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MTU M015710/04E Operating Instructions Manual

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Operating Instructions

Diesel engine
12 V 4000 G23, G43, G63, G83
16 V 4000 G23, G43, G63, G83, G83L
M015710/04E

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Summary of Contents for MTU M015710/04E

  • Page 1: Operating Instructions

    Operating Instructions Diesel engine 12 V 4000 G23, G43, G63, G83 16 V 4000 G23, G43, G63, G83, G83L M015710/04E...

  • Page 2: Table Of Contents

    3D, optimized exhaust emissions 7.1.2 Engine – Barring with starting system (EPA stage 2) 7.1.3 Engine – Test run 3.9 16 V 4000 G83L engine data: Standby operation 3D, optimized fuel consumption M015710/04E 2012-09 | Table of Contents | 3...
  • Page 3 9 Appendix B 7.13.3 Engine oil – Sample extraction and analysis 9.1 Special Tools 7.14 Oil Filtration / Cooling 9.2 Index 7.14.1 Engine oil filter – Replacement 7.14.2 Oil indicator filter – Check 4 | Table of Contents | M015710/04E 2012-09...

  • Page 4: General Information

    Other components are numbered in the same way, i.e. starting with No. 1 on driving end. 1 Left engine side 3 Right engine side 2 KGS = Free end 4 KS = Driving end M015710/04E 2012-09 | General Information | 19...

  • Page 5: Engine Layout

    Key to the engine model designations 12/16V 4000 Gx3(L) 12/16 Number of cylinders Cylinder arrangement: V engine 4000 Series Application Application segment (2, 4, 6, 8) Design index L (enhanced power / speed) 20 | General Information | M015710/04E 2012-09...

  • Page 6: Sensors, Actuators And Injectors - Overview

    B4.1 to B4.8 (engine side A) The injectors (Y39.1 to Y39.8, engine side A) are underneath the cylinder head covers of the cylinder. Injector replacement and necessary activities (→ Page 146). M015710/04E 2012-09 | General Information | 21...
  • Page 7 10 B06 (engine coolant before filter) 7 B48 (fuel pressure in temperature) 3 B05 (lube oil pressure common rail) after filter) 8 B43 (charge-air coolant 4 B33 (fuel temperature in pressure) common rail) 22 | General Information | M015710/04E 2012-09...
  • Page 8 4 B09 (charge-air temper‐ side B) ature) 2 B16 (coolant pressure) The injectors (Y39.11 to Y39.18, engine side B) are underneath the cylinder head covers of the cylinder. Injector replacement and required procedure (→ Page 146) M015710/04E 2012-09 | General Information | 23...
  • Page 9 1 B13 (crankshaft speed) 24 | General Information | M015710/04E 2012-09...

  • Page 10: Technical Data

    Continuous power as per ISO 3046 1560 1635 1710 General conditions (for maximum power) Number of cylinders Intake depression (new filter) mbar Intake depression, max. mbar Exhaust overpressure mbar Exhaust overpressure, max. mbar M015710/04E 2012-09 | Technical Data | 25...
  • Page 11 Lube-oil operating temperature before engine, from °C Lube-oil operating temperature before engine, to °C Lube-oil temperature before engine, warning °C Lube-oil temperature before engine, shutdown °C Lube-oil operating pressure before engine, from Lube-oil operating pressure before engine, to 26 | Technical Data | M015710/04E 2012-09...
  • Page 12 Acoustics Number of cylinders Exhaust noise, unsilenced - BL (sound power level dB(A) LW, ISO 6798) Engine surface noise with attenuated intake noise dB(A) (filter) - BL (sound power level LW, ISO 6798) M015710/04E 2012-09 | Technical Data | 27...

  • Page 13: Operation, Variable 3B, Optimized Fuel Consumption

    (10% overload capability, de‐ sign power DIN 6280, ISO 8528) General conditions (for maximum power) Number of cylinders Intake depression (new filter) A mbar Intake depression, max. mbar Exhaust overpressure mbar Exhaust overpressure, max. mbar 28 | Technical Data | M015710/04E 2012-09...
  • Page 14 Charge air pressure before bar abs cylinder - DL Coolant system (HT circuit) Number of cylinders Coolant temperature (at en‐ °C gine connection: outlet to cooling equipment) Coolant temperature after °C engine, warning M015710/04E 2012-09 | Technical Data | 29...
  • Page 15 Fuel system Number of cylinders Fuel pressure at engine inlet -0.1 -0.1 -0.1 -0.1 -0.1 connection, min. (when en‐ gine is starting) Fuel pressure at engine inlet connection, max. (when en‐ gine is starting) 30 | Technical Data | M015710/04E 2012-09...
  • Page 16 Number of cylinders Exhaust noise, unsilenced - dB(A) DL (sound power level LW, ISO 6798) Engine surface noise with at‐ dB(A) tenuated intake noise filter) - DL (sound power level LW, ISO 6798) M015710/04E 2012-09 | Technical Data | 31...

  • Page 17: Emissions (Ta-Luft)

    1205 1575 ity, design power DIN 6280, ISO 8528) General conditions (for maximum power) Number of cylinders Intake depression (new filter) mbar Intake depression, max. mbar Exhaust overpressure mbar Exhaust overpressure, max. mbar 32 | Technical Data | M015710/04E 2012-09...
  • Page 18 Coolant temperature (at engine connection: outlet to °C cooling equipment) Coolant temperature after engine, warning °C Coolant temperature after engine, shutdown °C Coolant antifreeze content, max. Pressure loss in off-engine cooling system, max. M015710/04E 2012-09 | Technical Data | 33...
  • Page 19 Charge-air coolant, engine side Liters Engine oil, total, for initial filling (standard oil system) Liters (option: max. operating inclinations) Oil change quantity, max. (standard oil system) (op‐ Liters tion: max. operating inclinations) 34 | Technical Data | M015710/04E 2012-09...
  • Page 20 Acoustics Number of cylinders Exhaust noise, unsilenced - DL (sound power level dB(A) LW, ISO 6798) Engine surface noise with attenuated intake noise dB(A) filter) - DL (sound power level LW, ISO 6798) M015710/04E 2012-09 | Technical Data | 35...

  • Page 21: Operation, Variable 3B, Optimized Fuel Consumption

    2280 load capability, design power DIN 6280, ISO 8528) General conditions (for maximum power) Number of cylinders Intake depression (new filter) mbar Intake depression, max. mbar Exhaust overpressure mbar Exhaust overpressure, max. mbar 36 | Technical Data | M015710/04E 2012-09...
  • Page 22 Coolant temperature (at engine connec‐ °C tion: outlet to cooling equipment) Coolant temperature after engine, warn‐ °C Coolant temperature after engine, shut‐ °C down Coolant antifreeze content, max. Pressure loss in off-engine cooling sys‐ tem, max. M015710/04E 2012-09 | Technical Data | 37...
  • Page 23 General operating data Number of cylinders Cold start capability: air temperature (w/ °C o start aid, w/o preheating) - (case A) Coolant preheating: preheating tempera‐ °C ture (min.) Firing speed, from Firing speed, to 38 | Technical Data | M015710/04E 2012-09...
  • Page 24 Number of cylinders Exhaust noise, unsilenced - DL (sound dB(A) power level LW, ISO 6798) Engine surface noise with attenuated in‐ dB(A) take noise filter) - DL (sound power level LW, ISO 6798) M015710/04E 2012-09 | Technical Data | 39...

