting The Engine Out Of Operation

    5.8 After stopping the engine – Putting the engine out of operation Preconditions ☑ MTU Preservation and Represervation Specifications (A001070/..) are available. After stopping the engine Item Action Coolant circuit Drain engine coolant (→ Page 113); Drain charge-air coolant (→ Page 119) if: •...

  • Page 51: Plant - Cleaning

    5.9 Plant – Cleaning Preconditions ☑ Engine is stopped and starting disabled. ☑ No operating voltage is applied. Special tools, Material, Spare parts Designation / Use Part No. Qty. High-pressure cleaning unit Cleaner (Hakupur 50/136) X00056700 WARNING Compressed air gun ejects a jet of pressurized air. Risk of injury to eyes and damage to hearing, risk of rupturing internal organs! •...

  • Page 52: Maintenance

    6 Maintenance 6.1 Maintenance task reference table [QL1] The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Mainte- nance Schedule is a stand-alone publication. The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule.

  • Page 53: Troubleshooting

    7 Troubleshooting 7.1 Troubleshooting Engine does not turn when starter is actuated Cause Corrective action Battery low or faulty u Charge or replace (→ manufacturer's documentation). Cable connections faulty u Check cable connections for secure seating (→ manufacturer's documentation). u Check whether cable connections are properly secured. Starter (electric): Engine cabling or starter faulty Contact Service.
  • Page 54 Vent fuel system (→ Page 91). u Contact Service. Engine governor defective Charge-air temperature too high Cause Corrective action u Check (→ MTU test kit). Engine coolant treatment incorrect Intercooler dirty u Contact Service. Engine room: Air-intake u Check fans and intake/exhaust lines.
  • Page 55 Blue exhaust gas Cause Corrective action u Drain engine oil (→ Page 106). Too much engine oil in the engine u Replace filter (→ Page 75). Oil separator of crankcase breather contaminated Exhaust turbocharger, cylinder u Contact Service. head, piston rings or cylinder liner defective White exhaust gas Cause...

  • Page 56: Fault Messages On Engine Governor

    7.2 Fault messages on engine governor The engine governor generates alarms which are indicated in different ways depending on the equipment configuration: • as four-digit code on a PIM • as alarm text on a display • as four-digit code on a dialog PC The four-digit code consists of one letter and three figures: •...
  • Page 57 Fault Alarm text Meaning Task code L2 COOLANT LEV- Engine coolant level too low Check coolant level and top up, if required (→ Page 111). ENGINE OVER- Engine overspeed; automatic 1. Acknowledge alarm. SPEED engine shutdown 2. Try to re-start the engine (→ Page 45). 3.
  • Page 58 Fault Alarm text Meaning Task code L1 P-EXTERN 1 Violation of first limit for exter- (Depending on the corresponding measur- nal pressure channel 1 ing point, which is read via CAN bus) L2 P-EXTERN 1 Violation of second limit for ex- (Depending on the corresponding measur- ternal pressure channel 1 ing point, which is read via CAN bus)
  • Page 59 Fault Alarm text Meaning Task code PREHEAT TEMP. Coolant preheating tempera- Check preheating pump / preheating sys- LIMIT2 ture too low during start (2nd tem (see manufacturer's documentation). limit value); Termination of starting proce- dure (depending on project de- sign) PREHEAT TEMP.
  • Page 60 Fault Alarm text Meaning Task code L1 5V BUFFER Power supply for pressure sen- 1. Disconnect connectors X2 and X3 from TEST sors defective. engine governor. If alarm does not dis- appear: Contact Service. 2. Check wiring (pressure sensors). 3. Contact Service. SENSORPOWER- Power supply for pressure sen- 1.
  • Page 61 Fault Alarm text Meaning Task code CAN PU-DATA EE- Error during project design da- Contact Service. FAIL ta download in EEPROMs CAN LESS MAIL- Error during CAN initialization. Contact Service. BOXES CAN1 BUS OFF Severe fault on Default CAN Contact Service. bus;...
  • Page 62 Fault Alarm text Meaning Task code SD POWER SUP- Sensor defect (engine governor Contact Service. operating voltage) SD T-ELECTRONIC Sensor defect (temperature in Contact Service. engine governor) SD CAN SPEED Sensor defect (CAN nominal 1. Check speed transmitter. DEMAND speed demand) 2.
  • Page 63 Fault Alarm text Meaning Task code TIMING CYLINDER Injection timing fault cylinder If fault occurs repeatedly: Contact Service. TIMING CYLINDER Injection timing fault cylinder If fault occurs repeatedly: Contact Service. TIMING CYLINDER Injection timing fault cylinder If fault occurs repeatedly: Contact Service. TIMING CYLINDER Injection timing fault cylinder If fault occurs repeatedly: Contact Service.
  • Page 64 Fault Alarm text Meaning Task code WIRING CYLINDER Faulty wiring to solenoid valve 1. Check wiring. cylinder A7; 2. Contact Service. Misfiring WIRING CYLINDER Faulty wiring to solenoid valve 1. Check wiring. cylinder A8; 2. Contact Service. Misfiring WIRING CYLINDER Faulty wiring to solenoid valve 1.
  • Page 65 Fault Alarm text Meaning Task code OPEN_LOAD CYL. Disconnection in wiring to sole- 1. Check wiring. noid valve cylinder A3; 2. Contact Service. Misfiring OPEN_LOAD CYL. Disconnection in wiring to sole- 1. Check wiring. noid valve cylinder A4; 2. Contact Service. Misfiring OPEN_LOAD CYL.
  • Page 66 Fault Alarm text Meaning Task code OPEN_LOAD CYL. Disconnection in wiring to sole- 1. Check wiring. noid valve cylinder B9; 2. Contact Service. Misfiring OPEN_LOAD CYL. Disconnection in wiring to sole- 1. Check wiring. noid valve cylinder B10; 2. Contact Service. Misfiring POWER STAGE Defect in engine governor (sol-...

