MTU 12 V 4000 T95 Operating Instructions Manual
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MTU 12 V 4000 T95 Operating Instructions Manual

MTU 12 V 4000 T95 Operating Instructions Manual

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Operating Instructions

Diesel engine
12 V 4000 T95
12 V 4000 T95 x
MS150120/00E

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Summary of Contents for MTU 12 V 4000 T95

  • Page 1: Operating Instructions

    Operating Instructions Diesel engine 12 V 4000 T95 12 V 4000 T95 x MS150120/00E...
  • Page 2 All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen GmbH reserves the right to change, delete or supplement the information provided as and when required.

  • Page 3: Table Of Contents

    7.6 Injector 7.6.1 Injector – Replacement 3 Technical Data 7.6.2 Injector – Removal and installation 7.7 Fuel System 3.1 12 V 4000 T95/T95L/T95R engine data 7.7.1 Fuel system – Venting 3.2 Firing order 3.3 Engine – Main dimensions 7.8 Fuel Filter 7.8.1 Fuel filter –...
  • Page 4 7.18.4 Charge-air coolant – Filling 8 Appendix A 7.18.5 Checking charge-air coolant pump pressure 8.1 Abbreviations relief port 8.2 MTU contact persons/service partners 7.19 Belt Drive 7.19.1 Drive belt – Condition check 9 Appendix B 7.20 Battery-Charging Generator 7.20.1 Checking battery-charging generator 9.1 Special Tools...

  • Page 5: Safety

    • 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 (→ Spare Parts Catalog/MTU contact/Service partner) •...

  • Page 6: Personnel And Organizational Requirements

    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.

  • Page 7: Transport

    Transport • Lift the engine/genset/system only with the lifting eyes provided. • Only use transport and lifting devices approved by MTU. • The engine/genset/system must only be transported in installation position. • Max. permissible diagonal pull 10°.

  • Page 8: Crankshaft Transport Locking Device

    1.4 Crankshaft transport locking device Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10-60 Nm F30452769 Torque wrench, 60-320 Nm F30452768 Engine oil Transport locking device Note: The locking device protects the crankshaft bearings from possible shocks and vibration damage during engine transport.
  • Page 9 Installing the transport locking device on driving end (KS), ver- sion A Screw holder (4) with spacer sleeves (5) and screws (6) onto crankshaft. Spacer sleeves (5) are optional. Tighten screws (6) with torque wrench to specified tightening torque. Name Size Type Lubricant...
  • Page 10 Note: Use only the screws supplied with or re- moved from the guard plates to secure the guard plates. Install guard plates (3), washers (2) and screws (1) on both sides. Tighten screws (1). Fitting the transport locking de- vice on driving end (KS), version Remove screws (1) with washers (2) and take off guard plates (3).
  • Page 11 Note: Only screw on the transport locking device with the screws supplied with or removed from the transport locking device. Secure the two plates (2) with screws (6) and washers (5) at the bores on both sides of the flywheel housing and tighten to the specified tightening torque.

  • Page 12: Safety Requirements For Startup And Operation

    1.5 Safety requirements for startup and operation Safety requirements for startup The product must be installed and accepted in accordance with manufacturers' specifications prior to initial startup. All the requisite regulatory approvals must have been granted and all startup requirements fulfilled prior to initial startup.

  • Page 13: Safety Requirements For Maintenance And Repair Work

    1.6 Safety requirements for maintenance and repair work Safety requirements before commencing maintenance and repair work Have maintenance or repair work carried out by qualified and authorized personnel only. Allow the product to cool down to less than 50°C (risk of explosion for oil vapors, fluids and lubricants, risk of burning).
  • Page 14 Pay particular attention to cleanliness at all times. Safety requirements after completing maintenance and repair work Ensure that all personnel is clear of danger zones before cranking. Check that all access ports/apertures which have been opened to facilitate working are closed again. Check that all safety equipment has been installed and that all tools and loose parts have been re- moved (especially the barring gear).
  • Page 15 Working on electrical/electronic assemblies Always obtain the permission of the duty supervisor before commencing maintenance or repair work or switching off any part of the electronic system required to do so. De-energize the appropriate areas prior to working on assemblies. Avoid damaging cabling during removal.

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

    The latest version can be found on the website on the "Technical Info" or "Spare Parts and Service" tabs at http://www.mtu-online.com. Consumable fluids and materials may also be hazardous or toxic. When using fluids, lubricants, consum- ables and other chemical substances, follow the safety regulations that apply to the product.

  • Page 17: Compressed Air

    Lead • Adopt suitable measures to avoid the formation of lead dust. • Switch on extraction system. • When working with lead or pastes that contain lead, avoid direct contact with the skin. Do not inhale lead vapors. • Wash hands after contact with lead or lead-containing substances. Compressed air Observe special safety precautions when working with compressed air: •...

  • Page 18: Standards For Safety Notices In The Text

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

  • Page 19: General Information

    2 General Information 2.1 Engine side and cylinder designations 1 Left engine side (A-side) 3 Right engine side (B-side) 2 Engine free end in accord- 4 Engine driving end in ac- ance with DIN ISO 1204 cordance with (KGS = Kupplungsgegen- DIN ISO 1204 (KS = Kup- seite) plungsseite)

  • Page 20: Engine Layout

    2.2 Engine layout Engine layout, driving end 1 EGR cooler 7 Air intake 13 Engine lifting equipment 2 Intercooler (low pressure) 8 Cylinder head 14 Flywheel 3 Exhaust turbocharger (high 9 Oil pan 15 Exhaust gas recirculation pressure) 10 Bypass flap system 4 Exhaust turbocharger (low 11 Oil dipstick...
  • Page 21 14 Crankcase breather 4 Charge-air line 10 Engine mounting KGS Free end 5 Additional fuel filter Engine model designation Key to the engine model designation 12 V 4000 T95/T95L/T95R Number of cylinders Cylinder arrangement: V-engine 4000 Series Application: Oil&Gas (onshore)

  • Page 22: Back Pack - Overview

    2.3 Back Pack – Overview Back Pack – Overview 1 Exhaust silencer 4 Air filter 7 Air intake elbow 2 Rain cap 5 Service indicator 8 Exhaust bellows 3 Air filter 6 Combined support for air/ exhaust system 22 | General Information | MS150120/00E 2014-11...

  • Page 23: Sensors And Actuators - Overview

    2.4 Sensors and actuators – Overview 1 XSY12 - Adaption for 2 B13 - Crankshaft speed emergency air shut-off flap (option) MS150120/00E 2014-11 | General Information | 23...
  • Page 24 1 M52 - Bypass flap 4 B90 - Intake air humidity 7 B16 - Coolant pressure 2 B44.2 - Turbocharger B (pressure, temperature) 8 B97 - ESD pressure, cylin- speed 5 B91.3 - Exhaust gas pres- ders B1-B6 3 B88.2 - NOx lambda B side sure 9 B10.2 - Charge-air pres- 6 B50 - Crankcase pressure...
  • Page 25 1 B88.1 - NOx lambda A side 8 B9 - Charge-air tempera- 15 B34.2 - Fuel pressure be- 2 B44.3 - Turbocharger A+B ture fore filter speed 9 XF70 - Water level in fuel 16 B34.1 - Fuel pressure after 3 B4 - Exhaust gas tempera- filter filter...
  • Page 26 1 Y44.1 - Fan control 5 Y44.2 - Fan control, exter- 9 B43 - Charge-air coolant 2 B89 - Lambda probe pressure 3 B44.1 - Turbocharger A 6 B48 - Pressure in HP fuel 10 B26 - Charge-air coolant speed system temperature 4 B5.1 - Lube oil pressure af-...

  • Page 27: Technical Data

    3 Technical Data 3.1 12 V 4000 T95/T95L/T95R engine data Explanation Abbrev. Meaning Reference value: Continuous power Reference value: Fuel stop power Design value Guaranteed value Guideline value Limit value up to which the engine can be operated without change (e.g. of power setting)

  • Page 28: High-Temperature Circuit

    Model related data (basic design) Description 12 V 4000 12 V 4000 12 V 4000 T95L T95R Engine with exhaust turbocharging (ETC) and charge- air cooling (CAC) Uncooled exhaust lines Number of cylinders Cylinder arrangement: V angle grees (°) Bore Stroke Displacement of a cylinder Liters...
  • Page 29 Description 12 V 4000 12 V 4000 12 V 4000 T95L T95R Pressure loss in off-engine cooling system, max. Thermostat: Starts to open °C Thermostat: Fully open °C Lube oil system Description 12 V 4000 12 V 4000 12 V 4000 T95L T95R Lube oil operating temperature before engine, from...
  • Page 30 Capacities Description 12 V 4000 12 V 4000 12 V 4000 T95L T95R Engine coolant, engine side (w/o cooling system) Liters Charge-air coolant, engine side Liters Total engine oil capacity at initial filling (standard oil Liters system) (option: max. operating inclinations) Oil change volume, max.

