MTU 12 V 1600 R50 Operating Instructions Manual
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MTU 12 V 1600 R50 Operating Instructions Manual

MTU 12 V 1600 R50 Operating Instructions Manual

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Operating Instructions

Diesel engine
12 V 1600 R50
MS15033/02E

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Summary of Contents for MTU 12 V 1600 R50

  • Page 1: Operating Instructions

    Operating Instructions Diesel engine 12 V 1600 R50 MS15033/02E...
  • Page 2 All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen GmbH reserves the right to change, delete or supplement the information provided as and when required.

  • Page 3: Table Of Contents

    Table of Contents 1 Safety 7.1.2 Cylinder head cover – Removal and installation 1.1 Important provisions for all products 7.2 Fuel System 1.2 Personnel and organizational requirements 7.2.1 Fuel system – Venting 1.3 Transportation 7.3 Fuel Filter 1.4 Safety regulations for startup and operation 1.5 Safety regulations for maintenance and 7.3.1 Fuel filter –...
  • Page 4 7.14 Accessories for (Electronic) Engine 8.2 MTU contact persons/service partners Governor / Control System 7.14.1 Injector functions 9 Appendix B 7.14.2 Engine governor and connectors – Cleaning 9.1 Special Tools 7.14.3 Engine governor – Checking plug-in 9.2 Index connections 7.14.4 NOx sensor – Replacement 7.14.5 Lambda sensor –...

  • 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 Replacing components with emission labels Emission labels are attached to all MTU engines. These must remain on the engine throughout its op- erational life. Engines used exclusively in land-based, military applications other than by US government agencies are excepted from this proviso.

  • Page 7: Personnel And Organizational Requirements

    1.2 Personnel and organizational requirements Organizational measures of the user/manufacturer 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 8: Transportation

    Only set down engine on a firm, level surface. Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate. Never set an engine down on the oil pan unless expressively authorized to do so by MTU on a case-to- case basis .

  • Page 9: Safety Regulations For Startup And Operation

    1.4 Safety regulations for startup and operation Safety requirements for startup Install the product correctly and carry out acceptance in accordance with the manufacturer's specifica- tions before putting the product into service. All necessary approvals must be granted by the relevant authorities and all requirements for initial startup must be fulfilled.

  • Page 10: Safety Regulations For Maintenance And Repair Work

    1.5 Safety regulations for maintenance and repair work Safety regulations prior to maintenance and repair work Have maintenance or repair work carried out by qualified and authorized personnel only. Allow the product to cool down to less than 50 °C (risk of explosion for oil vapors, fluids and lubricants, risk of burning).
  • Page 11 Ensure that all retainers and dampers are installed correctly. Ensure that O-rings are not installed ina slanted/twisted condition. Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent contact with other components. Do not place fuel or oil lines near hot components. Do not touch elastomeric seals (e.g.
  • Page 12 Working with batteries Observe the safety instructions of the battery manufacturer when working with batteries. Gases released from the battery are explosive. Avoid sparks and naked flames. Do not allow electrolyte to come into contact with skin or clothing. Wear protective clothing, goggles and protective gloves. Do not place tools on the battery.

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

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

  • Page 14: Compressed Air

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

  • Page 15: Standards For Safety Notices In The Text

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

  • Page 16: 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 17: Engine Overview

    2.2 Engine overview 1 Exhaust outlet 9 Fuel filter 17 Engine governor 2 Air intake 10 Thermostat housing 18 Oil pan 3 Intermediate intercooler 11 Oil filter 19 Exhaust elbow 4 Lifting eye, driving end 12 EGR flap before EGR cool- 20 Flywheel housing 5 Intermediate intercooler 21 Coupling...

  • Page 18: Sensors And Actuators - Overview

    2.3 Sensors and actuators – Overview Description Item Name B48.1 Fuel pressure in HP system, HP line, left side Charge-air pressure B5.1 Lube oil pressure after filter B9.3 Charge-air temperature after exhaust gas recirculation, right side B9.1 Charge-air temperature before exhaust gas recirculation B9.2 Charge-air temperature after exhaust gas recirculation, left side...
  • Page 19 Description Item Name Humidity, pressure, temperature of intake air B91.3 Exhaust gas pressure B48.2 Fuel pressure in HP system, HP line, right side Charge air coolant temperature Lube oil level and temperature (option) EIL (Engine Ident Label) Camshaft speed MS15033/02E 2015-02 | General Information | 19...
  • Page 20 Description Item Name B44.3 Speed of LP turbocharger, left side B44.4 Speed of LP turbocharger, right side B44.2 Exhaust turbocharger (high pressure) speed, right side M52.2 Bypass flap of HP turbocharger, right side Crankcase pressure (option) B4.22 Exhaust temperature, ritght side Crankshaft speed B44.1 Speed of HP turbocharger, left side...
  • Page 21 Description Item Name M53.2 EGR shut-off flap before cooler, right side Lube oil temperature M53.1 EGR shut-off flap before cooler, left side B34.1 Fuel pressure after filter B34.2 Fuel pressure before filter (option) B6.3 Engine coolant temperature in cylinder head MS15033/02E 2015-02 | General Information | 21...