  • Page 67: Task Description

    8 Task Description 8.1 Engine 8.1.1 Engine – Barring manually Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring device F6555766 Ratchet with extension F30006212 DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...
  • Page 68 Note: Use barring device F6555766. Engage barring device (2) in ring gear of fly- wheel and install it on flywheel housing. Fit ratchet (1) onto barring device (2). Note: No resistance other than compression resist- ance must be encountered. Rotate crankshaft in engine direction of rota- tion.

  • Page 69: Engine - Cranking On Starting System

    8.1.2 Engine – Cranking on starting system Special tools, Material, Spare parts Designation / Use Part No. Qty. Pipe gripping pliers F30017884 DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...

  • Page 70: Engine - Test Run

    8.1.3 Engine – Test run DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Before cranking the engine with starter system, make sure that there are no persons in the engine's danger zone.

  • Page 71: Cylinder Liner

    8.2 Cylinder Liner 8.2.1 Cylinder liner – Endoscopic examination Preconditions ☑ Engine is stopped and starting disabled Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring device F6555766 Ratchet with extension F30006212 Endoscope Y20097353 Preparatory steps Remove cylinder head cover (→ Page 77). Remove injector (→...
  • Page 72 Compile endoscopic report using the table. Use technical terms to describe the liner surface (→ Page 73). Depending on findings: • Do not take any action or • carry out a further endoscopic examination as part of maintenance work or •...

  • Page 73: Instructions And Comments On Endoscopic And Visual Examination Of Cylinder Liners

    8.2.2 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 examina- tion report. Findings Explanations/Action Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing products, particles, broken-off burrs).
  • Page 74 Evaluation of findings and further measures The findings in the start phase of oxidation discoloration and heat discoloration are similar. A thorough inves- tigation and compliance with the above evaluation criteria allow an unambiguous evaluation. To avoid unnec- essary disassembly work, it is recommended that another inspection be carried out after further operation of the engine.

  • Page 75: Crankcase Breather

    8.3 Crankcase Breather 8.3.1 Crankcase breather – Oil separator element replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 4–20 Nm F30044239 Ratchet adapter F30027340 Engine oil Filter element (→...
  • Page 76 Remove filter element (1) from housing (2). Insert new filter element in housing. Install cover with new O-ring. Tighten screws of cover tighten to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Screw Tightening torque (Engine oil) 6 Nm + 2 Nm Replace other oil separator elements in the same way.

  • Page 77: Valve Drive

    8.4 Valve Drive 8.4.1 Cylinder head cover – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Gasket (→ Spare Parts Catalog) Removing cylinder head cover Clean very dirty cylinder head covers (3) prior to removal.

  • Page 78: Valve Gear - Lubrication

    8.4.2 Valve gear – Lubrication Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil Lubricating valve gear (valve bridge with guide) Remove cylinder head covers (→ Page 77). Fill oil chambers of valve bridges with oil.