  • Page 31: Firing Order

    3.2 Firing order Firing order Number of cylinders Firing order A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1 MS150120/00E 2014-11 | Technical Data | 31...

  • Page 32: Engine - Main Dimensions

    3.3 Engine – Main dimensions Engine – Main dimensions Item Dimensions Length (A) approx. 2650 mm Width (B) approx. 1635 mm Height (C) approx. 1948 mm 32 | Technical Data | MS150120/00E 2014-11...

  • Page 33: Operation

    4 Operation 4.1 Putting the engine into operation after extended out-of-service periods (>3 months) Preconditions ☑Engine is stopped and starting disabled. ☑MTU Preservation and Represervation Specifications (A001070/..) are available. Putting into operation after extended out-of-service periods (>3 months) Item Action Engine Depreserve (→...

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

    4.2 Putting the engine into operation after scheduled out-of- service-period Preconditions ☑Engine is stopped and starting disabled. Startup Item Action Lube oil system Check engine oil level (→ Page 163). Coolant circuit Check engine coolant level (→ Page 171); Check charge-air coolant level (→ Page 180). Coolant circuit Heat coolant with coolant preheater (if available;...

  • Page 35: Operational Checks

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

  • Page 36: Starting The Engine In Manual Mode

    4.4 Starting the engine in manual mode Preconditions ☑Engine is not under load. ☑External start interlock is not activated. DANGER Rotating, moving engine parts. Risk of crushing! Risk of body parts being caught or drawn in! • Before barring with the starting system, make sure that no one is in the danger zone of the en- gine.

  • Page 37: Stopping The Engine In Manual Mode

    4.5 Stopping the engine in manual mode Preconditions ☑Engine is not under load. ☑Engine is running in manual mode. NOTICE Stopping the engine in full load operation causes extreme thermal and mechanical stress to the engine. Danger of component damage due to overheating! •...

  • Page 38: After Stopping The Engine - Putting The Engine Out Of Operation

    4.6 After stopping the engine – Putting the engine out of operation Preconditions ☑MTU Preservation and Represervation Specifications (A001070/..) are available. NOTICE Coolant sensors may freeze if there is a risk of frost. Risk of sensor damage! • Protect sensors from frost.

  • Page 39: Plant - Cleaning

    4.7 Plant – Cleaning Preconditions ☑Engine is stopped and starting disabled. ☑Operating voltage is not applied. Special tools, Material, Spare parts Designation / Use Part No. Qty. Steam jet cleaner Cleaner (Hakupur 312) 30390 WARNING Compressed air gun ejects a jet of pressurized air. Risk of injury to eyes and damage to hearing, risk of rupturing internal organs! •...

  • Page 40: Maintenance

    5 Maintenance 5.1 Maintenance task reference table [QL1] The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Maintenance Schedule is a stand-alone publication. The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule.
  • Page 41 Task Maintenance tasks W1577 Check turbine housing externally for cracks, perform endo- (→ Page 137) scopic examination to check it internally for cracks, replace if necessary. W1636 Reset drift correction parameters (CDC) and enter injector (→ Page 195) codes (IIG). W1675 Replace fuel prefilter or fuel prefilter element.

  • Page 42: Troubleshooting

    6 Troubleshooting 6.1 Troubleshooting Engine does not turn when starter is actuated Cause Corrective action u Charge or replace (→ manufacturer's documentation). Battery/UltraCaps low or faulty u Check cable connections for secure seating (→ manufacturer's Cable connections faulty documentation). Starter: Engine cabling, POM or u Check if cable connections are properly secured , contact starter defective.
  • Page 43 Engine governor defective u Contact Service Charge-air temperature too high Cause Corrective action Incorrect coolant concentration u Check (→ MTU test kit) Intercooler dirty u Contact Service Engine room: Air-intake u Check fans and air supply/exhaust ducts. temperature too high...
  • Page 44 Blue exhaust gas Cause Corrective action Too much engine oil in the u Drain engine oil (→ Page 164) engine Oil separator of crankcase u Replace filter (→ Page 115) breather contaminated u Contact Service Exhaust turbocharger, cylinder head, piston rings or cylinder liner defective White exhaust gas Cause...