  • Page 25: 12/16 V 4000 Gx3 Engine Data: Continuous Operation, Variable 3B, Optimized Exhaust Emissions (Epa Stage 2)

    2280 load capability, design power DIN 6280, ISO 8528) General conditions (for maximum power) Number of cylinders Intake depression (new filter) mbar Intake depression, max. mbar Exhaust overpressure mbar Exhaust overpressure, max. mbar 40 | Technical Data | M015710/04E 2012-09...
  • Page 26 Coolant temperature (at engine connec‐ °C tion: outlet to cooling equipment) Coolant temperature after engine, warn‐ °C Coolant temperature after engine, shut‐ °C down Coolant antifreeze content, max. Pressure loss in off-engine cooling sys‐ tem, max. M015710/04E 2012-09 | Technical Data | 41...
  • Page 27 General operating data Number of cylinders Cold start capability: air temperature (w/ °C o start aid, w/o preheating) - (case A) Coolant preheating: preheating tempera‐ °C ture (min.) Firing speed, from Firing speed, to 42 | Technical Data | M015710/04E 2012-09...
  • Page 28 Number of cylinders Exhaust noise, unsilenced - DL (sound dB(A) power level LW, ISO 6798) Engine surface noise with attenuated in‐ dB(A) take noise filter) - DL (sound power level LW, ISO 6798) M015710/04E 2012-09 | Technical Data | 43...

  • Page 29: 4000 Gx3 Engine Data: Standby Operation 3D, Optimized Fuel Consumption

    Fuel stop power ISO 3046 1575 1736 1750 1910 General conditions (for maximum power) Number of cylinders Intake depression (new filter) mbar Intake depression, max. mbar Exhaust overpressure mbar Exhaust overpressure, max. mbar 44 | Technical Data | M015710/04E 2012-09...
  • Page 30 Coolant temperature (at engine connec‐ °C tion: outlet to cooling equipment) Coolant temperature after engine, warn‐ °C Coolant temperature after engine, shut‐ °C down Coolant antifreeze content, max. Pressure loss in off-engine cooling sys‐ tem, max. M015710/04E 2012-09 | Technical Data | 45...
  • Page 31 General operating data Number of cylinders Cold start capability: air temperature (w/ °C o start aid, w/o preheating) - (case A) Coolant preheating: preheating tempera‐ °C ture (min.) Firing speed, from Firing speed, to 46 | Technical Data | M015710/04E 2012-09...
  • Page 32 Number of cylinders Exhaust noise, unsilenced - BL (sound dB(A) power level LW, ISO 6798) Engine surface noise with attenuated in‐ dB(A) take noise (filter) - BL (sound power lev‐ el LW, ISO 6798) M015710/04E 2012-09 | Technical Data | 47...

  • Page 33: 4000 Gx3 Engine Data: Standby Operation 3D, Optimized Fuel Consumption

    Fuel stop power ISO 3046 1965 2280 2185 2500 General conditions (for maximum power) Number of cylinders Intake depression (new filter) mbar Intake depression, max. mbar Exhaust overpressure mbar Exhaust overpressure, max. mbar 48 | Technical Data | M015710/04E 2012-09...
  • Page 34 Coolant temperature (at engine connec‐ °C tion: outlet to cooling equipment) Coolant temperature after engine, warn‐ °C Coolant temperature after engine, shut‐ °C down Coolant antifreeze content, max. Pressure loss in off-engine cooling sys‐ tem, max. M015710/04E 2012-09 | Technical Data | 49...
  • Page 35 General operating data Number of cylinders Cold start capability: air temperature (w/ °C o start aid, w/o preheating) - (case A) Coolant preheating: preheating tempera‐ °C ture (min.) Firing speed, from Firing speed, to 50 | Technical Data | M015710/04E 2012-09...
  • Page 36 Number of cylinders Exhaust noise, unsilenced - BL (sound dB(A) power level LW, ISO 6798) Engine surface noise with attenuated in‐ dB(A) take noise (filter) - BL (sound power lev‐ el LW, ISO 6798) M015710/04E 2012-09 | Technical Data | 51...

  • Page 37: 12/16 V 4000 Gx3 Engine Data: Standby Operation 3D, Optimized Exhaust Emissions (Epa Stage 2)

    Fuel stop power ISO 3046 1736 1910 2280 2500 General conditions (for maximum power) Number of cylinders Intake depression (new filter) mbar Intake depression, max. mbar Exhaust overpressure mbar Exhaust overpressure, max. mbar 52 | Technical Data | M015710/04E 2012-09...
  • Page 38 Coolant temperature (at engine connec‐ °C tion: outlet to cooling equipment) Coolant temperature after engine, warn‐ °C Coolant temperature after engine, shut‐ °C down Coolant antifreeze content, max. Pressure loss in off-engine cooling sys‐ tem, max. M015710/04E 2012-09 | Technical Data | 53...
  • Page 39 General operating data Number of cylinders Cold start capability: air temperature (w/ °C o start aid, w/o preheating) - (case A) Coolant preheating: preheating tempera‐ °C ture (min.) Firing speed, from Firing speed, to 54 | Technical Data | M015710/04E 2012-09...
  • Page 40 Number of cylinders Exhaust noise, unsilenced - BL (sound dB(A) power level LW, ISO 6798) Engine surface noise with attenuated in‐ dB(A) take noise (filter) - BL (sound power lev‐ el LW, ISO 6798) M015710/04E 2012-09 | Technical Data | 55...

  • Page 41: 4000 G83L Engine Data: Standby Operation 3D, Optimized Fuel Consumption

    Rated engine speed 1800 Fuel stop power ISO 3046 2740 General conditions (for maximum power) Number of cylinders Intake depression (new filter) mbar Intake depression, max. mbar Exhaust overpressure mbar Exhaust overpressure, max. mbar 56 | Technical Data | M015710/04E 2012-09...
  • Page 42 Pressure loss in off-engine cooling system, max. Coolant system (LT circuit) Number of cylinders Coolant temperature before intercooler (at engine connection: from cooling °C equipment) Coolant antifreeze content, max. Pressure loss in off-engine cooling system, max. M015710/04E 2012-09 | Technical Data | 57...
  • Page 43 Oil pan capacity at dipstick mark “max.” (standard oil system) (Option: max. Liters operating inclinations) Weights / main dimensions Number of cylinders Engine dry weight (basic engine configuration according to scope of deliv‐ 7700 ery specifications) 58 | Technical Data | M015710/04E 2012-09...
  • Page 44 Acoustics Number of cylinders Exhaust noise, unsilenced - BL (sound power level LW, ISO 6798+3) dB(A) Engine surface noise with attenuated intake noise (filter) - BL (sound power dB(A) level LW, ISO 6798) M015710/04E 2012-09 | Technical Data | 59...