  • Page 79: Valve Clearance - Check And Adjustment

    8.4.3 Valve clearance – Check and adjustment Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine coolant temperature is max. 40 °C. ☑ Valves are closed. Special tools, Material, Spare parts Designation / Use Part No. Qty. Feeler gage Y20098771 Torque wrench, 10–60 Nm F30452769...
  • Page 80 Checking valve bridge balance Fig. Component Guided valve bridge Flying valve bridge Note: Not applicable for engines with flying valve bridge. Prior to adjusting valve clearance, check valve bridge balance on all valve bridges. Use feeler gage to determine clearance be- tween valve bridge and rocker arm.
  • Page 81 Insert feeler gage with determined value be- tween valve bridge and valve-stem end (A). At the opposite valve-stem end (B), a feeler gage thicker by 0.05 mm should not fit, oth- erwise adjust valve bridge balance. Adjusting valve bridge balance Note: Not applicable for engines with flying valve bridge.
  • Page 82 Tighten locknut (2) to specified torque using a torque wrench holding valve bridge (1) in place with open-end wrench in so doing. Name Size Type Lubricant Value/Standard M 16 x 1.5 Preload torque (Engine oil) 35 Nm +5 Nm Recheck valve bridge balance. Checking valve clearance at two crankshaft positions Item Explanation...

  • Page 83: Adjusting Valve Clearance

    Item Explanation Inlet valve Exhaust valve Check TDC position of piston in cylinder A1: • The piston is at firing TDC when the rocker arms at cylinder A1 are unloaded. • The piston is at overlap TDC when the rocker arms at cylinder A1 are loaded. Check valve clearance with cold engine: •...

  • Page 84: Injection Pump / Hp Pump

    8.5 Injection Pump / HP Pump 8.5.1 HP fuel pump – Relief bore check DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running.

  • Page 85: Injector

    8.6 Injector 8.6.1 Injector – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Injector (→ Spare Parts Catalog) Injector – Replacement Remove injector and install new one (→ Page 86). M015565/03E 2016-02 | Injector | 85...

  • Page 86: Injector - Removal And Installation

    8.6.2 Injector – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Installation and removal jig F6794703 Milling cutter F30452739 Slotted screwdriver F30452578 Torque screwdriver, 1–5 Nm F30452774 Torque wrench, 10–60 Nm F30452769...
  • Page 87 Removing injector Note: Always replace the first and last injectors of one engine side first. Replace the inner injec- tors only after the installation of the outer in- jectors on this engine side is completed. Release the cable terminal threaded connec- tion (arrowed) on the injector and remove ca- ble terminals.
  • Page 88 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 bores, or seal with suitable plugs. Installing injector Prior to installation, remove all blanking plugs.
  • Page 89 Use slotted screwdriver to check thrust ring at both line ends for secure seating. Tighten loose thrust ring to specified tightening torque. Name Size Type Lubricant Value/Standard Thrust ring Tightening torque 5 Nm to 10 Nm Coat screw head mating face (2) and thread with engine oil.
  • Page 90 Tighten union nut of adapter (limiting valve) to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Union nut Tightening torque 140 Nm + 10 Nm Tighten union nut of adapter (injector) to specified torque using a torque wrench. Name Size Type...

  • Page 91: Fuel System

    8.7 Fuel System 8.7.1 Fuel system – Venting Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel WARNING Fuels are combustible and explosive. Risk of fire and explosion! •...

  • Page 92: Fuel Filter

    8.8 Fuel Filter 8.8.1 Fuel filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Engine oil Easy-change filter (→ Spare Parts Catalog) WARNING Fuels are combustible and explosive. Risk of fire and explosion! •...

  • Page 93: Fuel Prefilter - Cleaning

    8.8.2 Fuel prefilter – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel Sealing ring (→ Spare Parts Catalog) WARNING Fuels are combustible and explosive. Risk of fire and explosion! •...

  • Page 94: Fuel Prefilter - Differential Pressure Gage Check And Adjustment Of Gage

    8.8.3 Fuel prefilter – Differential pressure gage check and adjustment of gage DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running.

  • Page 95: Fuel Prefilter – Draining

    8.8.4 Fuel prefilter – Draining Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel Sealing (→ Spare Parts Catalog) WARNING Fuels are combustible and explosive. Risk of fire and explosion! •...

