MTU C13 User manual

Operating Instructions
Diesel engine
12 V 4000 C13, C13R, C13L
12 V 4000 C23, C23R
16 V 4000 C13, C13R, C13L
16 V 4000 C23, C23R
M015695/03E

Printed in Germany
© 2013 Copyright MTU Friedrichshafen GmbH
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior
written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, mi-
crofilming and storage or processing on electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage
during operation.
Subject to alterations and amendments.

Table of Contents
1 Safety
1.1 Important provisions for all products 5
1.2 Personnel and organizational requirements 6
1.3 Transport 7
1.4 Crankshaft transport locking device 8
1.5 Crankshaft transportation lock – For
transport with flange-mounted generator 10
1.6 Safety regulations for startup and operation 12
1.7 Safety regulations for maintenance and
repair work 13
1.8 Fire prevention and environmental
protection, fluids and lubricants, auxiliary
materials 16
1.9 Standards for safety notices in the text 18
2 General Information
2.1 Engine side and cylinder designations 19
2.2 Engine layout 20
2.3 Sensors and actuators – Overview 21
3 Technical Data
3.1 12/16 V 4000 C13/13R/13L engine data:
Application group 5A, optimized fuel
consumption 25
3.2 12/16 V 4000 C13/13R/13L engine data:
Application group 5A, optimized exhaust
emissions (EPA Stage 2) 32
3.3 12/16 V 4000 C23/23R engine data:
Application group 5B, optimized fuel
consumption 39
3.4 12/16 V 4000 C23/23R engine data:
Application group 5B, optimized exhaust
emissions (EPA Stage 2) 43
3.5 Firing order 47
3.6 Main engine dimensions 48
4 Operation
4.1 Preparations for recommissioning the
engine after extended out-of-service periods
(>3 months) 49
4.2 Putting the engine into operation after
scheduled out-of-service-period 50
4.3 Starting the engine in manual mode 51
4.4 Stopping the engine in manual mode 52
4.5 After shutting down the engine 53
4.6 Plant cleaning 54
5 Maintenance
5.1 Maintenance task reference table [QL1] 55
6 Troubleshooting
6.1 Troubleshooting 56
6.2 Fault messages of the engine governor
ADEC (ECU 7) for series 4000 C&I engines 59
7 Task Description
7.1 Engine 78
7.1.1 Cranking engine manually 78
7.1.2 Engine – Barring with starting system 80
7.2 Cylinder Liner 81
7.2.1 Cylinder liner – Endoscopic examination 81
7.2.2 Instructions and comments on endoscopic and
visual examination of cylinder liners 83
7.3 Crankcase Breather 85
7.3.1 Crankcase breather – Oil separator element
replacement, diaphragm check and
replacement 85
7.4 Running Gear 87
7.4.1 Grounding device – Carbon brush check 87
7.4.2 Grounding device – Carbon brush replacement 89
7.5 Valve Drive 90
7.5.1 Valve gear – Lubrication 90
7.5.2 Valve clearance – Check and adjustment 91
7.5.3 Cylinder head cover – Removal and
installation 95
7.6 Injection Pump / HP Pump 96
7.6.1 HP pump – Filling with engine oil 96
7.7 Injection Valve / Injector 97
7.7.1 Injector – Replacement 97
7.7.2 Injector – Removal and installation 98
7.8 Fuel System 103
7.8.1 Fuel system – Venting 103
7.9 Fuel Filter 104
7.9.1 Fuel filter – Replacement 104
7.9.2 Draining fuel prefilter 105
7.9.3 Fuel prefilter – Draining 106
7.10 Charge-Air Cooling 107
7.10.1 Intercooler – Checking condensate drain for
coolant discharge and obstructions 107
7.11 Air Intake 108
7.11.1 Service indicator – Signal ring position check 108
7.12 Starting Equipment 109
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7.12.1 Starter – Condition check 109
7.13 Lube Oil System, Lube Oil Circuit 110
7.13.1 Checking engine oil level 110
7.13.2 Checking engine oil level 111
7.13.3 Engine oil – Change 112
7.13.4 Engine oil – Sample extraction and analysis 114
7.14 Oil Filtration / Cooling 115
7.14.1 Automatic oil filter – Oil filter candles
replacement 115
7.14.2 Oil indicator filter – Cleaning and check 118
7.14.3 Centrifugal oil filter – Cleaning and filter-
sleeve replacement 120
7.15 Coolant Circuit, General, High-Temperature
Circuit 122
7.15.1 Engine coolant – Level check 122
7.15.2 Engine coolant – Change 123
7.15.3 Draining engine coolant 124
7.15.4 Engine coolant – Filling 126
7.15.5 Engine coolant pump – Checking pressure
relief port 129
7.15.6 Engine coolant filter – Replacement 130
7.15.7 Engine coolant – Sample extraction and
analysis 131
7.16 Low-Temperature Circuit 132
7.16.1 Charge-air coolant – Level check 132
7.16.2 Charge-air coolant – Change 133
7.16.3 Draining charge-air coolant 134
7.16.4 Charge-air coolant – Filling 135
7.16.5 Charge-air coolant pump – Checking pressure
relief port 138