  • Page 45: 4000 G83L Engine Data: Standby Operation 3D, Optimized Exhaust Emissions (Epa Stage 2)

    Rated engine speed 1800 Fuel stop power ISO 3046 2740 General conditions (for maximum power) Number of cylinders Intake depression (new filter) mbar Intake depression, max. mbar Exhaust overpressure mbar Exhaust overpressure, max. mbar 60 | Technical Data | M015710/04E 2012-09...
  • Page 46 Pressure loss in off-engine cooling system, max. Coolant system (LT circuit) Number of cylinders Coolant temperature before intercooler (at engine connection: from cooling °C equipment) Coolant antifreeze content, max. Pressure loss in off-engine cooling system, max. M015710/04E 2012-09 | Technical Data | 61...
  • Page 47 Oil pan capacity at dipstick mark “max.” (standard oil system) (Option: max. Liters operating inclinations) Weights / main dimensions Number of cylinders Engine dry weight (basic engine configuration according to scope of deliv‐ 7700 ery specifications) 62 | Technical Data | M015710/04E 2012-09...
  • Page 48 Acoustics Number of cylinders Exhaust noise, unsilenced - BL (sound power level LW, ISO 6798+3) dB(A) Engine surface noise with attenuated intake noise (filter) - BL (sound power dB(A) level LW, ISO 6798) M015710/04E 2012-09 | Technical Data | 63...

  • Page 49: Final Compression Pressure

    3.11 Final compression pressure Final compression pressure Final compression pressure at 120 rpm 24 bar to 28 bar 64 | Technical Data | M015710/04E 2012-09...

  • Page 50: Firing Order

    3.12 Firing order Firing order Num‐ Firing order ber of cylin‐ ders A1-B4-A4-A2-B3-A3-B2-B1 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 20 V A1-B5-A8-B7-A5-B2-A7-B10-A2-B3-A10-B6-A3-B4-A6-B9-A4-B1-A9-B8 M015710/04E 2012-09 | Technical Data | 65...

  • Page 51: Engine - Main Dimensions

    Engine model Length (A) Width (B) Height (C) 12 V 4000 Gx3 approx. 2520 mm approx. 1660 mm approx. 2160 mm 16 V 4000 Gx3 approx. 2990 mm approx. 1660 mm approx. 2160 mm 66 | Technical Data | M015710/04E 2012-09...

  • Page 52: Operation

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

  • Page 53: Putting The Engine Into Operation After Scheduled Out-Of-Service-Period

    Preheat coolant with preheating unit. Fuel prefilter Drain (→ Page 156). Monitoring equipment Carry out lamp test (see manufacturer's documentation). Engine/generator control Switch ON; system Select operating mode, e.g. MANUAL OPERATION, AUTOMATIC OPER‐ ATION. 68 | Operation | M015710/04E 2012-09...

  • Page 54: Start Engine In Manual Mode (Testing Mode)

    ) Item Task Switchgear cabinet, control Close the generator circuit breaker. panel etc. (depending on manufacturer) Engine Apply full load only after engine has reached operating temperature (cool‐ ant temperature approx. 75 °C). M015710/04E 2012-09 | Operation | 69...

  • Page 55: Safety System - Override

    Actuate start button, for further starting sequence, refer to engine start panel etc. (depending on (→ Page 69). manufacturer) Control and display panels During operation, check the displayed operational data (speed, tempera‐ ture, pressures). Constantly monitor plant limit values. 70 | Operation | M015710/04E 2012-09...

  • Page 56: Starting The Engine In Emergency Situations (Override Mode)

    • Engine is running at rated speed when the starting sequence is com‐ pleted. Connecting the generator (if fitted) to mains Item Task Control cabinet If generator is not connected to mains: Close generator circuit breaker. Engine Operate engine at rated power. M015710/04E 2012-09 | Operation | 71...

  • Page 57: Operational Checks

    Check relief bore (→ Page 190). Compressed-air system (if Check operating pressure on pressure gauge; installed) Always fill compressed-air tank to max. pressure; Drain condensate from compressed-air tank, pressure drop must not ex‐ ceed 1 bar. 72 | Operation | M015710/04E 2012-09...

  • Page 58: Stop Engine In Manual Mode (Testing Mode)

    Press stop button. panel etc. (depending on • Automatic stopping sequence is performed; manufacturer) • Engine is stopped. After stopping the engine Item Task Coolant pump Allow to run on for sufficient time after stopping. M015710/04E 2012-09 | Operation | 73...

  • Page 59: Emergency Stop

    • Signalization (e.g. by horn, flashing lamp) is released. After emergency stop from LOP Item Task Switching cabinet, control Press button for alarm acknowledgement. panel etc. (depending on • Audible and visual signalization stops. manufacturer) 74 | Operation | M015710/04E 2012-09...

  • Page 60: After Stopping The Engine - Engine Remains Ready For Operation

    4.9 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 M015710/04E 2012-09 | Operation | 75...

  • Page 61: After Stopping The Engine - Putting The Engine Out Of Service

    If the engine is to remain out of service for more than 1 week, seal the engine's air and exhaust sides. If the engine is to remain out of service for more than 1 month, preserve engine (→ MTU-Preservation and Represer‐ vation Specifications A001070/..).

  • Page 62: Plant Cleaning

    Spray on cleaner sparingly and leave it for 1 to 5 minutes. d) Use the high-pressure jet to remove the loosened dirt. Note: Never aim compressed air directly at electronic components. e) Dry engine. M015710/04E 2012-09 | Operation | 77...

  • Page 63: Maintenance

    (→ Page 191) adjust belt tension. W1463 Check general condition of engine mounting (visual in‐ (→ Page 194) spection). W1714 Check and clean oil indicator filter. (→ Page 172) Table 1: Maintenance task reference table [QL1] 78 | Maintenance | M015710/04E 2012-09...

  • Page 64: Troubleshooting

    Probable cause Task Fuel injection equip‐ Injector defective Replace (→ Page 146). ment Engine wiring Defective Check (→ Page 195). Fuel system Not vented Vent fuel system (→ Page 152). Engine Governor Defective Contact Service. M015710/04E 2012-09 | Troubleshooting | 79...
  • Page 65 Component Probable cause Task Air supply Air filter clogged Check signal ring position of service in‐ dicator (→ Page 165). Fuel injection equip‐ Injector defective Replace (→ Page 146). ment Engine Overloaded Contact Service. 80 | Troubleshooting | M015710/04E 2012-09...
  • Page 66 Task Engine Not at operating temperature Run engine to reach operating temper‐ ature. Fuel system Water in fuel Check fuel system on fuel prefilter. Drain fuel prefilter (→ Page 156). Intercooler Leaking Contact Service. M015710/04E 2012-09 | Troubleshooting | 81...

