Technical Publication Diesel Engine 12, 4000 M 16 V 4000 M Maintenance Manual! M020102/01E Order No. general @ bowl] DaimlerChrysler Off-HighwayPrinted in Germany Bie te ‘@ 2008 Copyright MTU Friedichshafan GmbH Diese Veroffentichung einschiefich errr Tells il urheberrectich geschitt. Jede Verwertung oder Nutzung bedar der verheigen schritichen Zustinmung der NTU Friedrichshafen GmbH. Das gi insbosondore fur Vorvisfaligung, Verbrotung, Gearoltung, Uoarsetung, Macoverimungen unde Enspeleerung und / oder Vraretung i elehronschenSyseren, enschtich Daerbenken Lund Online-Dienstan Das Handbuch ist zur Vermeidung von Storungen oder Schiden belm Betieu zu beacon und daher vom Bete Gem Jewellgen ‘Wartungs- und Bedienungspersonal zur Verfigung 2u stellen ‘Anderungen bleiben vorbefalten, Printed in Gocmany {© 2003 Copyright MTU Futedenshaten GmoH ‘This Publication i protected by copyright and may not be used in any way whether in whole or in part without the pric writen permission of MTU Friedrichshafen GmbH. This resiction also apples to copyright, distrbutlon translation, mlcrofiming and storage or processing on ‘Seotonic systems including data bases and onne services. ‘This handbook i provided for use by maintenance and operating personel inorder to avckd malfunctions or damage during operation Subject to ateratons and amenoments, lenpriné on Allemagne (©2003 Copyroht MTU Frecrichshaten GmoH “Tout drot servé pour col ouvrago dans on itégralté. Tote utfaation ou explolation request au préalable Faccord Bert de MTU Friiewichshafen GmbH. Cec s'appique notamment ala reproduction, la cfuson, la modification, la vaducion,rarcivage sur microfches, la mémarisation et ou le tralement sur des syetdmes Bactoriques, y campris los bases de donnéos at es servicos on igne, Le manuel deve etre observéen wie ¢'éviter des incidents ou des endommagements pendant le service. Aussi recommangons-nous & ‘explant dole metre la cspostin du personnel chargé de Fenretion ot do la conduit. Modiicaione reer Inmpreso en Alemania (© 2003 Copyrght MTU Friecrichshaton GmbH Esta publacin se encueniraprotogida, en lad su estensién, por ls derechos de autor. Cualqir ullizaion de fa misma, asi como su reproduccion, diusion, ranstormacion, waducci, micrafimacion,grabacténylo procesamiento en sistemas eleciSnicos, entre os que se Incluyen bancos do datos y servicios en nea, precisa dela autrizacon prea Ge MTU Fedrichshafen GmbH, i manual debe tenerse present para evita alos 0 datios duran el carci, y, pa dicho motvo, el usar debe ponetl @ dieposicién det personal de manterimleno y do servic, Nos reservamos el derecho introduc modiicacones, Stampato in Germania (© 2003 Copycght MTU Friecrichshaton Gmoti ‘Questa pubblicazione @ proeta dal dito dautoe in tutte le sue part. Ciascun impiego 0 uiizo, con partoolare guard ala riprocuzione, ala ifisione, ala modifica, alla raduzione,alfarchiviazione ir mrofim o ala memorizzazione o alleaborazione in sate elatrorc, ‘comprese banche date serv online, deve essere espressamente autorzzato por icrtto dalla MTU Friedrichshafen GmbH, ‘manuale va consitalo per eiare anomalle o quas durante I servi, per cui va mess9 a disposirione dal utente al persanaleaddtto 1 ala manutonzione @ ala condota, | Con sera dl modifche.Wichtig — Important - Importante Bitte die Karte ,,Inbetriebnahmemeldung” abtrennen und ausgefilllt an MTU Friedrichshafen GmbH. zurdicksenden. Die Informationen der Inbetriebnahmemeldung sind Grundlage fur den vertraglich vereinbarten Logistik- Support (Gewahrleistung, Ersatzteile etc.) 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 (warranty, spare parts, etc.) Veuillez séparer la carte “Signalisation de mise en service” et la renvoyer a la MTU Friedrichshafen GmbH. Les informations contenues dans la signalisation de mise en service constituent la base pour I'assistance en ‘exploitation contractuelle (garantie, rechanges, etc.) Rogamos separen la tarjeta “Aviso de puesta en servicio" y la devuelvan rellenada a MTU Friedrichshafen GmbH. Las informaciones respecto al aviso de puesta en servicio constituyen la base para el soporte logistico ‘contractual (garantia, piezas de repuesto, etc) Staccare “Aviso di messa in servizio“ e rispedirlo debitamente compilato alla MTU Friedrichshafen GmbH. rege Le informazioni vi registrate sono la base per il supporto logistioo contrattuale (garanzia,ricambi, ecc.). E gontileza cortar o cartéo Friedrichshafen. Os dades referentes a colocacao em servico representam a base para 0 suporte logistico (garantia, pegas- ‘sobressalentes, etc.) estabelecido contratualmente. I ' i articipacao da colocagao em servigo", proenché-lo e devolvé-lo a MTU Posteard MTU Friedrichshafen GmbH Department SCSD 88040 Friedrichshafen y ome cs SGERMANYBitte in Blockschift austullen! Please use block copitals! riére de rempli on lettres capitales! A rellonar en letras de imprental ‘Scrivere in stampatelio! Favor preencher com letras de forma! NAS rae no: Inbetriebnahmemeldung pedo. ‘Commissioning Note Beart Notice de mise on service Baiada ctcacho em svi ‘Aviso de puesta on servicio Sau Selig etal: 30 di massa in servi eagearaees oda dimeesa nerve Cae eee, articipagto da colocagto ‘om servigo.‘Amendment Service! ‘Any changes in contents will be sent to you in the form of an amendment, provided you complete the reverse of this receipt card and return itto us. 020102/01E | z | § Z @ 8 2 é Posteard 3 MTU Friedrichshafen GmbH Department SCT Lcshicahatboel 188040 Friedrichshafen y y GERMANY lPlease mark ail fled amendments here. Please use block capitals! <= No.} Date 10. 1. 12. 13. 14. 16. Receipt TICK ONE BOX ONLY! CJ Update as (PDF) file by E-mail J Update as (PDF) file as CD-ROM 1D Update in hardcopy form Publication number: M020102/01E. Name Manufacturer Department Fax Street Postal box number. (Postal code) City. Country Amendment No. 10. mn 12 13, 14, 15. 16.Table of Contents 1-1 1 General 44 Important Information oo... sscseeeessseeetssseertseeeeeees ‘.14 Reman assemblies ~ Prerequisites for maintenance taska and general assembly instructions 7 7 ‘ 1-01 4.2 General .. . ett 1-03 1.2.4 General conditions... tf ce 1-03 122 Personnel and organizational requirements Ber | 4-04 4.23 Safety precautions when working on the engine ...... cocceeeees 1205 1.24 Auxillary materials, fre prevention and environmental protection. 1-08 1.2.5 Standards for warning notices in the publication 1-10 1.26 General information regarding the Tolerances and Wear Limits List 1-11 1.27 Engine side and cylinder designations ale 1-12 1.2.8 Torque specifications for screws, nuts and bolts 1-13 129 — Settings : Sl : Te : 1-29 4.2.40 Conversion tables ....... peo erarccaseae r=] 4.2.11 Repairing tnreaded bores with threaded inserts (Hell-Cal) : ve 1287 1.2.42 Transport 41-40 M020102/01E 03-12 omTu1-1 Table of Contents Mo20102/01E 03-12 emTuImportant Information 1-08 14 Important Information 144 Reman assemblies — Prerequisites for maintenance tasks and general assembly instructions This manual is intended for use by technical personnel responsible for the maintenance and servicing of the MTU 4000 series diesel engine. Contents: Scheduled W6 maintenance tasks + Non-scheduled service operations on the individual assemblies. REMAN assemblies The following assemblies are only available through the exchange procedure: + High pressure pump + Injector + MDEC + Camshaft + Vibration damper Basic requirements for maintenance and service work Customers performing their own maintenance must ensure that the folowing conditions are fufited: + All safely regulations are observed. + Use of trained and qualified personnel + Suitable workshop equipment with general tools + Suitable test equipment. + Approved special tools. General assembly instructions All components that come into contact with oil, fuel, coolant and combustion air must be perfectly clean. Components with a "Special cleanness’ requirement (e.g. oil and fuel carrying parts) must be cleaned using a suitable cleaning process prior to assembly and checked for particular cleanness. Component packaging is to be removed immediately prior to assembly. Elastomer components (e.g. rubber and similar) must not be washed with diesel fuel, solvent or cold cleaners, + Remove oil or fuel coatings. The parts should be wiped with a dry cloth + Elastomer components such as engine mounts, damping elements, couplings and V-belts must not be painted, ‘They can only be installed after painting the engine or must be covered before painting work is carried out. Radial-lip shaft seals treated by the manufacturer with oil show as a result definite signs of swelling when delivered They must therefore be cleaned (not washed) only with an abrasion-proof paper cloth before installation. The surfaces of parts that slide against each other must be lubricated with SAE3O engine cil when installed, unless otherwise specified ‘O-rings and surfaces moving against them during installation (bores and shafts) must be coated with petroleum jelly, unless otherwise specified. When installing O-rings with counterrings in coolant pumps, always follow the installation instructions. After installing O-rings in shaft grooves, pass a rounded marking tool under the O-ring in the direction of the circumference if the O-ring diameter is suffciently large. Make sure that the O-ring is not damaged. Before shaft seal assembly: * On the shaft, the sealing lip of the shaft seal must be coated with petroleum jelly and the shaft running surface with thin-film lubricant or SAE 30 engine oil. + Inthe support bore, in the case of a metal outer jacket the outer surface must be coated with surface sealant, unless otherwise specified in the drawing. For elastomer outer jackets or combined metal/elastomer outer jackets, the outer surface must be coated with denaturated ethanol. ‘Moz0102/01E 03-12 omTu1-02 Important Information This symbol applies to radial-lip shaft seals and its significance depends on its position. The arrow indicates the position of the sealing lip. ‘Sealing paste must be used to fix the position of fiat gaskets. Sealing paste is to be thinly applied in spots on the flat gaskets or mating faces. Immediately after application of the sealing paste, the fat gaskets must be fitted to the component and then (no more than 20 minutes later) the seal components screwed together. Before installing antiiction bearings, lubricate the bearing seats. Only remove the bearings from ‘their original packaging immediately before installation. Do not remove the corrosion inhibitor from the bearings in original packaging. Use petroleum spirit or acid-free kerosene to clean the antifiction bearings. After cleaning, relubricate the bearings with engine oil * During assembly, do not apply (axial) forces to roling elements and do not hit the bearing rings with a hammer (use assembly aids) + Do not use an open fiame to heat bearing inner races + The temperature must be between 80 °C and 100 °C and never exceed 120 °C. + Deep-freezing for friction bearing installation is not permissible (risk of cracking, rusting through condensate). Do not oil dry bearings. ‘When installing gears, the splines must be lubricated with SAE 30 engine oil All support and mating surfaces of components (¢.9. mating surfaces for centring devices, flange and sealing surfaces, joint surfaces of press fits) must be clean, polished or provided with the specified surface protection and free ‘from warping and damage, Corrosion inhibitor (e.g. cil, grease) must be removed from the contact and mating faces. ‘After parts are joined which are installed by means of cooling using liquid nitrogen, all condensate must be removed and the parts coated with SAE 30 engine oi. ‘Sensors must be coated with long-life lubricant before installation in the immersion sleeves. Cable connections with cutting ring unions must be preassembled and tightened in a vice, after the threads have been previously coated with thin-film lubricant, H components are to be marked by etching, after the etching is completed the solution must be removed by means of neutralization agent. The affected parts must then be preserved with SAE 30 engine cil Components used in hot part areas (e.g. V-clamps, bellows, plug-in pipes) must be coated at the support and mating surfaces with assembly paste, unless otherwise specified The assembly surfaces of screws, nuts, washers and of parts to be tensioned must be clean and Polished or provided with the specified surface protection and free from warping and damage. Corrosion imibitors (e.g. of, grease) must be removed. Thread and screw contact