7.17 Belt Drive 139
7.17.1 Drive belt – Condition check 139
7.18 Battery-Charging Generator 140
7.18.1 Alternator – Removing and refitting 140
7.18.2 Battery-charging generator – Check 142
7.18.3 Battery-charging generator drive – Drive belt
tension adjustment 143
7.18.4 Battery-charging generator – Drive belt and
belt tensioner replacement 144
7.19 Fan Drive 146
7.19.1 Fan drive – Drive belt tension check /
adjustment 146
7.19.2 Fan drive – Drive belt replacement 148
7.20 Wiring (General) for Engine/Gearbox/Unit 149
7.20.1 Engine wiring – Check 149
7.21 Accessories for (Electronic) Engine
Governor / Control System 150
7.21.1 Engine governor and connectors – Cleaning 150
7.21.2 Engine governor plug connections – Check 151
8 Appendix A
8.1 Abbreviations 152
8.2 MTU contact persons/service partners 154
9 Appendix B
9.1 Special Tools 155
9.2 Index 162
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1 Safety
1.1 Important provisions for all products
Nameplate
The product is identified by nameplate, model designation or serial number and must match with the
information on the title page of this manual.
Nameplate, model designation or serial number can be found on the product.
General information
This product may pose a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Noncompliance with the safety instructions and warning notices
Correct use
The product is intended exclusively for the application specified in the contract or defined at the time of
delivery.
This means that the equipment must be operated:
• Within the permissible operating parameters in accordance with the (→ product data)
• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubri-
cants Specifications of the manufacturer)
• With spare parts approved by the manufacturer in accordance with the (→ applicable Spare Parts
Catalog)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writ-
ing (including engine control/parameters)
• In compliance with all safety instructions and in adherence to all warning notices in this manual
• In accordance with the maintenance requirements over the entire service life of the product (→ Main-
tenance Schedule)
• In compliance with the maintenance and repair instructions contained in this manual, in particular
with regard to the specified tightening torques
• With the exclusive use of technical personnel trained in commissioning, operation, maintenance and
repair
• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul
Any other use is considered improper use and increases the risk of personnel injury or material damage
in product operation.The manufacturer will accept no liability for such damage.
Modifications or conversions
Unauthorized modifications to the product compromise safety.
The manufacturer will accept no liability or warranty claims for any damage caused by unauthorized
modifications or conversions.
Spare parts
Only genuine spare parts must be used to replace components or assemblies.
The manufacturer will accept no liability or warranty claims for any damage caused by the use of other
spare parts.
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1.2 Personnel and organizational requirements
Organizational measures of the operator
This manual must be issued to all personnel involved in operation, maintenance, repair or transporta-
tion.
Keep this manual handy in the vicinity of the product such that it is accessible to operating, mainte-
nance, repair and transport personnel at all times.
Use this manual as a basis for instructing personnel on product operation and repair, whereby the safe-
ty-relevant instructions, in particular, must be read and understood.
This is particularly important in the case of personnel who only occasionally perform work on or around
the product. This personnel must be instructed repeatedly.
Personnel requirements
All work on the product shall be carried out by trained and qualified personnel only.
• Training at the Training Center of the manufacturer
• Qualified personnel specialized in mechanical and plant engineering
The operator must define the responsibilities of the personnel involved in operation, maintenance, re-
pair and transport.
Working clothes and protective equipment
Wear proper protective clothing for all work.
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1.3 Transport
Transport
Always use the lifting eyes on the engine and generator/gearbox when transporting gensets.
Always use the lifting eyes on the engine when transporting an engine separately.
Only use transport and lifting devices approved by MTU.