  • Page 67: Engine Governor Adec (Ecu 7) For Series 4000 Genset Engines - Fault Messages

    Charge-air temperature too high 1. Reduce power. Engine stop. 2. Check intercooler. 009 – HI T-Coolant Intercooler ZKP-Number: 2.0124.931 Limit value 1 Cause Corrective action Coolant temperature in u Reduce power. intercooler too high. 82 | Troubleshooting | M015710/04E 2012-09...
  • Page 68 2. Contact Service. 021 – HI T-Exhaust B ZKP-Number: 2.0127.931 Limit value 1 Cause Corrective action Exhaust gas temperature (B- 1. Check wiring (→ Page 195). side) too high. 2. Contact Service. M015710/04E 2012-09 | Troubleshooting | 83...
  • Page 69 Leak-fuel level too high. 1. Check fuel system. 2. Contact Service. 029 – HI ETC 2 Idle Speed too High ZKP-Number: 1.8004.206 Cause Corrective action Idle speed of ETC 2 too high. u Contact Service. 84 | Troubleshooting | M015710/04E 2012-09...
  • Page 70 Replace fuel filter (→ Page 153). too high. 036 – HI ETC 2 Overspeed ZKP-Number: 2.3013.931 Limit value 1 Cause Corrective action Speed of first secondary 1. Reduce power. turbocharger too high. 2. Contact Service. M015710/04E 2012-09 | Troubleshooting | 85...
  • Page 71 Reduce power. 052 – SS T-Lube Oil ZKP-Number: 2.0125.932 Limit value 2 Cause Corrective action Lube oil temperature too high. 1. Reduce power. Engine stop. 2. Check engine oil level (→ Page 169). 86 | Troubleshooting | M015710/04E 2012-09...
  • Page 72 2. Check engine coolant cooler, clean if dirty. 3. Contact Service. 063 – HI P-Crankcase ZKP-Number: 2.0106.931 Limit value 1 Cause Corrective action Crankcase pressure too high. 1. Reduce power. 2. Replace oil separator element (→ Page 138). M015710/04E 2012-09 | Troubleshooting | 87...
  • Page 73 Limit value 2 Cause Corrective action Coolant temperature too high; 1. Allow engine to cool down. Engine stop. 2. Check engine coolant cooler, clean if dirty. 3. Restart engine (→ Page 69). 4. Contact Service. 88 | Troubleshooting | M015710/04E 2012-09...
  • Page 74 ZKP-Number: 2.0128.931 Limit value 1 Cause Corrective action Recirculation temperature too u Reduce power. high. 086 – SS T-Umblasen ZKP-Number: 2.0128.932 Limit value 2 Cause Corrective action Recirculation temperature too u Reduce power. high. M015710/04E 2012-09 | Troubleshooting | 89...
  • Page 75 094 – LO T-Preheat ZKP-Number: 2.1090.921 Limit value 1 Cause Corrective action Preheating temperature too low; u Check preheater. coolant temperature too low for engine start. 90 | Troubleshooting | M015710/04E 2012-09...
  • Page 76 1. Check ECU supply voltage. 2. Contact Service. 120 – HI ECU Power Supply Voltage ZKP-Number: 2.0140.931 Limit value 1 Cause Corrective action Supply voltage too high. 1. Check ECU supply voltage. 2. Contact Service. M015710/04E 2012-09 | Troubleshooting | 91...
  • Page 77 1 hour within the last 12 hours. 176 – AL LifeData not available ZKP-Number: 2.4000.004 Cause Corrective action No (appropriate) LifeData u Contact Service. backup system available, ECU reset after expiration of time-out period. 92 | Troubleshooting | M015710/04E 2012-09...
  • Page 78 184 – AL CAN PU-Data Flash Error ZKP-Number: 2.0500.684 Cause Corrective action A programming error occurred u Contact Service. when attempting to copy a received PU data module into the Flash module. M015710/04E 2012-09 | Troubleshooting | 93...
  • Page 79 1. Check CAN bus for short circuit, rectify short circuit as warning. necessary. 2. Check shielding, improve shielding as necessary. 3. Contact Service. 190 – AL EMU Parameter Not Supported ZKP-Number: 2.0500.690 Cause Corrective action EMU parameters are not u Contact Service. supported. 94 | Troubleshooting | M015710/04E 2012-09...
  • Page 80 206 – SD T-Exhaust A ZKP-Number: 1.8004.576 Cause Corrective action Exhaust temperature sensor on u Check sensor and cabling (B4.21), replace if necessary. A-side faulty; short circuit or wire Error cleared after restarting the engine. break. M015710/04E 2012-09 | Troubleshooting | 95...
  • Page 81 214 – SD P-Crankcase ZKP-Number: 1.8004.568 Cause Corrective action Crankcase pressure sensor u Check sensor and cabling (B50), replace as necessary. faulty; short circuit or wire break. Error cleared after restarting the engine. 96 | Troubleshooting | M015710/04E 2012-09...
  • Page 82 222 – SD Level Leakage Fuel ZKP-Number: 1.8004.582 Cause Corrective action Leak-off fuel level sensor faulty; u Check sensor and cabling (F46), replace as necessary. short circuit or wire break. Error cleared after restarting the engine. M015710/04E 2012-09 | Troubleshooting | 97...
  • Page 83 Error cleared after restarting the engine. 231 – SD Crankshaft Speed ZKP-Number: 1.8004.499 Cause Corrective action Camshaft sensor faulty; short u Check sensor and cabling (B13), replace as necessary. circuit or wire break. Error cleared after restarting the engine. 98 | Troubleshooting | M015710/04E 2012-09...
  • Page 84 242 – SD T-Coolant (R) ZKP-Number: 1.8004.622 Cause Corrective action Redundant coolant pressure u Check sensor and cabling, replace as necessary. sensor faulty; short circuit or wire Error cleared after restarting the engine. break. M015710/04E 2012-09 | Troubleshooting | 99...
  • Page 85 Error cleared after restarting the engine. wire break. 270 – SD Frequency Input ZKP-Number: 2.8006.590 Cause Corrective action Frequency input faulty; short 1. Check cabling. circuit or wire break. 2. Check speed demand transmitter. 3. Contact Service. 100 | Troubleshooting | M015710/04E 2012-09...
  • Page 86 305 – AL Timing Cylinder A5 ZKP-Number: 1.8004.504 Cause Corrective action Time-of-flight measuring fault of u Replace injector concerned if the fault message appears injector: Time-of flight measured frequently (→ Page 146). value extremely low or extremely high. M015710/04E 2012-09 | Troubleshooting | 101...
  • Page 87 310 – AL Timing Cylinder A10 ZKP-Number: 1.8004.509 Cause Corrective action Time-of-flight measuring fault of u Replace injector concerned if the fault message appears injector: Time-of flight measured frequently (→ Page 146). value extremely low or extremely high. 102 | Troubleshooting | M015710/04E 2012-09...
  • Page 88 315 – AL Timing Cylinder B5 ZKP-Number: 1.8004.514 Cause Corrective action Time-of-flight measuring fault of u Replace injector concerned if the fault message appears injector: Time-of flight measured frequently (→ Page 146). value extremely low or extremely high. M015710/04E 2012-09 | Troubleshooting | 103...
  • Page 89 320 – AL Timing Cylinder B10 ZKP-Number: 1.8004.519 Cause Corrective action Time-of-flight measuring fault of u Replace injector concerned if the fault message appears injector: Time-of flight measured frequently (→ Page 146). value extremely low or extremely high. 104 | Troubleshooting | M015710/04E 2012-09...
  • Page 90 1. Check solenoid valve. cylinder. Result: Misfiring. 2. Contact Service. 327 – AL Wiring Cylinder A7 ZKP-Number: 1.8004.526 Cause Corrective action Short circuit in injector cabling to 1. Check solenoid valve. cylinder. Result: Misfiring. 2. Contact Service. M015710/04E 2012-09 | Troubleshooting | 105...
