MTU 12 V 4000 G73 Operating Instructions Manual
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MTU 12 V 4000 G73 Operating Instructions Manual

MTU 12 V 4000 G73 Operating Instructions Manual

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Operating Instructions

Diesel engine
12 V 4000 G73
16 V 4000 G73
Application group 3A
MS150029/02E

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Summary of Contents for MTU 12 V 4000 G73

  • Page 1: Operating Instructions

    Operating Instructions Diesel engine 12 V 4000 G73 16 V 4000 G73 Application group 3A MS150029/02E...
  • Page 2 This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, mi- crofilming and storage or processing on electronic systems including data bases and online services.

  • Page 3: Table Of Contents

    Table of Contents 1 Safety 6 Troubleshooting 1.1 Important provisions for all products 6.1 Troubleshooting 1.2 Personnel and organizational requirements 6.2 Fault messages on the SAM display 1.3 Transport (optional) 1.4 Crankshaft transport locking device 6.3 Fault messages of engine governor ADEC 1.5 Safety regulations for startup and operation (ECU 7) for Series 4000, application: oil &...
  • Page 4 7.15.4 Engine coolant – Filling 7.15.5 Engine coolant pump – Relief bore check 8.1 Abbreviations 7.15.6 Engine coolant – Sample extraction and 8.2 MTU contact persons/service partners analysis 7.15.7 Engine coolant filter – Replacement 9 Appendix B 7.16 Low-Temperature Circuit 7.16.1 Charge-air coolant –...

  • Page 5: Safety

    1 Safety 1.1 Important provisions for all products Nameplate The product is identified by nameplate, model designation or serial number and must match with the information on the title page of this manual. Nameplate, model designation or serial number can be found on the product. General information This product may pose a risk of injury or damage in the following cases: •...

  • 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

    Place the engine only on an even, firm surface. Ensure appropriate consistency and load-bearing capacity of the ground or support surface. Never place an engine on the oil pan, unless expressively authorized by MTU on a case-to-case basis to do so.

  • 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 F30510423 Torque wrench, 60-320 Nm F30047446 Engine oil Transport locking device Note: The locking device protects the crankshaft bearings from shocks and vibration damage during engine transport.
  • Page 9 Fitting the transport locking de- vice on driving end (KS) Note: Attach plate (6) only to the upper part of the openings. Secure plates (6) with screws (4) and washers (5) at the bores on both sides of the flywheel housing and tighten to the specified tightening torque.
  • Page 10 Installing guard plates and en- gine mounting brackets (if appli- cable) on driving end (KS) Note: Always use the screws supplied with the or removed from the guard plates and engine mounting brackets to secure them on the engine. Install engine mounting brackets (2) on both sides with guard plates (1) wash- ers (3), and screws (4).

  • Page 11: Safety Regulations For Startup And Operation

    1.5 Safety regulations for startup and operation Safety regulations for startup Install the product correctly and carry out acceptance in accordance the manufacturer's specifications before putting the product into service. Before the product is put into operation for the first time, all official authorizations must be available and commissioning preconditions met.

  • Page 12: Safety Regulations For Maintenance And Repair Work

    1.6 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 before starting maintenance work (risk of explosion of oil vapors, fluids and lubricants, risk of burning).
  • Page 13 Ensure particular cleanness during maintenance and repair work on the product. After completion of maintenance and repair work, make sure that no loose objects are in/on the product (e.g. cloths and cable ties) Safety regulations after completion of maintenance and repair work Before barring, make sure that nobody is standing in the danger zone of the product.
  • Page 14 Working on electrical and electronic assemblies Always obtain the permission of the person in charge before commencing maintenance and 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. Do not damage cabling during removal work.

  • Page 15: Fire Prevention And Environmental Protection, Fluids And Lubricants, Auxiliary Materials

    The Fluids and Lubricants Specifications will be amended or supplemented as necessary. Prior to opera- tion, make sure that the latest version is used. The applicable version may be downloaded at: http:// www.mtu-online.com/mtu/mtu-valuecare/mtu-valueservice-Technische-Dokumentation. Auxiliary materials, fluids and lubricants might be hazardous goods or toxic substances.When using flu- ids, lubricants, auxiliary materials and other chemical substances, follow the safety instructions that ap- ply to the product.

  • Page 16: Compressed Air

    Lead • Adopt suitable measures to avoid the formation of lead dust. • Switch on extraction system. • When working with lead or lead-containing compounds, avoid direct contact to the skin and 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 17: Standards For Warning Notices In The Text

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

  • Page 18: General Information

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

  • Page 19: Engine Layout

    2.2 Engine layout Illustration also applicable to 16 V 1 Oil heat exchanger 9 Flywheel 17 Oil pan 2 Crankcase breather 10 Lifting eye 18 Fuel filter 3 Exhaust pipe 11 Starter 19 HP fuel pump 4 Combustion-air inlet con- 12 Charge-air pipe 20 Engine oil filter, (automatic nection (elbows are op-...

  • Page 20: Sensors And Actuators - Overview

    2.3 Sensors and actuators – Overview Illustration also applicable to 16 V a Version with easy-change 3 F46 Leak fuel level moni- 7 B07 Engine oil tempera- filter toring ture b Version with automatic fil- 4 M8 Suction restrictor (HP 8 XY44 Solenoid valve of fan pump) clutch...
  • Page 21 1 B50 Crankcase pressure 4 B48 Fuel pressure in Com- 7 B26 Charge-air coolant 2 B05 Engine oil pressure mon Rail temperature 3 B33 Fuel temperature in 5 B01 Camshaft speed 8 B06 Engine coolant tem- Common Rail 6 B43 Charge-air coolant perature pressure MS150029/02E 2013-03 | General Information | 21...
  • Page 22 1 Injectors Y39.11 to Y39.n 3 B10 Charge-air pressure 5 B09 Charge-air tempera- (B-side) 4 XM2 Oil priming pump ture 2 B16 Engine coolant pres- 6 Engine governor sure The injectors are located below the cylinder head covers. Injector replacement and necessary activities (→...
  • Page 23 1 B13 Crankshaft speed MS150029/02E 2013-03 | General Information | 23...