  • Page 45: Fault Messages Of Engine Control Unit Ecu 9 For Series 4000

    6.2 Fault messages of Engine Control Unit ECU 9 for Series 4000 3 – HI T-Fuel ZKP-Number: 2.0122.931 Fuel temperature too high (limit value 1) Yellow alarm - warning Cause Corrective action Fuel tank may be exposed to 1. Reduce power. heat.
  • Page 46 9 – HI T-Coolant Intercooler ZKP-Number: 2.0124.931 Coolant temperature in intercooler too high (limit value 1) Yellow alarm - warning Cause Corrective action Coolant circuit for charge air 1. Reduce power. faulty. 2. Check intercooler and coolant cooler. 3. Contact Service. 10 –...
  • Page 47 20 – SS T-Exhaust A ZKP-Number: 2.0126.932 Exhaust temperature (A-side) too high (limit value 2) Red alarm - engine shutdown Cause Corrective action Cable damage. 1. Check air filter and wiring (→ Page 194). 2. Contact Service. 21 – HI T-Exhaust B ZKP-Number: 2.0127.931 Exhaust temperature (B-side) too high (limit value 1) Yellow alarm - warning...
  • Page 48 26 – SS P-Diff. Lube Oil ZKP-Number: 2.0154.932 Differential oil pressure at oil filter too high (limit value 2) Red alarm - engine shutdown Cause Corrective action Oil filter not operating correctly. 1. Replace oil filter (→ Page 167). 2. Contact Service. 27 –...
  • Page 49 33 – HI P-Diff. Fuel ZKP-Number: 2.0114.931 Fuel filter differential pressure too high (limit value 1) Yellow alarm - warning Cause Corrective action Fuel filter not operating 1. Replace fuel filter (→ Page 133). correctly. 2. Contact Service. 34 – SS P-Diff. Fuel ZKP-Number: 2.0114.932 Fuel filter differential pressure too high (limit value 2) Red alarm - engine shutdown...
  • Page 50 51 – HI T-Lube Oil ZKP-Number: 2.0125.931 Lube oil temperature too high (limit value 1) Yellow alarm - warning Cause Corrective action Insufficient oil. 1. Reduce power. 2. Check engine oil level (→ Page 163). 3. Contact Service. 52 – SS T-Lube Oil ZKP-Number: 2.0125.932 Lube oil temperature too high (limit value 2) Red alarm - engine shutdown...
  • Page 51 59 – SS T-Coolant L3 ZKP-Number: 2.0120.933 Coolant temperature too high / low (limit value 3) Red alarm - forced idle Cause Corrective action Coolant circuit not operating 1. Activate fan emergency operating mode if required. correctly (e.g. damage, leaks, 2.
  • Page 52 65 – LO P-Fuel ZKP-Number: 2.0102.921 Fuel supply pressure too low (limit value 1) Yellow alarm - warning Cause Corrective action Leaky or obstructed fuel lines or 1. Check fuel lines for leaks. fuel filter. 2. Check filter, fuel on low-pressure side. 3.
  • Page 53 81 – AL System Leaking ZKP-Number: 1.8004.046 Leakage Yellow alarm - warning Cause Corrective action During start: Pressure gradient 1. Check engine for leaks. in rail too low (HP system 2. Contact Service. leaking, air in system). During stop: Pressure gradient 1.
  • Page 54 90 – SS Idle Speed Not Reached ZKP-Number: 2.1090.925 Idle speed not reached Red alarm – warning Cause Corrective action Various causes possible. 1. Observe additional messages. 2. Contact Service. 91 – SS Release Speed Not Reached ZKP-Number: 2.1090.924 Runup speed was not attained Red alarm –...
  • Page 55 95 – AL Priming Fault ZKP-Number: 2.1090.920 Oil priming fault. Yellow alarm - warning Cause Corrective action Priming oil pressure not 1. Check priming system. reached. 2. Contact Service. 102 – AL Fuel Cons. Counter Defect ZKP-Number: 1.8004.624 Fault in fuel checksum Yellow alarm - warning Cause Corrective action...
  • Page 56 120 – HI ECU Supply Voltage ZKP-Number: 2.0140.931 Supply voltage too high (limit value 1) Yellow alarm - warning Cause Corrective action Supply voltage at engine 1. Check engine governor supply voltage. governor too high. 2. Contact Service. 121 – HIHI ECU Supply Voltage ZKP-Number: 2.0140.932 Supply voltage too high (limit value 2) Red alarm - start terminated or engine shutdown...
  • Page 57 180 – AL CAN1 Node Failure ZKP-Number: 2.0500.680 Connection to a node on CAN bus 1 failed Yellow alarm - warning Cause Corrective action Connection to or communication 1. Check devices connected to CAN. with a node at CAN bus 1 has 2.
  • Page 58 184 – AL CAN PU Data Flash Error ZKP-Number: 2.0500.684 CAN PU data flash fault Cause Corrective action u Contact electronic Service. A programming error occurred during attempt to copy a received PU data module to the flash module. 186 – AL CAN1 Bus Off ZKP-Number: 2.0500.686 CAN controller 1 is in "Bus-Off"...
  • Page 59 189 – AL CAN2 Error Passive ZKP-Number: 2.0500.689 CAN controller 2 error Yellow alarm - warning Cause Corrective action Missing associated nodes, minor 1. Check CAN bus for short circuit, rectify short circuit as disruptions or temporary bus required. overload. 2.
  • Page 60 204 – SD Level Lube Oil ZKP-Number: 1.8004.602 Lube oil level sensor signal error Yellow alarm - warning Cause Corrective action Lube oil level sensor faulty. 1. Check sensor and wiring, replace as necessary (→ Page 194). Short circuit or wire break. 2.
  • Page 61 208 – SD P-Charge Air ZKP-Number: 1.8004.566 Charge-air pressure sensor signal error Yellow alarm - warning Cause Corrective action Charge-air pressure sensor 1. Check sensor and wiring (B10), replace as necessary faulty. (→ Page 194). Short circuit or wire break. 2.
  • Page 62 214 – SD P-Crankcase ZKP-Number: 1.8004.568 Crankcase pressure sensor signal error Yellow alarm - warning Cause Corrective action Crankcase pressure sensor 1. Check sensor and wiring (B50), replace as necessary faulty. (→ Page 194). Short circuit or wire break. 2. Fault is corrected after engine is restarted (→ Page 36). 3.
  • Page 63 220 – SD Level Coolant Water ZKP-Number: 1.8004.584 Coolant level sensor signal error Yellow alarm - warning Cause Corrective action Coolant level sensor faulty. 1. Check sensor and wiring (F33), replace as necessary Short circuit or wire break. (→ Page 194). 2.
  • Page 64 227 – SD Oil Pressure Upstream of Filter ZKP-Number: 1.8004.620 Lube oil pressure sensor upstream of filter, signal error Yellow alarm - warning Cause Corrective action Lube oil pressure sensor 1. Check sensor and wiring (B5.3), replace as necessary upstream of filter faulty. (→...
  • Page 65 231 – SD Camshaft Speed ZKP-Number: 1.8004.499 Camshaft sensor signal error Yellow alarm - warning Cause Corrective action Camshaft sensor faulty. 1. Check sensor and wiring (B1), replace as necessary Short circuit or wire break. (→ Page 194). 2. Fault is corrected after engine is restarted (→ Page 36). 3.
  • Page 66 240 – SD P-Fuel ZKP-Number: 1.8004.565 Fuel pressure sensor signal error Yellow alarm - warning Cause Corrective action Fuel pressure sensor faulty. 1. Check sensor and wiring (B34), replace as necessary Short circuit or wire break. (→ Page 194). 2. Fault is corrected after engine is restarted (→ Page 36). 3.
  • Page 67 269 – SD Load P. Analog Filt. ZKP-Number: 2.8006.588 Load pulse analog signal faulty Yellow alarm - warning Cause Corrective action The filtered analog signal of load 1. Check wiring, replace as necessary (→ Page 194). pulse is not present. 2.
  • Page 68 323 – AL Wiring Cylinder A3 ZKP-Number: 1.8004.522 Wiring faulty, cylinder A3 Yellow alarm - misfiring Cause Corrective action Short circuit fault in injector 1. Check injector solenoid valve, replace injector if required wiring, cylinder A3. (→ Page 125). 2. Fault is corrected after engine is restarted (→ Page 36). 3.
  • Page 69 327 – AL Wiring Cylinder A7 ZKP-Number: 1.8004.526 Wiring faulty, cylinder A7 Yellow alarm - misfiring Cause Corrective action Short circuit fault in injector 1. Check injector solenoid valve, replace injector if required wiring, cylinder A7. (→ Page 125). 2. Fault is corrected after engine is restarted (→ Page 36). 3.
  • Page 70 331 – AL Wiring Cylinder B1 ZKP-Number: 1.8004.530 Wiring faulty, cylinder B1 Yellow alarm - misfiring Cause Corrective action Short circuit fault in injector 1. Check injector solenoid valve, replace injector if required wiring, cylinder B1. (→ Page 125). 2. Fault is corrected after engine is restarted (→ Page 36). 3.
  • Page 71 335 – AL Wiring Cylinder B5 ZKP-Number: 1.8004.534 Wiring faulty, cylinder B5 Yellow alarm - misfiring Cause Corrective action Short circuit fault in injector 1. Check injector solenoid valve, replace injector if required wiring, cylinder B5. (→ Page 125). 2. Fault is corrected after engine is restarted (→ Page 36). 3.
  • Page 72 339 – AL Wiring Cylinder B9 ZKP-Number: 1.8004.538 Wiring faulty, cylinder B9 Yellow alarm - misfiring Cause Corrective action Short circuit fault in injector 1. Check injector solenoid valve, replace injector if required wiring, cylinder B9. (→ Page 125). 2. Fault is corrected after engine is restarted (→ Page 36). 3.
  • Page 73 343 – AL Open Load Cylinder A3 ZKP-Number: 1.8004.542 Injector wiring fault, cylinder A3 Yellow alarm - misfiring Cause Corrective action Disruption fault in injector 1. Check injector wiring for disruption. wiring, cylinder A3. 2. Rule out any disruption in injector solenoid valve, replace injector if required (→...
  • Page 74 347 – AL Open Load Cylinder A7 ZKP-Number: 1.8004.546 Injector wiring fault, cylinder A7 Yellow alarm - misfiring Cause Corrective action Disruption fault in injector 1. Check injector wiring for disruption. wiring, cylinder A7. 2. Rule out any disruption in injector solenoid valve, replace injector if required (→...
  • Page 75 351 – AL Open Load Cylinder B1 ZKP-Number: 1.8004.550 Injector wiring fault, cylinder B1 Yellow alarm - misfiring Cause Corrective action Disruption fault in injector 1. Check injector wiring for disruption. wiring, cylinder B1. 2. Rule out any disruption in injector solenoid valve, replace injector if required (→...