  • Page 91 1. Check solenoid valve. cylinder. Result: Misfiring. 2. Contact Service. 334 – AL Wiring Cylinder B4 ZKP-Number: 1.8004.533 Cause Corrective action Short circuit in injector cabling to 1. Check solenoid valve. cylinder. Result: Misfiring. 2. Contact Service. 106 | Troubleshooting | M015710/04E 2012-09...
  • Page 92 Result: Misfiring. 2. Contact Service. 341 – AL Open Load Cylinder A1 ZKP-Number: 1.8004.540 Cause Corrective action Open circuit in injector wiring to 1. Check solenoid valve. cylinder. Result: Misfiring. 2. Contact Service. M015710/04E 2012-09 | Troubleshooting | 107...
  • Page 93 Result: Misfiring. 2. Contact Service. 348 – AL Open Load Cylinder A8 ZKP-Number: 1.8004.547 Cause Corrective action Open circuit in injector wiring to 1. Check solenoid valve. cylinder. Result: Misfiring. 2. Contact Service. 108 | Troubleshooting | M015710/04E 2012-09...
  • Page 94 Result: Misfiring. 2. Contact Service. 355 – AL Open Load Cylinder B5 ZKP-Number: 1.8004.554 Cause Corrective action Open circuit in injector wiring to 1. Check solenoid valve. cylinder. Result: Misfiring. 2. Contact Service. M015710/04E 2012-09 | Troubleshooting | 109...
  • Page 95 ZKP-Number: 1.8004.496 Cause Corrective action Internal electronic fault 1. Check solenoid valve cabling. (electronics possibly faulty: start 2. Replace Engine Control Unit. ITS).Check additional messages if ITS indicates diagnosis "Electronics OK" (e.g. cabling faulty). 110 | Troubleshooting | M015710/04E 2012-09...
  • Page 96 2. Replace Engine Control Unit. 372 – AL Wiring TO 2 ZKP-Number: 1.8004.635 Cause Corrective action Short circuit or wire break on 1. Check recirculation valve/cabling, repair as necessary. transistor output 2 (TO 2). 2. Replace ECU. M015710/04E 2012-09 | Troubleshooting | 111...
  • Page 97 3 (TOP 3). 384 – AL Wiring TOP 4 ZKP-Number: 2.8006.641 Cause Corrective action Short circuit or wire break on u Check cabling to plant. transistor output, plant-side 4 (TOP 4). 112 | Troubleshooting | M015710/04E 2012-09...
  • Page 98 1. Check cabling and sensor. reading too low. 2. Contact Service. 396 – TD T-Coolant Sensor Deviation ZKP-Number: 1.0480.193 Cause Corrective action Maximum coolant temperature 1. Check cabling and sensor. deviation. 2. Contact Service. M015710/04E 2012-09 | Troubleshooting | 113...
  • Page 99 404 – AL Open Load Digital Input 5 ZKP-Number: 2.8006.629 Cause Corrective action Line disruption on digital input 5; 1. Check cabling. Cabling faulty or no resistance 2. Check target device input. over switch. 3. Contact Service. 114 | Troubleshooting | M015710/04E 2012-09...
  • Page 100 1. Check cabling. 2. Check supply. 3. Contact Service. 411 – LOLO U-PDU ZKP-Number: 2.0141.922 Limit value 2 Cause Corrective action Injector voltage too low. 1. Check cabling. 2. Check supply. 3. Contact Service. M015710/04E 2012-09 | Troubleshooting | 115...
  • Page 101 Top up coolant (→ Page 187). too low. 416 – SS P-Coolant Intercooler ZKP-Number: 2.0107.922 Limit value 2 Cause Corrective action Coolant pressure in intercooler u Top up coolant (→ Page 187). too low; Engine stop. 116 | Troubleshooting | M015710/04E 2012-09...
  • Page 102 ZKP-Number: 2.0130.921 Limit value 1 Cause Corrective action Temperature signal of Aux 1 has u Determine cause of limit value violation and rectify fault. exceeded / not attained limit value 1, depending on configuration. M015710/04E 2012-09 | Troubleshooting | 117...
  • Page 103 ZKP-Number: 2.0110.931 Limit value 2 Cause Corrective action Pressure signal of Aux 1 has u Determine cause of limit value violation and rectify fault. exceeded / not attained limit value 2, depending on configuration. 118 | Troubleshooting | M015710/04E 2012-09...
  • Page 104 Error cleared after restarting the engine. 454 – SS Power Reduction Active ZKP-Number: 2.7000.011 Cause Corrective action Power reduction is active. 1. Note further fault messages. 2. Determine cause of power reduction and rectify fault M015710/04E 2012-09 | Troubleshooting | 119...
  • Page 105 1. Check cabling. value too low. 2. Contact Service. 462 – HI T-Coolant EMU ZKP-Number: 2.8006.654 Limit value 1 Cause Corrective action EMU coolant temperature value u Check configuration with DiaSys. too high / low. 120 | Troubleshooting | M015710/04E 2012-09...
  • Page 106 471 – SD Coil Current ZKP-Number: 1.8004.592 Cause Corrective action Control of HP fuel control block u Check sensor and cabling, replace as necessary. faulty; short circuit or wire break. Error cleared after restarting the engine. M015710/04E 2012-09 | Troubleshooting | 121...
  • Page 107 Cause Corrective action Initialization error of crash u Check settings with DiaSys. recorder. 478 – AL Comb. Alarm Yel (Plant) ZKP-Number: 2.8006.001 Cause Corrective action Combined alarm YELLOW from u Check additional messages. plant. 122 | Troubleshooting | M015710/04E 2012-09...
  • Page 108 1. Reduce power. side) too high. 2. Contact Service. 485 – SS T-Exhaust C ZKP-Number: 20.133.932 Limit value 2 Cause Corrective action Exhaust gas temperature (C- 1. Reduce power. side) too high. 2. Contact Service. M015710/04E 2012-09 | Troubleshooting | 123...
  • Page 109 Speed of the 3rd secondary u Reduce power. turbocharger too high. 491 – SS ETC4 Overspeed ZKP-Number: 23.015.932 Limit value 2 Cause Corrective action Speed of the 3rd secondary u Reduce power. turbocharger too high. 124 | Troubleshooting | M015710/04E 2012-09...
  • Page 110 Check connection between POM and battery-charging at the battery-charging generator. connection for the POM. 503 – AL Battery Not Charging ZKP-Number: 14.500.903 Cause Corrective action Battery is not charged by u Check battery-charging generator and cabling. battery-charging generator. M015710/04E 2012-09 | Troubleshooting | 125...
  • Page 111 If the number of 2. Check CPM, starter and cabling. automatic start attempts from PR 2.1090.134 Number of Start Attempts is used up then start is canceled. Check CPM, starter and cabling. 126 | Troubleshooting | M015710/04E 2012-09...
  • Page 112 526 – SD T-Coolant (R2) ZKP-Number: 18.004.639 Cause Corrective action Redundant coolant pressure u Check sensor and cabling, replace as necessary. sensor faulty. short circuit or wire break. M015710/04E 2012-09 | Troubleshooting | 127...
  • Page 113 Fault remains active until changes are revoked or data have cases in which the system been transferred by active maintenance. Fault is then configuration has been changed, automatically cleared. e.g. due to replacement of an ECU or a SAM. 128 | Troubleshooting | M015710/04E 2012-09...
  • Page 114 Limit value 2 Cause Corrective action Camshaft overspeed. 1. Acknowledge alarm. 2. Attempt to restart engine. 555 – AL Call MTU Field Service ZKP-Number: 20.555.001 Cause Corrective action This fault becomes active if a u Request enabling code via internet.
  • Page 115 Corrective action MD speed limitation demand => node failure (node 3,4 or 5) 581 – AL MD CAN Stop ZKP-Number: 21.063.515 Cause Corrective action MD CAN stop demand => node failure (node 3,4 or 5) 130 | Troubleshooting | M015710/04E 2012-09...