surfaces must be coated with lubricant before installation in accordance with tightening specifications. Unless otherwise specified, use engine cil as a lubricant (SAE 30) and assembly paste in hot-part areas. For threaded connections without tightening specifications, the tightening procedure can be selected as required, i.e. mechanical tightening with screwdriver or normal manual tightening with en open-end wrench ‘or box wrench is possible. If mechanical tightening is selected, the tightening torque must be taken from the ‘general tightening specifications in accordance with thread size and strength class, *+ The threaded connections must be tightened manually with a click wrench or angle-of-otation torque wrench. The specified tightening torques must be set without considering the specified tolerance at the click wrench. When using an angle-of-rotation torque wrench, the torque indicated must be within the torque specification limit value. Proceed in a similar manner with torsionally protected threaded connections. This information also applies to checking torques. + Ifo tolerance for tightening torque is stated, the tightening tolerance is + 10% of specified torque. + Rotation-angle tightening. The angles of further rotation specified in the tightening specifications must bbe achieved and may be exceeded within the specified tolerance. If no tightening tolerance is specified, the following tolerances must be observed: +5° for additional angle of rotation less than or equal to 90 +10° for additional angle of rotation greater than 90°. Before angle-of-rotation tightening, each screw head ‘must be color-marked so that after tightening itis possible to check that the angle of rotation is correct (exception: color-marking is not necessary in the case of a self-monitoring NC screwdriver) * Tightening to elongation. Tightening must be carried out in accordance with tightening ‘specifications taking the tightening tolerance into consideration, Mo20102/01E 03-12 emuGeneral 1-03 1.2 General 1.2.41 General conditions General In addition to the instructions in this publication, the applicable country-specific legistation and other compulsory regulations regarding accident prevention must be observed. This engine is a state-of-the art product and conforms with all applicable specifications and reguiations. Nevertheless, persons and property may be at risk in the event of: * Incorrect use + Operation, maintenance and repair by unqualified personnel + Modifications or conversions + Non-compliance with the Safety Instructions Correct use The engine is intended exclusively for the application specified in the contractor defined at the time of delivery. Any other use is considered improper use. The manufacturer will accept no liability for any resultant damage. The responsibilty is borne by the user alone. Correct use also includes observation of and compliance with the maintenance specifications. Modifications or Conversions Modifications made by the customer to the engine affect safety. 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. In the ‘event of any damage caused by the use of other spare parts, no liability nor warranty claims vis-&-vis the engine manufacturer will be accepted. Reworking components As part of repair work or an engine overhaul, reworking of components may be carried ‘out by workshops authorized by MTU. However, no generally valid instructions can be issued for the reworking of components as the machining tools available on site may differ. Mo20102/01E 03-12 eMTU1-04 General 1.2.2 Personnel and organizational requirements Personnel requirements ‘Work on the engine must oniy be carried out by property qualified and instructed personnel ‘The specified tega! minimum age must be observed. Responsibiltes of the operating, maintenance and repair personnel must be specified. Organizational measures ‘This publication must be issued to all personnel involved in operation, maintenance, repair or transportation. lt must be kept at hand near the engine and accessible at any time to all personnel involved in operation, maintenance, repair or transportation, The personne! must be instructed on engine operation and repair by means of this publication, and in particular the safely instructions must be explained. This is especially Important for personnel who work on the engine only on an occasional basis, ‘Such personnel must be given instructions repeatedly. Working clothes and protective equipment Wear proper work clothing for all work. Depending on the kind of work, use additional protective equipment, e.g. protective goggles, gloves, helmet, apron. Work clothing must be tight fitting so that it does not catch on rotating or projecting components. Do not wear jewelry (e.g. rings, chains etc) M020102/01E 03-12 MTUGeneral 1-05 1.2.3 Safety precautions when working on the engine Engine operation ‘When the engine is running, always wear ear protectors. Ensure that the engine room is well ventilated, Mop up any leaked or spit fluids and lubricants immediately or soak up with a suitable bonding agent. Exhaust gases from combustion engines are poisonous. Inhalation of poisonous exhaust gases is a health hazard. The exhaust pipework must be free of leaks and discharge the gases to atmosphere. During engine operation, de not touch battery terminals, generator terminals or cables, Inadequate protection of electrical components can lead to electric shocks and serious injuries ‘When the engine is running, never release coolant, oil, fuel, compressed-air or hydraulic lines. Maintenance and repair Compliance with maintenance and repair specifications is an important safety factor. Unless expressly permitted, no maintenance or repair work must be carried out with the engine running. Secure the engine against inadvertent starting. With electric starter, disconnect the battery. With pneumatic starter, close main shut-off valve of compressed-air system and release pressure from compressed-air supply line. Attach sign “Do not operate" in operating area or to control equipment. Persons not involved must keep clear. Never attempt to rectify faults or carry out repairs if you do not have the necessary experience or special tools required. Maintenance and repair work must only be carried out by authorized, qualified personnel Use only proper, calibrated tools. Do not work on engines or components which are only held by liting equipment or crane. Always support these components in accordance with regulations on suitable frames or stands before beginning any maintenance or repair work Before barring the engine, make sure that nobody is standing in the danger zone. After working on the engine, check that all guards have been installed and that all ois and loose components have been removed from the engine. Fluids emerging under high pressure can penetrate clothing and skin and may cause serious injury. Before starting work, relieve pressure in systems and H.P. lines which are to be opened. Never bend a fuel line and do not install bent lines. Keep fue! injection lines and connections clean, ‘Aiways seal connections with caps or covers if a line is removed or opened. During maintenance and repair work, take care not to damage the fue! lines. To tighten the connections when installing the lines, use the correct tightening torque and ensure that all retainers and dampers are installed correctly. Ensure that all fuel injection lines and pressurized oil lines have sufficient distance to other Components to avoid contact with them, Do not place fuel or oil nes near hot components, except when necessary for design reasons during installation, Elastomers (¢.9. "Viton" sealing rings) are stable under normal operating conditions. When subjected to fre or temperatures above 300 °C the material degenerates, giving off hydrogen fluoride gas. The resulting acid leads to serious buming if it contacts the skin. Do not touch elastomeric seals if they have carbonized or resinous appearance. Wear protective gloves! Take care with hot fluids in lines, pipes and chambers => Risk of injury! Note cooling period for components which ate heated for installation or removal => Risk of injury! Do not touch hot components of the compressor and the exhaust system => Risk of injury! Take special care when removing ventilation or plugs from engine. In order to avoid discharge of highly pressurized liquids, hold a cloth over the screw or plug. It is even more dangerous if the engine has recently been shut down, as the liquids can stil be hot. Take special care when draining hot fluids. => Risk of injury! When draining, collect fluids in a suitable container, mop up any spilt fuids or wipe or soak them with a suitable bonding agent. When changing the engine oll or working on the fuel system, ensure that the engine room is adequately ventilated. When working high on the engine, always use suitable ladders and work platforms. Make ‘sure components are placed on stable surfaces. In order to prevent back injuries when lifting heavy components adults, depending on age and sex, should only lift weights between max. 10 kg and 30 kg, therefore: + Use lifting gear or seek assistance. Mo20102/01E 03-12 omTu1-06 General + Ensure that all chains, hooks, slings, ete. are tested and authorized, are sufficiently strong and that hooks are correctly positioned. Lifting eyes must not be unevenly loaded Welding work Never carry out welding work on the engine or engine-mounted units. Never use the engine as a ground connection. (This prevents the welding current passing through the engine and causing scoring or burning at bearings, sliding surfaces and tooth flanks, which can lead to pitting or other material damage). "Never position the welding power supply cable adjacent to, or crossing MTU plant wiring harnesses. (The welding current could be induced in the cable harnesses and could possibly damage the electical plant). The welding unit ground connection must not be more than 60 cm from the weld point. | components (e.g. exhaust manifold) are to be welded, they must be removed from the engine. tts not necessary to remove the connector and the connections when carrying out welding operation ton MTU electronics if the master switch for power supply is switched from “ON" to “OFF” and the wire is disconnected from the negative and positive poles on the battery Hydraulic installation and removal ‘Only the hydraulic installation and removal equipment specified in the work schedule and in the assembly instructions must be used. The max. permissible push-on pressure specie for the equipment must not be exceeded. ‘The H.-P. lines for hydraulic installation and removal are tested with 3800 bar. Do not attempt to bend or apply force to lines. Before starting work, pay attention to the folowing + Vent the hydraulic installation/removal tool, the pumps and the lines at the relevant points for the system to be used (e.g, open vert plugs, pump uni bubble-ree air emerges, close vert plugs). + For hydraulic instalation, screw on the too! withthe piston retracted. * For hydraulic removal, screw on the tool with the piston extended. For a hydraulic installation/temoval tool with central expansion pressure supply, screw spindle into shaft end until correct sealing is achieved. During hydraulic installation and removal, ensure that nobody Is standing inthe immediate vicinity of the component to be installed/removed. As long as the system is under pressure, there is the risk that the component to be installed/removed may be suddenly released from the pressure connection. Before use, the tools must be checked at regular intervals (crack test). Working on electrical/electronic assembles ‘Authorization must be obtained from the superior prior to commencing maintenance and repair work and switching off parts of the electronic system required for this. Prior to working on assemblies, the power of the appropriate areas must be switched off, Any measures requiring power supply are expressly defined as such at the appropriate place in the manual. Gases released from the baltery are explosive, Avoid sparks and naked flames. Do not allow battery ‘acids to come in contact with skin or clothing. Wear protective goggles. Do nat place tools on the battery, Before connecting the cable to the battery, check battery polarity. Battery pole reversal may lead to injury through the sudden discharge of acid or bursting of the battery body. Do not damage wiring during removal work and when reinstalling wiring and ensure that during operation itis. ‘not damaged by contact with sharp objects, by