  • Page 22: Technical Data

    3 Technical Data 3.1 Firing order 12 V A1–B2–A5–B4–A3–B1–A6–B5–A2–B3–A4–B6 Direction of rotation Direction of rotation (as viewed on driving c.c.w., not reversible end) 22 | Technical Data | MS15033/02E 2015-02...

  • Page 23: Engine - Main Dimensions

    3.2 Engine – Main dimensions Dimensions Item Length (B) approx. 1871 mm Width (C) approx. 1228 mm Height (A) approx. 1327 mm MS15033/02E 2015-02 | Technical Data | 23...

  • Page 24: 12V1600R50 Product Data

    3.3 12V1600R50 product data Legend DL Ref. value: Continuous power. Continuously attainable power at standard conditions. BL Ref. value: Fuel stop power. Maximum engine power. Not continuously attainable in some appli- cations (margin for load fluctuations). A Design value. Value is used for the design of an external system (plant). R Guideline value.
  • Page 25 Model-related data (basic design) Number of cylinders Cylinder arrangement: V-angle Degrees (°) Bore Stroke Displacement, cylinder Liters 1.75 Displacement, total Liters Compression ratio 17.7 Number of inlet valves per cylinder Number of exhaust valves per cylinder Combustion air / exhaust gas Exhaust temperature after turbocharger °C Coolant system (high-temperature circuit)
  • Page 26 Engine oil capacity, initial filling (standard oil system) (Option: max. operating Liters inclinations) Oil change quantity, max. (standard oil system )(Option: max. operating incli- Liters nations) Oil pan capacity at dipstick mark “min.” (standard oil system) (Option: max. Liters operating inclinations) Oil pan capacity at dipstick mark “max.”...

  • Page 27: Operation

    4 Operation 4.1 Putting the engine into operation after scheduled out-of- service-period Preconditions ☑Engine is stopped and starting disabled. Startup Action Item Lube oil system Check engine oil level (→ Page 97). Coolant circuit Check engine coolant level (→ Page 100); Check charge-air coolant level (→...

  • Page 28: Putting The Engine Into Operation After Extended Out-Of-Service Periods (>3 Months)

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

  • Page 29: Starting The Engine

    4.3 Starting the engine Preconditions ☑Engine is not connected to load. ☑External start interlock is not active. DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Before cranking the engine with starter system, make sure that there are no persons in the en- gine's danger zone.

  • Page 30: Operational Checks

    4.4 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 31: Engine - Stop

    4.5 Engine – Stop Preconditions ☑Engine is not connected to load NOTICE Stopping the engine when it is running at full load subjects it to extreme thermal and mechanical stresses. Overheating of and, therefore, damage to components is possible! • Before shutting down the engine, allow it to idle until the engine temperatures decrease and constant levels are indicated.

  • Page 32: After Stopping The Engine

    Air intake and exhaust sys- Out-of-service-period > 1 week: tems • Seal engine's air and exhaust gas openings. Out-of-service-period > 1 month: • Carry out engine preservation (→ MTU Preservation and Represervation Specifications A001070/..). 32 | Operation | MS15033/02E 2015-02...

  • Page 33: Plant - Cleaning

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

  • Page 34: Engine - Barring Manually

    4.8 Engine – Barring manually Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring device F6790714 Barring device F6797426 Adapter F30011619 Ratchet adapter F30027340 DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...
  • Page 35 Engage barring device (1) in ring gear and install on flywheel housing (2). Fit adapter and ratchet adapter on barring device. Rotate crankshaft in engine direction of ro- tation. Apart from the normal compression resistance, there should be no resistance. For barring device removal, follow reverse sequence of working steps.

  • Page 36: 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 37: 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 low or faulty u Check if cable connections are properly secured Battery: Cable connections faulty (→ manufacturer's documentation). Starter: Engine cabling or starter u Check if cable connections are properly secured, contact faulty...
  • Page 38 Engine governor defective u Contact Service. Charge air temperature too high Cause Corrective action Engine coolant treatment u Check (MTU test kit). incorrect u Contact Service. Intercooler clogged Engine room: Air-intake u Check fans and intake/exhaust lines. temperature too high...
  • Page 39 White exhaust gas Cause Corrective action Engine is not at operating u Run engine to reach operating temperature. temperature Water in fuel u Check fuel system on fuel prefilter; Drain fuel prefilter (→ Page 91). u Contact Service. Intercooler leaky MS15033/02E 2015-02 | Troubleshooting | 39...