  • Page 76 355 – AL Open Load Cylinder B5 ZKP-Number: 1.8004.554 Injector wiring fault, cylinder B5 Yellow alarm - misfiring Cause Corrective action Disruption fault in injector 1. Check injector wiring for disruption. wiring, cylinder B5. 2. Rule out any disruption in injector solenoid valve, replace injector if required (→...
  • Page 77 359 – AL Open Load Cylinder B9 ZKP-Number: 1.8004.558 Injector wiring fault, cylinder B9 Yellow alarm - misfiring Cause Corrective action Disruption fault in injector 1. Check injector wiring for disruption. wiring, cylinder B9. 2. Rule out any disruption in injector solenoid valve, replace injector if required (→...
  • Page 78 363 – AL Stop Injector Output Stage ZKP-Number: 1.8004.560 Internal electronics fault. Red alarm - engine shutdown Cause Corrective action Electronics possibly faulty. 1. Start ITS. 2. Replace engine governor. 3. Check additional fault messages if ITS indicates "Electronics OK" (e.g. wiring faulty). 4.
  • Page 79 383 – AL Wiring TOP 3 ZKP-Number: 2.8006.640 Line disruption on digital input 3 Yellow alarm - warning Cause Corrective action u Check wiring to plant. Short circuit or broken wire on transistor output 3, plant side (TOP 3). 384 – AL Wiring TOP 4 ZKP-Number: 2.8006.641 Line disruption on digital input 4 Yellow alarm - warning...
  • Page 80 401 – AL Open Load Digital Input 2 ZKP-Number: 2.8006.626 Line disruption on digital input 2 Yellow alarm - warning Cause Corrective action Wiring faulty. 1. Check wiring (→ Page 194). No resistance over switch. 2. Check target device input. 3.
  • Page 81 405 – AL Open Load Digital Input 6 ZKP-Number: 2.8006.630 Line disruption on digital input 6 Yellow alarm - warning Cause Corrective action Wiring faulty. 1. Check wiring (→ Page 194). No resistance over switch. 2. Check target device input. 3.
  • Page 82 410 – LO U-PDU ZKP-Number: 2.0141.921 Injector voltage too low (limit value 1) Yellow alarm - warning Cause Corrective action Cable damage or faulty power 1. Check wiring (→ Page 194). supply. 2. Check power supply. 3. Contact Service. 411 – LOLO U-PDU ZKP-Number: 2.0141.922 Injector voltage too low (limit value 2) Red alarm - engine shutdown...
  • Page 83 414 – HI Water Level Fuel Prefilter ZKP-Number: 2.0156.931 Water level in fuel prefilter too high (limit value 1) Yellow alarm - warning Cause Corrective action u Drain fuel prefilter. Water content in fuel too high. Water ingress in fuel tank. 415 –...
  • Page 84 439 – HI P-Fuel 2 (Common Rail) ZKP-Number: 2.0116.931 Rail pressure > set value Red alarm - DBR fuel limitation, start of injection readjusted towards late Cause Corrective action u Contact Service. HP fuel block jamming or HP fuel control block wiring faulty. 441 –...
  • Page 85 448 – HI P-Charge Air ZKP-Number: 2.0103.931 Charge-air pressure too high (limit value 1) Yellow alarm - warning Cause Corrective action u Contact Service. Fault at turbine bypass flap. 449 – SS P-Charge Air ZKP-Number: 2.0103.932 Charge-air pressure too high (limit value 2) Red alarm - engine shutdown Cause Corrective action...
  • Page 86 466 – SD T-AUX 2 ZKP-Number: 1.8004.586 Signal fault, temperature Aux 2 Yellow alarm - warning Cause Corrective action Analog input for Aux 2 1. Check temperature sensor and wiring, replace as necessary temperature faulty. (→ Page 194). Short circuit or wire break. 2.
  • Page 87 472 – AL Stop SD ZKP-Number: 2.8006.593 Engine stops Red alarm - engine shutdown Cause Corrective action Engine stop, since all shutdown 1. Check wiring (→ Page 194). channels detect "sensor defect". 2. Contact Service. 474 – AL Wiring FO ZKP-Number: 2.8006.655 Wiring fault at FO Yellow alarm - warning...
  • Page 88 479 – AL Red Summary Alarm (Plant) ZKP-Number: 2.8006.002 Red summary alarm from system Red alarm Cause Corrective action u Observe additional messages. Various causes possible. 480 – AL Ext. Engine Protection ZKP-Number: 2.0291.921 External engine protection function active Yellow alarm - warning Cause Corrective action The external engine protection...
  • Page 89 491 – SS ETC4 Overspeed ZKP-Number: 2.3015.932 Speed of the 3rd secondary turbocharger too high (limit value 2) Red alarm - engine shutdown Cause Corrective action u Reduce power. Obstructed charge-air circuit or fault in turbocharger. 500 – AL Wiring POM Starter 1 ZKP-Number: 1.4500.900 Wiring faulty, connection of starter 1 at POM Yellow alarm - warning...
  • Page 90 504 – AL CAN POM Node Failure ZKP-Number: 1.4500.904 POM missing on CAN bus Yellow alarm - warning Cause Corrective action u Check connection and POM. If alarm 508 also appears, the resistance in the POM wiring is missing. 506 – AL Starter Voltage Too Low ZKP-Number: 1.4500.906 The battery voltage is too low for the starting process Yellow alarm - warning...
  • Page 91 514 – Flash memory write error ZKP-Number: 1.8004.611 Value was not transferred to flash memory Cause Corrective action u Contact Service. Flash memory faulty. 515 – AL Starter Not Engaged ZKP-Number: 2.1090.926 Yellow alarm – start termination possible Cause Corrective action Starter on POM could not be 1.
  • Page 92 558 – AL Wiring PWM_CM2 ZKP-Number: 1.1041.922 Wiring problem at PWM_CM2 channel Yellow alarm - warning Cause Corrective action Broken cable or short circuit at 1. Check wiring to connected device or check connected device channel PWM_CM2. itself (actuator/sensor) and replace if necessary (→ Page 194). 2.
  • Page 93 582 – AL Emergency Stop Failed ZKP-Number: 1.1005.006 Emergency stop command was not executed Flashing pre-alarm and alarm Cause Corrective action u Contact Service. Engine speed does not come to a stop within a parameterizable time. 586 – LO P-Oil Replenishment Pump ZKP-Number: 2.0159.911 Oil pressure in replenishment pump too low (limit value 1) Yellow alarm - warning...
  • Page 94 594 – AL L1 PRV Faulty ZKP-Number: 1.1301.900 Yellow alarm – warning pressure relief valve, first rail Cause Corrective action u Contact Service. HP fuel block jamming or HP fuel control block wiring faulty. 595 – AL L2 PRV Faulty ZKP-Number: 1.1301.901 Red alarm –...
  • Page 95 599 – AL L2 PRV Faulty ZKP-Number: 1.1302.901 Red alarm breather valve, second rail. Cause Corrective action HP fuel block jamming or HP 1. Check wiring and HP fuel control block (→ Page 194). fuel control block wiring faulty. 2. Contact Service. 600 –...
  • Page 96 608 – AL Wiring PWM_CM6 ZKP-Number: 1.1041.926 Wiring problem at PWM_CM6 channel Yellow alarm - warning Cause Corrective action Cable break or short circuit on 1. Check wiring to connected device or check connected device channel PWM_CM6. itself (actuator/sensor) and replace if necessary (→ Page 194). 2.
  • Page 97 612 – AL Wiring Pressure Regulating Valve 1 ZKP-Number: 1.1301.903 Wiring faulty, pressure regulating valve 1 Yellow alarm - warning Cause Corrective action Cable break or short circuit on 1. Check wiring (→ Page 194). PWM channel, pressure 2. Contact Service. regulating valve 1.
  • Page 98 625 – SD P-Fuel Upstream of Add. Filter ZKP-Number: 1.8004.600 Fuel pressure sensor before additional filter signal error Yellow alarm - warning Cause Corrective action Analog input signal for fuel 1. Check pressure transmitter and wiring, replace as necessary pressure before additional filter (→...
  • Page 99 629 – AL EGR Shutoff Flap A Defect ZKP-Number: 1.0700.011 EGR shutoff flap A faulty Yellow alarm - warning Cause Corrective action Actuator fault at exhaust gas 1. Replace actuator or flap. recirculation shutoff flap A or 2. Contact Service. flap mechanical system is defective.
  • Page 100 633 – SD P-Ambient Air (HDT2800) ZKP-Number: 1.0700.087 Moisture sensor signal error (TRICAN HDT2800) Yellow alarm - warning Cause Corrective action Moisture sensor (TRICAN 1. Check sensor and wiring, replace as necessary (→ Page 194). HDT2800) defective. 2. Contact Service. 634 –...
  • Page 101 640 – SD Smart NOx Oxidation Factor O2 ZKP-Number: 1.0700.145 Signal error, Smart NOx Sensor (Oxidation Factor O2) Yellow alarm - warning Cause Corrective action Smart NOx sensor (oxidation 1. Check sensor and wiring, replace as necessary (→ Page 194). factor O2) faulty.
  • Page 102 647 – SD P-Exhaust Lambda ZKP-Number: 1.0163.900 Exhaust gas sensor near lambda sensor signal error Yellow alarm - warning Cause Corrective action Exhaust gas sensor near lambda 1. Check sensor and wiring (B91), replace as necessary sensor faulty (→ Page 194). Short circuit or wire break.
  • Page 103 727 – AL L1 Delta T-NT Intercooler ZKP-Number: 2.1075.901 T-max. coolant intercooler has exceeded L1 Yellow alarm - warning Cause Corrective action Coolant circuit for charge air 1. Reduce power. faulty. 2. Check intercooler and coolant cooler. 3. Contact Service. 728 –...
  • Page 104 754 – SD Bosch LSU Lambda Sensor ZKP-Number: 1.0800.990 Signal fault, Lambda sensor Yellow alarm - warning Cause Corrective action Bosch Lambda sensor faulty. 1. Check sensors and wiring, replace as necessary (→ Page 194). Short circuit or wire break. 2.
  • Page 105 766 – AL EASF A to B Open ZKP-Number: 1.2510.127 Emergency-air shutoff flap A closed, but emergency-air shutoff flap B remained open Cause Corrective action u Check flap B (→ Page 152). Flap B stuck. Flap B was not energized. Check wiring (→...
  • Page 106 834 – AL Gas Line Warning ZKP-Number: 2.1600.010 Gas line warning Cause Corrective action Lambda sensor faulty. 1. Delete all other fault codes. Lambda regulator at stop. 2. Check sensor and wiring (→ Page 194). 3. Contact Service. 835 – AL Gas Line Fault ZKP-Number: 2.1600.012 Gas line fault Cause...