rubbing against other component or by a hot surface. Do not secure wiring to fuid-camying lines. ‘On completion of the maintenance and repair work, any cables which have become loose must be correctly connected and secured. ‘Always tighten connectors with connector pliers. ‘On completion of all repair work, the component and system must be subjected to a function check. Separate testing of the repaired component without system integration is insufficient. If wires are installed beside mechanical components and there is a risk of chafing, use ‘cable clamps to properly support the wires. For this purpose, no cable binders must be used as, during maintenance and / or repair work, the binders can be removed but not installed a second time. Mo20102/01E 03-12 emuGeneral Spare parts shall be properly stored prior to replacement, i.e. particularly protected against moisture. Defective electronic components and assemblies must De suitably packed when despatched for repair, ie. particularly protected against moisture and impact and wrapped in antistatic foil if necessary. Working with laser equipment When working with laser equipment, always wear special laser-protection goggles Laser equipment can generate extremely intensive, concentrated radiation by the effect of stimulated emission in the range of visible ight or in the infrared or vitraviolet spectral range. The photochemical, thermal and ‘optomechanical effects of the laser can cause damage. The main danger is ieparable damage to the eyes. Laser equipment must be fited with the protective devices necessary for safe ‘operation according to type and application, For conducting light-beam procedures and measurement work, only the following laser devices must be used: *+ Laser devices of classes 1, 2 oF 3A, + Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700 nm), @ maximum output of 5 mW, and in which the beam axis and surface are designed to prevent any risk to the eyes. Operation of electrical equipment When operating electrical equipment, certain components of this equipment are live. Noncompliance with the warning instructions given for this equipment may result in serious injury or damage to property. Mo20102/01E 03-12 MTU1-08 General 1.2.4 Auxiliary materials, fire prevention and environmental protection Fire prevention Rectify any fuel or oil leaks immediately; even splashes of cl or fuel on hot components can cause fires - therefore always keep the engine in a clean condition. Do not leave cloths soaked with fluids and lubricants lying around on the engine. Do not store combustible fluids neer the engine. Do not weld pipes and components carrying oll or fuel. Before welding, clean with an inflammable fluid, When starting the engine with a foreign power source, connect the ground lead last and remove it first. To avoid sparks in the vicinity of the battery, connect the ground lead from the foreign power source to the ground lead of the engine or to the ground terminal of the starter. Always keep suitable fire-fighting equipment (fire extinguishers) at hand and familiarize yourself with their use. Noiso Noise can lead to an increased risk of accident if acoustic signals, warning shouts or noises indicating danger are drowned. At all workplaces with a sound pressure level over 85 dB(A), always wear ear protectors (protective wadding, plugs or capsules) Environmental protection Dispose of used fluids, lubricants and fiters in accordance with local regulations. Manipulation ofthe injection control system can influence the engine performance and exhaust emissions. ‘As a result, compliance with environmental regulations may no longer be guaranteed. Only fuels of the specified quality required to achieve emission limits must be used. In Germany, the VAWS (= regulations governing the use of materials that may affect water quality) is applicable, which means work must only be carried out by authorized specialist companies (MTU is such a company) Auxiliary materials Use oniy fluids and lubricants that have been tested and approved by MTU. Fluids and lubricants must be Kept in suitable, properly designated containers. When using fluids, lubricants and other chemical substances, follow the safely instructions applicable to the product. Take care when handling hot, chilled or caustic materials. When using inflammable materials, avoid sparks and do not smoke. Lead ‘When working with tead or tead-containing pastes, avoid direct contact to the skin and do not inhale lead vapors. ‘Adopt suitable measures to avoid the formation of lead dust! ‘Switch on fume extraction system, ‘After coming into contact with lead or lead-containing materials, wash hands! Acids and alkaline solutions + When working with acids and alkalis, wear protective gogales or face mask, gloves and protective clothing + Immediately remove clothing wetted by acids and alkalis! + Rinse injuries with plenty of water! + Rinse eyes immediately with eyedrops or clean tap water. Paints + When painting in other than spray booths equipped with extractors, ensure good ventition. Make sure that adjacent work areas are not affected. No naked flame! No smoking, ‘Observe fire prevention regulations! Itis absolutely necessary to wear masks providing protection against paint and solvent fumes. nitrogen + Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers. + Do not bring liquid nitrogen in contact with the body (eyes, hands), as this causes frostbite and numbing, Lig ‘Wear protective clothing, including gloves and closed shoes, and protective goggles! Ensure that the room is well ventlated. Nitrogen concentration exceeding 88% of breathing air leads to suffocation. *+ Avoid all knocks and jars to the containers, fixtures or workpieces, Mo20102/01E 03-12 MTUGeneral ‘Compressed air Compressed air is air compressed at excess pressure and is stored in tanks from which it can be extracted. The pressure at which the air is Kept can be read off at pressure gauges which must be connected to the compressed air tanks and the compressed air lines, ‘When working with compressed ai, safety precautions must be constantly observed: + Pay special attention to the pressure level in the compressed air network and pressure vessel! + Connecting devices and equipment must either be designed for this pressure or, if the permitted pressure for the connecting elements is lower than the pressure required, a pressure reducing valve and safety valve (set to permitted pressure) must form an intermediate connection. Hose coupling and connections must be securely attached! + Always wear protective goggles when blowing off tools or extracting chips! + The snout of the air nozzle is provided with a protective disc (e.9. rubber disc), which prevents air-borne particles being reflected and thereby prevents injury to eyes, + First shut off compressed air lines before compressed air equipment is disconnected from the supply line or before equipment or tool is to be replaced! + Unauthorized use of compressed air, e.g. forcing flammable liquids (danger class Al, All ‘and B) out of containers, results in a risk of explosion! + Forcing compressed air into thin-walled containers (e.g. containers made of tin, plastic and giass) for drying purposes or to check for leaks, results in a risk of explosion! + Do not blow dity clothing with compressed alr when being worn on the body. Used oil Used oil may contain health-threatening combustion residues, Rub barrier cream into hands! ‘Wash hands after contact with used oil, M020102/01E 03-12 omTu4-10 General 1.2.6 Standards for warning notices in the publication in the event of immediate danger. ZA Gonseauences: Death or sera uy. DANGER In the event of possibly dangerous situations. ZX GCansegquences Deal or oho iuny WARNING In the event of dangerous situations. ZA Conseauences: Sight inury or materi damage CAUTION Note: This Publication contains especially emphasized safely instructions in accordance with the American standard ANSI 2535, which begin with one of the above signal words according to the degree of danger. Warning notices 1, Read and become acquainted with all cautions and symbols before operating or repairing this product 2. Pass on all safely instructions to your operating, maintenance, repair and transport personnell Moz0102/01E 03-12 omruGeneral 1.2.6 General information regarding the Tolerances and Wear Limits List ‘The tolerances and wear limits are intended as a guide for the examination of engine components as well as for engine inspection and repait. Explanation of terms for dimensions of now components Tolerance size Designed size foliowd by a fit symbol (e.9. 24 H6) or by the permissible dimensional deviation (e.g. 24 +0.013) Basic size Designed size without fit symbol or permissible [- dimensional deviation Deviation Permissible deviation from the basic or tolerance size. Deviation indicates the upper and lower limits ofthe tolerance sizefbasic size Clearance Difference between bore and shaft ciameter when bore ameter is greater than shaft diameter Interference Difference between bore and shaft diameter when bore diameter is smaller than shaft diameter Explanation of terms for reconditioning of components ‘Wear limit ‘The wear limits specified do not represent the maximum ‘wear limits permissible for satisfactory component operation. They indicate that the next major overhaul can be reached safely. If a wear limit is exceeded, the component must be replaced. Reworking instructions If wear limits are exceeded or values are below specification, the components concemed must be reworked as per reworking instructions or replaced. Deviations from roundness, cylindricity, parallelism and coaxiality must be within specified limits unless specifically indi ted. All dimensions are stated in "mm unless alternative units of measurement are specifically indicated. m020102/01E 03-12 omTu1-12 General 1.2.7 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). ‘The cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end. ‘The numbering of engine components is also from the driving end, starting with No. 1 00001 46e| 1 KGS = Free end 3 KS = Driving end 2 Right side 4 Left side Mo20102/01E 03-12 MTUGeneral 1-13 1.2.8 Torque specifications for screws, nuts and bolts Crankcase [eeugaldn [fora apecticatons tuna ‘Stud for crankshaft bearing cap in crankcase | 80Nm Engine of (to blind hole base) ‘Stud (nominal length: 347.5 mm to 348.5 mm): Stud elongation for erenkshaft bearing cap | Al= 1.18 mm +0.05 mm Residual screw elongation Al = 0.9 mm +0.05 mm Newly fited studs must be elongated before intial tightening, Lateral socketthead screws: 1 Starting, driving end: Left side all screws, | 80 Nm 2 Starting, driving end: Right side all screws. | 80 Nm 3. Final tightening torque, left side 280 Nm + 10. Nm 4 Final tightening torque, right side 280 Nm + 10. Nm Hex screws for oil pan made of aluminium rod and castings. Hex screw "A" is —_|e0Nm+ t0Nm Engine oil Hex screw °B* : 27.Nm + 10/Nm Stress bolt °C” 27.Nm + 10Nm Stress bolt D” 27.Nm +10 Nm Hex screw "E” 74.Nm + 10.Nm Running gear Designation Torque specifications Lubricant Screws for counterweight Engine ol ‘+ Nominal length: 129.6 mm to 130 mm + max. length: 132 mm 1 Pretightening torque 320 Nm +10.Nm 2 Further angle of rotation 120° + 10° |_3 Checking torque 800 Nm + 10. Nm Hex screws on vibration damper flange 500 Nm + 10. Nm Hex screws on side plate of vibration damper 400 Nm Engine oil on thread only Mo20102/01E 03-12 MTUGeneral Designation Torque specifications Lubricant Conrod screws + Nominal length: 102.6 mm to 103.2 mm +_max, elongation: 104.5 mm 1 Pretightening torque ‘Sequence: A Short arm B Long arm 240 Nm + 10 Nm 2 Further angle of rotation ‘Sequence: A Short arm B Long arm 90° + 10° 3 Checking torque ‘Sequence: A Short arm B Long arm 450 Nm+ 10. Nm Hex screws for seal carrier, free end 74.Nm+10.Nm Hex screws for measuring wheel 21.Nm+10.Nm Engine oil Piston crown screws + Nominal size, incl. allowance: 49 mm 20.1 mm. +_max, length for reassembly: 49.8 mm, + Nominal size, inel. allowance: 50 mm + 0.4 mm. +_max. length for reassembly: 0.8 mm, 1 Tighten screws diagonally and evenly. 17 Nm 2 Release screws Molykote Gn plus 3. Pretightening torque 4 Further angle of rotation 10 Nm + 10 Nm 60° + 5 5 Checking torque 20.Nm + 10.Nm M020102/01E 03-12 omTuGeneral 16 Cylinder head Designation Torque specifications Lubricant Sleeve for injector 60. Nm + 10 Nm Screw plug 60 Nm + 10 Nm Hex screw for cylinder head + Nominal length: 283 mm £ 0.3 mm + Nominal length: 333 mm 0.3 mm with engine lifting eve Tightening sequence of screws: 1 to6 1. Hand tightening 25 Nm 2 Pretightening torque 180 Nm +10 Nm Engine oil 3. Further angle of rotation aso e107 4 Checking torque 450 Nm a #1001029 ‘A Exhaust side B Inlet side Mo20102/01E 03-12 omTu1-16 General Valve gear Designation ‘Torque specifications Lubricant Hex screw for camshaft gear. 100 Nm + 10. Nm Engine oil Rocker shaft support hex screws. 