  • Page 24: Technical Data

    3 Technical Data 3.1 12, 16V 4000 G73 engine data, optimized exhaust emissions (EPA - Tier 2) Explanation: Abbrev. Meaning Ref. value: Continuous power Ref. 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 settings). Not yet defined value Not applicable Applicable...
  • Page 25 Model-related data (basic design) Number of cylinders Engine with exhaust turbocharging (ETC) and charge-air cooling (CAC) Uncooled exhaust lines Operating method: Four-stroke cycle, diesel, single-action Combustion method: direct fuel injection Cooling method: conditioned water Direction of rotation: c.c.w. (facing driving end) Number of cylinders Cylinder arrangement: V-angle Degrees...

  • Page 26: Fuel System

    Lube oil system Number of cylinders Lube oil operating temperature before engine, from °C Lube oil operating temperature before engine, to °C Lube oil temperature before engine, alarm °C Lube oil temperature before engine, shutdown °C Lube-oil operating pressure before engine, from Lube oil operating pressure before engine, to Fuel system Number of cylinders...

  • Page 27: Firing Order

    3.2 Firing order Number of Firing order cylinders 12 V A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1 16 V A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7 MS150029/02E 2013-03 | Technical Data | 27...

  • Page 28: Engine - Main Dimensions

    3.3 Engine – Main dimensions Engine model Length (A) Width (B) Height (C) 12 V 4000 G73 approx. 2550 mm approx. 1590 mm approx. 1870 mm 16 V 4000 G73 approx. 3020 mm approx. 1590 mm approx. 1870 mm 28 | Technical Data | MS150029/02E 2013-03...

  • Page 29: Operation

    4.1 Preparations for recommissioning the engine after extended out-of-service periods (>3 months) Preconditions ☑ Engine shut down and secured against being restarted. ☑ MTU Corrosion-proofing and Reproofing Regulations (A001070/..) are available. Recommissioning after long out-of-service periods (>3 months) Item Action Engine Remove corrosion-proofing (→...

  • Page 30: 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. Putting into operation Item Action Lube oil system Check engine oil level (→ Page 123). Coolant circuit Check engine coolant level (→ Page 137), check charge-air coolant level (→...

  • Page 31: Starting The Engine In Manual Mode (Test Run)

    4.3 Starting the engine in manual mode (test run) Preconditions ☑ Generator (if fitted) is not connected to network. ☑ External start interlock is not active. DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! •...

  • Page 32: Starting The Engine In Emergency Situations (Override Mode)

    4.4 Starting the engine in emergency situations (override mode) CAUTION Safety functions and engine shutdown alarms will be disregarded. Serious damage to plant! • Initiate emergency start only in emergency situations. Preparation Item Task Operating mode switch Set to emergency mode. Starting the engine in emergency situations Item Task...

  • Page 33: Operational Checks

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

  • Page 34: Stopping The Engine In Manual Mode (Test Run)

    4.6 Stopping the engine in manual mode (test run) Preconditions ☑ Generator (if fitted) is not connected to network. ☑ Engine is running in manual mode. NOTICE Stopping the engine when it is running at full load causes extreme stress to the engine. Risk of overheating, damage to components! •...

  • Page 35: Emergency Stop

    4.7 Emergency stop NOTICE An emergency stop causes extreme stress to the engine plant. Risk of overheating, damage to components! • Initiate emergency stop only in emergency situations. Emergency stop Item Action Emergency stop pushbutton Press EMERGENCY STOP pushbutton. Engine is stopped by disconnecting the power supply to the ECU; •...

  • Page 36: After Stopping The Engine - Engine Remains Ready For Operation

    4.8 After stopping the engine – Engine remains ready for operation After stopping the engine Item Action Engine/generator/pump Select operating mode, e.g. MANUAL, AUTOMATIC OPERATION. control 36 | Operation | MS150029/02E 2013-03...

  • Page 37: After Stopping The Engine - Putting The Engine Out Of Operation

    4.9 After stopping the engine – Putting the engine out of operation Preconditions ☑ MTU Preservation and Represervation Specifications (A001070/..) are available. After stopping the engine Item Action Coolant circuit Drain engine coolant (→ Page 139); Drain charge-air coolant (→ Page 149) if: freezing temperatures are to be expected and the engine is to remain •...

  • Page 38: 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 39: Troubleshooting

    6 Troubleshooting 6.1 Troubleshooting Engine does not turn when starter is actuated Component Cause Action Battery Low or faulty Charge or replace (see manufacturer's documentation). Cable connections defective Check if cable connections are properly secured (see manufacturer's documen- tation). Starter Engine wiring or starter defective Check if cable connections are properly secured, contact Service.
  • Page 40 Contact Service. Charge air temperature too high Component Cause Action Engine coolant Incorrect engine coolant concentration. Check (MTU test kit). Intercooler Contaminated Contact Service. Engine room Air inlet temperature too high. Check fans and intake/exhaust lines. Charge-air pressure too low...
  • Page 41 White exhaust gas Component Cause Action Engine Not at operating temperature. Run up to operating temperature. Fuel system Water in fuel. Check fuel system on fuel prefilter; Drain fuel prefilter Intercooler Leaking Contact Service. MS150029/02E 2013-03 | Troubleshooting | 41...

  • Page 42: Fault Messages On The Sam Display (Optional)

    6.2 Fault messages on the SAM display (optional) The fault code numbers are generated by the engine governor and transmitted to the following display: The fault code (1) comprises three digits. Fault messages can also be caused by faulty sensors/actuators. If the fault cannot be corrected with the troubleshooting information provided in the following table, contact Service.