  • Page 40: Fault Messages Of Engine Governor Ecu

    6.2 Fault messages of engine governor ECU 9 for Series 1600, rail applications 3 – HI T-Fuel ZKP-Number: 2.0122.931 Yellow alarm; warning Cause Corrective action Fuel temperature too high. u Reduce power. 4 – SS T-Fuel (Limit 2) ZKP-Number: 2.0122.932 Red alarm;...
  • Page 41 10 – SS T-Coolant Intercooler (Limit 2) ZKP-Number: 2.0124.932 Yellow alarm; power limitation < 20%; Cause Corrective action Coolant temperature in 1. Reduce power. intercooler too high. 2. Check engine lines for leaks. Check coolant cooler for leaks, contamination and operation. 3.
  • Page 42 21 – HI T-Exhaust B ZKP-Number: 2.0127.931 Yellow alarm; warning Cause Corrective action Exhaust gas temperature (B- 1. Reduce power. side) too high. 2. Check air filter. 3. Request towing locomotive if required. 22 – SS T-Exhaust B ZKP-Number: 2.0127.932 Red alarm;...
  • Page 43 31 – HI ETC1 Overspeed (Limit 1) ZKP-Number: 2.3011.931 Yellow alarm; power limitation > 20% Cause Corrective action ETC 1 (A-side) speed too high. 1. Reduce power. 2. Check air filter. 3. Check exhaust pipe visually for leaks. 4. Request towing locomotive if required. 32 –...
  • Page 44 37 – SS ETC2 Overspeed (Limit 2) ZKP-Number: 2.3013.912 Red alarm; power reduction ≥ 20% Cause Corrective action ETC 2 (B-side) speed too high. 1. Reduce power. 2. Check air filter. 3. Check exhaust pipe visually for leaks. 4. Request towing locomotive if required. 51 –...
  • Page 45 60 – SS T-Coolant (Limit 4) ZKP-Number: 2.0120.934 Red alarm; engine stop Cause Corrective action Coolant temperature too high. 1. Allow engine to cool down. 2. Check engine coolant cooler, clean if dirty. 3. Acknowledge alarm. 4. Restart engine (→ Page 29). 5.
  • Page 46 67 – HI T-Coolant (Limit 1) ZKP-Number: 2.0120.931 Yellow alarm; warning Cause Corrective action Coolant temperature too high. 1. Reduce power. 2. Check engine coolant cooler, clean if dirty. 68 – SS T-Coolant (Limit 2) ZKP-Number: 2.0120.932 Yellow alarm; power limitation < 20%; Cause Corrective action Coolant temperature too high.
  • Page 47 90 – SS Idle Speed Not Reached ZKP-Number: 2.1090.925 Yellow alarm; warning Cause Corrective action Idle speed not reached. 1. Check battery. 2. Check wiring and voltage supply. 3. Initiate new starting attempt. 4. Request towing locomotive if required. 91 – SS Release (Run up)Speed Not Reached (< ~300 RPM) ZKP-Number: 2.1090.924 Yellow alarm;...
  • Page 48 94 – LO T-Preheat ZKP-Number: 2.1090.921 Yellow alarm; warning Cause Corrective action Preheating temperature too low; 1. Extend preheating period. coolant temperature too low for 2. Check preheating unit. engine start. Excessive engine wear. Engine start might be inhibited by the locomotive control system.
  • Page 49 120 – HI ECU Power Supply Voltage ZKP-Number: 2.0140.931 Yellow alarm; warning Cause Corrective action u Check engine governor supply voltage. Supply voltage too high. 121 – HIHI ECU Power Supply Voltage (Limit 2) ZKP-Number: 2.0140.932 Red alarm; engine stop Cause Corrective action Supply voltage too high.
  • Page 50 182 – AL CAN Wrong Parameters ZKP-Number: 2.0500.682 Yellow alarm; warning Cause Corrective action u Contact Service. Incorrect parameter values entered in data record. 183 – AL CAN No PU-Data ZKP-Number: 2.0500.683 Yellow alarm; warning Cause Corrective action The selected CAN mode 1.
  • Page 51 188 – AL CAN2 Bus Off ZKP-Number: 2.0500.688 Yellow alarm; warning Cause Corrective action CAN controller 2 is in "Bus-Off" 1. Check CAN bus for short circuit, rectify short circuit as status. Automatic changeover to necessary. CAN 1; short circuit; massive 2.
  • Page 52 205 – SD T-Coolant Intercooler ZKP-Number: 1.8004.574 Yellow alarm; warning Cause Corrective action u Check sensor B26 and wiring, replace as necessary Intercooler coolant temperature sensor faulty; short circuit or (→ Page 119). wire break. 206 – SD T-Exhaust A ZKP-Number: 1.8004.576 Yellow alarm;...
  • Page 53 214 – SD P-CrankCase ZKP-Number: 1.8004.568 Yellow alarm; warning Cause Corrective action u Check sensor B50 and wiring, replace as necessary Crankcase pressure sensor faulty; short circuit or wire (→ Page 119). break. 215 – SD P-HD High Pressure Fuel ZKP-Number: 1.8004.567 Yellow alarm;...