250 Nm + 10 Nm. max. shaft length: 180.8 mm Version |: 24 AVF locknut of valve bridge for | 80 Nm + 10. Nm ‘exhaust vaive clearance of adjusting screw Version |; 24 A/F locknut of valve bridge for 90. Nm + 10 Nm inlet and valve clearance of adjusting screw Version Il: 19 AF locknut of valve bridge for | 35 Nm + 10. Nm | exhaust valve clearance of adjusting serew Version Il: 19 A/F locknut of valve bridge for | 35 Nm +10 Nm inlet valve clearance of adjusting screw Locknut on adjusting screw for valve bridge 35.Nm + 10 Nm Hex screw for cylinder head cover 42Nm Fuel system - high-pressure Designation Torque specifications. Lubricant Nut for H.P. line at limiting valve 120 Nm + 10. Nm. Engine oil [Nut for H.P. line at injector 120./Nm +10 Nm HP. accumulator on crankcase 57 Nm + 10.Nm Thrust screw for H.P. accumulator seal 550 Nm + 10 Nm Hex screw for hold-down clamp at injector | 100. Nm + 10 Nm Socket-head screws of 15.Nm + 10 Nm pressure-relief valve High-pressure lines from pump to H.P. 100 Nm + 10 Nm accumulator Exhaust turbocharger 8V Designation Torque specifications Lubricant Hex nut on turbine housing 151Nm M020102/01E 03-12 oMmTUGeneral 1-17 Exhaust turbocharger 12V/16V Designation Torque specifications Lubricant Hex screw on compressor housing | 21 Nm + 10 Nm Engine of Nut with dished washer for turbine | 21 Nm + 10 Nm housing Nut without dished washer for 42Nm+10Nm turbine housing Hex screw on housing cover 9Nm+10Nm Magnetic nut on turbine wheel Ultra-Therm 1 Pratightening torque (efthend | 50 Nm + 10 Nm thread) rains | 2 Further angle of rotation cor + 5 Starting system Designation ‘Torque specifications Lubricant Hex nut M12 terminal 30 30 Nm + 10 Nm Engine oil Hex nut M12 terminal 30b 30. Nm +10. Nm | Hex nut M12 terminal 31 30 Nm +10 Nm | Hex nut M5 terminal 60 4+ 10 Nm Exhaust system | Designation Torque specifications Lubricant | Hex screws for exhaust distibution 70.Nm+ 10.Nm Uttra-Therm MTU or Molykote housing/exhaust line M12 x 60 P37 Lube oil system Designation Torque specifications Lubricant Pressure reduction valve in equipment carrier | 60 Nm + 10 Nm Engine oi! Hex screw for oil pump 60. Nm + 10Nm Nut for cooler insert 100 Nm Oil spray nozzle 21.Nm +10 Nm Moz0t02/01 03-12 omTu1-18 Coolant system General on crankcase Designation Torque specifications Lubricant Hex screws for cover plate on | 180./Nm+ 18. Nm Engine ol Coolant cooler Hex screws for securing carrier to | 42 Nm +10 Nm base plate Hex sorews for securing expansion | 74 Nm + 10 Nm tank to carrier Power supply, engine side Designation Torque specifications Lubricant Hex screws for mounting bracket 74Nm +10 Nm Engine oil Hex screws for carrier on equipment | 100 Nm + 10 Nm cartier ‘Socket-head screws for shaft 21.Nm+10Nm coupling ‘Stud for coupling in flange 21.Nm + 10Nm Nut for flange on generator 200 Nm + 10 Nm Mounting/support Designation Torque specifications Lubricant Hex screw (M10) for engine carrier | 42 Nm + 10. Nm Engine oil Hex screw (420) for engine cartier fon crankcase 350. Nm + 10 Nm ‘Nut for damping element on engine cartier ‘580. Nm +10. Nm Hex screw (M120) for engine ‘support on crankcase 74.Nm + 10Nm Hex screw (M20) for engine support ‘on crankcase 180 Nm +18 Nm Mo20102I01E 03-12 MTUGeneral 1-19 PTO systems, driving and free end (coupling) Designation Torque specifications Lubricant 4 Assembly sorews 150 Nm+ 10. Nm Hex screw MI6 for coupling on flywheel Et Engine oil Beet 1 Pretightening torque 120.Nm + 10 Nm |_ 2 Further angle of rotation 60" to 65° Hox serew M16 (alotted) 480 Nm Hex serew M10 45.Nm Molykote 1000 Dished washers Loctite 270 Geistinger coupling F56 with bearing housing Hex sorews for bearing housing | 100 Nm+ 10 Nm Engine ol cover Auxiliary systems/supplementary unit Designation Torque specifications Lubricant Hex screw for bearing housing on | 74 Nm + 10 Nm Engine ol carrier housing Hex screw for bilge pump on bearing | 74 Nm + 10 Nm housing 1 Stress bolt for bige pump | 90.Nm + 10 Nm Molykote G-n plus impeller 2 Checking torque forimpetter_| 350 Nm Mo20102/01E 03-12 omTu1-24 General Tightening torques Ma are given for screw plugs made of steel (St) with surface protected by a phosphate coating and oiled or galvanized. Thread and mating faces beneath heads must be coated in engine oll prior to ‘assembly. When tightening manually (defined tightening), an assembly tolerance of +10 % of the table values is permitted for unavoidable deviations of the tightening torque from the table value during the tightening process - e.g. resulting from inaccurate readings and overtightening during assembly. Tightening torques for plugs DIN 908, DIN 910 and DIN 7604A (with short screwed plug) 7 insorted in Thread Stooligroy cast iron My Al alloy My (nm) (Nm) M10 x1 18 1 M12 x 1.5 35 25 M14 x 1.5 35 25 M16 x 1.5 40 20 M18 x 1.5 50 35 20x 1.5 7 55 45 M22 x 1.5 60 50 M24 x 1.5 70 60 M26 x 1.5 80 70 M27 x2 80 70 M30 x 1.5 4100 80 M30 x2 95 85 M33 x2 120 110 M36 x 1.5 130 : 115 M38 x 1.5 140 : wo | M42 x 1.5 a 150 430 MAS x15 160 140 M48 x 1.5 170 145 M52 x15 180 150 M56 x2 190 160 M64 x2 205 175 MA = tightening torques Mo20102/01E 03-12 omTuGeneral Tightening torques for plugs as per DIN 7604C (with long screwed plug) inserted in HEHE Thread Steel/grey cast iron My Al alloy Ma (Nm) (wm) Me x4 10 10 | M22 x 1.5 80 65 J M26 x 1.5 405 80 M30 x 1.5 130 130 M38 x 1.5 140 120 M45 x 1.5 160 140 MA = tightening torques MMN 223 90002218] Tightening torques for banjo screws as per MTN 5183-2 standard This standard applies to banjo screws as per MMN 223 and N 15011 sealed with sealing ring DIN 7603-Cu Mo20102/01€ 03-12 emu1-28 General N 15011 ‘Tightening torques Ma are given for banjo screws made of steal (St) with surface protected by a phosphate coating and oiled or galvanized and for banjo screws made of copper-aluminium alloys. ‘Thread and mating faces beneath heads must be coated in engine oil prior to assembly. ‘When tightening manually (defined tightening), an assembly tolerance of +10 % of the table values is permitted for unavoidable deviations of the tightening torque from the table value during the tightening process - e.g. resulting from inaccurate readings and overtightening during assembly. Tightening torques for banjo screws made of steel reed inserted in stootarey hos IroniAl alloy My Me x4 10 Miox1 18 Mi2x 15 20 M14 x15 7 25 Migx15 26 Mig x 15 30 M22 x 1.5 60 M26 x 1.5 80 M30 x 1.5 130 M38 x15 140 M45 x 1.5 oo MA = tightening torques Mo20102/01E 03-12 omtuGeneral 1-27 Tightening torques for banjo screws made of copper/aluminium alloys aunha Inserted in steeligrey cast iron/Al alloy Ma, (Nm) M10 x1 16 MiG x 1.5 30 MA = tightening torques Tightening torques for male connector as per MTN 5183-3 standard This standard applies to male connectors DIN 2353, row L with screwed plug DIN 3852, model A (Sealed by sealing ring DIN 7603-Cu) DIN 2353 C ‘90000222 Tightening torques MA are given for male connectors made of steel (St) with surface protected by @ phosphate coating and oiled or galvanized, ‘Thread and mating faces beneath heads must be coated in engine oil prior to assembly. Moz0102/01E 03-12 omTu1-28 General ‘When tightening manually (defined tightening), an assembly tolerance of +10 % of the table values is permitted for unavoidable deviations of the tightening torque from the table value during the tightening process - e.g. resulting from inaccurate readings and overtightening during assembly Thread inserted in stole cast ron Ma Mi0x4 id | M2 x15 a { Mia x18 7" TI Mi6x 15 in Miex 15 a M22 x45 fs M26 x 1.5 a a2 x2 ory Maa x2 oh — 320 MA = tightening torques Tightening torques for union nuts on screwed plugs ISO 6149-3 000003188] 1 Union nut 3 O-ring 2 Union body 4 Ball bush Union nut. When installing the linear ball bearing, the union nut should be tightened firmly by hand (noticeable increase in force) a quarter of a turn (80°) beyond this point. Moz0102/01E 03-12 emTuGeneral 4-29 1.2.9 — Settings Firing order for Series 4000 engines BV A1-B4-A4-A2-B3-A3-B2-B1 12v__ | A1-B2— Ab - B4— A3- B1 - AB- BS-AZ~B3~A4- BE Hy tev _| AI-AT-B4-B6-A4-8-A2-A6-B2-85-A3-A6-52-A6-B1-B7 20V, (A1-B5-A8-B7-A5-B2-A7-B10-A2-B3-A10-B6-A3-B4-A6-B9-A4-B1-A9-B8 Direction of rotation, viewed towards driving end Component | Direction of rotation Crankshaft left eo Camshaft right H.P. fue! pump left Oil pump left _| Engine coolant pump lett Charge air coolant pump left Batterycharging generator tet (if available) Hydrostatic pump (if available) left Valve clearance, engine cold (20 °C) Inlet 0.20 mm Exhaust 0.50 mm moZ0T02/01E 05-12 owTu1-30 Vaive timing with valve clearance adjusted General No. Valve position Crank angle 1 Inlet opens 42.6" before TDC 2 Inlet closes 66.6" after BDC 3 Exhaust opens 87.6° before TOC 4 Exhaust closes 30.4" after TOC 5 Overlap 73° 6 Start of delivery Performance-map controlled Top dead center (TDC) Bottom dead center (BDC) Cam and valve lift for camshaft adjustment Intet Exhaust | | Cam itt at TOC 1.43 mm 4.43 mm Valve lit at TDC (zero valve 2.00 mm 2.00 mm clearance) M020102/01E 03-12 mtuGeneral 1-31 1.240 Conversion tables Length Unit A ‘multiplied by factor = Unit B in 254 = mm ft 0.3048 =m yd oad =m stat, mile 1.809 =km yo 3 = yo 38 =in Unit B ‘multiplied by factor = Unit A mom 0.9937 =in m 3.281 = km 0.6215 = stat,_mile Area Unit A multiplied by factor = Unit B in? 645.16 = mm? fe 0.0929 yd? 0.8361 stat. mile? 2.5889 ker Unit B multiplied by factor mm? 0.00185 mm? 10.7643 = me 1.1960 = ye km2 0.3863, stat, ile? M020102/01E 03-12 omTu1-32 General Volume Unit A ‘multiplied by factor = Unit B int 16387 = mm 18 0.02832 =m? yo 0.7646 =m gallon (US) 3.787 = am? gallon (Brit) 4.546 = dm? Unit 8 multiplied by factor = Unit A ems 0.06102 = in? ms 36.31 =f ms 0.2642 = gallon (US) m3 0.22 = gallon (Brit.) Speed Unit A ‘multiplied by factor = Unit B tus 0.3048 = mis stat,_mile/h (mph) 1.809 = kmih knot (Brit) 1.862 = kmih Unit B ‘multiplied by factor = Unit B mis 3.281 = fs env 0.6215 = stat. milefh (mph) kewvh 0.54 = knot (Brit) Mo20102/01E 03-12 omTuGeneral -33 Mass = Unit A multipliod by factor = Unit B b 0.4536 = oz 28.36 = ton 1.016 st Unit B multiplied by factor = Unit A 8 0.03527 Foz kg 2.205 = lb t 0.9843, = ton Force Unit A ‘multiplied by factor = Unit B b 0.4536 =kp b 4.4683 = Unit B multiplied by factor = Unit A kp 2.208 = N 0.101972 = ko 9.20665 = Density Unit A multiplied by factor = Unit B tb sate 5154 = kgin? Unit B multiplied by factor kgim? 0.00194 Mo20102/01E 03-12 emu1-34 General Torque Unit A multiplied by factor = Unit B fib 1.3863 =Nm Unit B multiplied by factor = UnitA { Nm 0.7373 =f Pressure Unit A multiplied by factor = UnitB Ibisa in (psi) 703.4 kp? (mm WS) {bisa in (psi) 0.06895 = bar Ibvsa ft 47.883 =Pa ings 0.03386 = bar ings 345.3 = kpim Unit B multiplied by factor = Unit A atm 760 = mm as atm 1.0133 = bar atm 10332 pim? (ram WS) atm 1.0392 = kplem? (at) atm 14.696 = Ibisa in bar 14.603 = Ibisq in Mass moment, 2nd grade Unit A multiplied by factor = Unit B zl ftlb s? 1.3863 kgm Unit B ‘multiplied by factor = Unit A kg m2 0.7373 = ft? Mo20102/01E 03-12 omTuGeneral Energy Unit A multiplied by factor = Unit B ftlb 1.366 5 kcal 4186.8 = BTU 1065 =u cHU 1999 = Unit B multiplied by factor = Unit A J 0.7376 = fib J 0.0002389 = kcal J 0.009479 = BTU J 0.00052686 = CHU Power Unit A multipliod by factor = Unit B Ps 0.7355 = kW HP. 0.7487 RW. BTUs 1.055 = kW kealih 1.163 =W HP 850 Unit B multiplied by factor kw 1.36 kw 1.341 kw 0.9478 w 0.8598 flbis 0.0018 Mo20102/01E 03-12 omTu1-36 General Temperature Celsius _ | Kelvin Fahrenheit Réaumur xc =x + 273.16 K = 9/5x + 32 °F = (4/5x) °R xK = x= 273.18°C = 9/5(x ~ 273.15) + 32 °F = 415 (x ~ 273,15) F i 5/9(x - 32) °C re (x ~ 32) + 273.15 = 4/9 (x ~ 32) °R [aR = 51x °C = (6/4x)+273.18K | = (9/4x) + 32°F Fuel consumption Unit A multiplied by factor mile/gal (US) 0.4251 galmile (US) 2.3527 Unit B ‘multiplied by factor = Unit A ken 22827 = mile/gal (US) Varn 0.4251 = galimile (US) Moz0102/01E 03-12 mtuGeneral 1-37 1.2.11 Repairing threaded bores with threaded inserts (Heli-Coil) Thread ‘Twist drill diameter Me 6.1-6.2-625 | MB 81-8.2-8.26-8. Maxt 8.32/8.04 81-8.2-8.25-8.3 M10 10.4/10.05 10.25 M12 12.5/12.05 12.25-125 M12x15 12.43/12.05 12.25 M14 14.63/14.08 14.25-14.5 M 14x15 14.43/14.05 1425 M15x2 15.9152 18.28 M16 16.53/16.06 16.25-16.6 M16 x45 16.43/16.05 16.25 M24 x18 24.43/24.05 24.25 M26 x 1.5 26.43/26.05 26.25 [M90x 1.5 30.49/30.05 30.25 4. Remove thread insert with suitable removal {ool from bore (lef). 