  • Page 116: Task Description

    Place ratchet (1) onto barring device (2). Rotate crankshaft in engine direction of ro‐ tation. Apart from the normal compression resistance, there should be no further re‐ sistance. For barring device removal, follow reverse sequence of working steps. M015710/04E 2012-09 | Task Description | 131...

  • Page 117: Engine - Barring With Starting System

    Let the crankshaft rotate until oil pressure is indicated. Engine start is automatically interrupted when specified starting period has passed. If necessary, re-start the engine after approx. 20 seconds. Connect connector X4 to engine governor and latch in position. 132 | Task Description | M015710/04E 2012-09...

  • Page 118: Engine - Test Run

    Engine – Test run Start engine (→ Page 69). Perform test run not below 1/3 load and at least until steady-state temperature is reached. Carry out operational checks (→ Page 72). Stop engine (→ Page 73). M015710/04E 2012-09 | Task Description | 133...

  • Page 119: Cylinder Liner

    Use technical terms for description of the liner surface (→ Page 136). Depending on findings: • do not take any action or • carry out a further endoscopic examination as part of maintenance work or • contact Service; cylinder liner must be replaced. 134 | Task Description | M015710/04E 2012-09...
  • Page 120 Final steps Install injector (→ Page 147). Install cylinder head cover (→ Page 144). M015710/04E 2012-09 | Task Description | 135...
  • Page 121 TDC to BDC in the running surface and the start of localized damage to the honing pattern. Cylinder liners with a large number of black lines around the running surface have limited service life and should be replaced. 136 | Task Description | M015710/04E 2012-09...
  • Page 122 To avoid unnecessary disassembly work, it is recommended that another inspection be carried out after fur‐ ther operation of the engine. M015710/04E 2012-09 | Task Description | 137...

  • Page 123: Crankcase Breather

    Use torque wrench to tighten the screws of cover (2) to the specified torque. Name Size Type Lubricant Value/Standard Screw Tightening torque (Engine oil) 10 Nm −2 Nm Replace further oil separator elements in the same way. 138 | Task Description | M015710/04E 2012-09...
  • Page 124 Use torque wrench to tighten the screws of cover (4) to the specified torque. Name Size Type Lubricant Value/Standard Screw Tightening torque (Engine oil) 10 Nm −2 Nm Check diaphragms in further oil separators in the same way. M015710/04E 2012-09 | Task Description | 139...

  • Page 125: Valve Drive

    Remove cylinder head covers (→ Page 144). Fill oil chambers of valve bridges with oil. Fill oil chambers of rocker arms and adjust‐ ing screws with oil. Install cylinder head covers (→ Page 144). 140 | Task Description | M015710/04E 2012-09...
  • Page 126 Note: The OT mark (if fitted) on the flywheel must not be used for reference. Rotate crankshaft with barring device in en‐ gine direction of rotation until "OT-A1" mark and pointer are aligned. M015710/04E 2012-09 | Task Description | 141...
  • Page 127 2 Cylinder A1 is in overlap TDC I Inlet valve X Exhaust valve Use feeler gauge to determine the distance between valve bridge and rocker arm. If the deviation from the reference value exceeds 0.1 mm, adjust valve clearance. 142 | Task Description | M015710/04E 2012-09...

  • Page 128: Adjusting Valve Clearance

    90 Nm +9 Nm Replace or rectify adjusting screws and/or locknuts which do not move freely. Check valve clearance. Final steps Remove barring device (→ Page 131). Install cylinder head cover (→ Page 144). M015710/04E 2012-09 | Task Description | 143...

  • Page 129: Cylinder Head Cover – Removal And

    Coat O-ring (6) with grease. Position O-ring (6) in groove of cylinder head cover (1). Fit cylinder head cover (1) on cylinder head (7). Install cylinder head cover (1) with screws (3, 4) and washers (2, 5). 144 | Task Description | M015710/04E 2012-09...
  • Page 130 • Make sure that the high-pressure fuel pump is filled with engine oil before installation or initial operation. Filling HP pump Remove plug screw (1). Use pump oiler to fill HP pump with engine oil until engine oil emerges. Insert plug screw (1). M015710/04E 2012-09 | Task Description | 145...
  • Page 131 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 147). 146 | Task Description | M015710/04E 2012-09...
  • Page 132 • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Preparatory steps Shut off fuel supply to engine. Remove cylinder head cover (→ Page 144). Removing injector Disconnect cable connector on injector. M015710/04E 2012-09 | Task Description | 147...
  • Page 133 Remove O-rings (3), O-ring (2) and damper ring (1) from injector. Clean all mating and sealing surfaces. Cover all connections and bores, or seal with suitable plugs. 148 | Task Description | M015710/04E 2012-09...
  • Page 134 Insert injector into cylinder head, ensuring that the HP line adapter is correctly aligned. Use installation/removal tool to press in in‐ jector. Remove installation/removal tool. M015710/04E 2012-09 | Task Description | 149...
  • Page 135 Mount single-walled HP line (5) and use torque wrench to tighten to the specified torque. Tightening se‐ quence: 1 Rail (6) 2 Adapter (4) Name Size Type Lubricant Value/Standard Union nut / thrust Tightening torque 30 Nm + 5 Nm screw 150 | Task Description | M015710/04E 2012-09...
  • Page 136 Reset drift compensation (CDC) with Dia‐ Sys® (→ E531920/...). If DiaSys® is not available, contact Service. Final steps Install cylinder head cover (→ Page 144). Open fuel supply to engine. M015710/04E 2012-09 | Task Description | 151...

  • Page 137: Fuel System

    Operate the pump with the handle (2) until bubble-free fuel emerges from the vent plug (1). Close vent plug (1). Screw in handle by turning it clockwise. Verify that fuel priming pump (2) is locked: handle must be tightened. 152 | Task Description | M015710/04E 2012-09...

  • Page 138: Fuel Filter

    Slightly lubricate seal on the easy-change filter (arrow). Screw on the easy-change filter by hand until the seal makes contact and tighten fin‐ ger-tight. Replace further easy-change filters in the same way. Vent fuel system (→ Page 152). M015710/04E 2012-09 | Task Description | 153...

  • Page 139: Fuel Prefilter Cleaning

    Wash filter housing with clean fuel. Insert filter element into filter housing and secure with nut. Place new sealing ring into groove in filter head. Fit cover with seal and secure it with nuts crosswise. Open fuel supply. 154 | Task Description | M015710/04E 2012-09...