  • Page 43: Fault Messages Of Engine Governor Adec (Ecu 7) For Series 4000, Application: Oil & Gas

    6.3 Fault messages of engine governor ADEC (ECU 7) for Series 4000, application: oil & gas 003 – HI T-Fuel ZKP-Number: 2.0122.931 Preliminary warning Cause Corrective action Fuel temperature too high. u Contact Service. 004 – SS T-Fuel ZKP-Number: 2.0122.932 Main warning Cause Corrective action...
  • Page 44 010 – AL L2 T-Coolant Intercooler ZKP-Number: 2.0124.932 Main warning Cause Corrective action Coolant temperature in u Reduce power. intercooler too high;Engine stop. 015 – LO P-Lube Oil ZKP-Number: 2.0100.921 Cause Corrective action Oil pressure too low (1st limit u Check oil level, top up as necessary (→ Page 123). value).
  • Page 45 022 – SS T-Exhaust B ZKP-Number: 2.0127.932 Cause Corrective action Exhaust temperature bank B to 1. Check wiring (→ Page 162). high (2nd limit value). 2. Contact Service. 023 – LO Coolant Level ZKP-Number: 2.0152.921 Cause Corrective action Coolant level too low (1st limit u Check coolant level in expansion tank (→...
  • Page 46 029 – HI ETC2 Idle Speed too High ZKP-Number: 1.8004.206 Cause Corrective action Idle speed of ETC 2 too high. u Contact Service. 030 – SS Engine Overspeed ZKP-Number: 2.2510.932 Cause Corrective action Engine overspeed; automatic 1. Acknowledge alarm. engine emergency stop. 2.
  • Page 47 038 – AL ETC Speed Deviation ZKP-Number: 1.8004.205 Cause Corrective action Synchronization error between 1. Reduce power. exhaust turbocharger 1 and 2. 2. Contact Service. 039 – AL ETC2 Cutin Failure ZKP-Number: 1.8004.204 Cause Corrective action ETC2 failed to cut in. 1.
  • Page 48 058 – SS P-Coolant ZKP-Number: 2.0101.922 Cause Corrective action Coolant pressure too low u Automatic engine shutdown. (2nd limit value). Check coolant level (→ Page 137). 063 – HI P-Crankcase ZKP-Number: 2.0106.931 Preliminary warning Cause Corrective action Crankcase pressure too high. 1.
  • Page 49 068 – SS T-Coolant ZKP-Number: 2.0120.932 Cause Corrective action Coolant temperature too high 1. Allow engine to cool down. (2nd limit value), automatic 2. Check engine coolant cooler, clean if dirty. engine shutdown. 3. Contact Service. 4. Restart engine (→ Page 31). 081 –...
  • Page 50 086 – HIHI T-Umblasen ZKP-Number: 2.0128.932 Main warning Cause Corrective action Recirculation temperature too u Reduce power. high. 089 – AL Engine Speed too Low ZKP-Number: 2.2500.030 Cause Corrective action The engine speed stays below u Check for additional messages. 200 rpm.
  • Page 51 094 – LO T-Preheat ZKP-Number: 2.1090.921 Cause Corrective action Alarm configuration limit value u Check preheater. 1; Preheating temperature too low; coolant temperature too low for engine start. 095 – AL Prelubrication Fault ZKP-Number: 2.1090.920 Cause Corrective action Alarm configuration; Oil priming u Check priming system.
  • Page 52 120 – HI ECU Power Supply Voltage ZKP-Number: 2.0140.931 Cause Corrective action Supply voltage too high 1. Check supply voltage of engine governor. (1st limit value). 2. Contact Service. 121 – HIHI ECU Power Supply Voltage ZKP-Number: 2.0140.932 Cause Corrective action Supply voltage too high (2nd 1.
  • Page 53 140 – TE BUF. ECU DEFECT ZKP-Number: - Cause Corrective action Supply voltage of temperature u Contact Service.Check sensors;replace engine governor. sensors faulty. 142 – BANK1 ECU DEFECT ZKP-Number: - Cause Corrective action Power output stage for solenoid u Replace engine governor. valve activation on bank 1 defective;...
  • Page 54 148 – L1 AD-TEST2 SUPPLY ZKP-Number: - Cause Corrective action A/D converter supply voltage u Replace engine governor. too low. 149 – AD-TEST2 ECU DEFECTIVE ZKP-Number: - Cause Corrective action Internal electronics defect; u Replace engine governor. automatic engine shutdown. 150 –...
  • Page 55 180 – AL CAN1 Node Lost ZKP-Number: 2.0500.680 Cause Corrective action Alarm configuration; Connection u Contact Service. to a node on CAN bus 1 failed. 181 – AL CAN2 Node Lost ZKP-Number: 2.0500.681 Cause Corrective action Alarm configuration; Connection u Contact Service. to a node on CAN bus 2 failed.
  • Page 56 186 – AL CAN1 Bus Off ZKP-Number: 2.0500.686 Cause Corrective action CAN 1 in Bus-Off state: Either 1. Check CAN bus for short circuit, rectify short circuit as short circuit on bus, or intense necessary. magnetic fields are interfering 2. Check shielding, improve shielding as necessary. with the bus.
  • Page 57 202 – SD T-Fuel ZKP-Number: 1.8004.572 Cause Corrective action Sensor B33 defective (fuel 1. Check cabling. temperature). 2. Replace as necessary. 203 – SD T-Charge Air ZKP-Number: 1.8004.571 Cause Corrective action Sensor B09 defective (charge-air 1. Check cabling. temperature) A side. 2.
  • Page 58 211 – SD P-Lube Oil ZKP-Number: 1.8004.563 Cause Corrective action Sensor B05 defective (lube oil 1. Check cabling. pressure). 2. Replace as necessary. 212 – SD P-Coolant ZKP-Number: 1.8004.564 Cause Corrective action Sensor B16 defective (coolant 1. Check cabling. pressure). 2.
  • Page 59 219 – SD T-Intake Air ZKP-Number: 1.8004.573 Cause Corrective action Sensor B03 defective (intake air 1. Check cabling. temperature). 2. Replace as necessary. 220 – SD Level Coolant Water ZKP-Number: 1.8004.584 Cause Corrective action Sensor F33 defective (coolant 1. Switch system off and back on; level 1).
  • Page 60 229 – AL Stop Camshaft Sensor Defect ZKP-Number: 1.8004.562 Cause Corrective action Crankshaft speed sensor and 1. Check cabling. camshaft speed sensor 2. Contact Service.Check sensor. defective. 230 – SD Crankshaft Speed ZKP-Number: 1.8004.498 Cause Corrective action Sensor B13 defective 1.
  • Page 61 241 – SD T-Umblasen ZKP-Number: 1.8004.581 Cause Corrective action Sensor B49 defective 1. Check cabling and sensor. (recirculation temperature). 2. Contact Service. 242 – SD T-Coolant (R) ZKP-Number: 1.8004.622 Cause Corrective action Sensor defective (redundant 1. Check cabling and sensor. coolant temperature sensor).
  • Page 62 270 – SD Frequency Input ZKP-Number: 2.8006.590 Cause Corrective action Sensor defective, frequency 1. Check cabling. setting. 2. Contact Service.Check speed demand transmitter. 301 – AL Timing Cylinder A1 ZKP-Number: 1.8004.500 Cause Corrective action Timing bank 1 (solenoid valve 1) u Replace injector concerned if the fault message appears frequently (→...
