MTU 20 V 4000 C22 Operating Instructions Manual
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MTU 20 V 4000 C22 Operating Instructions Manual

MTU 20 V 4000 C22 Operating Instructions Manual

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Operating Instructions

Diesel engine
20 V 4000 C22
M015675/05E

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Summary of Contents for MTU 20 V 4000 C22

  • Page 1: Operating Instructions

    Operating Instructions Diesel engine 20 V 4000 C22 M015675/05E...
  • Page 2 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, micro‐ filming and storage or processing on electronic systems including data bases and online services.
  • Page 3 Commissioning Note Important Please complete and return the “Commissioning Note” card below to MTU Friedrichshafen GmbH. The Commissioning Note information serves as a basis for the contractually agreed logistic support (war‐ ranty, spare parts, etc.).

  • Page 5: Table Of Contents

    Table of Contents 1 Safety 6 Troubleshooting 1.1 General conditions 6.1 Troubleshooting 1.2 Personnel and organizational requirements 6.2 ECU 4 alarms 1.3 Transport 1.4 Crankshaft transport locking device – For transport with flanged-on generator 7 Task Description 1.5 Safety regulations for startup and operation 1.6 Explosion hazard when removing 7.1 Engine inspection port cover on engine...
  • Page 6 8 Appendix A 7.16 Low-Temperature Circuit 8.1 Abbreviations 7.16.1 Charge-air coolant – Level check 8.2 MTU contacts/service partners 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 – Relief bore check 9 Appendix B 7.17 Belt Drive...

  • Page 7: Safety

    Modifications or conversions Unauthorized modifications to the engine represent a safety risk. MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or conversions. Spare parts Only genuine MTU spare parts must be used to replace components or assemblies. MTU accepts no liability whatsoever for damage or injury resulting from the use of other spare parts and the warranty shall be voided in such case.

  • Page 8: Personnel And Organizational Requirements

    1.2 Personnel and organizational requirements Personnel requirements Work on the engine must only be carried out by appropriately qualified and instructed personnel. Observe the minimum legal age. Responsibilities of the operating, maintenance and repair personnel must be specified by the operating company.

  • Page 9: 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.

  • Page 10: Crankshaft Transport Locking Device - For Transport With Flanged-On Generator

    1.4 Crankshaft transport locking device – For transport with flanged-on generator Transport This locking device protects the crankshaft bearings from shocks and vibration damage during unit trans‐ port. For removal of the transport locking device follow the following instructions: • The transport locking device should remain installed as long as possible during unit installation in or‐ der to avoid damage.
  • Page 11 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. •...

  • Page 12: Safety Regulations For Startup And Operation

    Safety requirements for initial operation Prior to initial operation of the unit, install the assembly or unit according to the specifications and check the installation according to the MTU specifications. Before putting the device or plant into operation, always ensure: •...

  • Page 13: Explosion Hazard When Removing Inspection Port Cover On Engine

    1.6 Explosion hazard when removing inspection port cover on engine DANGER Explosion hazard due to oil vapors. Risk of serious injury – danger to life! • Allow the engine to cool down before opening the crankcase! • Avoid open flames, electrical sparks and ignition sources. Safety instructions Before starting maintenance work, allow the engine to cool down for at least 10 min.

  • Page 14: Safety Precautions When Working On The Engine

    Do not use the assembly or plant as a ground terminal. Never place the welding cable across or near wiring harnesses of MTU plants. The welding current may otherwise induce an interference voltage in the wiring harnesses which could damage the electrical sys‐...
  • Page 15 If welding has to be carried out on components (e.g. exhaust manifold), these components must first be removed from the engine. Hydraulic installation and removal Check the tools and devices to be used for perfect operation and safe condition. Only use the specified devices for force-fitting/removing parts.

  • Page 16: Fluids And Lubricants, Fire Prevention And Environmental Protection

    Only fuels of the specified quality required to achieve emission limits must be used. Dispose of used fluids, lubricants and filters in accordance with local regulations. Batteries can be returned within the EU to MTU FN / MTU Onsite Energy free of charge for correct recy‐ cling/disposal.
  • Page 17 Lead • When working with lead or lead-containing compounds, avoid direct contact to the skin and do not inhale lead vapors. • Prevent the buildup of white powder of lead. • Switch on fume extraction system. • After coming into contact with lead or lead-containing materials, wash your hands! Compressed air When working with compressed air, safety precautions must be constantly observed: •...