  • Page 140: Fuel Prefilter – Differential Pressure Gauge

    With the engine running at full load or rated power, read off pressure at gauge (1). If differential pressure as indicated between position of adjustable pointer (2) and pressure-indicating pointer (3) of pressure gauge is ≥ 0.3 bar, flush filter element of the cut-in filter (→ Page 157). M015710/04E 2012-09 | Task Description | 155...
  • Page 141 Fill filter housing with clean fuel. Place new gasket in cover (2). Fit cover with gasket and secure it with screws. Cut in the cut-out filter again. Close threaded vent plug (5) when fuel emerges. 156 | Task Description | M015710/04E 2012-09...
  • Page 142 Engine noise above 85 dB (A). Risk of damage to hearing! • Wear ear protectors. Fuel prefilter ‒ Flushing Cut out clogged filter. I Left filter cut in II Right filter cut in M015710/04E 2012-09 | Task Description | 157...
  • Page 143 Fit cover with gasket and secure it with screws. Check differential pressure (→ Page 155). Result: If flushing did not lead to an improvement of the differential pressure, replace filter element of fuel prefil‐ ter (→ Page 159). 158 | Task Description | M015710/04E 2012-09...
  • Page 144 Risk of fire and explosion! • Avoid open flames, electrical sparks and ignition sources. • Do not smoke. Replacing filter element Cut out filter to be drained. I Left filter cut in II Right filter cut in M015710/04E 2012-09 | Task Description | 159...
  • Page 145 Place new gasket in cover (2). Fit cover with gasket and secure it with screws. Cut in the cut-out filter again. Close threaded vent plug (5) when fuel emerges. Adjust the differential pressure gauge (→ Page 155). 160 | Task Description | M015710/04E 2012-09...

  • Page 146: Intercooler – Checking Condensate Drain For

    Emergency measures prior to engine start with a leaking intercooler Remove injectors (→ Page 147). Bar engine manually (→ Page 131). Bar engine with starting system to blow out combustion chambers (→ Page 132). Install injectors (→ Page 147). M015710/04E 2012-09 | Task Description | 161...

  • Page 147: Air Filter

    Designation / Use Part No. Qty. Air filter (→ Spare Parts Catalog) Air filter – Replacement Remove air filter and install new one (→ Page 164). Reset signal ring of service indicator (→ Page 165). 162 | Task Description | M015710/04E 2012-09...
  • Page 148 Designation / Use Part No. Qty. Air filter (→ Spare Parts Catalog) Air filter – Check Check entire circumference of air filter for damage. Fit new air filter if damaged (→ Page 164). M015710/04E 2012-09 | Task Description | 163...
  • Page 149 Verify that there are no objects in the con‐ necting flange of the intake housing (3) and clean it. Place new air filter (1) with clamp (2) onto intake housing (3). Tighten clamp (2). 164 | Task Description | M015710/04E 2012-09...

  • Page 150: Air Intake

    If the signal ring is completely visible in the control window (2), replace air filter (→ Page 162). After installation of new filter, press reset button (1). Result: Engaged piston with signal ring moves back to initial position. M015710/04E 2012-09 | Task Description | 165...

  • Page 151: Starting Equipment

    Risk of damage to hearing! • Wear ear protectors. Air starter – Manual operation Press pushbutton for manual start and hold Allow compressed air to enter the air start‐ er, until the engine fires evenly. Release pushbutton. 166 | Task Description | M015710/04E 2012-09...

  • Page 152: Lube Oil System, Lube Oil Circuit

    7.13 Lube Oil System, Lube Oil Circuit 7.13.1 Engine oil – Change Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine is at operating temperature. ☑ MTU fluids and lubricants specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty.
  • Page 153 Open cover on filler neck. Pour engine oil through the filler neck up to the "max." mark on the oil dipstick. Close cover on filler neck. Check engine oil level (→ Page 169). 168 | Task Description | M015710/04E 2012-09...
  • Page 154 Insert oil dipstick into guide tube up to stop, withdraw after approx. 10 seconds and check oil level. Oil level must be between marks (1) and (2). Top up with oil to mark (1) as necessary (→ Page 167). Insert oil dipstick into guide tube up to the stop. M015710/04E 2012-09 | Task Description | 169...
  • Page 155 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 156: Oil Filtration / Cooling

    Replace other engine oil filters in the same way. Check engine oil level (→ Page 169). After changing engine oil and replacing oil filter(s), bar engine with starting equipment (→ Page 132). M015710/04E 2012-09 | Task Description | 171...
  • Page 157 • Use appropriate cleaning tool. Removing strainer Clean oil indicator filter before disassem‐ bling it. Remove screws (1). Take off cover (2) with O-ring (3). Remove strainer (5) from housing and allow oil to drip into container. 172 | Task Description | M015710/04E 2012-09...
  • Page 158 Coat square-section ring (4) on strainer (5) with engine oil and install strainer (5). Insert strainer into housing. Fill housing with new engine oil. Coat O-ring (3) with engine oil and fit in filter housing. Fit cover (2) and secure with screws (1) and washers. M015710/04E 2012-09 | Task Description | 173...

  • Page 159: Centrifugal Oil Filter – Cleaning And Filter

    • Avoid contact with skin. • Do not inhale oil vapor. WARNING Compressed air Risk of injury! • Do not direct compressed-air jet at persons. • Wear protective goggles / safety mask and ear protectors. 174 | Task Description | M015710/04E 2012-09...
  • Page 160 Value/Standard Clamp Tightening torque 8 N to 10 Nm Tighten cover nut (2) with torque wrench to the specified torque. Name Size Type Lubricant Value/Standard Screw Tightening torque 5 Nm to 7 Nm M015710/04E 2012-09 | Task Description | 175...

  • Page 161: Coolant Circuit, General, High

    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 162: Engine Coolant – Change

    7.15.2 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant – Change Drain engine coolant (→ Page 178). Fill with engine coolant (→ Page 179). M015710/04E 2012-09 | Task Description | 177...

  • Page 163: Engine Coolant – Draining

    • Preheating unit • Thermostat housing • Twin elbow • HT coolant pump elbow; • Crankcase, left and right sides. Close all open drain points. Place breather valve on filler neck and close. 178 | Task Description | M015710/04E 2012-09...

  • Page 164: Engine Coolant – Filling

    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 165 Fit breather valve and close it. Repeat the steps from "Start engine" (→ Step 9) until coolant is no longer needed to be topped up. Disconnect pump and hose. 180 | Task Description | M015710/04E 2012-09...
  • Page 166 (→ Step 6) until coolant is no longer needed to be topped up. Final steps Start the engine and run it without load for some minutes. Check coolant level (→ Page 176) and top up engine coolant as required. M015710/04E 2012-09 | Task Description | 181...

  • Page 167: Engine Coolant Pump – Relief Bore Check

    Clean the relief bore with a wire if it is dirty. • Permissible coolant discharge: up to 10 drops per hour; • Permissible oil discharge: up to 5 drops per hour. If discharge exceeds the specified limits: Contact Service. 182 | Task Description | M015710/04E 2012-09...

  • Page 168: 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 169: 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 170: Charge-Air Coolant – Change

    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 186). Fill with charge-air coolant (→ Page 187). M015710/04E 2012-09 | Task Description | 185...

  • Page 171: Charge-Air Coolant – Draining

    • at the LT thermostat housing. Draining of residual coolant: • at the intercooler Close all drain valves and screw in drain plugs with new sealing rings. Place breather valve on filler neck and close. 186 | Task Description | M015710/04E 2012-09...

