MTU 12 V 4000 G21R Operating Instructions Manual
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MTU 12 V 4000 G21R Operating Instructions Manual

MTU 12 V 4000 G21R Operating Instructions Manual

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Operating Instructions

Diesel engine
12 V 4000 G21R
12 V 4000 G41R
MS150064/01E

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Summary of Contents for MTU 12 V 4000 G21R

  • Page 1: Operating Instructions

    Operating Instructions Diesel engine 12 V 4000 G21R 12 V 4000 G41R MS150064/01E...

  • Page 2: 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 3: Engine Layout

    2.2 Engine layout Illustration valid for 8/12/16V 4000 Gxy engines 1 Coolant line 8 Air supply 16 Fuel line (low pressure) 2 Exhaust system 9 Starting equipment 17 Lube oil filter 3 Exhaust turbocharger 10 Oil filler neck 18 Fuel pump (high pres‐ 4 Air intake 11 Mounting / support sure)

  • Page 4: Technical Data

    3 Technical Data 3.1 12V 4000 engine data, continuous operation, variable 3B, optimized fuel consumption Explanation Abbr. 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 changes (e.g. of power set‐ ting) Not yet defined value Not applicable...
  • Page 5 CONSUMPTION Number of cylinders Lube oil consumption after engine % of B run-in (B = hourly fuel consumption) MODEL RELATED DATA (basic design) Number of cylinders Cylinder arrangement: V angle Degrees (°) Bore Stroke Displacement per cylinder liter 4.06 4.06 4.06 Displacement, total liter...
  • Page 6 LUBE OIL SYSTEM Number of cylinders Lube oil temperature before engine, °C from Lube oil operating temperature before °C engine, to Lube oil temperature before engine, °C alarm Lube oil operating pressure before engine, from Lube oil operating pressure before engine, to Lube oil pressure before engine, alarm...
  • Page 7 CAPACITIES Number of cylinders Engine coolant capacity (without cool‐ liter ing equipment) Charge-air coolant capacity, engine liter side Engine oil at initial filling (standard oil liter system) (Option: max. operating incli‐ nations) Oil pan capacity at dipstick mark liter "min." (standard oil system) (Option: max.
  • Page 8 3.2 12V 4000 engine data, continuous operation, variable 3B, emissions optimized w/o certificate Explanation Abbr. 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 changes (e.g. of power set‐ ting) Not yet defined value Not applicable...
  • Page 9 MODEL RELATED DATA (basic design) Number of cylinders Number of cylinders Cylinder arrangement: V angle Degrees (°) Bore Stroke Displacement per cylinder liter 4.06 4.06 Displacement, total liter 48.7 48.7 Compression ratio 15.5 15.5 Number of inlet valves per cylinder Number of exhaust valves per cylinder Standard flywheel housing flange (engine main PTO)
  • Page 10 Number of cylinders Lube oil operating pressure before engine, Lube oil pressure before engine, alarm Lube oil pressure before engine, shutdown FUEL SYSTEM Number of cylinders Fuel pressure at supply connection to en‐ -0.1 -0.1 gine, min. (when engine is starting) Fuel pressure at engine supply connection, max.
  • Page 11 ACOUSTICS Number of cylinders Exhaust noise, unsilenced, BL (free-field dB(A) sound pressure level Lp, 1m distance, ISO 6798, +3dB(A) tolerance) Engine surface noise with attenuated intake dB(A) noise (filter), BL, (free-field sound-pressure level Lp, 1m distance, ISO 6798+2dB(A) tol‐ erance) 30 | Technical Data | MS150064/01E 2011-11...
  • Page 12 3.3 12V 4000 engine data, continuous operation, variable 3B, emissions optimized (TA-Luft) Explanation Abbr. 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 changes (e.g. of power set‐ ting) Not yet defined value Not applicable...
  • Page 13 MODEL RELATED DATA (basic design) Number of cylinders Number of cylinders Cylinder arrangement: V angle Degrees (°) Bore Stroke Displacement per cylinder liter 4.06 Displacement, total liter 48.7 Compression ratio 15.5 Number of inlet valves per cylinder Number of exhaust valves per cylinder Standard flywheel housing flange (engine main PTO) COMBUSTION AIR / EXHAUST GAS Number of cylinders...
  • Page 14 FUEL SYSTEM Number of cylinders Fuel pressure at supply connection to engine, min. -0.1 (when engine is starting) Fuel pressure at engine supply connection, max. (when engine is starting) GENERAL OPERATING DATA Number of cylinders Cold start capability: air temperature (w/o start aid, w/ °C o preheating) (case A) Coolant preheating, preheating temperature (min.)