  • Page 96: Fuel Prefilter – Flushing

    8.8.5 Fuel prefilter – Flushing Preconditions ☑ Engine is stopped and starting disabled (only in the case of single fuel prefilter). Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel Seal (→ Spare Parts Catalog) DANGER Rotating and moving engine parts.
  • Page 97 Fuel prefilter – Flushing Note: Only in the case of double fuel prefilter: Cut out the contaminated filter. 1 Left filter cut in 2 Right filter cut in Open threaded vent plug (5) of filter to be flushed. Unlock drain valve (6) by pressing toggle, open it and drain fuel.

  • Page 98: Fuel Prefilter – Filter Element Replacement

    8.8.6 Fuel prefilter – Filter element replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel Filter element (→ Spare Parts Catalog) Gasket (→ Spare Parts Catalog) WARNING Fuels are combustible and explosive.
  • Page 99 Open threaded vent plug (5) of contaminated filter. Unlock drain valve (6) by pressing toggle and open it. Drain water and contamination from filter. Close drain valve (6). Remove screws securing the cover and take off cover (2). Remove spring housing (4) and filter ele- ment (3).

  • Page 100: Charge-Air Cooling

    8.9 Charge-Air Cooling 8.9.1 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! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running.

  • Page 101: Air Filter

    8.10 Air Filter 8.10.1 Air filter ‒ Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Air filter (→ Spare Parts Catalog) Air filter ‒ Replacement Remove air filter and install new one (→ Page 102). Reset signal ring of service indicator (→ Page 103). M015565/03E 2016-02 | Air Filter | 101...

  • Page 102: Air Filter – Removal And Installation

    8.10.2 Air filter – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Air filter – Removal and installa- tion Loosen clamp (2). Remove air filter (1) and clamp (2) from con- necting flange of intake housing (3). Verify that there are no objects in the flange of the intake housing (3) and clean it.

  • Page 103: Air Intake

    8.11 Air Intake 8.11.1 Service indicator – Signal ring position check Preconditions ☑ Engine is stopped and starting disabled. Checking signal ring position If the signal ring is completely visible in the control window (2), replace air filter (→ Page 101). After installation of new filter, press reset button (1).

  • Page 104: Starting Equipment

    8.12 Starting Equipment 8.12.1 Air starter – Manual operation DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Before cranking the engine with starter system, make sure that there are no persons in the engine's danger zone.

  • Page 105: Lube Oil System

    8.13 Lube Oil System 8.13.1 Engine oil – Level check Preconditions ☑ Engine is stopped and starting disabled. WARNING Hot oil. Oil can contain combustion residues which are harmful to health. Risk of injury and poisoning! • Wear protective clothing, gloves, and goggles / safety mask. •...

  • Page 106: Engine Oil – Change

    8.13.2 Engine oil – Change Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine is at operating temperature. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 60–320 Nm...
  • Page 107 Draining residual oil from equip- ment carrier (only with un- scheduled engine oil change) Provide a suitable container in which to col- lect the engine oil. Remove drain plug (1) and drain engine oil from engine oil heat exchanger and from en- gine oil filter.

  • Page 108: Oil Filtration / Cooling

    8.14 Oil Filtration / Cooling 8.14.1 Engine oil filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Engine oil Oil filter (→ Spare Parts Catalog) WARNING Hot oil.

  • Page 109: Centrifugal Oil Filter – Cleaning And Filter Sleeve Replacement

    8.14.2 Centrifugal oil filter – Cleaning and filter-sleeve replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 4–20 Nm F30044239 Torque wrench, 10–60 Nm F30452769 Cold cleaner (Hakutex 60) X00056750 Filter sleeve (→...
  • Page 110 Centrifugal oil filter, cleaning and filter-sleeve replacement Remove clamp (14). Release cover nut (2) and take off cover (1). Carefully lift rotor (11), allow oil to drain and remove from housing. Holding the rotor (11) firmly, release rotor cover nut (3). Take off rotor cover (4).

  • Page 111: Circuit

    8.15 Coolant Circuit, General, High-Temperature Circuit 8.15.1 Engine coolant – Level check Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...

  • Page 112: Engine Coolant – Change

    8.15.2 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change Drain engine coolant (→ Page 113). Fill with engine coolant (→ Page 114). 112 | Coolant Circuit, General, High-Temperature Circuit | M015565/03E 2016-02...

  • Page 113: Engine Coolant – Draining

    8.15.3 Engine coolant – Draining Preconditions ☑ Engine is stopped and starting disabled. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask. Preparatory steps Provide a suitable receptacle to catch the coolant.