2. Bore core hole with suitable twist dil - see table 3, Cut thread with special tap. 4. Do not countersink hole! 5. Mount spindle (2) and snout (1) corresponding with thread. Pe 6. Groove on snout must be aligned with markings ‘000001208 1 Snout 2 Spindle ‘on installation tool (arrows) M020102/01E 03.12 omTu1-38 General 7. Insert thread insert (2) into spindle (1) in installation tool 8. Driver journal ofthe thread insert must be in groove (arrow), 00001216] 1 Spindle 2 Thread insert 9. Use spindle to tum thread insert through snout Until its flush at front (arrow). 000001226] Moz0102/01E 03-12 omTUGeneral 10. Mount installation tool on threaded hole and instal thread insert without applying pressure to spindle. 11. insert thread insert 1/2 to 1 1/2 turns deeper than the threaded hole surface. 12. Use screw shearer to remove driver journals up to M 14. With threaded inserts over M14, use pointed pliers to move driver journal up and. down and remove, 00001230) Moz0102/01E 03-12 omTu1-40 General 4.212 Transport Transport Lif the engine only with the liting eyes provided. Use only the transport and liting equipment approved by MTU. Take note of the engine center of gravity. ‘The engine must only be transported in installation position, max. permissible diagonal pull 10°. In the case of special packaging with aluminium foil, suspend the engine on the lifting eyes of the transport pallet or transport with equipment for heavy loads (forklift truck) Prior to transporting the engine, it's imperative to instal transport locking devices for crankshaft and engine mounts. Secure the engine against titing during transportation. The engine must be especially secured against slipping or tiling when going up or down inclines and ramps. Setting the engine down after transport Place the engine only on an even, firm surface. Ensure appropriate consistency and load-bearing capacity of the ground or support surface. Never place an engine on the oil pan, unless expressively authorized by MTU on a case-to-case basis to do s0. Mo20102/01E 03-12 omTuTable of Contents 2-1 2 Operation Schedules 21 Engine condition check before a major overhaul 22 Preface ...... 2-04 2-02 2.3 Maintenance schedule matrix... 24 Maintenance tasks . 2-03 2-06 2-08 2.5 Engine removal 2.6 — Engine Disassembly 2-09 2-12 2-14 2-15 2-47 2.7 Engine Assembly . 2.8 — Engine installation 29 Enginerunin . 2.40 Putting the engine into operation M020102/01E 03-12 mtu2-1 Table of Contents, Mo20102/01E 03-12 omTuOperation Schedules 24 Engine condition check before a major overhaul Before the engine is removed, a brief test should be conducted to assist in evaluating its condition and running behavior. Deviations from the Engine Acceptance Test Record Data found during the test run provide valuable information for subsequent overhaul services. Operations to be performed Seo Put the engine into operation after a scheduled outof-service period. (Operating Instructions) Start engine at LOP. Run engine until operating temperature is reached. (Operating Instructions) Test engine at highest possible power. If this is not possible, operate the engine at adjustable upper and lower no-load speed. (-+Acceptance test record) Perform operational checks. (Operating Instuctons) Take engine oil sample and analyze. (SOperating Instructions) Take engine coolant sample and analyze. (SOperating Instructions) ‘Shut down engine at LOP. (SOperating Instructions) Drain engine coolant. (Operating Instructions) If engine coolant sample is not OK, fil with cleaning agent. (GFluids and Lubricants Specification) Start engine at LOP. (Operating Instructions) Flush engine cooling system. (Fluids and Lubricants Specification) Shut down engine at LOP. (Operating Instructions) Moz0102/01E 03-12 omTu2-02 Operation Schedules 2.2 Preface General Low operating and maintenance costs as well as operational reliability and availabilty depend on maintenance and servicing being carried out in compliance with MTU’s specifications and instructions, The overall system, of which the engine Is an integral part, must be maintained in such a way as to ensure trouble-free engine operation, For this purpose always: + ensure that sufficient fuel of specified quality is available + that the combustion air is dry and clean Preventive maintenance instructions: * Special care should be taken to keep the machinery plant in a clean and serviceable condition at all times to facilitate detection of possible leaks and prevent subsequent damage. + Protect rubber and synthetic parts from oll and fuel, never treat with organic detergents, only wipe with dry cloth. + Always replace al! seals and gaskets. Our Service partner will aways be available should assistance be required. MTU maintenance concept ‘The MTU maintenance concept is a preventive maintenance concept. Preventive maintenance permits advance operational planning and increases availabilly, ‘The time intervals at which the maintenance work is to be carried out, and the relevant checks and tasks involved, are average results based on operational experience and therefore represent guidelines ‘only. Specific operating conditions may require modifications to the Maintenance Schedule. Exchange parts (reliabilt®) are available for components to be replaced. Note ‘The maintenance task matrix covers all tasks up to a major overhaul. After a major overhaul, the maintenance tasks must continue to be performed in accordance with the specified schedule. The specification of fluids and lubricants, guidelines for maintenance and change intervals as well as a lst of approved fluids and lubricants are provided in the MTU Fluids and Lubricants Specifications AOO1061, Use only fluids and lubricants which comply with the MTU Fluids and Lubricants Specifications, ‘The user/customer must perform the following maintenance tasks: + Fuel prefiter: Maintenance depends on fuel quality (purity). The fiter elements of the fuel prefiter must be replaced every 2 years at the latest. + Battery: Maintenance depends on load and ambient conditions of the batteries. The specifications of the battery manufacturer are binding, Out-of-service periods If the engine is to remain out of service for more than 1 month, carry out engine preservation procedures according to the Fluids and Lubricants Specifications, MTU Publication No, A001061, Mo20102/01E 03-12 MTUOperation Schedules 2-03 2.3 Maintenance schedule matrix Maintenance schedule matrix (8,000 to 15,000 operating hours) V 4000 M40 A/B Maintenance schedule matrix Item Interval, Operating hours [h] years Ary 7 B\S\a)e Turbocharger : x ‘Component maintenance : x Extended component maintenance | 18 x Maintenance schedule matrix (8,000 to 32,000 operating hours) V 4000 M50 A/B Maintenance schedule matrix item Interval, Operating hours [h] oo giaisigge 3 : Sele] |s]s Turbocharger c x x x x Component maintenance ro x x x x Grinder nese : TL HP fuel pump conwor block |= de Extended component maintenance | 18 x Moz0102/01E 03-12 e@mTuOperation Schedules Maintenance schedule matrix (10,000 to 24,000 operating hours) V 4000 M60 Maintenance schedule matrix Item Interval, | Operating hours [h} yeas fgigigig gisigle | Cylinder head : iL Pl | | Turbocharger a 1 Ix} |x Component maintenance | _| |e x | HP. fuel pump control block : x| |x [ Extended component maintenance | 18 i x | Maintenance schedule matrix (12,000 to 30,000 operating hours) V 4000 M60R Maintenance schedule matrix Item Interval, Operating hours [h] years {gigiaig s{3/a\8 H.P. fuel pump control block i x x Cylinder head Fi x x Turbocharger 7 x] [x Component maintenance - x] [x [ Extended component maintenance | 18 x TEE Mo20102/01E 03-12 omTuOperation Schedules Maintenance schedule matrix (8,000 to 15,000 operating hours) V 4000 M70 Maintenance schedule matrix Item Interval, Operating hours [h] tH 2188 Eels Tuvocharger ; x Component manignance ; x Cyinder need : 7 HAP fue! pump contol lock | x Extnded component maintenance | 18 7 Maintenance schedule matrix Maintenance schedule matrix (4,500 to 9,01 ing hours) V 4000 M90 item Interval, Operating hours th years 1 a8 Turbocharger : «|x Component maintenance : x|x HP. fuel pump control block Fi x Cylinder ead x Extendea component maintenance | 18 x Moz0102/01E 03-12 MTU2-06 ‘Operation Schedules 24 Maintenance tasks Table of maintenance tasks Quatit. | interval Item Maintonance tasks Code cation Ihours}_| [years] ws ‘Component Before starting maintenance work, carry out | W812 maintenance test run and record operating parameters Then drain coolant and flush cooling systems (-» Page 2-01), WS Inspect rocker arms, valve bridges, swing | W601 followers and swing follower bearings for wear (-» Page 3-281), ws Check vibration damper (+ Page 3-185). | W611 ws Clean air intakersupply pipework ws02 Page 3-496). | ws Clean intercoolers and check for leaks | W803 (+ Page 3-484). ws Crankcase breather: only 12/16V: Replace | Wo26 fiterfiter element (-+ Page 3-78). WS Replace H.P. fuel sensor (— Page 3-873). | W604 WS Overhaul: W615 + Engine coolant pump (~+ Page 3-678) + Raw water pump (— Page 3-754) + Bilge pump (if fitted) (+ Page 3-835). WS Clean engine coolant cooler and check for | W617 leaks if possible (+ Page 3-730). ws Clean engine oil cooler and check for leaks | W618 (> Page 3-643). WS ‘Check centrifugal oil fitter (if fitted) for wear | W609 C Page 3-829) WS Measure adjustment dimension at central | W620 buffer of engine mounts (—+ Page 3-797). WS ‘Check operation of diverter valves (if fitted) | W621 (@ Page 3-529). WS ‘Overhaul starter (—+ Page 3-591). ‘W610 [ws Cylinder head Overhaul cylinder heads (-» Page 3-241). | W124 WS Inspect piston crowns and wear pattern of | W622 Fl cylinder liners. Wo ‘Turbocharger Overhaul turbocharger (> Page 3-444)... | W078 WS HP. fuel pump Replace control block (> Page 3-370)... wo23 Mo20102/01E 03-12 mtuOperation Schedules 2-07 Quatifi-_ | interval tem Maintenance tasks Code cation [hours} | tyears} aoe ws Extended Disassemble engine completely. Inspect | W700 ‘component engine components as per Maintenance ‘maintenance Manual instructions, repair or fit new components as required (-+ Page 2-09). we Replace all elastomer components and | W701 seals. we Fit new piston rings (-» Page 3-198). | W702 we Fit new conrod bearings (+ Page 3-198). | W703 we Fit new crankshaft bearings wros (Page 3-128), We Fit new cylinder liners (~» Page 3-34). | W705 ws Fit new aux. PTO antifiction bearing wr0s we Fit new H.P. fuel pump (—+ Page 3-361). | W707 we Replace oil separator of crankcase breather | W709 (G Page 3-78). we Fit new fuel delivery pump (+ Page 3-405). | W710 we Fit new actuating cylinder of air-low control | W714 flaps (+ Page 3-600) we Fit new actuating oylinder of exhaustflow | W712 ‘control flaps (-+ Page 3-636). we Fit new exhaust-control flap bearing wits (G Page 3-500). we Fit new pressure relief valve in common rail | W721 ( Page 3~ 382) we Overhaul battery-charging generator wre, (G Page 3-788), MoZ0102/01E 03-12 out2-08 2.5 Engine removal ‘Operation Schedules Operations to be performed See ‘Shut off fuel supply. Close raw water supply line. Drain engine oll at operating temperature. (Operating Instructions) Examine oil siudge for metallic residues. Drain engine coolant (coolant temperature < 60 ‘C) +Operating Instructions) Drain raw water. ‘Wash machinery plant (as required, without chemical detergent) Disconnect all connections. Install non-fibrous plugs and blanking plates to seal all ‘open connections. Release engine securing screws. Remove engine and place on stands. ‘Attach engine to lifing device in accordance with transportation regulations, (Operating Instructions) Moz0102/01E 03-12 omTuOperation Schedules 2.6 Engine - Disassembly The sequence of the following listed work steps ensures a practical assembly process, Before disassembling the engine, itis advisable to take photographs of the engine from all sides or to mark all components installed. ‘The exact Task Description must be taken from the respective Function Group. Operations to be performed Se Remove PTO system. (+ Page 3-813) Mark and disconnect electric cables. Remove ECU housing. Remove air intake, (Page 3-495) Remove crankcase breather. (Page 3-87) Remove control block and control line for air and exhaust flow control flaps. (+ Page 3-838) Remove exhaust