  • Page 15: Final Compression Pressure

    3.4 Final compression pressure Final compression pressure Final compression pressure at 120 rpm 24 bar to 28 bar 34 | Technical Data | MS150064/01E 2011-11...

  • Page 16: Firing Order

    3.5 Firing order Firing order Number of cylin‐ Firing order ders A1-B4-A4-A2-B3-A3-B2-B1 A1-B2-A5-B4-A3-B1-A6-B5-A2-B3-A4-B6 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 MS150064/01E 2011-11 | Technical Data | 35...

  • Page 17: Engine - Main Dimensions

    3.6 Engine – Main dimensions Engine – Main dimensions Engine model Length (A) Width (B) Height (C) 8 V 4000 Gxy approx. 1940 mm approx. 1550 mm approx. 1760 mm 12 V 4000 Gxy approx. 2410 mm approx. 1550 mm approx.

  • Page 18: Operation

    4.1 Putting the engine into operation after extended out-of- service periods (>3 months) Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specification (A001061/..) is available. Putting the engine into operation after extended out-of-service-periods (>3 months) Item Task Engine Depreserve (→...

  • Page 19: 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 the engine into operation Item Task Lube oil system Check oil level (→ Page 98); Cooling system Check engine coolant level (→ Page 105); Check charge-air coolant level (→...

  • Page 20: Start Engine In Manual Mode (Testing Mode)

    4.3 Start engine in manual mode (testing mode) Preconditions ☑ Generator (if provided) not connected to network. ☑ External start interlock is not activated. 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 21: 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 22: 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 23: Stop Engine In Manual Mode (Testing Mode)

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

  • Page 24: Emergency Stop

    4.7 Emergency stop CAUTION An emergency stop causes extreme stress to the engine. Risk of overheating, damage to components! • Initiate emergency stop only in emergency situations. Emergency stop from LOP Item Task EMERGENCY STOP but‐ Press. • Engine is stopped by switching off power supply to ECU; •...

  • Page 25: 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 44 | Operation | MS150064/01E 2011-11...

  • Page 26: 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 Fluids and Lubricants Speci‐ fications A001061/.. ).

  • Page 27: Plant - Cleaning

    4.10 Plant – Cleaning Preconditions ☑ Engine is stopped and starting disabled. ☑ Operating voltage is not applied. Special tools, Material, Spare parts Designation / Use Part No. Qty. Steam jet cleaner Cleaner (Hakupur 312) 30390 WARNING Compressed air Risk of injury! •...

  • Page 28: Maintenance Task Reference Table [Ql1]

    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 29: Troubleshooting

    6 Troubleshooting 6.1 Troubleshooting Engine does not turn when starter is actuated Component Probable cause Task Battery Low or defective Charge or replace (see manufacturer's documentation). Cable connections defective Check if cable connections are proper‐ ly secured (see manufacturer's docu‐ mentation).
  • Page 30 Defective Contact Service. Charge-air temperature too high Component Probable cause Task Engine coolant Incorrect coolant concentration Check (MTU test kit). Intercooler Contaminated Contact Service. Engine room Air-intake temperature too high Check fans and air supply / ventilation ducts. Charge air pressure too low...
  • Page 31 Exhaust gas blue Component Probable cause Task Engine oil Too much engine oil in the engine Drain engine oil (→ Page 99). Oil separator of crankcase breather Replace (→ Page 70). contaminated Exhaust turbocharg‐ Defective Contact Service. er, cylinder head, pis‐ ton rings, cylinder lin‐...