  • Page 18: Conventions For Safety Instructions In The Text

    1.9 Conventions for safety instructions in the text DANGER In the event of immediate danger. Consequences: Death or serious injury • Remedial action WARNING In the event of potentially dangerous situations. Consequences: Death or serious injury • Remedial action CAUTION In the event of dangerous situations.

  • Page 19: General Information

    2 General Information 2.1 Engine side and cylinder designations Engine sides are always designated as viewed from the driving end (KS). The cylinders of the left engine side are designated "A" and those of the right side "B" (as per DIN ISO 1204).

  • Page 20: Engine Layout

    2.2 Engine layout 1 Centrifugal oil filter 7 Starter (A side) 11 Crankcase 2 Engine lifting eye 8 Engine Control Unit ECU 12 HP fuel pump 3 Fan drive 13 Engine oil filter (automat‐ 4 Drive belt 9 Fuel priming pump ic filter) 5 Charge-air coolant inlet 10 Fuel filter (easy-change...
  • Page 21 1 Engine lifting eye 4 Intercooler 8 Oil pan 2 Cylinder head cover / cyl‐ 5 Flywheel 9 Oil dipstick inder head 6 Charge-air coolant outlet 10 Oil filler neck 3 Oil heat exchanger 7 Engine coolant inlet 11 Starter (B side) M015675/05E 2011-10 | General Information | 21...
  • Page 22 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 Combustion air inlet (B tion (B side) 3 Exhaust turbocharger (A side) 9 Air supply before inter‐...

  • Page 23: Sensors, Actuators And Injectors - Overview

    2.3 Sensors, actuators and injectors – Overview 1 B07 (T-Lube oil) 3 B34 (P-Fuel after filter) 2 Injectors Y39.1 to Y39.10 4 B48 (P-Fuel) (A side cylinders) 5 B33 (T-Fuel) The injectors are underneath the cylinder head covers of the cylinder. Injector replacement and necessa‐ ry activities (→...
  • Page 24 1 Injectors Y39.11 to 2 B16 (P-Coolant) 4 B09 (T-Charge Air) Y39.20 (B side cylinders) 3 B10 (P-Charge Air) 1 B44 (N-Turbocharger) 2 B03 (T-Intake Air) 24 | General Information | M015675/05E 2011-10...
  • Page 25 1 B13 (N-Crankshaft) M015675/05E 2011-10 | General Information | 25...
  • Page 26 1 B50 (P-Crankcase) 4 B01 (N-Camshaft) 6 B26 (T-Coolant Intercool‐ 2 F25 (P-Lube Oil Diff.after 5 B43 (P-Coolant Intercool‐ Filter) 7 B06 (T-Coolant) 3 B05 (P-Lube Oil) 26 | General Information | M015675/05E 2011-10...

  • Page 27: Technical Data

    3 Technical Data 3.1 20V 4000 C22 engine data Explanation: DL Ref. value: Continuous power (CP) BL Ref. value: Fuel stop power (FSP) A Design value G Guaranteed value R Guideline value L Limit value, up to which the engine can be operated, without change (e.g. of power setting) N Not yet defined value - Not applicable X Applicable...
  • Page 28 MODEL-RELATED DATA (basic design) Number of cylinders 20V 4000 Number of cylinders Cylinder configuration: V angle degrees Bore Stroke Cylinder displacement liter 4.49 Total displacement liter 89.81 Number of inlet valves, per cylinder Number of exhaust valves, per cylinder COMBUSTION AIR / EXHAUST GAS Number of cylinders 20V 4000 Charge-air pressure before cylinder...
  • Page 29 LUBE OIL SYSTEM Number of cylinders 20V 4000 Lube oil operating temperature before engine, from °C Lube oil operating temp. before engine, to °C Lube oil operating pressure before engine (measuring block) Lube oil pressure before engine, alarm Lube oil pressure before engine, shutdown FUEL SYSTEM Number of cylinders 20V 4000...
  • Page 30 CAPACITIES Number of cylinders 20V 4000 Engine coolant capacity (without cooling equipment) liter Engine oil capacity, initial filling (standard oil system) (Option: max. liter operating inclinations) Oil pan capacity, dipstick mark min. (standard oil system) (Option: liter max. operating inclinations) Oil pan capacity, dipstick mark max.

  • Page 31: Firing Order

    3.2 Firing order Firing order Number of cylin‐ Firing order ders A1-B4-A4-A2-B3-A3-B2-B1 A1-B2-A5-B4-A3-B1-A6-B5-A2-B3-A4-B6 16 V A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7 20 V A1-B5-A8-B7-A5-B2-A7-B10-A2-B3-A10-B6-A3-B4-A6-B9-A4-B1-A9-B8 M015675/05E 2011-10 | Technical Data | 31...