  • Page 63 307 – AL Timing Cylinder A7 ZKP-Number: 1.8004.506 Cause Corrective action Timing bank 1 (solenoid valve 7) u Replace injector concerned if the fault message appears frequently (→ Page 99). 308 – AL Timing Cylinder A8 ZKP-Number: 1.8004.507 Cause Corrective action Timing bank 1 (solenoid valve 8) u Replace injector concerned if the fault message appears frequently (→...
  • Page 64 314 – AL Timing Cylinder B4 ZKP-Number: 1.8004.513 Cause Corrective action Timing bank 2 (solenoid valve 4) u Replace injector concerned if the fault message appears frequently (→ Page 99). 315 – AL Timing Cylinder B5 ZKP-Number: 1.8004.514 Cause Corrective action Timing bank 2 (solenoid valve 5) u Replace injector concerned if the fault message appears frequently (→...
  • Page 65 321 – AL Wiring Cylinder A1 ZKP-Number: 1.8004.520 Cause Corrective action Wiring bank 1 (solenoid valve 1) 1. Check solenoid valve. 2. Contact Service. 322 – AL Wiring Cylinder A2 ZKP-Number: 1.8004.521 Cause Corrective action Wiring bank 1 (solenoid valve 2) 1.
  • Page 66 328 – AL Wiring Cylinder A8 ZKP-Number: 1.8004.527 Cause Corrective action Wiring bank 1 (solenoid valve 8) 1. Check solenoid valve. 2. Contact Service. 329 – AL Wiring Cylinder A9 ZKP-Number: 1.8004.528 Cause Corrective action Wiring bank 1 (solenoid valve 9) 1.
  • Page 67 335 – AL Wiring Cylinder B5 ZKP-Number: 1.8004.534 Cause Corrective action Wiring bank 2 (solenoid valve 5) 1. Check solenoid valve. 2. Contact Service. 336 – AL Wiring Cylinder B6 ZKP-Number: 1.8004.535 Cause Corrective action Wiring bank 2 (solenoid valve 6) 1.
  • Page 68 342 – AL Open Load Cylinder A2 ZKP-Number: 1.8004.541 Cause Corrective action Open load bank 1 (solenoid 1. Check solenoid valve. valve 2) 2. Contact Service. 343 – AL Open Load Cylinder A3 ZKP-Number: 1.8004.542 Cause Corrective action Open load bank 1 (solenoid 1.
  • Page 69 349 – AL Open Load Cylinder A9 ZKP-Number: 1.8004.548 Cause Corrective action Open load bank 1 (solenoid 1. Check solenoid valve. valve 9) 2. Contact Service. 350 – Open Load Cylinder A10 ZKP-Number: 1.8004.549 Cause Corrective action Open load bank 1 (solenoid 1.
  • Page 70 356 – AL Open Load Cylinder B6 ZKP-Number: 1.8004.555 Cause Corrective action Open load bank 2 (solenoid 1. Check solenoid valve. valve 6) 2. Contact Service. 357 – AL Open Load Cylinder B7 ZKP-Number: 1.8004.556 Cause Corrective action Open load bank 2 (solenoid 1.
  • Page 71 362 – AL Power Stage high ZKP-Number: 1.8004.497 Cause Corrective action Alarm configuration; Internal 1. Check solenoid valve cabling. electronic fault (electronics 2. Replace engine governor. possibly defective: start ITS).Check additional messages if ITS indicates diagnosis "Electronics OK" (e.g. cabling faulty).
  • Page 72 373 – AL Wiring TO 3 ZKP-Number: 1.8004.636 Cause Corrective action Alarm configuration; Short circuit or wire break on transistor output 3 (TO 3). 374 – AL Wiring TO 4 ZKP-Number: 1.8004.637 Cause Corrective action Alarm configuration; Short circuit or wire break on transistor output 4 (TO 4).
  • Page 73 384 – AL Wiring TOP 4 ZKP-Number: 2.8006.641 Cause Corrective action Alarm configuration; Short u Check cabling to plant. circuit or wire break on transistor output, plant-side 4 (TOP 4). 390 – AL MCR exceeded ZKP-Number: 1.1085.009 Cause Corrective action Alarm configuration;...
  • Page 74 395 – SS P-Lube Oil Red ZKP-Number: 2.0112.922 Main warning Cause Corrective action Alarm configuration limit value 1. Check cabling and sensor. 2; Redundant lube oil pressure 2. Contact Service. reading too low. 396 – AL T-Coolant Max Deviation ZKP-Number: 1.8004.626 Cause Corrective action Alarm configuration;...
  • Page 75 403 – AL Open Load Digital Input 4 ZKP-Number: 2.8006.628 Cause Corrective action Alarm configuration; Line 1. Check cabling. disruption on digital input 4; 2. Contact Service.Check target device input. Cabling defective or no resistance over switch. 404 – AL Open Load Digital Input 5 ZKP-Number: 2.8006.629 Cause Corrective action...
  • Page 76 408 – AL Open Load Emerg. Stop Input ESI ZKP-Number: 2.8006.633 Cause Corrective action Alarm configuration; Open 1. Check cabling. circuit at input for emergency 2. Contact Service.Check target device input. stop. Cabling defective or no resistance over switch. 410 – LO U-PDU ZKP-Number: 2.0141.921 Preliminary warning Cause...
  • Page 77 414 – HI Level Water Fuel Prefilter ZKP-Number: 2.0156.931 Cause Corrective action Alarm configuration limit value u Drain water. 1; Warning: water level in fuel prefilter too high. 415 – LO P-Coolant Intercooler ZKP-Number: 2.0107.921 Preliminary warning Cause Corrective action Alarm configuration limit value u Top up coolant (→...
  • Page 78 421 – L2 Aux 1 ZKP-Number: 2.0160.922 Cause Corrective action Alarm configuration limit value u Determine cause of limit value violation and rectify fault. 1; Input signal of Aux 1 has exceeded/not attained limit value 2, depending on configuration. 428 – L1 T-Aux 1 ZKP-Number: 2.0130.921 Preliminary warning Cause...
  • Page 79 445 – SD P-Ambient Air ZKP-Number: 1.8004.580 Cause Corrective action SD alarm configuration; Ambient u Replace engine governor. air pressure sensor defective. 448 – HI P-Charge Air ZKP-Number: 2.0103.931 Preliminary warning Cause Corrective action Alarm configuration limit value u Contact Service. 1;...
  • Page 80 456 – AL Aux 1 Plant L2 ZKP-Number: 2.8006.651 Cause Corrective action Alarm configuration limit value u Determine cause of limit value violation and rectify fault. 2; Input signal of Aux 1 (plant side) has exceeded/not attained limit value 2, depending on configuration.
  • Page 81 464 – SD P-AUX 1 ZKP-Number: 1.8004.589 Cause Corrective action SD alarm configuration; Analog u Check pressure sensor and cabling. input signal for Aux 1 pressure Error cleared after restarting the engine. defective; Short circuit or wire break. 465 – SD P-AUX 2 ZKP-Number: 1.8004.588 Cause Corrective action...
  • Page 82 469 – SD AUX 1 ZKP-Number: 1.8004.590 Cause Corrective action SD alarm configuration; Analog u Check signal transmitter and cabling, replace as necessary. input signal for Aux 1 defective; Error cleared after restarting the engine. Short circuit or wire break. 470 –...
  • Page 83 475 – AL CR Trigger Engine Stop ZKP-Number: 1.8010.009 Cause Corrective action Alarm configuration; activated u Determine and rectify cause of triggering / engine shutdown. when crash recorder triggered by an engine shutdown 476 – AL Crash Rec. Init. Error ZKP-Number: 1.8010.007 Cause Corrective action...