  • Page 32: Fault Messages On Engine Governor

    6.2 Fault messages on engine governor The engine governor generates alarms which are indicated in different ways depending on the equip‐ ment configuration: • as four-digit code on a PIM • as alarm text on a display • as four-digit code on a dialog PC The four-digit code consists of one letter and three figures: •...
  • Page 33 Fault Alarm text Meaning Task code L1 COOLANT Engine coolant level too low Check coolant level and top up, if re‐ LEVEL quired (→ Page 105). L2 COOLANT Engine coolant level too low Check coolant level and top up, if re‐ LEVEL quired (→...
  • Page 34 Fault Alarm text Meaning Task code L2 T-EXTERN 1 Violation of second limit for (Depending on the corresponding meas‐ external temperature channel uring point, which is read via CAN bus) L1 T-EXTERN 2 Violation of first limit for exter‐ (Depending on the corresponding meas‐ nal temperature channel 2 uring point, which is read via CAN bus) L2 T-EXTERN 2...
  • Page 35 Fault Alarm text Meaning Task code RUN UP SPEED Run-up speed not reached Note further alarms. within a specified period; Termination of starting proce‐ dure. START SPEED Starter speed not reached Note further alarms. within a specified period; Termination of starting proce‐ dure.
  • Page 36 Fault Alarm text Meaning Task code L2 SUPPLY Supply voltage too high (2nd Check engine governor supply voltage. VOLT. HIGH limit value); If engine was stopped: Start engine automatic engine shutdown (→ Page 39). (depending on project design) L1 T-ELEC‐ Temperature in engine gover‐...
  • Page 37 Fault Alarm text Meaning Task code AD-TEST3 ECU Electronic equipment defec‐ Contact Service. DEFECT tive; automatic engine shutdown MI MODULE Module in maintenance pre‐ Contact Service. FAIL dictor either defective or miss‐ MI NOT ACTIVE Maintenance predictor no Contact Service. more activated MODULE WRITE EEPROM write limit reached...
  • Page 38 Fault Alarm text Meaning Task code SD P-LUBE OIL Sensor defect (lube oil pres‐ 1. Check wiring. sure) 2. Contact Service. SD P-RAIL FUEL Sensor defect (common rail 1. Check wiring. pressure); 2. Contact Service. HP controller in emergency mode SD T-LUBE OIL Sensor defect (lube oil tem‐...
  • Page 39 Fault Alarm text Meaning Task code SD EXT.COOL‐ External coolant-level monitor‐ Contact Service. ANT LEVEL ing defective (CAN) SD INTERCOOL‐ External charge-air coolant- Contact Service. ER LEVEL level monitoring defective (CAN) SD BIN-EXTERN External device defective Contact Service. (CAN BIN-EXTERN 3) SD BIN-EXTERN External device defective Contact Service.
  • Page 40 Fault Alarm text Meaning Task code TIMING CYLIN‐ Injection timing fault cylinder If fault occurs repeatedly: Contact Serv‐ DER B10 ice. WIRING CYLIN‐ Faulty wiring to solenoid valve 1. Check wiring. DER A1 cylinder A1; 2. Contact Service. Misfiring WIRING CYLIN‐ Faulty wiring to solenoid valve 1.
  • Page 41 Fault Alarm text Meaning Task code WIRING CYLIN‐ Faulty wiring to solenoid valve 1. Check wiring. DER B4 cylinder B4; 2. Contact Service. Misfiring WIRING CYLIN‐ Faulty wiring to solenoid valve 1. Check wiring. DER B5 cylinder B5; 2. Contact Service. Misfiring WIRING CYLIN‐...
  • Page 42 Fault Alarm text Meaning Task code OPEN_LOAD Disconnection in wiring to sol‐ 1. Check wiring. CYL. A8 enoid valve cylinder A8; 2. Contact Service. Misfiring OPEN_LOAD Disconnection in wiring to sol‐ 1. Check wiring. CYL. A9 enoid valve cylinder A9; 2.
  • Page 43 Fault Alarm text Meaning Task code STOP POWER Solenoid valve or wiring or en‐ 1. Check wiring. STAGE 1 gine governor defective 2. Try to re-start the engine (→ Page 39). automatic engine shutdown 3. Contact Service. STOP POWER Solenoid valve or wiring or en‐ 1.