  • Page 32: Main Engine Dimensions

    3.3 Main engine dimensions Main engine dimensions Length (A) approx. 3630 mm Width (B) approx. 1450 mm Height (C) approx. 2252 mm 32 | Technical Data | M015675/05E 2011-10...

  • Page 33: Operation

    4.1 Putting the engine into operation after extended out-of- service periods (>3 months) Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Putting into operation after long out-of-service periods (>3 months) Item Action Engine Depreserve (→...

  • Page 34: Putting The Engine Into Operation After Scheduled Out-Of-Service-Period

    4.2 Putting the engine into operation after scheduled out-of- service-period Preconditions ☑ Engine is stopped and starting disabled. Startup Item Action Lube oil system Check engine oil level (→ Page 96). Coolant circuit Check engine coolant level (→ Page 105); Check charge-air coolant level (→...

  • Page 35: Engine - Start In Manual Mode

    4.3 Engine – Start in manual mode Preconditions ☑ Engine with no load. ☑ External start interlock is not activated. DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Before barring or starting the engine, make sure that nobody is in the danger zone. WARNING Engine noise above 85 dB (A).

  • Page 36: Operational Checks

    4.4 Operational checks DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...

  • Page 37: Engine - Shutdown In Manual Mode

    4.5 Engine – Shutdown in manual mode Preconditions ☑ Engine is not under load ☑ Engine in manual mode CAUTION Stopping the engine when it is running at full load causes extreme stress to the engine. Risk of overheating, damage to components! •...

  • Page 38: After Stopping The Engine

    4.6 After stopping the engine Preconditions ☑ MTU Fluids and Lubricants Specification (A001061/..) is available. After stopping the engine Item Task Coolant circuit Drain coolant (→ Page 107)(→ Page 115)if freezing temperatures are ex‐ pected and: • the engine is to remain out of service for an extended period and cool‐...

  • Page 39: Plant - Cleaning

    4.7 Plant – Cleaning Preconditions ☑ Engine is stopped and starting disabled. ☑ Operating voltage is not applied. Special tools, Material, Spare parts Designation / Use Part No. Qty. Steam jet cleaner Cleaner (Hakupur 312) 30390 WARNING Compressed air Risk of injury! •...

  • Page 40: Maintenance

    5 Maintenance 5.1 Maintenance 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.

  • Page 41: Troubleshooting

    6 Troubleshooting 6.1 Troubleshooting Engine does not turn when starter is actuated Component Probable Cause Task Battery Low or defective Charge or replace (see manufacturer's documentation). Cable connections defective Check if cable connections are proper‐ ly secured (see manufacturer's docu‐ mentation).
  • Page 42 Defective Contact Service. Charge-air temperature too high Component Probable Cause Task Engine coolant Incorrect coolant concentration Check (MTU test kit). Intercooler Contaminated Contact Service. Engine room Air-intake temperature too high Check fans and air supply / ventilation ducts. Charge air pressure too low...
  • Page 43 Exhaust gas white Component Probable Cause Task Engine Not at operating temperature Run engine to reach operating temper‐ ature. Fuel system Water in fuel Check fuel system on fuel prefilter. Drain fuel prefilter Intercooler Leaking Contact Service. M015675/05E 2011-10 | Troubleshooting | 43...