  • Page 84: Task Description

    7 Task Description 7.1 Engine 7.1.1 Engine – Barring manually Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring device F6555766 Ratchet with extension F30006212 DANGER Unguarded rotating and moving engine components. Risk of serious injury –...

  • Page 85: Engine - Barring With Starting System

    7.1.2 Engine – Barring with starting system DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Before barring or starting the engine, ensure that nobody is in the danger zone. • After working on the engine, check that all protective devices have been reinstalled and all tools removed from the engine.

  • Page 86: Engine - Test Run

    7.1.3 Engine – Test run DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Before barring or starting the engine, make sure that nobody is in the danger zone. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...

  • Page 87: 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. Rigid endoscope Y20097353 Preparatory steps Remove cylinder head cover (→ Page 97). Remove injector (→...
  • Page 88 Final steps Install injector (→ Page 100). Install cylinder head cover (→ Page 97). 88 | Task Description | MS150029/02E 2013-03...

  • Page 89: 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 Action Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing products, particles, broken-off burrs).
  • Page 90 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 91: Crankcase Breather

    7.3 Crankcase Breather 7.3.1 Crankcase breather – Oil separator element replacement, diaphragm check and replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 6-50 Nm F30027336 Ratchet F30027340 Engine oil Filter element...
  • Page 92 Checking diaphragm Remove cover (4). Remove spring (5), gasket (2) and dia- phragm (3). Check diaphragm (3) for damage, fit new diaphragm if used one is damaged. Install diaphragm (3) on housing (1). Install new seal (2) and spring (5) together with cover (4).

  • Page 93: 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 covers (→ Page 97). Fill oil chambers of valve bridges with oil.

  • Page 94: Valve Clearance - Check And Adjustment

    7.4.2 Valve clearance – Check and adjustment Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine coolant temperature is max. 40 °C. ☑ Valves are closed. Special tools, Material, Spare parts Designation / Use Part No. Qty. Feeler gauge Y20098771 Torque wrench, 60-320 Nm F30452768...
  • Page 95 Diagram for 12 V engines (two crankshaft positions) Diagram for 16 V engines (two crankshaft positions) Checking valve clearance at two crankshaft positions Check TDC position of piston in cylinder A1: • If the rocker arms are unloaded on cylinder A1, the piston is in firing TDC. •...

  • Page 96: Adjusting Valve Clearance

    Adjusting valve clearance Release locknut (1). Insert feeler gauge (3) between valve bridge and rocker arm. Using Allen key, set adjusting screw (2) so that the specified valve clearance is provid- Feeler gauge (3) must just pass through gap. Tighten locknut (1) with torque wrench to the specified tightening torque, holding the adjusting screw (2) to prevent it from turning.

  • Page 97: 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. Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 O-ring (→ Spare Parts Catalog) Removing cylinder head cover Clean very dirty cylinder head covers (1) prior to removal.

  • Page 98: 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 99: Injection Valve / Injector

    7.6 Injection Valve / Injector 7.6.1 Injector – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Injector (→ Spare Parts Catalog) Replacing injector Remove injector and install new injector (→ Page 100). MS150029/02E 2013-03 | Task Description | 99...