  • Page 44: 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 45: Engine - Barring With Starting System

    7.1.2 Engine – Barring with starting system Special tools, Material, Spare parts Designation / Use Part No. Qty. Connector pliers 0135315483 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. •...

  • Page 46: 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 47: Cylinder Liner - Endoscopic Examination

    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 75). Remove injector (→...
  • Page 48 Final steps Install injector (→ Page 78). Install cylinder head cover (→ Page 75). MS150064/01E 2011-11 | Task Description | 67...

  • Page 49: Cylinder Liner - Instructions And Comments On Endoscopic And Visual Examination

    7.2.2 Cylinder liner - Instructions and comments on endoscopic and visual examination Terms used for endoscopic examination Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic exami‐ nation report. Findings Measure Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing prod‐...
  • Page 50 Findings Measure Burn mark This is caused by a malfunction in the liner / ring tribosystem. Usually they run over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring and becoming more visible from the second TDC-ring 2 onwards and less pro‐ nounced from TDC-ring 1.

  • Page 51: Crankcase Breather - Oil Separator Replacement, Diaphragm Check And Replacement

    7.3 Crankcase Breather 7.3.1 Crankcase breather – Oil separator 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 adapter F30027340 Engine oil Filter element...
  • Page 52 Checking diaphragm Remove cover (4). Remove spring (5), seal (2) and diaphragm (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 53: 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 75). Fill oil chambers of valve bridges with oil.

  • Page 54: 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 Y20010128 Torque wrench, 60-320 Nm F30047446...

  • Page 55: Adjusting Valve Clearance

    Checking valve clearance at two crankshaft positions Check TDC position of piston in cylinder • If the rocker arms are unloaded on cylin‐ der A1, the piston is in firing TDC. • If the rocker arms are under load on cyl‐ inder A1, the piston is in overlap TDC.

  • Page 56: Cylinder Head Cover - Removal And Installation

    7.4.3 Cylinder head cover – Removal and installation Preconditions ☑ Engine shut down and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Gasket (→ Spare Parts Catalog) Removing cylinder head cover Clean cylinder head covers prior to removal if they are heavily soiled.

  • Page 57: Injection Pump / Hp Pump

    7.5 Injection Pump / HP Pump 7.5.1 HP 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 58: 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 78). MS150064/01E 2011-11 | Task Description | 77...