  • Page 172: Charge-Air Coolant – Filling

    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. Coolant WARNING Coolant is hot and under pressure.
  • Page 173 Place breather valve on filler neck and close. Repeat the steps from "Start engine" (→ Step 9) until coolant is no longer needed to be topped up. Disconnect pump and hose. 188 | Task Description | M015710/04E 2012-09...
  • Page 174 (→ Step 6) until coolant is no longer needed to be topped up. Final steps Start the engine and run it without load for some minutes. Check coolant level (→ Page 184) and top up coolant as required. M015710/04E 2012-09 | Task Description | 189...

  • Page 175: Charge-Air Coolant Pump – Relief Bore Check

    Clean the relief bore with a wire if it is dirty. • Permissible coolant discharge: up to 10 drops per hour; • Permissible oil discharge: up to 5 drops per hour. If discharge exceeds the specified limits: Contact Service. 190 | Task Description | M015710/04E 2012-09...

  • Page 176: Belt Drive

    Findings Action Drive belt A Singular cracks None Drive belt Belt is oily, shows signs of over‐ Replace (→ Page 193) heating Drive belt B Cracks on entire circumference Drive belt C Chunking M015710/04E 2012-09 | Task Description | 191...

  • Page 177: Battery-Charging Generator

    Screw M10x1.5 Tightening torque 60 Nm +5 Nm Tighten screw (1) to specified tightening torque using a torque wrench. Name Size Type Lubricant Value/Standard Screw M10x1.5 Tightening torque 42 Nm Install protective cover. 192 | Task Description | M015710/04E 2012-09...
  • Page 178 Tighten screw (2) with torque wrench to the specified tightening torque. Name Size Type Lubricant Value/Standard Screw M10x1.5 Tightening torque 42 Nm Install protective cover. Readjust belt tension after 30 minutes and again after 8 hours engine runtime (→ Page 192). M015710/04E 2012-09 | Task Description | 193...

  • Page 179: Engine Mounting / Support

    7.19 Engine Mounting / Support 7.19.1 Engine mounting – Check Engine mounting – Check Item Findings Action Visually inspect mounts. • Damage Replace (contact Service). • Brittleness • Deformation • Crack formation • Swelling visible 194 | Task Description | M015710/04E 2012-09...

  • Page 180: Wiring (General) For Engine/Gearbox/Unit

    (→ Contact Service) if cable conductors are damaged. Note: Close male connectors that are not plugged in with the protective cap supplied. Clean dirty connector housings, sockets and contacts with isopropyl alcohol. Ensure that all sensor connectors are securely engaged. M015710/04E 2012-09 | Task Description | 195...

  • Page 181: Accessories For (Electronic) Engine

    Seal unused connectors with the supplied protective cap. Release the latch and pull off connectors. Clean connector housings, connector socket housings and all contacts with isopropyl alcohol. When connectors, sockets and all contacts are dry: Fit connectors and lock them. 196 | Task Description | M015710/04E 2012-09...

  • Page 182: Engine Governor – Checking Plug-In Connections

    Always use test connectors to enter the connectors. Never use test leads for this purpose.Otherwise the contacts could be bent. Checking plug-in connections on engine governor Check all plug-in connections for secure seating. Latch connectors if loose. M015710/04E 2012-09 | Task Description | 197...

  • Page 183: Ecu 7 Engine Governor – Removal And

    Installing Engine Control Unit on engine Install in reverse order. In doing so, ensure correct assignment of connectors and sockets. Check rubber mounts before installation. Result: Replace rubber mounts if they are found porous or defective. 198 | Task Description | M015710/04E 2012-09...

  • Page 184: Appendix A

    Electronic control unit of the DDEC system Engine Control Unit Engine governor Engine Data Module Memory module for engine data EE‐ Electrically Erasable Programmable Read PROM Only Memory EFPA Electronic Foot Pedal Assembly Exhaust Gas Recirculation M015710/04E 2012-09 | Appendix A | 199...
  • Page 185 Modulated signal P-xyz Pressure-xyz Pressure measuring point, xyz specifies the meas‐ uring point designation Redundancy Lost Alarm: Redundant CAN bus failure Society of Automotive Engineers U.S. standardization organization Sensor Defect Alarm: Sensor failure 200 | Appendix A | M015710/04E 2012-09...
  • Page 186 Throttle Position Sensor Timing Reference Sensor T-xyz Temperature-xyz Temperature measuring point, xyz specifies the measuring point designation Unterer Totpunkt Bottom dead center (BDC) Variable nozzle turbine Variable-speed governor Vehicle Speed Sensor Werkzeugkatalog Tool Catalog M015710/04E 2012-09 | Appendix A | 201...

  • Page 187: Mtu Contact Persons/Service Partners

    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 188: Special Tools

    7.4.2 Valve clearance – Check and adjustment (→ Page 141) Filter wrench Part No.: F30379104 Qty.: Used in: 7.8.1 Fuel filter – Replacement (→ Page 153) Qty.: Used in: 7.14.1 Engine oil filter – Replacement (→ Page 171) M015710/04E 2012-09 | Appendix B | 203...
  • Page 189 7.15.6 Engine coolant – Sample extraction and analysis (→ Page 183) Ratchet adapter Part No.: F30027340 Qty.: Used in: 7.3.1 Crankcase breather – Oil separator element re‐ placement, diaphragm check and replacement (→ Page 138) 204 | Appendix B | M015710/04E 2012-09...
  • Page 190 Y20097353 Qty.: Used in: 7.2.1 Cylinder liner – Endoscopic examination (→ Page 134) Ring socket, 24 mm Part No.: F30039526 Qty.: Used in: 7.4.2 Valve clearance – Check and adjustment (→ Page 141) M015710/04E 2012-09 | Appendix B | 205...
  • Page 191 Part No.: F30510423 Qty.: Used in: 1.4 Crankshaft transport locking device (→ Page 8) Torque wrench, 10-60 Nm Part No.: F30452769 Qty.: Used in: 7.6.2 Injector – Removal and installation (→ Page 147) 206 | Appendix B | M015710/04E 2012-09...
  • Page 192 Part No.: F30047446 Qty.: Used in: 7.4.2 Valve clearance – Check and adjustment (→ Page 141) Torque wrench, 60-320 Nm Part No.: F30047446 Qty.: Used in: 1.4 Crankshaft transport locking device (→ Page 8) M015710/04E 2012-09 | Appendix B | 207...
  • Page 193 Torque wrench, 60-320 Nm Part No.: F30452768 Qty.: Used in: 7.6.2 Injector – Removal and installation (→ Page 147) 208 | Appendix B | M015710/04E 2012-09...
  • Page 194 – Drive belt tension adjustment  192 Engine coolant pump – Relief bore check  182 Engine governor Centrifugal oil filter – Checking plug-in connections  197 – Cleaning and filter sleeve replacement  174 – Cleaning  196 M015710/04E 2012-09 | Appendix B | 209...
  • Page 195 – Safety regulations  11 Stop engine in manual mode (testing mode) 73 Injector – Removal and installation  147 – Replacement  146 Transport 7 Injectors Troubleshooting 79 – Overview  21 Inspection port cover – Explosion hazard  12 210 | Appendix B | M015710/04E 2012-09...
  • Page 196 Valve clearance – Adjustment  141 – Check  141 Valve gear – Lubrication  140 Wiring - engine – Check  195 M015710/04E 2012-09 | Appendix B | 211...

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