  • Page 54 227 – SD P-Lube Oil before Filter ZKP-Number: 1.8004.620 Yellow alarm; warning Cause Corrective action u Check sensor B5.3 and wiring, replace as necessary Sensor for lube oil pressure before filter faulty; short circuit (→ Page 119). or wire break. 228 –...
  • Page 55 232 – SD Charger 1 Speed ZKP-Number: 1.3011.128 Yellow alarm; warning Cause Corrective action u Check sensor B44.1 and wiring, replace as necessary Speed sensor of primary turbocharger faulty; short circuit (→ Page 119). or wire break. 233 – SD Charger 2 Speed ZKP-Number: 1.3011.129 Yellow alarm;...
  • Page 56 266 – SD Speed Demand ZKP-Number: 2.8006.586 Red alarm; forced idle Cause Corrective action Analog nominal speed setting 1. Check wiring (→ Page 119). faulty; short circuit or wire 2. Check speed setting. break. 3. Contact Service. 270 – SD Frequency Input ZKP-Number: 2.8006.590 Red alarm;...
  • Page 57 324 – AL Wiring Cylinder A4 ZKP-Number: 1.8004.523 Yellow alarm; warning Cause Corrective action u Check solenoid valve. Short circuit in cylinder injector wiring. Result: Misfiring. 325 – AL Wiring Cylinder A5 ZKP-Number: 1.8004.524 Yellow alarm; warning Cause Corrective action u Check solenoid valve.
  • Page 58 334 – AL Wiring Cylinder B4 ZKP-Number: 1.8004.533 Yellow alarm; warning Cause Corrective action u Check solenoid valve. Short circuit in cylinder injector wiring. Result: Misfiring. 335 – AL Wiring Cylinder B5 ZKP-Number: 1.8004.534 Yellow alarm; warning Cause Corrective action u Check solenoid valve.
  • Page 59 344 – AL Open Load Cylinder A4 ZKP-Number: 1.8004.543 Yellow alarm; warning Cause Corrective action u Check solenoid valve. Open circuit in cylinder injector wiring. Result: Misfiring. 345 – AL Open Load Cylinder A5 ZKP-Number: 1.8004.544 Yellow alarm; warning Cause Corrective action u Check solenoid valve.
  • Page 60 354 – AL Open Load Cylinder B4 ZKP-Number: 1.8004.553 Yellow alarm; warning Cause Corrective action u Check solenoid valve. Open circuit in cylinder injector wiring. Result: Misfiring. 355 – AL Open Load Cylinder B5 ZKP-Number: 1.8004.554 Yellow alarm; warning Cause Corrective action u Check solenoid valve.
  • Page 61 363 – AL Stop Power Stage ZKP-Number: 1.8004.560 Red alarm; engine stop Cause Corrective action Internal electronic fault, 1. Check wiring (→ Page 119). electronics possibly faulty. 2. Acknowledge alarm. 3. Restart engine. 4. Request towing locomotive if required. 365 – AL Stop MV-Wiring Ground (Injector Amplifier Ground) ZKP-Number: 1.8004.561 Red alarm;...
  • Page 62 384 – AL Wiring TOP 4 ZKP-Number: 2.8006.641 Yellow alarm; warning Cause Corrective action u Check wiring to plant (→ Page 119). Short circuit or wire break on transistor output 4 plant-side (TOP 4). 408 – AL Open Load Emerg. Stop Input ESI ZKP-Number: 2.8006.633 Yellow alarm;...
  • Page 63 413 – HIHI U-PDU (Injector Voltage) (Limit 2 ZKP-Number: 2.0141.932 Red alarm; engine stop Cause Corrective action Injector voltage too high. 1. Check wiring (→ Page 119). 2. Check supply. 3. Acknowledge alarm. 4. Restart engine. 5. Request towing locomotive if required. 414 –...
  • Page 64 439 – HI P-Fuel 2 (Common Rail) ZKP-Number: 2.0116.931 Red alarm; power reduction ≥ 20% Cause Corrective action u Contact Service. Rail pressure above desired value; DBR reduction. HP fuel control block faulty, short circuit or wire break. 441 – AL Rail 2 Leakage ZKP-Number: 1.8004.047 Yellow alarm;...
  • Page 65 454 – SS Power Reduction Active ZKP-Number: 2.7000.011 CAN message Cause Corrective action Alarm is only available as a 1. Observe any other messages. separate CAN message, power 2. Determine and rectify cause of power reduction. reduction is active. 467 – AL L2 T-Aux 1 ZKP-Number: 2.0130.922 Red alarm;...
  • Page 66 476 – AL Crash Rec. Init. Error (Occurs when ADEC has power) ZKP-Number: 1.8010.007 Yellow alarm; warning Cause Corrective action u Check setting with DiaSys. Initialization error of crash recorder. 478 – AL Comb. Alarm Yel (Plant) ZKP-Number: 2.8006.001 Yellow alarm; warning Cause Corrective action u Observe any other messages.
  • Page 67 502 – AL Open Load POM Alternator ZKP-Number: 1.4500.902 Yellow alarm; warning Cause Corrective action u Check connection between POM and battery-charging A line interruption was detected at the battery-charging generator. generator connection for the POM. 503 – AL Battery Not Charging ZKP-Number: 1.4500.903 Yellow alarm;...