  • Page 107: Task Description

    7 Task Description 7.1 Engine 7.1.1 Engine – Barring manually Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring gear F6792918 Barring gear F6555766 Ratchet with extension F30006212 DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...
  • Page 108 Note: Use barring gear F6555766. Engage barring gear (2) in ring gear of fly- wheel and mount on flywheel housing. Fit ratchet (1) on barring gear. Note: No resistance other than compression re- sistance may be encountered. Rotate crankshaft in engine direction of ro- tation.

  • Page 109: Barring Engine With Starting System

    7.1.2 Barring engine with starting system DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Before barring the engine, make sure that there are no persons in the engine's danger zone. •...

  • Page 110: Engine - Test Run

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

  • Page 111: Cylinder Liner

    7.2 Cylinder Liner 7.2.1 Cylinder liner – Endoscopic examination Preconditions ☑Engine is stopped and starting disabled Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring device F6555766 Ratchet with extension F30006212 Endoscope Y20097353 Preparatory steps Remove cylinder head cover (→ Page 121). Remove injector (→...
  • Page 112 Compile endoscopic report using the table. Use technical terms to describe the liner surface (→ Page 113). Depending on findings: • Do not take any action or • carry out a further endoscopic examination as part of maintenance work or •...

  • Page 113: Instructions And Comments On Endoscopic And Visual Examination Of Cylinder Liners

    7.2.2 Instructions and comments on endoscopic and visual examination of cylinder liners Terms used for endoscopic examination Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic ex- amination report. Findings Explanations/Action Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing products, particles, broken-off burrs).
  • Page 114 Evaluation of findings and further measures The findings in the start phase of oxidation discoloration and heat discoloration are similar. A thorough investigation and compliance with the above evaluation criteria allow an unambiguous evaluation. To avoid unnecessary disassembly work, it is recommended that another inspection be carried out after further operation of the engine.

  • Page 115: Crankcase Breather

    7.3 Crankcase Breather 7.3.1 Oil mist fine separator – Replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10-60 Nm F30452769 Engine oil Oil mist fine separator (→ Spare Parts Catalog) Sealing ring (→...
  • Page 116 Unscrew locknut (1) and remove together with washer (2). Remove filter cover (3), cover (4) and seal- ing ring (5). Remove threaded rod (6). Replace oil mist fine separator (7). Replace sealing ring (5) if necessary. Remove sealing ring (5), cover (4) and filter cover (3).

  • Page 117: Valve Drive

    7.4 Valve Drive 7.4.1 Valve gear – Lubrication Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil Valve gear – Lubrication Remove cylinder head upper section (→ Page 121). Fill oil chambers of valve bridges with oil.

  • Page 118: Valve Clearance - Check And Adjustment

    7.4.2 Valve clearance – Check and adjustment Preconditions ☑Engine is stopped and starting disabled. ☑Coolant temperature max. 40 °C. ☑Valves are closed. Special tools, Material, Spare parts Designation / Use Part No. Qty. Feeler gage Y20098771 Allen key F30002815 Torque wrench, 60-320 Nm F30452768 Socket wrench, 24 mm F30039526...

  • Page 119: Adjusting Valve Clearance

    Diagram for 12 V engines (two crankshaft positions) 1 Cylinder A1 is in firing TDC 2 Cylinder A1 is in overlap TDC I Inlet valve X Exhaust valve Checking valve clearance at two crankshaft positions Check OT/TDC position of piston in cylinder A1: •...
  • Page 120 Final steps Remove barring device (→ Page 107). Install cylinder head upper section (→ Page 121). Enable engine start. 120 | Task Description | MS150120/00E 2014-11...

  • Page 121: Cylinder Head Cover - Removal And Installation

    7.4.3 Cylinder head cover – Removal and installation Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 4-20 Nm F30044239 Assembly compound (Kluthe Hakuform 30-15) X00067260 Sealing ring (→ Spare Parts Catalog) Removing cylinder head cover Clean very dirty cylinder head cover upper section (2) prior to removal.
  • Page 122 Installing cylinder head cover Clean mounting surface. Check sealing ring (1) for damage, replace if necessary. Coat sealing ring (1) with assembly com- pound. Place sealing ring (1) and cylinder head cover lower section (2) onto cylinder head. Install cylinder head cover lower section (2) with screws (4, 5) and washers (3, 6).

  • Page 123: Injection Pump / Hp Pump

    7.5 Injection Pump / HP Pump 7.5.1 HP pump – Filling with engine oil Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil WARNING Fuels are combustible. Risk of fire and explosion! •...
  • Page 124 Filling HP pump Remove plug screw (1). Use pump oiler to fill HP pump with engine oil until engine oil emerges. Screw in plug screw (1). 124 | Task Description | MS150120/00E 2014-11...

  • Page 125: Injector

    7.6 Injector 7.6.1 Injector – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Injector (→ Spare Parts Catalog) Injector – Replacement Remove injector and install new one (→ Page 126). MS150120/00E 2014-11 | Task Description | 125...

  • Page 126: Injector - Removal And Installation

    • Do not smoke. Nameplate 1 DMC - Data Matrix Code 2 Serial number 3 L'Orange part number 4 MTU part number 5 EIM-ID Preparatory steps Shut off fuel supply to engine. Remove cylinder head cover (→ Page 121). 126 | Task Description | MS150120/00E 2014-11...
  • Page 127 Removing injector Disconnect connectors on injector (arrow). Unscrew union nuts (2, 5) and remove HP line (3) from rail (4) and cylinder head. Note: While the adapter is removed, the injector is drained. Provide suitable container to collect escap- ing fuel. Remove adapter (1).
  • Page 128 Install installation/removal jig (2) on cylin- der head. Remove injector (1) and hold-down clamp with puller (2). Remove puller (2). Remove O-rings (2, 3) and damper ring from injector (1). Clean all mating and sealing surfaces. If carbon residue is present, clean sealing face on cylinder head and protective sleeve with milling cutter.
  • Page 129 Note: New sealing rings are included in the scope of delivery of the injector. Fit new O-rings (2, 3) and damper ring on injector (1) and coat with assembly com- pound. Insert injector (1) together with hold-down clamp into cylinder head, ensuring that the high-pressure fuel line connection is aligned correctly.
  • Page 130 Insert screw (2) and use torque wrench to tighten to specified initial tightening torque. Name Size Type Lubricant Value/Standard Screw Preload torque (Engine oil) 5 Nm to 10 Nm Note: Ensure special cleanness. Coat thread and sealing cone of adapter (1) with engine oil.
  • Page 131 Install return line (6) and tighten union nuts. Fit connectors on injector. Note: If the CDC parameters are not reset, the emission certification of the engine be- comes invalid. Reset CDC parameters (→ Page 195). Final steps Install cylinder head cover (→ Page 121). Open fuel supply to engine.

  • Page 132: Fuel System

    7.7 Fuel System 7.7.1 Fuel system – Venting Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel WARNING Fuels are flammable and explosive. Danger to life! Risk of burns! •...