  • Page 44: Ecu 4 Alarms

    6.2 ECU 4 alarms Faults in the overall system are indicated as a four-digit code on the PIM display. The fault code numbers are generated by the ECU. The four-digit code consists of one letter and three figures: • The letter encodes when the fault occurred the last time: A = currently present B = within the last operating hour C = one to four operating hours ago...
  • Page 45 Fault code Alarm text Meaning Task L2 P-LUBE OIL Lube-oil pressure too low 1. Check engine-oil level and top (2nd limit) up, if required; (→ Page 96); 2. Try to re-start the engine Automatic engine shut‐ (→ Page 35). down. 3.
  • Page 46 Fault code Alarm text Meaning Task L1 P-FUEL Fuel supply pressure too 1. Check fuel lines for leaks; repair low (1st limit) defective lines. 2. Clean fuel prefilter 3. Flush fuel prefilter 4. Replace filter element of fuel prefilter. 5. Fuel filter replacement (→...
  • Page 47 Fault code Alarm text Meaning Task ENGINE SPEED Engine speed lower than Re-start the engine (→ Page 35). 200 rpm; Automatic engine shut‐ down. IDLE SPEED LOW Idle speed not reached Note further alarms. within a specified period; Termination of starting pro‐ cedure.
  • Page 48 Fault code Alarm text Meaning Task L2 SUPPLY VOLT. Supply voltage too low Check ECU supply voltage. (2nd limit) L1 SUPPLY VOLT. Supply voltage too high Check ECU supply voltage. HIGH (1st limit) L2 SUPPLY VOLT. Supply voltage too high Check ECU supply voltage.
  • Page 49 Fault code Alarm text Meaning Task AD-TEST1 ECU DE‐ Electronic equipment de‐ Contact Service. FECT fective; Automatic engine shut‐ down. L1 AD-TEST2 SUP‐ A/D-converter supply volt‐ Contact Service. age too low. AD-TEST2 ECU DE‐ Electronic equipment de‐ Contact Service. FECT fective;...
  • Page 50 Fault code Alarm text Meaning Task CAN2 ERROR PAS‐ Light fault on Redundant (none) SIVE CAN bus (e.g. short-time overload) SD T-COOLANT Sensor defect (coolant 1. Check wiring. temperature) 2. Contact Service. SD T-FUEL Sensor defect (fuel temper‐ 1. Check wiring. ature) 2.
  • Page 51 Fault code Alarm text Meaning Task SD T-ELECTRONIC Sensor defect (temperature Contact Service. in ECU) SD SPEED DE‐ Sensor defect (analog 1. Check speed transmitter MAND AN. speed demand) 2. Check wiring. 3. Contact Service. TIMING CYLINDER Injection timing fault cylin‐ If fault occurs repeatedly: Contact der A1 Service.
  • Page 52 Fault code Alarm text Meaning Task WIRING CYLINDER Faulty wiring to solenoid 1. Check wiring. valve cylinder A2; 2. Contact Service. Misfiring WIRING CYLINDER Faulty wiring to solenoid 1. Check wiring. valve cylinder A3; 2. Contact Service. Misfiring WIRING CYLINDER Faulty wiring to solenoid 1.
  • Page 53 Fault code Alarm text Meaning Task WIRING CYLINDER Faulty wiring to solenoid 1. Check wiring. valve cylinder B7; 2. Contact Service. Misfiring WIRING CYLINDER Faulty wiring to solenoid 1. Check wiring. valve cylinder B8; 2. Contact Service. Misfiring WIRING CYLINDER Faulty wiring to solenoid 1.
  • Page 54 Fault code Alarm text Meaning Task OPEN_LOAD CYL. Disconnection in wiring to 1. Check wiring. solenoid valve cylinder B1; 2. Contact Service. Misfiring OPEN_LOAD CYL. Disconnection in wiring to 1. Check wiring. solenoid valve cylinder B2; 2. Contact Service. Misfiring OPEN_LOAD CYL.
  • Page 55 Fault code Alarm text Meaning Task STOP SOLENOID- Solenoid-valve wiring faul‐ 1. Check wiring. WIRING 2. Try to re-start the engine (→ Page 35). Automatic engine shut‐ 3. Contact Service. down. TRAN.OUT1 PLANT Binary transistor output Contact Service. plant 1 defective TRAN.OUT2 PLANT Binary transistor output Contact Service.

  • Page 56: Task Description

    7 Task Description 7.1 Engine 7.1.1 Engine – Barring manually Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring device F6555766 Barring device F6783293 Adapter F6558528 Ratchet F30006212 DANGER Unguarded rotating and moving engine components.
  • Page 57 Barring engine manually (installation on lower side) Remove grounding device or guard plate. Engage barring device (2) with ring gear (1) and mount on flywheel housing. • For 12/16V engines, use barring device F6555766 with adapter F6558528. • For 20V engines, use barring de‐ vice F6783293.

  • Page 58: Engine - Barring With Starting System

    7.1.2 Engine – Barring with starting system Special tools, Material, Spare parts Designation / Use Part No. Qty. Connector pliers 0135315483 DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • before barring or starting the engine, ensure that nobody is in the danger zone. •...

  • Page 59: Cylinder Liner

    7.2 Cylinder Liner 7.2.1 Cylinder liner – Endoscopic examination Preconditions ☑ Engine is stopped and starting disabled Special tools, Material, Spare parts Designation / Use Part No. Qty. Endoscope Y20097353 Preparatory steps Remove cylinder head cover (→ Page 76). Remove injector (→ Page 79). Positioning crankshaft at BDC Using barring device, turn crankshaft until crankshaft journal of the cylinder to be tested has reached BDC.
  • Page 60 Final steps Install injector (→ Page 79). Install cylinder head cover (→ Page 76). 60 | Task Description | M015675/05E 2011-10...