  • Page 68 510 – AL Override applied ZKP-Number: 2.7002.010 No alarm, fault is entered Cause Corrective action u Deactivate Override. Override Acknowledged 515 – Al Starter Not Engaged ZKP-Number: 2.1090.926 Yellow alarm; warning Cause Corrective action Starter on POM could not be 1.
  • Page 69 551 – SS Engine Overspeed Camshaft ZKP-Number: 2.2510.933 Red alarm; engine stop Cause Corrective action Engine overspeed - camshaft 1. Acknowledge alarm. 2. Restart engine (→ Page 29). 3. Request towing locomotive if required. 558 – AL Wiring PWM_CM2 ZKP-Number: 1.1041.922 Yellow alarm;...
  • Page 70 596 – AL Develop PR Set ZKP-Number: 1.8004.645 Yellow alarm; warning Cause Corrective action u Contact Service. Standard production data record available. The data record stored is for testing. 598 – AL L1 UDV Defekt Rail 2 ZKP-Number: 1.1302.900 Yellow alarm; warning Cause Corrective action Pressure relief valve of second...
  • Page 71 606 – AL Double Nodes Lost CAN 1+2 ZKP-Number: 2.0500.691 Red alarm; forced idle Cause Corrective action No communication between 1. Check wiring and power supply of plant. ADEC and PAU. 2. Acknowledge alarm. 3. Restart engine (→ Page 29). 4.
  • Page 72 628 – AL Wiring PWM_CM10 ZKP-Number: 1.1041.930 Yellow alarm; warning Cause Corrective action u Check wiring to connected device or check connected device Wire break or short circuit on channel PWM_CM10. (actuator/sensor), replace if necessary. 629 – AL AGR Throttle A Defect ZKP-Number: 1.0700.011 Yellow alarm;...
  • Page 73 634 – SD T0-Ambient Air (HDT2800) ZKP-Number: 1.0700.089 Yellow alarm; warning Cause Corrective action u Check sensor B90 and wiring, replace as necessary. T0 ambient air HDT2800 CAN temperature sensor faulty; short circuit or wire break. 635 – SD Air Humidity (HDT2800) ZKP-Number: 1.0700.091 Yellow alarm;...
  • Page 74 647 – SD P-Exhaust Lambda ZKP-Number: 1.0163.900 Yellow alarm; warning Cause Corrective action Exhaust pressure sensor near 1. Check sensor B91.3 and wiring, replace as necessary. lambda sensor faulty; short 2. Restart engine (→ Page 29). circuit or wire break. 648 –...
  • Page 75 728 – AL L2 Delta T-NT Intercooler ZKP-Number: 2.1075.903 No alarm, fault is entered Cause Corrective action T-Max. Coolant Intercooler 1. Reduce power. Exceeded L2. 2. Check intercooler and coolant cooler. 3. Check charge-air coolant circuit. 745 – AL Emission Fault ZKP-Number: 2.1600.004 Red alarm;...
  • Page 76 797 – AL HIHI T-Charge Air B ZKP-Number: 2.0146.932 Yellow alarm; power limitation < 20%; Cause Corrective action Charge-air temperature too high. 1. Reduce power. 2. If fault code number 9 is signaled at the same time, then it has priority.
  • Page 77 834 – AL Gas Path Warning ZKP-Number: 2.1600.010 Yellow alarm; warning Cause Corrective action Gas path warning alarm. 1. Check flap control. 2. Check sensors. 835 – AL Gas Path Fault ZKP-Number: 2.1600.012 Red alarm; power reduction ≥ 20% Cause Corrective action Gas path fault alarm.
  • Page 78 851 – External Start and HD too high ZKP-Number: 1.1026.901 Red alarm; power reduction ≥ 20% Cause Corrective action u Stop engine. Excessive pressure in HP fuel system when the engine is Restart. starting Repeat the process if necessary. 855 – AL Bypass Throttle 2 Defect ZKP-Number: 1.0700.841 Yellow alarm;...
  • Page 79 878 – AL Bypass B Fast learn failed ZKP-Number: 1.0700.851 Yellow alarm; warning Cause Corrective action u Replace actuator or flap. Actuator at bypass flap or flap mechanism faulty. 898 – AL Trican Communication Lost ZKP-Number: 1.0700.099 Yellow alarm; warning Cause Corrective action Wire break or sensor faulty.
  • Page 80 953 – AL Lambda value invalid ZKP-Number: 1.1600.903 Yellow alarm; warning Cause Corrective action Invalid Lambda value. 1. Check if coolant temperature (HT coolant circuit) is > 60 °C. 2. If fault code number 754 is output at the same time, replace Lambda sensor.
  • Page 81 958 – AL Lambda ctrlvar limit min active ZKP-Number: 1.1600.913 Yellow alarm; warning Cause Corrective action u Contact Service. Internal engine fault. 959 – AL Lambda ctrlvar max BOI min act ZKP-Number: 1.1600.915 Yellow alarm; warning Cause Corrective action u Contact Service. Internal engine fault.
  • Page 82 964 – AL GPS p5 ctrlvar min active ZKP-Number: 1.1600.925 Yellow alarm; warning Cause Corrective action u Contact Service. Internal engine fault. 973 – AL Check Sum IIG ZKP-Number: 1.1025.902 Yellow alarm; warning Cause Corrective action u Contact Service. Wrong injector code. 1024 –...