  • Page 133: Fuel Filter

    7.8 Fuel Filter 7.8.1 Fuel filter – Replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Engine oil Easy-change filter (→ Spare Parts Catalog) WARNING Fuels are flammable and explosive. Danger to life! Risk of burns! •...

  • Page 134: Additional Fuel Filter - Replacement

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

  • Page 135: Fuel Prefilter - Draining

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

  • Page 136: Fuel Prefilter - Filter Element Replacement

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

  • Page 137: Exhaust Turbocharger

    7.9 Exhaust Turbocharger 7.9.1 Exhaust turbocharger – Turbine housing check Special tools, Material, Spare parts Designation / Use Part No. Qty. Turbine housing (→ Spare Parts Catalog) Exhaust turbocharger (low-pressure charger) Check turbine housing (→ Page 138). Exhaust turbocharger (high pressure) Check turbine housing (→...

  • Page 138: Exhaust Turbocharger (Lp) - Turbine Housing Check

    7.9.2 Exhaust turbocharger (LP) – Turbine housing check Preconditions ☑Engine is stopped and starting disabled. ☑MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Endoscope Y20097353 Torque wrench, 10-60 Nm...
  • Page 139 Remove screws (1) and take off with hold- er (2) and washers. Remove screws (3) and take off with hold- er (4) and washers. Remove screws (2, 3) and take off with heat shield (1) and washers. Removing exhaust elbow Note: Mark position of clamp.
  • Page 140 Clamp Tightening torque (Assembly paste (Ul- 27 Nm +2 Nm tra-Therm MTU)) Coat threads of screw (4) with assembly paste prior to installation. Install screws (4) and spacer sleeves (5) on console and tighten to specified tightening torque. Name Size...
  • Page 141 Installing heat shield Install heat shield (1) with washers and screws (2, 3) and tighten to specified tightening torque. Name Size Type Lubricant Value/Standard Screws Tightening torque (Engine oil) 42 Nm +4 Nm Install holder (4) with washers and screws (3) and washers and tighten. Install holder (2) with washers and screws (1) and washers and tighten.
  • Page 142 Install retainers (4) and lashing plate (2). Install spacer sleeves (3) and screws (1) and tighten. 142 | Task Description | MS150120/00E 2014-11...

  • Page 143: Exhaust Turbocharger (Hp) - Turbine Housing Check

    7.9.3 Exhaust turbocharger (HP) – Turbine housing check Preconditions ☑Engine is stopped and starting disabled. ☑MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10-60 Nm F30452769 Torque wrench, 60-320 Nm...
  • Page 144 Remove screws (1) and take off with hold- er (2) and washers. Remove screws (2) and take off with heat shield (1) and washers. Removing exhaust pipe insula- tion Release clamps (1) and remove insula- tion (2). 144 | Task Description | MS150120/00E 2014-11...
  • Page 145 Removing exhaust pipe Release clamp (2) and take off with ex- haust pipe (3) and sealing ring (1) from tur- bine housing. Removing insulation of exhaust pipe bellows Release clamps (1) and remove insulation (2). Checking turbine housing Note: Cracks are only permissible in the direction of circumference of the spiral.
  • Page 146 Tighten nut of clamp (2) with torque wrench to specified tightening torque. Name Size Type Lubricant Value/Standard Tightening torque (Assembly paste (Ul- 27 Nm +2 Nm tra-Therm MTU)) Installing exhaust pipe insula- tion Install insulation (2) on exhaust pipe and secure with clamps (1). 146 | Task Description | MS150120/00E 2014-11...
  • Page 147 Installing heat shield Install heat shield (1) with washers and screws (2) and tighten to specified tightening torque. Name Size Type Lubricant Value/Standard Screws Tightening torque (Engine oil) 42 Nm +4 Nm Install holder (2) with washers and screws (1) and washers and tighten. MS150120/00E 2014-11 | Task Description | 147...
  • Page 148 Install retainers (4) and lashing plate (2). Install spacer sleeves (3) and screws (1) and tighten. 148 | Task Description | MS150120/00E 2014-11...

  • Page 149: Charge-Air Cooling

    7.10 Charge-Air Cooling 7.10.1 Intercooler – Leak check DANGER Rotating, moving engine parts. Risk of crushing! Risk of body parts being caught or drawn in! • Take special care when the engine is running. • Stay well clear of danger zones at the engine. WARNING Loud engine noises with the engine running: Risk of hearing damage!

  • Page 150: Air Filter

    7.11 Air Filter 7.11.1 Air filter – Replacement Preconditions ☑Engine is stopped and starting disabled. Air filter – Replacement Release latches (1). Remove cover (2). Remove filter insert (3) and filter ele- ment (4). Wipe out filter housing (5) and cover (2) with a damp cloth.

  • Page 151: Air Intake

    7.12 Air Intake 7.12.1 Service indicator – Signal ring position check Preconditions ☑Engine is stopped and starting disabled. Checking signal ring position If the signal ring is completely visible in the control window (2), replace air filter (→ Page 150). After installation of new filter, press reset button (1).

  • Page 152: Emergency Air-Shutoff Flaps - Functional Check With Electric Actuation

    7.12.2 Emergency air-shutoff flaps – Functional check with electric actuation DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Before cranking the engine with starter system, make sure that there are no persons in the en- gine's danger zone.
  • Page 153 Option 2: Check function while engine is stopped Check both emergency-air shutoff flaps and their wiring for mechanical damage. Make sure that the pointers (1) of both emergency-air shutoff flaps are pointing to OPEN / ON and the emergency-air shutoff flaps are open.

  • Page 154: Exhaust Gas Recirculation

    7.13 Exhaust Gas Recirculation 7.13.1 Exhaust flaps – Overview 1 EGR shutoff flap 2 Donor cylinder flap 154 | Task Description | MS150120/00E 2014-11...
  • Page 155 1 Bypass flap MS150120/00E 2014-11 | Task Description | 155...

  • Page 156: Exhaust Flaps - Checking Coupling Rods Operability And Play

    7.13.2 Exhaust flaps – Checking coupling rods operability and play Preconditions ☑Engine is stopped and starting disabled. ☑Operating voltage is not applied. WARNING Exhaust flaps / air flaps close rapidly. Risk of crushing! • Using a suitable tool, check exhaust flaps / air flaps by pressing the actuating linkage to its limit several times and releasing it.
  • Page 157 Check operability and ease of movement of coupling rod (1) by moving it at the speci- fied points (arrows) and make sure that there is no excessive play. Result: Replace coupling rod (1) if it is jamming, sluggish or features excessive play (→...

  • Page 158: Replacement

    Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 6-50 Nm F30027336 Ratchet adapter F30027340 Assembly paste (Ultra-Therm MTU) 50547 Coupling rod (→ Spare Parts Catalog) Coupling rod (→ Spare Parts Catalog) Locknut (→ Spare Parts Catalog) Locking screw (→...
  • Page 159 Size Type Lubricant Value/Standard Nut / screw Tightening torque (Assembly paste (Ul- 6 Nm + 2 Nm tra-Therm MTU)) Tighten washers (1) and locknuts (2) to the specified tightening torque. Name Size Type Lubricant Value/Standard Tightening torque (Assembly paste (Ul- 16 Nm ±...
  • Page 160 Note: Following each change to the mechanism of the exhaust recirculation system, an actuator test (teach-in routine) with DiaSys® must be carried out. (→ Page 196). 160 | Task Description | MS150120/00E 2014-11...