  • Page 59: Injector - Removal And Installation

    7.6.2 Injector – Removal and installation Preconditions ☑ Engine shut down and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Installation and removal tool for injector F6790161 Milling cutter F30452739 Slotted nut screwdriver F30452578 Torque wrench, 0.5-5 Nm 0015384230 Torque wrench, 10-60 Nm F30510423...
  • Page 60 Removing injector Note: Always replace the first and last injectors of one engine side first. Replace the inner in‐ jectors only after the installation of the outer injectors on this engine side is completed. Undo cable terminal screws (arrow) on in‐ jector and remove cable terminals.
  • Page 61 Remove sealing ring (1) from injector or use a self-made wire hook to extract it from the cylinder head. Remove O-rings (2) from injector. Cover all connections and bores, or seal with suitable plugs. Installing injector Remove all plugs before installing. Coat nozzle retaining nut area of injector with assembly paste.
  • Page 62 Use slotted screwdriver to check thrust ring at both line ends for secure seating. Tighten loose thrust ring to the specified tightening torque. Name Size Type Lubricant Value/Standard Thrust ring Tightening torque 5 Nm to 10 Nm Coat screw head mating face (2) and thread with engine oil.
  • Page 63 Tighten union nut of connecting piece (limiting valve) to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Union nut Tightening torque 140 Nm + 10 Nm Tighten union nut of connecting piece (injector) to specified torque using a torque wrench. Name Size Type...

  • Page 64: Fuel System - Venting

    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 65: Fuel Filter - Replacement

    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 66: 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 67: 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 68: 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 69: Fuel Prefilter - Flushing

    7.8.5 Fuel prefilter ‒ Flushing Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel 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 70 Open threaded vent plug (5) of filter to be flushed. Unlock drain valve (6) by pressing 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 71: 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 72 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 73: Charge-Air Cooling

    7.9 Charge-Air Cooling 7.9.1 Intercooler – Check drain for coolant leakage and obstruction 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 74: Air Filter - Replacement

    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 94). Reset signal ring of service indicator (→ Page 95). MS150064/01E 2011-11 | Task Description | 93...

  • Page 75: Air Filter - Removal And Installation

    7.10.2 Air filter – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Air filter – Removal and installation Release clamp (2). Remove air filter (3) and clamp (2) from flange of intake housing (1). Verify that there are no objects in the flange of the intake housing (1) and clean it.

  • Page 76: Air Intake

    7.11 Air Intake 7.11.1 Contamination indicator – Signal ring position check Preconditions ☑ Engine is stopped and starting disabled. Checking signal ring position If the signal ring is completely visible in the control window (2), replace air filter (→ Page 93). After installation of new filter, press reset button (1).

  • Page 77: 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 78: Starter - Condition Check

    7.12.2 Starter – Condition check Preconditions ☑ Engine is stopped and starting disabled. Checking starter condition Check securing screws of starter for secure seating and tighten if required. Check wiring (→ Page 125). MS150064/01E 2011-11 | Task Description | 97...

  • Page 79: Lube Oil System, Lube Oil Circuit

    7.13 Lube Oil System, Lube Oil Circuit 7.13.1 Engine oil level – Check Preconditions ☑ Engine shut down and starting disabled. Checking oil level prior to engine start Withdraw oil dipstick from guide tube and wipe it. Insert oil dipstick into guide tube up to stop, withdraw after approx.

  • Page 80: Engine Oil Change

    7.13.2 Engine oil – Change Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine is at operating temperature. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 40-200 Nm...
  • Page 81 Tighten drain plugs (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) 100 Nm +10 Nm Filling with new engine oil Open cap on filler neck. Pour in engine oil at filler neck up to “max.”...

  • Page 82: Engine Oil - Sample Extraction And Analysis

    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 83: Oil Filtration / Cooling

    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 84: Centrifugal Oil Filter - Cleaning And Filter Sleeve Replacement

    7.14.2 Centrifugal oil filter – Cleaning and filter sleeve replacement Preconditions ☑ Engine shut down and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Torque wrench, 6-50 Nm F30027336 Ratchet adapter F30027339 Cold cleaner (Hakutex 60) 50602 Grease (Kluthe Hakuform 30-10/emulsifier)
  • Page 85 Cleaning centrifugal oil filter and replacing filter sleeve Undo 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 undo knurled nut (7). Take off rotor cap (8).

  • Page 86: Coolant Circuit, General, High-Temperature Circuit

    7.15 Coolant Circuit, General, High-Temperature Circuit 7.15.1 Coolant level - Check Preconditions ☑ Engine shut down and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...