The engine/genset must only be transported in installation position: maximum permissible diagonal pull
10°.
Remove any loose parts on the genset.
Raise the engine/genset slowly. The lifting ropes or chains must not make contact with the engine or
its components. Readjust lifting device as necessary.
Pay attention to the center of gravity of the engine/genset.
For special packaging with aluminium foil: Suspend the engine/genset by the lifting eyes on the bearing
pedestal or transport by means of handling equipment (forklift truck) capable of bearing the load.
Fit the crankshaft transportation lock on the engine and fit the engine mount locking devices prior to
transport.
Secure the engine/genset such as to preclude tipping during transport. Secure such as to preclude slip-
ping and tipping when driving up or down inclines and ramps.
Placement after transport
Place the engine/genset on a firm, flat surface only.
Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.
Never set an engine down on the oil pan unless expressively authorized to do so by MTU on a case-to-
case basis.
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1.4 Crankshaft transport locking device
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Torque wrench, 10-60 Nm F30452769 1
Torque wrench, 60-320 Nm F30452768 1
Engine oil
Transport locking device
Note: The locking device on both ends protects the crankshaft bearings from shocks and vibration damage
during engine transport.
For installation and removal of the transport locking device, follow the in-
structions below:
1. The transport locking device must remain installed on both ends as long as possible during engine in-
stallation in order to avoid damage.
2. Prior to every engine transport, the transport locking device must be reinstalled on both sides according
to the instructions.
3. If the engine is to be moved together with the generator, the transport locking device for the generator
must also be installed.
4. Always use the screws supplied with or installed in the transport locking device to secure it on the en-
gine.
5. Starting or barring the engine is allowed only with the transport locking device removed. If the genera-
tor is already mounted on the engine, ensure that the transport locking device of the generator is also
removed.
6. Attach these instructions, clearly visible, to the engine.
Fitting the transport locking de-
vice on driving end (KS)
Note: Attach plate (6) only to the upper part of the openings.
1. Secure the two plates (6) with screws (4) and washers (5) at the bores on both sides of the flywheel
housing and tighten to the specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw M16 Tightening torque (Engine oil) 250 Nm +25 Nm
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2. Screw locknut (2) onto screw (1) up to the end of the thread.
3. The long end of holder (3) must face downwards. Push holder (3) through the plate openings (6).
Note: The holders (3) must lock the flywheel only, not the ring gear.
4. Install screw (1) into the bore of holder (1) until the holder (1) is locked in position.
Note: Tighten screw (1) alternately on both sides of the flywheel housing.
5. Tighten screw (1) alternately to specified tightening torque.
Name Size Type Lubricant Value/Standard
Screw M10 Tightening torque (Engine oil) 30 Nm +3 Nm
6. Fit locknut (2) of screw (1) on plate (6) and secure.
Removing the transport locking
device from driving end (KS)
1. Release the locknut (2) on both sides of
the flywheel housing, remove screw (1) and
take off the two holders (3).
2. Unscrew screws (4) and remove together
with washers (5) and plate (6).
3. Store the removed parts of the transport
locking device together with this documen-
tation carefully for possible reuse.
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1.5 Crankshaft transportation lock – For transport with flange-
mounted generator
Special tools, Material, Spare parts
Designation / Use Part No. Qty.
Torque wrench, 10-60 Nm F30452769 1
Ratchet F30027340 1
Engine oil
Transportation lock
Note: The transportation lock on the engine protects the crankshaft bearings from potential damage caused
by shocks and vibration when transporting the genset.
For installation and removal of the transportation lock, follow the instructions
below:
1. The transportation lock must remain in place on the engine for as long as possible during installation of
the genset in order to prevent damage.
2. The engine must never be started or cranked with the transportation lock in place. Make sure that the
transportation lock on the generator is also removed.
3. The transportation lock must always be refitted on the engine according to the instructions whenever
the genset is transported. The generator transportation lock should also be installed.
Removing transportation lock on
driving end (KS)
1. Unscrew screw (4) on both sides of the fly-
wheel housing (5).
2. Remove retainer (2) and washer (3).
3. Remove guard plate from flywheel housing.
4. Store the removed parts safely so that they
are ready for reuse when required.
Installing the transportation lock on driving end (KS)
Note: Keep guard plate and screws on the engine. They must be refitted when the transportation lock has
been removed.
1. Remove guard plate from flywheel housing.
2. Install barring device (→ Page 78).
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