  • Page 161: Starting Equipment

    7.14 Starting Equipment 7.14.1 Starter – Condition check Preconditions ☑Engine is stopped and starting disabled. Checking starter condition Check securing screws of starter for secure seating and tighten if required. Check wiring (→ Page 194). MS150120/00E 2014-11 | Task Description | 161...
  • Page 162 7.15 Lube Oil System, Lube Oil Circuit 7.15.1 Engine oil level – Check at sight glass Preconditions ☑Engine is stopped and starting disabled. Engine oil level check at sight glass Make a preliminary visual check of oil lev- el (2) at the sight glass (1). A proper engine oil level check must al- ways be carried out using the oil dipstick (→...
  • Page 163 7.15.2 Engine oil – Level check with oil dipstick Checking oil level prior to en- gine start Pull out dipstick from guide tube and wipe Insert dipstick into guide tube up to the stop, pull out after approx. 10 seconds. Check oil level on oil dipstick side marked "5 Min.
  • Page 164 7.15.3 Engine oil – Change Preconditions ☑Engine is stopped and starting disabled. ☑Engine is at operating temperature. ☑MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 40-200 Nm...
  • Page 165 Draining residual oil from equip- ment carrier (only with unsched- uled engine oil change) Provide a suitable container in which to col- lect the engine oil. Remove drain plug (1) and drain engine oil from engine oil heat exchanger and from engine oil filter.
  • Page 166 7.15.4 Engine oil – Sample extraction and analysis Preconditions ☑MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. MTU test kit 5605892099/00 DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...
  • Page 167 7.16 Oil Filtration / Cooling 7.16.1 Engine oil filter – Replacement Preconditions ☑Run engine to reach operating temperature. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Engine oil Oil filter (→ Spare Parts Catalog) Sealing ring (→...
  • Page 168 Remove engine oil filter using the filter wrench. Clean sealing surface on connecting piece. Note: Only install engine oil filter with an integrat- ed safety valve. Check condition of the new oil filter sealing ring and coat it with engine oil. Screw the engine oil filter on and tighten by hand.
  • Page 169 7.16.2 Centrifugal oil filter and filter sleeve – Cleaning and replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Torque wrench, 6-50 Nm F30027336 Ratchet adapter F30027339 Cold cleaner (Hakutex 60) 50602 Grease (Kluthe Hakuform 30-10/Emulgier)
  • Page 170 Cleaning centrifugal oil filter and replacing filter sleeve Release screw (1) and remove. Remove clamp (3) and take off cover (2). Carefully remove rotor assemble (12) from housing (5). Hold rotor assembly (12) firmly in position with filter wrench and release knurled nut (13).
  • Page 171 7.17 High-Temperature Circuit 7.17.1 Engine coolant – Level check Preconditions ☑Engine is stopped and starting disabled. ☑MTU Fluids and Lubricants Specifications (A001061/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down.
  • Page 172 7.17.2 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change Drain engine coolant (→ Page 173). Fill with engine coolant (→ Page 175). 172 | Task Description | MS150120/00E 2014-11...
  • Page 173 7.17.3 Engine coolant – Draining Preconditions ☑Engine is stopped and starting disabled. WARNING Coolant is hot and highly pressurized. Risk of injury! Risk of scalding! • Allow engine to cool down. • Wear protective clothing, protective gloves, and safety glasses / facial protection. Preparatory steps Provide a suitable container to collect the coolant.
  • Page 174 Drain remaining engine coolant at EGR cooler, A and B side (arrow). Final steps Close all open drain points. Fit cover on filler neck and close it. 174 | Task Description | MS150120/00E 2014-11...
  • Page 175 7.17.4 Engine coolant – Filling Preconditions ☑Engine is stopped and starting disabled. ☑MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine coolant WARNING Coolant is hot and highly pressurized.
  • Page 176 Filling with engine coolant using pump Connect appropriate pump with hose to drain valve (1). Open vent points on EGR cooler (1, 8), dis- tributors (2, 5), exhaust turbochargers (3, 4, 7) and oil heat exchanger (6). Open drain valve and pump coolant into en- gine at 0.5 bar minimum.
  • Page 177 Alternatively: Filling with cool- ant through filler neck Open vent points on EGR cooler (1, 8), dis- tributors (2, 5), exhaust turbochargers (3, 4, 7) and oil heat exchanger (6). Fill engine coolant in expansion tank via fill- er neck until coolant level at top edge of filler neck remains constant.
  • Page 178 7.17.5 Engine coolant pump – Relief bore check DANGER Rotating, moving engine parts. Risk of crushing! Risk of body parts being caught or drawn in! • Take special care when the engine is running. • Stay well clear of danger zones at the engine. WARNING Loud engine noises with the engine running: Risk of hearing damage!
  • Page 179 7.17.6 Engine coolant – Sample extraction and analysis Preconditions ☑MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. MTU test kit 5605892099/00 DANGER Rotating, moving engine parts. Risk of crushing! Risk of body parts being caught or drawn in! •...
  • Page 180 7.18 Low-Temperature Circuit 7.18.1 Charge-air coolant – Level check Preconditions ☑Engine is stopped and starting disabled. ☑MTU Fluids and Lubricants Specifications (A001061/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down.
  • Page 181 7.18.2 Charge-air coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Charge-air coolant – Change Drain charge-air coolant (→ Page 182). Fill with charge-air coolant (→ Page 185). MS150120/00E 2014-11 | Task Description | 181...
  • Page 182 7.18.3 Charge-air coolant – Draining Preconditions ☑Engine is stopped and starting disabled. ☑Operating voltage is not applied. ☑MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Sealing ring (→ Spare Parts Catalog) WARNING Component is hot.
  • Page 183 Drain remaining charge-air coolant at inter- cooler (high pressure) (arrow). Drain remaining charge-air coolant at inter- cooler (low pressure) A-side (arrows). Drain remaining charge-air coolant at inter- cooler (low pressure) B-side (arrow). MS150120/00E 2014-11 | Task Description | 183...
  • Page 184 Note: • The procedure is only described for one exhaust flap, but also applies to the re- maining exhaust flaps. Exhaust flap over- view (→ Page 154). • Collect emerging engine coolant in a suitable container. Loosen the union nut (4) of the lower cool- ant line (3).
  • Page 185 7.18.4 Charge-air coolant – Filling Preconditions ☑Engine is stopped and starting disabled. ☑MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Charge-air coolant WARNING Coolant is hot and highly pressurized.
  • Page 186 Filling with engine coolant through filler neck Open vent points at intercooler (high pres- sure) (4), intercooler (low pressure) (1, 3) and distributor (2, ). Fill in charge-air coolant at expansion tank via filler neck until coolant level at top edge of filler neck remains constant.
  • Page 187 Open vent points at intercooler (high pres- sure) (4), intercooler (low pressure) (1, 3) and distributor (2, ). Open drain valve and pump charge-air cool- ant into engine at 0.5 bar minimum. Fill expansion tank until overflow edge is reached. Close drain valve.
  • Page 188 7.18.5 Checking charge-air coolant pump pressure relief port DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running.

  • Page 189: Belt Drive

    7.19 Belt Drive 7.19.1 Drive belt – Condition check Preconditions ☑Engine is stopped and starting disabled. ☑Guard is removed. Drive belt – Condition check Item Findings Action Drive belt A Singular cracks None Drive belt B Cracks on entire circumference Replace (→...
  • Page 190 7.20 Battery-Charging Generator 7.20.1 Checking battery-charging generator Preconditions ☑Engine is stopped and starting disabled. WARNING Air jet from compressed-air gun. Risk of injury to eyes and organs! Risk of hearing damage! • Never direct a compressed-air jet at persons. • Wear goggles/safety mask and ear protectors. Checking battery-charging generator Item Findings...
  • Page 191 7.20.2 Battery-charging generator drive – Drive belt tension adjustment Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 60-320 Nm F30452768 Ratchet F30027341 Torque wrench, 10-60 Nm F30452769 Ratchet F30027340 WARNING Spring/circlip/tensioning roller preload.
  • Page 192 7.20.3 Battery-charging generator drive – Drive belt replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 60-320 Nm F30452768 Ratchet F30027341 Torque wrench, 10-60 Nm F30452769 Ratchet F30027340 Drive belt (→...
  • Page 193 7.21 Engine Mounting / Support 7.21.1 Engine mounting – Check Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 80 to 400 Nm F30027338 Ratchet F30027341 Engine oil Checking general condition Item Findings Action...
  • Page 194 7.22 Wiring (General) for Engine/Gearbox/Unit 7.22.1 Еngine cabling ‒ Check Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Solvent (isopropyl alcohol) X00058037 Еngine cabling ‒ Check Check securing screws of cable clamps on engine and tighten loose threaded connections. Ensure that cables are fixed in their clamps and cannot swing freely.
  • Page 195 7.23 Accessories for (Electronic) Engine Governor / Control System 7.23.1 Resetting CDC parameter and entering IIG with DiaSys® Preconditions ☑Engine is stopped and starting disabled. Note: If the parameters for the drift correction (CDC) are not reset, the emission certification becomes invalid. Resetting parameters for drift correction (CDC) with DiaSys®...
  • Page 196 7.23.2 Actuators – Visual inspection and test Preconditions ☑Engine is stopped and starting disabled. WARNING Exhaust flaps close automatically. Danger of crushing hands! • Keep clear of the danger zone around the exhaust flaps when calibrating. • Switch off the Engine Control Unit operating voltage when performing mechanical tests. •...
  • Page 197 Item Findings Action Connector (1) Damaged Replace Actuator cable connection (2) Damaged, protective cap not seat- Replace, fit protective cap correct- ed correctly. Actuator general condition Heavily contaminated by black ex- Replace haust. Checking actuators with DiaSys® Note: For installation position of exhaust flaps, refer to overview (→ Page 154). Switch on ECU.
  • Page 198 7.23.3 Engine governor and connectors – Cleaning Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Solvent (isopropyl alcohol) X00058037 Note: Always use test connectors to enter the connectors. Never use test leads for this purpose. Otherwise the contacts could be bent.
  • Page 199 7.23.4 Engine governor plug connections – Check Preconditions ☑Engine stopped and starting disabled. NOTICE Insertion of unsuitable test probe, e.g. test prod. The contacts in the plug connection can be bent! • Carry out check of plug connection only with test connectors. Checking plug connections at engine governor Check all plug connections for secure seating.
  • Page 200 7.23.5 NOx sensor – Replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10-60 Nm F30452769 Ratchet F30027340 Assembly compound (Molykote P 37) 50564 NOx sensor (→ Spare Parts Catalog) WARNING Component is hot.
  • Page 201 Installing NOx sensor Note: Note the following: • If the sensor (3) was subjected to shock or impact load, it is considered to be de- fective and may not be used. • Always replace NOx sensor (3) together with control unit (1). Install control unit (1) at the eyelets.
  • Page 202 7.23.6 Lambda sensor – Replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10-60 Nm F30452769 Ratchet adapter F30027340 Assembly compound (Molykote P 37) 50564 Lambda sensor (→ Spare Parts Catalog) WARNING Component is hot.
  • Page 203 Installing Lambda sensor Note: If the sensor was subjected to shock or im- pact load, it is considered to be defective and may not be used. Remove protective cap on thread only just before installation. Note: Do not wipe off the thread lubricant applied by the manufacturer.