  • Page 87: Engine Coolant - Change

    7.15.2 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine coolant Changing engine coolant Drain engine coolant (→ Page 107). Fill with engine coolant (→ Page 108). 106 | Task Description | MS150064/01E 2011-11...

  • Page 88: Engine Coolant - Draining

    7.15.3 Engine coolant – Draining Preconditions ☑ Engine is stopped and starting disabled. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down. • Wear protective clothing, gloves, and goggles / safety mask. Preparatory steps Provide an appropriate container to drain the coolant into.

  • Page 89: 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. Engine coolant WARNING Coolant is hot and under pressure.
  • Page 90 Filling with coolant using a pump Connect suitable pump and hose to engine coolant pump drain valve (arrowed) or drain and filling line between engine and radiator. Undo screw connection (arrowed) of the vent line on the distributor. Open drain valve and pump coolant into en‐ gine with a pressure of at least 0.5 bar until coolant escapes from the open connection.
  • Page 91 Alternatively: Filling with coolant through filler neck Undo screw connection (arrowed) of the vent line on the distributor. Fill in coolant via filler neck on expansion tank until the coolant level at bottom edge of filler neck remains constant. Tighten connection (arrowed). Check proper condition of breather valve and clean sealing faces if required.

  • Page 92: Engine Coolant Pump - Relief Bore Check

    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 93: Coolant - Sample Extraction And Analysis

    7.15.6 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. Risk of serious injury – danger to life! •...

  • Page 94: 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 95: Charge-Air Coolant - Change

    7.16.2 Charge-air coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Charge-air coolant Charge-air coolant – Change Drain charge-air coolant (→ Page 115). Fill with charge-air coolant (→ Page 116). 114 | Task Description | MS150064/01E 2011-11...

  • Page 96: Charge-Air Coolant - Draining

    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 97: 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. Charge-air coolant WARNING Coolant is hot and under pressure.
  • Page 98 Filling with charge-air coolant using a pump Connect suitable pump and hose to charge- air coolant pump drain valve (arrowed) or drain and filling line between engine and ra‐ diator. Undo plug screws (1) on coolant lines to and from intercooler and connection (2) of the vent line on the distributor.
  • Page 99 Alternatively: Filling with coolant through filler neck Undo plug screws (1) on coolant lines to and from intercooler and connection (2) of the vent line on the distributor. Fill in coolant via filler neck on expansion tank until the coolant level at bottom edge of filler neck remains constant.
  • Page 100 7.16.5 Charge-air 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 (→ Tools Catalog) DANGER Unguarded rotating and moving engine components.

  • Page 101: Charge-Air Coolant Pump - Relief Bore Check

    7.16.6 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 102: Drive Belt - Condition Check

    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 103: Battery-Charging Generator

    7.18 Battery-Charging Generator 7.18.1 Battery-charging generator drive – Drive belt tension adjustment Preconditions ☑ Engine is stopped and starting disabled. Adjusting belt tension Loosen locknut (2) and screws (1). Tension drive belt with tensioning nut (3) and check belt tension (→ Page 123). Tighten locknut (2).
  • Page 104 7.18.2 Battery-charging generator drive – Drive belt tension check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Belt tension tester Y4345711 Preparatory steps Remove guard cover. Check belt condition visually (→ Page 121). Checking drive belt tension Fit measuring head (2) on belt-tension tester (3) and hit drive belt (1) with a suitable tool.

  • Page 105: Battery-Charging Generator Drive - Drive Belt Replacement

    7.18.3 Battery-charging generator drive – Drive belt replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Drive belt (→ Spare Parts Catalog) Note: In the event of drive belt failure during engine operation fit a new drive belt as quickly as possible. Non‐ compliance with these instructions may lead to severe consequential damage to drive unit and gear train, since pretension by the drive belt is no longer provided.