  • Page 61: Instructions And Comments On Endoscopic And Visual Examination Of Cylinder Liners

    7.2.2 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 exami‐ nation report. Findings Measure Light scoring Minor dirt scores can occur during the assembly of a new engine (honing prod‐...
  • Page 62 Findings Measure Discolorations (Heat) 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 pro‐ nounced from TDC-ring 1.

  • Page 63: Crankcase Breather

    7.3 Crankcase Breather 7.3.1 Crankcase breather – Oil separator replacement, diaphragm check and replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 6 to 50 Nm F30027336 Ratchet F30027340 Engine oil...
  • Page 64 Crankcase breather – Replacing filter element (variant B) 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. Use torque wrench to tighten the screws of cover (2) to the specified torque. Name Size Type...

  • Page 65: Crankcase Breather - Cleaning

    7.3.2 Crankcase breather – Cleaning Special tools, Material, Spare parts Designation / Use Part No. Qty. Cleaner (Snow-White 11-0) 40460 Cleaner (Hakupur 312) 30390 WARNING Compressed air Risk of injury! • Do not direct compressed-air jet at persons. • Wear protective goggles / safety mask and ear protectors. WARNING Cleaner is extremely caustic.

  • Page 66: Crankcase Breather - Filter Element Replacement

    7.3.3 Crankcase breather – Filter element replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench 10-60 Nm F30510423 Filter element (→ Spare Parts Catalog) WARNING Hot oil. Oil can contain combustion residues which are harmful to health.
  • Page 67 Crankcase breather (open-circuit crankcase ventilation) – Filter element cleaning or replacement Clean filter (6) outside. Undo clamp (2) and screw (7). Pull hose (1) off cover (3). Loosen clamp (5). Remove cover (3). Clean filter element (4) (→ Page 65) or re‐ place.

  • Page 68: Running Gear

    7.4 Running Gear 7.4.1 Grounding device – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Removing grounding device Clean grounding device (2) prior to remov‐ Remove screws (1). Remove screws (3) from grounding device (2). Remove grounding device (2). Installing grounding device Install grounding device (2) with screws (3) on belt pulley.

  • Page 69: Grounding Device - Replacement

    7.4.2 Grounding device – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Grounding device (→ Spare Parts Catalog) Remove grounding device and install new one . (→ Page 68) M015675/05E 2011-10 | Task Description | 69...

  • Page 70: Valve Drive

    7.5 Valve Drive 7.5.1 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 Remove cylinder head covers (→ Page 76). Fill oil chambers of rocker arms and adjust‐ ing screws with oil.

  • Page 71: Valve Clearance - Check And Adjustment

    7.5.2 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 gauge Y20010128 Torque wrench 60-320 Nm F30047446...
  • Page 72 Checking valve-bridge balance X Valve bridge with guide Y 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 gauge to determine the distance between valve bridge and rocker arm.
  • Page 73 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. M015675/05E 2011-10 | Task Description | 73...
  • Page 74 Adjusting valve-bridge balance Note: 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).

  • Page 75: Adjusting Valve Clearance

    Checking valve clearance at two crankshaft positions Check TDC position of piston in cylinder • If the rocker arms are unloaded on cylin‐ der A1, the piston is in firing TDC. • If the rocker arms are loaded on cylinder A1, the piston is in overlap TDC.

  • Page 76: Cylinder Head Cover - Removal And Installation

    7.5.3 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 cylinder head covers prior to removal if they are heavily soiled.

  • Page 77: Injection Pump / Hp Pump

    7.6 Injection Pump / HP Pump 7.6.1 HP fuel pump – Relief bore check DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A).

  • Page 78: Injection Valve / Injector

    7.7 Injection Valve / Injector 7.7.1 Injector – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Injector (→ Spare Parts Catalog) Remove injector and install new injector. (→ Page 79) 78 | Task Description | M015675/05E 2011-10...

  • Page 79: Injector - Removal And Installation

    7.7.2 Injector – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Installation and removal tool for injector F6790161 Milling cutter F30452739 Slotted nut screwdriver F30452578 Torque wrench, 0.5-5 Nm 0015384230 Torque wrench, 10-60 Nm F30510423...
  • Page 80 Removing injector Note: Always replace the first and last injectors of one engine side first. Replace the inner in‐ jectors only after the installation of the outer injectors on this engine side is completed. Undo cable terminal screws (arrowed) on injector and remove cable terminals.
  • Page 81 Remove sealing ring (1) from injector or use a self-made wire hook to extract it from the cylinder head. Remove O-rings (2) from injector. Cover all connections and bores, or seal with suitable plugs. M015675/05E 2011-10 | Task Description | 81...