  • Page 83: Task Description

    7 Task Description 7.1 Valve Drive 7.1.1 Valve clearance – Check and adjustment Preconditions ☑Engine is stopped and starting disabled. ☑Engine coolant temperature is max. 40 °C. ☑Valves are closed. Special tools, Material, Spare parts Designation / Use Part No. Qty.
  • Page 84 Checking valve clearance ‒ Variant (A) Check TDC position of piston in cylinder A1: • If rocker arms on cylinder A1 are unloaded, the piston is in firing TDC. • If rocker arms on cylinder A1 are loaded, the piston is in overlap TDC. Check valve clearance with cold engine: •...

  • Page 85: Adjusting Valve Clearance

    Adjusting valve clearance Loosen locknut (1) and unscrew adjusting screw (2) by a few threads. Insert feeler gauge between valve bridge and rocker arm (3). Readjust adjusting screw (2) so that the feeler gauge just passes through the gap. Tighten locknut (1) with torque wrench to specified torque, holding adjusting screw (2) firm with Allen screw.

  • Page 86: Cylinder Head Cover - Removal And Installation

    7.1.2 Cylinder head cover – Removal and installation Preconditions ☑Engine is stopped and starting disabled. Removing and installing cylin- der head cover Note: Cover the engine beneath the cylinder head with rags to soak up escaping residual oil. Remove screws (2). Remove cylinder head cover (1).

  • Page 87: Fuel System

    7.2 Fuel System 7.2.1 Fuel system – Venting Preconditions ☑Engine is stopped and starting disabled. ☑Engine cooled down to ambient temperature. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 4–20 Nm F30044239 Ratchet adapter F30027340 WARNING Fuels are combustible.
  • Page 88 Venting fuel filter Unlock fuel priming pump, unscrew han- dle (arrow). Provide a suitable container in which to col- lect the fuel. Note: Do not remove threaded vent plug. Open threaded vent plug (arrow). Screw in threaded vent plug (arrowed) and tighten to specified torque using a torque wrench. Name Size Type...

  • Page 89: Fuel Filter

    7.3 Fuel Filter 7.3.1 Fuel filter – Replacement Preconditions ☑Engine is stopped and starting disabled. ☑Engine cooled down to ambient temperature. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 4–20 Nm F30044239 Torque wrench, 20–100 Nm F30026582 Ratchet adapter F30027340...
  • Page 90 Vent fuel system (→ Page 87). 90 | Task Description | MS15033/02E 2015-02...

  • Page 91: Fuel Prefilter - Drain Condensate

    7.3.2 Fuel prefilter – Drain condensate Preconditions ☑Engine is stopped and starting disabled. WARNING Fuels are combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Draining condensate from fuel prefilter Provide a suitable container to collect the water.

  • Page 92: Fuel Prefilter - Filter Element Replacement

    7.3.3 Fuel prefilter – Filter element replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 8–40 Nm F30043446 Ratchet adapter F30027340 Diesel fuel Filter element (→ Spare Parts Catalog) Sealing ring (→...

  • Page 93: Air Filter

    7.4 Air Filter 7.4.1 Air filter element – Removal and installation (optional) Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Sealing (→ Spare Parts Catalog) Air filter element – Removal and installation Release latches (9).

  • Page 94: Air Filter Element And (Optional) Dust Bowl - Cleaning

    7.4.2 Air filter element and (optional) dust bowl ‒ Cleaning Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Sealing (→ Spare Parts Catalog) 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 95: Air Filter - Replacement (Option)

    7.4.3 Air filter – Replacement (option) Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Air filter (→ Spare Parts Catalog) Replacing air filter Remove air filter and install new one (→ Page 93). Reset signal ring of service indicator (→...

  • Page 96: Air Intake

    7.5 Air Intake 7.5.1 Service indicator – Signal ring position check Preconditions ☑Engine is stopped and starting disabled. Checking signal ring position Replace air filter if the signal ring (2) is completely visible in the red area of the ob- servation window (3) (→...