  • Page 114: Engine Coolant – Filling

    8.15.4 Engine coolant – Filling Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant WARNING Coolant is hot and under pressure.
  • Page 115 Filling coolant from below with pump Connect appropriate pump with hose to drain valve of engine coolant pump (arrow). Loosen vent line union on distributor piece (arrowed). Open drain valve and pump coolant into en- gine at 0.5 bar minimum. Tighten union (arrow) if coolant leaks out at loose union.

  • Page 116: Engine Coolant Pump – Relief Bore Check

    8.15.5 Engine coolant pump – Relief bore check DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running.

  • Page 117: Low-Temperature Circuit

    8.16 Low-Temperature Circuit 8.16.1 Charge-air coolant – Level check Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down.

  • Page 118: Charge-Air Coolant – Change

    8.16.2 Charge-air coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Charge-air coolant – Change Drain charge-air coolant (→ Page 119). Fill with charge-air coolant (→ Page 120). 118 | Low-Temperature Circuit | M015565/03E 2016-02...

  • Page 119: Charge-Air Coolant Draining

    8.16.3 Charge-air coolant draining Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Sealing ring (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...

  • Page 120: Charge-Air Coolant – Filling

    8.16.4 Charge-air coolant – Filling Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Charge-air coolant Sealing ring (→ Spare Parts Catalog) WARNING High level of engine noise when the engine is running.
  • Page 121 Filling charge-air coolant Pour in treated coolant via the filling point on the coolant line to the intercooler and via the filler neck of the expansion tank until coolant is visible at the marker plate. Install plug screws of filling points with new sealing rings.

  • Page 122: Charge-Air Coolant Pump – Relief Bore Check

    8.16.5 Charge-air coolant pump – Relief bore check DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running.

  • Page 123: Belt Drive

    8.17 Belt Drive 8.17.1 Drive belt – Condition check Preconditions ☑ Engine is stopped and starting disabled. ☑ Guard is removed. Drive belt – Condition check Item Findings Action Drive belt A Singular cracks None Drive belt B Cracks on entire circumference Replace (→...

  • Page 124: Battery-Charging Generator

    8.18 Battery-Charging Generator 8.18.1 Battery-charging generator drive – Drive belt tension adjustment Preconditions ☑ Engine is stopped and starting disabled. Adjusting belt tension Loosen locknut (2) and screws (1). Tension drive belt with tensioning nut (3) and check belt tension (→ Page 125). Tighten locknut (2).

  • Page 125: Battery-Charging Generator Drive – Drive Belt Condition Check

    8.18.2 Battery-charging generator drive – Drive belt condition check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Belt tension tester Y4345711 Preparatory steps Remove protective cover. Check belt condition visually (→ Page 123). Checking drive belt tension Fit sensor head on belt tension tester and tap drive belt with a suitable tool.

  • Page 126: Battery-Charging Generator Drive – Drive Belt Replacement

    8.18.3 Battery-charging generator drive – Drive belt replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Drive belt (→ Spare Parts Catalog) Note: In the event of drive belt failure during engine operation fit a new drive belt as quickly as possible. Noncom- pliance 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.

  • Page 127: Engine Mounting / Support

    8.19 Engine Mounting / Support 8.19.1 Engine mounting – Resilient mount check Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine filled with coolant and engine oil. Engine mounting – Checking the condition of resilient mounts Wipe rubber surface with dry cloth, do not use organic detergents.

  • Page 128: Cabling

    8.20 Cabling 8.20.1 Engine cabling – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Solvent (isopropyl alcohol) X00058037 Engine cabling – Check Check securing screws of cable clamps on engine and tighten loose screw connections. Ensure that cables are securely seated in clamps and cannot move freely.

  • Page 129: Accessories For (Electronic) Engine Governor / Control System

    8.21 Accessories for (Electronic) Engine Governor / Control System 8.21.1 Engine Control Unit and connectors – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Pipe gripping pliers F30017884 Solvent (isopropyl alcohol) X00058037 Cleaning Engine Control Unit...

  • Page 130: Engine Control Unit – Plug Connection Check

    8.21.2 Engine Control Unit – Plug connection check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Pipe gripping pliers F30017884 Checking Engine Control Unit plug connections Check that all plug connections on the En- gine Control Unit are properly seated using pipe gripping pliers (3).