  • Page 100: Injector - Removal And Installation

    7.6.2 Injector – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Installation/removal tool F6789889 Milling cutter F30452739 Torque wrench, 0.5-5 Nm 0015384230 Torque wrench, 10-60 Nm F30452769 Ratchet F30027340...
  • Page 101 Remove HP fuel line (4). Remove return line (5). Note: The injector accumulator will be emptied when removing the adapter. Remove adapter (3). Remove screw (2) and take off hold-down clamp (1). Install installation/removal tool on cylinder head. Remove injector with installation/removal tool.
  • Page 102 Installing injector Remove plug before installing the injec- tor. (Do not remove the plug from the HP line before installing the adapter.) Coat injector with assembly paste at the seat of the nozzle clamping nut. Fit new sealing ring (included in the scope of supply of the injector) with grease on in- jector, observe installation position of seal- ing ring.
  • Page 103 Coat screw head mating face (2) and thread with engine oil. Fit hold-down clamp (1) in the correct position and use torque wrench to tighten screw (2) to the speci- fied initial tightening torque. Name Size Type Lubricant Value/Standard Screw Preload torque (Engine oil) 5 Nm to 10 Nm...
  • Page 104 Mount double-walled HP line (5) and use torque wrench to tighten to the specified torque. Tightening sequence: 1 Adapter (4) 2 Rail (6) Name Size Type Lubricant Value/Standard Union nut / thrust Tightening torque 40 Nm + 5 Nm screw Fit cable connector onto injector.

  • Page 105: 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 combustible. Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. •...

  • Page 106: 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 combustible. Risk of fire and explosion! •...

  • Page 107: Fuel Prefilter Cleaning

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

  • Page 108: Fuel Prefilter - Differential Pressure Gauge Check And Adjustment

    7.8.3 Fuel prefilter – Differential pressure gauge check and adjustment DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...

  • Page 109: Fuel Prefilter - Draining

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

  • Page 110: Fuel Prefilter - Flushing

    7.8.5 Fuel prefilter – Flushing Special tools, Material, Spare parts Designation / Use Part No. Qty. Fuel Gasket (→ Spare Parts Catalog) DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Fuels are combustible.
  • Page 111 Open threaded vent plug (5) of filter to be flushed. Unlock drain valve (6) by pressing valve toggle, open it and drain fuel. Result: Fuel flows from filtered side back to the un- filtered side, flushing the filter deposits downwards out of the filter. Close threaded vent plug (5) and drain valve (6).

  • Page 112: Fuel Prefilter - Filter Element Replacement

    7.8.6 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.
  • Page 113 Open threaded vent plug (5) of contaminat- ed filter. Unlock drain valve (6) by pressing toggle and open it. Drain water and dirt from filter. Close drain valve (6). Remove screws securing the cover and take off cover (2). Remove spring housing (4) and filter ele- ment (3).

  • Page 114: Charge-Air Cooling

    7.9 Charge-Air Cooling 7.9.1 Intercooler – Checking condensate drain for coolant discharge and obstructions DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A).

  • Page 115: Air Filter

    7.10 Air Filter 7.10.1 Air filter – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Air filter (→ Spare Parts Catalog) Air filter – Replacement Remove air filter and install new one (→ Page 116). Reset signal ring of service indicator (→ Page 118). MS150029/02E 2013-03 | Task Description | 115...

  • Page 116: Air Filter - Removal And Installation

    7.10.2 Air filter – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 4-20Nm F30044239 Removing and installing air fil- Release clamp (2). Remove air filter (1) and clamp (2) from connecting flange of intake housing (3).
  • Page 117 7.10.3 Rubber sleeves between air intake elbow and turbocharger – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Rubber sleeve (→ Spare Parts Catalog) Preparatory steps Remove air filter (→ Page 115). Replacing rubber sleeves Note: This illustration applies analogously to...

  • Page 118: Air Intake

    7.11 Air Intake 7.11.1 Service indicator – Signal ring position check (optional) 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 115). After installation of new filter, press reset button (1).
  • Page 119 7.11.2 Emergency air-shutoff flaps – Electric control check DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Before barring or starting the engine, make sure that nobody is in the danger zone. WARNING Air flaps close abruptly.
  • Page 120 7.11.3 Emergency shut-off flaps – Lubrication Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil Emergency shut-off flaps – Lubri- cation Clean grease nipple (1). Press in grease. Clean bearings of moving parts.
  • Page 121 7.11.4 Rubber sleeves in air pipework before intercooler – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Rubber sleeve (→ Spare Parts Catalog) O-ring (→ Spare Parts Catalog) Preparatory steps Remove air filter (→...

  • Page 122: Starting Equipment

    7.12 Starting Equipment 7.12.1 Air starter – Manual operation DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Before barring or starting the engine, make sure that nobody is in the danger zone. WARNING Engine noise above 85 dB (A).
  • Page 123 7.13 Lube Oil System, Lube Oil Circuit 7.13.1 Engine oil – Level check Preconditions ☑ Engine is stopped and starting disabled. Checking oil level prior to en- gine start Withdraw oil dipstick from guide tube and wipe it. Insert oil dipstick into guide tube up to stop, withdraw after approx.
  • Page 124 7.13.2 Engine oil – Change Preconditions ☑ Engine shut down 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, 40-200Nm...
  • Page 125 Tighten drain screws (2) and (3) with torque wrench to the specified torque. Name Size Type Lubricant Value/Standard Screw M26 x 1.5 Tightening torque (Engine oil) 100Nm +10Nm Filling with new engine oil Open cover on filler neck. Pour oil in at filler neck up to "max." mark at oil dipstick.
  • Page 126 7.13.3 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 Unguarded rotating and moving engine components.
  • Page 127 Drain approx. 1 liter engine oil into a clean container. Close screw (1). Using the equipment and chemicals in the MTU test kit, analyze the engine oil for: • Dispersing capacity (spot test); • Water content; • Dilution by fuel.
  • Page 128 7.14 Oil Filtration / Cooling 7.14.1 Engine oil filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Engine oil Oil filter (→ Spare Parts Catalog) WARNING Hot oil.
  • Page 129 7.14.2 Automatic oil filter – Oil filter candles replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 Engine oil O-ring (→ Spare Parts Catalog) Oil filter candles (→...
  • Page 130 Withdraw oil filter element (1). Remove O-ring. Remove screw (2). Withdraw plastic spinner (1) with spring. Remove nut (3). Take off spring washer and washer. Remove screw (4). Remove flushing arm (5) from screen plate (6). Turn filter element by 180° and use appro- priate tool to push out filter candles (1).
  • Page 131 Installing oil filter candles For installation follow reverse sequence of working steps. Additionally, the following instructions are to be observed: • Replace all sealing elements. • Coat O-rings with grease. • Insert O-rings in grooves. • Observe position of cylinder screw to elongated hole on shaft. MS150029/02E 2013-03 | Task Description | 131...
  • Page 132 7.14.3 Oil indicator filter – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Cleaner (Snow-White 11-0) 40460 Cleaner (Hakupur 312) 30390 Engine oil Strainer (→ Spare Parts Catalog) Square-section ring (→...
  • Page 133 Cleaning strainer Shake coarse contamination out of strainer (5). Clean all metallic parts with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 312). Use a soft brush to remove stubborn deposits from strainer if required. Ensure that the mesh is not damaged.