  • Page 82: Installing Injector

    Installing injector Remove all plugs before installing. Coat nozzle retaining nut area of injector with assembly paste. Fit new O-rings on injector and coat with grease. Fit new sealing ring on injector with grease ensuring correct installation position of seal‐ ing ring.
  • Page 83 Tighten loose thrust ring to the 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. Place hold-down clamp (1) in correct installation position. Tighten screw (2) with torque wrench to the specified initial tightening torque.
  • Page 84 Twist cable several times. Insert cable terminals (arrowed) underneath screws on injector and tighten screws to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Screw Tightening torque 1.5 Nm Final steps Install cylinder head cover (→ Page 76). Open up fuel supply to engine.

  • Page 85: Fuel System

    7.8 Fuel System 7.8.1 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. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. •...

  • Page 86: Fuel Filter

    7.9 Fuel Filter 7.9.1 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. Risk of fire and explosion! •...

  • Page 87: Edge-Type Fuel Filter - Draining

    7.9.2 Edge-type fuel filter – Draining 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. Risk of fire and explosion! •...

  • Page 88: Fuel Prefilter - Draining

    7.9.3 Fuel prefilter – Draining Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. •...

  • Page 89: Charge-Air Cooling

    7.10 Charge-Air Cooling 7.10.1 Intercooler – Check drain for coolant leakage and obstruction DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...

  • Page 90: Air Filter

    7.11 Air Filter 7.11.1 Air filter element and dust bowl – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Seal (→ Spare Parts Catalog) WARNING Compressed air Risk of injury! •...

  • Page 91: Visual Inspection

    Visual inspection Use inspection lamp to check cleaned filter element for damage. Fit new filter element if old one is damaged (→ Page 92). M015675/05E 2011-10 | Task Description | 91...

  • Page 92: Air Filter - Replacement

    7.11.2 Air filter – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Air filter (→ Spare Parts Catalog) Remove air filter and install new one . (→ Page 93) Reset signal ring of service indicator . (→...

  • Page 93: Air Filter Element – Removal And Installation

    7.11.3 Air filter element – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Seal (→ Spare Parts Catalog) Air filter element – Removal and installation Release latches (9). Remove dust bowl (8) and partition (7).

  • Page 94: Service Indicator - Signal Ring Position Check

    7.11.4 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 92). After installation of new filter, press reset button (1).

  • Page 95: Starting Equipment

    7.12 Starting Equipment 7.12.1 Starter – Condition check Preconditions ☑ Engine is stopped and starting disabled. Checking starter condition Check securing screws of starter for secure seating and tighten if required. Check wiring (→ Page 128). M015675/05E 2011-10 | Task Description | 95...

  • Page 96: Lube Oil System, Lube Oil Circuit

    7.13 Lube Oil System, Lube Oil Circuit 7.13.1 Engine oil level – Check Checking engine oil level prior to engine start Withdraw oil dipstick from guide tube and wipe it. Insert dipstick into guide tube up to the stop, withdraw after approx. 10 seconds. Check oil level on oil dipstick side marked "5 Min.

  • Page 97: Engine Oil – Change

    7.13.2 Engine oil – Change Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine is at operating temperature. ☑ MTU Fluids and Lubricants Specification (A001061/..) is available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil Sealing ring (→...

  • Page 98: Oil Filtration / Cooling

    7.14 Oil Filtration / Cooling 7.14.1 Automatic oil filter – Filter candles replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 Engine oil O-ring (→...
  • Page 99 Oil filter candles – Removal Remove nuts (2) from oil filter cover (1). Remove oil filter cover. Withdraw filter insert (1). Remove O-ring. Remove screw (2). Withdraw spinner (1) with spring. Remove nut (3). Take off spring washer and washer. Remove screw (4).
  • Page 100 Turn filter insert upside down and use ap‐ propriate tool to push out filter candles (1). Turn filter insert by 180°and insert new filter candles (1) with chamfer facing downwards. Oil filter candles – Installation For installation follow reverse sequence of working steps. In addition, the following work must be performed: •...