system after engine, Remove exhaust flap with actuators. Remove exhaust system after exhaust turbocharger. (© Page 3~587) ( Page 3-569) ( Page 3-582) Remove centrifugal oil iter. (= Page 3-632) Remove coolant pipework from/to intercoolers (G Page 3-726) Remove engine coolant ventiiation and charge air cooling (= Page 3-720) Remove coolant drain lines. (> Page 3-712) Disconnect coolant lines. (+ Page 3-701} Disconnect turbocharger oil supply. (> Page 3-669} Remove exhaust turbocharger. ( Page 3-448) Remove constant-pressure manifold ( Page 3-545) Remove intercooler. (> Page 3-487) Remove engine lifting attachment (> Page 3-62) Remove air pipework from left side to right side, driving end. Remove fuel pipework. (~ Page 3-531) (+ Page 3-415) (~ Page 3-432) Remove fuel fier. (+ Page 3-423) Remove fuel delivery pump. (Page 3-408) Remove leak-off fuel pipework. (Page 3-440) Remove H.P. fuel line. ( Page 3-387) Remove H.P. fuel pump. (+ Page 3-363) Remove expansion tank (Page 3-783) a [Remove coolant cooler and fuel cooler. (G Page 3-732) Mo20102/01E 03-12 emtOperation Schedules Operations to be performed se Disconnect raw water lines. (+ Page 3-777) Remove raw-water pump. (Page 3-758) Remove bilge pump, (+ Page 3-839) Remove engine coolant pump. (G Page 3-680) Remove battery-charging generator. (G Page 3-789) Remove starter. Remove vibration damper on PTO, free end. (G Page 3-594) (G Page 3-185) Remove oil fiter with oil fiter housing. (Page 3-620} Remove oil cooler, ( Page 3-657) Remove crankcase from crankcase rotation device. (Page 3~25) Remove camshaft drive. (> Page 3-300) Replace thrust bearing of camshaft, (Page 3-308) Remove camshaft Remove sealing caps. (GPage 3-283) (Page 3-06) Moz0102/01& 03-12 MTUOperation Schedules 2-11 Operations to be performed Seo Remove studs. (G Page 3-06) Remove camshaft bearing bush & Page 3-06) Mo20102/01E 03-12 MTU2-12 Operation Schedules 27 Engine - Assembly ‘The sequence of the work steps stated below corresponds to practical assembly procedure. ‘The exact Task Description must be taken from the respective Function Group. Operations to be performed Se Clean crankcase, : (+ Page 3-10) (Check crankcase. ( Page 3- 12) Assemble crankcase, ( Page 3-25) Install camshaft. (Page 3-291) Install crankcase in crankcase rotation device. (+ Page 3-06) Install cylinder liners. ( Page 3-44) Install oll system in crankcase. Install crankshaft. ( Page 3-663) ( Page 3-161) Install piston with conrod. (+ Page 3-234) Install gear case, free end, (+ Page 3-109) Install lube ell pump with drive (+ Page 3-615) Install oil pan. (+ Page 3-53) Install end housing, oriving end. (+ Page 3-76) Remove crankcase from crankcase rotation device. (= Page 3-25) Install camshaft drive. (= Page 3-305) Install camshaft thrust bearing, ( Page 3-308) Install vibration damper on PTO, free end. ( Page 3-193) Install PTO flange, flywheel driving end. (+ Page 3-179) Install cylinder heads. (+ Page 3-277) Install engine lifting attachment. (+ Page 3-66) Install vaive gear. (G Page 3-350) Install main ol gallery (+ Page 3-25) Install starter. (+ Page 3-598) Install H.P. fuel pump. (~ Page 3-367) Install fuel injector. (= Page 3-379) Install cylinder head cover. (= Page 3-359) Install fuel delivery pump. (> Page 3-410) Install fuel pipework. (> Page 3-418) (Page 3-435) Install H.P. fuel tine (© Page 3-397) Install fuel fier. ( Page 3-428) Mo20102/01E 03-12 omTUOperation Schedules 2-13 ‘Operations to be performed Install leak-off fuel pipework. Install charge air manifolds, See (Page 3-443) (+ Page 3-521) (-» Page 3-627) Install coolant pipework with thermostat (G Page 3-752) Connect engine coolant lines. (= Page 3-704) (+ Page 3-729) Install il fiter with ol fiter housing (Page 3-626) Install oil cooler piates. ( Page 3-852) {Install centrifugal oi! fiter. (+ Page 3-642) Install intercooler. Install bilge pump. Install raw water pump. (G Page 3-492) (~ Page 3-857) ( Page 3-774) Install pipework for raw water pump. (Page 3-780) install expansion tank. ( Page 3-786) Install coolant cooler and fuel cooler. (& Page 3-738) Install constant-pressure manifold, (G Page 3-551) Install ar pipework from left side to right side, driving end, (> Page 3-534) Install exhaust system after exhaust turbocharger. ( Page 3-585) Install crankcase ventilation. ( Page 3-95) Install exhaust turbocharger. (Page 3-478) Install intake housing. (Page 3-518) Install air filter. (+ Page 3-499) Install exhaust flow control lap with actuator. (= Page 3-578) Install exhaust system after engine. (= Page 3-590) Install control black and control line for alt and exhaust ‘low control flaps. (= Page 3-541) Connect turbocharger oil supply. (> Page 3-672) Install engine coolant ventilation and charge air cooling. (> Page 3-723) Install engine coolant drain lines. (= Page 3-715) Install and connect electric wiring (4+ Page 3-870) (- Page 3-890) Install engine mounts, free and driving ends. ( Page 3-804) Install ECU housing, f = install PTO systems, free and driving ends. (& Page 3-820) Moz0102/01E 03-12 omTu2-14 28 Engine installation Operation Schedules Operations to be performed Seo Open ail connections, remove cover and rubber plugs. ‘Attach engine only at transportation eyelets and install a8 per transportation regulations. (Operating Instructions) Connect coolant lines, fuel ines and engine monitoring. Fill engine coolant system. (Operating Instructions) Fill ol system with engine ol. (=Operating Instructions) Align engine. Moz0102/01E 03-12 emuOperation Schedules 2-16 29 Engine run: Run in engine after component replacement. * When pistons, piston rings or cylinder liners are replaced, the engine must be run in in accordance with the applicable running-in schedule. Correct running in is decisive for the service Ife and operational reliablity of the engine. + To destroy the braking energy, use the alternator or brake * Power must be transmitted from the engine to the brake by means of a resilient coupling, ‘Set engine operational values. * Set temperatures, fuel and intake air in accordance with the temperature values in the MTU Acceptance Test Record. Note the following + The coolant temperature depends on the operating range of the coolant thermostat. * Fuel temperature depends on the volume of the service tank insofar as there is no fuel-cooling device on the test stand * Record readings for power, fuel, oll, coolant, charge air and exhaust gas at each test point {time, speed and effective power) of the run-in schedule and enter readings under “Engine Run-in" in “MTU Diesel Engine Factory Test” record | Operations to be performed Seo Install engine on test stand. 7 Connect engine to dynamometer or generator. - Connect air intake, exhaust, engine coolant, raw water | ~ and fue! pipework Connect dialogue unit to ECU. = Fill expansion tank with coolant with 2% corrosion _ (+Operating instructions) inhibitor oil up to max. mark. Vent coolant lines until bubble-free coolant emerges. | ~ Check that fuel in service or supply tank is to (Fluids and Lubricants Specification) specification eH Ventitueltystem2 (Operating Instructions) | Fil system with engine ot (SOperatingiinstructions)(f--BAL) =e | Lubricate valve gear. (Operating Instructions) ‘Check operation of engine governor before starting | — engine | Check emergency shutdown system. 7 Start engine at LOP. (Operating Instructions) Afier approx. 1 minute idiing operation, shut down —_| (-»Oppetating instnuctions}c] BAC) ‘engine and: * Check engine oil level. ifnecessary, top up oil + Check valve gear lubrication, Start engine and check idle speed. - Check for leaks at coolant, oll and fuel lines, crankcase | - seals, air system and exhaust lines, Run in engine in accordance with run-in program and | (—-Acceptance test record) record measured values. Mo20102/01E 03-12 omTu2-16 ‘Operation Schedules Operations tobe performed Compareicheck injection, temperatures, pressures and speeds at gauge dialogue units with Acceptance Test Record. Check exhaust gas color and enter. Enter barometric pressure and relative air humidity in Test Record. (Acceptance test record) Check engine for abnormal running noises and leaks. Check engine monitoring, After running in, run down engine and switch off (Operating Instructions) Cut open one ei fter and check for residues, Carry out acceptance test in accordance with MTU Engine Acceptance Test Record. Enter operational data in Acceptance Test Record. (Acceptance test record) Compare values with measured values in MTU Acceptance Test Record and evaluate (Acceptance test record) ‘After completion of acceptance test, run down engine and switch off (Operating Instructions) Preserve engine ifit is to be out of service for a prolonged period. (Fluids and Lubricants Specifications) ‘Take protective measures for sea transportation. Remove sensors and measuring lines and seal ‘measuring points. Remove engine from test stand. Prepare engine for paint spraying and coat with protective paint. Mo20102/01E 03-12 omTuOperation Schedules 2.10 2-17 Putting the engine into operation Operations to be performed Carry out before-operation services (Operating Instructions) Preheat engine (optional) Start engine at LOP. (Operating Instructions) Perform operational checks. Check monitoring system and ECU, (Operating Instructions) operation). ‘Shut down engine at LOP. Notify Service 4 : Perform test run. (Acceptance test record) Measure intake depression (only for intial operation). _| Notify Service. Measure exhaust backpressure (only for intial Notify Service, (Operating Instructions) Perform after-shutdown operations. (Operating Instructions) For extended out-of-service period: * Carty out external preservation + Disable engine start + Seal air inlet and exhaust outlet + Intemal preservation (air, ol, fue) (MTU Fluids and Lubricants Specification) Moz0102/01E 03-12 MTU2-18 Operation Schedules M020102/01E 03-12 omTuTable of Contents, 3-1 3 Task Descriptions 34 Engine Layout «0.2... .eeeeseeeeeeeeees 3.4.1 Engine layout 32 Grankcase and Attachments Sohechiaaisteah 3.2.1 Crankease and attachments - Overview 32.2 Crankcase - Overview 3.2.3 Crankcase — Disassembly 3.24 — Crankcase - Cleaning 3.2.5 — Crankcase - Check 3.2.6 — Crankcase tolerances 327 Crankcase ~ Assembly 3.28 Cylinder liner - Overview 3.29 Cylinder liner — Removal 3.2.10 Cylinder liner — Cleaning 3.2.11 Cylinder tiner ~ Check 3.2.12 Cylinder tiners ~ Tolerances 3.2.13 Cylinder liner Installation 3.2.14 — Oilpan-Overview 3.2.48 Oil pan— Removal 3.2.16 Oil pan—Cleaning 32.47 Oil pan—Check 3.2.18 Oil pan- Installation 32.19 Ollpan— Tightening sequence forollpans made of aluminium billet and aluminium castings ....... 3-67 32.20 Engine ling equipment - Overview 2 za - 3-60 3.221 Engine ling equipment ~ Removal 3-62 3222 Engine ling equipment — Cleaning 7 vesereeee 3-63 3223 Engine liting equipment - Check 3-64 3.224 Engine lifting equipment - Installation 3-65 3.2.25 End housing, df ing end Overview .... etal cee 3-68 3.226 End housing, driving end—Removal ......-2..000+5 2 c+ 3-68 32.27 End housing, driving end — Disassembly. ae cess 3270 32.28 End housing, driving end ~ Cleaning eee ieee tat se aetee S71. 3.2.29 End housing, driving end - Check 3-72 3.2.30 End housing KS ~ Tolerances 3 3.2.31 End housing, driving end — Assembly 3 3.2.32 End housing, driving end — Installation 3 32.83 Crankcase ventilation - Overview 3 32.34 — Crankcase ventiation - Overview a 32,38 Crankcase ventilation - Overview. : coves 8584 32.38 Crankcase ventilation ~ Removal alee 3-87 3-88 3 a 3 3 3 3.2.37 Crankcase ventilation - Cleaning 3.2.38 Crankcase ventilation — Check .... 3.2.39 Hengst oll separator — Disassembly 32.40 Hengst oll separator ~ Check 3.2.41 Hengst oil separator — Assembly 3.2.42 _ Crankcase ventilation ~ installation Mo20102/01E 03-12 oMTU3-l 3.3 GearTrain 2.2.2... 334 3.3.2 333 334 3.3.6 336 337 33.8 3.3.9 3.3.10 33.11 3.3.12 33.13 33.14 3.3.15 Gearcase, free end — Overview Gearcase, free end - Removal Gearcase, free end — Disassembly Gearcase, free end ~ Cleaning Gearcase, free end — Check Goarcase, fee end — Tolerances Gearcase, free end — Assembly Gearcase, free end - Installation Gear train, free end — Overview free end ~ Removal Gear train, ree end — Cleaning Gear train, free end — Check Gear train, free end ~ Tolerances Bearing bush — Removal and installation Gear train, free end ~ installation Table of Contents 3-968 3-96 3-98 3-101 3-102 3-103 3-104 3-105 3-109 3-114 3-116 3-118 3-119 3-120 3-122 9-124 Moz0102/01€ 03-12 omruTable of Contents 3-1) 3.4 Running Gear ... SRSnSSPRSeseon 3-127 3.4.1 Running gear ~ Overview 3-127 342 Crankshaft overview . 