  • Page 134: Centrifugal Oil Filter – Cleaning And Filter

    7.14.4 Centrifugal oil filter – Cleaning and filter-sleeve replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 6-50 Nm F30027336 Filter wrench F30379104 Cold cleaner (Hakutex 60) 50602 Grease (Kluthe Hakuform 30-10/Emulgier) X00029933...
  • Page 135 Cleaning centrifugal oil filter and replacing filter sleeve, var- iant A Remove clamp (14). Release cover screw (2) and take off hood (1). Carefully lift rotor (11), allow oil to drain and remove from housing. Holding the rotor (11) firmly, release rotor cover nut (3).
  • Page 136 Cleaning centrifugal oil filter and replacing filter sleeve, var- iant B Release screw (1) and remove. Remove clamp (3) and take off hood (2). Carefully remove rotor (5) from housing. Hold rotor assembly (5) firmly in position with filter wrench and release knurled nut (7).

  • Page 137: Coolant Circuit, General, High-Temperature

    7.15 Coolant Circuit, General, High-Temperature Circuit 7.15.1 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! •...
  • Page 138 7.15.2 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant – Change Drain engine coolant (→ Page 139). Fill with engine coolant (→ Page 141). 138 | Task Description | MS150029/02E 2013-03...
  • Page 139 7.15.3 Engine coolant – Draining Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Sealing rings (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...
  • Page 140 Draining point driving end, left and right side. Final steps Close all drain valves and screw in drain plugs with new sealing rings. Set breather valve onto filler neck and close it. 140 | Task Description | MS150029/02E 2013-03...
  • Page 141 7.15.4 Engine coolant – Filling Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant WARNING Coolant is hot and under pressure.
  • Page 142 Filling coolant with pump Connect a suitable pump with a hose to the drain valve of the engine coolant pump (ar- row). Release union at distributor (arrow). Open drain valve and pump coolant into en- gine at 0.5 bar minimum. Close venting point when coolant emerges from the released union.
  • Page 143 Alternatively: Filling coolant through filler neck Release union at distributor (arrow). Fill in coolant via filler neck on expansion tank until the coolant emerges from the re- leased union. Tighten union (arrow). Fill expansion tank until overflow edge is reached. Check proper condition of breather valve, clean sealing faces if required.
  • Page 144 7.15.5 Engine coolant pump – Relief bore check DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...

  • Page 145: Engine Coolant – Sample Extraction And

    7.15.6 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 Unguarded rotating and moving engine components.
  • Page 146 7.15.7 Engine coolant filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Engine oil Coolant filter (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...

  • Page 147: Low-Temperature Circuit

    7.16 Low-Temperature Circuit 7.16.1 Charge-air coolant – Level check Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down.
  • Page 148 7.16.2 Charge-air coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Charge-air coolant – Change Drain charge-air coolant (→ Page 149). Fill with charge-air coolant (→ Page 150). 148 | Task Description | MS150029/02E 2013-03...
  • Page 149 7.16.3 Charge-air coolant – Draining Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Sealing ring (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...
  • Page 150 7.16.4 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 under pressure.
  • Page 151 Filling with charge-air coolant using pump Connect a suitable pump with a hose to the drain valve (arrowed). Release union at distributor (arrow). Open drain valve and pump coolant into en- gine at 0.5 bar minimum. Close venting point when coolant emerges from the released union.
  • Page 152 Alternatively: Filling coolant through filler neck Open venting point at distributor (arrow). Fill in coolant in expansion tank via filler neck until coolant level at top edge of filler neck remains constant. Close venting point when coolant emerges. Check proper condition of breather valve, clean sealing faces if required.
  • Page 153 7.16.5 Charge-air coolant pump – Relief bore check DANGER Unguarded rotating and moving engine components. Risk of serious injury – danger to life! • Take special care when working on a running engine. WARNING Engine noise above 85 dB (A). Risk of damage to hearing! •...

  • Page 154: Belt Drive

    7.17 Belt Drive 7.17.1 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 Belt is oily, shows signs of over- Replace (→...
  • Page 155 7.18 Battery-Charging Generator 7.18.1 Battery-charging generator – Check Preconditions ☑ Engine shut down and starting disabled. WARNING Compressed air Risk of injury! • Do not direct compressed-air jet at persons. • Wear protective goggles / safety mask and ear protectors. Checking battery-charging generator Item Findings...
  • Page 156 7.18.2 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...
  • Page 157 7.18.3 Battery-charging generator – Drive belt and belt tensioner replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 20-100Nm F30026582 Ratchet adapter F30027340 Drive belt (→ Spare Parts Catalog) Belt tensioner (→...
  • Page 158 Install protective cover. Readjust belt tension after 30 minutes and again after 8 hours engine runtime (→ Page 156). 158 | Task Description | MS150029/02E 2013-03...