  • Page 131: Abbreviations

    Abgasturbolader/Abgasturboaufladung Exhaust turbocharger/exhaust turbocharging Air Temperature Sensor Baureihe Series Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Publica- tion No. A01061/.. Controller Area Network Data bus system, bus standard Calibration Drift Compensation Drift correction setting with DiaSys in engine gover- Check Engine Lamp...
  • Page 132 Abbre- Meaning Explanation viation Engine Control Unit Engine governor Engine Data Module Memory module for engine data Electrically Erasable Programmable Read Electrically Erasable Programmable Read Only Mem- PROM Only Memory EFPA Electronic Foot Pedal Assembly Electronic accelerator pedal Exhaust Gas Recirculation Engine Ident Label EIM-ID Emission Identification Number Engine Monitoring Unit...
  • Page 133 Abbre- Meaning Explanation viation Not Applicable Low Pressure Normal Null Reference surface for heights above sea level Niedertemperatur Low temperature Original Equipment Manufacturer Optimized Idle Oil Level Sensor Monitors oil level Oil Pressure Sensor Monitors oil pressure Oil Temperature Sensor Monitors oil temperature Oberer Totpunkt Top Dead Center...

  • Page 134: Mtu Contact/Service Partners

    Local Support Experienced and qualified specialists place their knowledge and expertise at your disposal. For locally available support, go to the MTU Internet site: http://www.mtu-online.com 24h Hotline With our 24h hotline and high flexibility, we're your contact around the clock: during each operating phase, preventive maintenance and corrective operations in case of a malfunction, for information on changes in conditions of use and for supplying spare parts.

  • Page 135: Special Tools

    10 Appendix B 10.1 Special Tools Barring device Part No.: F6555766 Qty.: Used in: 8.1.1 Engine – Barring manually (→ Page 67) Qty.: Used in: 8.2.1 Cylinder liner – Endoscopic examination (→ Page 71) Belt tension tester Part No.: Y4345711 Qty.: Used in: 8.18.2 Battery-charging generator drive –...
  • Page 136 Crossbeam Part No.: T80092360 Qty.: Used in: 2.1 Transportation (→ Page 16) Endoscope Part No.: Y20097353 Qty.: Used in: 8.2.1 Cylinder liner – Endoscopic examination (→ Page 71) Feeler gage Part No.: Y20098771 Qty.: Used in: 8.4.3 Valve clearance – Check and adjustment (→...
  • Page 137 High-pressure cleaning unit Part No.: Qty.: Used in: 5.9 Plant – Cleaning (→ Page 51) Installation and removal jig Part No.: F6794703 Qty.: Used in: 8.6.2 Injector – Removal and installation (→ Page 86) Milling cutter Part No.: F30452739 Qty.: Used in: 8.6.2 Injector –...
  • Page 138 Ratchet adapter Part No.: F30027340 Qty.: Used in: 8.3.1 Crankcase breather – Oil separator element re- placement (→ Page 75) Ratchet adapter Part No.: F30027341 Qty.: Used in: 8.13.2 Engine oil – Change (→ Page 106) Ratchet with extension Part No.: F30006212 Qty.: Used in:...
  • Page 139 Slotted screwdriver Part No.: F30452578 Qty.: Used in: 8.6.2 Injector – Removal and installation (→ Page 86) Torque screwdriver, 1–5 Nm Part No.: F30452774 Qty.: Used in: 8.6.2 Injector – Removal and installation (→ Page 86) Torque wrench, 10–60 Nm Part No.: F30452769 Qty.:...
  • Page 140 Torque wrench, 60–320 Nm Part No.: F30452768 Qty.: Used in: 2.3 Crankshaft transport locking device (→ Page 18) Qty.: Used in: 8.4.3 Valve clearance – Check and adjustment (→ Page 79) Qty.: Used in: 8.6.2 Injector – Removal and installation (→ Page 86) Qty.: Used in: 8.13.2 Engine oil –...

  • Page 141: Index

    10.2 Index Abbreviations 131 Differential pressure gage  After stopping the engine  – Adjustment   – Putting the engine out of operation  50 – Fuel prefilter  94 Air filter  – Check   – Installation  102 – Fuel prefilter  94 – Removal  102 Dimensions ...
  • Page 142 Transport locking device  – Crankshaft   – Installation/removal  18 Main dimensions  Transportation  – Engine  42 – Description  16 Maintenance schedule  – Lifting requirements  17 – Maintenance task reference table [QL1]  52 Troubleshooting 53 MTU contact persons 134 142 | Index | M015565/03E 2016-02...
  • Page 143 Valve clearance  – Adjustment  79 – Check  79 Valve gear  – Lubrication  78 M015565/03E 2016-02 | Index | 143...

Table of Contents