3-128 343 Crankshaft Removal 3-131 344 Crankshaft Disassembly 3-136 345 Crankshaft— Cleaning 3-137 3.46 Crankshaft ~ Check 3-138 34.7 Cranksheft-Tolerances ... 3-142 34,8 Crankshaft Assembly 3-152 3.498 Crankshaft Balancing 3-154 3.4.10 Main bearing shells - Check 3-156 3.4.11 Main bearing bore ~ Check 3-158 3.4.12 Crankshaft — Installation 3-161 3.4.13 PTO flange, driving end, flywheel - Overview 3-169 3.4.14 PTO flange, driving end, fywhee! — Removal 3-171 3.4.15. Radiablip shaft seal, diving end ~ Removal 3-175 3.4.18 PTO flange, driving end, flywheel ~ Cleaning 3-176 3.4.17 PTO flange, driving end - Flywheel check 3-177 3.4.18 Radiablip shaft seal - installation 3-178 3.4.19 PTO fiange, driving end, flywheel — installation 3-178 3.4.20 Crankshaft PTO, free end - Overview 3-183 3.4.21 Vibration damper on PTO, free end — Removal 3-185 3.4.22 Vibration damper on PTO, free end — Disassembly 3-189 3.4.23 Vibration damper on PTO, free end — Cleaning 3-190 3.4.24 Vibration damper on PTO, free end — Check 3-191 3.4.25 Vibration damper on PTO, free end — Tolerances 3-192 3.4.26 Vibration damper on PTO, free end — Installation 3-193 3.4.27 Pistons and conrods - Overview 3-198 3.4.28 Piston and conrod ~ Removal 3-200 3.4.29 Piston and conrod ~ Disassembly 3-206 3.4.30 Piston ~ Cleaning 3-206 3.4.31 Piston - Check 3-207 3.4.32 Piston — Tolerances -. 3-210 3.4.33 Piston - Assembly . 3-214 3.4.34 —Conrod ~ Cleaning 3-218 34.35 Conrod~ Check cee 32219 34.36 Contod ~ Tolerances - 3-226 3.4.37 Contod- Assembly 3-230 34.38 Contod bearing shell - Assessment 3-232 3.4.38 Piston and conrod — Installation 3-234 Mo20102/01E 03-12 omtu3-V 3.5 CylinderHead ........ 35.1 3.5.2 353 364 35.5 356 387 358 3.5.9 3.5.10 3.5.11 Cylinder head and attachments ~ Overview Cylinder head ~ Removal Cylinder head ~ Disassembly Cylinder head — Cleaning Cylinder head - Check Cylinder head tolerances Cylinder head — Repair a \Valve-seat turning machine for cylinder head Cylinder head — Plug repair Cylinder head - Assembly Cylinder head - Installation Table of Contents, 3-241 3-241 3-243 3-247 3-249 9-250 3-253 3-264 3-267 3-272 3-273 3-277 Mo20102/01E 03-12 omTuTable of Contents a-v Lo gr ve. 3-281 3.6.1 Valve gear - Overview : a 3-281 3.6.2 Camshaft overview... 00s... 3-282 3.6.3 Camshaft— Removal 3-283 3.64 Camshaft - Cleaning : : 3-285 365 Camshaft~Check ........ ell : 3-286 366 Camshaft Tolerances ..... F eee 3-288 3.6.7 Camshaft—Repair ....... Set eal 3-290 3.6.8 Camshaft Installation eens 3-291 3.6.9 Camshaft drive ~ Overview 3-299 3.6.10 Camshaft drive - Removal 3-300 3.6.11 Camshaft drive — Cleaning : : coven 9-303 3.6.12 Camshaft drive Check .. eet 3-304 3.6.13 Camshaft drive - installation ee : ee 3-305 3.6.14 Camshaft thrust bearing- Overview .. a cevceeerees 32907 3.6.15 Camshaft thrust bearing — Replacement OoeEee! 3-308 3.6.16 Camshaft thrust bearing — Cleaning 3-309 3.6.17 Camshaft thrust bearing ~ Check - 3-310 36.18 Valve drive—Overview ...... pee EGE vee 828M 3.6.19 Valve drive—Removal .. ls i coos 3-314 3.6.20 Valve drive Disassembly... Seer ceveeerees 92816 36.21 Velve drive~ Cleaning ..... : eet 3-318 3.6.22 Valve drive ~ Check : eek aee 3-319 3.623 Valve drive— Tolerances 3-322 3.6.24 Valve drive - Assembly as eet 3-324 3.6.25 Valve drive— Installation... i 3-327 3.6.28 Valve drive - Overview a Te 3-331 3.6.27 Valve drive - Removal : a voces 92985 3.6.28 Valve drive - Disassembly : peer 3-337 3.6.29 Valve drive - Cleaning 3-340 3.6.30 Valve drive ~ Check - 3-341 36.31 Valve drive Tolerances ........ a coves 3-344 36.32 Valve drive - Assembly oct coeeee 3-346 3.6.33 Valve drive — Installation F : cece 97850 3.6.34 Cylinder head cover Overview 2.2... : + 3-365 3.6.35 Cylinder head cover~ Removal .. 7 3-356 3.6.38 Cylinder head cover - Cleaning 3-357 3.6.37 Cylinder head cover ~ Check coos 3-988 3.6.38 Cylinder head cover - installation eb 3-359 Moz0102/01E 03-12 MTU3-w Table of Contents. 3.7 HP, Fuel System Sip ctiee tater + 3-360 37.1 HIP. fuel system ~ overview 3-360 37.2 HIP fuel pump — overview sees 32361 3.7.3 HLP fuel pump removal : ae : 3-363 3.7.4 — HP. fuel pump disassembly .......... : 3-365 37.5 HP. fuel pump inspection oat ceceeeees 8366 3.7.6 HP. fuel pump instalation feectt ttt tcteteeceeress 32887 3.7.7 HP. fuel pump — Control block replacement .... 3-370 3.7.8 Fuelinjector - overview 3-372 37.9 Fuel injector removal Eel we- 94373 3.7.10 Fuel injector disassembly Ase siveeeeesees 92976 3.7.11 Fuel injector cleaning seve 3-377 3.7.12 Fuel injector inspection : : : 3-378 3.7.13. Fuel injector installation... : Peaches --. 3-378 3.7.14 HP fuel line - Overview 3-382 37.18 HP fuelline — Removal 3-387 37.46 HP. fuelline ~ Disassembly REEL cd 3-391 3.7.17 HP .fuelline- Cleaning ..... : aes ceeves 92392 3.7.48 HP fuel ine ~ Check Bs ae 3-393 3.7.49 HP. fuelline—Assembly ........... atte 3-394 3.7.20 HP fuel ine ~ Installation ete Reda 3-397 3.7.21 HP. fuel system — Leak check 3-402 MoZ0102/01E 03-12 omTuTable of Contents 3-vil 3.8 LP Fucl System oo. eee ecceeeeesteeeeneeeee 3-403 3.8.1 Fuel system - Overview 3-403 3.8.2 Fuel delivery pump - Overview 3-405 3.8.3 Fuel delivery pump ~ Removal 3-406 3.84 Fuel delivery pump - Disassembly 3-407 3.8.5 Fuel delivery pump ~ Cleaning 3-408 3.8.6 Fuel delivery pump — Check 3-409 3.8.7 Fuel delivery pump — Installation 3-410 3.8.8 Fuel supply from pump to fiter and fuel cooler 3-413 3.8.9 Fuel lines from pump to fiter - Removal 3-415 3.8.10 Fuel lines from pump to fiter ~ Cleaning 3-416 3.8.11 Fuel lines from pump to fiter - Check 3-417 3.8.12 Fuel lines from pump to fer — installation 3-418 3.8.13 Fuel duplex fiter - Overview 3-420 3.8.14 Fuel duplex fiter — Removal 3-423 3.8.15 Fuel duplex fiter ~ Disassembly 3-424 3.8.16 Fuel duplex fiter- Cleaning 3-425 3.8.17 Fuel duplex fiter — Check 3-426 3.8.18 Fuel duplex filter Assembly 3-427 3.8.19 Fuel duplex fiter — Installation 3-428 3.8.20 Fuel supply from fuel iter to HP. pump — Overview 3-430 3.8.21 Fuel supply pipework from fuel fiter to H.P. pump ~ Removal 3-492 3.8.22 Fuel supply pipework from fuel fter to H.P. pump ~ Cleaning 3-433 3.8.23 Fuel supply pipework from fuel fer to H.P. pump - Check 3-434 3.8.24 Fuel supply pipework from fuel fiter to H.P. pump - installation 3-435 3.8.25 Leak-off fuel line - Overview 3-437 3.8.26 Leakoff fuel line ~ Removal 3-440 3.8.27 Lealcoff fuel line - Cleaning 3-441 3.8.28 Leakcoff fuel line - Check 3-442 3.8.29 _Leak-off fuel line - Installation 3-443 3.9 Exhaust Turbocharger feet ieens Sad 3.9.1 Exhaust turbocharger 3-444 Turbocharger - Overview 3-445 Turbocharger — Removal 3-448 Turbocharger — Disassembly 3-454 Turbocharger - Cleaning - 3-457 Turbocharger — Check 3-458 Turbocharger - Tolerances 3-463 ‘Turbocharger ~ Assembly 3-468 Turbocharger ~ Installation 3-478 340° Charge-Air Cooling ......+.+ : 3-483 3.10.1. Charge air cooling - Overview 3-483 3.10.2 Intercooler ~ Overview - 3-484 3.10.3 Intercooler ~ Removal 3-487 3.10.4 intercooler ~ Disassembly - 3-488 3.10.5 Intercooler ~ Cleaning 3-489 3.40.6 Intercooler ~ Check 3-490 3.10.7 Intercooler — Installation 3-492 Mo20102I01E 03-12 emTu3-vill Table of Contents 3411 Air Intake / Air Supply Fe alert taal beeteeeeenees SA495 3.11.1 Air intake/air supply ~ Overview = 3-495 3.412 Airfiter— Overview 3-496 3.11.3 Air iter Removal 3-497 3.114 Airfiter— Check 3-498 3.11.5 Airfiter~ Installation - 3-499 3.41.6 Intake housing - Overview 3-500 3.11.7 Intake housing — Removal 3-502 3.11.8 Intake housing — Disassembly - 3-803 3.11.9 Intake housing — Cleaning 3-506 3.11.10 Intake housing - Check 3-507 3.11.11 Intake housing — Tolerances 3-509 3.11.12 _ Intake housing - Assembly 3-511 3.11.13 _ Intake housing — Installation . 3-515 3.14.14 Intake air system to cylinders, left - Overview 3-517 3.11.15 Air supply system to cylinders, left ~ Removal 3-518 3.11.16 Air supply system to cylinders, left— Cleaning 3-519 3.11.17 Air supply system to cylinders, left ~ Check 3-520 3.11.18 Air supply system to cylinders, let Installation 3-521 3.11.19 Air supply system to cylinders, right — Overview 3-523 3.11.20 Air supply system to cylinders, right - Removal 3-524 3.11.21 Air supply system to cylinders, right ~ Cleaning 3-525 3.11.22 Air supply system to cylinders, right - Check 3-526 3.11.23 Cylinder air supply pipework, right — Installation 3-527 3.11.24 Air supply system from left side to right side, driving end — Overview 3-529 3.11.25 Air supply system from left side to right side, driving end ~ Removal 3-531 3.11.26 Air supply system from left side to right side, driving end ~ Cleaning 3-592 3.11.27 Air supply system from left side to right side, driving end ~ Check 3-533 3.11.28 Air supply system from left side to right side, driving end — Installation 3-534 3.1128 Gontel back and contol ne fr ar andextaust fow contol fas ~ Overview 3.11.30 Control block and conto line for air an exhaust flow control Naps ~ Removal 3-538 3.11.31 Control block and control line for air and exhaust flow control flaps -Cieaning ... 3-539 3.11.32 Control block and control line for air and exhaust flow control flaps ~ Check 3-540 3.1738 Cantel block and conte ine for air and exhaust fw conte faps—Inetafston Peet tot sit tle -541 MoZ0102/01E 03-12 MTUTable of Contents 3-IK 342 Exhaust System eee. ee eee ce eeeteeetteeerieee te ieeene, 32543 3.12.1 Exhaust system ~ Overview 3-543 3.12.2 Constant-pressure manifold ~ Overview 3-844 3.12.3 Constant-pressure manifold — Removal 3-546 3.12.4 — Constant-pressure manifold — Disassembly 3-547 3.12.5 Constant-pressure manifold — Cleaning 3-548 3.12.6 Constant-pressure manifold ~ Check 3-549 3.12.7 Constant-pressure manifold — Assembly 3-550 3.12.8 Constant-pressure manifold ~ Installation 3-551 3.12.9 Cartier housing - Overview 3-554 3.12.10 Carrier housing ~ Removal 3-555 3.12.11 Carrier housing - Disassembly 3-558 3.12.12 Carrier housing ~ Cleaning 3-559 3.12.43 Carrier housing — Check 3-560 3.12.14 Carrier housing ~ Assembly 3-561 342.15 Carrier housing ~ Installation hiact 3-563 3.12.16 Exhaust flow control flap with actuators - Overview 3-567 3.12.17 Exhaust flap with actuators ~ Removal 3-569 3.12.18 Exhaust flow control flap with actuators — Disassembly 3-571 3.12.19 Exhaust flow control flap with actuators — Cleaning 3-572 3.42.20 Exhaust flow contro flap with actuators ~ Check 3-573 3.12.21 Exhaust flow control flap with actuators - Tolerances... 3-575 3.12.22 Exhaust flow contro! flap with actuators ~ Assembly 3-576 3.12.23 Exhaust flow contro! flap with actuators — Installation 3-578 3.12.24 Exhaust system after exhaust turbocharger — Overview 3-580 3.12.25 Exhaust system after exhaust turbocharger — Removal 3-582 3.42.26 Exhaust system after exhaust turbocharger — Cleaning 3-583 3.12.27 Exhaust system after exhaust turbocharger — Check 3-584 3.12.28 Exhaust system after exhaust turbocharger ~ Installation 3-585 3.12.29 Exhaust pipe bellows after engine — Overview 3-586 3.12.30 Exhaust pipe bellows after engine - Removal 3-587 3.12.31 Exhaust pipe bellows after engine — Cleaning 3-588 3.12.32 Exhaust pipe bellows after engine — Check 3-589 3.12.33 Exhaust pipe bellows after engine — installation 3-590 3.43 Starting Equipment (Electric) a See 3-591 3.13.1 Starting equipment - Overview 3-591 3.13.2 Electric starter — Overview 3-592 3.13.3 Starter - Removal 3-594 3.13.4 — Starter —_Disassembly 3-595 3.43.5 Starter — Cleaning 3-596 3.43.6 Starter — inspection 3-597 3.13.7 Starter ~ Installation 3-598 3.44 Starting Equipment (Compressed Air) Pear eee sey 3-600 3.14.1 Starting equipment - Overview 3-600 3.14.2 Starter— Removal 3-602 3.14.3 Starter — Disassembly 3-603 3.14.4 Starter — Cleaning 3-604 3.14.5 — Starter—Check 3-605 3.14.8 Starter — Installation 3-606 Mo20102/01E 03-12 omTuTable of Contents, 3.15 Lube Oil System 3.15.1 Lube oil system - Overview 3.15.2 Lube oil pump with drive ~ Overview 3.15.3 Lube oil pump with drive - Removal et ‘ 3.15.4 Lube oil pump with drive — Disassembly 3-611 3.15.5 Lube oil pump with drive - Cleaning 3-612 3.15.6 Lube oil pump with drive ~ Check Fee : 3-613 3.15.7 Lube oll pump with drive ~ Installation 3-615 3.158 Oil fiter— Overview - 3-617 3.159 Oil fiter with ol fiter housing ~ Removal : soos, 3-620 3.15.10 Oilfiter housing — Disassembly... er : 3-621 3.15.11 Oil fiter with ol fiter housing ~ Cleaning... : 3-622 3.45.42 Oilfiter housing— Check .... : 3-623 3.15.13 Oil fiter housing ~ Assembly : : 3-624 3.15.14 Oil fiter with ol fiter housing — installation 3-626 3.15.15 Centrifugal ol fiter - Overview : 3-629 3.18.16 Centrifugal oil fiter Removal 3-632 3.15.17 Centrifugal oll fiter Disassembly... anna fovceeesees 37683 3.48.48 Centrifugal ol fiter ~ Cleaning 5 setae - 3-635 3.45.19 Centrifugal oll fter— Check . pee aoa veo 3-636 3.15.20 Centrifugal oil filter — Bearing clearance check... 