  • Page 97: Lube Oil System, Lube Oil Circuit

    7.6 Lube Oil System, Lube Oil Circuit 7.6.1 Engine oil level – Check Preconditions ☑Engine is stopped and starting disabled. Checking oil level prior to en- gine start Withdraw oil dipstick (arrow) from guide tube and wipe it. Insert oil dipstick (arrow) into guide tube up to the stop, withdraw after approx.

  • Page 98: Engine Oil - Change

    7.6.2 Engine oil – Change Preconditions ☑Engine is stopped and starting disabled. ☑Engine is at operating temperature. ☑MTU Fluids and Lubricants Specifications (A001063/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil WARNING Hot oil.

  • Page 99: Oil Filtration / Cooling

    7.7 Oil Filtration / Cooling 7.7.1 Engine oil filter – Replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 8–40 Nm F30043446 Ratchet adapter F30027340 Socket, 32 mm F30006120 Engine oil Oil filter element...

  • Page 100: Coolant Circuit, General, High-Temperature Circuit

    7.8 Coolant Circuit, General, High-Temperature Circuit 7.8.1 Engine coolant – Level check Preconditions ☑Engine is stopped and starting disabled. ☑MTU Fluids and Lubricants Specifications (A001063/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down.

  • Page 101: Engine Coolant Change

    7.8.2 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change Drain engine coolant (→ Page 102). Fill with engine coolant (→ Page 104). MS15033/02E 2015-02 | Task Description | 101...

  • Page 102: Engine Coolant - Draining

    7.8.3 Engine coolant – Draining Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Sealing ring (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...
  • Page 103 Open drain plugs and drain coolant at crankcase, right side (1,2). Open drain plugs and drain coolant at crankcase, left side (1,2). Install drain plug with new sealing ring. Position breather valve on filler neck and close. MS15033/02E 2015-02 | Task Description | 103...

  • Page 104: Engine Coolant - Filling

    7.8.4 Engine coolant – Filling Preconditions ☑Engine is stopped and starting disabled. ☑MTU Fluids and Lubricants Specifications (A001063/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...
  • Page 105 Final steps Start the engine and operate it at idle speed for some minutes. Check coolant level (→ Page 100), top up with coolant if required. MS15033/02E 2015-02 | Task Description | 105...

  • Page 106: Engine Coolant Pump - Relief Bore Check

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

  • Page 107: Low-Temperature Circuit

    7.9 Low-Temperature Circuit 7.9.1 Charge-air coolant level – Check Preconditions ☑Engine is stopped and starting disabled. ☑MTU Fluids and Lubricants Specifications (A001063/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down.

  • Page 108: Charge-Air Coolant - Change

    7.9.2 Charge-air coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Charge-air coolant – Change Drain charge-air coolant (→ Page 109). Fill with charge-air coolant (→ Page 110). 108 | Task Description | MS15033/02E 2015-02...

  • Page 109: Charge-Air Coolant - Draining

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

  • Page 110: Charge-Air Coolant - Filling

    7.9.4 Charge-air coolant – Filling Preconditions ☑Engine is stopped and starting disabled. ☑MTU Fluids and Lubricants Specifications (A001063/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Sealing ring (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure.
  • Page 111 Final steps Start the engine and operate it at idle speed for some minutes. Check coolant level (→ Page 107). MS15033/02E 2015-02 | Task Description | 111...

  • Page 112: Charge-Air Coolant Pump - Relief Bore Check

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

  • Page 113: Belt Drive

    7.10 Belt Drive 7.10.1 Coolant pump – Drive belt replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Assembly jig F6794712 Poly-vee belt (→ Spare Parts Catalog) DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...
  • Page 114 Replacing charge-air coolant pump drive belt (LT circuit) Fit new poly-vee belt (2) on front three grooves of belt pulley (1) to crankshaft. Fit poly-vee belt (2) on front three grooves of belt pulley (3) to crankshaft and preload with assembly jig (4). Bar engine with barring gear until poly-vee belt (2) lies completely on belt pulley (3).

  • Page 115: Battery-Charging Generator

    7.11 Battery-Charging Generator 7.11.1 Battery-charging generator – Belt tensioner and diverter pulley replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 20–100 Nm F30026582 Ratchet adapter F30027340 Engine oil Belt tensioner (→...
  • Page 116 Replacing diverter pulley Remove screw (2). Remove diverter pulley (1). Coat thread of screw (2) with engine oil. Install new diverter pulley (1) with screw (2). Tighten screw (2) to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Screw Tightening torque...

  • Page 117: Battery-Charging Generator - Drive Belt Removal And Installation

    7.11.2 Battery-charging generator – Drive belt removal and installation Preconditions ☑Engine is stopped and starting disabled. WARNING Belt tensioner spring is pretensioned. Risk of hands being crushed! • Lock belt tensioner in position. • Only use specified tools and devices. Remove battery-charging gener- ator drive belt Fit square wrench with extension into...