  • Page 159: Fan Drive

    7.19 Fan Drive 7.19.1 Fan drive – Drive belt tension check / adjustment Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Optibell 2 belt tension tester Y4345711 Preparatory steps Remove protective cover.
  • Page 160 Adjusting drive belt tension Release screws (2) until fan coupling can be moved. Tighten tensioning screw (1) until the re- quired frequency is achieved. Tighten screws (2) to 100 Nm ± 10 Nm. 160 | Task Description | MS150029/02E 2013-03...
  • Page 161 7.19.2 Fan drive – Drive belt replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Drive belt (→ Spare Parts Catalog) Preparatory steps Remove protective cover. Remove fan. Replacing drive belt Release screws (2).
  • Page 162 7.20 Wiring (General) for Engine/Gearbox/Unit 7.20.1 Engine wiring – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol X00058037 Engine wiring – Check Check securing screws of cable clamps on engine and tighten loose threaded connections. Ensure that cables are fixed in their clamps and cannot swing freely.
  • Page 163 7.21 Accessories for (Electronic) Engine Governor / Control System 7.21.1 Engine governor and connectors – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. 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 164 7.21.2 EMU and connectors – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Isopropyl alcohol EMU and connectors – Cleaning Remove coarse dirt from housing surface using a cloth moistened with isopropyl alcohol. Remove dirt from connector and cable surfaces with isopropyl alcohol.
  • Page 165 7.21.3 Engine governor plug connections – Check Preconditions ☑ Engine is stopped and starting disabled. Note: Always use test plugs to check the connections. Never use test leads. Otherwise, the contacts might be bent. Engine governor plug connections – Check Check all plug connections for secure seating.
  • Page 166 7.21.4 EMU – Checking plug-in connections Preconditions ☑ Engine is stopped and starting disabled. EMU – checking plug-in connections Verify that all plug-in connections are securely seated. Secure loose connectors and latch. 166 | Task Description | MS150029/02E 2013-03...
  • Page 167 7.21.5 ECU 7 engine governor – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. NOTICE Wrong engine governor installed. Engine damage! • When reassembling an engine, make sure that the governor with the data record for the given engine is installed.
  • Page 168 7.21.6 EMU 7 – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. NOTICE Wrong engine governor installed. Engine damage! • When reassembling an engine, make sure that the governor with the data record for the given engine is installed. Removing ECU with EMU from engine Note or mark assignment of cables and...
  • Page 169 Abgasturbolader Exhust turbocharger (ETC) Air Temperature Sensor Baureihe Series Betriebsstoffvorschrift MTU Fluids and Lubricants Specifications, publica- tion No. A01061/.. Controller Area Network Data bus system, bus standard Calibration Drift Compensation Setting of drift compensation in engine governor with DiaSys...
  • Page 170 Abbre- Meaning Explanation viation Ersatzteilkatalog Spare Parts Catalog (SPC) Electronic Unit Injector Fuel Pressure Sensor Fuel Differential Pressure Sensor Fuel Temperature Sensor FWCP Fire Water Control Panel Ground High pressure High Alarm: Measured value exceeds 1st maximum limit HIHI High High Alarm: Measured value exceeds 2nd maximum limit value High Temperature...
  • Page 171 Abbre- Meaning Explanation viation Synchronous Reference Sensor TDC cylinder 1 Safety System Safety system alarm Turbocharger Boost Sensor Monitors charge-air pressure Turbo Compressor Inlet Turbo Compressor Outlet Transmitter Deviation Alarm: Deviation in transmitter values Throttle Position Sensor Timing Reference Sensor T-xyz Temperature-xyz Temperature measuring point, xyz specifies the...
  • Page 172 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 173: Appendix B

    9 Appendix B 9.1 Special Tools Barring device Part No.: F6555766 Qty.: Used in: 7.1.1 Engine – Barring manually (→ Page 84) Feeler gauge Part No.: Y20098771 Qty.: Used in: 7.4.2 Valve clearance – Check and adjustment (→ Page 94) Filter wrench Part No.: F30379104...
  • Page 174 7.6.2 Injector – Removal and installation (→ Page 100) Milling cutter Part No.: F30452739 Qty.: Used in: 7.6.2 Injector – Removal and installation (→ Page 100) MTU test kit Part No.: 5605892099/00 Qty.: Used in: 7.13.3 Engine oil – Sample extraction and analysis (→ Page 126) Qty.:...
  • Page 175 Ratchet Part No.: F30027340 Qty.: Used in: 7.3.1 Crankcase breather – Oil separator element re- placement, diaphragm check and replacement (→ Page 91) Qty.: Used in: 7.6.2 Injector – Removal and installation (→ Page 100) Qty.: Used in: 7.18.2 Battery-charging generator drive – Drive belt tension adjustment (→...
  • Page 176 Rigid endoscope Part No.: Y20097353 Qty.: Used in: 7.2.1 Cylinder liner – Endoscopic examination (→ Page 87) Socket wrench, 24 mm Part No.: F30039526 Qty.: Used in: 7.4.2 Valve clearance – Check and adjustment (→ Page 94) Torque wrench, 0.5-5 Nm Part No.: 0015384230 Qty.:...
  • Page 177 Torque wrench, 10-60 Nm Part No.: F30452769 Qty.: Used in: 7.6.2 Injector – Removal and installation (→ Page 100) Qty.: Used in: 7.18.2 Battery-charging generator drive – Drive belt tension adjustment (→ Page 156) Torque wrench, 20-100Nm Part No.: F30026582 Qty.: Used in: 7.18.3 Battery-charging generator –...
  • Page 178 Torque wrench, 6-50 Nm Part No.: F30027336 Qty.: Used in: 7.14.4 Centrifugal oil filter – Cleaning and filter-sleeve replacement (→ Page 134) Torque wrench, 6-50 Nm Part No.: F30027336 Qty.: Used in: 7.3.1 Crankcase breather – Oil separator element re- placement, diaphragm check and replacement (→...

  • Page 179: Index

    9.2 Index Numerics Cylinder   – Designation  18 12, 16V 4000 G73 engine data  Cylinder head cover  – Optimized exhaust emissions (EPA - Tier 2)  24 – Removal and installation  97 Cylinder liner  – Endoscopic examination  87 Abbreviations 169 – Instructions and comments on endoscopic and visual Actuators ...
  • Page 180 – Check  94 – Condensate drain(s) – Check for coolant discharge   Valve gear  – Lubrication  93 Main dimensions 28 Warning notices, standards 17 MTU contact persons 172 Wiring - engine  – Check  162 Oil indicator filter  – Check  132 Operational checks 33 180 | Appendix B | MS150029/02E 2013-03...

This manual is also suitable for:

16 v 4000 g73

Table of Contents