3-637 3.15.21 Centrifugal oil fiter ~ Assembly 3-638 3.15.22 Centrifugal oil filter ~ Installation ie 3-642 3.15.23 Oil cooler plates — Overview . ace : | 3-643 3.18.24 Oil cooler plates — Removal anes et : 3-644 3.16.25 Cooler plates — Disassembly ae : 3-646 3.18.28 Cooler plates - Cleaning aati : 3-647 3.15.27 Cooler plates - Check 3-650 3.15.28 Cooler plates ~ Assembly : 3-651 3.16.29 Oil cooler plates —Installation <2... et 3-652 3.15.30 Oil system in crankcase - Overview leh + 3-655 3.15.31 Oil system in crankcase ~ Removal 3-657 3.46.32 Oil system in crankcase — Cleaning eater vies 3-660 3.18.33 Oil system in crankcase—Check ........ Seb tble 3-661 3.15.34 Oil system in crankcase — Installation 3-663 3.15.35 Turbocharger oil supply - Overview cove 9-668 3.18.36 Turbocharger oil supply ~ Removal 3-669 3.15.37 Turbocharger oil supply ~ Cleaning 3-670 3.16.38 Turbocharger oil supply ~ Check 3-671 3.18.39 Turbocharger oil supply system — Installation 3-672 3.46 Cooling System ....... es Sale seveeee 32673 3.46.1 Coolant system = Overview... ee ceeees 3-673 3.16.2 Cooling system — Leak test 3-675 3.16.3. Engine coolant pump - Overview aor 3-678 3.16.4 Engine coolant pump — Removal - 3-680 3.16.5 Engine coolant pump — Disassembly - 3-681 3.46.6 Engine coolant pump ~ Cleaning - 3-686 3.46.7 _ Engine coolant pump - Check 3-687 3.16.8 Engine coolant pump - Tolerances 3-689 Mo20102/01E 03-12 mtuTable of Contents 3-xI 3.16.9 Engine coolant pump — Assembly 3-692 3.16.10 Engine coolant pump ~ Installation eee 3-698 3.16.11 Coolant supply for engine coolant pump, intake side ~ Overview 3-700 3.16.12 Coolant supply for engine coolant pump, intake side — Removal 3-701 3.16.13 Coolant supply for engine coolant pump, intake side — Cleaning 3-702 3.16.14 Coolant supply for engine coolant pump, intake side — Check 3-703 3.16.18 Coolant supply for engine coolant pump, intake side — Installation 3-704 3.16.16 Preheating unit - Overview 3-705 3.16.17 Preheating unit - Removal 3-707 3.16.18 Preheating unit - Disassembly 3-708 3.16.19 Preheating unit - Installation 3-709 3.16.20 Engine coolant drain lines ~ Overview 3-711 3.18.21 Engine coolant drain lines — Removal 3-712 3.16.22 Engine cootant drain lines - Cleaning 3-713 3.16.23 Engine coolant drain lines ~ Check 3-714 3.16.24 Engine cootant drain lines ~ Installation 3-715 3.16.25 Engine cootant ventilation and charge air cooling ~ Overview 3-716 3.16.26 Engine coolant ventilation and charge air cooling ~ Removal - 3-720 3.16.27 Engine coolant ventilation and charge air cooling ~ Cleaning 3-724 3.16.28 Engine coolant ventilation and charge air cooling ~ Check 3-722 3.16.29 Engine coolant ventilation and charge air cooling — Installation 3-723 3.16.30 Coolant pipework from /to intercooler ~ Overview 3-724 3.16.31 Coolant pipework from/to intercooler ~ Removal 3-126 3.16.32 Coolant pipework from /to intercooler ~ Cleaning . 3-727 3.16.33 Coolant pipework from /to intercooler ~ Check 3-728 3.16.34 Coolant pipework from /to intercooler ~ Installation 3-729 3.46.35 Coolant cooler and fuel cooler - Overview 3-780 3.46.36 Coolant cooler and fuel cooler ~ Removal 3-732 3.16.37 Coolant cooler and fuel cooler ~ Disassembly 3-734 3.16.38 Coolant cooler and fuel cooler ~ Cleaning 3-735 3.16.39 Coolant cooler and fuel cooler - Check 3-736 3.16.40 Coolant cooler and fuel cooler — Assembly 3-737 3.16.41 Coolant cooler and fuel cooler - Installation 3-738 3.16.42 Coolant pipework with thermostat ~ Overview . 3-742 3.16.43 Coolant pipework with thermostat - Removal. 3-744 3.16.44 Coolant pipework with thermostat ~ Disassembly 3-746 3.16.45 Coolant pipework with thermostat ~ Cleaning 3-747 3.16.46 Coolant pipework with thermostat ~ Check 3-748 3.16.47 Coolant pipework with thermostat ~ Assembly . 3-750 3.46.48 Coolant pipework with thermostat - Installation . 9-752 3.46.49 Raw water pump - Overview . 3-754 3.46.50 Raw water pump ~ Removal . 3-756 3.16.51 Raw water pump ~ Disassembly 3-157 3.46.52 Raw water pump - Cleaning 3-762 3.16.53 Raw-water pump — Check - 3-763 3.16.54 Raw water pump — Tolerances - 3-765 3.16.55 Raw water pump — Assembly 3-768 3.16.56 Raw water pump — Installation 3-774 3.16.57 Coolant pipework to raw water pump — Overview . 3-776 3.16.58 Coolant pipework to raw water pump ~ Removal 3-117 Mo20102/01E 03-12 MTU3-xIl Table of Contents 3.16.59 Coolant pipework to raw water pump ~ Cleaning 3-778 3.16.60 Coolant pipework to raw water pump ~ Check 3-779 3.16.61 Coolant pipework to raw water pump ~ Installation 3-780 3.16.62 Expansion tank - Overview - 3-782 3.16.63 Expansion tank - Removal 3-783 3.16.64 Expansion tank — Cleaning 3-784 3.16.65 Expansion tank ~ Check 3-785 3.16.66 Expansion tank — Installation 3-786 3.47 Engine Power Supply beeteeeeene 3-788 3.17.1 Battery-charging generator - Overview 3-788 3.17.2 Battery-charging generator - Removal 3-789 3.17.3 Battery-charging generator — Disassembly . 3-791 3.17.4 Battery-charging generator — Cleaning 3-792 3.17.5 Battery-charging generator — Inspection 3-793 3.17.6 Battery-charging generator - Installation 3-794 3.48 Engine Mounting eoearreoa Penal 3-797 3.48.1 Engine mounting / support - Overview 3-797 3.18.2 — Engine mounting - Overview 3-798 3.183 Engine mounting — Removal +. 3-800 3.18.4 Engine mounting ~ Cleaning - 3-802 3.48.5 Engine mounting - Check 3-803 3.48.6 Engine mounting — Installation 3-804 3.49. PTO Systems, Driving End and Free End (Coupling) see seeetteeetteeees 32808 3.19.1 Geislinger steel-spring coupling ~ Overview 3-809 3.19.2 Geislinger steel-spring coupling - Overview 3-811 3.19.3 Steel-spring coupling ~ Removal 3-813 3.19.4 Geislinger steel-spring coupling ~ Disassembly 3-815 3.19.5 Geislinger steel-spring coupling - Cleaning 3-816 3.49.6 Geislinger steel-spring coupling - Check 3-817 3.19.7 Geislinger steel-spring coupling — Assembly 3-819 3.19.8 Geislinger steel-spring coupling - installation 3-820 3.18.9 Geislinger steel-spring coupling with bearing housing - Overview 3-824 3.19.10 Geislinger steel-spring coupling with bearing housing ~ Removal 3-825 3.19.11 Geislinger steel-spring coupling with bearing housing — Cleaning 3-228 3.19.12 Geislinger steel-spring coupling with bearing housing - Check 3-829 3.19.13 Geislinger steel-spring coupling with bearing housing ~ Installation 3-830 3.20. Auxiliary Systems / Accessory Equipment. Sata 3-834 3.20.1. Auxiliary systems / accessory equipment - Overview . 3-834 3.20.2 _ Bilge pump - Overview 3-835 3.20.3 Bilge pump - Removal 3-839 320.4 _ Bilge pump - Disassembly 3-840 3.20.5 Bilge pump - Cleaning else tte - 3-843 320.6 Bilge pump Check .. : Sia 3-844 3.20.7 Bilge pump - Tolerances ce. 3-846 3.20.8 Bilge pump - Assembly . 3-849 3.20.9 Bilge pump - installation 3-857 Mo20102/01E 03-12 emuTable of Contents 3-xXill 3.21. Monitoring, Control and Regulation Equipment .......0.e000ee08 - 3-859 321.1. Monitoring, control and regulation devices — Overview : +. 3-859 3.21.2 Wiring and engine wiring harnesses - Overview... : 3-061 321.3 Engine wiring hamess ~ Check coceeeess 37866 321.4 Engine wiring hares - Removal 3-867 3.21.5 Engine wiring hamesses — Installation ...... 3-870 3.21.6 Sensors, actuators and injectors - Overview ..... ot 3-873 3.21.7 Sensors, actuators and injectors - Removal ..... -. 3-883 3.21.8 Sensors, actuators and injectors - Check... 3-889 3.21.9 Sensors, actuators and injectors - Installation... 3-890 3.22 Index cee eetteeeerteeereres 32897, Mo20102/01E 03-12 omTu3-xIV Table of Contents Mo20102/01E 03-12 omTuEngine Layout 3-01 3.1 Engine Layout 3.441 Engine layout Group Survey Deviations from illustrations are insignificant ‘Also applies to 12V 4000 M 200 180 290 010 200 050 200 140 120 190 140 030 020 080 010 180 030 180 010 oooo0t38a 010 Crankcase and attachments 110 Intercooler (-» Page 3-484) 230 Mounting/support (-+ Page 3-02) 120 Air intake / air supply (G Page 3-797) 020 Gear train (+ Page 3-96) (G Page 3-495) 250 PTO systems, driving and free 030 Running gear (+ Page 3-127) 140 Exhaust system ends (~» Page 3-809) (040 Cylinder head (-» Page 3-241) Page 3-543) 260 Aunty systems and i uipment (no ne ie tas a Page3-261) 170 reg, iustrated) (—» Page 3-835) (he Page 3-380) 480 Lube cil system {500 Monitoring and control system, G Page 3-607) general electric devices 080 Fuel system (low pressure) (= Page 3-859) (Page 3-403), 200 Engine cooling system (Page 3-673) 100 Exhaust turbocharger (Page 3-443) 240 Power supply (> Page 3-788) Mo2z0102/01€ 03-12 omTUCrankcase and Attachments 3.2 3.2.1 Crankcase and attachments ~ Overview Overview of crankcase and attachments omTu Mo20102/01E 03-12Crankcase and Attachments 3-03 3.2.2 Crankcase — Overview Crankcase with cover 11007260 1 Crankcase 8 Sealing ring 47 Washer 2 Block 10 Blanking plug 18 O-ring 3 Screw MM Screw 19 Oxing 4 Drain valve 12 O-ring 20 Inspection port cover 6 Dowel pin 13 Holder 21 Gasket 6 Cover 14 Screw 22 Screw 7 Stud 18 O-ring 8 Plug 16 Screw Moz0102/01€ 03-12 mtu3-04 Crankcase and Attachments Crankcase 11002269 1 Crankcase 4 Stud * 7 Washer 2 Main bearing cap 5 Nut 8 End cover 3 Main bearing cap 6 Screw 9 Camshaft bearing () Newly fitted studs must be elongated before inttal tightening M020102/01E 03-12 omTuCrankcase and Attachments 3-05 filler neck with oil dipstick ono904ta 1 Inspection port cover 5 O-ring 2 Sealing ring 6 Cover for oil filer neck 3 Unions 7 Gasket 4 Oil dipstick @ Hex screw M020102/01E 03-12 omTu3-08 3.2.3 Crankcase — Disassembly Preconditions + Engine is stopped and starting disabled. Special tools Crankcase and Attachments, Designation / Use Part No. Magnetic-base indicator holder with dial gauge for stress measurement | Hydraulic clamping device for main bearing stud Installation/removal tool for main bearing stud Drive-in mandrel for end cover [Removal tool ‘Removal pipe for camshaft bearing ‘Crankcase barring tool AX __ Suspended toad. Danger to lifet DANGER + "Use appropriate iting devices and appliances. + Never stand beneath a suspended load ZX Components have sharp edges. Risk of injury! WARNING + Wear protective gloves. Proparatory steps When performing these tasks, a distinction must be made as to whethor: 1 The engine is to be completely disassembled 2 The engine is to be removed but not disassembled 3. The engine is to remain installed 1 [2 [3 _| Operations See x |= |__| Remove engine ( Page 2-08) x |= |= | isassembie engine (Page 2-08) Removing attachments Remove cover (-» Page 3-03). Remove guide tube (+ Page 3-03). Remove oil filer neck (-> Page 3-03) Remove inspection-port cover (+ Page 3-03). Remove gaskets and O-rings. Mo20102/01E 03-12 omTuCrankcase and Attachments 3-07 Installing crankcase in rotatable assembly stand 1. Install supports (1) for crankcase roll-over stand (2) on left and right side ofthe crankcase. 2. Raise crankcase with liting device and ropes. 3. Install crankcase in rotatable assembly stand and secure, Removing main bearing cap and studs 1. Remove main bearing cap (+ Page 3-131), Note: Remove studs only if damaged or over-elongated. When removing, replace studs in pairs. 2. Place installation/removal tool (arrow) on studs. 3. Remove respective studs with installation/removal tool Removing first bearing bush, driving or free end 41, Cover bottom of camshaft chamber so that the bearing bush does not fall into the running gear. 2. If only one bearing is being replaced, protect the next bearing (arrow) against damage. o20102/01E 03-12 emTuCrankcase and Attachments 3, Insert thrust pad (1) into appropriate bearing, 4. Place removal pipe (1) in thrust pad (2) support. 5. Drive camshaft bearing carefully out of crankcase. Removing next camshaft bearing bush 1. Insert thrust pad (3) into next bearing bush which is stil installed 2. Insert removal tool (2) with guide washers (1) into camshaft bearing bore on crankcase. 3. Drive out camshaft bearing bush. 4. Follow same procedure to remove other camshaft bearing bushes. M020102/01E 03-12 omTuCrankcase and Attachments. Removing end cover Note: Do not dil nto end cover. Metal chippings in the housing coolant chamber ‘may lead to local overheating, 1. Using a drt and hammer, carefully knock the edge of one side of the end cover inwards unfit its inthe bore. 2. Use pliers to withdraw end cover, taking care that tend cover does not fall into bore. M020102/01E 03-12, omTU