  • Page 101: Oil Indicator Filter – Check

    7.14.2 Oil indicator filter – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Strainer (→ Spare Parts Catalog) Square-section ring (→ Spare Parts Catalog) O-ring (→ Spare Parts Catalog) WARNING Hot oil.
  • Page 102 Checking strainer Item Findings Task Strainer Metallic residues • Clean • Monitor engine operation • Check strainer daily • Contact Service. Strainer Damaged Replace Square-section ring Damaged Replace O-ring Damaged Replace Cleaning strainer Wash strainer (5) with cleaner. Remove stubborn deposits with soft brush. Blow out strainer (5) with compressed air from inside.
  • Page 103 7.14.3 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, 6-50 Nm F30027336 Cold cleaner (Hakutex 60) X00056750 Filter sleeve (→...
  • Page 104 Centrifugal oil filter – Cleaning and filter-sleeve replacement Remove clamp (3). Release cover screw (1) and take off cover (2). Carefully lift rotor (6), allow oil to drain and remove from housing. Holding the rotor (6) firmly, release rotor cover nut (7). Take off rotor cover (8).

  • Page 105: Coolant Circuit, General, High Temperature Circuit

    7.15 Coolant Circuit, General, High-Temperature Circuit 7.15.1 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 106: Engine Coolant – Change

    7.15.2 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine coolant Drain engine coolant. (→ Page 107) Fill with engine coolant. (→ Page 108) 106 | Task Description | M015675/05E 2011-10...

  • Page 107: Engine Coolant – Draining

    7.15.3 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 an appropriate container to drain the coolant into.

  • Page 108: Engine Coolant – Filling

    7.15.4 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. Engine coolant WARNING Coolant is hot and under pressure.
  • Page 109 Filling coolant with 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 valve. Check proper condition of breather valve, clean sealing faces if required.

  • Page 110: Engine Coolant Pump – Relief Bore Check

    7.15.5 Engine coolant pump – Relief bore check DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...

  • Page 111: Coolant – Sample Extraction And Analysis

    7.15.6 Coolant – Sample extraction and analysis Preconditions ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. MTU test kit 5605892099/00 DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! •...

  • Page 112: Coolant Filter – Replacement

    7.15.7 Coolant filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Engine oil Coolant filter (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...

  • Page 113: Low-Temperature Circuit

    7.16 Low-Temperature Circuit 7.16.1 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 114: Charge-Air Coolant – Change

    7.16.2 Charge-air coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Charge-air coolant Drain charge-air coolant. (→ Page 115) Fill with charge-air coolant. (→ Page 116) 114 | Task Description | M015675/05E 2011-10...

  • Page 115: Charge-Air Coolant – Draining

    7.16.3 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 116 7.16.4 Charge-air coolant system – Filling Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specification (A001061/..) is available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Charge-air coolant Sealing ring (→ Spare Parts Catalog) WARNING Engine noise above 85 dB (A).
  • Page 117 Charge-air coolant system – Filling 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.

  • Page 118: Charge-Air Coolant Pump – Relief Bore Check

    7.16.5 Charge-air coolant pump – Relief bore check DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...

  • Page 119: Belt Drive

    7.17 Belt Drive 7.17.1 Drive belt – Condition check Preconditions ☑ Engine is stopped and starting disabled. ☑ Guard is removed. Item Findings Task Drive belt A Breaks in a few individual places None Drive belt Belt is oily, shows signs of over‐ Fit new belt (→...

  • Page 120: Battery-Charging Generator

    7.18 Battery-Charging Generator 7.18.1 Battery-charging generator – Removal Preconditions ☑ Engine is stopped and starting disabled WARNING Heavy object. Risk of crushing! • Use appropriate lifting devices and appliances. Battery-charging generator – Removal Remove guard cover. Label and disconnect electrical cables on battery-charging generator.

  • Page 121: Battery-Charging Generator – Check

    7.18.2 Battery-charging generator – Check Preconditions ☑ Engine is stopped and starting disabled. WARNING Compressed air Risk of injury! • Do not direct compressed-air jet at persons. • Wear protective goggles / safety mask and ear protectors. Battery-charging generator check Item Diagnosis Task...
  • Page 122 7.18.3 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 123). Tighten locknut (2).
  • Page 123 7.18.4 Battery-charging generator drive – Drive belt tension 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 guard cover. Check belt condition visually (→ Page 119). Checking drive belt tension Fit measuring head (2) on belt-tension tester (3) and hit drive belt (1) with a suitable tool.
  • Page 124 7.18.5 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. 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.

  • Page 125: Fan Drive

    Hold measuring tip of belt tension tester over belt drive. Tap drive belt (arrowed) 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 Belt tension adjustment 36 Hz ±...
  • Page 126 Adjusting drive belt tension Release screws (2) until fan coupling can be moved. Tighten stud (1) until the required frequency is achieved. Tighten screws (2) to 250 Nm ± 25 Nm. 126 | Task Description | M015675/05E 2011-10...