  • Page 118: Drive Systems, Driving End And Free End (Coupling)

    7.12 Drive Systems, Driving End and Free End (Coupling) 7.12.1 Coupling – Checking (radial / axial) play Preconditions ☑Engine is stopped and starting disabled. ☑Guard is removed. Checking radial play “A” Mount dial gauge on engine-side coupling flange. Set dial-gauge anvil onto outer coupling part.

  • Page 119: Wiring (General) For Engine/Gearbox/Unit

    7.13 Wiring (General) for Engine/Gearbox/Unit 7.13.1 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 120: Injector Functions

    7.14 Accessories for (Electronic) Engine Governor / Control System 7.14.1 Injector functions Preconditions ☑Engine is stopped and starting disabled. Note: Failure to reset drift compensation parameters (CDC) will void the emissions certification for the en- gine. Resetting drift correction parameters (CDC) with DiaSys® (→...
  • Page 121 7.14.2 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 122 7.14.3 Engine governor – Checking plug-in connections Preconditions ☑Engine is stopped and starting disabled. Checking plug-in connections on engine governor Check firm seating of all connectors on the engine governor. Ensure that the clips (1) are engaged. Check firm seating of all screws (2) on en- gine governor cable clamps.

  • Page 123: Nox Sensor – Replacement

    7.14.4 NOx sensor – Replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 20–100 Nm F30026582 Ratchet adapter F30027340 Assembly compound (Molykote P 37) 50564 NOx sensor (→ Spare Parts Catalog) WARNING Hot components/surfaces.
  • Page 124 Installing NOx sensor Note: Note the following: • If the sensor (3) was subjected to shock or impact load, it is considered to be defective and may not be used. • Always replace NOx sensor (3) together with control unit (1). Install control unit (1) at the eyelets and tighten screws to the specified tightening torque.

  • Page 125: Lambda Sensor – Replacement

    7.14.5 Lambda sensor – Replacement Preconditions ☑Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 20–100 Nm F30026582 Ratchet adapter F30027340 Assembly compound (Molykote P 37) 50564 Lambda sensor (→ Spare Parts Catalog) WARNING Hot components/surfaces.
  • Page 126 Installing Lambda sensor Note: When the sensor was subjected to shock or impact load, it is deemed 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 127: Abbreviations

    American National Standards Institute Association of American standardization organiza- tions Backup Data Module Data backup module Series Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU publica- tion no. A00.. Controller Area Network Data bus system, bus standard CaPoS Capacitor Power System Capacitor-based starting system...
  • Page 128 Abbre- Meaning Explanation viation International Organization for Standardiza- International umbrella organization for all national tion standardization institutes Integrated Test System Kupplungsgegenseite Engine free end in accordance with DIN ISO 1204 Kupplungsseite Engine driving end in accordance with DIN ISO 1204 Light Emitting Diode Alarm: Measured value lower than 1st minimum limit LOLO...
  • Page 129 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 130: Special Tools

    9 Appendix B 9.1 Special Tools Adapter Part No.: F30011619 Qty.: Used in: 4.8 Engine – Barring manually (→ Page 34) Allen key, 5 mm Part No.: F30002815 Qty.: Used in: 7.1.1 Valve clearance – Check and adjustment (→ Page 83) Assembly jig Part No.: F6794712...
  • Page 131 Barring device Part No.: F6790714 Qty.: Used in: 4.8 Engine – Barring manually (→ Page 34) Qty.: Used in: 7.1.1 Valve clearance – Check and adjustment (→ Page 83) Barring device Part No.: F6797426 Qty.: Used in: 4.8 Engine – Barring manually (→ Page 34) Box wrench, 14 mm Part No.: F30028346...
  • Page 132 Ratchet adapter Part No.: F30027340 Qty.: Used in: 4.8 Engine – Barring manually (→ Page 34) Qty.: Used in: 7.2.1 Fuel system – Venting (→ Page 87) Qty.: Used in: 7.3.1 Fuel filter – Replacement (→ Page 89) Qty.: Used in: 7.3.3 Fuel prefilter –...
  • Page 133 Torque wrench, 20–100 Nm Part No.: F30026582 Qty.: Used in: 7.1.1 Valve clearance – Check and adjustment (→ Page 83) Qty.: Used in: 7.3.1 Fuel filter – Replacement (→ Page 89) Qty.: Used in: 7.11.1 Battery-charging generator – Belt tensioner and diverter pulley replacement (→...
  • Page 134 9.2 Index Abbreviations 127 Diverter pulley  Actuators  – Replacement   – Overview  18 – On battery-charging generator  115 After stopping the engine 32 Drift correction parameters  Air filter  – Reset  120 – Replacement  95 Drive belt  – Service indicator check  96 – Charge-air coolant pump   Air filter element ...
  • Page 135  28 – After scheduled out-of-service-period  27 Main engine dimensions 23 Maintenance schedule  Technical data  – Maintenance task reference table [QL1]  36 – 12V1600R50  24 MTU contact persons 129 Troubleshooting 37 NOx sensor  Valve clearance  – Replacement  123 – Adjustment  83 – Check  83 Operational checks 30...

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