  • Page 204: Exhaust System

    7.24 Exhaust System 7.24.1 Exhaust silencer – Condensate drain check Preconditions ☑Engine is stopped and starting disabled. Exhaust silencer – Condensate drain check Provide a suitable container to collect the condensate. Open drain plug (1). Allow the condensate to drain off. Close drain plug (1).
  • Page 205 7.24.2 Back Pack – Visual inspection of securing screws Preconditions ☑Engine is stopped and starting disabled. Back Pack – Visual inspection of securing screws Item Findings Measure Check securing screws for damage and de- Damaged, deformation visi- Replace formation. ble. MS150120/00E 2014-11 | Task Description | 205...
  • Page 206 7.24.3 Back Pack – Checking securing screws for firm seating Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10-60 Nm F30452769 Torque wrench, 60-320 Nm F30452768 Check securing screws for firm seating Check-tighten securing screws (1).
  • Page 207 Check-tighten securing screws (1). Name Size Type Lubricant Value/Standard Screw M10x50 Tightening torque 79 Nm MS150120/00E 2014-11 | Task Description | 207...
  • Page 208 Abgasturbolader Exhaust turbocharger (ETC) Air Temperature Sensor Baureihe Series Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Publica- tion No. A01061/.. Controller Area Network Data bus system, bus standard Calibration Drift Compensation Drift correction setting with DiaSys in engine gover- Check Engine Light...
  • Page 209 Abbre- Meaning Explanation viation Engine Data Module Memory module for engine data Electrically Erasable Programmable Read PROM Only Memory EFPA Electronic Foot Pedal Assembly Electronic accelerator pedal Exhaust Gas Recirculation Engine Ident Label EIM-ID Emission Identification Number Engine Monitoring Unit ESCM Extreme Site Condition Management Power reduction with extreme site conditions...
  • Page 210 Abbre- Meaning Explanation viation Not Applicable Normalnull Reference area for heights above sea level Original Equipment Manufacturer Optimized Idle Oil Level Sensor Monitors oil level Oil Pressure Sensor Monitors oil pressure Oil Temperature Sensor Monitors oil temperature Oberer Totpunkt Top Dead Center (TDC) Panel Control panel Peripheral Interface Module...
  • Page 211 Local support Experienced and qualified specialists place their knowledge and expertise at your disposal. For locally available support, go to the MTU Internet site: http://www.mtu-online.com 24h hotline With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist you –...

  • Page 212: Special Tools

    9 Appendix B 9.1 Special Tools Allen key Part No.: F30002815 Qty.: Used in: 7.4.2 Valve clearance – Check and adjustment (→ Page 118) Barring device Part No.: F6555766 Qty.: Used in: 7.2.1 Cylinder liner – Endoscopic examination (→ Page 111) Barring gear Part No.: F6792918...
  • Page 213 Barring gear Part No.: F6555766 Qty.: Used in: 7.1.1 Engine – Barring manually (→ Page 107) Endoscope Part No.: Y20097353 Qty.: Used in: 7.2.1 Cylinder liner – Endoscopic examination (→ Page 111) Qty.: Used in: 7.9.2 Exhaust turbocharger (LP) – Turbine housing check (→...
  • Page 214 7.6.2 Injector – Removal and installation (→ Page 126) Milling cutter Part No.: F30452739 Qty.: Used in: 7.6.2 Injector – Removal and installation (→ Page 126) MTU test kit Part No.: 5605892099/00 Qty.: Used in: 7.15.4 Engine oil – Sample extraction and analysis (→ Page 166) Qty.:...
  • Page 215 Ratchet Part No.: F30450902 Qty.: Used in: 7.15.3 Engine oil – Change (→ Page 164) Ratchet Part No.: F30027340 Qty.: Used in: 7.20.2 Battery-charging generator drive – Drive belt tension adjustment (→ Page 191) Qty.: Used in: 7.20.3 Battery-charging generator drive – Drive belt re- placement (→...
  • Page 216 Ratchet with extension Part No.: F30006212 Qty.: Used in: 7.1.1 Engine – Barring manually (→ Page 107) Qty.: Used in: 7.2.1 Cylinder liner – Endoscopic examination (→ Page 111) Socket for lambda sensor / NOx sensor Part No.: F30453932 Qty.: Used in: 7.9.2 Exhaust turbocharger (LP) –...
  • Page 217 Torque wrench, 0.5-5 Nm Part No.: 0015384230 Qty.: Used in: 7.6.2 Injector – Removal and installation (→ Page 126) Torque wrench, 10-60 Nm Part No.: F30452769 Qty.: Used in: 1.4 Crankshaft transport locking device (→ Page 8) Qty.: Used in: 7.3.1 Oil mist fine separator –...
  • Page 218 Torque wrench, 300-800 Nm Part No.: F30047798 Qty.: Used in: 7.15.3 Engine oil – Change (→ Page 164) Torque wrench, 4-20 Nm Part No.: F30044239 Qty.: Used in: 7.4.3 Cylinder head cover – Removal and installation (→ Page 121) Torque wrench, 40-200 Nm Part No.: F30027337 Qty.:...
  • Page 219 Torque wrench, 60-320 Nm Part No.: F30452768 Qty.: Used in: 1.4 Crankshaft transport locking device (→ Page 8) Qty.: Used in: 7.4.2 Valve clearance – Check and adjustment (→ Page 118) Qty.: Used in: 7.6.2 Injector – Removal and installation (→ Page 126) Qty.: Used in: 7.9.2 Exhaust turbocharger (LP) –...
  • Page 220 9.2 Index Cylinder head cover  – Removal and installation  121 Abbreviations 208 Cylinder liner  Actuators  – Endoscopic examination  111 – Function test  196 – Instructions and comments on endoscopic and visual – Overview  23 examination  113 – Visual inspection  196 Additional fuel filter  –...
  • Page 221 Engine oil filter  – Replacement  167 Maintenance schedule  Engine oil level  – Maintenance task reference table [QL1]  40 – Check at sight glass  162 MTU contact persons 211 – Check with oil dipstick  163 Engine sides  – Designation  19 NOx sensor  Exhaust flaps ...
  • Page 222 Sensors  – Overview  23 – Replacement   – Lambda  202 – NOx  200 Service indicator  – Signal ring position check  151 Service partners 211 Spare parts service 211 Starter  – Condition check  161 Technical data 27 transport 7 Transport locking device  – Installation   –...

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