  • Page 106: Wiring (General) For Engine/Gearbox/Unit

    7.19 Wiring (General) for Engine/Gearbox/Unit 7.19.1 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 107: Accessories For (Electronic) Engine Governor / Control System

    7.20 Accessories for (Electronic) Engine Governor / Control System 7.20.1 Engine control unit and connectors – Cleaning Preconditions ☑ Engine shut down and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Connector pliers 0135315483 Isopropyl alcohol 46181 Cleaning engine control unit and connectors...

  • Page 108: Engine Control Unit Plug Connections - Check

    7.20.2 Engine control unit plug connections – Check Preconditions ☑ Engine shut down and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Connector pliers 0135315483 Checking engine control unit plug connections Use connector pliers (3) to make certain that all plug connections on engine control unit are securely seated.
  • Page 109 Abgasturbolader Exhaust turbocharger (ETC) Air Temperature Sensor Baureihe Series Betriebsstoffvorschrift MTU Fluids and Lubricants Specifications, Publication No. A01061/.. Controller Area Network Data bus system, bus standard Calibration Drift Compensation Setting of drift compensation in engine gov‐ ernor with DiaSys...
  • Page 110 Abbreviation Meaning Explanation Exhaust Gas Recirculation Engine Monitoring Unit Ersatzteilkatalog Spare Parts Catalog (SPC) Electronic Unit Injector Fuel Pressure Sensor Monitors fuel pressure Fuel - Differential Pressure Sensor Fuel Temperature Sensor Monitors fuel temperature FWCP Fire Water Control Panel Control cabinet Ground Hochdruck High Pressure (HP)
  • Page 111 Abbreviation Meaning Explanation Society of Automotive Engineers U.S. standardization organization Sensor Defect Alarm: Sensor failure Stop Engine Light 1st function: Warning lamp (stop engine and rectify fault) 2nd function: Read out fault codes System Identifier Synchronous Reference Sensor TDC cylinder 1 Safety System Safety system alarm Turbocharger Boost Sensor...

  • Page 112: Mtu Contacts/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 - either during operation, for preventive maintenance, corrective work in case of malfunction or changed operating conditions, or for spare parts supply.

  • Page 113: Special Tools

    9 Appendix B 9.1 Special Tools Allen key Part No.: F30002817 Qty.: Used in: 7.4.2 Valve clearance – Check and adjustment (→ Page 73) Barring device Part No.: F6555766 Qty.: Used in: 7.1.1 Engine – Barring manually (→ Page 63) Belt tension tester Part No.: Y4345711...
  • Page 114 Milling cutter Part No.: F30452739 Qty.: Used in: 7.6.2 Injector – Removal and installation (→ Page 78) MTU test kit Part No.: 5605892099/00 Qty.: Used in: 7.13.3 Engine oil – Sample extraction and analysis (→ Page 101) Qty.: Used in: 7.15.6 Coolant –...
  • Page 115 Socket wrench, 24 mm Part No.: F30039526 Qty.: Used in: 7.4.2 Valve clearance – Check and adjustment (→ Page 73) Steam jet cleaner Part No.: Qty.: Used in: 4.10 Plant – Cleaning (→ Page 46) Torque wrench, 0.5-5 Nm Part No.: 0015384230 Qty.: Used in:...
  • Page 116 9.2 Index 12V 4000 engine data, continuous operation, variable Engine 3B, emissions optimized (TA-Luft) 31 – Barring manually  63 12V 4000 engine data, continuous operation, variable – Main dimensions  36 3B, emissions optimized w/o certificate 27 – Test run  65 12V 4000 engine data, continuous operation, variable –...
  • Page 117 Inspection port cover – Explosion hazard  14 Intercooler – Drain, coolant leakage  92 Maintenance and repair work – Safety regulations  15 MTU contact persons 131 Operational checks 41 Personnel and organizational requirements 8 Plant – Cleaning  46 Putting the engine into operation after extended out-of- service periods (>3...

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