  • Page 127: Fan Drive – Drive Belt Replacement

    7.19.2 Fan 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) Preparatory steps Remove protective cover. Remove fan. Replacing drive belt Release screws (2).

  • Page 128: Engine Wiring – Check

    7.20 Wiring (General) for Engine/Gearbox/Unit 7.20.1 Engine wiring – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol X00058037 Engine wiring – Check Check securing screws of cable clamps on engine and tighten loose threaded connections. Ensure that cables are fixed in their clamps and cannot swing freely.

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

    7.21 Accessories for (Electronic) Engine Governor / Control System 7.21.1 Engine control unit and connectors – Cleaning Preconditions ☑ Engine shut down and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Connector pliers 0135315483 Isopropyl alcohol 46181 Cleaning engine control unit and connectors...

  • Page 130: Engine Governor Plug-In Connections – Check

    7.21.2 Engine governor plug-in connections – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Connector pliers 0135315483 Engine governor plug-in connections – Check Use connector pliers (3) to make certain that all plug-in connections on engine gov‐...

  • Page 131: Appendix A 8.1 Abbreviations

    Abgasturbolader Exhaust turbocharger (ETC) Air Temperature Sensor Baureihe Series Betriebsstoffvorschrift MTU Fluids and Lubricants Specifications, Publication No. A01061/.. Controller Area Network Data bus system, bus standard Calibration Drift Compensation Setting of drift compensation in engine gov‐ ernor with DiaSys...
  • Page 132 Abbreviation Meaning Explanation Exhaust Gas Recirculation Engine Monitoring Unit Ersatzteilkatalog Spare Parts Catalog (SPC) Electronic Unit Injector Fuel Pressure Sensor Monitors fuel pressure Fuel - Differential Pressure Sensor Fuel Temperature Sensor Monitors fuel temperature FWCP Fire Water Control Panel Control cabinet Ground Hochdruck High Pressure (HP)
  • Page 133 Abbreviation Meaning Explanation Society of Automotive Engineers U.S. standardization organization Sensor Defect Alarm: Sensor failure Stop Engine Light 1st function: Warning lamp (stop engine and rectify fault) 2nd function: Read out fault codes System Identifier Synchronous Reference Sensor TDC cylinder 1 Safety System Safety system alarm Turbocharger Boost Sensor...

  • Page 134: Mtu Contacts/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 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.

  • Page 135: Appendix B 9.1 Special Tools

    9 Appendix B 9.1 Special Tools Air filter Part No.: Qty.: Used in: 7.11.2 Air filter – Replacement (→ Page 92) Coolant filter Part No.: Qty.: Used in: 7.15.7 Coolant filter – Replacement (→ Page 112) Diaphragm Part No.: Qty.: Used in: 7.3.1 Crankcase breather –...
  • Page 136 Gasket Part No.: Qty.: Used in: 7.5.3 Cylinder head cover – Removal and installation (→ Page 76) Grounding device Part No.: Qty.: Used in: 7.4.2 Grounding device – Replacement (→ Page 69) Injector Part No.: Qty.: Used in: 7.7.1 Injector – Replacement (→ Page 78) O-ring Part No.: Qty.:...
  • Page 137 Sealing ring Part No.: Qty.: Used in: 7.9.2 Edge-type fuel filter – Draining (→ Page 87) Qty.: Used in: 7.13.2 Engine oil – Change (→ Page 97) Qty.: Used in: 7.14.3 Centrifugal oil filter – Cleaning and filter-sleeve replacement (→ Page 103) Qty.: Used in: 7.14.3 Centrifugal oil filter –...

  • Page 138: Index

    9.2 Index  98 Dust bowl 20V 4000 C22 engine data 27 – Cleaning  90 Abbreviations 131 ECU 4 alarms 44 After stopping the engine 38 Edge-type fuel filter – Draining 87 Air filter Engine – Replacement  92 – Barring manually  56 Air filter element – Shutdown in manual mode  37 –...
  • Page 139 Instructions and comments on endoscopic and visual ex‐ amination of cylinder liners 61 Intercooler – Drain, coolant leakage  89 Main engine dimensions 32 Maintenance and repair work – Safety requirements  14 MTU contact persons 134 Oil indicator filter – Check 101 Operational checks 36 Personnel and organizational requirements 8 Plant – Cleaning  39 Putting into operation –...

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